Mitsubishi 4G1 series Service Manual Download

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ENGINE Piston and Connecting Rod

Piston king

INSPECTION

PISTON

(1) Replace the piston if scratches or seizure is evident on its

surfaces (especially the thrust

Replace the piston

if it is cracked.

PISTON PIN

(1) Insert the piston pin into the piston

hole with a thumb.

You should feel a slight resistance. Replace the piston pin if

it can be easily inserted or there it an excessive play.

(2) The piston and piston pin must be replaced as an assembly.

PISTON RING

Check for side clearance.

If the limit is exceeded, replace the

or piston, or both.

Standard value:

No. 1

0.05 0.09 mm

in.)

No. 2

0.02 0.06 mm

in.)

Limit: 0.1 mm

in.)

(2) Insert the piston ring into the cylinder bore. Force it down

with a piston, the piston crown

in contact with the

ring, to correctly position it at right

gles to the cylinder

wall. Then, measure the end gap

a thickness gauge. If

the end gap is excessive, replace

piston ring.

Standard value:

No. 1

0.30

No. 2

0.20 0.35 mm

Oil 0.20 0.70
Limit:

0.8 mm

in.)

1.0 mm

in.)

No. 1,

Oil

CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE
METHOD)

Remove oil from crankshaft pin and

rod bearing.

(2) Cut the plastic

the same I

gth the width of

bearing and place it on crankshaft pin

with its axis.

(3) Install the connecting rod cap carefully and tighten the bolts

to the specified torque.

(4) Carefully remove the connecting rod cap.
(5) Measure the width of the plastic gauge at its widest part by

using a scale printed on the plastic gauge package.

Standard value: 0.02 0.05

in.)

Limit: 0.1 mm

in.)

TSB

Revision

Summary of Contents for 4G1 series

Page 1: ...t at the time this manual was released This BACKUP DSM manual IS to be used ONLY as a BACKUP Please DO NOT REDISTRIBUTE WHOLE SECTIONS This BACKUP was sold to you under the fact that you do indeed OWN a GENUINE DSM MANUAL It CANNOT BE considered a REPLACEMENT Unless your original manual was lost or destroyed Please See README N or READMEHTML for additional Information T h a n k y o u Gimmiemymanua...

Page 2: ......

Page 3: ...ION CONTENTS ENGINE MODEL TABLE 4 SPECIAL TOOL NOTE 5 EXPLANATION OF MANUAL CONTENTS 2 TORQUE REFERENCES I 5 FORM IN PLACE GASKET I 6 Disassembly 6 1 Form In Place Gasket Application _ 6 Surface Preparation 6 _ ...

Page 4: ...reassembly is im ossi ble in reverse order of disassembly Omitted if reassembly is possible verse order of disassembly steps Classification of Major Maintenance Service Points When there are major points relative to mainte nance and servicing procedures such as essential maintenance and service points maintenance and service standard values information regarding the use of special tools etc these ...

Page 5: ...non reusable TSB Revision This number corresponds to the number appearing in Removal steps Disassembly steps ln stallation steps or Reassembly steps I Operating procedures cautions etc on removal installation dis assembly and reassembly are de scribed I ...

Page 6: ...V bgmante h ntero Truck Diamante 3000GT 6G72 Turbo 3 0 183 6O V DOHC per bank 4 3000GT K c ENGINE MODEL TABLE 1993 4G9 6G7 4664 2 4 146 In line SOHC 4 E po LRV Expo 4G93 1 8 1 IO In line SOHC 4 age Expo LRV 6672 3 0 I 83 6O V SOHC 2 Diamante per bank Mhtero Truck 6672 3 0 183 6O V DOHC 4 per bank C mante 3000GT 6G72 Turbo 3 0 183 6O V DOHC 4 3600GT per bank 1 TSB Revision ...

Page 7: ...BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA A new type of bolts to be tightened in plastic area is currently used in so me parts of the engine The tightening method for the bolts is different from the conventional one Be sure to observe the method described in the text when tightening the bolts Service limits are provided for the bolts Make sure that the service limits described in the text ar...

Page 8: ...e sealant between the joined surfaces may have to be broken bylightly striking with a mallet or similar tool A flat gasket scraper may be lightly hammered in between the joined surfaces In this case however care must be taken to prevent damage to the joined surfaces Surface Preparation Thoroughly remove all substances deposited on the gasket application surfaces using a gasket scraper or wire brus...

Page 9: ...T CASE AND OIL PUMP 39 FUEL AND EMISSION PARTS 22 GENERAL INFORMATION 2 GENERAL SPECIFICATIONS 5 GENERATOR AND IGNITION SYSTEM 14 CONTENTS INTAKE MANIFOLD 26 PISTON AND CONNECTING ROD 43 ROCKER ARMS AND CAMSHAFT 30 SEALANT 11 SERVICE SPECIFICATIONS 6 SPECIAL TOOLS 12 THROlTLE BODY 24 TIMING BELT 17 TORQUE SPECIFICATIONS 10 ...

Page 10: ...IlA 2 4Gl ENGINE General Information GENERAL INFQRMATION ENGINE SECTIONAL VIEW TSB Revision 3 1 EN0086 ...

Page 11: ...4Gl ENGINE General Information TSB Revision 1 ...

Page 12: ...VA 4 4Gl ENGINE General Information UBRICATION SYSTEM P 0 Z t7 ii ii I OTJ 09 1 TSB Revision ...

Page 13: ...valve Injector type and number Injector identification No Fuel regulated pressure kpa psi Throttle bore mm in Throttle position sensor Closed throttle position switch 2 From 1993 models Specifications In line OHV SOHC 4 Pentroof type 1 468 89 58 75 5 2 972 82 3 228 9 2 1 I 6 14 15 51 53 51 57 14 15 Pressure feed full flow filtration Trochoid type Water cooled forced circulation Centrifugal impelle...

Page 14: ...seat ring hole primary 0 3 012 27 42 27 44 1 0795 1 0803 0 6 024 27 72 27 74 1 0913 1 0922 Oversize rework dimensions of intake valve seat ring hole secondary 0 3 012 32 43 32 45 1 2768 1 2776 0 6 024 32 73 32 75 1 2886 1 2894 Oversize rework dimensions of exhaust valve seat ring hole 0 3 012 35 43 35 45 1 3949 1 3957 0 6 024 35 73 35 75 1 4067 1 4075 I 1 Camshaft Cam height 1 Intake 38 78 1 5268 ...

Page 15: ...perature lalve seat eat angle lalve contact width Gnkage iervice size Standard value 100 75 3 9665 101 05 3 9783 6 57 6 58 2587 2591 6 53 6 55 2571 2579 45 45 30 1 o 039 1 5 l 059 0 02 0 05 0008 0020 0 05 0 09 0020 0035 0 07 0028 Up to 1992 models 0 09 0035 From 1993 models 0 17 0067 46 1 1 815 46 8 1 843 230 40 51 I 57 290140 64 l 57 Max 2 44 1 732 49 5 1 949 6 60 6 62 2598 2606 12 055 12 065 474...

Page 16: ...i Press in temperature Connecting rod 18 003 18 005 l 7088 7089 5 000 15 000 1 102 3 307 Room temperature Big end center to small end center length Bend Twist Big end side clearance Crankshaft End play Journal O D Pin O D Dut of roundness and taper of journal and pin 3il clearance of journal 3il clearance of pin Cylinder block D Ilatness of gasket surface Grinding limit of gasket surface Total res...

Page 17: ... sensor Resistance kR Idle speed control motor Coil resistance rc1 Idle air control motor Coil resistance 0 Idle speed control motor position sensor Resistance kfi Standard value L i m i t rn fq in i I i 0 03 0 08 LOOI 2 0031 0 04 0 10 0016 0039 O lO 0 18 0039 0071 0 3 5 Orl38 5 5 7 0 22 28 8 0 32 13 16 at 20 C 68 F 3 5 6 5 5 35 at 20 C 68 F 28 33 at 20 C 68 F 4 6 1 TSB Revision ...

Page 18: ...nifold Cable bracket bolt Engine coolant temperature gauge unit Engine coolant temperature sensor Therm0 switch flater outlet fitting bolt Thermostat housing bolt and nut Intake manifold stay bolt Engine support bracket stay Intake manifold bolt and nut Exhaust manifold and water pump Exhaust manifold cover A bolt Exhaust manifold cover A and B mounting bolt Exhaust manifold cover B bolt Exhaust m...

Page 19: ...ngine support bracket front 7011 stopper bracket front 3011 stopper bracket rear N m 73 40 7 19 45 I4 IO 20 I 4 turns 135 11 9 11 53 19 36 60 65 120 _ c ft lbs I 8 53 29 5 14 33 11 8 14 5 l 4 turns 98 8 7 8 38 14 26 43 47 87 SEALANT Items Therm0 switch Engine coolant temperature sensor Engine coolant temperature gauge unit Oil pan Oil pressure switch threads Specified sealant Quantity 3M Nut Locki...

Page 20: ...D99801 1 MD99801 I 01 Installation of crankshaft rear oil seal Crankshaft rear oil seal installer Crankshaft front oil seal installer MD99871 3 MD998713 01 Installation of camshaft oil seal Camshaft oil seal i Removal of oil pan ompresslon 0 TSB Revision ...

Page 21: ...4Gl ENGINE Special Tools Valve stem seal compressor Flywheel stopper 1 TSB Revision ...

Page 22: ... lbs 24Nr l 17 ft lbs 9Nm 12 Nm 9 ftJp3 I 85 Nm 81 ft lbs Removal steps 1 Oil level gauge 2 Oil level gauge guide 3 O ring C4 4 Drive belt 5 Water pump pulley 6 Generator brace 7 Generator IA B4 8 Crankshaft bolt 9 Special washer IO Crankshaft pulley 11 Damper pulley 12 Spark plug cable 13 Spark plug A4 ll s butor 1 EN0325 1 TSB Revision 1 ...

Page 23: ...o the top dead center on compression stroke 2 Align the mating mark on thedistributor housing with that on the coupling key 3 Install the distributor with the coupling key fitted in the keyway at the end of the camshaft r 64 CRANKSHAFT BOLT INSTALLATION I Using the special tool hold the drive plate or flywheel 2 Install the crankshaft bolt c4 DRIVE BELT TENSION ADJUSTMENT I Adjust the belt deflect...

Page 24: ... Or using a tension gauge adjust the tension to the standard value Standard value New belt 5 0 0 700 N 116 154 Ibs Used belt 400 N 88 Ibs 3 Tighten the lock bolt to the specified torque 4 Tighten the nut for pivot bolt to th specified torque 1 TSB Revision I I ...

Page 25: ...8 17 ft lbs 7 Removal steps 1 Timing belt upper cover 2 Timing belt lower cover I eC4 3 Timing belt 4 Engine support bracket left 5 Tensioner spring B4 6 Tensioner OBO 7 Crankshaft sprocket 8 Flange I A4 9 Camshaft sprocket bolt 10 Camshaft sprocket 1 EN0327 TSB Revision I ...

Page 26: ... so the removed timing belt sprocket and tensioner must be kept free from oil and water Do not immerse parts in cleaning solvent 2 If there is oil or water on any part check the front case oil seal camshaft oil seal and wfter pump for leaks 4Bo CRANKSHAFT SPROCKET REldOVAL o CAMSHAFT SPROCKET BOLT LOOSENING INSPECTION TIMING BELT Replace belt if any of the following conditions exist 1 Hardening of...

Page 27: ...back 3 Cracks or peeling of canvas 4 Cracks on rib root 5 Cracks on belt sides 6 Abnormal wear of belt sides The sides are normal if they are sharp as if cut by a knife 7 Abnormal wear on teeth 8 Missing tooth INSTALLATION SERVICE POIFTS I A4 CAMSHAFT SPROCKET BOLT TIGHTENING I B4 TENSIONER INSTALLATION I Move the tensioner pulley toward the water pump and tighten the tensioner mounting bolts TSB ...

Page 28: ... crankshaft sprocket with their timing marks 2 Set the timing belt first on crankshaft sprocket and then keeping the tension side belt tight set on the camshaft sprocket 4 3 Loosen the tensioner mounting bolts and 0 4 Check that the belt completely meshes with the sprocket Also check the timing marks on the sprockets for align ...

Page 29: ... bolt is tightened first the tensioner will turn together with the bolt resulting in an overtensioned belt 7 Check the belt tension Hold the tensioner and timing belt together by hand and give the belt a slight thumb pressure at a point level with tensioner center Make sure that belt cog crest comes as deep as about l 4 of the width of the slot side tensioner bolt head TSB Revision ...

Page 30: ... AND INSTALLATION TSB Revision 19 Nm 14 ft lbs Removal steps 1 Throttle body 2 Gasket 3 Injectors and fuel rail 4 Insulator eB4 Fuw ressure regulator 7 Insulator A4 8 Injector clip A4 9 Injector 10 O ring 11 Grommet 12 Fuel rail 13 EGR valve For California 14 Gasket 1 EN0238 ...

Page 31: ... Hg to make sure that vacuum is maintained If there is a leak replace the EGR valve In addition check the valve for its opening and closing motion by applying and removing vacuum INSTALLATION SERVICE POINTS A4 INJECTORS INJECTOR CLIP INSTALLATICjbi 1 Before installing an injector the rubber O ring must be lubricated with a drop of clean engine oil to aid in installation 2 Install injector top end ...

Page 32: ...mbly steps 4ArJ bA4 1 Throttle position sensor 2 Idle speed control motor 3 Throttle valve set screw 4 Throttle body 6FU1292 From 1993 models p 2Nm 1 4 ft lbs Disassembly steps 8 I A4 I Throttle position sensor 2 Idle arr control motor 4BO 3 O ring 4 Throttle body 5 Fixed speed adjusting screw TSB Revision 1 EN0336 ...

Page 33: ... the sensor and motor to clean Clean them with shop towel aB0 THROlTLE BODY REMOVAL 1 Do not remove the throttle valve 2 Check if the vacuum port or passage is clogged Use compressed air to clean the vacuum passage REASSEMBLY SERVICE POINT A4 THROTTLE POSITION SENSOR INSTALLATION 1 Check correct installation of the throttle position sensor While moving the throttle lever in both open and close dir...

Page 34: ...ant temperature gauge unit eB4 3 Engine coolant temperature sensor AiJ 4 Thermoswitch For AIT 5 Water outlet fitting 6 Water outlet fitting gasket 7 Thermostat 8 Outer cable bracket 9 Inner cable bracket k E 10 Engine hanger 11 Thermostat housing 12 Intake manifold stay 13 Engine support bracket stay From 1993 models 14 Intake manifold 15 Intake manifold gasket TSB Revision I ...

Page 35: ...THERM0 SWIT Specified sealant f i 3M Nut Locking Part No 4171 or equivalent I B4 SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE GAUGE UNIT Specified sealant 3M ATD Part No 8660 or equivalent I c4 SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE SENSOR Specified sealant 3M Nut Locking Part No 4171 or equivalent 1 TSB Revision ...

Page 36: ...30 Nm 22 ft lbs 1 14 Nm 10 ft lbs 7 14 Nm 10 ftlbs Removal steps 1 Exhaust manifold cover A 2 Oxygen sensor 1992 1993 FED models1 3 Engine hanger 4 Exhaust manifold 5 Exhaust manifold cover B 6 Exhaust manifold gasket 7 Water hose A4 8 Water inlet pipe AC 9 O ring 10 Water pump 11 Water pump gasket 1 EN0339 TSB Revision ...

Page 37: ... Water Pump O ring I Water pump Water inlet pipe 6EN0594 INSTALLATION SERVICE POINT I A4 WATER PIPE O RING INSTALLATION p 1 Wet the O ring with water to facilitateFas 6embly Caution Keep the O ring free of oil or grease TSB Revision ...

Page 38: ...V hose 3 Rocker cover 4 Rocker cover gasket C4 5 Oil seal eB4 6 Rocker arm and rocker arm shaft Bd 7 Rocker arm and rocker arm shaft 8 Rocker arm D 9 Wave washer 10 Spacer 11 Rocker arm C 12 Rocker arm shaft exhaust side 13 Rocker arm B 14 Rocker arm spring 15 Rocker arm A 16 Rocker arm shaft intake side 17 Adjusting screw 18 Nut A4 19 Camshaft 1 EN0340 TSB Revision ...

Page 39: ...smoothty or if looseness is evident replace the rocker arm l Check the inside diameter If damage or seizure is evident replace the rocker arm l Check the screw end for wear If considerable wear is evident replace the adjusting screw INSTALLATION SERVICE POINTS I A4 CAMSHAFT INSTALLATION 1 Position the dowel pin of the camshaft as shown in the illustration I B4 ROCKER ARM AND ROCKER ARM SHAFT INSTA...

Page 40: ...e adjusting screw locknut 4 Using a feeler gauge adjust the valve clearance by turning the adjusting screw Standard value on cold engine Intake 0 07 mm 0028 in Up to 1992 models 0 09 mm 0035 in From 1993 models Exhaust 0 17 mm 0067 in 5 While holding the adjusting screw with a screwdriver tighten the lock nut 6 Rotate clockwise the crankshaft one complete turn 360 degrees 7 Adjust the valve cleara...

Page 41: ...5 Valve spring retainer B4 6 Valvespring 7 Intake valve primary 8 intake valve secondary IBM bC4 9 Retainer lock 10 Valve spring retainer B4 11 Valve spring 12 Exhaust valve I A4 13 Valve stem seal 14 Valve spring seat I A4 15 Valve stem seal 16 Valve spring seat 17 Intake valve guide 18 Exhaust valve guide 19 Intake valve seat primary 20 Intake valve seat secondary 21 Exhaust valve seat 22 Cylind...

Page 42: ...EMOVAL 1 Do not reuse removed valve stem seals i INSPECTION CYLINDER HEAD 1 Check the cylinder head gasket face for flatness by using a straightedge and thicknessygauge Standard value 0 05 mm 0020 jn Limit 0 2 mm 008 in 2 If the service limit is exceeded correct to meet specifica tion Grinding limit 0 2 m m 008 ind Total resurfacing depth of bo cylinder head and cylinder block Cylinder head height...

Page 43: ...e 46 1 mm 1 815 in Exhaust 48 8 mm 1 643 in Limit Intake 45 1 mm 1 776 in Exhaust 45 8 mm 1 803 in 2 Measure the squareness of the spring and if the limit is exceeded replace Standard value 2 or less Limit 4 T TSB Revision VALVE GUIDE 1 Measure the clearance between the valve guide and the valve stem If the limit is exceeded replace the valve guide or the valve or both Standard value Intake 0 02 0...

Page 44: ...ard the combustion chamber side using a press 2 Rebore the valve guide hole in the cylinder head to the size corresponding to the oversize valve guide to be installed Caution Do not install a valve guide of the same size again Valve guide hole diameter See Service Specifica tions in page IIA 6 3 Install the valve guide until it projects 17 mm 67 in from the cylinder head as illustrated NOTE 1 The ...

Page 45: ... stem seal I D4 CYLINDER HEAD GASKET INSTALLATlON 1 Clean both gasket surfaces of cylinder block and cylinder head 2 Do not apply sealant 3 Confirm the identification mark on cylinder head gasket The identification mark is stamped on the top surface of the gasket at its front end Identification mark 3Vll Up to 1992 models 1CG From 1993 models I E4 CYLINDER HEAD BOLT INSTALLATION 1 Using the specia...

Page 46: ...1 IA 38 461 ENGINE Cvlinder Head and Valves TSB Revision ...

Page 47: ...I 7 Removal steps eD4 1 Oil filter 2 Drain plug 3 Drain plug gasket QAI C 4 Oil pan 5 Oil screen 6 Oil screen gasket 7 Relief plug 8 Gasket 9 Relief spring 10 Relief plunger B4 11 Oil seal 12 Front case 13 Front case gasket 14 Oil pump cover I A4 15 Outer rotor I A4 16 Inner rotor lEN0165 TSB Revision ...

Page 48: ...ial tool along the oil pan to remove it OBo OUTER ROTOR INNER ROTOR REMOVAL I Make alignment marks on the outer and inner rotors for reference in reassembly INSPECTION OIL PUMP 1 Check the tip clearance Standard value 0 03 0 08 mm 00 2 0031 in 2 Check the side clearance Standard value 0 04 0 10 mm 0016 0039 in fI 3 Check the body clearance Standard value 0 10 0 18 mm I 0039 0071 in Limit 0 35 138 ...

Page 49: ... to the entire rotor surface I lEN00801 MD998305 n eB4 CRANKSHAFT FRONT OIL SEAL INSTALLATION 1 Set the special tool on the crankshaft front end and apply engine oil to its outer circumference 2 Apply a light coat of engine oil to the oil seal lip and then slide the oil seal down along the special tool by hand until it touches the front case Install the oil seal in the front case using the other s...

Page 50: ...Genuine Part No lD970389 or equiva lent i 3 The oil pan should be installed within 15 minutes after the application of sealant 4 mm I 6 in diameter based sealant Groove portion Bog hole po on t J I 04 OIL FILTER INSTALLATION 1 Clean the filter installation surface of the filter bracket 2 Apply engine oil to the O ring of the oil filter 3 Screw the oil filter on the bracket until the O ring contact...

Page 51: ... AND INSTALLATION Removal steps OAo 1 k khecting rod cap 3 Connecting rod bearing iI4 4 Piston and connecting rod 5 Connecting rod bearing eC4 6 Piston ring No 1 eC4 7 Piston ring No 2 I B4 8 Oil ring oBoeA 9 Piston pin 10 Piston 11 Connecting rod 12 Bolt TSB Revision 1 EN0245 ...

Page 52: ...n Piston Support Press Pin Stop Screw Nut 2 Select the correct piston support for your applrcatron See above Fit the piston support onto the base Place the base on the press support blocks 3 Insert the press pin through the piston pin hole Select the correct connecting rod guide pin See above Thread the guide pin onto the threaded portion of the press pin 4 Position the piston assembly on the pist...

Page 53: ...he piston ring Standard value No 1 0 20 0 40 mm 0079 0157 in No 2 0 20 0 35 mm 0079 0138 in Oil 0 20 0 70 mm 0079 0276 in Limit No 1 No 2 0 8 mm 031 in Oil 1 0 mm 038 in llT E yFT PlN OIL CLEARANCE PLASTIC GAUGE 1 Remove oil from crankshaft pin and connecting rod bearing 2 Cut the plastic gauge to the same length as the width of bearing and place it on a crankshaft pin in parallel with its axis 3 ...

Page 54: ...the press support blocks 4 Slide the piston pin over the threaded end of the press pin and thread the correct guide pin up against it 5 Coat the piston pin with oil and with the connecting rod held in position slide the guide pin through the piston and the connecting rod 6 Press the piston pin through the connecting rod until the guide pin contacts the stop screw 7 Remove the piston assembly from ...

Page 55: ...ation Caution Do not use piston ring expander when installing the side rail 3 Install the lower side rail in the same procedure as described in step 2 4 Make sure that the side rails move smoothly in either direction I c4 PISTON RING No 2 PISTON RING iuo 1 IN STALLATION 1 Using piston ring expander fit No 2 and then No 1 piston ring into position NOTE 1 Note the difference in shape between No l an...

Page 56: ...es come on the same side as shown e TSB Revision 2 Make sure that connecting rod big end side clearance meets the specification Standard value 0 10 0 25 mm f 0039 00 38 in Limit 0 4 mm 018 in 3 I F4 CONNECTING ROD CAP NUT NSTALLATION 1 Since the connecting rod bolts and nuts are torqued using a new procedure they should be examined BEFORE reuse If the bolt threads are necked down the bolts should ...

Page 57: ...l steps 1 Flywheel bolt 2 Flywheel 3 Drive plate bolt 4 Adaptor plate 5 Drive plate 6 Adaptor plate 7 Crankshaft bushing For MIT 8 Rear plate 9 Bell housing cover 10 Oil seal case 11 Oil seal case gasket Cl4 12 Rear oil seal 13 Bearing cap bolt C4 14 Bearing cap B 15 Crankshaft bearing lower 16 Crankshaft B4 17 Crankshaft bearing upper A4 18 Oil pressure switch 19 Cylinder block 1 EN343 1 TSB Revi...

Page 58: ...raightedge and feeler gaugzcheck the block top surface for warpage Make sure thagthe surface is free from gasket chips and other foreignimatters Standard value 0 05 mm 002 in Limit 0 1 mm 004 in 2 If the distortion is excessive correct within the allowable limit or replace Grinding limit 0 2 mm 008 in The total resurfacing depth of both cylinder block and mating cylinder head is 0 2 mm 008 in at m...

Page 59: ... from temperature rise during honing bore cylinders in this order No 2 to No 4 to No 1 to No 3 5 Hone to the final finish dimension piston O D clearance between piston O D and cylinder 6 Check the clearance between piston and cylinder Clearance between piston and cylinder 0 02 0 04 mm OOOS 0016 in NOTE When boring cylinders finish all of four cylinders to the same oversize Do not bore only one cyl...

Page 60: ...Timing belt side Cap No 1 EN017E 1 EN028C TSB Revision Oil seal Oil seal case 1 EN027 2 After installing the bearing caps make sure that the crankshaft turns smoothly and the end play is correct If the end play exceeds the limit replace crankshaft bearings Standard value 0 05 0 18 mm 0020 0071 in Limit 0 3 mm 012 in eD4 OIL SEAL INSTALLATION ...

Page 61: ...ATION l lA 53 65 Nm 47 ft lbs 2 60 Nm 44 ft 1bs h GFL 36 Nm 26 ft lbs yy 1 120 Nm 67 ftlbs Removal steps 1 Exhaust pipe support bracket 2 Engine support bracket front 3 Roll stopper bracket front 4 Roll stopper bracket rear 1 EN0347 TSB Revision I ...

Page 62: ...N O T E S ...

Page 63: ...T CASE OIL PUMP AND OIL PAN FUEL AND EMISSION PARTS GENERAL INFORMATION GENERAL SPECIFICATIONS 62 58 39 32 45 26 2 5 GENERATOR AND IGNITION SYSTEM INTAKE MANIFOLD PISTON AND CONNECTING ROD ROCKER ARMS AND CAMSHAFT SEALANT SERVICE SPECIFICATIONS SPECIAL TOOLS THROTTLE BODY TIMING BELT TORQUE SPEClklCATlONS 16 30 52 34 12 6 13 28 18 10 ...

Page 64: ...IIB 2 4G3 ENGINE General Information GENERAL INFORMATION ENGINE SECTIONAL VIEW 3ENOO86 1 TSB Revision I ...

Page 65: ...4G3 ENGINE General Information pqJp3 I 3EN0087 TSB Revision ...

Page 66: ...IIB 4 4G3 ENGINE General Information JBRICATION SYSTEM 3LUOO20 TSB Revision ...

Page 67: ...em Water pump type EGR type Injector type and number Injector identification mark Fuel regulated pressure kPa psi Throttle bore mm in Throttle position sensor Closed throttle position switch Specifications In line OHV SOHC 4 _ Compact type 1 755 107 10 I _ 80 6 3 17 86 3 39 9 0 AR 20 BTDC 52 ATDC 55 BBDC 17 ATDC Pressure feed full flow filtration Involute gear type Water cooled forced circulation ...

Page 68: ...15 5323 Oversize rework dimensions of intake valve seat ring hole 0 30 012 43 30 43 33 1 7047 1 7059 0 60 024 43 60 43 63 1 7165 1 7177 Oversize rework dimensions of exhaust valve seat ring hole 0 30 012 37 30 37 33 1 4685 1 4697 0 60 024 37 60 37 63 1 4803 1 4815 Camshaft I Cam height 35 91 1 4138 35 41 1 3941 Fuel pump driving cam diameter 40 1 57 39 5 1 555 Journal diameter 33 94 33 95 1 3362 1...

Page 69: ... 0 06 0012 0024 0 10 0039 Exhaust 0 05 0 09 0020 0035 0 15 c qaq l Valve spring Free height 49 2 1 937 48 2 1 896 Load installed height N mm Ibs in 31 O 37 3 68 l 469 Out of squareness Max 2 4 Valve guide Overall length Intake 44 1 73 Exhaust 48 1 89 I D 7 2 7 25 2835 2854 O D 13 06 13 07 5142 5146 Service size 0 05 002 0 25 Ol 0 50 02 oversize Press in temperature Room temperature Valve seat 4 Se...

Page 70: ...6 Service size 0 25 Ol 0 50 02 0 75 03 1 OO 04 oversize Piston ring End gap No 1 ring 0 30 0 45 0118 0177 0 8 031 No 2 ring 0 20 0 35 0079 0138 0 8 031 Oil ring 0 20 0 70 LOO79 0276 1 o 039 Ring to ring groove clearance No 1 ring 0 05 0 09 0020 0035 No 2 ring 0 02 0 06 0008 0024 Service size 0 25 Ol 0 50 02 0 75 03 1 OO 04 oversize Piston pin O D 19 00 19 01 7480 7484 Press in load N Ibs 5 000 15 ...

Page 71: ... 0 50 020 U S 44 49 44 50 1 7516 1 7520 0 75 030 U S 44 24 44 25 1 7417 1 7421 Cylinder block I D 80 60 80 63 3 1732 3 1744 Flatness of gasket surface 0 05 002 0 i IboT Grinding limit of gasket surface 0 2 068 Total resurfacing depth of both cylinder block and cylinder head Dverall height 285 1 285 3 11 224 11 232 3il pump side clearance Drive gear 0 08 0 14 0031 0055 Driven gear 0 06 0 12 0024 00...

Page 72: ... body Throttle position sensor attaching bolts Intake manifold Engine coolant temperature gauge unit Engine coolant temperature sensor Water outlet fitting bolt Intake manifold plenum stay bolt Intake manifold plenum bolt and nut Thermostat housing bolt and nut Intake manifold stay bolt Intake manifold bolt and nut Exhaust manifold and water pump Oil level guide bolt gauge Exhaust manifold cover A...

Page 73: ... drain plug Oil pan bolt Oil screen nut Oil pump cover bolt Oil pump driven gear bolt Oil relief valve plug 3ear plate bolt 3ell housing cover bolt 3il seal case bolt 3earing cap bolt 3racket Exhaust pipe support bracket 3011 stopper bracket front 3011 stopper bracket rear Ingine support bracket right 53 38 36 26 65 47 120 87 65 47 TSB Revision I ...

Page 74: ... Oil pressure switch Specified sealant 3M Nut Locking Part No 4171 or equivalent 3M ATD Part No 8660 or equivalent 3M ATD Part No 8660 or equivalent MITSUBISHI GENUINE Part MD970389 or equivalent 3M ATD Part No 8660 or equivalent 3M ATD Part No 8660 or equivalent Ouantity ps required ps required As required ks required As required s required 1 T TSB Revision ...

Page 75: ...8280 MD998280 01 Installation of silent shaft bearing front Silent shaft Use with MIT21 5869 bearing installer 0 MD998282 Silent shaft bearing puller M D998282 01 Removal of silent shaft bearing front Use with MIT304204 MD998283 Silent shaft bearing puller M D998283 01 Removal of silent shaft bearing rear Use with MIT304204 MD998285 MD998285 01 Installation of crankshaft front oil seal Crankshaft ...

Page 76: ...tion of camshaft oil seal Camshaft oil seal installer MD998719 Pulley holding pins 2 M IT308239 Holding camshaft sprocket when loosening or torquing bolt _ M D998727 Oil pan remover Removal of oil pan M D998728 MD998728 01 Installation of valve stem seal Valve stem seal installer 1 TSB Revision I ...

Page 77: ...463 ENGINE Special Tools Removal of crankshaft sprocket 1 TSB Revision ...

Page 78: ...7 ft lbs 14 ilm 10 ft lbs I 19 Nm 9Nm 7 14 ft lbs 7 ftlbs 17 Nm 12 ft lbs 17 Nm 12 ft lbs Removal steps B4 1 Drive belt 2 Water pump pulley 3 Generator brace 4 Generator 5 6 Damper pulley Adapter 7 Crankshaft pulley 8 Spark plug cable 9 Spark plug 10 Distributor 11 O ring 25 Nm 18 ft lbs 12 Nm 9 ft lbs 3EN0212 ...

Page 79: ... aligning the fine cut groove or projection of the distributor s installation flange with the center of the distributor installation stud I B4 DRIVE BELT TENSION ADJUSTMENT 1 Move the generator to give greater tension to the belt so that the specified deflection is obtained L Standard value New belt 6 5 8 mm 26 31 in Used belt 8 11 mm 31 43 in Or using a tension gauge adjust the tension to the sta...

Page 80: ...belt G4 4 Tensioner G4 5 Tensioner spring 461 F4 6 Oil pump sprocket I E4 7 Crankshaft bolt 8 Crankshaft sprocket 9 Flange 10 Tensioner B OEo II4 11 Timing belt 6 IFI eC4 12 Silent shaft sprocket B4 13 Spacer SO 14 Crankshaft sprocket B 15 Engine support bracket left IHO A4 16 Camshaft sprocket bolt 17 Camshaft sprocket 18 Timing belt under upper cover 19 Timing belt under lower cover TSB Revision...

Page 81: ...side of the cylinder block 2 Insert a Phillips screwdriver shank diameter 8 mm 31 in to block the left silent shaft 3 Remove the nuts 4 Remove the oil pump sprocket r CRANKSHAFT BOLT LOOSENING 1 Using the special tool hold the drive plate or flywheel 2 Remove the crankshaft bolt IDO CRANKSHAFT SPROCKET REMOVAL IEI TIMING BELT B REMOVAL 1 Mark the belt running direction for reference in reinstalla ...

Page 82: ...SPROCKET BOLT LOOSENING INSPECTION B TIMING BELT TIMING BELT B Replace belt if any of the following ditions exist 1 Hardening of back rubber the ba ide is glossy without resilience and leaves no indent whe pressed with finger nail k 4 2 Cracks on rubber back 3 Cracks or peeling of canvas 4 Cracks on rib root 5 Cracks on belt sides TSB Revision ...

Page 83: ... wear of belt sides The sides are normal if they are sharp as if cut by a knife 7 Abnormal wear in teeth 8 Missing tooth INSTALLATION SERVICE POINTS I A4 CAMSHAFT SPROCKET BOLT INSTALLATION B4 SPACER INSTALLATION 1 Install the spacer with the chamfered end toward the oil seal I c4 SILENT SHAFT SPROCKET INSTALLATION 1 TSB Revision ...

Page 84: ...the direction of arrow while lifting with a finger to give a sufficient tension to the tension side of timing belt In this condition tighten the bolt to secure tensioner B When the bolt is tightened use care to prevent the shaft from turning together If the shaft is turned together the belt will be overtensioned c 5 Check to ensure that the timing marks on the sprockets and front case are in align...

Page 85: ...he left silent shaft 2 Install the oil pump sprocket 3 Tighten the nuts to the specified torque I Gg TENSIONER TENSIONER SPRING INSTALLATION 1 Hook the tensioner spring ends to the water pump body and tensioner bracket 2 Move the tensioner fully toward the water pump and tighten the nut and bolt I H4 TIMING BELT INSTALLATION I Align the timing marks on the camshaft sprocket and crankshaft sprocket...

Page 86: ...ealign the timing marks Then check to ensure that the screwdriver can be inserted 60 mm 2 4 in or more Keep the screwdriver inserted until installation of the timing belt is finished 4 Install the timing belt on the crankshaft sprocket oil pump sprocket and camshaft sprocket in t t order There should be no slack on the tension side 5 Loosen the tensioner mounting bol and nut z i 45 6 Turn the cran...

Page 87: ...urns as the bolt is tightened resulting in an excessive belt tension 9 Hold the center of the tension side span of the timing belt between the camshaft and oil pump sprockets between your thumb and index finger as shown Then make sure that the clearance between the belt back surface and cover is standard value Standard value 12 mm 47 in 1 TSB Revision I ...

Page 88: ... AND INSTALLATION 12 Nm 9 ft lbs 2 4 I L 3 19 Nm 14ftJbs 22 Nm 16 ft lbs Removal steps 1 Throttle body assembly 2 Gasket 3 Injector and fuel rail B4 4 Fuel pressure regulator 5 O ring 6 Fuel rail 7 Insulator 8 Insulator A4 9 Injector 10 G ring 11 Wornmet 3EN0150 TSB Revision ...

Page 89: ...nipple 3 Apply a vacuum of 500 mm Hg 19 7 in Hg to make sure that vacuum is maintained If there is a leak replace the EGR valve In addition check the valve for its opening and closing motion by applying and removing vacuum INSTALLATION SERVICE POINTS I A4 INJECTOR INSTALLATION 1 Before installing an injector the rubber O ring must be lubricated with a drop of clean engine oil to aid in installatio...

Page 90: ...sensor 2 Idle speed control motor 3 Throttle valve set screw OBO 4 Throttle body 6FU1292 DISASSEMBLY SERVICE POINTS IAI THRO ITLE POSITION SENSOR AND IDLE SPEED CONTROL MOTOR REMOVAL 1 Do not disassemble the sensor an8 motor 2 Do not immerse in solvent the sensor and motor Clean them with shop towel a r 1 TSB Revision ...

Page 91: ...vacuum port or b sage is clog e compressed air to clean the vacuum passage REASSEMBLY SERVICE POINT I A4 THROlTLE POSITION SENSOR INSTALLATION 1 Check correct installation of the throttle position sensor While moving the throttle lever in both open and close directions check to see that resistance between terminals ij and or and changes If resistance changes smoothly the throttle position sensor h...

Page 92: ... Engine coolant temperature gauge unit A4 4 Engine coolant temperature sensor 5 Water outlet fitting 6 Water outlet fitting gasket 7 Thermostat 8 Intake manifold plenum stay 9 Intake manifold plenum IO Intake manifold plenum gasket 11 Intake manifold stay 12 Engine hanger 13 Thermostat housing 14 Intake manifold 15 Intake manifold gasket 18N m 13 ft lbs 3EN0154 TSB Revision I ...

Page 93: ...ERVICE POlNTS I A4 SEALANT APPLICATION TO EyGlNE Coo ANT TEMPERATURE SENSOR Specified sealant 3M Nut Locking Part No 4171 or equivalent r 64 SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE GAUGE UNIT Specified sealant 3M ATD Part No 8660 or equivalent TS8 Revision ...

Page 94: ...N 30 Nm 14 Nm 10 ft lbs 14 Nm 10 ft lbs Removal steps 1 Oil level gauge 2 Oil level gauge guide 3 O ring 4 Exhaust manifold cover A 5 Engine hanger 6 Exhaust manifold 7 Exhaust manifold gasket 8 Exhaust manifold cover B A4 9 Water inlet pipe 10 O ring 11 Water pump 12 Water pump gasket 3EN0222 TSB Revision ...

Page 95: ... Water Pump 1 INSTALLATION SERVICE POINT O ring Water pump JE I A4 WATER INLET PIPE INSTALLATION 1 Wet the 0 ring with water to facilitate assembly Caution Keep the O ring free of oil or grease Water inlet pipe 6EN059 TSB Revision I ...

Page 96: ...er cover 5 Gasket 6 Rocker arm and rocker shaft 7 Rear camshaft bearing cap 8 Rocker arm E4 9 Wave washer DC 10 Camshaft bearing cap No 4 11 Rocker shaft spring eD4 12 Camshaft bearing cap No 3 D4 13 Camshaft bearing cap No 2 C4 14 Right rocker shaft eC4 15 Left rocker shaft 16 Front bearing cap 6Ab MI 17 Lash adiuster iA4 il S tular packing eF4 20 Camshaft oil seal 3EN0156 TSB Revision ...

Page 97: ...41 mm 1 3941 in ROCKER ARM 1 Visually check the roller and replace if dent damage or seizure is evident 2 Check roller for smooth rotation Replace if it is binding or there is an excessive play 3 Check the inside diameter and replace the rocker arm if damage or seizure is observed LASH ADJUSTER LEAK DOWN TEST Caution 1 The lash adjuster is a precision part Keep it free from dust and other foreign ...

Page 98: ... all the wayreadily bleed the lash adjuster again and test again If the plunger is still loose replace the lash adjuster Caution Upon completion of air bleeding hold the lash adjuster upright to prevent inside diesel fuel from spilling 4 After air bleeding set the lash adjuster on the special tool Leak down tester MD998440 5 After the plunger has gone down somewhat 0 2 0 5 mm 008 020 in measure ti...

Page 99: ...unger up and down four or five times to bleed out the air 3 Insert the lash adjuster to the rocker arm being careful not to spill the diesel fuel Then use the special tool to prevent the lash adjuster from falling while installing the rocker arm and shaft assembly to the cylinder head I c4 ROCKER SHAFT INSTALLATION 1 Install the rocker shafts with notches up and toward the front bearing cap 2 The ...

Page 100: ...B 38 4G3 ENGINE Rocker Arms and Camshaft Wave washer Wave washer E4 WAVE WASHER INSTALLATIdN Install the wave washer in correct direction as shown I 3EN0081 eF CAMSHAFT OIL SEAL INSTALLATION 1 TSB Revision ...

Page 101: ...eC4 4 Retainer lock 5 Valve spring retainer I B4 6 Valve spring 7 Intake valve IBI I CC 8 Retainer lock 9 Valve spring retainer I B4 10 Valve spring 11 Exhaust valve IQ I A4 12 Valve stem seal 13 Valve spring seat OCrJ I A4 14 Valve stem seal 15 Valve spring seat 16 Intake valve guide 17 Exhaust valve guide 18 Intake valve seat 19 Exhaust valve seat 20 Cylinder head 3EN0196 TSB Revision ...

Page 102: ...r No and location to aid reassembly I VALVE STEM SEAL REMOVAL 1 Do not reuse removed valve stem seals INSPECTION CYLINDER HEAD L 1 1 Check the cylinder head gasket su iface for flatness by using a straightedge and thickness gauge Standard value 0 05 mm 0020 In Limit 0 2 mm 008 in 2 If the service limit is exceeded correct to meet the specification Grinding limit 0 2 mm 008 in Total resurfacing dep...

Page 103: ...ue 49 2 mm 1 937 in Limit 48 2 mm 1 898 in 2 Measure the squareness of the spring and if the limit is exceeded replace Standard value 2 or less Limit 4 VALVE GUIDE 1 Measure the clearance between the valve guide and valve stem If the limit is exceeded replace the valve guide or valve or both Standard value Intake 0 03 0 06 mm 0012 0024 in Exhaust 0 05 0 09 mm 0020 0035 in Limit Intake 0 10 mm 0039...

Page 104: ...EMENT PROCEDURE 1 Push out the valve guide toward the combustion chamber side using a press 2 Rebore the valve guide hole of the cylinder head to the size corresponding to the oversize valve guide to be installed Caution Do not install a valve guide of the same size again Seat hole diameter See Servic Specifications in page 11 B 6 3 Install the valve guide until it projects 14 mm 55 in as illustra...

Page 105: ...to be in contact with and damage the stem seal D4 CYLINDER HEAD GASKET INSTALLATION 1 Clean both gasket surfaces of cylinder block and cylinder head 2 Do not apply sealant 3 Confirm the identification mark on cylinder head gasket The identification mark is stamped on the top surface of the gasket at its front end I E4 CYLINDER HEAD BOLT INSTALLATION 1 Using the special tool and a torque wrench tig...

Page 106: ...11 B 44 4G3 ENGINE Cylinder Head and Valves 3EN018E TSB Revision ...

Page 107: ... n3t l Y Y v r 9 Oil screen 10 Oil screen gasket 11 Oil pump cover 12 Oil pump oil seal _ 3 Oil pump cover gasket 4 Flange bolt 5 Oil pump driven gear 6 Oil pump drive gear 7 Plug 8 Relief spring 9 Relief plunger 0 Front case 1 1 I 16 ft lbs 7Nm 5 ft lbs 40 Nm 29 ftlbs 21 Front case gasket Cl4 22 Silent shaft oil seal C4 2 3 Crankshaft oil seal 24 Silent shaft right 25 Silent shaft left II eB4 26 ...

Page 108: ...hank diameter 8 mm 32 in into the plug hole on the left side of the cylinder block to block the silent shaft 0 FRONT CASE REMOVAL 1 The front case may be sticking to the cylinder block In such a case insert a screwdriver into the slot shown in the illustration and pry up Never attempt to pry at any other positions where flange is thinner Also avoid applying impact to the front case for removal 1 c...

Page 109: ... each gear Standard value 0 08 0 14 mm 0031 0055 in Drive gear 0 06 0 12 mm 0024 0047 in Driven gear 2 Check for ridge wear on the surface of the oil pump cover that is in contact with the pump gear side INSTALLATION SERVICE POINTS A4 SILENT SHAFT REAR BEARING INSTALLATION 1 Apply engine oil to the rear bearing outer circumference and bearing hole in the cylinder block 2 Using the special tool and...

Page 110: ... the special tool install the crankshaft oil seal into the front case I D4 SILENT SHAFT OIL SEAL INSTALLATION 1 Using a socket wrench press in the silent shaft oil seal into the front case nt case 3EN019 Eg FRONT CASE INSTALLATION 1 I Set the special tool on the front end of the crankshaft and apply engine oil to the outer circumference of the special tool 3EN0172 2 Install the front case TSB Revi...

Page 111: ...screwdriver shank diameter 8 mm 32 in into the plug hole on the left side of cylinder block to block the silent shaft then tighten the flange bolt I H OIL PUMP COVER GASKET INSTALLATION 1 Install a new oil pump cover gasket in the groove of the front case When installing the gasket direct the round side to the oil oumo cover 3EN0200 Flat iron plate I4 OIL PUMP OIL SEAL INSTALLATION 1 Install the o...

Page 112: ...i tpNT APPLICATION TO OIL PRESSURE GAUGE 1 Coat the threads of the oil pressure gauge unit with sealant and install the unit using the special tool Specified sealant 3M ATD Part No 8666 or equivalent Caution 1 Keep the end of threaded portion clear of sealant 2 Avoid an overtightening I L4 SEALANT APPLICATION TO OIL PRESSURE SWITCH 1 Coat the threads of the oil pressure switch with sealant and ins...

Page 113: ...an I M4 OIL FILTER INSTALLATION 1 Clean the installation surface of the filter bracket side 2 Apply engine oil to the 0 ririg of ihe bil filter 3 Screw the oil filter on until the O ring contacts the base Then tighten one turn TSB Revision 1 ...

Page 114: ...lON 6 7 8 Removal steps 1 Nut c Ar I E4 2 Connecting rod cap 3 Connecting rod bearing II4 4 Piston and connecting rod Cg 5 Connecting rod bearing 6 eC4 Piston ring No 1 7 Piston ring No 2 BC 8 Oil ring c Brj A4 9 Piston pin 10 Piston 11 Connecting rod 12 Connecting rod bolt TSB Revision 3EN0155 ...

Page 115: ...essing operations 3 Place the insert into the anvil opening 4 Place the piston and connecting rod on the anvil with the arrow mark or identification mark facing upward At this time push the lip of the insert in between the connecting rod boss and the inside surface of piston The connecting rod boss should bear on the insert surface as much as possible 5 Adjust the connecting rod rear support until...

Page 116: ...e cylinder bore Force it down with a piston the piston crown bei in contact with the ring to correctly position it at right gles to the cylinder wall Then measure the end gap witti a thickness gauge If the end gap is excessive replace ihe piston ring Standard value No 1 0 30 No 2 0 20 0 35 mm Oil 0 20 0 70 m Limit 7 0 8 mm 031 in 1 0 mm 039 in No 1 Np 2 Oil CRANKSHAFT PIN OIL CLEARANCE PLASTIC GAU...

Page 117: ... and align them Lubricate pin and insert it into the piston 6 Attach the piston pin pusher to the piston pin and push the pin through the connecting rod until the pin protrudes same distance measured and recorded above in step 4 NOTE The piston must be free to float during installation check frequently 7 Apply hydraulic pressure to the pin and adjust the stop plug until it comes in contact with th...

Page 118: ... difference in shape between No 1 and No 2 piston ring 2 Install piston rings No 1 and No 2 with the side having marks facing up on the piston lcrown side I D4 PISTON AND CONNECTING ROD ASSEMBLY INSTALLATION Ii 1 Apply engine oil on the circumference of the piston piston ring and oil ring 2 Arrange the piston ring and oil rini gaps side rail and spacer as shown in the figure 1 3 Rotate the cranksh...

Page 119: ...isassembly ins 4 the bearing cap to the connecting r od If the con c is new with no index mark make sure that the bearing locking notches come on the same side as shown 2 Make sure that connecting rod big end side clearance meets the specification Standard value 0 10 0 25 mm 0039 0098 in Limit 0 4 mm I 016 in TSB Revision ...

Page 120: ...5 Nm 98 ft lbs b 6 Removal steps 1 Flywheel bolt 2 Flywheel For MIT 3 Drive plate bolt 4 Adaptor plate 5 Drive plate For AIT 6 Crankshaft bushinn 7 Rear plate 8 Bell housing cover 9 Oil seal case 10 Gasket C4 11 Oil seal 12 Bearing cap bolt eB4 13 Bearing cap A4 14 Crankshaft bearing lower 15 Crankshaft A4 16 Crankshaft bearing upper 17 Cylinder block 3EN0036 TSB Revision 1 ...

Page 121: ... feeler gauge check the block top surface for warpage Make sure that the surface is free from gasket chips and other foreign matters Standard value 0 05 mm 0020 in Limit 0 1 mm 0039 in 2 If the distortion is excessive correct within the allowable limit or replace Grinding limit 0 2 mm 0079 in The total resurfacing depth of both cylinder block and mating cylinder head is 0 2 mm 0079 in at maximum C...

Page 122: ...margin 4 Bore all cylinders to the calculated boiing finish dimension Caution To prevent distortion that may res It from temperature rise during honing bore cylinders x1 the order of No 2 No 4 No 1 and No 3 5 Hone to final finish dimension pisGn 0 D clearance between piston O D and cylinder 6 Check the clearance between pisto r and cylinder Clearance between piston and cdinder 0 01 0 03 mm 0004 00...

Page 123: ...ING CAP INSTALLATION 1 Install according to the front mark and cap No i 2 After installing the bearing caps make sure that the crankshaft turns smoothly and the end play is correct If the end play exceeds the limit replace the crankshaft bearings Standard value 0 05 0 18 mm 0020 0071 in Limit 0 3 mm 012 in 4 OIL SEAL INSTALLATION TSB Revision ...

Page 124: ...et BRACKET REMOVAL AND INSTALLATION 65 Nm 47 ftlbs 1 Exhaust pipe support bracket 2 Engine support bracket right 3 Roll stopper bracket front 4 Roll stopper bracket rear 65 Nm 47 ft lbs TSB Revision 120 Nm 67 ft lbs 3EN0240 ...

Page 125: ...FRONT CASE SILENT SHAFT AND OIL PAN 85 FUEL AND EMISSION CONTROL PARTS 46 GENERAL INFORMATION 2 GENERAL SPECIFICATIONS 8 GENERATOR AND IGNITION SYSTEM SOHC GENERATOR AND IGNITION SYSTEM DOHC 26 INTAKE MANIFOLD 56 PISTON AND CONNECTING ROD 95 ROCKER ARMS AND CAMSHAFT SOHC 66 SPECIAL TOOLS 20 SEALANT 19 SERVICE SPECIFICATIONS 10 THROTTLE BODY 50 TIMING BELT SOHC 28 TIMING BELT DOHC 36 TORQUE SPECIFI...

Page 126: ...IIC 2 466 ENGINE 1992 General Information GENERAL INFQRMATION I ENGINE SECTIONAL VIEW SOHC 6EN0313 TSB Revision I ...

Page 127: ...4G6 ENGINE 1992 General Information 6EN0314 TSB Revision I ...

Page 128: ...IIC 4 466 ENGINE 1992 General Information NGlNE SECTIONAL VIEW DOHC TSB Revision ...

Page 129: ...6EN0244 TSB Revision ...

Page 130: ...UBRICATION SYSTEM SOHC Rocker shaft Camshaft Oil pressure switch rankshaft 6LUOO39 ENGINE LUBRICATION SYSTEM DOHC Camshaft Oil cooler Oil cooler by pass valve Silent shaft I lressure switch Oil puml Crankshaft I1 t A Silent shaft TSB Revision 6LUOO55 I ...

Page 131: ...INE LUBRICATION SYSTEM DOHC TURBO Oil To Camshaft ee EIe Silent shaft From thermostat case n filter K Oil cooler I IJ To turbocharger water inlet pipe i I 41 Key Oil pressure sw h Oil pump k Silent shaft Crankshaft 7 6LUOW6 1 TSB Revision 1 ...

Page 132: ...tic 4 N210H Variable resistor type Contact type incorporated in idle speed control motor Type Number of cylinders Combustion chamber Total displacement cm3 cu in I Cylinder bore mm in Piston stroke mm in Compression ratio Valve timing camshaft identification mark Intake valve Open BTDC Close ABDC Exhaust valve Open BBDC Close ATDC Lubrication system Oil pump type Cooling system Water pump type EGR...

Page 133: ...ust valve Open BBDC Close ATDC Lubrication system 3il pump type Cooling system JVater pump type EG R system njector type and number njector identification mark Non turbo Turbo for GALANT ECLIPSE M T Turbo for ECLIPSE A T Throttle position sensor Closed throttle position switch piiEzGi In line OHV DOHC 4 Pentroof type 1 595 97 3 82 3 3 24 75 2 95 3 2 33 F 16 26 8 38 13 53 17 7 ressure feed full flo...

Page 134: ... block Overall height Oversize rework dimensions of valve guide hole both intake and exhaust 0 05 002 0 25 OlO 0 50 020 Oversize rework dimensions of intake valve seat ring hole 0 30 i 012 0 60 024 Oversize rework dimensions of exhaust valve seat ring hole 0 30 l 012 0 60 024 Standard Limit 0 05 0020 0 2 008 0 2 008 _I 89 9 90 1 3 539 3 547 I I 13 05 13 07 5138 5146 13 25 13 27 5217 5224 i 13 50 1...

Page 135: ... mark is stamped In the rear end of the camshaft lournal diameter Xl clearance locker arm SOHC D sacker arm to shaft clearance ash adjuster eak down test Remarks Diesel fuel at 15 20 C 59 68 F Standard 42 40 1 6693 42 40 1 6693 44 53 1 7531 44 53 1 7531 38 1 50 33 94 33 95 1 3362 1 3366 0 05 0 09 0020 0035 35 49 1 3972 35 20 1 3858 35 20 1 3858 35 49 1 3972 35 91 1 3744 25 95 25 97 1 0217 1 0224 0...

Page 136: ...ter Intake 6 57 6 58 2587 2591 Exhaust 6 53 6 55 2571 2579 Face angle 45 45 30 Thickness of valve head margin Intake 1 o 039 0 7 02 Exhaust 1 5 059 1 o l 039 Stem to guide clearance Intake 0 02 0 05 OOO 0020 0 10 004 Exhaust 0 05 0 09 0020 0035 0 15 006 Valve spring SOHC Free height 49 8 1 961 48 8 1 921 w nstalled I N mm Ibs in 329 40 4 73 I 591 Out of squareness 2 or less Max 4 Valve spring DOHC...

Page 137: ... 6520 1 6528 40 95 40 97 1 6122 1 6130 18 47 18 48 7272 0 7276 40 95 40 97 1 6122 1 6130 0 03 0 06 LOO1 2 0024 0 05 0 09 0020 0036 0 02 0 05 OOO 0020 0 05 0 09 0020 0036 iston SOHC I D 4663 4G64 Won to cylinder clearance service size 84 97 85 00 3 3453 3 3465 86 47 86 50 3 404 3 4055 0 02 0 04 0008 0016 0 25 LOlO 0 50 020 0 75 030 1 OO f 039 over size Won DOHC I D 4G61 4663 Non turbo 4G63 Turbo is...

Page 138: ...60 f 0177 0236 0 20 0 70 LOO79 0276 0 03 0 07 0012 0028 0 03 0 07 LOO1 2 0028 0 25 LOlO 0 50 020 0 75 030 1 OO 039 over size 0 8 031 0 8 031 0 8 031 1 o f 039 0 1 004 0 1 004 Piston pin 3 D Press in load N Ibs press in temperature Connecting rod 3ig end center to small end center length 3end rwist 3ig end side clearance Crankshaft fnd play Journal O D in O D ht of roundness and taper of journal an...

Page 139: ...0 82 33 3 2402 3 2413 85 00 85 03 3 3465 3 3476 86 50 86 53 3 4055 3 4067 0 05 0020 274 9 275 1 10 823 10 831 283 9 284 1 11 177 11 185 289 9 290 1 11 413 11 421 0 08 0 14 0031 0055 0 06 0 12 0024 0047 7 5 9 0 30 35 8 0 32 7 0 10 0 28 39 500 700 11 O 154 400 88 34 5 1 358 normal temperature 40 1 57 or more _ mm ir Limit 0 1 004 0 2 008 ejector Ioil resistance Non turbo Q T u r b o R Jle speed cont...

Page 140: ...oil bolt Ignition power transistor bolt Crankshaft position sensor nut Timing belt SOHC Tensioner bolt Tensioner spacer Oil sprocket nut pump Crankshaft sprocket bolt Tensioner B bolt Silent shaft sprocket bolt right Engine supports bracket bolt left Camshaft sprocket bolt riming belt D O H C Tensioner pulley bolt Tensioner arm bolt Idler pulley bolt 3il pump sprocket nut Crankshaft sprocket bolt ...

Page 141: ...e gauge unit Engine coolant temperature sensor Thermostat case nut Exhaust manifold and water pump Oil level guide bolt gauge Heat protector bolt GALANT AND EXPO TRUCK Exhaust manifold nut SOHC Exhaust manifold nut DOHC Engine hanger bolt DOHC Air outlet fitting bolt Turbocharger bolt and nut Exhaust fitting bolt Water inlet pipe bolt Water bolt pump Water pipe A and B eye bolt Water pipe A bolt W...

Page 142: ...mp Plug Silent shaft left flange bolt Oil filter bracket bolt Front case bolt M8 Ml0 Oil cooler by pass valve Oil switch pressure Oil unit pressure gauge Relief plug Oil cover bolt pump Check valve Piston and connecting rod Connecting rod cap nut Crankshaft flywheel and drive plate wheel bolt Irive plate bolt 3il seal case bolt 3earing cap bolt SOHC 3earing cap bolt DOHC Nm ftlbs r 12 9 6 4 24 17 ...

Page 143: ...g Oil pan gasket Engine coolant temperature gauge unit Engine coolant temperature sensor Oil pressure switch Oil pressure gauge unit Specified sealant Quantity 3M ATD Part No 8660 or equivalent As required 3M ATD Part No 8660 or equivalent As required MITSUBISHI GENUINE PART As required MD970389 or equivalent 3M ATD Part No 8660 or equivalent As required 3M Nut Locking Part No 4171 As required or ...

Page 144: ...Use with MIT304204 c Q Q MD998374 M D998374 0 1 Bearing installer stopper MD998375 MD998375 01 Crankshaft front oil seal installer MD998376 MD998376 01 Crankshaft rear Use with oil seal installer MB990938 01 Application Holding camshaft spr ket when loosening or torquing bolt For SOHC engine only Loosening or torquing of cylinder head bolt Removal and installation of front case cap plug Installati...

Page 145: ... MD99871 9 Pulley holding pins 2 M IT308239 Holding camshaft sprocket when loosening or torquing bolt For SOHC engine only MD998727 Oil pan remover Removal of oil pan MD998729 MD998729 01 Installation of valve stem seal Valve stem seal For SOHC engine only installer TSB Revision ...

Page 146: ...E 1992 Special Tools M D998779 Sprocket stopper Holding silent shaft sprocket MD998780 Piston pin setting tool M IT2 16941 Removal and installation of piston pin MD998781 Flywheel stopper Holding flywheel TSB Revision ...

Page 147: ...a RWD 9 Nm 7 ftlbs Removal steps 11 Nm 8 ft lbs B4 1 Drive belt 2 Cooling fan 3 Fan clutch 4 Water pump pulley 5 Water pump pulley 6 Generator brace 7 Generator 8 Crankshaft pulley 9 Spark plug cable 10 Spark plug 11 High tension cable NOTE A4 12 Distributor Engine with power steering 13 Ignition coil Engine with cooling fan 14 Ignition power transistor Engine without cooling fan 6EN0631 TSB Revis...

Page 148: ...in the spring pin so that the slit is at a right angle relative to the shaft 64 DRIVE BELT TENSION ADJUSTMENT ADJUSTER TYPE 1 Adjust the belt deflection to the standard value Turn the adjusting bolt clockwise to increase the belt tension and turn the adjusting bolt counterclockwise to decrease the belt tension Standard value V ribbed type belt New belt 7 5 9 0 mm 30 35 in Used belt 8 0 mm 32 in V ...

Page 149: ...t deflection to the standard value Standard value V ribbed type belt New belt 7 5 9 0 mm 30 35 in Used belt 8 0 mm 32 in V type belt 7 0 10 0 mm 28 39 in When using a tension gauge for V ribbed belt only Standard value New belt 500 700 N 110 154 Ibs Used belt 400 N 88 Ibs 2 Tighten the brace bolt to the specified torque 3 Tighten the nut for the pivot bolt to the specified torque TSB Revision ...

Page 150: ...23 Nm I 14 Nm 10 ft lbs 24 Nm I 17 ftlbs 24 Nm 17 ftlbs Removal steps eB4 1 Drive belt 2 Water pump pulley 3 Water pump pulley For driving power steering pump 4 Generator brace 5 Generator 6 Crankshaft pulley 7 Center cover 8 Spark plug cable 9 Spark plug 10 Ignition coil 11 Ignition power transistor A4 12 Crankshaft position sensor 13 O ring 11 TSB Revision I ...

Page 151: ...he crankshaft so that the No 1 cylinder is at top dead center 2 Align the punch mark on the crankshaft position sensor housing with the notch in the plate 3 Install the crankshaft position sensor on the cylinder head eB4 DRIVE BELT TENSION ADJUSTMENT Refer to I B4 DRIVE BELT TENSION ADJUSTMENT on page 11 C 24 1 TSB Revision I I I ...

Page 152: ...r IAI eH4 3 Timing belt Gg 4 Tensioner spring Gg 5 Tensioner QBg eF4 6 Oil pump sprocket 81 E4 7 Crankshaft bolt 8 Crankshaft sprocket 9 Flange 10 Tensioner B c ErJ eD4 11 Timing belt B IFI C4 12 Silent shaft sprocket right B4 13 Spacer 0 14 Crankshaft sprocket B 15 Engine support bracket left IHI A4 16 Camshaft sprocket bolt 17 Camshaft sprocket 18 Timing belt rear cover 6EN0633 TSB Revision ...

Page 153: ...t a Phillips screwdriver shank diameter 8 mm 31 in to block the left silent shaft 3 Remove the nut 4 Remove the oil pump sprocket CRANKSHAFT BOLT REMOVAL 1 Using the special tool hold the drive plate or flywheel 2 Remove the crankshaft bolt I CRANKSHAFT SPROCKET REMOVAL QEo TIMING BELT B REMOVAL 1 Make a mark on the back of the timing belt indicating the direction of rotation so that it may be rea...

Page 154: ...L aHo CAMSHAFT SPROCKET BOLT REMOVAL INSPECTION TIMING BELT Replace belt if any of the following conditions exist 1 Hardening of back rubber the back side is glossy without resilience and leaves no indent when pressed with finger nail 2 Cracks on rubber back 3 Cracks or peeling of canvas 4 Cracks on rib root 5 Cracks on belt sides 1 TSB Revision ...

Page 155: ...ilkt Chamfer shaft b 6EN061 E 6 Abnormal wear of belt sides The sides are normal if they are sharp as if cut by a knife 7 Abnormal wear on teeth 8 Missing tooth INSTALLATION SERVICE POINTS I A4 CAMSHAFT SPROCKET BOLT INSTALLATION I B4 SPACER INSTALLATION 1 Install the spacer with the chamfered end toward the oil seal I c4 SILENT SHAFT SPROCKET INSTALLATION 1 TSB Revision I ...

Page 156: ...ation 4 Move the tensioner B in the direction of arrow while lifting with a finger to give a sufficient tension to the tension side of timing belt In this condition tighten the bolt to secure tensioner B When the bolt is tightened use care to prevent shaft from turning together If the shaft is turned together the belt will be over tensioned 5 Check to ensure that the timing marks on the sprockets ...

Page 157: ...gine oil to the bearing surface of the nut 4 Tighten the nut to the specified torque I G4 TENSIONER INSTALLATION 1 Hook the tensioner spring ends to the water pump body projection and tensioner bracket 2 Move the tensioner fully toward the water pump and tighten the bolt and tensioner spacer I H4 TIMING BELT INSTALLATION 1 Align the timing marks on camshaft sprocket and crank shaft sprocket with t...

Page 158: ...lign the timing marks Then check to ensure that the screwdriver can be inserted 60 mm 2 4 in or more Keep the screwdriver inserted until installation of the timing belt is finished 4 Install the timing belt on the crankshaft sprocket oil pump sprocket and camshaft sprocket in that order There should be no slack on the tension side 5 Loosen the tensioner mounting bolt and tensioner spacer 6 Turn th...

Page 159: ...ensioner turns as the tensioner spacer is tightened resulting in an excessive belt tension 9 Hold the center of the tension side span of the timing belt between the camshaft and oil pump sprockets between your thumb and index finger as shown Then make sure that the clearance between the belt back surface and cover is standard value Standard value 14 mm 55 in TSB Revision ...

Page 160: ...sioner arm I4 6 Auto tensioner 7 Idler pulley Brj H4 8 Oil pump sprocket I eG4 9 Crankshaft sprocket bolt 10 Crankshaft sprocket 11 Flange 12 Spacer 13 Tensioner B OEo eF4 14 Timing belt B IFO eE4 15 Silent shaft sprocket D4 16 Spacer 4GO 17 Crankshaft sprocket B I C4 18 Rocker cover B4 19 Semi circular packing IHO A4 20 Camshaft sprocket bolt 21 Camshaft sprocket 22 Engine support bracket 23 Timi...

Page 161: ... from oil and water These parts should not be washed Replace parts if seriously contaminated 2 If there is oil or water on each part check the front case oil seals camshaft oil seal and water pump for leaks OBo OIL PUMP SPROCKET REMOVAL ENGINE WITH SILENT SHAFTS Refer to o OIL PUMP SPROCKET REMOVAL on page 11 c 29 of CRANKSHAFT BOLT REMOVAL 1 Using the special tool hold the drive plate or flywheel...

Page 162: ...AFT SPROCKET REMOVAL 1 Using a wrench hold the camshaft at its hexagon between the No 2 and No 3 journals and remove the camshaft sprocket bolt Caution Locking the camshaft sprocket with a tool damages the sprocket 2 Remove the camshaft sprockets INSPECTION TIMING BELTS Refer to INSPECTION on page 1 IC 29 TSB Revision ...

Page 163: ... jaws Caution The plug protrudes at the bottom of the auto tensioner Insert a plain washer as illustrated to prevent the plug from being in direct contact with the vise 5 Turning the vise handle push in the auto tensioner rod If the rod can be easily retracted replace the auto tensioner You should feel a fair amount of resistance when pushing the rod in INSTALLATION SERVICE POINTS A4 CAMSHAFT SPRO...

Page 164: ...ATION ON SEMI CIRCULAR PACKING Specified sealant 3M ATD Part No 8660 or equivalent ec4 SEALANT APPLICATION ON ROCKER COVER Apply sealant to the areas indicated in the illustration Specified sealant 3M ATD Part No 8660 or equivalent I IOmm f 39 in Apply sealant Apply sealant BEN0396 1 TSB Revision ...

Page 165: ...NSTALLATION ENGINE WITH SILENT SHAFTS Refer to Page 11 C 32 Note that the timing mark locations differ from those on the single camshaft engine I G CRANKSHAFT BOLT INSTALLATION 1 Using the special tool hold the drive plate or flywheel 2 Install the crankshaft bolt H4 OIL PUMP SPROCKET INSTALLATION ENGINE WITH SILENT SHAFTS Refer to I F4 OIL PUMP SPROCKET INSTALLATION on page 11 C 33 1 TSB Revision...

Page 166: ...ug from being in direct contact with the vise 3 Push in the rod little by little with the vise until the set hole in the rod is aligned with the hole I in the cylinder 4 Insert a wire I 4 mm 055 in in diameter into the set holes 5 Unclamp the auto tensioner from the vise 6 Install the auto tensioner to front case and tighten to the specified torque Caution Leave the wire installed in the auto tens...

Page 167: ...mshaft use the timing mark on the right with the dowel pin hole on top For the intake camshaft sprocket use the one on the left with the dowel pin hole on top 2 Align the crankshaft sprocket timing marks 3 Align the oil pump sprocket timing marks Engine with silent shafts 4 Insert a Phillips screwdriver shank diameter 8 mm 31 in through the plug hole Engine with silent shafts If it can be inserted...

Page 168: ...a clip 8 Thread the timing belt over the idler pulley the oil pump sprocket the crankshaft sprocket and the tensioner pulley in the order shown 9 Remove the two clips 1O Lift up the tensioner pulley in the direction of arrow and tighten the center bolt IlKheck to see that all timing marks are lined up 12 Remove the screwdriver inserted in step 4 and fit the plug Engine with silent shafts 13 Give t...

Page 169: ...t lbs with the torque wrench 16 Holding the tensioner pulley with the special tool and torque wrench tighten the center bolt to the specification 17 After giving two clockwise turns to the crankshaft let it alone for approx 15 minutes Then make sure that the auto tensioner setting wire moves freely NOTE If the wire does not move freely repeat step 13 above until it moves freely 18 Remove the auto ...

Page 170: ... GALANT EXPO P 12 Nm 9 ft lbs I 4 7 9Nm 7 ft lbs P6 12 Nm 9 ftlbs 19 Nm 14 klbs Removal steps I Throttle body 2 Throttle body gasket 3 EGR valve 4 EGR valve gasket 5 Injectors and fuel rail 6 Insulator 7 Fuel pressure regulator B4 8 O ring 9 Insulator A4 IO Injectors 11 O ring 12 Grommet 13 Fuel rail 6EN0518 TSB Revision ...

Page 171: ...CK I 12 Nm 9 ft lbs 5 12 Nm 9 ft lbs 9Nm 7 ft lbs 19Nm 14 ft lbs Removal steps 1 Throttle body 2 Throttle body gasket 3 EGR valve 4 EGR valve gasket 5 Injectors and fuel rail 6 Insulator 7 Fuel pressure regulator B4 8 O ring 9 Insulator AC 10 injectors 11 O ring 12 Grommet 13 Fuel rail 6EN0534 ...

Page 172: ...bs 8 19 Nm 14 ftlbs 19Nm 14 ft lbs Removal steps 1 Throttle body stay 2 Throttle body 3 Throttle body gasket 4 EGR valve 5 EGR valve gasket 6 Injectors and fuel rail 7 Insulator 8 Fuel pressure regulator B4 9 O ring 10 Insulator A4 II Injectors 12 O ring 13 Grommet 14 Fuel rail 6EN0519 TSB Revision ...

Page 173: ...cuum 1 Using an ohmmeter circuit tester test for continuity between terminals of injector the circuit should be closed If failure is detected replace the injector Standard value Non turbo 13 16 IR at 20 C 68 F l Turbo 2 3 R at 20 C 68 F INSTALLATION SERVICE POINTS I A4 INJECTOR INSTALLATION 1 Before installing an injector the rubber O ring must be lubricated with a drop of clean engine oil to aid ...

Page 174: ...e bracket 8 A4 2 Throttle position sensor 3 Idle air control motor 4 Throttle valve set screw OBO 5 Throttle body 1 4 ft lbs 6FU1657 SOHC for GALANT TRUCK 2Nm 1 4 ft lbs Disassembly steps A4 1 Throttle position sensor 2 Idle speed control motor 3 Throttle valve set screw 30 4 Throttle body 3 5 Nm 2 5 ft lbs 6FU1292 TSB Revision ...

Page 175: ...tle Body IIC 51 DOHC 2Nm 1 4ft lbs 5 Disassembly steps IAI AC I Throttle position sensor OAO 2 Idle air control motor stepper motor 3 Closed throttle position switch 4 Adjusting nut PO 5 Throttle body 6FU1427 1 TSB Revision ...

Page 176: ...motor 2 Do not immerse the sensor and motor in cleaning solvent Clean them with shop towel BI THROTTLE BODY REMOVAL 1 Do not remove the throttle valve 2 Check if the vacuum port or passage is clogged Use compressed air to clean the vacuum passage Operational Check 1 Connect Test Harness to the idle air control motor connector 2 Connect the positive 0 terminal of 6 volt battery to white clip and gr...

Page 177: ...of the power supply to the red and black clip Repeat the tests in sequence from to 0 4 If as a result of these tests vibration is detected the stepper motor can be considered to be normal IDLE SPEED CONTROL MOTOR POSITION SENSOR SOHC for GALANT and TRUCK 1 Measure the resistance between terminals and Standard value 4 6 kQ 2 Disconnect the idle speed control motor connector 3 Connect DC 6V between ...

Page 178: ... the resistance changes smoothly when the throttle valve is slowly moved to the fully open position 4 Check for continuity between terminals closed throttle position switch and ground with the throttle valve both fully closed and fully open I Throttle valve position I Continuity 1 I Fully closed I Conductive I Fully oDen I Non conductive I If there is no continuity with the throttle valve fully cl...

Page 179: ...t 7FUO535 I 2 Turn the throttle position sensor 90 clockwise to set it and tighten the screws 3 Connect a circuit tester between ground and output or between output and power Then make sure that the resistance changes smoothly when the throttle valve is slowly moved to the fully open position TSB Revision ...

Page 180: ... Nm 22 ft lbs 11 2iNm 16 ft lbs Removal steps 1 Water hose 2 Water hose efl4 3 Engine coolant temperature gauge unit Cg 4 Engine coolant temperature sensor 5 Water outlet fitting eB4 6 Gasket 7 Thermostat 8 Intake manifold plenum stay 9 Intake manifold plenum 10 Intake manifold plenum gasket 11 Intake manifold stay 12 Engine hanger 13 Intake manifold 14 Intake manifold gasket 6lN0109 TSB Revision ...

Page 181: ...tlbs Removal steps 1 Water hose 2 Water hose 3 Water hose turbo 4 Water hose turbo DC 5 Engine coolant temperature gauge unit Q 6 Engine coolant temperature sensor fl4 7 Water outlet fitting 8 Gasket 9 Thermostat 10 Thermostat case 11 Gasket 12 Intake manifold stay A4 13 Intake manifold 14 Intake manifold gasket 6ENO460 TSB Revision ...

Page 182: ...ed to a different torque eB4 WATER OUTLET FITTING GASKET INSTALLATION FOR RUBBER COATED METAL GASKET ONLY 1 Install the water outlet fitting gasket with its UP mark facing up toward the water outlet fitting side ec4 SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE SENSOR Specified sealant 3M Nut Locking Part No 4171 or equivalent eD4 SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE GAUGE UNIT Sp...

Page 183: ...10 ftlbs 18 Nm 13 ft lbs 24Nm Removal steps 17 ft lbs 1 Oil level gauge 2 Oil level gauge guide 3 O ring 4 Heat protector 5 Engine hanger 6 Exhaust manifold 7 Exhaust manifold gasket A4 8 Water inlet pipe A4 9 O ring 10 Water pump 11 Water pump gasket NOTE GALANT and EXPO TRUCK 14 Nm 10 ft lbs 6EN0647 1 TSB Revision ...

Page 184: ...4 Nm 10 ft lbs 10 ft lbs 4 60 Nm 43 ftlbs 14 Nm 10 ft lbs 4 24 Nm 17 ft lbs Removal steps 1 Oil level gauge 2 Oil level gauge guide 3 O ring 4 Heat protector A 5 Heat protector B 6 Engine hanger 7 Exhaust manifold 8 Exhaust manifold gasket A4 9 Water inlet pipe A4 10 O ring 11 Water pump 12 Gasket 6EN0646 TSB Revision ...

Page 185: ...ing 4 Heat protector A 5 Heat protector B 6 Exhaust fitting 7 Gasket 8 Air outlet fitting 9 Gasket I 0 Water pipe B 11 Oil return pipe 12 Gasket 13 Turbocharger assembly 14 Gasket 24 Nm 17 ft lbs 15 Ring 16 Oil pipe 17 Water pipe A 18 Turbocharger 19 Engine hanger 20 Exhaust manifold 21 Exhaust manifold gasket 22 Water pipe 23 Water hose 24 Water hose A4 25 Water inlet pipe A4 26 O ring 27 Water p...

Page 186: ... Exhaust Manifold and Water Pump O ring _jlr 6EN059 INSTALLATION SERVICE POINT I A4 WATER PIPE O RING INSTALLATION 1 Wet the O ring with water to facilitate assembly Caution Keep the O ring free of oil or grease TSB Revision ...

Page 187: ... REASSEMBLY Disassembly steps W4 inspection of turbocharger waste gate actuator operation 1 Snap pin 2 Turbocharger waste gate actuator E4 3 Coupling DC 4 Turbine housing C4 5 Snap ring eB4 6 Turbine wheel assembly 7 Compressor cover A4 8 O ring 6lNOO52 TSB Revision ...

Page 188: ...rosion and traces of contact on the back side and replace if defective 2 Check the oil passage of the turbine wheel assembly for deposit and clogging 3 In the case of water cooled type check also the water passage for deposit and clogging 4 Check the turbine wheel and compressor wheel for light and smooth turning REASSEMBLY SERVICE POINTS A4 O RING INSTALLATION 1 Apply a light coat of engine oil t...

Page 189: ...s of the turbine wheel I E4 COUPLING INSTALLATION 1 Install the coupling and tighten it to the specified torque eF4 WASTE GATE ACTUATOR OPERATION CHECK 1 Using a tester apply a pressure of approx 72 kPa 10 3 psi to the actuator and make sure that the rod moves Caution Do not apply a pressure of more than 85 kPa 12 4 psi to the actuator Otherwise the diaphragm may be damaged Never attempt to adjust...

Page 190: ...s and rocker shafts 9 Rear bearing cap eC4 10 Rocker arm D v 11 Spring EC 12 Rocker arm D Dir 13 Bearing cap No 4 34 14 Rocker arm C C4 15 Rocker arm C _ rq I Beanng cap No 3 I 4 18 Rocker arm D C4 20 Rocker arm D 04 21 Bearing cap No 2 C4 22 Rocker arm C eC4 23 Rocker arm C 24 Spring B4 25 Wave washer A4 26 Right rocker shafts A4 27 Left rocker shafts 28 Front bearing cap IAO E4 29 Lash adjuster ...

Page 191: ...st 44 53 1 7531 44 03 I 7335 NOTE The camshaft identification mark is stamped on the opposite end of the camshaft sprocket side ROCKER ARM 1 Check the roller surface If any dent damage or seizure is evident replace the rocker arm 2 Check rotation of the roller If it does not rotate smoothly or if looseness is evident replace the rocker arm 3 Check the inside diameter If damage or seizure is eviden...

Page 192: ...again If the plunger is still loose replace the lash adjuster Caution Upon completion of air bleeding hold the lash adjuster upright to prevent inside diesel fuel from spilling 4 After air bleeding set the lash adjuster on the special tool Leak down tester MD998440 5 After the plunger has gone down somewhat 2 5 mm measure time taken for it to go down 1 mm Replace if the measured time is out of the...

Page 193: ...MSHAFT BEARING CAP IDENTIFICATION 1 No 3 bearing cap looks very similar to No 2 and No 4 bearing caps Use the identification marks shown at left for identification NOTE No 2 bearing cap is the same as No 4 bearing cap 2 Install the bearing caps with their front marks pointing to camshaft sprocket side I Eg LASH ADJUSTER INSTALLATION 1 Immerse the lash adjuster in clean diesel fuel 2 Using a small ...

Page 194: ...amshaft SOHC Apply sealant DEN0052 IOmm Semi circular packing Gasket r of cvlinder head 6EN042 I F4 CAMSHAFT OIL SEAL INSTALLATION I G4 SEMI CIRCULAR PACKING INSTALLATION Specified sealant 3M ATD Part No 8660 or equivalent TSB Revision ...

Page 195: ...LLATION 20 Nm 14 t t lbs 6 11 Nm 8 ftlbs Removal steps fiC4 1 Bearing cap rear Q 2 Bearing cap front 04 3 Camshaft oil seal C4 4 No 5 eC4 Bearing cap 5 Bearing cap No 2 eC4 6 No 4 eC4 Bearing cap 7 Bearing cap No 3 eB4 8 Camshaft 9 Rocker arm A4 10 Lash adjuster 11 Oil delivery body 6EN0524 TSB Revision ...

Page 196: ... Check rotation of the roller If it does not rotate smoothly or if looseness is evident replace the rocker arm 3 Check the inside diameter If damage or seizure is evident replace the rocker arm LASH ADJUSTER LEAK DOWN TEST Refer to LASH ADJUSTER LEAK DOWN TEST on pages 1 lC 67 and 11 C 68 Also note the following When the lash adjuster is set on a tester remove the adjusting screw of the tester and...

Page 197: ...of the crankshaft and turn the crankshaft until the timing marks are lined up setting No 1 cylinder to the TDC 4 Set the camshafts so that their dowel pins are positioned at top I c4 BEARING CAP INSTALLATION 1 According to the identification mark stamped on top of each bearing cap install the caps to the cylinder head Only L or R is stamped on No 1 bearing cap Cap No is stamped on No 2 to No 5 bea...

Page 198: ... Gasket I I C4 5 Retainer lock 6 Valve spring retainer 64 7 Valve spring 8 Intake valve QBr SC4 9 Retainer lock 10 Valve spring retainer I B 11 Valve spring 12 Exhaust valve A A4 13 Valve stem seal 14 Valve spring seat 10 A4 15 Valve stem seal 16 Valve spring seat 17 Intake valve guide 18 Exhaust valve guide 19 Intake valve seat 20 Exhaust valve seat 21 Cylinder head RI7 III184 v 6EN0309 TSB Revis...

Page 199: ...e exhaust OAo CYLINDER HEAD BOLT REMOVAL 1 Using the special tool loosen the cylinder head bolts Loosen evenly little by little tJB0 RETAINER LOCK REMOVAL 1 Using the special tool compress the spring 2 Remove the retainer locks Keep removed parts in order according to the cylinder number and intake exhaust a VALVE STEM SEAL REMOVAL 1 Do not reuse valve stem seal 1 TSB Revision ...

Page 200: ...ng a valve refacer The valve seat contact should be maintained uniform at the center of the valve face 2 If the margin exceeds the service limit replace the valve Standard value Intake 1 2 mm LO47 in Exhaust 2 0 mm 079 in Limit Intake 0 7 mm 028 in Exhaust 1 5 mm 059 in VALVE SPRING 1 Measure the free height of spring and the limit replace Identification color White Standard value 49 8 mm 1 961 Li...

Page 201: ...t ring hole diameter See Service Specifications on page IIC 10 3 Before fitting ttie valve seat either heat the cylinder head up to approximately 250 C 482 F or cool the valve seat in liquid nitrogen to prevent the cylinder head bore from galling 4 Using a valve seat cutter correct the valve seat to the specified width and angle See VALVE SEAT RECONDITIONING PROCEDURE VALVE GUIDE REPLACEMENT PROCE...

Page 202: ...ATION 1 Install the valve spring seat 2 Using the special tool install a new stem seal to the valve guide Caution Do not reuse the valve stem seal I VALVE SPRING INSTALlATlON I Direct the valve spring end with identification color end toward the spring retainer I c4 RETAINER LOCK INSTALLATION 1 Using the special tool compress the valve spring and insert the retainer lock into position TSB Revision...

Page 203: ... HEAD GASKET IDENTIFICATION Identification mark 4663 63 4664 64 Caution Do not apply sealant to cylinder head gasket I E4 CYLINDER HEAD BOLT INSTALLATION 1 Tighten the cylinder head bolts in the sequence shown Each bolt should be tightened in two to three steps torquing progressively Tighten to the specified torque in the final sequence TSB Revision ...

Page 204: ...ssembly D4 4 Gasket IBM Cc 5 Retainer lock 6 Valve spring retainer 7 Valve spring 8 Intake valve 9 Retainer lock 10 Valve spring retainer II Valve spring 12 Exhaust valve 13 Valve stem seal 14 Valve spring seat 15 Valve stem seal 6 Valve spring seat 17 Intake valve guide 18 Exhaust valve guide 19 Intake valve seat 20 Exhaust valve seat 21 Cylinder head 6EN0196 1 TSB Revision I ...

Page 205: ...y little by little OBo RETAINER LOCK REMOVAL 1 Using the special tool compress the spring 2 Remove the retainer locks Keep removed parts in order according to the cylinder number and intake exhaust 0 VALVE STEM SEAL REMOVAL 1 Do not reuse the stem seals INSPECTION 1 Only features differing from the single camshaft engine are described in the following Refer to Pages 1 lC 76 TSB Revision ...

Page 206: ...xhaust 1 0 mm 039 in VALVE SPRING Free height 48 3 mm 1 902 in Limit 47 4 mm I 866 in Squareness 1 5 or less Limit Max 4 VALVE GUIDE Valve guide to valve stem clearance Intake 0 02 0 05 mm OOOS 0020 in Exhaust 0 05 0 09 mm 0020 0035 in Limit Intake 0 10 mm 004 in Exhaust 0 15 mm 006 in VALVE SEAT RECONDITIONING PROCEDURE 1 Refer to Page 11 C 77 noting that the only difference is in the special too...

Page 207: ...UIDE REPLACEMENT PROCEDURE 1 Refer to Page 11 C 77 noting that there are differences in the diameter of the valve guide hole as well as in the guide s installed height Valve Guide Hole Diameter 0 05 mm 002 in O S 12 05 12 07 mm 4744 4752 in 0 25 mm OIO in O S 12 25 12 27 mm 4823 4831 in 0 50 mm 002 in O S 12 50 12 52 mm 4921 4929 in INSTALLATION SERVICE POINTS A4 VALVE STEM SEAL INSTALLATION 1 Ins...

Page 208: ... the valve spring and insert the retainer lock into position I D4 CYLINDER HEAD GASKET IDENTIFICATION Identification mark I6 4661 2 0 4663 Eg CYLINDER HEAD BOLT INSTALLATION 1 Tighten the cylinder head bolts in the sequence shown Each bolt should be tightened in two to three steps torquing progressively Tighten to the specified torque in the final sequence TSB Revision ...

Page 209: ...Flange nut 10 Oil pump sprocket IQ MCl 1 Plug 12 O ring IQ L I 13 Flange bolt 14 Oil filter bracket 15 Oil filter bracket gasket KC 16 Front case 17 Front case gasket NOTE 18 Silent shaft left DOHC 19 Silent shaft right Engine with silent shafts IEIJ I4 20 Silent shaft front bearing xxx Engine with turbocharger IFO I4 21 Silent shaft rear bearing left Engine without silent shafts IGO H4 22 Silent ...

Page 210: ...fts Engine with air cooling type oil cooler 1 Oil cooler by pass valve G4 2 Oil pressure switch eF4 3 Oil pressure gauge unit pm 6 Relief spring 7 Relief plunger 8 Oil filter bracket 9 Oil pump cover 10 Oil pump shaft 04 11 Oil pump driven gear I D4 12 Oil pump drive gear eC4 13 Crankshaft front oil seal Bg 14 Oil p u m p o l seal I A ig t shaft oil seal 17 Front case 18 Check valve 19 Oil jet 20 ...

Page 211: ...e will result in oil leakage IBI FLANGE NUT REMOVAL ENGINE WITH SILENT SHAFTS 1 Remove the plug on the side of the cylinder block 2 Insert a Phillips screwdriver shank diameter 8 mm 32 in into the plug hole to lock the silent shaft 3 Loosen the oil pump sprocket flange nut PLUG REMOVAL 1 If the plug is too tight hit the plug head with a hammer two to three times and the plug will be easily loosene...

Page 212: ...left silent shaft rear bearing from the cylinder block QGo REAR BEARING REMOVAL ENGINE WITH SILENT SHAFTS Using the special tool remove the right silent shaft rear bearing from the cylinder block INSPECTION FRONT CASE 1 Check oil holes for clogging and clean if necessary 2 Check left silent shaft front bearing section for wear damage and seizure If there is anything wrong with the section replace ...

Page 213: ... 0036 in Left 0 05 0 09 mm 0020 0036 in OIL PUMP 1 Assemble the oil pump gears in the front case and rotate them to ensure smooth rotation with no looseness 2 Ensure that there is no ridge wear on the gear contact surface of the front case and the oil pump cover 3 Check the side clearance Standard value Drive gear 0 08 0 14 mm 0031 0055 in Driven gear 0 06 0 12 mm 0024 0047 in OIL COOLER BYPASS VA...

Page 214: ...nstall the crankshaft front oil seal into the front case I D4 OIL PUMP DRIVEN GEAR OIL PUMP DRIVE GEAR INSTALLATION I Apply engine oil amply to the gears and line up the alignment marks E4 FLANGE NUT INSTALLATION ENGINE WITHOUT SILENT SHAFTS Caution Before installing the flange nut apply an appropriate amount of oil to the seating surface I Clamp the oil pump shaft end in a vise 2 Tighten the oil ...

Page 215: ... with sealant and install the switch using the special tool Specified sealant 3M ATD Part No 8660 or equivalent Caution 1 Keep the end of threaded portion clear of sealant 2 Avoid an overtightening I H4 RIGHT SILENT SHAFT REAR BEARING INSTALLA TION ENGINE WITH SILENT SHAFTS 1 Apply engine oil to the outer surface of the bearing 2 Using special tools install the right rear bearing Make sure that th...

Page 216: ... SHAFT FRONT BEARING INSTALLATION ENGINE WITH SILENT SHAFTS 1 Using the special tools install the front bearing I K4 FRONT CASE INSTALLATION 1 Set the special tool on the front end of the crankshaft and apply a thin coat of engine oil to the outer circumference of the special tool to install the front case 2 Install the front case assembly through a new front case gasket and temporarily tighten th...

Page 217: ... without silent shafts only I 14 FLANGE BOLT INSTALLATION ENGINE WITH SILENT SHAFTS 1 Insert a Phillips screwdriver into the hole on the left side of the cylinder block to lock the silent shaft 2 Secure the oil pump driven gear on the left silent shaft by tightening the flange bolt to the specified torque eM4 PLUG INSTALLATION 1 Install a new O ring in the groove of the front case 2 Using the spec...

Page 218: ...e bead of sealant to the entire circumference of the oil pan flange Specified sealant MITSUBISHI GENUINE PART No MD970389 or equivalent 3 The oil pan should be installed in 15 minutes after the application of sealant 6FNn71R 1 Crank pulley side Oil pan viewed from bottom 6EN044E 4 Note that the bolts at the location shown are different in length from the others TSB Revision ...

Page 219: ...L AND INSTALLATION 6 7 8 4 9 ll Removal steps 1 Nut IAO E4 2 Connecting rod cap 3 Connecting rod bearing eD4 4 Piston and connecting rod assembly 5 Connecting rod bearing eC4 6 Piston ring No 1 C4 7 Piston ring No 2 B4 8 Oil ring QBo AC 9 Piston pin IO Piston Ch 7t ecting rod 6EN0526 ...

Page 220: ...t Connecting Rod Guide Pin Piston Support Press Pin Stop Screw Nut 1 Remove the stop screw from the base 2 Select the correct piston support for your application See above Fit the piston support onto the base Place the base on press support blocks 3 Insert the press pin through the piston pin hole Select the correct connecting rod guide pin See above Thread the guide pin onto the threaded portion ...

Page 221: ...groove If the limit is exceeded replace the ring or piston or both Standard value No 1 0 03 0 07 mm 0012 0028 in No 2 SOHC 0 02 0 06 mm OOOS 0024 in No 2 DOHC 0 03 0 07 mm 0012 0028 in Limit 0 1 mm 004 in 3 Install the piston ring into the cylinder bore Force it down with a piston its crown being in contact with the ring to correctly position it at right angles to the cylinder wall Then measure th...

Page 222: ...t until the press pin touches the stop screw 2 Using the graduations on the press pin adjust the stop screw to the de pth shown below Depth SOHC and 4G61 DOHC 56 mm 2 20 in 4663 DOHC 55 mm 2 17 in 3 Place the base on press support blocks 4 Slide the piston pin over the threaded end of the press pin and thread the correct guide pin up against it 5 Coat the piston pin with oil and with the connectin...

Page 223: ...ove then press the remaining portion into position by finger See illustration Caution Do not use piston ring expander when installing side rail 3 Install the lower side rail in the same procedure as described in step 2 4 Make sure that the side rails move smoothly in either direction I c4 PISTON RING NO 2 PISTON RING NO 1 IN STALLATION 1 Using a piston ring expander fit No 2 and then No 1 piston r...

Page 224: ...e 4 Use suitable thread protectors on the connecting rod bolts before inserting the piston and connecting rod assembly into the cylinder block Care must be taken not to nick the crank pin 5 Using a suitable piston ring compressor tool install the piston and connecting rod assembly into the cylinder block I E4 CONNECTING ROD CAP INSTALLATION 1 Verifying the mark made during disassembly install the ...

Page 225: ...4G6 ENGINE 1992 Piston and Connecting Rod 1 IC 101 TSB Revision ...

Page 226: ...3 Ball bearing 17 Bell housing cover 4 Drive plate bolt 18 Oil seal case 5 Adapter plate 19 Gasket 6 Drive plate 04 20 Oil separator 7 Crankshaft bushing C4 21 Oil seal 8 Drive plate bolt 22 Bearing cap bolt 9 Adapter plate B4 23 Bearing cap 10 Drive plate A4 24 Crankshaft bearing lower 11 Crankshaft bushing 25 Crankshaft 12 Drive plate bolt A4 26 Crankshaft bearing upper 13 Adapter plate 27 Cylin...

Page 227: ...uge package Standard value 0 02 0 05 mm 0008 0020 in Limit 0 1 mm 004 in CYLINDER BLOCK 1 Visually check for scratches rust and corrosion Use also a flaw detecting agent for the check If defects are evident correct or replace 2 Using a straightedge and feeler gauge check the block top surface for warpage Make sure that the surface is free from gasket chips and other foreign matter Standard value 0...

Page 228: ...S 1 00 I I I NOTE Size mark is stamped on the piston top Piston O D Thrust direction 6EN0554 2 Measure outside diameter of piston to be used Measure it in thrust direction as shown 3 Based on the measured piston O D calculate the boring finish dimension Boring finish dimension Piston O D clearance between piston 0 D and cylinder 0 02 mm 0008 in honing margin 4 Bore all cylinders to the calculated ...

Page 229: ... provided with oil groove 2 The lower bearings on the cap side for Nos 1 2 4 and 5 journals are not provided with oil groove 3 No 3 bearings are flanged and provided with no groove Common bearings are used on the cap side and cylinder block side I 64 BEARING CAP INSTALLATION 1 Check the bearing cap for the identification mark before it is installed 2 After installing the bearing caps make sure tha...

Page 230: ...01 DEN0052 Oil seal Oil separator case 0 0 a2 8 0 0 nil t hole 6EN055i I c4 OIL SEAL INSTALLATION I D4 OIL SEPARATOR INSTALLATION 1 Force the oil separator into the oil seal case so that the oil hole in the separator is directed downward arrow in illustration TSB Revision 1 ...

Page 231: ...lbs I Engine support bracket right 45 Nm 2 Engine support bracket left 2 33 ft lbs 6EN350 Front wheel drive and all wheel drive I Roll stopper bracket front 2 Engine support bracket front 3 Exhaust pipe support bracket 4 Roll stopper bracket rear I 4 I 120 N 87 ftlbs 6EN0722 TSB Revision ...

Page 232: ...NOTES ...

Page 233: ...HAFT 29 CYLINDER HEAD AND VALVES 32 SEALANT 10 EXHAUST MANIFOLD 28 SERVICE SPECIFICATIONS 6 FRONT CASE AND OIL PUMP 36 SPECIAL TOOLS 11 FUEL AND EMISSION PARTS 20 THROlTLE BODY 22 GENERAL INFORMATION 2 TIMING BELT 16 GENERAL SPECIFICATIONS 5 TORQUE SPECIFICATIONS 9 GENERATOR AND IGNITION SYSTEM 13 INTAKE MANIFOLD AND WATER PUMP 25 ...

Page 234: ...llD 2 4G9 ENGINE General Information GENERAL INFORMATION ENGINE SECTIONAL VIEW TSB Revision 9EN0104 ...

Page 235: ...4G9 ENGINE General Information llD 3 ru l 9EN0105 TSB Revision ...

Page 236: ...11D 4 4G9 ENGINE General Information UBRICATION SYSTEM 9EN0106 TSB Revision ...

Page 237: ...stem water pump type EGR valve Injector type and number Injector identification mark Fuel regulated pressure Throttle bore Throttle position sensor Closed throttle position switch Specifications In line OHV SOHC 4 Pentroof type 1834 111 9 81 3 19 89 3 50 9 5 1 18 BTDC 50 ATDC 58 BBDC IO ABDC Pressure feed full flow filtration Trochoid type Water cooled forced circulation Centrifugal impeller type ...

Page 238: ...0 3 012 O S 29 30 29 32 1 1535 1 1543 0 6 024 O S 29 60 29 62 1 1654 1 lSSl Camshaft Cam height Intake 37 78 1 4874 Exhaust 38 09 1 4996 Journal O D 44 93 44 94 1 7689 1 7693 Bearing oil clearance 0 05 0 09 0020 0035 Rocker arm I D 20 02 20 04 7882 7890 Rocker arm to shaft clearance 0 02 0 05 0008 OOZO Rocker arm shaft O D 19 99 20 00 7870 7874 Valve Valve length Intake 110 15 4 3366 Exhaust 113 7...

Page 239: ...012 0 6 024 oversize 80 98 80 99 3 1882 3 1886 0 02 0 04 LOO08 0016 0 25 Ol 0 50 02 0 75 03 1 OO 04 oversize Limit 49 9 1 965 4 0 2 008 iston ring End gap No 1 ring No 2 ring Oil ring Gng to ring groove clearance No 1 ring No 2 ring Service size 0 25 0 40 0098 0157 0 40 0 55 0157 0217 0 20 0 60 0079 0236 0 03 0 07 0012 0028 0 02 0 06 0008 0024 0 25 Ol 0 50 02 0 75 03 1 OO 04 oversize 0 8 t 031 0 8...

Page 240: ...arance Side clearance Body clearance Drive belt deflection Vew belt Jsed belt njector Zoil resistance 0 Throttle position sensor qesistance 0 dle air control motor Ioil resistance fi Standard value 0 05 0 25 0020 0098 49 982 49 994 1 9678 1 9683 44 980 44 995 1 7709 1 7715 0 003 OOOl 0 02 0 04 0008 0016 0 02 0 05 0008 0020 81 OO 81 03 3 1890 3 1902 0 05 002 263 5 10 37 0 03 0 08 0012 0031 0 04 0 1...

Page 241: ...ld mounting bolt and nut flater pump mounting bolt Timing belt cover mounting bolt Engine support bracket left mounting bolt Water pipe mounting bolt Engine coolant temperature sensor Engine coolant temperature gauge unit Thermostat housing mounting bolt rlVater outlet fitting mounting bolt Exhaust manifold 3xygen sensor Exhaust manifold cover A mounting bolt M8 M6 Exhaust manifold bracket mountin...

Page 242: ... Thermostat housing Mitsubishi Genuine Part No MD970389 or equivalent As required Engine coolant temperature sensor 3M Nut Locking part No 4171 or equivalent As required Engine coolant temperature gauge unit 3M ATD Part No 8660 or equivalent As required Oil pressure switch 3M ATD Part No 8660 or equivalent As required Water outlet fitting Mitsubishi Genuine Part No MD970389 or equivalent As requir...

Page 243: ...1 3 01 Installation of camshaft oil seal 0 Camshaft oil seal 3 4 installer 62 MD99871 6 MD99871 6 01 Crankshaft Turning crankshaft wrench fQ MD9987 17 MD99871 7 01 Installation of front oil seal Crankshaft front oil seal installer I M D9987 19 M 11308239 H Holding crankshaft sprocket Pulley holding pins 2 MD998727 Oil pan remover Removal of oil pan MD998772 Valve spring compressor Compressing valv...

Page 244: ...IName I Use MD998776 Use with of crankshaft rear oil seal Crankshaft rear MB990938 01 oil seal installer Use with MB990938 Cl 6 MD998780 MIT216941 Removal and installation of piston pin IJB Piston pin setting tool Holding flywheel TSB Revision I ...

Page 245: ... AND INSTALLATION i I I 8 185 Nm 134ftlbs Removal steps I Oil level gauge 2 Oil level gauge guide 3 O ring 4 Drive belt 5 Generator brace 6 Generator 7 Crankshaft bolt 8 Crankshaft pulley 9 Spark plug cable 0 Spark plug I Distributor 33 ft lbs 2 O ring 12Nm 9 ftlbs 9EN0267 TSB Revision ...

Page 246: ...he top dead center on compression stroke 2 Align the mating marks on the distributor housing with that of the coupling key 3 Install the distributor with the coupling key fitted in the keyway at the end of camshaft B4 CRANKSHAFT BOLT TIGHTENING 1 Using the special tool hold the drive plate or flywheel 2 Install the crankshaft bolt c4 DRIVE BELT TENSION ADJUSTMENT 1 Adjust the belt deflection with ...

Page 247: ...rator 9ENOOOl 2 Clru ing a tension gauge adjust the tension to the standard Standard value New belt 500 700 N 110 154 Ibs Used belt 400 N 88 Ibs 3 Tighten the lock bolt to the specified torque 4 Tighten the nut for pivot bolt to the specified torque TSB Revision ...

Page 248: ...ALLATION 90 Nm 65 ft lbs 6 1 Removal steps 1 Flange 2 Timing belt upper cover 3 Timing belt lower cover IAO C4 4 Timing belt eB4 5 Tensioner B4 6 Tensioner spring 7 Crankshaft sprocket IBIJ A4 8 Camshaft sprocket bolt 9 Camshaft sprocket 9EN0269 TSB Revision ...

Page 249: ...th pliers unhook it from the bracket hook on the tensioner to free the tensioner spring 4 Loosen the tensioner mounting bolt and remove the timing belt at30 CAMSHAFT SPROCKET BOLT LOOSENING INSPECTION TIMING BELT Replace belt if any of the following conditions exist 1 Hardening of back rubber Back side is glossy without resilience and leaves no indent when pressed with fingernail 2 Cracks on rubbe...

Page 250: ...nstall the tensioner spring and spacer Do not fully tighten the bolt from the tightened position back it off three turns 2 Mount the timing belt tensioner Push the tensioner in the direction of the arrow and tighten the bolt to secure the tensioner in that position 3 Pinching the front end of the tensioner spring hook it onto the tensioner bracket hook Caution When hooking the tensioner spring use...

Page 251: ...lign the timing mark on the camshaft sprocket with that on the cylinder head 3 Align the timing mark on the crankshaft sprocket with that on the front case 4 Install the timing belt first on the crankshaft sprocket and then keeping the tension side belt tight set on the camshaft sprocket Finally get the belt around the tension er pulley I the tensioner pulley lrarily tightened 1 TSB Revision mount...

Page 252: ...19 Nm 14 ft lbs Removal steps 1 Throttle body 2 Gasket 3 Fuel rail and injector 4 Insulator 5 Fuel return pipe 6 Fuel hose eB4 7 Fuel pressure regulator 8 O ring 9 Insulator A4 10 Injector Il O ring 12 Grommet 13 Fuel rail 14 EGR valve 1 MIRAGE 15 tiasket 1 For California 16 EGR temperature sensor J TSB Revision ...

Page 253: ...lug other nipple 3 Apply a vacuum of 500 mmHg 19 7 in Hg to check that the vacuum is retained If there is a leak replace the EGR valve 4 Check also that the valve opens and closes properly by applying and releasing a vacuum INSTALLATION SERVICE POINTS I A4 INJECTOR INSTALLATION 1 Before installing an injector the rubber O ring must be lubricated with a drop of clean engine oil to aid in installati...

Page 254: ...lbs Removal steps 8 A4 1 Throttle position sensor 2 Idle air control motor 3 O ring PO 4 Throttle body 5 Accelerator cable bracket a 96N0275 L MIRAGE 2Nm 1 4ft lbs b 4 cd 8 Removal steps QAr A4 1 Throttle position sensor 0 2 Idle air control motor 3 O ring OW 4 Throttle body 1 EN0336 TSB Revision ...

Page 255: ...rottle position sensor to the throttle body as shown in the illustration 2 Turn the throttle position sensor 90 counterclockwise and tighten the screws 3 Connect a circuit tester between ground and output or between output and power Then make sure that the resistance changes smoothly when the throttle valve is slowly moved to the fully open position 4 Check for continuity across terminals Closed t...

Page 256: ... Connect a circuit tester between ground and output or between output and power Then make sure that the resistance changes smoothly when the throttle valve is slowly moved to the fully open position 4 Check for continuity across terminals Closed throttle position switih and ground with the throttle valve both fully closed and fully open 01 If there is not continuity with the throttle valve fully c...

Page 257: ... lbs 5 4 3u Nrn 22 ft lbs 16 Removal steps 1 Water hose A z Water hose B Engine coolant temperature gauge unit 4 Engine coolant temperature sensor 5 Water inlet fitting 6 Thermostat 7 Thermostat housing 8 O ring 9 Intake manifold stay 7 E tM manlfold 2 Water pipe 3 O ring 4 Timing belt cover 5 Engine support bracket left 6 Water pump I 31 Nm 22 ft lbs 9ENOO36 TSB Revision ...

Page 258: ...sembly Caution 1 Keep the O ring free of oil or grease 2 Secure the water pipe after the thermostat housing has been installed I c4 dU APPLICATION TO THERMOSTAT Specified sealant Mitsubishi Genuine Part No MD970389 or equiva lent I D4 THERMOSTAT INSTALLATION 1 Install the thermostat in the thermostat housing in such a way that the jiggle valve is located as illustrated Eg SEALANT APPLICATION TO EN...

Page 259: ...4G9 ENGINE Intake Manifold and Water Pump 1 m27 Sealant I F4 SEALANT APPLICATION TO ENGINE CFL JT TEMPERATURE GAUGE UNIT Specified sealant 3M ATD Part No 8660 or equivalent 9EN0092 TSB Revision ...

Page 260: ...m 26 klbs 30 Nm 22 ft lbs Removal steps 1 Oxygen sensor 1992 1993 Federal models 2 Exhaust manifold cover A 3 Exhaust manifold bracket B 4 Exhaust manifold bracket A 1993 models 5 Exhaust manifold bracket I _ 1992 models 6 Exhaust manifold 1992 1993 Federal models 7 Exhaust manifold 1993 California models 8 Exhaust manifold cover B 1992 1993 Federal models 9 Gasket 9EN0281 TSB Revision ...

Page 261: ...Rocker cover 4 Rocker cover gasket 5 Oil seal B4 6 Oil seal A4 7 Rocker arms and rocker arm shaft 8 Rocker arms and rocker arm shaft A4 9 Rocker shaft spring 10 Rocker arm A 11 Rocker arm B 12 Rocker arm shaft Intake side 1 z rstrng screw 15 Rocker arm C 16 Rocker arm shaft Exhaust side 17 Adjusting screw 18 Nut 19 Camshaft 9EN0282 1 TSB Revision I ...

Page 262: ...ge or seizure is evident replace the rocker arm l Check the screw end for wear If considerable wear is evident replace the adjusting screw INSTALLATION SERVICE POINTS I A4 ROCKER SHAFT SPRING ROCKER ARMS ROCKER ARM SHAFT 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 abo...

Page 263: ...y turning the adjusting screw Standard value Intake 0 09 mm LOO4 in Exhaust 0 20 mm LOO8 in 5 While holding the adjusting screw with a screwdriver tighten the lock nut 6 Rotate clockwise the crankshaft one complete turn 7 Adjust the valve clearance at the points shown in the illustration 8 Repeat steps 3 to 5 to adjust the valve clearance of remaining valves 1 TSB Revision I ...

Page 264: ...sure switch eD4 5 Cylinder head bolt 6 Cylinder head assembly 7 Cylinder head gasket JAI Q 8 Retainer lock 9 Valve spring retainer B4 10 Valve spring 11 Intake valve IAI C4 12 Retainer lock 13 Valve spring retainer eB4 14 Valve spring 15 Exhaust valve IBI A4 16 Valve stem seal 17 Valve spring seat IBIJ A4 18 Valve stem seal 19 Valve spring seat 20 Intake valve guide 21 Exhaust valve guide 22 Intak...

Page 265: ...012 in Limit 0 2 mm 008 in 2 If the service limit is exceeded correct to meet the specification Grinding limit 0 2 mm 008 in Total resurfacing depth of both cylinder head and cylinder block Cylinder head height Specification when new 119 9 120 1 mm 4 720 4 728 in VALVE 1 Check the valve face for correct contact If incorrect reface using a valve refacer Valve should make a uniform contact with the ...

Page 266: ...e guide or valve or both Standard value Intake 0 02 0 04 mm 0008 0016 in Exhaust 0 03 0 06 m m 0012 0024 in Limit Intake 0 10 mm 0039 in Exhaust 0 15 mm 0059 in REASSEMBLY SERVICE POINTS I A4 VALVE STEM SEAL INSTALLATION 1 Install the valve spring seat 2 The special tool must be used to install the valve stem seal Improper installation could result in oil leaking past the valve guide Caution Do no...

Page 267: ... tighten the bolts to 75 Nm 54 ft lbs 5 Loosen the bolts completely 6 Torque the bolts to 20 Nm 14 5 ft lbs 7 Tighten the bolts l 4 turns 90 more 8 Tighten the bolts l 4 turns 90 additionally fi c Timing belt side 9EN0066 I OF NfKlOdl diameter bead sealant 9EN0095 r E4 SEALANT APPLICATION TO OIL PRESSURE SWITCH 1 Apply sealant to the threads of the switch Specified sealant 3M ATD Part No 8660 or e...

Page 268: ...45 Nm 33 ft lbs Removal steps E4 1 Oil filter 2 Drain plug 3 Drain plug gasket 4Ar I D4 4 Oil pan 5 Oil screen 6 Oil screen gasket 7 Relief plug 8 Relief spring 9 Relief plunger C4 10 Oil seal B4 11 Oil pump case 12 O ring 13 Oil pump case cover c Br AC 14 Outer rotor cJB A4 15 Inner rotor I 40 Nm 29 ft lbs 9EN0040 TSB Revision ...

Page 269: ...ol along the oil pan to remove the oil pan QBo OUTER ROTOR INNER ROTOR REMOVAL 1 Make alignment dots on the outer and inner rotors for reference in reassembly INSPECTION OIL PUMP 1 Check the tip clearance Standard value 0 03 0 08 mm LOO12 0031 in 2 Check the side clearance Standard value 0 04 0 10 mm LOO16 0039 in 3 Check the body clearance Standard value 0 10 0 18 mm LOO39 0071 in Limit 0 35 mm I...

Page 270: ...ALLATION 1 Apply engine oil to the rotors Then install the rotors ensuring that the alignment dots made at disassembly are properly aligned eB4 SEALANT APPLICATION TO OIL PUMP CASE Specified sealant Mitsubishi Genuine Part No MD970389 or equiva lent I c4 CRANKSHAFT FRONT OIL SEAL INSTALLATION Using the special tool top the oil seal into the oil pump case ...

Page 271: ...tion Specified sealant Mitsubishi Genuine Part No MD970389 or equiva lent 3 The oil pan should be installed within 15 minutes after the application of sealant u L 1 I L l 4 mm I6 in diameter k bc ad sealant 9EN0097 I E4 OIL FILTER INSTALLATION 1 Clean the filter installation surface of the filter bracket 2 Apply engine oil to the O ring of the oil filter 3 Screw in the oil filter until its O ring ...

Page 272: ... REMOVAL AND INSTALLATION Removal steps a 7 8 1 Nut 2 Connecting rod cap 3 Connecting rod bearing 4 Piston and connecting rod 5 Connecting rod bearing 6 Piston ring No 1 7 Piston ring No 2 8 Oil ring 9 Piston pin 0 Piston 1 Connecting rod 2 Bolt L2 1 9EN0043 TSB Revision ...

Page 273: ...Press Pin Stop Screw Nut 2 Select the correct piston support for your application See above Fit the piston support onto the base Place the base on the press support blocks 3 Insert the press pin through the piston pin hole Select the correct connecting rod guide pin See Above Thread the guide pin onto the threaded portion of the press pin 4 Position the piston assembly on the piston support in the...

Page 274: ...ith a feeler gauge If the ring gap is excessive replace the piston ring Standard value No 1 0 25 0 40 mm 0098 0157 in No 2 0 40 0 55 mm 0157 0217 in Oil 0 20 0 60 mm 0079 0236 in Limit No 1 No 2 0 8 mm 031 in Oil 1 0 mm 039 in CRANKSHAFT PIN OIL CLEARANCE PLASTIC GAUGE METHOD 1 Remove oil from crankshaft pin and connecting rod bearing 2 Cut the plastic gauge to the same length as the width of bear...

Page 275: ...at the piston pin with oil and with the connecting rod held in position slide the guide pin through the piston and the connecting rod 6 Press the piston pin through the connecting rod until the guide pin contacts the stop screw 7 Remove the piston assembly from the base Remove the guide pin and the press pin from the assembly IMPORTANT Due to production tolerance variations it is necessary to visu...

Page 276: ... 2 Install piston rings No 1 and No 2 with their side having marks facing up on the piston crown side I D4 PISTON AND CONNECTING ROD INSTALLATION 1 Liberally coat engine oil on the circumference of the piston piston ring and oil ring 2 Arrange the piston ring and oil ring gaps side rail and spacer as shown in the illustration 3 Rotate crankshaft so that the crank pin is on center of the cylinder b...

Page 277: ...n mark Connecting rod bearing Identification mark Identification color 1 Sl Brown I 2 I s2 I Black 1 F4 CONNECTING ROD CAP INSTALLATION 1 Mate the correct bearing cap with the correct connecting rod by checking with the alignment marks marked during disassembly If a new connecting rod is used which has no alignment mark position the notches for locking the bearing on the same side 2 Check if the t...

Page 278: ... can be checked by running a nut with fingers to the full length of the bolt s thread If the nut does not run down smoothly the bolt should be replaced 2 Install the connecting rod cap on the big end of the connecting rod 3 Before installing the nuts the threads should be oiled with engine oil 4 Install both nuts on each bolt finger tight then alternately torque each nut to assemble the cap proper...

Page 279: ...9Nm 7 ft lbs I 8 100 Nm 72 ft lbs I Removal steps E4 1 Flywheel bolt 2 Flywheel E4 3 Drive plate bolt 4 Adapter plate 5 Drive plate 6 Crankshaft bushing 1 M T 1 1 Al r 7 Rear plate 8 Bell housing cover 9 Oil seal case 0 011 seal 1 Bearing cap bolt 2 Bearing cap 3 Crankshaft bearing lower 4 Crankshaft 5 Thrust bearing 6 Crankshaft bearing upper 7 Cylinder block 9EN0041 1 TSB Revision I ...

Page 280: ...uge check the block top surface for warpage Make sure that the surface is free from gasket chips and other foreign matter Standard value 0 05 mm 0020 in or less Limit 0 1 mm 0040 in 2 If the distortion is excessive correct within the allowable limit or replace Grinding limit 0 2 mm 008 in The total thickness of the stock allowed to be removed from cylinder block and mating cylinder head is 0 2 mm ...

Page 281: ...ured piston O D calculate the boring finish dimension Boring finish dimension Piston O D Clearance between piston O D and cylinder 0 02 mm 0008 in honing margin 4 Bore all cylinders to the calculated boring finish dimension Caution To prevent distortion that may result from temperature rise during honing bore cylinders in the order of No 2 No 4 No 1 and No 3 5 Hone to the final finish dimension pi...

Page 282: ...e cylinder block No 5 No 4 k No l i Crank pin OD Identification r J mark Journal OD identlflcation mark 9EN013C No 3 No 2 122OP Cylinder ID ldentificatlon 1 2 1 2 1 1 5 4 1 9 mark for cylinder block bearing support section IC J 9EN0131 cation cation Oil groove Identifi catron color 9EN013 2 Install the bearings having an oil groove to the cylinder block 3 Install the bearings having no oil groove ...

Page 283: ...that the crankshaft turns smoothly and the end play is correct If the end play exceeds the limit replace the crankshaft bearings Standard value 0 05 0 25 mm 0020 0098 in Limit 0 4 mm 016 in ec4 OIL SEAL INSTALLATION D4 SEALANT APPLICATION TO OIL SEAL CASE Specified sealant Mitsubishi Genuine Part No MD970389 or equiva lent E4 DRIVE PLATE BOLT FLYWHEEL BOLT INSTALLATION 1 Remove all the remaining s...

Page 284: ...NOTES ...

Page 285: ...ERAL INFORMATION 2 GENERAL SPECIFICATIONS 12 GENERATOR AND DRIVE BELT 27 IGNITION SYSTEM 44 INTAKE MANIFOLD AND FUEL PARTS 62 INTAKE MANIFOLD PLENUM AND THROTTLE BODY 32 OIL PAN AND OIL PUMP 102 PISTON AND CONNECTING ROD 108 ROCKER ARMS AND CAMSHAFTS 77 SEALANT 23 SERVICE SPECIFICATIONS 14 SPECIAL TOOLS 24 THROTTLE BODY 37 TIMING BELT SOHC 48 TIMING BELT DOHC 54 TORQUE SPECIFICATIONS 19 TURBOCHARG...

Page 286: ... HE 2 6G7 ENGINE General Information GENERAL INFORMATION SECTIONAL VIEW SOHC ENGINE for DIAMANTE 7EN0323 TSB Revision ...

Page 287: ...6G7 ENGINE General Information llE 3 TEN0324 1 Revision ...

Page 288: ...IIE 4 6G7 ENGINE General Information SECTIONAL VIEW SOHC ENGINE for MONTERO AND TRUCK TSB Revision 7EN0135 I ...

Page 289: ...667 ENGINE General Information TSB Revision 7EN0120 I ...

Page 290: ...WE 6 6G7 ENGINE General Information SECTIONAL VIEW DOHC NON TURBO ENGINE TSB Revision 7EN0325 ...

Page 291: ......

Page 292: ...IIE 8 6G7 ENGINE General Information SECTIONAL VIEW DOHC TURBO ENGINE 1 TSB Revision 7EN0335 ...

Page 293: ...667 ENGINE General Information IIE 9 TSB Revision 7EN0334 ...

Page 294: ...IIE 10 6G7 ENGINE General Information JJBRICATION SYSTEM SOHC Oil pressure switch n t Oil pressure gauge unit Oil cooler by pass valve MONTERO only Rocke Lash adjuster 7LUOO34 TSB Revision ...

Page 295: ...neral Information llE41 UBRICATION SYSTEM DOHC To turbo Oil pressure switch charger turbo only is Oil pressure gauge unit Las To oil cooler Turbo only II Oil cooler by pass valve Turbo only Relief valve TSB Revision ...

Page 296: ...Exhaust valve Opens 56 BBDC Closes 26 ATDC Valve timing Rear wheel drive Intake valve Opens 19 BTDC Closes 59 ABDC Exhaust valve Opens 59 BBDC Closes 19 ATDC Lubrication system Pressure feed full flow filtration 3il pump type Trochoid type Cooling system Water cooled forced circulation JVater pump type Centrifugal impeller type EG R type Single type njector type and number Electromagnetic 6 njecto...

Page 297: ...ump type Cooling system tiater pump type EGR type Injector type njector identification mark Non turbo Turbo Throttle bore mm in Throttle position sensor Closed throttle position switch Specifications 6O V DOHC per bank 6 Compact type 2 972 181 4 91 1 x 76 0 3 59 x 2 99 10 0 8 0 16 BTDC 55 ABDC 48 BBDC 15 ATDC 16 BTDC 55 ABDC 50 BBDC 17 ATDC Pressure feed full flow filtration Trochoid type Water co...

Page 298: ... 6 024 38 60 38 63 1 5197 1 5209 Cylinder head DOHC Flatness of gasket surface Less than 0 03 0012 0 2 008 Grinding limit of gasket surface 0 2 008 Total resurfacing depth of both cylinder head and cylinder block 3verall height 132 5 20 Dversize rework dimensions of valve guide hole Iboth intake and exhaust 0 05 002 12 05 12 07 4744 4752 0 25 OlO 12 25 12 27 4823 4831 0 50 020 12 50 12 52 l 4921 4...

Page 299: ...hickness of valve head Margin Intake Exhaust Standard 35 49 1 3972 34 91 1 3744 35 20 1 3858 34 91 1 3744 26 1 02 0 05 0 09 020 0035 18 91 18 93 7445 7453 0 01 0 04 0004 0016 18 89 18 90 7437 7441 333 5 13 130 102 97 4 0539 102 67 4 0421 7 96 7 98 3134 3142 7 93 7 95 3122 3130 45 45 5 0 03 0 06 0012 0024 0 05 0 09 0020 0035 1 2 047 2 0 i 079 106 28 4 1842 105 40 4 1496 6 57 6 58 2587 2591 6 53 6 5...

Page 300: ...5 002 0 25 LO1 0 0 50 020 Oversize Valve guide DOHC Overall length Intake Exhaust I D O D Service size 45 5 1 791 50 5 1 988 6 60 6 62 2598 2607 12 06 12 07 4748 4752 0 05 002 0 25 LO1 0 0 50 020 Oversize Valve seat Seat angle valve contact width Sinkage Service size Piston SOHC 3 D iston to cylinder clearance Service size 44 44 5 0 9 1 3 035 051 0 30 012 0 60 t 024 Oversize 91 I 3 587 0 02 0 04 0...

Page 301: ...shaft engine Four camshaft engine aper of journal and pin il clearance of journal il clearance of pin NOTE O D Outer Diameter Standard 0 30 0 45 0118 0177 0 45 0 60 0177 0236 0 25 0 45 LOO98 0177 0 20 0 60 LOO79 0236 0 20 0 70 0079 0276 0 03 0 07 LOOI 2 0028 0 05 0 09 0020 0035 0 02 0 06 0008 0024 0 30 0 45 0118 0177 0 45 0 60 0177 0236 0 20 0 70 0079 0276 0 03 0 07 0012 0028 0 02 0 06 0008 0024 2...

Page 302: ...Ibs New belt 700 900 154 198 Used belt 500 I IO Drive belt SOHC for MONTERO and TRUCK Deflection New belt 6 5 8 0 256 315 Used belt 9 0 354 Tension gauge N Ibs New belt 500 700 110 154 Used belt 400 88 Irive belt DOHC Ieflection New belt 3 5 4 0 138 157 Used belt 4 0 5 0 157 197 rension N Ibs New belt 650 850 143 187 Used belt 450 500 99 132 njector Zoil resistance Non turbo R 13 16 at 20 C 68 F T...

Page 303: ...t 23 17 Generator brace bolt F SOHC DIAMANTE 14 IO SOHC MONTERO AND TRUCK Side bolt 10 7 Exhaust manifold tightening side bolt 13 9 Generator bracket bolt 24 17 45 33 lrankshaft bolt SOHC 155 122 DOHC 185 134 ntake manifold plenum and throttle body iGR pipe bolt 18 13 ntake manifold plenum stay bolt 18 13 GR valve bolt 22 16 hrottle body bolt 12 8 SOHC MONTERO AND TRUCK 14 10 gnition coil bolt 2 5...

Page 304: ...oner bolt rensioner pulley bolt rensioner arm assembly bolt dler pulley bolt dler pulley bracket bolt jocker cover bolt Camshaft sprocket bolt ntake manifold and fuel parts njector and fuel rail bolt uel regulator bolt pressure uel pipe bolt leat pipe bolt ngine coolant temperature gauge unit ngine coolant temperature sensor SOHC DIAMANTE hermo switch dater outlet fitting bolt ltake manifold nut J...

Page 305: ...rbocharger waste gate actuator bolt locker arms and camshafts SOHC il filler bolt locker cover bolt Iistributor adaptor bolt locker arm shaft and bearing cap bolt Camshafts rocker arms and bearing caps DOHC lrankshaft position sensor adaptor bolt learing caps front and rear bolt rearing cap bolts No 2 3 4 lylinder head and valve SOHC ylinder head bolt ylinder head and valve DOHC ylinder head bolt ...

Page 306: ... plug 40 29 Oil bolt pan 6 4 Oil screen bolt 19 14 Plug 45 33 Oil case bolt pump 14 10 Oil cover bolt pump 10 7 Piston and connecting rod Connecting rod cap nut 52 38 Crankshaft flywheel and drive plate wheel bolt 75 54 Irive plate bolt 75 54 3ear plate bolt 11 8 3ell housing cover bolt 9 7 3il seal case bolt 11 8 3earing cap stay bolt 48 35 3earing cap bolt SOHC 79 57 DOHC 93 67 1993 models DOHC ...

Page 307: ...M ATD Part No 8660 Rocker cover 3M ATD Part No 8660 Bearing cap 3M NUT Locking Part No 41 71 Oil pressure switch 3M ATD Part No 8660 Oil pressure gauge unit 3M ATD Part No 8660 Oil pan MITSUBISHI GENUINE Part No MD970389 Oil seal case MITSUBISHI GENUINE Part No MD970389 Quantity As required As required As required As required As required As required As required As required As required TSB Revision...

Page 308: ...24 6G7 ENGINE SDecial Tools SPECIAL TOOLS MD99871 9 or SOHC engine only Leak down tester Air bleed wire Camshaft oil seal installer For SOHC engine only ton and timing belt For SOHC engine only TSB Revision ...

Page 309: ...king installer MD99871 7 01 MD998718 01 Use with MB990938 01 MIT308239 MD998735 01 M IT308239 IInstallation of crankshaft rear oil seal iolding camshaft sprocket when loosening x torquing bolt or SOHC engine only fqemoval of oil pan nstallation of valve stem seal or SOHC engine only lemoval and installation of valve and re jted parts l lolding crankshaft sprocket when loosen irlg or torquing bolt ...

Page 310: ...11 E 26 6G7 ENGINE Special Tools seal installer compressor Installation of flywheel TSB Revision ...

Page 311: ...TE 1 3 2 30 ft lbs il 7 155 Nm 112 ft lbs 23 Nm 8 I 14 Nm 10 ft lbs Removal steps A4 I Drive belt 2 Tensioner pulley 3 Adjusting bolt 4 Adjusting stud 5 Tensioner bracket 6 Pivot bolt 7 Generator 8 Generator brace QArJ B4 9 Crankshaft bolt 10 Special washer 11 Crankshaft pulley 7EN0487 1 TSB Revision I ...

Page 312: ...emoval steps 13 Nm 9 ftlbs 13 1 Drive belt 2 Cooling fan 3 Fan clutch 4 Fan pulley 5 Idler pulley 6 Tensioner pulley 7 Adjusting bolt 8 Adjusting stud 9 Tensioner bracket 0 Cooling fan bracket assembly 1 Tensioner bracket stay 2 Generator brace 3 Generator 4 Crankshaft bolt 5 Special washer 6 Crankshaft pulley 7EN0488 TSB Revision ...

Page 313: ...bs I 4 8 I 45 Nm 33 ft lbs 50 Nm 2 36 klbs 50 Nm I 165 Nm 134ft lbs Removal steps A4 1 Drive belt 2 Idler pulley 3 Tensioner pulley 4 Adjusting bolt 5 Adjusting stud 6 Tensioner bracket 7 Generator 8 Generator bracket 9 Bracket IA J 64 IO Crankshaft bolt 11 Special washer 12 Crankshaft pulley 7EN0489 TSB Revision ...

Page 314: ...BELT TENSION ADJUSTMENT DRIVE BELT TENSION CHART Generator drive belt SOHC for New DIAMANTE USed SOHC for New MONTERO USed and TRUCK DOHC New Used I Deflection mm in I TenEo bt uge 4 5 16 20 700 900 154 198 7 l 28 500 110 6 5 8 0 26 32 500 700 110 154 9 35 400 88 3 5 4 0 14 16 650 850 143 187 4 5 16 20 450 600 99 132 TSB Revision 1 Loosen the tensioner pulley locking nut 2 Tighten the adjusting bo...

Page 315: ... MONTERO and TRUCK 7EL0070 DOHC 3 If you use a tension gauge tighten the adjusting bblt to adjust the belt tension to the specification shown in the chart I B4 CRANKSHAFT BOLT TIGHTENING 1 Using the special tool hold the drive plate or flywheel 2 Install the crankshaft bolt TSB Revision 1 ...

Page 316: ...ft lbs 22 Nm 16 ftlbs 18Nm 13 ft lbs Removal steps 1 EGRpipe 2 Ignition coil For California 3 High tension cable 4 Intake manifold plenum stay rear 5 Intake manifold plenum stay front 6 EGR valve 7 EGR valve aasket 1 For California 8 Throttle body 9 Throttle body gasket 10 Ignition power transistor 11 Intake manifold plenum 12 Intake manifold plenum gasket 7EN0405 TSB Revision ...

Page 317: ... 13 ft lbs 18 Nm Removal steps 1 EGR pipe 2 EGR pipe gasket I For California 3 Intake inariifold plenum stay rear 4 Intake manifold plenum stay front 5 EGR valve 6 EGR valve gasket For California 7 Throttle body 8 Throttle body gasket 9 Intake manifold plenum 10 Intake manifold plenum gasket 22 Nm 16 ft lbs 7EN0408 TSB Revision ...

Page 318: ...3 ftlbs 22 Nm 16 ft lbs 18Nm 13 ft lbs 3 18Nm 13 ftlbs Removal steps 1 EGR pipe For California 2 Intake manifold plenum stay rear 3 Intake manifold plenum stay front 5 EGR valve 6 EGR valve gasket I For California 7 Throttle body 8 Intake manifold plenum 9 Intake manifold plenum gasket Cb 18Nm 13 fklbs TSB Revision 7EN0411 ...

Page 319: ...fornia 3 Intake manifold plenum stay rear 4 Intake manifold plenum stay front 5 EGR valve 6 EGR valve aasket I For California 7 Throttle bo iy 8 Throttle body gasket 9 Intake manifold plenum 10 Intake manifold plenum gasket 18 Nm 13 ftlbs 6G7 ENGINE Intake Manifold Plenum and Throtiib B ijdy qq ps5 1 TSB Revision I I 1 ...

Page 320: ...e for sticking or carbon deposits If such conditions exist clean or replace the EGR valve 2 Connect a hand vacuum pump to the nipple of the EGR valve and plug other nipple 3 If there is vacuum leakage replace the EGR valve 4 Blow air in from one passage of the EGR to check its condition as follows TSB Revision ...

Page 321: ...Nm 1 8 ft lbs Disassembly steps QArJ A4 1 Throttle position sensor 2 Idle air control motor O 3 Throttle body 7FU1282 DISASSEMBLY AND REASSEMBLY For VEHICLES with TRACTION CONTROL Nm 1 4 ft lbs 4 I ii 3 5 Nm 2 5 ftlbs 3 5 Nm 2 5 ft lbs 5 Disassembly steps 1 Water hose B4 6 Throttle body 1 4 ft lbs sensor 7FU1283 TSB Revision ...

Page 322: ...els IAO A4 5 Throttle position sensor 6 Idle air control motor 0 7 Throttle body DISASSEMBLY AND REASSEMBLY SOHC for MONTERO and TRUCK 3 I n 1 cz J T Disassembly steps OAO B4 1 Throttle position sensor Within closed throttle position switch 2 Idle air control motor assembly 3 Throttle body 3 5 Nm 2 5 ftlbs 2Nm 1 4 ft lbs 1 TSB Revision 7FUO532 I ...

Page 323: ...OT DOHC TURBO Up to 1992 models 1 Push the rod of the dash pot all the way in and close the nipple with the fingers 2 If the rod does not protrude after releasing it the dash pot is functioning normally 3 If the rod protrudes a broken diaphragm is suspected Therefore replace the dash pot From 1993 models 1 Push the dash pot rod in lightly and confirm the resistance NOTE 1 Resistance increases as t...

Page 324: ...e 6 Make sure that the negative pressure leaks out as soon as it is applied 7 Remove the hand vacuum pump from the valve 8 Install the filter onto the black nipple of the valve IDLE AIR CONTROL MOTOR Checking the Coil Resistance 1 Connect Test Harness to the motor connector 2 Measure the resistance between the white clip of Test Harness and the red clip or blue clip Standard value 28 33 LR at 20 C...

Page 325: ...e 0 terminal of the power supply to the red and yellow clip Connect the negative 0 terminal of the power supply to the red and black clip Repeat the tests in sequence from to 0 4 If as a result of these tests vibration is detected the stepper motor can be considered to be normal CHECKING VACUUM ACTUATOR VEHICLES with TRACTION CONTROL 1 With the throttle valve opened apply a vacuum of 200 mmHg 7 9 ...

Page 326: ... If there is no continuity with the throttle valve fully closed turn TPS counterclockwise and then check again NOTE Some throttle position sensors are not provided with the position switch In that case the check described in step 4 cannot be accomplished 5 If the above specifications are not met replace TPS I B4 rNHslA EP tSITION SENSOR TPS SOHC for MONTERO and TRUCK 1 Install the throttle positio...

Page 327: ...al position sensor 90 clockwise to set it and tighten the screws 3 Connect a circuit tester between ground and output or between output and power Then make sure that the resistance changes smoothly when the throttle valve is slowly moved to the fully open position 4 Check for continuity across terminals closed throttle position switch and ground with the throttle valve both fully closed and fully ...

Page 328: ...11 E 44 6G7 ENGINE Ignition System IGNITION SYSTEM SOHC for DIAMANTE 25 Nm 18 ft lbs Removal steps 1 Spark plug cables 2 Spark plug 3 Distributor 4 O ring 7EN0406 TSB Revision I ...

Page 329: ...6G7 ENGINE Ignition Svstem OHC for MONTERO AND TRUCK 25 Nm 18 ft lbs Removal steps 1 Spark plug cables 2 Spark plugs 3 High tension cable A4 4 Distributor 5 O ring 6 Ignition coil 7EN0409 TSB Revision I ...

Page 330: ...val steps 1 Center cover 2 Spark plug cables 3 Soark oluas 4 Ciamp um From 5 Ignition 1993 coil models 6 Engine hanger 7 Ignition power transistor DIAMANTE eB4 8 ignition power transistor _ 3000GT 9 Crankshaft position sensor Up to 1992 models 10 O ring 7EN0492 I I L I 1 TSB Revision ...

Page 331: ...ributor housing and gear mating marks 3 With the stud located in the center of the adjusting slot at the distributor install the distributor Mating mark 7FI OOWi I I B4 RAFKSHAFT POSITION SENSOR INSTALLATION 1 Turn the crankshaft so that the No 1 cylinder is at compressi on top dead center 2 Install lining up the matchmarks on the crankshaft position sensor housing and the coupling TSB Revision ...

Page 332: ...Access cover 3 Timing belt front upper cover right 4 Timing belt cover cap 5 Timing belt front upper cover left 6 Timing belt front lower cover 7 Flange 4AO CC 8 Timing belt iB4 9 Tensioner 10 Tensioner spring 11 Crankshaft sprocket QBrJ A4 12 Camshaft sprocket bolt 13 Camshaft sprocket 14 Timing belt rear cover left 15 Timing belt rear cover right 7EN0493 TSB Revision ...

Page 333: ...r 2 Timing belt front upper cover right 3 Timing belt front upper cover left 4 Timing belt front lower cover 5 Flange IO C4 6 Timing belt eB4 7 Tensioner 8 Tensioner spring 9 Crankshaft sprocket IBIJ A4 10 Camshaft sprocket bolt 11 Camshaft sprocket 12 Timing belt rear upper cover left 13 Generator stay 14 Generator bracket 7EN0494 TSB Revision ...

Page 334: ... If there is oil or water on any part check the front case oil seal camshaft oil seal and water pump for leaks BI CAMSHAFT SPROCKET BOLT REMOVAL Abnormal wear Fluffy strand INSPECTION TIMING BELT Replace belt if any of the following conditions exist 1 Hardening of back rubber back side is glossy without resilience and leaves no indent when pressed with finger nail 2 Cracks on rubber back 3 Cracks ...

Page 335: ...canvas fiber exposed INSTALLATION SERVICE POINTS A4 CAMSHAFT SPROCKET BOLT INSTALLATION I B4 TIMING BELT TENSIONER INSTALLATION 1 Insert a screwdriver into the hole of the timing belt tensioner arm move it all the way in the direction of the arrow and tighten the tensioner lock bolt to temporarily hold this position 1 TSB Revision I ...

Page 336: ... mark on belt cover Timing mark on rear cover or generator bracket Camshaft sprocket wht Timing belt tensioner on front case Crankshaft sprocket on sprocket side I ImIng maw on sprocket Camshaft left sprocket 4 Install the flange onto the front end of the crankshaft 5 Install the special tool onto the crankshaft 6 Loosen the tensioner lock bolt one or two turns and allow the spring to tension the ...

Page 337: ...N024 il I D4 ENGINE SUPPORT BRACKET INSTALLATION DIAMANTE I Tighten the engine support bracket bolts in the order shown in the illustration NOTE The bolt used at the location shown in the illustration is a reamer bolt head mark R TSB Revision ...

Page 338: ... Timing belt front upper cover left 4 Timing belt front lower cover 4AO 04 5 Timing belt C4 6 Auto tensioner 7 Tensioner pulley 8 Tensioner arm assembly 9 Idler pulley 10 Idler pulley bracket 11 Crankshaft sprocket B4 12 Rocker cover 13 Rocker cover gasket A 14 Rocker cover gasket B IB J A4 15 Camshaft sprocket bolt 16 Camshaft sprocket 17 Timing belt rear cover right 18 Timing belt rear cover lef...

Page 339: ...Washer Removal steps eE4 1 Engine support bracket 2 Crankshaft position sensor bracket 3 Timing belt front upper cover right 4 Timing belt front upper cover left 5 Timing belt front lower cover OAo eD4 6 Timing belt 7 Crankshaft position sensor 8 Camshaft position sensor B4 17 Rocker cover 18 Rocker cover gasket A 19 Rocker cover gasket B rBr A4 20 Camshaft sprocket bolt 21 Camshaft sprocket 22 Ca...

Page 340: ...ROCKET BOLT REMOVAL 1 Hold the hexagonal portion of the camshaft with a wrench when removing the camshaft sprocket bolt INSPECTION TIMING BELT Refer to INSPECTION on page IIE 50 AUTO TENSIONER 1 Check for oil leaks If oil leaks are evident replace the auto tensioner 2 Check the rod end for wear or damage and replace the auto tensioner if necessary 3 Measure the rod projection length If the reading...

Page 341: ...quivalent 2 Tighten the rocker cover bolts in the sequence shown in the illustration I c4 AUTO TENSIONER INSTALLATION If the auto tensioner rod is fully extended set it in the retracted position with the following procedure 1 Set the auto tensioner in a vice 2 Slowly close the vice to force the rod in until the set hole A of the rod is lined up with the set hole B of the cylinder 3 Insert a wire I...

Page 342: ... turn clockwise or counterclockwise after lining up the timing marks of the other camshaft sprocket the intake and exhaust valves might interfere Consequently if a camshaft sprocket was turned too far in lining up the timing marks be sure to rotate it back from that position to line up again the timing marks 4 Install the timing belt on the exhaust side camshaft sprocket for right bank and hold it...

Page 343: ...ming belt on the idler pulley 8 Install the timing belt on the crankshaft sprocket 9 Install the timing belt on the tensioner pulley 1O Using the special tool rotate the tensioner pulley clockwise to tighten the center bolt 1 l Remove the four paper clips 12 Using the special tool turn the crankshaft a quarter turn counterclockwise Then rotate it clockwise to line up the timing marks and check tha...

Page 344: ...tool and a torque wrench on the pull ey While holding the pulley with approximately 10 Nm 7 ftlbs torque to prevent it from turning tighten the center bolt to the specified torque 14 Turn the crankshaft two turns clockwise and leave it alone for about five minutes Then move in and out the auto tensioner setting metal wire to check that the wire moves smoothly NOTE If the metal wire does not move s...

Page 345: ...o tensioner is within the standard limit Standard value 3 8 4 5 mm I50 I77 in r E4 ENGINE SUPPORT BRACKET INSTALLATION 1 Tighten the engine support bracket bolts in the order shown in the illustration NOTE The bolt used at the location shown in the illustration is a reamer bolt head mark R TSB Revision I ...

Page 346: ...jector harness 2 Injector and fuel rail 3 insulator eG4 4 Fuel pressure regulator 5 O ring 6 Insulator eF4 87 lnj e rs 9 Gromet 10 Fuel pipe 11 O ring 12 Fuel rail D4 13 Engjne coolant temperature gauge unit C4 14 Engrne coolant temperature sensor I34 15 Therm0 switch 16 Water outlet fitting 17 Water outlet fitting gasket 18 Thermostat 19 Intake manifold 20 Intake manifold gasket 7EN0499 1 TSB Rev...

Page 347: ...pe 2 Insulator 13 Heat pipe gasket eG4 3 Fuel pressure regulator 14 Water hose 4 O ring eD4 15 Engine coolant temperature gauge unit 5 Insulator eC4 16 Engine coolant temperature sensor F4 6 Injectors eB4 17 Therm0 switch 7 O ring 18 Water outlet fitting 8 Gromet 19 Water outlet fitting gasket 9 Fuel rail 20 Thermostat 10 Water hose A 21 Intake manifold Il Water hose B 22 Intake manifold gasket 7E...

Page 348: ...r 7 eF4 Injector clip 8 Injectors 9 O ring 10 Gromet 11 Fuel pipe 12 O ring 13 Fuel rail E4 14 Intake manifold 15 Intake manifold gasket I Dg 16 Engine coolant temperature gauge unit eC4 17 Engine coolant temperature sensor B4 18 Therm0 switch TE 19 Water hose 20 Water hose A 21 Water outlet fitting 3000GT 22 Water outlet fitting 23 Water outlet fitting gasket DIAMAN 24 Water inlet fitting A4 25 T...

Page 349: ...rbo 13 16 R at 20 C 68 F Turbo 2 3 IR at 20 C 68 F INSTALLATION SERVICE POINTS A4 THERMOSTAT INSTALLATION DOHC 1 install the thermostat and line up the jiggle valve with the alignment mark on the thermostat housing I B4 SEALANT APPLICATION TO THERM0 SWITCH Specified sealant 3M Part No 8660 or equivalent c SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE SENSOR Specified sealant 3M Nut Locking No ...

Page 350: ... bbnk again in that order I Fg INSTALLATION OF INJECTOR 1 Before installing the injector the rubber O ring must be lubricated with a drop of clean engine oil for easy installation 2 Insert the injector top end into the fuel rail Be careful not to damage O ring during installation 3 Install the injector clip by sliding the open ends onto both injector and fuel rail I G4 FUEL PRESSURE REGULATOR INST...

Page 351: ...ring 4 Heat protector 5 Engine hanger right 6 Exhaust manifold right BC 7 Exhaust manifold gasket 8 Heat protector right 9 Bracket 10 Exhaust manifold left B4 11 Exhaust manifold gasket 12 Water hose 13 Water hose 14 Water by pass hose D 1SNm 14 ft lbs A4 15 Water inlet pipe B A4 16 O ring For M l A4 17 Water inlet pipe A A4 18 Water inlet pipe A4 19 O ring For A T 20 Water pump 21 Water pump gask...

Page 352: ...ring 4 Heat protector right 5 Engine hanger 6 Exhaust manifold right eB4 7 Exhaust manifold gasket 8 Heat protector left 9 Bracket 10 Exhaust manifold left B4 11 Exhaust manifold gasket 12 Water hose 13 Water hose A 14 Heater pipe 15 Heater pipe gasket 16 Water pipe A4 17 O ring A4 18 Water inlet pipe 19 Water inlet fitting gasket 20 Water pump 21 Water pump gasket 7ENO360 TSB Revision ...

Page 353: ...Nm IO ftlbs 45 Nm 33 ft lbs Removal steps 1 Oil level gauge 2 Oil level gauge guide 3 O ring 4 Heat protector right 5 Engine hanger 6 Exhaust manifold right 7 Exhaust manifold gasket 8 Heat protector left 9 Exhaust manifold left 0 Exhaust manifold gasket 1 O ring 2 Water inlet pipe 3 O ring 4 Water pump 15 Water pump gasket 7EN0503 ...

Page 354: ...fold REMOVAL AND INSTALLATION DOHC TURBO 14 Nm 10 ftlbs Removal steps 1 Oil level gauge 2 Oil level gauge guide 3 O ring A4 4 O ring A4 5 Water inlet pipe 17 ftlbs A4 6 O ring 7 Water pump 8 Water pump gasket 7EN0504 TSB Revision I ...

Page 355: ... A 11 Turbocharger stay 12 Exhaust fitting 13 Exhaust fitting gasket 14 Oil pipe 15 Water pipe A right 16 Water hose 17 Water pipe B right 18 Water hose 19 Turbocharger right 20 Turbocharger gasket 21 Ring 22 Oil return pipe right 23 Oil return pipe gasket 24 Exhaust manifold sta right C4 25 Exhaust manifold rig t 26 Exhaust manifold gasket 71N0120 TSB Revision ...

Page 356: ...m IO ftlbs 25 Nm 18 ft lbs 9 ml V m 10 Nm 28 14Nm IO ft lbs 27 3im 27 Heat protector D 28 Exhaust fitting left 29 Exhaust fitting gasket left 30 Heat protector C 31 Oil return pipe 32 Oil return pipe gasket 33 Oil pipe 34 Water pipe 6 left 35 Water hose 7lN0121 i TSB Revision ...

Page 357: ...1 Install gaskets with cylinder number 0 and embos sed on their top side to the right bank and install those with cylinder number 0 and J to the left bank I c4 RIGHT EXHAUST MANIFOLD INSTALLATION DOHC TURBO Tighten the nuts in the following order 1 Tighten five nuts to 30 Nm 22 ftlbs 2 Tighten nuts to 50 Nm 36 ft lbs 3 Back off nuts I until a torque value of 10 Nm 7 ft lbs is achieved 4 Tighten nu...

Page 358: ...nly tighten the turbocharger to the exhaust man 3 Tighten nut to 30 Nm 22 ft lbs 4 Tighten nuts and to 50 Nm 36 ftlbs 5 Back off nuts and until a torque value of 10 Nm 7 ft lbs is achieved 6 Tighten nuts and to 30 Nm 22 ftlbs NOTE 1 Fit the cone disc spring with the grooved side facing the nut 2 Install the nut cone disc spring and washer in the order shown in the illustration TSB Revision ...

Page 359: ...RBOCHARGER 1 Manually open and close the waste gate valve to make sure it operates freely 2 Inspect the oil passage in the cartridge for signs of deposits or blockage 3 Clean the inlet section of the compressor cover with a rag Inspect it for signs of contact with the compressor turbine If worn replace it REASSEMBLY SERVICE POINTS A4 O RING INSTALLATION 1 Apply a light coat of engine oil to a new ...

Page 360: ...ile aligning the dowel pin and the hole Caution Use care not to damage the blades of the turbine wheel and compressor wheel cg SNAP RING INSTALLATION 1 Fit the snap ring with its chamfered side facing up I 04 TURBINE HOUSING INSTALLATION 1 Install the turbine housing while aligning the dowel pin and the hole Caution Use care not to damage the blades of the turbine wheel TSB Revision I ...

Page 361: ...I CAMSHAFTS SOHC REMOVAL AND INSTALLATION DIAMANTE 9Nm 9 7 ft lbs 7 30 7 Removal steps E4 Fi c cover elII4 3 Circular packing C4 4 Camshaft oil seal 5 Distributor adaptor 6 O ring B4 7 Rocker arms shafts and bebring caps OAO A4 98 pa Smhs W er 7EN0362 TSB Revision ...

Page 362: ...UCK 13Nm t 9 ft lbs d 9Nm Q 7 ft lbs 9Nm I 7 ft lbs 0 8 Removal steps 1 Oil filler 2 Oil filler tube eE4 3 Rocker cover 4 Gasket D4 5 Circular packing I C4 6 Camshaft oil seal 7 Distributor adaptor 8 O ring B4 9 Rocker arms shafts and bearing caps aA0 A4 7 p dfutster 7EN0363 TSB Revision ...

Page 363: ...o check the cylinder head for damage Also check the cylinder head oil holes for clogging 2 Check the tooth surface of the distributor drive gear teeth of the camshaft and replace if abnormal wear is evident 3 Check the cam surface for abnormal wear and damage and replace if defective Also measure the cam height and replace if out of limit Standard value 41 25 mm 1 6240 in Limit 40 75 mm 1 6643 in ...

Page 364: ... Caution Upon completion of air bleeding hold the lash adjuster upright to prevents the inside diesel fuel from spilling 4 After air bleeding set the lash adjuster on the special tool Leak down tester MD998440 5 After the plunger has gone down somewhat 0 2 0 5 mm 008 020 in measure the time taken for it to go down 1 mm 04 in Replace if the measured time is out of specification Standard value 4 20 ...

Page 365: ...out onto the cam journal surface of the cylinder head If it swells out immediately wipe it off before it can dry Specified sealant 3M NUT Locking No 4171 or equivalent Apply sealant Apply sealant No 1 and No 4 bearing cap mating surface of cylinder head 2 Install the rocker arms shafts and bearing caps such that the arrow mark on the bearing cap faces in the same direction as the arrow mark on the...

Page 366: ...ker arm shaft assembly A Arrow mark bearing cap 7EN0176 3 Tighten the bearing cap bolts to the specified torque 4 Remove the special tools from all rocker arms ec4 CAMSHAFT OIL SEAL INSTALLATION 1 Apply a slight amount of engine oil all over the circumfer ence of the camshaft oil seal lip 2 Using the special tool insert the oil seal TSB Revision I ...

Page 367: ...59 in thick spacer to the special tool and drive in the circular packing NOTE Use of MD724328 spacer for transmission is recom mended Caution The packing is overdriven if no spacer is fitted to the special tool I E4 ROCKER COVER INSTALLATION 1 Apply specified sealant on the area specified in the illustration Specified sealant 3M ATD Part No 6660 or equivalent 1 TSB Revision ...

Page 368: ...aring cap No 3 5 Bearing cap No 2 A4 6 Rocker arm shaft B A4 7 Rocker arm shaft A 8 Bearing cap No 1 DISASSEMBLY SERVICE POINT OAo ROCKER ARM REMOVAL 1 Before disassembly identify the original location of each rocker arm by a symbol For example put symbols as shown below 1 IN For No 1 cylinder intake 6EX For No 6 cylinder exhaust __ TSB Revision ...

Page 369: ...eter and replace the rocker arm if damage or seizure is observed ROCKER ARM SHAFT 1 Check the rocker arm mounting portions of the rocker arm shafts for wear or damage Replace as necessary 2 Check to ensure that the oil holes are clear REASSEMBLY SERVICE POINT A4 ROCKER ARM SHAFT INSTALLATION 1 Install the rocker arm shafts A and B to the camshaft bearing cap No 1 and insert the bolts into the hole...

Page 370: ... equally shaped Assemble the rocker arms according to the symbols put before disassembly The bearing caps are also equally shaped Assemble the caps according to the identification marks as to right and left banks put before disassembly Front mark Camshaft bearing Camshaft bearing cap No 1 Camshaft bearing cap No 2 cap No 4 Cap No 7EN0079 TSB Revision I ...

Page 371: ...NSTALLATION 20 Nm Removal steps 1 Crankshaft position sensor E4 2 Circular packing eD4 3 Camshaft oil seal 4 Bearing cap front 5 Bearing cap rear 6 Bearing cap No 2 7 Bearing cap No 4 8 Bearing cap No 3 W B 9 Camshaft 10 Rocker arm A4 11 Lash adjuster adaptor Up to F r o m 1992 models 1993 models 7EN0505 1 TSB Revision I ...

Page 372: ...mm 1 3661 in From 1993 models Intake side 34 41 mm 1 3547 in Exhaust side 34 41 mm 1 3547 in LASH ADJUSTER LEAK DOWN TEST Refer to LASH ADJUSTER LEAK DOWN TEST on pages 11 E 79 and 11 E 80 Also note the following When the lash adjuster is set on a tester remove the adjusting screw of the tester and adjust it to the height of the lash adjuster as shown in the illustration INSTALLATION SERVICE POINT...

Page 373: ...Exhaust side E Non turbo Intake side Exhaust side ii J K 4 Install the camshafts with their dowel pins positioned as shown in the illustration Left bank Right bank KY ApproFi Front mark Identification 7EN031 t ec4 BEARING CAP INSTALLATION 1 Install the bearing caps according to the identification mark and cap number No 2 3 and 4 bearing caps bear the front mark Install these caps with the front ma...

Page 374: ...Bearing Caps DOHC I D4 CAMSHAFT OIL SEAL 1 Apply engine oil sparingly all around the lip of the camshaft oil seal 2 Using the special tool install the oil seal E4 CIRCULAR PACKING 1 Install the circular packing with the special tool TSB Revision ...

Page 375: ...r head assembly D4 4 Cylinder head gasket BI eC4 5 Retainer lock 6 Valve spring retainer B4 7 Valve spring 8 Inlet valve BI C4 9 Retainer lock 10 Valve spring retainer 1 Valve spring 2 Exhaust valve 3 Valve stem seal 4 Valve spring seat 5 Valve stem seal 6 Valve spring seat 7 Inlet valve guide 3 Snap ring 3 Exhaust valve guide I Inlet valve seat I Exhaust valve seat 2 Cylinder head 7EN0522 TSB Rev...

Page 376: ...ing to the cylinder number and intake exhaust OAo CYLINDER HEAD BOLT REMOVAL 1 Using the special tool loosen the cylinder head bolts Loosen evenly little by little BI RETAINER LOCK REMOVAL 1 Using the special tool compress the spring 2 Remove the retainer locks o VALVE STEM SEAL REMOVAL I Do not reuse removed valve stem seals 1 TSB Revision I I ...

Page 377: ...ing depth of both cylinder head and cylinder block Overall height 84 mm 3 31 in VALVE 1 If the valve stem is worn ridge wear or otherwise damaged replace Also replace the valve if the stem end that contacts the rocker arm adjusting screw has a dent 2 Check the valve face for correct contact If incorrect reface using a valve refacer Valve should make a uniform contact with the seat at the center of...

Page 378: ...ALVE SEAT RECONDITIONING PROCEDURES 1 Before valve seat reconditioning check the valve stem to guide clearance 2 Recondition the valve seat with a seat grinder or cutter The valve seat width should be the specified value at the center of the valve face Inspect the valve seat with prussian blue to determine where the valve contacts the seat To do this coat the valve seat lightly with prussian blue ...

Page 379: ...nder head to a selected oversize valve seat diameter Intake valve seat hole diameter 0 30 O S 44 30 44 33 mm 1 7441 1 7453 in 0 60 O S 44 66 44 63 mm 1 7559 1 7571 in Exhaust valve seat hole diameter 0 30 O S 38 30 38 33 mm 1 5079 1 5091 in 0 60 O S 38 60 38 63 mm 1 5197 1 5209 in 3 Before fitting the valve seat either heat the cylinder head up to approximately 250 C 482 F or cool the valve seat i...

Page 380: ...ve been replaced check for valve contact and correct the valve seats as necessary INSTALLATION SERVICE POINTS I A4 VALVE STEM SEAL INSTALLATION 1 Install the valve spring seat 2 Using the special tool install a new stem seal to the valve guide Caution Do not reuse removed valve stem seals I 64 VALVE SPRING INSTALLATION 1 Direct the valve spring end with identification color toward the spring retai...

Page 381: ...apply sealant to the cylinder head gasket Identification mark DIAMANTE and MONTERO 72 TRUCK 72W E4 CYLINDER HEAD BOLT INSTALLATION 1 Tighten the cylinder head bolts in the sequence shown Each bolt should be tightened in two to three steps torquing progressively Tighten to the specified torque in the final sequence TSB Revision ...

Page 382: ...Cylinder head assembly 4 Cylinder head gasket 5 Retainer lock 6 Valve spring retainer 7 Valve spring 8 Intake valve 9 Retainer lock 0 Valve spring retainer 1 eB4 11 Valve spring 12 Exhaust valve QCr A4 13 Valve stem seal 14 Valve spring seat Gr A4 15 Valve stem seal 16 Valve spring seat 17 Intake valve guide 18 Exhaust valve guide 19 Intake valve seat 20 Exhaust valve seat 21 Cylinder head 7EN0254...

Page 383: ...linder head bolts Loosen evenly little by little IBM RETAINER LOCK REMOVAL 1 Using the special tool compress the spring 2 Remove the retainer locks I VALVE STEM SEAL REMOVAL 1 Do not reuse removed stem seals INSPECTION For inspection only variations from the SOHC engine are described below Refer to page 11 E 93 94 95 and 96 TSB Revision I ...

Page 384: ...VE STEM SEAL INSTALLATION 1 Install the valve spring seat 2 Using the special tool install a new stem seal to the valve guide Caution Do not reuse removed valve stem seal I B4 VALVE SPRING INSTALLATION 1 Install the valve spring so that the end with identification color is positioned on the rocker arm end c4 INSTALLATION OF RETAINER LOCKS 1 Using the special tool compress the valve spring and inse...

Page 385: ...cation mark Non turbo 2DN Turbo 2DT I E4 CYLINDER HEAD BOLT INSTALLATION Turbo engine 1 Tighten the bolts in two to three stages in the illustrated sequence 2 Back off the bolts once and tighten them to the specified torque in the same procedure as shown in step 1 Intake side p y y q Exhaust side 7EN026 TSB Revision ...

Page 386: ...ion stay left eG4 3 Oil pressure switch F4 4 Oil pressure gauge unit E4 5 Oil filter 6 Oil cooler by pass valve 7 Oil filter bracket stay 8 Oil filter bracket 9 Oil filter bracket gasket 10 Drain plug eO4 11 Drain plug gasket c ArJ eC4 12 Oil pan 13 Oil screen 14 Oil screen gasket 15 Plug 16 Relief spring 17 Relief plunger Bg 18 Crankshaft oil seal 19 Oil pump case 20 Oil pump gasket 21 Oil pump c...

Page 387: ...e switch F4 2 Oil pressure gauge unit MONTERO E4 3 Oil filter 4 Oil cooler by pass valve MONTEBO 5 Oil filter bracket 6 Oil filter bracket gasket 7 Drain plug III4 8 Drain plug gasket IAI eC4 9 Oil pan 10 Oil screen Il Oil screen gasket 12 Plug 13 Relief spring 14 Relief plunger B4 15 Crankshaft oil seal 16 Oil pump case 17 Oil pump gasket 18 Oil pump cover IBI A4 19 Oil pump outer rotor I A4 20 O...

Page 388: ...e slide it along the oil pan to remove it BI OUTER ROTOR INNER ROTOR REMOVAL 1 Make alignment dots on the outer and inner rotors for reference in reassembly INSPECTION OIL PUMP 1 Check the tip clearance Standard value 0 03 0 08 mm 0012 0031 in 2 Check the side clearance Standard value 0 04 0 10 mm 0016 0039 3 Check the body clearance Standard value 0 10 0 18 mm 0040 0070 Limit 0 35 mm 0138 TSB Rev...

Page 389: ...ension must be the standard value when measured after the valve has been dipped in 100 C 212 F oil Dimension L 40 mm 1 57 in or more INSTALLATION SERVICE POINTS A INNER ROTOR OUTER ROTOR INSTALLATION 1 Apply engine oil to the rotors Then install the rotors ensuring that the alignment dots made at disassembly are properly aligned I B4 CRANKSHAFT FRONT OIL SEAL INSTALLATION 1 Using the special tool ...

Page 390: ...nt to the oil pan flange See Form In Place Gasket in introduction Specified sealant Mitsubishi Genuine Part No MD970389 or equivalent 3 The oil pan should be installed within 15 minutes after the application of sealant 4 Tighten the flange bolts in the sequence shown in the illustration Bolt hole area 7 Timing belt side Tightening sequence of flange bolts bottom view a Timing belt side TSB Revisio...

Page 391: ...d portion clear of sealant 2 Avoid an overtightening 9EN009 4 TSB Revision APP I E4 OIL FILTER INSTALLATION 1 Clean the installation surface of the filter bracket 2 Apply engine oil to the O ring of the oil filter 3 Screw the oil filter on until the O ring contacts the bracket Then tighten 3 4 turn I F4 SEALANT APPLICATION TO OIL PRESSURE GAUGE UNIT 1 Coat the threads of the gauge unit with sealan...

Page 392: ...ON ROD 4 52 Nm 38 ft lbs Removal steps 1 Nut GAO E4 2 Connecting rod cap 3 Connecting rod bearing lower eD4 4 Piston connecting rod assembly 5 Connecting rod bearing upper 6 Piston rina No 1 1 1 7 Piston rini No 2 8 Oil ring 9 Piston pin 0 Piston 1 Connecting rod 2 Bolt 7EN0424 TSB Revision ...

Page 393: ...necting Rod Guide Pin Piston Support Press Pin Stop Screw Nut 1 Remove the stop screw from the base 2 Select the correct piston support for your application See above Fit the piston support onto the base Place the base on the press support blocks 3 Insert the press pin through the piston pin hole Select the correct connecting rod guide pin See above Thread the guide pin onto the threaded portion o...

Page 394: ...laced with new ones 2 Check for clearance between the piston ring and ring groove If the limit is exceeded replace the ring or piston or both Standard value No 1 DIAMANTE and 3000GT 0 03 0 07 m m 0012 0026 in MONTERO and TRUCK 0 05 0 09 mm 0020 0035 in No 2 0 02 0 06 m m OOOS 0024 in Limit 0 1 mm 004 in 3 Insert the piston ring into the cylinder bore Force the ring down with a piston the piston cr...

Page 395: ...ring cap over it and tighten the bolts to the specified torque 5 Remove the bolts and gently remove the crankshaft bearing cap 6 Measure the width of the smashed plastic gauge at its widest section by using a scale printed on the plastic gauge bag Standard value 0 02 0 05 mm OOOS 0020 in Limit 0 1 mm 004 in INSTALLATION SERVICE POINTS A4 PISTON PIN INSTALLATION 1 Thread the stop screw and lock nut...

Page 396: ... necessary to visually inspect the piston pin depth after installation to verify that the piston pin is centered Adjust if necessary B4 OIL RING INSTALLATION 1 Fit the oil ring spacer into the piston ring groove NOTE The side rails and spacer may be installed in either direction 2 Install the upper side rail To install the side rail first fit one end of the rail into the piston groove then press t...

Page 397: ...oil ring gaps side rail and spacer as shown in the illustration 3 Rotate the crankshaft so that the crank pin is on the center of the cylinder bore 4 Use suitable thread protectors on the connecting rod bolts before inserting the piston and connecting rod assembly into the cylinder block Care must be taken not to nick the crank pin 5 Using a suitable piston ring compressor tool install the piston ...

Page 398: ...he correct connecting rod by checking with the alignment marks marked during disassembly If a new connecting rod is used which has no alignment mark position the notches for locking the bearing on the same side 2 Check if the thrust clearance in the connecting rod big end is correct Standard value 0 10 0 25 mm 0039 0098 in Limit 0 4 mm 0157 in TSB Revision ...

Page 399: ...D A T 8 Rear plate 9 Bell housing cover eF4 IO Oil seal case 7k Nm 54 ft lbs 75 Nm 54 ft lbs 6 48Nm 35 ft lbs eE4 11 Crankshaft rear oil seal eD4 12 Bearing cap stay __ 1992 models Turbo eC4 13 Bearing cap bolt eC4 14 Bearing cap C4 15 Bearing cap bolt C4 16 Bearing cap I 1993 models Turbo I34 17 Thrust beanng A B4 18 Thrust bearing B eB4 19 Crankshaft bearing lower 20 Crankshaft B4 21 Thrust bear...

Page 400: ...RANCE PLASTIC GAUGE METHOD The crankshaft oil clearance can be measured easily by using a plastic gauge as follows 1 Remove oil and grease and any other foreign matters from the crankshaft journal and bearing inner surface 2 Install the crankshaft 3 Cut the plastic gauge to the same length as the width of the bearing and place it on the journal in parallel with its axis 4 Gently place the cranksha...

Page 401: ... Thrust direction 7EN0462 4 Check the cylinder walls for scratches and seizure If defects are evident correct rebore to an oversize or replace 5 Using a cylinder gauge measure the cylinder bore and cylindricity If worn badly correct by boring the cylinders to an oversize and replace pistons and piston rings Measure at the points shown in the illustration Standard value Cylinder I D 91 10 91 13 mm ...

Page 402: ...piston O D clearance between piston 0 D and cylinder 6 Check the clearance between the piston and cylinder Clearance between piston and cylinder 0 01 0 04 mm 0004 0016 in NOTE When boring cylinders finish all of six cylinders to the same oversize Do not bore only one cylinder to an oversize INSTALLATION SERVICE POINTS I A4 DETONATION SENSOR BRACKET INSTALLATION 1 Check that the bracket is in intim...

Page 403: ...sify the crankshaft bearings upper and lower by whether there is an oil groove or not Then assemble as shown in the illustration 2 Assemble the thrust bearings A and B on the No 3 journal area as shown Caution Install them with the groove side facing outward 7EN0463 TSB Revision Oil groove Crankshaft bearing upper No oil groove Timing belt side Timing belt side ...

Page 404: ... end plate If it exceeds the limit value replace the thrust bearing Standard value 0 05 0 25 mm 0020 0098 in Limit 0 3 mm 012 in I Dg BEARING CAP STAY INSTALLATION DOHC TURBO 1 Apply engine oil to the thread and bearing surface of each bolt 2 Temporarily tighten the bolts on the cylinder block side 3 Tighten the bolts on the bearing cap side to the specified 4 Frr tighten the bolts on the cylinder...

Page 405: ...ool press fit a new crankshaft rear oil seal into the oil seal case I F4 OIL SEAL CASE INSTALLATION 1 Apply specified sealant to the area shown in the illustration Specified sealant MITSUBISHI GENUINE Part No MD970389 or equivalent 2 Apply a small amount of engine oil to the entire circuinfer ence of the oil seal lip section and place the oil seal on the cylinder block 1 TSB Revision I I I ...

Page 406: ...E and 3000GT 42Nm 30 ft lbs 2 I Removal steps 1 Engine support bracket right 2 Engine support bracket left 7EN0521 REMOVAL AND INSTALLATION MONTERO and TRUCK 30 ft lbs Removal steps 1 Roll stopper bracket front 2 Roll stopper bracket rear 1 TSB Revision 25 Nm 18 ft lbs ...

Page 407: ...SHAFT 76 CYLINDER HEAD AND VALVES 85 SEALANT 24 EXHAUST MANIFOLD AND SERVICE SPECIFICATIONS 14 WATER PUMP 68 SPECIAL TOOLS 25 FRONT CASE SILENT SHAFT AND OIL PAN THROllLE BODY 57 95 FUEL AND EMISSION CONTROL PARTS 52 TIMING BELT 33 GENERAL INFORMATION 2 TORQUE SPECIFICATIONS 21 GENERAL SPECIFICATIONS 10 TURBOCHARGER 73 GENERATOR AND IGNITION SYSTEM 28 ...

Page 408: ...llF 2 4G6 ENGINE 1993 General Information GENERAL INFORMATION ENGINE SECTIONAL VIEW SOHC 8 VALVE 6EN0629 TSB Revision ...

Page 409: ...4G6 ENGINE 1993 General Information TS8 Revision 6EN0630 ...

Page 410: ...llF 4 4G6 ENGINE 1993 General Information ENGINE SECTIONAL VIEW SOHC 16 VALVE 6EN0616 TSB Revision ...

Page 411: ...466 ENGINE 1993 General Information 6EN0614 TSB Revision ...

Page 412: ...4G6 ENGINE 1993 General Information ENGINE SECTIONAL VIEW DOHC 6EN0619 TSB Revision ...

Page 413: ...4G6 ENGINE 1993 General Information I W7 6EN0620 TSB Revision ...

Page 414: ...neral Information ENGINE LUBRICATION SYSTEM SOHC 8 VALVE Rocker shaft T u C r a n k s h a f t Silent shaft Oil pump IA L 6LUOO39 ENGINE LUBRICATION SYSTEM SOHC 16 VALVE I Crankshaft valve Oil pump 1 TSB Revision MN0734 I ...

Page 415: ...YSTEM DOHC Oil w Camshaft Oil cooler Relief valve Oil pumr I Oil I n l Crankshaft Silent shaft 6LUOil55 ENGINE LUBRICATION SYSTEM DOHC TURBO 6LUOO56 From thermostat case Oil filter To wate Oil jet I xessure switch Crankshaft Oil pump A S i l e n t s h a f t ...

Page 416: ...ooling system Water pump type EGR valve Injector type and number Injector identification No Fuel regulated pressure kpa psi Throttle bore mm in Throttle position sensor Closed throttle position switch Specifications In line OHV SOHC 4 Pentroof type 1 997 121 9 85 3 35 88 3 46 9 5 11 53 63 21 Pressure feed full flow filtration Involute gear type Water cooled forced circulation Centrifugal impeller ...

Page 417: ...tem Water pump type EG R valve njector type and number njector identification No Gel regulated pressure kpa psi Throttle bore mm in Throttle position sensor Closed throttle position switch Specifications In line OHV SOHC 4 Pentroof type 2 350 143 4 86 5 3 41 100 3 94 8 5 20 64 64 20 Pressure feed full flow filtration Involute gear type Water cooled forced circulation Centrifugal impeller type Sing...

Page 418: ... Water pump type EGR valve Injector type and number Injector identification No Fuel regulated pressure kpa psi Throttle bore mm in Throttle position sensor Closed throttle position switch Specifications In line OHV SOHC 4 Pentroof type 2 350 143 4 86 5 3 41 100 3 94 9 5 18 58 58 18 Pressure feed full flow filtration Involute gear type Water cooled forced circulation Centrifugal impeller type Singl...

Page 419: ...tem lNater pump type G R valve njector type and number njector identification No Non turbo Turbo uel regulated pressure kpa psi Non turbo Turbo hrottle bore mm in hrottle position sensor Iosed throttle position switch Specifications In line OHV OHC 4 Pentroof type 1 997 121 9 85 3 35 88 3 46 9 8 9 0 7 8 B C AA DS LA 21 26 21 16 43 46 51 48 57 55 57 5 5 18 9 15 9 Pressure feed full flow filtration ...

Page 420: ...cylinder head and cylinder block q latness of manifold mounting surface 3verall height 3versize rework dimensions of valve guide hole both intake and exhaust 0 05 002 0 25 OlO 0 50 020 3versize rework dimensions of intake valve seat ring hole 0 30 012 0 60 024 3versize rework dimensions of exhaust valve eat ring hole 0 30 012 0 60 024 Standard 0 05 0020 89 9 90 1 3 508 3 547 13 05 13 07 5138 5146 ...

Page 421: ...seat ring hole 0 30 012 33 30 33 33 1 3110 1 3122 0 60 024 33 60 33 63 1 3228 1 3240 samshaft SOHC 8 VALVE Xam height Intake 42 40 1 6693 41 90 1 6496 Exhaust 42 40 1 6693 41 90 1 6496 Journal diameter 33 94 33 95 1 3362 1 3366 3il clearance 0 05 0 09 0020 0035 lamshaft SOHC 16 VALVE Zam height Intake 37 39t1 4720 36 89 1 4524 Exhaust 37 47 1 4752 36 97 1 4555 ournal diameter 44 93 44 94 1 7689 1 ...

Page 422: ...04 Rocker shaft SOHC 8 VALVE 3 D 3verall length Intake Exhaust 3ocker shaft SOHC 16 VALVE I D Iverall length Intake Exhaust falve SOHC 8 VALVE Iverall length Intake Exhaust item diameter Intake Exhaust ace angle hickness of valve head margin Intake Exhaust item to guide clearance Intake Exhaust 18 89 18 90 7437 7441 385 5 15 177 372 5 14 665 19 99 20 00 i 7870 7874 417 25 16 427 417 25 16 427 106 ...

Page 423: ...6 VALVE ree height oad installed height N mm 1bs iin j jut of squareness alve spring DOHC ree height oad installed height N mm Ibsiin jut of squareness Standard 112 3 4 421 114 1 4 492 5 97 5 98 i 2350 2354 5 95 5 97 2343 2350 45 45 30 1 o 039 1 2 047 0 02 0 05 i 0008 0020 0 03 0 07 LOOI 2 0028 109 5 4 311 109 7 4 319 6 57 6 58 2587 2591 6 53 6 55 i 2571 2579 45 45 30 1 o 039 1 5 059 0 02 0 05 l 0...

Page 424: ... 06 13 07 5142 5146 0 05 002 0 25 OlO 0 50 020 oversize Room temperature 45 5 1 79 50 5 1 99 6 00 6 02 236 237 11 06 11 07 4354 4358 0 05 002 0 25 Ol 0 50 02 over size Room temperature 45 5 1 791 50 5 1 988 6 60 6 62 2598 2606 12 06 12 07 4748 4752 3 05 002 0 25 010 0 50 020 oversize 3oom temperature 43 30 44 I 9 1 3 035 051 I 3 012 0 6 024 over size 11 96 41 98 1 6520 1 6528 10 95 40 97 1 6122 1 ...

Page 425: ...03 0 07 0012 0028 0 25 OlO 0 50 020 0 75 030 1 OO 039 over size 0 8 031 0 8 031 0 8 031 1 o 039 1 o 039 0 1 004 0 1 004 Piston ring DOHC End gap No 1 ring No 2 ring Oil ring qing to ring groove clearance No 1 ring Non turbo Turbo No 2 ring Service size 0 25 0 40 0098 0157 0 45 0 60 l 0177 0236 0 13 0 38 0051 0150 0 02 0 06 0008 0024 0 03 0 07 0012 0028 0 02 0 06 0008 0024 0 25 OlO 0 50 020 0 75 03...

Page 426: ...d cylinder head Overall height 4663 283 9 284 1 11 177 11 185 4664 289 9 290 1 11 413 11 421 Oil pump Side clearance Drive gear 0 08 0 14 0031 0055 Driven gear 0 06 0 12 0024 0047 Drive belt Deflection V ribbed type belt New belt 7 5 9 0 30 35 Used belt 8 0 32 V type belt 7 0 10 0 28 391 Tension V ribbed type belt New belt N Ibs soo 700 110 154 Used belt N Ibs 400 88 Oil cooler by pass valve Iimen...

Page 427: ...ner bolt dler pulley bolt SOHC dler pulley bolt DOHC Xl pump sprocket nut Crankshaft bolt rensioner B bolt silent shaft sprocket bolt Camshaft sprocket bolt Iming belt rear cover SOHC 16 VALVE M8 Ml0 ingine support bracket bolt uel and emission parts GR valve bolt hrottle body stay bolt DOHC hrottle body bolt el regulator bolt pressure hrottle body hrottle position sensor bolt Jle speed control se...

Page 428: ...vel gauge guide bolt M8 Ml0 ieat protector bolt M6 M8 Ml0 ixhaust manifold nut SOHC xhaust manifold nut DOHC jir outlet fitting bolt urbocharger bolt and nut ixhaust fitting bolt water inlet pipe bolt Vater bolt pump Vater pipe A and B eye bolt Yater pipe A bolt Yater pipe B flare nut Yater pipe bolt M8 M6 il return pipe bolt Xl pipe Cylinder head side Turbocharger side urbocharger urbocharger was...

Page 429: ...lief plug 3il cover bolt pump 3il unit pressure gauge iston and connecting rod Connecting rod cap nut Crankshaft flywheel and drive plate lywheel bolt Irive plate bolt Xl seal case bolt searing cap bolt SOHC 3earing cap bolt DOHC Bracket eft and right engine support bracket bolt ront roll stopper bracket bolt Iear roll stopper bracket bolt ront engine support bracket bolt ixhaust pipe support brac...

Page 430: ...60 or equivalent 3M ATD Part No 8660 or equivalent 3M ATD Part No 8660 or equivalent MITSUBISHI GENUINE PART MD970389 or equivalent MITSUBISHI GENUINE PART MD970389 or equivalent 3M ATD Part No 8660 or equivalent 3M Nut Locking Part No 4171 or equivalent 3M ATD Part No 8660 or equivalent 3M ATD Part No 8660 or equivalent MITSUBISHI GENUINE PART MD970389 or equivalent Quantity As required As requir...

Page 431: ...4G6 ENGINE 1993 Special Tools SPECIAL TOOLS Use with M IT304204 Use with MIT304204 Crankshaft front oil seal installer TSB Revision ...

Page 432: ...998705 M D998373 0 1 Installation of silent shaft bearing CR Silent shaft bearing installer 0 0 MD998713 M D9987 13 01 Installation of camshaft oil seal Camshaft oil J 8 seal installer MD99871 9 M IT308239 Holding camshaft sprocket when loosening Pulley holding or torquing bolt pins 2 For SOHC engine only M D998727 Oil pan remover Removal of oil pan M D998729 MD998729 01 Installation of valve stem...

Page 433: ...pecial Tools I IF 27 tool name compressor Crankshaft rear oil seal installer MD998779 M D998780 Piston pin setting tool MIT21 6941 Removal and installation of piston pin Supporting flywheel and drive plate TSB Revision ...

Page 434: ...bs 1 0 11 Nm 8 ftlbs 25 N m 18 ft lbs 11 Nm 8 ft lbs Removal steps DC 1 Drive belt 2 Cooling fan 3 Fan clutch 4 Water pump pulley 5 Power steering pump pulley 6 Generator brace 7 Generator 8 Crankshaft pulley 9 Spark plug cable 10 Spark plug 11 High tension cable A4 12 Ignition coil and ignition power transistor 13 Distributor 6EN0654 TSB Revision 1 ...

Page 435: ...INSTALLATION SOHC 16 VALVE r 14 Nm 10 ft lbs 24Nm 17 ftlbs 25 Nm 18 ft lbs Removal steps eD4 1 Drive belt 2 Water pump pulley 3 Power steering pump pulley 4 Generator brace 5 Generator 6 Crankshaft pulley 7 Spark plug cable 8 Spark plug BC 9 Distributor TSB Revision ...

Page 436: ... pulley 8 Spark plug cable 3 Power steering pump pulley 9 Spark plug 4 Generator brace 10 Ignition power transistor 5 Generator 1 1 Ignition coil 6 Crankshaft pulley C4 12 Crankshaft position sensor TSB Revision 3Nm 2 ft lbs Nm ft lbs 24 Nm 17 ft lbs 8 23 Nm 17 ft lbs 25 Nm 18 ft lbs 19 Nm 14 ft lbs 11 Nm 8 ft lbs d 4 0 10 24 h 17 klbs 6EN0656 ...

Page 437: ...SSEMBLY INSTALLATION 1 Turn the crankshaft to bring No 1 cylinder to the top dead center on compression stroke 2 Align the mating marks on the distributor housing with that of the coupling key 3 Install the distributor assembly on the engine while aligning the stud bolt used for securing the distributor with the slot in the mounting flange of the distributor I c4 CRANKSHAFT POSITION SENSOR INSTALL...

Page 438: ... tension gauge for V ribbed belt only Standard value New belt 500 700 N 110 154 Ibs Used belt 400 N 88 Ibs 2 Tighten the lock bolt to the specified torque 3 Tighten the nut for the pivot bolt to the specified torque BRACE BOLT TYPE 1 Move generator to adjust belt deflection to standard value Standard value V ribbed type belt New belt 7 5 9 0 mm 30 35 in Used belt 8 0 mm 32 in V type belt 7 0 10 0 ...

Page 439: ...ing belt front upper cover 2 Timing belt front lower cover IAI NC 3 Timing belt K4 4 Tensioner spring Kg 5 Tensioner pulley ODrJ Jg 6 Oil pump sprocket 8 I4 7 Crankshaft bolt 8 Crankshaft sprocket 9 Flange 10 Tensioner B AG J H 11 Timing belt B OHrJ Gg 12 Silent shaft sprocket F4 13 Spacer 14 Crankshaft sprocket B 8 AC 15 Camshaft sprocket bolt 16 Camshaft sprocket 17 Timing belt rear cover 6EN065...

Page 440: ...arm 120 Nm 87 ftlbs upper lower ap I 24 Nm 6 Auto tensioner 17 ft lbs eL4 7 Idler 2 pulley QOr eJ4 8 Oil pump sprocket 818 I4 10 9 Crankshaft Crankshaft sprocket bolt 11 Flange 12 Tensioner B OGr eH4 13 Timing belt B IHO eG4 14 Silent shaft sprocket eF4 15 010 Spacer 16 Crankshaft sprocket B C4 17 Engine support bracket JI A 18 Camshaft sprocket bolt 19 Camshaft sprocket 20 Timing belt rear cover ...

Page 441: ...ley 5 Tensioner arm eL4 6 Auto tensioner 7 Idler pulley 100 8 Oil pump sprocket 18 I4 9 Crankshaft bolt 10 Crankshaft sprocket 11 Flange 12 Tensioner B ICI Hg 13 Timing belt B OHr eG4 14 Silent shaft sprocket eF4 15 Spacer 010 16 Crankshaft sprocket B eE4 17 Rocker cover D I 18 Semi circular packing C4 19 Engine support bracket rKrJ eB4 20 Camshaft sprocket bolt 21 Camshaft sprocket 22 Timing belt...

Page 442: ... tensioner mounting bolt and remove the timing belt OBo TIMING BELT REMOVAL 1 Mark belt running direction for reinstallation NOTE 1 Water or oil on the belt shorten its life drastically so the removed timing belt sprocket and tensioner must be free from oil and water These parts should not be washed Replace parts if seriously contaminated 2 If there is oil or water on each part check front case oi...

Page 443: ...e direction if it is to be reused NOTE 1 Water or oil on the belt shortens its life drastically so the removed timing belt sprocket and tensioner must be free from oil and water These parts should not be washed Replace parts if seriously contaminated 2 If there is oil or water on each part check front case oil seals camshaft oil seal and water pump for leaks OH0 SILENT SHAFT SPROCKET REMOVAL 010 C...

Page 444: ... remove the camshaft sprocket bolt Caution Locking the camshaft sprocket with a tool damages the sprocket 2 Remove the camshaft sprockets INSPECTION TIMING BELT Replace belt if any of the following conditions exist 1 Hardening of back rubber Back side is glossy without resilience and leaves no indent when pressed with fingernail 2 Cracks on rubber back 3 Cracks or peeling of canvas 4 Cracks on rib...

Page 445: ... as necessary 2 Check the rod end for wear or damage and replace as necessary 3 Measure the rod protrusion If it is out of specification replace the auto tensioner Standard value 12 mm 47 in 4 Clamp the auto tensioner in a vise with soft jaws Caution The plug at the bottom of the auto tensioner protrudes Insert a plain washer as illustrated to prevent the plug from being in direct contact with the...

Page 446: ... hold the camshaft at its hexagon between the No 2 and No 3 journals and tighten the bolt to the specification Caution Locking the camshaft sprocket with a tool damages the sprocket cg ENGINE SUPPORT BRACKET INSTALLATION 1 Coat the bolts illustrated with sealant before tightening Specified sealant 3M ATD Part No 8660 or equivalent TSR Revision I ...

Page 447: ... Belt I IF 41 Apply sealant d i a a DEN0053 I0 mr S _ n 19 in Apply sealant I Z 2 I Cylinder head 3EN0044 IbDC SEALANT APPLICATION ON SEMI CIRCULAR PACKING Specified sealant 3M ATD Part No 8660 or equiva lent TSB Revision I ...

Page 448: ... the areas indicated in the illustration Specified sealant 3M ATD Part No 8660 or equivalent IOmm Apply sealant 6EN0396 Y k Chamfer 6EN061 Ei L lseal I F4 SPACER INSTALLATION 1 Install the spacer with the chamfered end toward the oil seal I G4 SILENT SHAFT SPROCKET INSTALLATION 1 TSB Revision I ...

Page 449: ...enter is as shown in the illustration 4 Move the tensioner B in the direction of arrow while lifting with a finger to give a sufficient tension to the tension side of timing belt In this condition tighten bolt to secure tensioner B When the bolt is tightened use care to prevent shaft from turning together If shaft is turned together belt will be overtensioned 5 Check to ensure that timing marks on...

Page 450: ...rojection and tensioner bracket 2 Move tensioner fully toward water pump and tighten the bolt and tensioner spacer I L4 AUTO TENSIONER INSTALLATION 1 If the auto tensioner rod is in its fully extended position reset it as follows 2 Clamp the auto tensioner in the vise with soft jaws Caution The plug at the bottom of the auto tensioner protrudes Insert a plain washer as illustrated to prevent the p...

Page 451: ...nsioner pulley in such direction that its two small holes are arranged vertically I N4 TIMING BELT INSTALLATION 1 Check that the timing belt tensioner has been installed in position See I K 2 Align timing mark on camshaft sprocket with timing mark on cylinder head 3 Align timing mark on crankshaft sprocket with timing mark on front case 4 Align the timing mark on oil pump sprocket with its mating ...

Page 452: ...he screwdriver inserted until installation of timing belt is finished 6 Install the timing belt on the crankshaft sprocket oil pump sprocket and camshaft sprocket in that order There should be no slack on the tension side 7 Loosen the tensioner mounting bolt and tensioner spacer 8 Turn the crankshaft clockwise by two teeth of camshaft sprocket or crankshaft sprocket 9 Apply force to the tensioner ...

Page 453: ...procket with timing mark on cylinder head 3 Align timing mark on crankshaft sprocket with timing mark on front case 4 Align the timing mark on oil pump sprocket with its mating mark 5 Remove the plug on cylinder block and insert a Phillips screwdriver shank diameter 8 mm 31 in through the hole Engine with silent shafts If it can be inserted as deep as 60 mm 2 4 in or more the timing marks are corr...

Page 454: ... and loosen the tensioner pulley center bolt NOTE If the special tool is not available use a commercially available torque wrench that is capable of measuring 0 3 Nm 0 2 2 ft lbs 12 Torque to 2 6 2 8 Nm 1 88 2 03 ft lbs with the torque wrench 13 Holding the tensioner pulley with the special tool and torque wrench tighten the center bolt to specification 14 After giving two clockwise turns to the c...

Page 455: ...amshaft use the timing mark on the right with the dowel pin hole on top For the intake camshaft sprocket use the one on the left with the dowel pin hole on top 2 Align the crankshaft sprocket timing mark 3 Align the oil pump sprocket timing mark Engine with silent shafts 4 Insert a Phillips screwdriver shank diameter 8 mm 31 in through the hole Engine with silent shafts If it can be inserted as de...

Page 456: ...lip 8 Thread the timing belt over the idler pulley the oil pump sprocket the crankshaft sprocket and the tensioner pulley in the order shown 9 Remove the two clips 1O Lift up the tensioner pulley in the direction of arrow and tighten the center bolt 11 Check to see that all timing marks are lined up 12 Remove the screwdriver inserted in step 4 and fit the plug Engine with silent shafts 13 Give the...

Page 457: ...bs with the torque wrench 16 Holding the tensioner pulley with the special tool and torque wrench tighten the center bolt to specification 17 After giving two clockwise turns to the crankshaft let it alone for approx 15 minutes Then make sure that the auto tensioner setting wire moves freely NOTE If the wire does not move freely repeat step 13 above until it moves freely 18 Remove the auto tension...

Page 458: ...LRV 6 12Nm 9 ftlbs 22 Nm 16 ft lbs u 5 11Nm 6 ft lbs Removal steps I Throttle body 2 Throttle body gasket 3 EGR valve 4 EGR valve gasket 5 EGR temp sensor For California 6 Injectors and delivery pipe 7 Insulator 8 Fuel pressure regulator 1 K11Sor A4 11 Injector clip eB4 12 Injectors 13 O ring 14 Grommet 15 Fuel rail 6EN0676 TSB Revision I ...

Page 459: ... 9 ft lbs 9Nm Removal steps 1 Throttle body 2 Throttle body gasket 3 EGR valve 4 EGR valve gasket 5 EGR temp sensor For California 6 Injectors and fuel rail 7 Insulator 8 Fuel pressure regulator 9 O ring 10 Insulator 11 Injectors 12 O ring 13 Grommet 14 Fuel rail 22km 16 ft lbs 6EN0677 1 TSB Revision I ...

Page 460: ...le body stay 2 Throttle body 3 Throttle body gasket 4 EGR valve 5 EGR valve gasket 6 EGR temp sensor For California 7 Injectors and fuel rail 8 Insulator 9 Fuel pressure regulator C4 10 O ring 11 Insulator I34 12 Injectors 13 O ring 14 Grommet 15 Fuel rail 19 Nm 14 ft lbs 1 I 19 Nm 14 ftlbs 22 Nm 16ft lbs 6EN0678 TSB Revision ...

Page 461: ...ohmmeter circuit tester test for continuity between terminals of injector the circuit should be closed If failure is detected replace the injector Standard value Non turbo 13 16 fi at 20 C 68 F l Turbo 2 3 Cl at 20 C 68 F INSTALLATION SERVICE POINTS I A4 INJECTORS INJECTOR CLIP INSTALLATION 1 Before installing an injector the rubber O ring must be lubricated with a drop of clean engine oil to aid ...

Page 462: ...jector top end into fuel rail Be careful not to damage the O ring during installation 6EN0521 I c4 FUEL PRESSURE REGULATOR INSTALLATION 1 Before installing pressure regulator the O ring must be lubricated with a drop of clean engine O ring to aid in installation TSB Revision ...

Page 463: ...mbly steps Ar A4 1 Throttle position sensor aA 2 Speed control motor 3 Throttle valve set screw eB4 4 Throttle body 6FU1292 SOHC TRUCK California SOHC GALANT 2Nm Disassembly steps g A4 I Throttle position sensor 2 Idle air control motor 3 5 Nm 3 Throttle valve set screw 2 5 lbs 30 4 Throttle body 6EN0711 1 TSB Revision ...

Page 464: ...s I I A4 2 Throttle position sensor 3 Idle air control motor 4 Throttle valve set screw O 5 Throttle body 6FU1857 2Nm 1 4ft lbs Disassembly steps 1 Dash pot l 2 Hose GALANT 3 Vacuum valve 18 A4 4 Throttle posltlon sensor 5 idle air control motor 6 Idle position switch 7 Adjusting nut QW 8 Throttle body 1 TSB Revision 6EN0712 I ...

Page 465: ...ge M D998463 7FU0 M D998463 7FU0 MD998463 7F110071 INSPECTION IDLE AIR CONTROL MOTOR DOHC Checking the Coil Resistance 1 Connect Test Harness to the motor connector 2 Measure the resistance between white clip of Test Harness and red clip or blue clip Standard value 28 33 fl at 20 C 68 F 3 Measure the resistance between green clip of the Test Harness and yellow clip or black clip Standard value 28 ...

Page 466: ...t the negative 0 terminal of the power supply to the red and black clip Repeat the tests in sequence from to 7 4 If as a result of these tests vibration is detected the stepper motor can be considered to be normal MOTOR POSITION SENSOR SOHC for TRUCK I Measure the resistance between terminals and Standard value 4 6 kfi 2 Disconnect the idle speed control motor connector 3 Connect 6V DC between ter...

Page 467: ...sure that the resistance changes smoothly when the throttle valve is slowly moved to the fully open position 4 Check for continuity between terminals closed throttle position switch and ground with the throttle valve both fully closed and fully open Throttle valve position I Continuity I 1 Fully closed Conductive 1 Fully open I Non conductive I If there is not continuity with the throttle valve fu...

Page 468: ...5 2 Turn the throttle position sensor 90 in the clockwise direction to set it and tighten the screws 3 Connect the circuit tester between ground and output or between output and power Then make sure that the resistance changes smoothly when the throttle valve is slowly moved to the fully open position TSB Revision ...

Page 469: ...ngine coolant temperature gauge unit E 4 Engine coolant temperature sensor 5 Water outlet fitting B4 6 Gasket 7 Thermostat 8 Thermostat housing 9 Gasket 10 Intake manifold plenum stay 11 Intake manifold plenum 12 Intake manifold plenum gasket 13 Intake manifold stay 14 Engine hanger 15 Intake manifold 16 Intake manifold gasket 13 6EN0679 TSB Revision ...

Page 470: ... lhe 3 ub18Nm 13 ft lbs Removal steps 1 Water hose 2 Water hose F4 3 Engine coolant temperature sensor eE4 4 Engine coolant temperature gauge unit eD4 5 Water inlet fitting 6 Thermostat 7 Water outlet fitting C l 8 Thermostat housing 9 Intake manifold stay 10 Intake manifold 11 Intake manifold gasket 31 ium 22 ft lbs 6EN0660 TSB Revision ...

Page 471: ...r hose 2 Water hose 3 Water hose turbo 4 Water hose turbo F4 5 Engine coolant temperature gauge unit eE4 6 Engine coolant temperature sensor 7 Water outlet fitting 8 Gasket 9 Thermostat eC4 10 Thermostat case 11 Gasket 12 Intake manifold stay A4 13 Intake manifold 14 Intake manifold gasket 20 ftlbs TSB Revision 6EN0460 I ...

Page 472: ...t torque I Bg WATER OUTLET FITTING GASKET INSTALLATION FOR RUBBER COATED METAL GASKET ONLY I install the water outlet fitting gasket with its UP mark facing up toward the water outlet fitting side c4 Al AlN z APPLICATION TO THEREMOSTAT Specified sealant Mitsubishi Genuine Part No MD970389 or equivalent I D4 SEALANT APPLICATION TO WATER OUTLET FITTING Specified sealant Mitsubishi Genuine Part No MD...

Page 473: ...4G6 ENGINE 1993 Intake Manifold 11 F 67 I F4 SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE GAUGE UNIT Specified sealant 3M ATD Part No 8660 or equivalent 7cooo2 TSB Revision ...

Page 474: ...LVE 30 Nm 22 ft lbs I 4 18 Nm 13 ft lbs 3 14 Nm lo ft lbs 14 Nm 10 ft lbs Removal steps I Oxgen sensor Federal 2 Oil level gauge 3 Oil level gauge guide 4 Heat protector 5 Engine hanger 6 Exhaust manifold 7 Exhaust manifold gasket A4 8 Water inlet pipe A4 9 O ring 10 Water pump 11 Water pump gasket TSB Revision 6EN0663 A _ ...

Page 475: ...0 ft lbs 14 Nm 10 ft lbs Removal steps 1 Oxgen sensor GALANT EXPO Federal 2 Oil level gauge 3 Oil level gauge guide 4 O ring 5 Heat protector 6 Heat protector GALANT EXPO EXP LRV Federal 7 Engine hanger 8 Exhaust manifold 9 Exhaust manifold gasket A4 10 Water inlet pipe A4 11 O ring 12 Water pump 13 Water pump gasket 6EN0664 TSB Revision ...

Page 476: ...m 33 ft lbs 14 Nm 10 ft lbs 60 Nm 43 ft lbs 14 Nm lo ftlbs Removal steps 1 Oxygen sensor 2 Oil level gauge 3 Oil level gauge guide 4 O ring 5 Heat protector A 6 Heat protector B 7 Engine hanger 8 Exhaust manifold 9 Exhaust manifold gasket A4 10 Water inlet pipe A4 11 O ring 12 Water pump 13 Gasket 6EN0665 TSB Revision ...

Page 477: ...ector B 6 Exhaust fitting 7 Gasket 8 Air outlet fitting 9 Gasket 10 Water pipe B 11 Oil return pipe 12 Gasket 13 Turbocharger assembly 14 Gasket 15 Ring 14 Nm 10 ftlbs I13 J 27 28 I I I I 4 Nm w 24 Nm 10 ft lbs 17 ft lbs 16 Oil pipe 17 Water pipe A 18 Turbocharger 19 Engine hanger 20 Exhaust manifold 21 Exhaust manifold gasket 22 Water pipe 23 Water hose 24 Water hose A4 25 Water inlet pipe A4 26 ...

Page 478: ...Exhaust Manifold and Water Pump O ring dtlr 6EN0594 INSTALLATION SERVICE POINT I A4 WATER PIPE O RING INSTALLATION 1 Wet the O ring with water to facilitate assembly Caution Keep the O ring free of oil or grease TSB Revision ...

Page 479: ...LY 7 l l F 73 Disassembly steps V4 Inspection of turbocharger waste gate actuator operation 1 Snap pin 2 Turbochargerwaste gate actuator EC 3 Coupling eO4 4 Turbine housing C4 5 Snap ring Bg 6 Turbine wheel assembly 7 Compressor cover A4 8 O ring 6lN0052 TSB Revision ...

Page 480: ...and compressor wheel blades for bend burr damage corrosion and traces of contact on the back side and replace if defective 2 Check the oil passage of the turbine wheel assembly for deposit and clogging 3 In the case of water cooled type check also the water passage for deposit and clogging 4 Check the turbine wheel and compressor wheel for light and smooth turning REASSEMBLY SERVICE POINTS r A4 O ...

Page 481: ...TALLATION 1 Install the coupling and tighten to specified torque F4 TURBOCHARGER WASTE GATE ACTUATOR OPERATION INSPECTION 1 Using a tester apply a pressure of approx 72 kPa 10 3 psi to the actuator and make sure that the rod moves Caution Do not apply a pressure of more than 85 kPa 12 4 psi to the actuator Otherwise the diaphragm may be damaged Never attempt to adjust the turbocharger waste gate v...

Page 482: ... o 5 Removal steps 1 Breather hose 2 P C V hose 6 Oil filter cap Rocker cover Gasket Semi circular packin Rocker arms and rot er shafts g Rear bearing cap Rocker arm D Spring Bearing cap No 4 Rocker arm C Bearing cap No 3 Bearing cap No 2 Wave washer Right rocker shafts Left rocker shafts Front bearing cap Lash adjuster Oil seal Camshaft 6EN0523 TSB Revision ...

Page 483: ...r cover 5 Rocker cover gasket 6 Oil seal eH4 7 Oil seal rare G4 8 Rocker arms and rocker arm shaft Jr eG4 9 Rocker arms and rocker arm shaft eG4 10 Rocker shaft spring 11 Rocker arm A 12 Rocker arm B 13 Rocker arm shaft Intake side F4 14 Lash adjuster 15 Rocker arm C 16 Rocker arm shaft Exhaust side F4 17 Lash adjuster 18 Camshaft 6EN0686 TSB Revision ...

Page 484: ...14 ftlbs 11 Nm 8 ft lbs Removal steps Eg 1 Bearing cap rear Eg 2 Bearing cap front eH4 3 Camshaft oil seal eE4 4 Bearing cap No 5 eE4 5 Bearing cap No 2 eE4 6 Bearing cap No 4 E4 7 Bearing cap No 3 A4 8 Camshaft 9 Rocker arm F4 10 Lash adjuster 11 Oil delivery body 6EN0524 TSB Revision ...

Page 485: ... 40 1 6693 41 90 1 6496 37 47 1 4752 36 97 1 4555 DOHC mm in Identification mark Standard value Limit I I I Intake A D B E Exhaust A C 35 49 1 3972 34 99 1 3776 35 20 I 3858 34 70 1 3661 35 20 1 3858 34 70 1 3661 35 49 1 3972 34 99 1 3776 NOTE The camshaft identification mark is stamped on the opposite end of the camshaft sprocket side ROCKER ARM 1 Check the roller surface If any dents damage or s...

Page 486: ...ess the plunger If the plunger is hard to be pushed in the lash adjuster is normal If the plunger can be pushed in all the way readily bleed the lash adjuster again and test again If the plunger is still loose replace the lash adjuster Caution Upon completion of air bleeding hold lash adjuster upright to prevent inside diesel fuel from spilling DOHC L I 6EN0421 JSB Revision LASH ADJUSTER LEAK DOWN...

Page 487: ...lue 4 20 seconds 1 mm 04 in Diesel fuel at 15 20 C 59 68 F REASSEMBLY SERVICE POINTS I A4 CAMSHAFT INSTALLATION 1 Apply engine oil to journals and cams of the camshafts 2 Install the camshafts on the cylinder head Use care not to confuse the intake camshaft with the exhaust one The intake camshaft has a slit on its rear end for driving the crankshaft position sensor 3 Install the crankshaft sprock...

Page 488: ...p looks very similar to No 2 and No 4 bearing caps Use the identification marks shown at left for identification NOTE No 2 bearing cap is the same as No 4 bearing cap 2 Install the bearing caps with their front marks pointing to camshaft sprocket side E BEARING CAPS INSTALLATION 1 According to the identification mark stamped on top of each bearing cap install the caps to the cylinder head Only L o...

Page 489: ...ing while installing it I G4 ROCKER SHAFT SPRING INSTALLATION ROCKER ARMS AND ROCKER ARM SHAFT 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 exhaust side roc...

Page 490: ...11 F 84 4G6 ENGINE 1993 Rocker Arms and Camshaft Apply sealant DENOOX 10mm IOmm 39 in 14 SEMI CIRCULAR PACKING INSTALLATION Specified sealant 3M ATD Part No 8660 or equivalent ...

Page 491: ...ck 5 Valve spring retainer eB4 6 Valve spring 7 Intake valve 8 Retainer lock 9 Valve spring retainer B4 10 Valve spring 11 Exhaust valve c BrJ A4 12 Valve stem seal 13 Valve spring seat IBI A4 14 Valve stem seal 15 Valve spring seat 16 Intake valve guide 17 Exhaust valve guide 18 intake valve seat 19 Exhaust valve seat 20 Cylinder head 6EN0309 TSB Revision ...

Page 492: ...er head gasket IBI C4 4 Retainer lock 5 Valve spring retainer eB4 6 Valve spring 7 Intake valve IBP C4 8 Retainer lock 9 Valve spring retainer B4 10 Valve spring 11 Exhaust valve r A4 12 Valve stem seal 13 Valve spring seat I A4 14 Valve stem seal 15 Valve spring seat 16 Intake valve guide 17 Exhaust valve guide 18 Intake valve seat 19 Exhaust valve seat 20 Cylinder head 6EN0669 TSB Revision ...

Page 493: ...lock 5 Valve spring retainer eB4 6 Valve spring 7 Intake valve cJBr eC4 8 Retainer lock 9 Valve spring retainer eB4 10 Valve spring 11 Exhaust valve QCrJ A4 12 Valve stem seal 13 Valve spring seat 10 A4 14 Valve stem seal 15 Valve spring seat 16 Intake valve guide 17 Exhaust valve guide 18 Intake valve seat 19 Exhaust valve seat 20 Cylinder head 16i U 2 0 6EN0196 TSB Revision ...

Page 494: ...g to the cylinder number and intake exhaust c Ao CYLINDER HEAD BOLTS REMOVAL 1 sing the 12 mm 12 points socket wrench loosen the cylinder head bolts Loosen evenly little by little cjBQ RETAINER LOCK REMOVAL 1 Store removed valves springs and other parts tagged to indicate their cylinder No and location for reassembly TSB Revision I ...

Page 495: ...SEAL REMOVAL 1 Do not reuse valve stem seal INSPECTION CYLINDER HEAD 1 Check the cylinder head gasket surface for flatness by using a straightedge and thickness gauge Standard value 0 05 mm 0020 in Limit 0 2 mm 008 in 2 If the service limit is exceeded correct to meet specifica tion ...

Page 496: ... replace the valve Standard value SOHC 8VALVE Intake 1 2 mm 047 in Exhaust 2 0 mm 079 in SOHC 16VALVE Intake 1 0 mm 039 in Exhaust 1 2 mm 047 in DOHC Intake 1 0 mm 039 in Exhaust 1 5 mm 059 in Limit SOHC 8VALVE Intake 0 7 mm 028 in Exhaust 1 5 mm 059 in SOHC 16VALVE Intake 0 5 mm 020 in Exhaust 0 7 mm 028 in DOHC I Intake 0 7 mm 028 in Exhaust 1 0 mm 039 in VALVE SPRING 1 Measure the free height o...

Page 497: ...5 in SOHC 16VALVE Intake 0 02 0 05 m m 0008 0020 in Exhaust 0 03 0 07 m m 0012 0028 in DOHC Intake 0 02 0 05 m m 0008 0020 in Exhaust 0 05 0 09 mm 0020 0035 in Limit Intake 0 10 mm 004 in Exhaust 0 15 mm 006 in VALVE SEAT RECONDITIONING PROCEDURE 1 Before correcting the valve seat check for clearance between the valve guide and valve and if necessary replace the valve guide 2 Using the special too...

Page 498: ...CEDURE 1 Using the special tool and a press remove the valve guide toward cylinder head gasket surface 2 Rebore valve guide hole to the new oversize valve guide outside diameter Valve guide hole diameter See Service Specifica tions on page llF 14 NOTE Do not install a valve guide of the same size again 3 Using the special tool press fit the valve guide working from the cylinder head top surface 4 ...

Page 499: ... VALVE SPRINGS INSTALLATION 1 Direct the valve spring end with identification color end toward the spring retainer c4 RETAINER LOCK INSTALLATION 1 The valve spring if excessively compressed causes the bottom end of retainer to be in contact with and damage the stem seal TSB Revision I ...

Page 500: ...hat the shank length of each bolt meets the limit If the limit is exceeded replace the bolt Limit Max SOHC 8VALVE 120 4 mm 4 74 in SOHC l ALVE 99 4 mm 3 91 in DOHC 99 4 mm 3 91 in 2 Apply engine oil to the threaded portions of bolts and to the washers 3 According to the tightening sequence tighten the bolts to the specified torque 80 Nm 58 ft lbs use with 12 mm 12 points socket wrench 4 Loosen bol...

Page 501: ...r by pass valve F4 13 Oil pressure switch eE4 14 Oil pressure gauge unit 15 Relief plug 16 Gasket 17 paliaf cnrinn Engine with turbocharger 19 Oil filter bracket 20 Oil filter bracket gasket 21 Oil pump cover D4 22 Oil pump driven gear 4 23 Oil pump drive gear L 24 Crankshaft front oil seal Q 25 Oil pump oil seal A 26 Silent shaft oil seal eJ4 27 Front case 28 Front case gasket 29 Silent shaft lef...

Page 502: ...M PLUG REMOVAL 1 If the plug is too tight hit the plug head with a hammer two to three times and the plug will be easily loosened I FLANGE BOLT REMOVAL 1 Remove the plug on the side of cylinder block 2 Insert a Philjips screwdriver shank diameter 8 mm 32 in into the plug hole to lock the silent shaft ODo SILENT SHAFT FRONT BEARING REMOVAL Using the special tool remove the silent shaft front bearin...

Page 503: ...ont case for cracks and other damage Replace cracked or damaged front case OIL SEAL 1 Check the oil seal lip for wear and damage Replace oil seal if necessary 2 Check the oil seal lip for deterioration Replace oil seal if necessary SILENT SHAFT 1 Check oil holes for clogging 2 Check journal for seizure damage and contact with bearing If there is anything wrong with the journal replace silent shaft...

Page 504: ...r 0 06 0 12 mm 0024 0647 in OIL COOLER BYPASS VALVE ENGINE WITH AIR COOLING TYPE OIL COOLER 1 Make sure that the valve moves smoothly 2 Ensure that the dimension L measures the standard value under normal temperature and humidity Standard value L 34 5 1 356 in 3 The dimension must be the standard value when measured after the valve has been dipped in 100 C 212 F oil Standard value L 40 mm 1 57 in ...

Page 505: ...660 or equivalent Caution 1 Keep the end of threaded portion clear of sealant 2 Avoid an overtightening F4 SEALANT APPLICATION TO OIL PRESSURE SWITCH 1 Coat the threads of switch with sealant and install the switch using the special tool Specified sealant 3M ATD Part No 8660 or equivalent Caution 1 Keep the end of threaded portion clear of sealant 2 Avoid an over tightening eG4 RIGHT SILENT SHAFT ...

Page 506: ...g outer circumference and bearing hole in cylinder block 3 Using the special tool install the rear bearing NOTE The left rear bearing has no oil holes 1 14 SILENT SHAFT FRONT BEARING INSTALLATION 1 Using special tools install front bearing I J4 FRONT CASE INSTALLATION 1 Set the special tool on the front end of crankshaft and apply a thin coat of engine oil to the outer circumference of the special...

Page 507: ... 6EN056L I K4 FLANGE BOLT INSTALLATION 1 Insert a Phillips screwdriver into a hole in the left side of the cylinder block to lock the silent shaft 2 Secure the oil pump driven gear onto the left silent shaft by tightening the flange bolt to specified torque I L4 PLUG INSTALLATION 1 Install a new O ring to the groove of front case 2 Using the special tool install the plug and tighten to specified t...

Page 508: ...il pan and cylinder block 2 Apply a 4 mm I6 in wide bead of sealant to the entire circumference of the oil pan flange Specified sealant MITSUBISHI GENUINE PART No MD997110 or equivalent 3 The oil pan should be installed in 15 minutes after the application of sealant 6EN0213 4 Note the difference in bolt lengths at the location shown ...

Page 509: ...AND INSTALLATION Removal steps IAI t k kkkecting rod cap E4 3 Connecting rod bearing D4 4 Piston and connecting rod assembly E4 5 Connecting rod bearing C4 6 Piston ring No 1 C4 7 Piston ring No 2 B4 8 Oil ring aB0 A4 9 Piston pin 10 Piston 12 tnecting rod TSB Revision 6EN0526 ...

Page 510: ...e Pin Piston Support Connecting Rod Guide Pin Piston Support Press Pin zip Screw 2 Select the correct piston support for your application See above Fit the piston support onto the base Place the base on press support blocks 3 Insert the press pin through the piston pin hole Select the correct connecting rod guide pin See above Thread the guide pin onto the threaded portion of the press pin 4 Posit...

Page 511: ... and ring groove If the limit is exceeded replace the ring or piston or both Standard value No I SOHC 4663 DOHC Non turbo 0 02 0 06 m m OOOS 0024 in SOHC 4664 DOHC Turbo 0 03 0 07 m m 0017 0028 in No 2 SOHC 4G63 DOHC 0 02 0 06 m m OOOS 0024 in SOHC 4664 0 03 0 07 m m LOO17 0028 in Limit 0 1 mm 004 in 3 Install the piston ring into the cylinder bore Force it down with a piston its crown being in co...

Page 512: ...he connecting rod cap 5 Measure the width of the plastic gauge at its widest part by using a scale printed on the plastic gauge package Standard value 0 02 0 05 mm 0008 0020 in Limit 0 1 mm 004 in INSTALLATION SERVICE POINTS A4 PISTON PIN INSTALLATION 1 Thread the stop screw and lock nut assembly into the base Fit the correct piston support on top of the base Insert the press pin threaded end up i...

Page 513: ...TANT Due to production tolerance variations it is necessary to visually inspect the piston pin depth after installation to verify that the piston pin is centered Adjust if necessary 7EN042 8 Check that the piston moves smoothly Side rail gap 1 EN0261 I B4 OIL RING INSTALLATION 1 Fit the oil ring spacer into the piston ring groove NOTE The side rails and spacer may be installed in either direction ...

Page 514: ...de I D4 PISTON AND CONNECTING ROD INSTALLATION 1 Liberally coat engine oil on the circumference of the piston piston ring and oil ring 2 Arrange the piston ring and oil ring gaps side rail and spacer as shown in the figure 3 Rotate crankshaft so that crank pin is on center of cylinder bore 4 Rotate crankshaft so that the crank pin is on the center of the cylinder bore 5 Use suitable thread protect...

Page 515: ...at the connecting rod big end side clearance meets the specification Standard value 0 10 0 25 mm 0039 0098 in 1 Limit 0 4 mm 016 in I G4 CONNECTING ROD CAP NUT INSTALLATION 1 Since the connecting rod bolts and nuts are torqued using a new procedure they should be examined BEFORE reuse If the bolt threads are necked down the bolts should be replaced Necking can be checked by running a nut with fing...

Page 516: ...ve plate SOHC 8VALVEAt f SOHC 1 GVALVE AA IOHC I M 6 urrve plate bolt 7 Adapter plate 8 Drive plate 9 Drive plate bolt 10 Adapter plate 11 Drive plate 1 12 Crankshaft bushins 13 Rear plate 14 Bell housing cover eD4 15 Oil seal case C4 16 Oil seal eB4 17 Bearing cap bolt eB4 18 Bearing cap A4 19 Crankshaft bearing lower 20 Crankshaft A4 21 Crankshaft bearing upper 22 Cylinder block 6EN0702 TSB Revi...

Page 517: ... 2 Using a straightedge and feeler gauge check the block top surface for warpage Make sure that the surface is free from gasket chips and other foreign matter Standard value 0 05 mm 0020 in Limit 0 1 mm 004 in 3 If the distortion is excessive correct within the allowable limit or replace Grinding limit 0 2 mm 008 in The total thickness of the stock allowed to be removed from cylinder block and mat...

Page 518: ...dimension Piston O D clearance between piston O D and cylinder 0 02 mm LOO08 in honing margin 4 Bore all cylinders to calculated boring finish dimension Caution To prevent distortion that may result from temperature rise during honing bore cylinders working from No 2 to No 4 to No 1 to No 3 5 Hone to final finish dimension piston O D clearance between piston O D and cylinder 6 Check clearance betw...

Page 519: ...2 None I 1 I 3 I I 2 I 4 I I 0 I 3 I White 1 4 2 5 2 Install the upper crankshaft bearings to the cylinder block There is an oil groove in the upper cranksahft bearing There is no difference between upper and lower bearings for the center with flange 3 Install the lower crankshaft bearings to bearing cap and apply engine oil to bearing surface 64 BEARING CAP BEARING CAP BOLT INSTALLATION 1 Install...

Page 520: ...re that the crankshaft turns smoothly and the end play is correct If the end play exceeds the limit replace crankshaft bearings Standard value 0 05 0 25 mm 0020 0098 in Limit 0 4 mm 016 in I cg OIL SEAL INSTALLATION I D4 SEALANT APPLICATION TO OIL SEAL CAqE Specified sealant Mitsubishi Genuine Part No MD970389 or equiva lent ...

Page 521: ...bracket right 2 Engine support bracket left 6EN350 Front wheel drive and all wheel drive 65 Nm 47 ft lbs 26 ft lbs 1 Roll stopper bracket front 2 Engine support bracket front 3 Exhaust pipe support bracket 4 Roll stopper bracket rear 0 e 4 9 126 Nm 87 ft lbs 6EN0722 1 _ I HY206012 522 1 Revision ...

Page 522: ...NOTES ...

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Mitsubishi 4G1 series, Service Manual

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