Page 1 4G1 l ........
Page 3: Table Of Contents
INTRODUCTION CONTENTS SPECIAL TOOL NOTE ..........5 ENGINE MODEL TABLE .
Page 4 INTRODUCTION EXPLANATION OF MANUAL CONTENTS Maintenance and Servicing Procedures The part designation number corresponds (1) A diagram of the component parts is to the number in the illustration to indicate provided near the front of each section in removal steps. order to give the reader a better under- Disassembly steps: standing of the installed condition of...
Page 5 INTRODUCTION Indicates the section title. Denotes non-reusable This number corresponds to the number appearing in “Removal steps”, “Disassembly steps”, “ln- stallation steps” or “Reassembly steps” Operating procedures, cautions, etc. on removal, installation, dis- assembly and reassembly are de- scribed. TSB Revision...
Page 6: Engine Model Table
INTRODUCTION ENGINE MODEL TABLE - 1992 Engine Series, In-line, SOHC 3.0 (I 83) (per bank) 3.0 (183) (per bank) 3.0 (183) (per bank) ENGINE MODEL TABLE - 1993 In-line, SOHC 1.8 (1 IO) In-line, SOHC 3.0 (I 83) Diamante, (per bank) 3.0 (183) (per bank) 3.0 (183)
Page 7: Special Tool Note
INTRODUCTION SPECIAL TOOL NOTE Please refer to the special tool cross reference chart which is located in the service manual at the beginning of each group, for a cross reference from the MMC special tool number to the special tool number that is available in your market.
Page 8: Form-In-Place Gasket
INTRODUCTION FORM-IN-PLACE GASKET The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the fluid feed line.
Page 9 4G15 CONTENTS INTAKE MANIFOLD ..........BRACKET ..............PISTON AND CONNECTING ROD ....CRANKSHAFT, FLYWHEEL AND DRIVE PLATE ............ROCKER ARMS AND CAMSHAFT ....CYLINDER HEAD AND VALVES ......33 SEALANT ..............EXHAUST MANIFOLD AND SERVICE SPECIFICATIONS ..................WATER PUMP SPECIAL TOOLS ............
Page 10 GENERAL INFQRMATION ENGINE SECTIONAL VIEW 1 EN0086 TSB Revision...
Page 11 TSB Revision...
Page 13 GENERAL SPECIFICATIONS Specifications In-line OHV, SOHC Number of cylinders Combustion chamber Total displacement 1,468 (89.58) Cylinder bore mm (in.) 75.5 (2.972) Piston stroke mm (in.) 82 (3.228) Compression ratio Valve timing Intake valve Opens BTDC 14” 15” Closes ABDC 51” 53”...
Page 14 1 IA-6 SERVICE SPECIFICATIONS mm (in.) Items Standard value Limit Cylinder head Flatness of gasket surface "0.2 (.008) Grinding limit of gasket surface Total resurfacing depth of both cylinder head and cylinder block Overall height Oversize rework dimensions of valve guide hole (both intake and exhaust) 0.05 (.002) 0.50 (.020)
Page 15 mm (in.) Items Limit Standard value . 7/ Valve Overall length Intake 100.75 (3.9665) Exhaust 101.05 (3.9783) Stem diameter 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 0.5 (020) 1 .o (.039)
Page 16 mm (in.) Items Standard value Limit Piston 75.48 - 75.50 (2.9716 - 2.9724) 0.02 - 0.04 (0008 - .0016) Piston-to-cylinder clearance 0.25 t.01). 0.50 (.02), 0.75 (.03), 1 .OO (.04) Service size oversize Piston ring End gap 0.20 - 0.40 l.0079 - .0157) 0.8 (.031) No.
Page 17 Standard value L i m i t Oil pump Tip clearance 0.03 - 0.08 LOOI 2 - .0031) Side clearance Body clearance 0 . 3 5 (.Orl38) Drive belt deflection New belt 5.5 -7.0 (.22 - .28) Used belt 8.0 (.32) Injector Coil resistance fI? Throttle position sensor...
Page 18 1 IA-IO TORQUE SPECIFICATIONS Generator and ignition system Oil level gauge guide mounting bolt W a t e r p u l l e y b o l t pump Generator brace bolt Generator brace mounting bolt Generator pivot nut Crankshaft bolt Crankshaft pulley bolt Spark plug...
Page 19: Crankshaft, Flywheel And Drive Plate
Engine support bracket, front SEALANT Quantity Specified sealant Items As required As required Engine coolant temperature sensor As required Engine coolant temperature gauge unit As required Mitsubishi Genuine Part No. MD970389 or equivalent Oil pan As required Oil pressure switch threads TSB Revision...
Page 20 1 IA-12 SPECIAL TOOLS Tool Installation of crankshaft rear oil seal Crankshaft rear oil seal installer Crankshaft front oil seal installer Installation of camshaft oil seal Camshaft oil seal Removal of oil pan TSB Revision...
Page 21 Valve stem seal compressor Flywheel stopper...
Page 22: Generator And Ignition System
GENERATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION 12 Nm 9 ftJp3. 23 Nm 14 Nm 17 ft.lbs. 85 Nm 81 ft.lbs. Removal steps 2. Oil level gauge guide 3. O-ring 5. Water pump pulley 6. Generator brace 7. Generator 9. Special washer IO.
Page 23 REMOVAL SERVICE POINT CRANKSHAFT BOLT REMOVAL (I) Using the special tool, hold the drive plate or flywheel. (2) Remove the crankshaft bolt. INSTALLATION SERVICE POINTS DISTRIBUTOR ASSEMBLY INSTALLATlOy / (1) Turn the crankshaft to bring the No. I cylinder piston to the top dead center on compression stroke.
Page 24 (2) Or using a tension gauge, adjust the tension to the standard value. Standard value: New belt 5 0 0 - 700 Used belt Ibs.) 400 N (88 (3) Tighten the lock bolt to the specified torque. (4) Tighten the nut for pivot bolt to th$ specified torque.
Page 25 TIMING BELT REMOVAL AND INSTALLATION 17 ft.lbs. Removal steps 1. Timing belt upper cover 2. Timing belt lower cover 4. Engine support bracket, left 5. Tensioner spring 7. Crankshaft sprocket 8. Flange 9. Camshaft sprocket bolt 10. Camshaft sprocket 1 EN0327 TSB Revision...
Page 26 B e l t R E M O V A L S E R V I C E P O I N T S ~ TIMING BELT REMOVAL (1) Mark belt running direction for reference in reinstallation. (2) Loosen the tensioner bolts and move the tensioner toward the water pump.
Page 27: Water Pump
Cracks on rubber back (5) Cracks on belt sides Peeling Cracks 1 EN024E are sharp as if cut by a knife. Roundededge Abnormal wear (Fluffy strand) (7) Abnormal wear on teeth (8) Missing tooth Rubber exposed Tooth missing and canvas fiber INSTALLATION SERVICE POIFTS CAMSHAFT SPROCKET BOLT TIGHTENING 01 PO281...
Page 28 (1) Align the timing marks on the camshaft sprocket and the 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. 1 EN033 (3) Loosen the tensioner mounting bolts @ and 0.
Page 29 (5) Turn the crankshaft clockwise by 3 crankshaft teeth. (6) Tighten bolt @ first and then bolt 0. If bolt @ is tightened first, the tensioner will turn together with the bolt, resulting in an overtensioned belt. 1 ENOOOE (7) Check the belt tension. Hold the tensioner and ‘timing belt together by hand and give the belt a slight thumb pressure Tensioner slot side at a point level with tensioner center.
Page 30: Fuel And Emission Parts
FUEL AND EMISSION PARTS REMOVAL AND INSTALLATION 19 Nm Removal steps 1. Throttle body 2. Gasket 3. Injectors and fuel rail 4. Insulator 11. Grommet 12. Fuel rail 13. EGR valve (For California) 14. Gasket 1 EN0238 TSB Revision...
Page 31 INSPECTION INJECTORS (1) Using an ohmmeter (circuit tester), test for, cont$u~ty, between terminals of injector; the circuit should be closed. If failure is detected, replace the injector. Standard value: 13 - 16 Cn [at 20°C (68”F)l EGR VALVE (1) Check the EGR valve for sticking or carbon deposits. If such conditions exist, clean or replace the EGR valve.
Page 32 1 M-24 THROTTLE BODY DISASSEMBLY AND REASSEMBLY Up to 1992 models 1.4 ftlbs. Disassembly steps 2. Idle speed control motor 3. Throttle valve set screw 4. Throttle body From 1993 models 1.4 ft.lbs. Disassembly steps 2. Idle arr control motor 3.
Page 33 DISASSEMBLY SERVJCE POINTS POSITION SENSOR AND IDLE SPEED THROTTLE CONTROL CONTROL MOTOR / IDLE AIR REMOVAL not disassemble the sensor and motor. not immerse in solvent the sensor and motor to clean. Clean them with shop towel. (1) Do not remove the throttle valve. (2) Check if the vacuum port or passage is clogged.
Page 34 REMOVAL AND INSTALLATION 14 Nm 13 ft.lbs. Removal steps For AIT 5. Water outlet fitting 6. Water outlet fitting gasket 7. Thermostat 8. Outer cable bracket 9. Inner cable bracket 11. Thermostat housing 12. Intake manifold stay 13. Engine support bracket stay (From 1993 models) 14.
Page 35 INSTALLATION SERVICE POINTS SEALANT APPLICATION TO THERM0 SWIT& Sealant Specified sealant: SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE GAUGE UNIT Sealant Specified sealant: TEMPERATURE SENSOR Specified sealant: Sealant...
Page 36 1 IA-28 EXHAUST MANIFOLD AND WATER PUMP REMOVAL AND INSTALLATION 14 Nm 10 ft.lbs. 30 Nm 22 ft.lbs. 7 klbs. 14 Nm Removal steps 2. Oxygen sensor - [1992,1993 (FED) models1 3. Engine hanger 4. Exhaust manifold 5. Exhaust manifold cover “B” 6.
Page 37 INSTALLATION SERVICE POINT O-ring pump Water WATER PIPE / O-RING INSTALLATION. ‘ Caution Keep the O-ring free of oil or grease Water inlet pipe Revision...
Page 38: Rocker Arms And Camshaft
ROCKER ARMS AND CAMSHAFT REMOVAL AND INSTALLATION 32 Nm 23 ft.lbs. Removal steps 2. PCV hose 3. Rocker cover 4. Rocker cover gasket 8. Rocker arm “D” 9. Wave washer 10. Spacer 11. Rocker arm “C” 12. Rocker arm shaft (exhaust side) 13.
Page 39 INSPECTION CAMSHAFT (1) Measure the cam height. Standard value: Intake 38.78 mti (1.5268 ‘in.) 3 9 . 1 0 m m (1.53& Sii.) Exhaust Limit: 38.28 mm (1.5071 in.) Intake Exhaust 38.60 mm (1.5197 in.) 1 EN009s ROCKER ARM Check the roller surface. If any dents, damage or seizure is evident, replace the rocker arm.
Page 40 1 IA-32 VALVE CLEARANCE ADJUSTMENT ~ Exhaust 1 Exhaust 3 (1) Position the No. 1 cylinder at the top dead center on compression stroke. (2) Adjust the valve clearance at the points shown in the illustration. Intake 1 Intake 2 (3) Loosen the adjusting screw locknut’.
Page 41 CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION 73 Nm 53 ft.lbs. Removal steps 2. Cylinder head, valve assembly 5. Valve spring retainer 7. Intake valve (primary) 8. intake valve (secondary) 12. Exhaust valve 14. Valve spring seat 16. Valve spring seat 17.
Page 42 REMOVAL SERVICE POINTS j CYLINDER HEAD BOLT REMOVAL RETAINER LOCK REMOVAL (1) Store the removed valves, springs and other parts, tagged to indicate their cylinder No. and location to aid reassembly. (1) Do not reuse removed valve stem seals. INSPECTION CYLINDER HEAD (1) Check the cylinder head gasket &$-face for flatness by using a straightedge and thicknessygauge.
Page 43 VALVE (1) Check the valve face for correct contact. If incorrect, reface using valve refacer. Valve should“ma,ke a uniform contact with the seat at the center of valve ‘face. (2) If the margin is smaller than the ser@cefimit, replace the valve.
Page 44 1 IA-36 VALVE SEAT REPLACEMENT PROCEDURE 0.5 - 1 mm f.02 - .04 in.) wall thickness. Then, remove the valve seat. (2) Rebore the valve seat hole in cylinder head to a selected oversize valve seat diameter. ring Seat hole diameter: See “Service Specifications” in page llA-6 (3) Before fitting the valve seat, either &at the cylinder head up to approximately 250°C (482°F) or cool the valve seat...
Page 45 VALVE SPRING INSTALLATION Spring retainer (1) ~.s$~~;~ valve spring with the painted end on the rocker Painted end Stem seal Spring seat (1) The valve spring, if excessively compressed, causes the bottom end of retainer to be in contact with, and damage, the stem seal.
Page 46 TSB Revision...
Page 47: Front Case And Oil Pump
FRONT CASE AND OIL PUMP REMOVAL AND INSTALLATION 45 Nm 33 ft.lbs. Removal steps 2. Drain plug 3. Drain plug gasket 5. Oil screen 6. Oil screen gasket 7. Relief plug 8. Gasket 9. Relief spring 10. Relief plunger 12. Front case 13.
Page 48 1 IA-40 R E M O V A L S E R V I C E P O I N T S 1 OIL PAN REMOVAL (1) Knock the special tool deeply between the oil pan and the cylinder block. (2) Hitting the side of the special tool, slide the special tool along the oil pan to remove it.
Page 49 INSTALLATION SERVICE POINTS INNER ROTOR / OUTER ROTOR INSTALLATION (1) Install the outer rotor in the same direction as before noting the mark put at the time of removal. Apply engine oil to the entire rotor surface. CRANKSHAFT FRONT OIL SEAL INSTALLATION (1) Set the special tool on the crankshaft front end and apply engine oil to its outer circumference.
Page 50 (2) Apply a 4 mm (16 in.) diameter beid of sealant to the oil pan flange. Specified sealant: Mitsubishi Genuine Part No. ‘%lD970389 or equiva- lent (3) The oil pan should be installed within 15 minutes after the application of sealant.
Page 51 REMOVAL AND INSTALLATION Removal steps 3. Connecting rod bearing 5. Connecting rod bearing 11. Connecting rod 12. Bolt TSB Revision...
Page 52 ENGINE DISASSEMBLY ,SERVlCE POINT6 CONNECTING ROD CAP REMOVAL number on the side of the connecting rod cylinder big end for correct reassembly. PISTON PIN REMOVAL Piston pin setting tool MIT21 6941 Description Part No. Base Piston Support Connecting Rod Guide Pin Connecting Rod Guide Pin Connecting Rod Guide Pin Piston Support...
Page 53 INSPECTION PISTON RING If the limit is exceeded, replace the ring or piston, or both. Standard value: No. 1 0.03 - 0.07 mm (A012 - .0028 h.) No. 2 0.02 - 0.08 mm (&IO8 - .0024.‘in.) Limit: 0.1 mm (.004 in.) (2) insert the piston ring into the cylinder bore.
Page 54 11 A-46 REASSEMBLY SERVICE POINTS- PISTON PIN INSTALLATION ,’ Fit the correct piston support on the top of the base. Insert the press pin, threaded end up, into t?re hole in the piston support until the press pin touches (2) Using the graduations on the press screw to the correct depth of 49 mm (1.93 in.) (3) Place the base on the press support blocks.
Page 55 NOTE The side rails and spacer may be installed in either direction. 1 EN027; (2) Install the upper side rail. Side rail gap To install the side rail, first fit one end of the rail into the piston groove, then press the remaining portion into position by finger.
Page 56 R o d (3) Rotate crankshaft so that the crank pi^n is on the center of Timing belt the cylinder bore. (4) Use suitable thread protectors on theconnecting rod bolts before inserting piston and connecting rod assembly into the cylinder block. Care must be taken not to nick the crank pin.
Page 57 CRANKSHAFT, FLYWHEEL AND DRIVE PLATE REMOVAL AND INSTALLATION 11 Nm 8 ft.lbs. I f L 19 Nm Removal steps For MIT 2. Flywheel 3. Drive plate bolt 53 Nm 4. Adaptor plate 38 ft.lbs. 5. Drive plate 6. Adaptor plate 7.
Page 58 1 IA-50 INSPECTION CRANKSHAFT JOURNAL OIL CLEARANCE (PLASTIC GAUGE METHOD) (1) Remove oil from the crankshaft journal and the crankshaft bearing. (2) Install the crankshaft. (3) Cut the plastic gauge to the same length as the width of bearing and place it on the journal in parallel with its axis. (4) Install the crankshaft bearing cap carefully and tighten the bolts to the specified torque.
Page 59 BORING CYLINDER (1) Oversize pistons to be used should be determined on the basis of the largest bore cylinder. Piston size identification Identification Size Thrust direction 0.25 mm (.02 in.) O.S. 0.50 0.50 in.) OS. 0.75 0.75 in.) OS. 1 .oo NOTE Size mark is stamped on the piston top.
Page 60 (1) Install according to the front mark end cap Timing belt side Cap No. 1 EN017E (2) After installing the bearing caps, make sure that the crankshaft turns smoothly and the end play 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.) 1 EN028C...
Page 61 REMOVAL AND INSTALLATION 47 ft.lbs. 60 Nm 44 ft.1bs.h 36 Nm 26 ft.lbs. 67 ftlbs. Removal steps 2. Engine support bracket, front 3. Roll stopper bracket, front 4. Roll stopper bracket, rear 1 EN0347 TSB Revision...
Page 62 N O T E S...
Page 63 ENGINE CONTENTS ..BRACKET ............GENERATOR AND IGNITION SYSTEM INTAKE MANIFOLD ..........
Page 64: General Information
GENERAL INFORMATION ENGINE SECTIONAL VIEW...
Page 66 TSB Revision...
Page 67: General Specifications
Description Specifications In-line OHV, SOHC Number of cylinders Combustion chamber Compact type Total displacement 1.755 (107.10) Cylinder bore mm (in.) 80.6 (3.17) Piston stroke mm (in.) 86 (3.39) Compression ratio Valve timing: Intake valve Opens 20” BTDC 52” ATDC Closes Exhaust valve 55”...
Page 68 mm (in.) Limit Standard Cylinder head Flatness of gasket surface 0.05 (.0020) 0.2 (.008) “0.2 (008) Grinding limit of gasket surface and cylinder block 88.4 - 88.6 (3.480 - 3.4881 Overall height Oversize rework dimensions of valve guide hole (both intake and exhaust) 0.05 (002) 0.25 (.OlO) 13.25 - 12.27 (5217 - 95224)
Page 69 mm (in.) Standard Limit Valve Overall length Intake 98.2 (3.866) Exhaust 95.5 (3.760) Stem diameter Intake Exhaust 7.93 - 7.95 (.312 - ,313) Face angle 45” - 45”30’ Thickness of valve head (margin) Intake 1.2 (.047) 0.7 (.028) Exhaust 1.5 (.059) 1 .o i.039) Stem-to-guide clearance...
Page 70 mm (in.) Standard Limit Silent shaft Journal diameter 38.96 - 38.98 (1.5339 - 1.5346) (rear) 35.95 - 35.97 (1.4154 - 1.4161) Left (front) 18.47 - 18.48 (.7272 - .7276) (rear) 35.95 - 35.97 (I .4154- 1.4161) Oil clearance 0.02 - 0.06 (.0008 - .0024) (rear) 0.05 - 0.09 (.0020 - .0035) Left Ifrar$)
Page 71 Standard Limit Crankshaft End play 0.3 (;012~ Journal O.D. 57 (2.24) Pin O.D. 45 (1.77) Out-of-roundness and taper of journal Within 0.01 (0004) and pin Oil clearance of journal 0.10 (.0039) Oil clearance of pin 0.02 - 0.05 (.0008 - .0020) 0.10 (.0039) Journal undersize 0.25 (.OlO) U.S.
Page 72: Timing Belt
TORQUE SPECIFICATIONS Generator and ignition system W a t e r p u l l e y b o l t pump Generator brace bolt Generator brace mounting bolt Generator pivot nut Damper pulley bolt Crankshaft pulley bolt Spark plug Distributor mounting nut Timing belt Tensioner bolt and nut...
Page 73: Bracket
Rocker cover bolt Camshaft bearing cap bolt (M8) Camshaft bearin Oil pressure gauge unit Oil filter bracket Oil pan drain plug Oil pan bolt Oil screen nut Oil pump cover bolt Oil pump driven gear bolt Oil relief valve plug Exhaust pipe support bracket Ingine support bracket, right...
Page 74 Specified sealant Engine coolant temperature sensor Engine coolant temperature gauge unit As required Semi-circular packing MITSUBISHI GENUINE Part Oil pan Oil pressure gauge unit Oil pressure switch TSB Revision...
Page 75 SPECIAL TOOLS Number and Application tool name Use with MIT308239 or torquing bolt. Installation of crankshaft rear oil seal Crankshaft rear Use with oil seal installer Removal and Installation of piston pin Piston pin setting Installation of silent shaft bearing front Silent shaft Use with MIT21 5869 bearing installer...
Page 76 Leak-down tester Air bleed wire Installation of camshaft oil seal Camshaft oil seal installer Holding camshaft sprocket when loosening Pulley holding or torquing bolt pins (2) Removal of oil pan Oil pan remover Installation of valve stem seal Valve stem seal installer...
Page 77 Removal of crankshaft sprocket...
Page 78: Generator And Ignition System
GENERATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION 25 Nm 23 Nm 14 ilm 19 Nm 7 ftlbs. 14 ft.lbs. 12 Nm 9 ft.lbs. 12 ft.lbs. 17 Nm 12 ft.lbs. Removal steps 2. Water pump pulley 3. Generator brace 4. Generator Damper pulley Adapter 7.
Page 79 INSTALLATION SERVICE POINTS DISTRIBUTOR INSTALLATION center. (2) Align the distributor housing and gear mating marks. (3) Install the distributor to the engine while aligning the fine cut (groove or projection) of the distributor’s installation flange with the center of the distributor installation stud. DRIVE BELT TENSION ADJUSTMENT (1) Move the generator to give greater tension to the belt so that the specified deflection is obtained.
Page 80 TIMING BELT REMOVAL AND INSTALLATION 26 ft.lbs. 37 Nm 27 ft.lbs. Removal steps 1. Timing belt front upper cover 2. Timing belt front lower cover 8. Crankshaft sprocket 9. Flange 14. Crankshaft sprocket “B” 15. Engine support bracket, left 17. Camshaft sprocket 18.
Page 81 REMOVAL SERVICE POINTS TIMING BELT REMOVAL (1) Mark the belt running direction for reference -in reihstalla- tion. OIL PUMP SPROCKET REMOVAL (1) Remove the plug on the left side of the cylinder block. (2) Insert a Phillips screwdriver [shank diameter 8 mm (31 in.)] to block the left silent shaft.
Page 82 B e l t SILENT SHAFT SPROCKET REMOVAL CRANKSHAFT SPROCKET “B’ REMOVAL CAMSHAFT SPROCKET BOLT LOOSENING INSPECTION TIMING BELT / TIMING BELT “B” Replace belt if any of the following ide is glossy without (1) Hardening of back rubber - the ba resilience and leaves no indent whe pressed with finger- nail.
Page 83 are sharp as if cut by a knife. Rounded edge Abnormal wear (Fluffy strand) (7) Abnormal wear in teeth (8) Missing tooth Rubber exposed Tooth missing and canvas INSTALLATION SERVICE POINTS CAMSHAFT SPROCKET BOLT INSTALLATION, SPACER INSTALLATION seal.
Page 84 11 B-22 silent shaft sprocket with the marks on the front case respectively. (2) Install the timing belt “B” on the crankshaft sprocket “B” and silent shaft sprocket. There should be no slack on the tension side. (3) Make sure that the relationship between the tensioner pulley center and the bolt center’...
Page 85 OIL PUMP SPROCKET INSTALLATION through the plug hole on the left side of the cylinder block to Screwdriver block the left silent shaft. (2) Install the oil pump sprocket. (3) Tighten the nuts to the specified torque. TENSIONER / TENSIONER SPRING INSTALLATION and tensioner bracket.
Page 86 11 B-24 (2) Align the timing mark on the oil pump sprocket with its mating mark. (3) Remove the plug on the cylinder block and insert a Phillips screwdriver [shank diameter 8 mm (.31 in.)] through the hole. If it can be inserted as deep ‘8s 60 mm (2.4 in.) or more, the timing marks are correctly *lioned.
Page 87 (8) Tighten the tensioner attaching nut, then tighten ‘the tensioner attaching bolt. Caution If the bolt is tightened first, tensioner turns 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.
Page 88 11 B-26 Fuel and Emission Parts FUEL AND EMISSION PARTS REMOVAL AND INSTALLATION 12 Nm 9 ft.lbs. 19 Nm Removal steps 2. Gasket 3. Injector and fuel rail 5. O-ring 6. Fuel rail 7. Insulator 8. Insulator 11. Wornmet TSB Revision...
Page 89 INSPECTION . . - ’ INJECTORS (1) Using an ohmmeter (circuit tester), test for con&uity between terminals of injector; the circuit should be closed. If failure is detected, replace the injector. Standard value: 13 - 16 n at 20°C (68°F) EGR VALVE (1) Check EGR valve for sticking or carbon deposits.
Page 90 DISASSEMBLY AND REASSEMBLY Disassembly steps 2. Idle speed control motor 3. Throttle valve set screw 4. Throttle body DISASSEMBLY SERVICE POINTS 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.
Page 91 (2) Check if the vacuum port or b&sage is clog&~& ‘&e compressed air to clean the vacuum passage. REASSEMBLY SERVICE POINT Throttle position Ground While moving the throttle lever in both open and close directions, check to see that resistance between terminals smoothly, the throttle position sensor has been installed Throttle poskion View P...
Page 92 INTAKE MANIFOLD REMOVAL AND INSTALLATION 19 Nm 18 Nm 13 ftlbs. 13 ft.lbs. 16 ftlbs. Removal steps 2. Water hose “B” 5. Water outlet fitting 6. Water outlet fitting gasket 7. Thermostat 8. Intake manifold plenum stay 9. Intake manifold plenum 11.
Page 93 INSTALLATION SERVICE POlNTS SEALANT APPLICATION TO EyGlNE Coo&ANT TEMPERATURE SENSOR Specified sealant: TEMPERATURE GAUGE UNIT Sealant Specified sealant:...
Page 94: Exhaust Manifold And Water Pump
11 B-32 EXHAUST MANIFOLD AND WATER PUMP REMOVAL AND INSTALLATION 30 Nm 14 Nm 10 ft.lbs. 14 Nm 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.
Page 95 ENGINE O-ring Water pump WATER INLET PIPE INSTALLATION (1) Wet the 0- . ring (with water) to facilitate assembly.” -’ Caution Keep the O-ring free of oil or grease TSB Revision...
Page 96 ROCKER ARMS AND CAMSHAFT REMOVAL AND INSTALLATION 20 Nm 14 ft.lbs. 11 Nm 8 ft.lbs. + Removal steps 1. Breather hose 2. P.C.V. hose 3. Oil seal 4. Rocker cover 5. Gasket 6. Rocker arm and rocker shaft 7. Rear camshaft bearing cap 8.
Page 97 REMOVAL SERVICE POINT ’ ROCKER ARM AND ROCKkR SHAFT REMOVAL (2) Remove the lash adjuster holders and the lash adjusters. INSPECTION CAMSHAFT Standard value: 35.91 mm (j.4138 in.) Limit: 35.41 mm (1.3941 in.) ROCKER ARM (1) Visually check the roller and replace if dent, damage, or seizure is evident.
Page 98 (1) Immerse the lash adjuster in cleati diesel fuel. (2) While lightly pushing down inner steel ball using a small wire, move the plunger up and do9 four or five times to bleed air. Use of the Retainer facilitates the aitbleeding of the rocker arm mounted type lash adjuster.
Page 99 LASH ADJUSTER IiUSTALLATlON (2) While using a small wire to lightly press the check ball downward, move the plunger 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.
Page 100 11 B-38 WAVE WASHER INSTALLATIdN Install the wave washer in correct ‘direction as shown. Wave washer Wave washer CAMSHAFT OIL SEAL INSTALLATION...
Page 101 REMOVAL AND INSTALLATION Removal steps 2. Cylinder head assembly 5. Valve spring retainer 7. Intake valve 9. Valve spring retainer 13. Valve spring seat 15. Valve spring seat 16. Intake valve guide 17. Exhaust valve guide 18. Intake valve seat 19.
Page 102 POINTS : REMOVAL SERVICE CYLINDER HEAD BOLT REMqVAL (1) Using the special tool, loosen the cylinder head bolts Loosen evenly, little by little. (1) Store removed valves, springs and other parts, tagged to indicate their cylinder No. and location to aid reassembly. INSPECTION CYLINDER HEAD using a straightedge and thickness <gauge.
Page 103 ENGINE VALVE using a valve refacer. Valve should make a uniform contact with the seat at the center of valve face. (2) If the margin is smaller than the service limit, replace the valve. Standard value: 1.2 mm (047 in.) Intake 1.5 mm (.059 in.) Exhaust...
Page 104 VALVE SEAT REPLACEMENT PROCEDURE 0.5 - 1 mm (.02 - .04 in,) (1) Cut the valve seat to be replaced from the inside to thin the wall thickness. Then, remove the valve seat. (2) Rebore the valve seat hole in the cylinder head to a selected oversize valve seat diameter.
Page 105 Spring retainer (1) Install the valve spring with the painted end on’the rocker Identification arm side. color Stem seal Spring seat (1) The valve spring, if excessively compressed, causes the bottom end of retainer to be in contact with, and damage, the stem seal.
Page 106 TSB Revision...
Page 107 FRONT CASE, OIL PUMP AND OIL PAN REMOVAL AND INSTALLATION 17 Nm 16 ft.lbs. 33 ftlbs. Removal steps 2. Oil pressure switch 3. Oil pressure gauge unit 4. Oil filter bracket 5. Gasket 6. Drain plug 5 ft.lbs. 9. Oil screen 11.
Page 108 11 B-46 REMOVAL SERVICE POINTS General General OIL PAN REMOVAL (1) Knock the special tool deeply between the oil pan and the cylinder block. (2) Hitting the side of the special tool, slide the special tool along the oil pan to remove it. insert a Phillips screwdriver [shank diameter 8 mm (32 in.)] into the plug hole on the left side of the cylinder block to block the silent shaft.
Page 109 ENGINE INSPECTION SILENT SHAFT (2) Check journal for seizure, damage, and contact with bearing. If there is anything wrong with the journal, replace the silent shaft, bearing or front case assembly. (3) Check the silent shaft oil clearance. If the clearance is excessive due to wear, replace the silent shaft bearing, silent shaft or front case assembly.
Page 110 (4) Set the special tool on the guide pints and drive the bearing into the cylinder block. (1) Using the special tool, install the crankshaft oil seal into the front case. SILENT SHAFT OIL SEAL INSTALLATION the front case. nt case FRONT CASE INSTALLATION 1 apply engine oil to the outer circumference of the special (2) Install the front case.
Page 111 GEAR OIL PUMP DRIVEN GEAR / OIL PUMP DRIVE INSTALLATION (1) install the oil pump drive gear and driven gear to the front case, lining up the timing marks. Lubricate the gears with engine oil. FLANGE BOLT INSTALLATION (1) Insert a Phillips 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.
Page 112 (2) Apply a 4 mm (.I6 in.) diameter beqd of sealant to the oil pan flange. Specified sealant: MITSUBISHI GENUINE Part “No. MD970389 or equivalent (3) The oil pan should be installed withi; 15 minutes after the application of sealant.
Page 113 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...
Page 114 11 B-52 PISTON AND CONNECTING ROD REMOVAL AND IhJSTALLATlON Removal steps 1. Nut 3. Connecting rod bearing 5. Connecting rod bearing Piston ring No. 1 7. Piston ring No. 2 11. Connecting rod 12. Connecting rod bolt TSB Revision...
Page 115 REMOVAL SERVICE POINTS CONNECTING ROD CAP REMOVAL inder No. big end for correct reassembly. PISTON PIN REMOVAL Rear support tools (MD998184-01). (2) Assemble set components on a press, with the press plates under the base. Caution Press plates must be used to provide adequate support to the base during pressing operations.
Page 116 INSPECTION PISTON (1) Replace the piston if scratches or seizure is evident on its surfaces (especially the thrust surfa$e). Replace the piston if it is cracked. PISTON PIN (1) Insert the piston pin into the piston #in hole with a thumb. You should feel a slight resistance.
Page 117 REASSEMBLY SERVICE POINTS PISTON PIN INSTALLATION special tools (MD9981 84-01). (2) Thread the stop plug approximately half way into the bottom of the receiving tube. (3) Select the piston pin guide that will pass through the piston and the connecting rod. Install spring, spacer, and guide into the receiving tube.
Page 118 11 B-56 between the groove and the spac&. side rail While holding the end firmly, press the portion to be inserted with finger as illustrated until the side rail is in position. Caution Do not use piston ring expander td install the side rail. 1 EN0269 INSTALLATION ring in position.
Page 119 CONNECTING ROD CAP INSTALLATION bearing cap to the connecting r’od. If the con&c&$/?&! is new with no index mark, make sure that the bearing locking notches come on the same side as shown. Notches (2) Make sure that connecting rod big end side clearance meets the specification.
Page 120 CRANKSHAFT, FLYWHEEL AND DRIVE PLATE REMOVAL AND INSTALLATION 135 Nm 88 ftlbs. 8 ftlbs. 7 ft.lbs. 135 Nm 98 ft.lbs. Removal steps 1. Flywheel bolt For MIT 2. Flywheel 3. Drive plate bolt 4. Adaptor plate For AIT 5. Drive plate 6.
Page 121 INSPECTION CRANKSHAFT JOURNAL OIL CLEARANCE GAUGE METHOD) (1) Remove oil from crankshaft journal and crankshaft bearing. (2) install the crankshaft. (3) Cut the plastic gauge to the same length as the width of bearing and place it on journal in parallel with its axis. (4) Install the crankshaft bearing cap carefully and tighten the bolts to the specified torque.
Page 122 CYLINDER BORING (1) Oversize pistons to be used should be determined on the basis of the largest bore cylinder. . Piston size identification ’ Size Piston O.D. “A” mm (.Ol in.) O.S. 0.25 0.25 mm (.02 in.) O.S. 0.50 0.50 mm (.03 in.) O.S.
Page 123 BEARING CAP INSTALLATION Timing belt side Front (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. in.) Standard value: 0.05 - 0.18 mm (.0020 - .0071 Limit: 0.3 mm’...
Page 124 BRACKET REMOVAL AND INSTALLATION 65 Nm 47 ft.lbs. 120 Nm 67 ft.lbs. 47 ftlbs. 2. Engine support bracket, right 3. Roll stopper bracket, front 4. Roll stopper bracket, rear TSB Revision...
Page 125: Intake Manifold
ENGINE 4G61, 4663, 4664 <1992> CONTENTS BRACKET ..... , ........107 GENERATOR AND IGNITION SYSTEM - SOHC ..........
Page 126 GENERAL INFQRMATION ENGINE SECTIONAL VIEW - SOHC TSB Revision...
Page 127 TSB Revision...
Page 128 TSB Revision...
Page 130 ENGINE LUBRICATION SYSTEM - SOHC Rocker shaft Camshaft Oil pressure switch rankshaft ENGINE LUBRICATION SYSTEM - DOHC Camshaft Oil cooler Oil cooler by-pass valve Silent shaft&I) Crankshaft Oil puml ’ ‘Silent shaft...
Page 131 ENGINE LUBRICATION SYSTEM DOHC-TURBO Camshaft Silent shaft From thermostat case filter water inlet pipe i I Oil pressure sw&h Oil pump /...
Page 132 GENERAL SPECIFICATIONS In-line OHV, SOHC Number of cylinders Combustion chamber Compact type Total displacement 1,997 (121.9) Cylinder bore mm (in.) 85 (3.35) Piston stroke mm (in.) 88 (3.46) Compression ratio Valve timing Intake valve Open BTDC 19" ABDC Close 57” Exhaust valve Open BBDC...
Page 133 In-line OHV, DOHC Number of cylinders Combustion chamber Total displacement 1,595 (97.3) Cylinder bore mm (in.) Piston stroke mm (in,) 75 (2.95) Compression ratio Valve timing Open BTDC 26” Close ABDC 38” Exhaust valve Open BBDC 53” Close ATDC 7” Oil pump type nvolute gear type Cooling system...
Page 134 SERVICE SPECIFICATIONS mm (in.) Limit Standard Cylinder head - SOHC 0.2 (008) 0.05 (.0020) Flatness of gasket surface Grinding limit of gasket surface and cylinder block. 89.9 - 90.1 (3.539 - 3.547) Overall height Oversize rework dimensions of valve guide hole (both intake and exhaust) 0.05 (.002) 0.25 (.OlO)
Page 135 mm (in.) Standard Limit Camshaft - SOHC Identification mark: D Cam height 42.40 (1.6693) Exhaust 42.40 (1.6693) 41.90 (1.6496) Identification mark: AR Cam height Intake 44.53 (1.7531) 44.03 (1.7335) Exhaust 44.53 (1.7531) 44.03 (1.7335) NOTE: The camshaft identification mark is stamped on the rear end of the camshaft.
Page 136 mm (in.) Limit Standard Valve - SOHC Intake Overall length 106.6 (4.197) Exhaust 108.7 (4.280) 105.2 (4.142) Stem diameter Intake Exhaust 7.93-7.95 (.3122-.3130) Face angle Thickness of valve Intake 1.2 (047) 0.7 (02%) head (margin) Exhaust 2.0 (.079) 1.5 (.059) Stem-to guide clearance Intake...
Page 137 mm (in.) Standard Limit Valve guide - DOHC Overall length 45.5 (1.791) 50.5 (1.988) I.D. 6.60 - 6.62 (.2598 - .2606) 12.06 - 12.07 (.4748 - .4752) Service size 0.05 (.002), 0.25 (.OlO), 0.50 (.020) over size Press-in temperature Room temperature Va Ive seat Seat angle Valve contact width...
Page 138 mm (in.) Limit Standard Piston ring - SOHC End gap No. 1 ring 0.25 - 0.40 LOO98 - .0157) 0.8 (031) No. 2 ring 0.20 - 0.35 LOO79 - .0138) 0.8 (.031) 0.20 - 0.40 LOO79 - .0157) 0.8 (.031) Oil ring 0.20 - 0.70 LOO79 - .0276) Ring-to-ring groove...
Page 139 Standard Limit Cylinder block Cylinder I.D. 82.30 - 82.33 (3.2402 - 3.2413) 86.50 - 86.53 (3.4055 - 3.4067) Flatness of gasket surface 0.05 (0020) 0.1 (004)” Grinding limit and cylinder block. Overall height 274.9 - 275.1 (10.823 - 10.831) 283.9-284.1 (11.177-11.185) Oil pump Side clearance Drive gear...
Page 140 TORQUE SPECIFICATIONS Generator and ignition system - SOHC Cooling fan bolt Water pump pulley bolt - Engine without cooling fan Water pulley bolt - Engine with cooling fan pump Generator brace bolt Generator mounting bolt Generator pivot nut Crankshaft pulley bolt Spark plug Distributor nut Ignition coil bolt...
Page 141 Fuel and emission parts EGR valve bolt Throttle body stay nut - DOHC Throttle body bolt - SOHC Throttle body bolt - DOHC Fuel regulator bolt pressure Fuel rail bolt Throttle body Throttle position sensor bolt Idle speed control motor bolt Idle air control motor bolt Intake manifold Intake manifold bolt and nut...
Page 142 Turbocharger Turbocharger waste gate actuator bolt Rocker arms and camshaft- SOHC Rocker cover bolt Bearing cap bolt Camshafts and rocker arms - DOHC Bearing cap bolt Oil delivery body bolt Cylinder head and valves - SOHC Cylinder head bolt Cylinder head and valves- DOHC Cylinder head bolt Front case, silent shaft and oil pan Oil cooler bolt...
Page 143 SEALANT Specified sealant Quantity Rocker cover As required Semi-circular packing As required Oil pan gasket MITSUBISHI GENUINE PART As required Engine coolant temperature gauge unit As required Engine coolant temperature sensor As required or equivalent As required Oil pressure switch...
Page 144 SPECIAL TOOLS Application Number and Tool tool name Holding camshaft spr&ket when loosening End yoke holder Use with MIT308239 or torquing bolt. For SOHC engine only Use with Loosening or torquing of cylinder head bolt Cylinder head bolt wrench Removal and installation of front case cap Plug wrench Installation of crankshaft front oil seal Crankshaft front...
Page 145 Camshaft oil seal installer Holding camshaft sprocket when loosening or torquing bolt Pulley holding pins (2) For SOHC engine only Removal of oil pan Oil pan remover Installation of valve stem seal For SOHC engine only Valve stem seal installer TSB Revision...
Page 146 Holding silent shaft sprocket Sprocket stopper Removal and installation of piston pin Piston pin setting tool Holding flywheel Flywheel stopper TSB Revision...
Page 147 1 IC-23 GENERATOR AND IGNITION SYSTEM - SOHC REMOVAL AND INSTALLATION 25 Nm 14 Nm 23 Nm 17 ft.lbs. 14 Nm 24 Nm 17 ftlbs. 9 Nm** Removal steps 7 ftlbs. 11 Nm*** 8 ft.lbs. 2. Cooling fan*** 3. Fan clutch*** 4.
Page 148 1 IC-24 Generator and Ignition System - SOHC INSTALLATION SERVICE ,POINTS DISTRIBUTOR INSTALLATION the gear to the distributor shaft. (2) When aligning the driven gear’s mating mark and the housing’s mating marks, make the combination so that notch “A” at the shaft end is at the position shown in the figure, and then align the spring pin holes and drive in a new spring pin.
Page 149 BRACE BOLT TYPE Water pulley 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. Crankshaft pulley Standard value: New belt 500 - 700 N (110 - 154 Ibs.)
Page 150 11 C-26 GENERATOR AND IGNITION SYSTEM - DOHC REMOVAL AND INSTALLATION 18 ft.lbs. 19 Nm 14 ftlbs. 23 Nm 14 Nm 24 Nm 17 ftlbs. 11 Nm 8 ft.lbs. 24 Nm 17 ftlbs. Removal steps 2. Water pump pulley 3. Water pump pulley (For driving power steering pump) 4.
Page 151 INSTALLATION SERVICE POINTS CRANKSHAFT POSITION INSTALLATION (1) Turn the 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. DRIVE BELT TENSION ADJUSTMENT Refer to “I)B4 DRIVE BELT TENSION ADJUSTMENT”...
Page 152 TIMING BELT - SOHC REMOVAL AND INSTALLATION 40 ft.lbs. 87 ft.lbs. Removal steps 1. Timing belt front upper cover 2. Timing belt front lower cover 8. Crankshaft sprocket 9. Flange 13. Spacer 14. Crankshaft sprocket “B” 15. Engine support bracket, left 17.
Page 153 ENGINE <1992> - Timing Belt - S O H C REMOVAL SERVICE POINTS TIMING BELT REMOVAL (1) Mark the belt running direction for reference in reinstalla- tion. 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.
Page 154 SILENT SHAFT SPROCKET REMOVAL CRANKSHAFT SPROCKET “B” REMOVAL 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 and leaves no indent when pressed with finger- resilience nail.
Page 155 are sharp as if cut by a knife. Roundededge Abnormal wear (Fluffy strand) Rubber exposed Tooth missing and canvas fiber INSTALLATION SERVICE POINTS CAMSHAFT SPROCKET BOLT INSTALLATION SPACER INSTALLATION Spacer Oil seal seal. Chamfer shaft...
Page 156 11 C-32 TIMING BELT “B” ‘INSTALLATION (1) Align timing marks on the crankshaft sprocket “B” and silent shaft sprocket with the marks on the front case respectively. (2) Install the timing belt “B” on the crankshaft sprocket “B” and silent shaft sprocket. There should be no slack on the tension side.
Page 157 OIL PUMP SPROCKET INSTALLATION (1) Insert a Phillips screwdriver [shank diameter 8 mm (31 in.)] through the plug hole on the left side of the cylinder block to block the left silent shaft. (2) Install the oil pump sprocket. (3) Apply an appropriate amount of engine oil to the bearing surface of the nut.
Page 158 (3) Remove the plug on the 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 correctly aligned.
Page 159 SOHC (8) Tighten the tensioner attaching bolt, then tighten the tensioner spacer. Caution If the tensioner spacer is tightened first, the tensioner 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.
Page 160: Removal And Installation
TIMING BELT - DOHC REMOVAL AND INSTALLATION 2.2 ft.lbs. -fl Removal steps 1. Timing belt front upper cover 2. Timing belt front lower cover 5. Tensioner arm 7. Idler pulley 11. Flange 12. Spacer* 13. Tensioner “B”** 17. Crankshaft sprocket “B”** 20.
Page 161 REMOVAL SERVICE POINTS TIMING BELT REMOVAL (1) Make a mark on the back of the timing belt indicating the direction of rotation so that it may be reassembled in the same 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.
Page 162 1 IC-38 DOHC SILENT SHAFT SPROCKET REMOVAL CRANKSHAFT SPROCKET “B” REMOVAL CAMSHAFT SPROCKET REMOVAL 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”...
Page 163 AUTO TENSIONER 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. Brass or Caution aluminum laws...
Page 164 SEALANT APPLICATION ON SEMI-CIRCULAR PACKING Apply sealant Specified sealant: 3M ATD Part No. 8660 or equivalent SEALANT APPLICATION ON ROCKER COVER Apply sealant to the areas indicated in the illustration. Specified sealant: 3M ATD Part No. 8660 or equivalent Apply sealant Apply sealant...
Page 165 SHAFTS) Refer to “eB4 SPACER INSTALLATION” on page 11 C-31. SILENT SHAFT SPROCKET INSTALLATION TIMING BELT “B” INSTALLATION (ENGINE WITH SILENT SHAFTS) Refer to Page 11 C-32. Note that the timing mark locations differ from those on the single camshaft engine. CRANKSHAFT BOLT INSTALLATION (2) Install the crankshaft bolt.
Page 166 11 C-42 (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 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.
Page 167 1 IC-43 D O H C T I M I N G B E L T I N S T A L L A T I O N Camshaft sprocket on top. Then, align the timing marks facing each other with the top surface of the cylinder head.
Page 168 (5) Thread the timing belt over the intake side camshaft sprocket and fix it at indicated position by a clip. (6) Thread the timing belt over the exhaust side sprocket, while aligning the timing marks with the cylinder head top surface using two wrenches.
Page 169 Wrench, on the tensioner pulley, 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 ftlbs.). wrench. torque wrench, tighten the center bolt to the specification.
Page 170: Fuel And Emission Control Parts
11 C-46 FUEL AND EMISSION CONTROL PARTS REMOVAL AND INSTALLATION - SOHC for GALANT/EXPO 12 Nm 9 ft.lbs 12 Nm 7 ft.lbs. 19 Nm 14 klbs. Removal steps 2. Throttle body gasket 3. EGR valve 4. EGR valve gasket 5. Injectors and fuel rail 6.
Page 171 12 Nm 9 ft.lbs. I - - - - 12 Nm 9 ft.lbs. 7 ft.lbs. 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.
Page 172 11 C-48 Fuel and Emission Control Parts 12 Nm 9 ft.lbs. 19 Nm 14 ftlbs. 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.
Page 173 INSPECTION EGR VALVE If such conditions exist, clean or replace EGR valve. (2) Connect a hand vacuum pump to the nipple of EGR valve and plug other nipple. (3) Apply a vacuum of 500 mmHg (19.7 in. Hg) to make sure that a vacuum is maintained.
Page 174 11 c-50 THROTTLE BODY DISASSEMBLY AND REASSEMBLY SOHC for EXPO Disassembly steps 1.4 ft.lbs. 1. Accelerator wire bracket 3. Idle air control motor 4. Throttle valve set screw 5. Throttle body SOHC for GALANT/TRUCK 3.5 Nm 2.5 ft.lbs. 1.4 ft.lbs. Disassembly steps 2.
Page 175 DOHC Disassembly steps 2. Idle air control motor (stepper motor) 3. Closed throttle position switch 4. Adjusting nut 5. Throttle body...
Page 176 11 C-52 DISASSEMBLY SERVICE POINTS THROTTLE POSITION SENSOR AND IDLE AIR/ SPEED CONTROL MOTOR REMOVAL (1) Do not disassemble the sensor and motor. (2) Do not immerse the sensor and motor in cleaning solvent. Clean them with shop towel. THROTTLE BODY REMOVAL (1) Do not remove the throttle valve.
Page 177 (3) Holding the idle air control motor as shown in the illustration, connect the negative 0 terminal of the power supply to each clip as described in the following steps, and check whether or not a vibrating feeling (a feeling of very slight vibration of the stepper motor) is generated as a result of the activation of the stepper motor.
Page 178 REASSEMBLY SERVICE POINTS THROTTLE POSITION SENSOR INSTALLATlON - SOHC FOR EXPO (1) Install the throttle position sensor to the throttle body as shown in the illustration. (2) Turn the throttle position sensor 90” counterclockwise to set it in position and tighten the screws. (3) Connect a circuit tester between @ (ground) and @ (output), or between @(output) and @ (power).
Page 179 (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, Throttle position sensor power make sure that the resistance changes smoothly when the round throttle valve is slowly moved to the fully open position.
Page 180 11 C-56 INTAKE MANIFOLD REMOVAL AND INSTALLATION - SOHC 18 Nm 13 ftlbs. 18 Nm 30 Nm 22 ft.lbs. 18 Nrn 13 ftlbs. 8 ftlbs. 18 Nm 13 ftlbs. 16 ft.lbs. Removal steps 8. Intake manifold plenum stay 1. Water hose 9.
Page 181 turbocharger) ;Xzr, ,, Nm Removal steps 2. Water hose 3. Water hose (turbo) 20 ftlbs. 4. Water hose (turbo) 7. Water outlet fitting 8. Gasket 9. Thermostat 11. Gasket 12. Intake manifold stay 14. Intake manifold gasket TSB Revision...
Page 182 INSTALLATION SERVICE POINTS INTAKE MANIFOLD INSTALLATION - DOHC (1) Tighten the intake manifold bolts. Note that the bolts installed at the locations indicated in the illustration are tightened to a different torque. WATER OUTLET FITTING GASKET INSTALLATION (FOR RUBBER COATED METAL GASKET ONLY) facing up (toward the water outlet fitting side).
Page 183 EXHAUST MANIFOLD AND WATER PUMP REMOVAL AND INSTALLATION - SOHC 14 Nm* 18 Nm 14 Nm Removal steps 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 11.
Page 184 11 C-60 28 Nm 20 ftlbs. 14 Nm 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.
Page 185 Exhaust Manifold and Water Pump 31 ft.lbs. 14 Nm 8 ftlbs. 14 Nm 24 Nm 17 ft.lbs. 7 ft.lbs. Removal steps 15. Ring 1. Oil level gauge 16. Oil pipe 2. Oil level gauge guide 17. Water pipe “A” 3. O-ring 18.
Page 186 INSTALLATION SERVICE POINT O-ring 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. Revision...
Page 187 DISASSEMBLY AND REASSEMBLY Disassembly steps inspection of turbocharger waste gate actuator operation 1. Snap pin 2. Turbocharger waste gate actuator Compressor cover TSB Revision...
Page 188 11 C-64 INSPECTION TURBINE HOUSING (1) Check the housing for traces of contact with the turbine wheel, cracks due to overheating, pitching, deformation and other damage. Replace with a new turbine housing if cracked. (2) Operate the waste gate valve lever manually to check that the gate can be opened and closed smoothly.
Page 189 11 C-65 TURBINE HOUSING INSTALLATION (1) Install the turbine housing on the compressor cover while aligning the dowel pin with the dowel pin hole. Caution Use care not to damage the blades of the turbine wheel. COUPLING INSTALLATION (1) Install the coupling and tighten it to the specified torque. Coupling WASTE GATE ACTUATOR OPERATION CHECK to the actuator and make sure that the rod moves.
Page 190 ROCKER ARMS AND CAMSHAFT - SOHC REMOVAL AND INSTALLATION 1. Breather hose 2. P.C.V. hose 3. Packing 4. Oil seal 5. Rocker cover 6. Gasket 8. Rocker arms and rocker shafts 9. Rear bearing cap 11. Spring EC 12. Rocker arm D 24.
Page 191 Camshaft - SOW Arms - - - REMOVAL SERVICE POINT ROCKER ARM AND CAMSHAFT REMOVAL (1) Before removing rocker arms and shafts assembly, install the special tool as illustrated to prevent adjuster from dropping. INSPECTION (1) Measure the cam height D: Intake 42.40 (1.6692) 41.90 (1.6496)
Page 192 (2) While lightly pushing down the inner steel ball using a small wire, move the plunger up and down four or five times to bleed air. Use of the retainer facilitates the air bleeding of a rocker arm mounted type lash adjuster. (3) Remove the small wire and press the plunger.
Page 193 WAVE WASHER INSTALLATION Wave washer side rocker arm identification Identification mark: for No. 1 and 3 cylinders No. 1 No. 2 No. 3 No. 4 for No. 2 and 4 cylinders No. 1 No. 2 N o . 3 No. 4 Rocker cover mounting bolt hole bearing caps.
Page 194 CAMSHAFT OIL SEAL INSTALLATION SEMI-CIRCULAR PACKING INSTALLATION Apply sealant Specified sealant: Semi-circular Gasket r$ of packing TSB Revision...
Page 195 CAMSHAFTS AND ROCKER ARMS - DOHC REMOVAL AND INSTALLATION 20 Nm 14 t=t.lbs.- 8 ftlbs. Removal steps Bearing cap No. 5 5. Bearing cap No. 2 Bearing cap No. 4 7. Bearing cap No. 3 9. Rocker arm TSB Revision...
Page 196 11 C-72 INSPECTION CAMSHAFT (1) Measure the cam height. Limit Identification mark Standard value Intake 35.49 (1.3972) 34.99 (1.3776) 35.20 (1.3858) 34.70 (I .3661) Exhaust 35.49 35.20 (1.3972) (1.3858) 34.99 34.70 (1.3776) (1.3661) 35.91 (1.3744) 34.41 (1.3547) Roller The camshaft identification mark is stamped on the rear end of camshaft.
Page 197 Camshaft sprocket side (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. Intake side camshaft (3) Install the crankshaft sprocket B or spacer and flange to an Dowel pin...
Page 198 11 c-74 CYLINDER HEAD AND VALVES - SOHC REMOVAL AND INSTALLATION 95 Nm 69 fklbs. --1 Removal steps 6. Valve spring retainer 8. Intake valve 12. Exhaust valve 14. Valve spring seat 16. Valve spring seat 17. Intake valve guide 18.
Page 199 SOHC REMOVAL SERVICE POINTS PRECAUTION FOR REMOVED PARTS (1) Keep removed parts in order according to the cylinder number and intake/exhaust. CYLINDER HEAD BOLT REMOVAL Loosen evenly, little by little. RETAINER LOCK REMOVAL (1) Using the special tool, compress the spring. (2) Remove the retainer locks.
Page 200 1 IC-76 INSPECTION CYLINDER HEAD (1) Check the cylinder head gasket surface for flatness by using a straightedge in the directions of A through shown in the illustration. Standard value: 0.05 mm (JO20 in.) Limit: 0.2 mm (008 in.) (2) If the service limit is exceeded, correct to meet the specification.
Page 201 VALVE SEAT RECONDITIONING PROCEDURE between the valve guide and valve and, if necessary, replace the valve guide. (2) Using the special tool or seat grinder, correct to obtain the specified seat width and angle. (3) After correction, valve and valve seat should be lapped with a lapping compound.
Page 202 1 IC-78 INSTALLATION SERVICE POINTS 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 the valve stem seal. toward the spring retainer. Identification color Stem seal...
Page 203 CYLINDER HEAD GASKET IDENTIFICATION Identification mark Identification mark: Caution Do not apply sealant to cylinder head gasket. CYLINDER HEAD BOLT INSTALLATION Camshaft sprocket side Each bolt should be tightened in two to three steps, torquing progressively. Tighten to the specified torque in the final sequence.
Page 204 CYLINDER HEAD AND VALVES - DOHC REMOVAL AND INSTALLATION Removal steps 1. Cylinder head bolt 2. Washer 3. Cylinder head assembly 6. Valve spring retainer 7. Valve spring 8. Intake valve 9. Retainer lock 12. Exhaust valve 13. Valve stem seal 14.
Page 205 1 W-81 Valves - DOHC REMOVAL SERVICE POINTS CYLINDER HEAD BOLT REMOVAL (1) Using the special tool, loosen the cylinder head bolts. Loosen evenly, little by little. 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.
Page 206 CYLINDER HEAD Cylinder head height (when new): mm (5.193 - 5.201 in.) 131.9 - 132.1 VALVE Margin: Intake 1.0 mm (.039 in.) Exhaust I.5 mm (.059 in.) Limit: Intake 0.7 mm (.028 in.) Exhaust 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”...
Page 207 VALVE SEAT REPLACEMENT PROCEDURE the reboring size. Intake valve seat hole diameter 0.3 mm (.012 in.) O.S..... 35.30- 35.33 mm (1.3898 - I .3909 in.) 0.6 mm (.024 in.) O.S.
Page 208 11 C-84 the retainer lock into position. Identification mark: 2 0 4663 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.
Page 209 ENGINE CASE, SILENT SHAFT AND OIL PAN REMOVAL AND INSTALLATION 22 ** 24 Nm **** 40 ftlbs. Removal steps 1. Oil filter 2. Oil cooler bolt*** 3. Oil cooler*** 4. Drain plug 5. Drain plug gasket 6. Oil pan 7. Oil screen 8.
Page 210 Front Case, Silent Shaft and Oil Pan 33 Nm 24 ft.lbs. -189 45 Nm 33 ft.lbs. 40 ft.lbs. 55 Nm 40 ft.lbs. 7. Relief plunger 8. Oil filter bracket 9. Oil pump cover NOTE 18. Check valve 19. Oil jet 20.
Page 211 REMOVAL SERVICE POINTS Service tool : OIL PAN REMOVAL (1) Remove the all oil pan bolts. (2) Drive in the service tool between the cylinder block and oil pan. NOTE Never use a screwdriver or chisel, instead of the service tool, as a deformed oil pan flange will result in oil leakage.
Page 212 (2) Remove the oil pump sprocket nut. SILENT SHAFT FRONT BEARING REMOVAL Engine with silent shafts (ENGINE WITH SILENT SHAFTS) Using the special tool, remove the silent shaft front bearing from the cylinder block. NOTE Be sure to remove the front bearing first. If it has not been removed, the Rear Bearing Puller cannot be used.
Page 213 SILENT SHAFT (ENGINE WITH SILENT SHAFTS) Engine with silent shafts (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, bearing or front case assembly. (3) Check the silent shaft oil clearance.
Page 214 and Oil Pan Front Case, Silent Shaft OIL PUMP OIL SEAL INSTALLATION CRANKSHAFT FRONT OIL SEAL INSTALLATION into the front case. OIL PUMP DRIVEN GEAR / OIL PUMP DRIVE GEAR INSTALLATION alignment marks. FLANGE NUT INSTALLATION IEngine without silent shafts (ENGINE WITHOUT SILENT SHAFTS) Caution Before installing the flange nut, apply an appropriate...
Page 215 SEALANT APPLICATION TO OIL PRESSURE GAUGE UNIT and install the unit 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. SEALANT APPLICATION TO OIL PRESSURE SWITCH install the switch using the special tool.
Page 216 (3) Using the special tool, install the rear bearing. Engine with silent shafts NOTE The left rear bearing has no oil holes. SILENT SHAFT FRONT BEARING INSTALLATION Engine with silent shafts (ENGINE WITH SILENT SHAFTS) Cylinder’ block FRONT CASE INSTALLATION apply a thin coat of engine oil to the outer circumference of the special tool to install the front case.
Page 217 Front Case, Silent Shaft and Oil Pan (3) Mount the oil filter bracket with oil filter bracket gasket. Then, install the four bolts with washers. (4) Tighten the bolts to the specification. NOTE (1) The bolt marked with *I in the illustration differs in tightening torque.
Page 218 (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. MD970389 or equivalent (3) The oil pan should be installed in 15 minutes after the application of sealant.
Page 219 1 IC-95 PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION Removal steps 1. Nut 3. Connecting rod bearing 5. Connecting rod bearing...
Page 220 REMOVAL SERVICE POINTS CONNECTING ROD CAP REMOVAL big end for correct reassembly. number (2) Keep the removed connecting rods, caps, and bearings in order according to the cylinder number. PISTON PIN REMOVAL Description Base Piston Support Connecting Rod Guide Pin Connecting Rod Guide Pin Connecting Rod Guide Pin Piston Support...
Page 221 INSPECTION PISTON surfaces (especially the thrust surface). Replace the piston if it is cracked. PISTON PIN You should feel a slight resistance. Replace the piston pin if it can be easily inserted or there is an excessive play. (2) The piston and piston pin must be replaced as an assembly. PISTON RING (1) Check the piston ring for damage, excessive wear, and breakage and replace if defects are evident.
Page 222 11 C-98 (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 mm (0008 - .0020 in.) Limit: 0.1 mm (.004 in.) 1 EN0271...
Page 223 (8) Check that the piston moves smoothly. 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 Side rail gap piston groove, then press the remaining portion into position by finger.
Page 224 DOHC Non-turbo Turbo PISTON AND CONNECTING ROD INSTALLATION No. 1 (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. pulley side ‘Lower...
Page 226 Crankshaft, Flywheel and Drive Plate CRANKSHAFT, FLYWHEEL AND DRIVE PLATE 135 Nm REMOVAL AND INSTALLATION 11 Nm 8 ft.lbs. 98 ft.lbs. 6 ** 135 Nm 98 ftlbs. Removal steps 14. Drive plate* 2. Flywheel 16. Rear plate 17. Bell housing cover 3.
Page 227 INSPECTION CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE METHOD) (1) Remove oil from the crankshaft journals and crankshaft bearings. (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) Install the crankshaft bearing cap carefully and tighten the bolts to the specified torque.
Page 228 (4) Check 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 the cylinder to an oversize and replace the piston and piston rings. Measure at the points shown in illustration.
Page 229 INSTALLATION SERVICE POINTS CRANKSHAFT BEARING IDENTIFICATION (1) The upper bearings (on the cylinder block side) for Nos. 1,2, Upper bearing 4 and 5 journals are provided with oil groove. (for No. 1,2.4,5) (2) The lower bearings (on the cap side) for Nos. 1, 2, 4 and 5 Lower bearing (for No.
Page 230 OIL SEPARATOR INSTALLATION Oil separator Oil seal (1) Force the oil separator into the oil seal case so that the oil case hole in the separator is directed downward (arrow in illustration). TSB Revision...
Page 231 1 I-C-I 07 BRACKET Rear wheel drive and four wheel drive 33 ft.lbs. Engine support bracket, right Engine support bracket, left Front wheel drive and all wheel drive 120 N, Roll stopper bracket, front 87 ftlbs. Engine support bracket, front Exhaust pipe support bracket Roll stopper bracket, rear...
Page 232 NOTES...
Page 233 ENGINE 4G93 CONTENTS PISTON AND CONNECTING ROD ....CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE PLATE ......47 ROCKER ARMS AND CAMSHAFT ....CYLINDER HEAD AND VALVES ......32 SEALANT ..............EXHAUST MANIFOLD ........SERVICE SPECIFICATIONS ........ FRONT CASE AND OIL PUMP ......SPECIAL TOOLS ............
Page 234 GENERAL INFORMATION ENGINE SECTIONAL VIEW TSB Revision...
Page 235 TSB Revision...
Page 236 TSB Revision...
Page 237 ENGINE Description Specifications In-line OHV, SOHC Number of cylinders Combustion chamber Total displacement 1834 (111.9) Cylinder bore mm (in.) 81 (3.19) Piston stroke mm (in.) 89 (3.50) Compression ratio Valve timing Intake valve Opens 18” BTDC Closes 50” ATDC Exhaust valve Opens 58”...
Page 238 SERVICE SPECIFICATIONS mm (in.) Limit Standard value Cylinder head 0.2 (.008) 0.03 LOOI 2) Flatness of gasket surface “0.2 (008) Grinding limit of gasket surface Total resurfacing depth of both cylinder head and cylinder block Overall height Oversize rework dimensions of valve guide hole (both intake and exhaust) 0.05 (002) O.S.
Page 239 mm (in.) Items Standard value Limit Valve spring Free height 50.9 (2.004) 49.9 (1.965) Load/installed height N/mm (Ibs./in.) Out of squareness Less than 2” 4" Valve guiide Length Intake 45.5 (1.791) Exhaust 50.5 (1.988) I.D. 6.00 - 6.01 (2362 - .2366) O.D.
Page 240 mm (in.) Items Standard value Limit Crankshaft End play 0.05 - 0.25 (0020 - .0098) 0.4 (016) Journal O.D. 49.982 - 49.994 (1.9678 - 1.9683) Pin O.D. Out-of-roundness and taper of journal and pin Oil clearance of journal 0.02 - 0.04 (.0008 - .0016) 0.1 (004) Oil clearance of pin 0.02 - 0.05 (.0008- .0020)
Page 241 TORQUE SPECIFICATIONS Generator and ignition system Oil level gauge guide mounting bolt Generator brace bolt Generator brace mounting bolt Generator pivot nut Crankshaft bolt Spark plug Distributor Timing belt Tensioner bolt Tensioner spring bolt Camshaft sprocket bolt Fuel and emission parts Throttle body mounting bolt Fuel rail mounting bolt Fuel pressure regulator bolt...
Page 242 25 + 114 turns SEALANT Quantity Items Specified sealant As required Water pump Mitsubishi Genuine Part No. MD970389 or equivalent As required Thermostat housing Mitsubishi Genuine Part No. MD970389 or equivalent As required Engine coolant temperature sensor As required Engine coolant temperature gauge unit...
Page 243 Tool Number and Supersession Application tool name Use with MIT308239 or torqurng bolt Installation of crankshaft rear oil seal Installation of camshaft oil seal Camshaft oil seal installer Turning crankshaft Crankshaft wrench Installation of front oil seal Crankshaft front oil seal installer Holding crankshaft sprocket Pulley holding pins (2)
Page 244 ENGINE Number IN ame I Use Tool of crankshaft rear oil seal Use with Crankshaft rear oil seal installer Use with Removal and installation of piston pin Piston pin setting Holding flywheel TSB Revision...
Page 245 GENERATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION 9 ftlbs. 185 Nm 33 ft.lbs. Removal steps 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.
Page 246 REMOVAL SERVICE POINT CRANKSHAFT BOLT LOOSENING (1) Using the special tool, hold the drive plate on flywheel. (2) Remove the crankshaft bolt. INSTALLATION SERVICE POINTS DISTRIBUTOR ASSEMBLY INSTALLATION (1) Turn the crankshaft to bring No. 1 cylinder to the top dead center on compression stroke.
Page 247 Generator 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 REMOVAL AND INSTALLATION 90 Nm 65 ft.lbs. Removal steps 1. Flange 2. Timing belt upper cover 3. Timing belt lower cover 7. Crankshaft sprocket 9. Camshaft sprocket TSB Revision...
Page 249 REMOVAL SERVICE POINTS TIMING BELT REMOVAL (2) Back off the tensioner spring mounting bolt three turns. (3) Pinching the end of the tensioner spring on the tensioner side with 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.
Page 250 (6) Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife. Rounded edge (Fluffy strand) (7) Abnormal wear on teeth. (8) Missing tooth. Rubber exposed Tooth missing and canvas INSTALLATION SERVICE POINTS CAMSHAFT SPROCKET BOLT TIGHTENING TENSIONER SPRING / TENSIONER INSTALLATION (1) Install the tensioner spring and spacer.
Page 251 (1) Check that the timing belt tensioner and spring have been installed in position. (See (2) Align 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.
Page 252 11 D-20 FUEL AND EMISSION PARTS REMOVAL AND INSTALLATION 12 Nm 9 ftlbs. 19 Nm 14 ft.lbs. Removal steps 2. Gasket 3. Fuel rail and injector 4. Insulator MIRAGE 6. Fuel hose 8. O-ring 9. Insulator 12. Grommet 13. Fuel rail 14.
Page 253 1 I’D-21 INSPECTION INJECTORS (1) Using an ohmmeter (circuit tester), test for continuity between terminals of injectors; the circuit should be closed. If failure is detected, replace the injector. Standard value: 13 - 16 IR at 20°C (68°F) EGR VALVE (1) Check the EGR valve for sticking or carbon deposits.
Page 254 THROTTLE BODY DISASSEMBLY AND REASSEMBLY EXPO 1.4 ft.lbs. Removal steps 2. Idle air control motor 3. O-ring 4. Throttle body 5. Accelerator cable bracket MIRAGE Removal steps 2. Idle air control motor 3. O-ring 4. Throttle body 1 EN0336...
Page 255 DISASSEMBLY SERVICE POINTS THROTTLE POSITION SENSOR AND IDLE AIR CONTROL MOTOR REMOVAL (1) Do not disassemble the sensor and motor. (2) Do not clean the sensor and motor using solvent. Clean them with shop towel. (2) Check if the vacuum port or passage is clogged. Use shown in the illustration.
Page 256 11 D-24 THROTTLE POSITION SENSOR INSTALLATION <MIRAGE> (1) Install the throttle position sensor to the throttle body as shown in the illustration. (2) Turn the throttlep.osition sensor 90” clockwise, and tighten the screws. (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.
Page 257 INTAKE MANIFOLD AND WATER REMOVAL AND INSTALLATION 11 Nm 8 ft.lbs. 19 Mm 14 ftlbs. 24 Nm 50 Nm 36 ft.lbs. 22 ft.lbs. Removal steps 1. Water hose A Water hose B 31 Nm Engine coolant temperature gauge unit 22 ft.lbs. 4.
Page 258 11 D-26 INSTALLATION SERVICE POINTS SEALANT APPLICATION TO WATER PUMP Specified sealant: Mitsubishi Genuine Part No. MD970389 or equiva- lent WATER PIPE / O-RING INSTALLATION Caution 1. Keep the O-ring free of oil or grease. 2. Secure the water pipe after the thermostat housing has been installed.
Page 259 SEALANT APPLICATION TO ENGINE CFL+JT TEMPERATURE GAUGE UNIT Sealant Specified sealant: TSB Revision...
Page 260: Exhaust Manifold
EXHAUST MANIFOLD REMOVAL AND INSTALLATION 45 Nm 33 ftlbs. 30 Nm 22 ftlbs. 18 Nm 13 ftlbs. 22 ftlbs. 36 Nm 18 Nm 26 klbs. 13 ftlbs. 36 Nm 26 ft.lbs. 30 Nm 22 ft.lbs. Removal steps 2. Exhaust manifold cover A 3.
Page 261 ROCKER ARMS AND CAMSHAFT REMOVAL AND INSTALLATION 3.3 Nm Removal steps 12. Rocker arm shaft (Intake side) 2. P.C.V. hose 3. Rocker cover 4. Rocker cover gasket 5. Oil seal 16. Rocker arm shaft (Exhaust side) 17. Adjusting screw 18. Nut 8.
Page 262 Rocker Arms and Camshaft INSPECTION CAMSHAFT (1) Measure the cam height Standard value: Intake mm (1.4874 in.) 37.78 38.09 mm (1.4996 in.) Exhaust Limit: mm (1.4677 in.) Intake 37.28 Exhaust 37.59 mm (1.4799 in.) ROCKER ARM Check the roller surface. If any dents, damage or seizure is evident, replace the rocker arm.
Page 263 (3) Loosen the adjusting screw locknut. (4) Using a feeler gauge, adjust the valve clearance by turning the adjusting screw. Standard value: 0.09 mm LOO4 in.) Intake 0.20 mm LOO8 in.) Exhaust (5) While holding the adjusting screw with a screwdriver, tighten the lock nut.
Page 264 11 D-32 CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION 14 Nm 10 ft.lbs. 12 Nm 12 Nm 9 ftlbs. Removal steps 13. Valve spring retainer 2. Engine hanger 15. Exhaust valve 17. Valve spring seat 6. Cylinder head assembly 7. Cylinder head gasket 20.
Page 265 ENGINE REMOVAL SERVICE POINTS RETAINER LOCK REMOVAL (1) Store the removed valves, springs and other parts, tagged to indicate their cylinder No. and location to aid reassembly. VALVE STEM SEAL REMOVAL (1) Do not reuse removed valve stem seals. INSPECTION CYLINDER HEAD (1) Check the cylinder head gasket surface for flatness by using a straightedge and thickness gauge.
Page 266 11 D-34 VALVE SPRING out of Measure the free height of the spring and, if it is smaller square than the limit, replace. Standard value: 50.9 mm (2.004 in.) Limit: 49.9 mm (1.955 in.) Measure the squareness of the spring and, if the limit is exceeded, replace.
Page 267 SEALANT APPLICATION TO OIL PRESSURE SWITCH (1) Apply sealant to the threads of the switch. Specified sealant: Caution Use care not to allow the sealant to plug the oil passage. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equiva- lent diameter bead sealant...
Page 268: Front Case And Oil Pump
FRONT CASE AND OIL PUMP REMOVAL AND INSTALLATION 14 Nm 33 ft.lbs. 40 Nm Removal steps 1 Oil filter 2. Drain plug 3. Drain plug gasket 5. Oil screen 6. Oil screen gasket 7. Relief plug 8. Relief spring 9. Relief plunger 12.
Page 269 REMOVAL SERVICE POINTS OIL PAN REMOVAL (1) Knock in the special tool deeply between the oil pan and the cylinder block. (2) Hitting the side of the special tool, slide the special tool along the oil pan to remove the oil pan. OUTER ROTOR / INNER ROTOR REMOVAL (1) Make alignment dots on the outer and inner rotors for reference in reassembly.
Page 270 SEALANT APPLICATION TO OIL PUMP CASE Specified sealant: Mitsubishi Genuine Part No. MD970389 or equiva- lent CRANKSHAFT FRONT OIL SEAL INSTALLATION Using the special tool, top the oil seal into the oil pump case.
Page 271 (2) Apply a 4 mm (.16 in.) diameter bead of sealant to the oil pan flange. See “Form In-Place Gasket” in introduction. 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.
Page 272 11 D-40 PISTON AND CONNECTING REMOVAL AND INSTALLATION Removal steps 1. Nut 2. Connecting rod cap 3. Connecting rod bearing 5. Connecting rod bearing 6. Piston ring No. 1 8. Oil ring 9. Piston pin 0. Piston 2. Bolt TSB Revision...
Page 273 DISASSEMBLY SERVICE POINTS CONNECTING ROD CAP REMOVAL (1) Mark the cylinder number on the side of the connecting rod big end for correct reassembly. PISTON PIN REMOVAL Piston pin setting tool MIT21 6941 Description Base Piston Support Connecting Rod Guide Pin Connecting Rod Guide Pin Connecting Rod Guide Pin Piston...
Page 274 INSPECTION PISTON RING groove. If the limit is exceeded, replace the ring or piston, or both. Standard value: 0.03 - 0.07 mm (.0012 - .0028 in.) No. 1 No. 2 0.02 - 0.06 mm (.OOOS - .0024 in.) Limit: No. 1 0.1 mm (.004 in.) No.
Page 275 INSTALLATION SERVICE POINTS PISTON PIN INSTALLATION Fit the correct piston support on the top of the base. Insert the press pin, threaded end up, into the hole in the piston support until the press pin touches the stop screw. (2) Using the graduations on the press pin, adjust the stop screw to the correct depth of 50 mm (1.97 in.) (3) Place the base on the press support blocks.
Page 276 NOTE Side rail gap Do not use any piston ring expander when installing the side rail. Use of a ring expander to expand the side rail end gap can break the side rail, unlike other piston rings. (3) Install the lower side rail in the same procedure as described in step (2).
Page 277 CONNECTING ROD BEARING INSTALLATION (1) When the bearings are to be replaced, select correct ones and install them in the correct positions according to the identification marks stamped in the crankshaft. Crank pin OD Connecting rod bearing identification mark Identification mark Identification color Brown Black...
Page 278 CONNECTING ROD CAP NUT INSTALLATION 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 fingers to the full length of the bolt’s thread. If the nut does not run down smoothly, the bolt should be replaced.
Page 279 CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE PLATE REMOVAL AND INSTALLATION 100 Nm 72 ft.lbs. 11 Nm 8 ftlbs. 72 ft.lbs. 7 ft.lbs. Removal steps 2. Flywheel 4. Adapter plate 5. Drive plate 6. Crankshaft bushing 7. Rear plate 8. Bell housing cover 0.
Page 280 11 D-48 INSPECTION CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE METHOD) (1) Remove oil from the crankshaft journal and the crankshaft bearing. (2) Install the crankshaft. (3) Cut the plastic gauge to the same length as the width of bearing and place it on the journal in parallel with its axis. (4) Install the crankshaft bearing cap carefully and tighten the bolts to the specified torque.
Page 281 BORING CYLINDER basis of the largest bore cylinder. Piston size identification Size Identification mark Thrust direction mm (.Ol in.) O.S. 0.25 0.25 mm (.02 in.) OS. 0.50 0.50 mm (.03 in.) O.S. 0.75 0.75 1 .OO mm (.04 in.) O.S. 1.00 NOTE Size mark is stamped on the piston top.
Page 282 REASSEMBLY SERVICE POINTS CRANKSHAFT BEARING INSTALLATION (1) When the bearings are to be replaced, select correct ones Check digit and install them in the correct positions according to the identification marks stamped on the crankshaft and the top Crank pin OD surface of the cylinder block.
Page 283 Standard value: 0.05 - 0.25 mm (.0020 - .0098 in.) Limit: 0.4 mm (.016 in.) SEALANT APPLICATION TO OIL SEAL CASE Specified sealant: Mitsubishi Genuine Part No. MD970389 or equiva- lent DRIVE PLATE BOLT / FLYWHEEL BOLT INSTALLATION Seal (1) Remove all the remaining sealant from the bolts and the thread holes of the crankshaft.
Page 284 NOTES...
Page 285: Contents Intake Manifold
ENGINE CONTENTS INTAKE MANIFOLD PLENUM AND BRACKET ..............122 THROTTLE BODY ..........32 CAMSHAFT, ROCKER ARMS AND OIL PAN AND OIL PUMP .
Page 286 GENERAL INFORMATION SECTIONAL VIEW - SOHC ENGINE for DIAMANTE TSB Revision...
Page 288: General Information
SECTIONAL VIEW - SOHC ENGINE for MONTERO AND TRUCK TSB Revision...
Page 289 TSB Revision...
Page 290 SECTIONAL VIEW - DOHC NON-TURBO ENGINE TSB Revision...
Page 292 SECTIONAL VIEW - DOHC TURBO ENGINE...
Page 293 TSB Revision...
Page 294 Oil pressure switch Oil pressure gauge unit Oil cooler by-pass valve - MONTERO only Lash adjuster TSB Revision...
Page 295 charger Oil pressure switch -turbo only Oil pressure gauge unit To oil cooler - Turbo only Oil cooler by-pass Relief valve valve -Turbo only TSB Revision...
Page 296: General Specifications
GENERAL SPECIFICATIONS SOHC Description Specifications Number of cylinders Combustion chamber Compact type Total displacement 2,972 (181.4) Cylinder bore x stroke mm (in.) 91 .I x 76.0 (3.59 x 2.99) Compression ratio Front wheel drive vehicle 10.0 Rear wheel drive vehicle Valve timing: Front wheel drive Intake valve Opens...
Page 297 DOHC Description Specifications Number of cylinders Combustion chamber Compact type Total displacement 2,972 (181.4) Cylinder bore x stroke mm (in.) 91.1 x 76.0 (3.59 x 2.99) Compression ratio Non-turbo Turbo Valve timing-Non-turbo Intake valve Opens 16” BTDC Closes 55” ABDC Exhaust valve Opens 48”...
Page 298 SERVICE SPECIFICATIONS mm (in.) Standard Limit Cylinder head - SOHC 0.2 (.008) Flatness of gasket surface Less than 0.05 (.0019) Grinding limit of gasket surface cylinder head and cylinder block Overall height 84 (3.31) Oversize rework dimensions of valve guide hole (both intake and exhaust) 0.05 (.002) 0.25 (.OlO)
Page 299 mm (in.) Standard Limit Camshaft - DOHC Cam height Intake 34.41 (1.3547)"' Exhaust 34.70 (1.3661)"' 34.41 (1.3!%7)"2 Journal diameter Oil clearance Rocker arm - SOHC I.D. 18.91 -18.93(.7445-.7453) Rocker arm-to-shaft clearance 0.01 -0.04(.0004-.0016) Rocker shaft - SOHC Intake 102.97 (4.0539) Exhaust 102.67 (4.0421) Intake...
Page 300 mm (in.) Limit Standard Valve spring - SOHC 48.8 (1.921) Free length 49.8 (1.961) Load/Installed height N/mm (Ibs./in.) 4” Out-of-squareness Less than 2” Valve spring - DOHC 44.2 (1.740)*’ Free length 45.2 (1.780)*‘, 46.4 (1.827)“’ 45.4 (1.787)“’ Load/installed height N/mm (Ibs.in.1 4”...
Page 301 mm (in.) Standard Limit Piston ring - SOHC End gap No. 1 ring 0.8 (.031) No. 2 ring Front wheel drive vehicle 0.45 - 0.60 (.0177 - .0236) 0.8 (.031) Rear wheel drive vehicle 0.25 - 0.45 LOO98 - .0177) 0.8 (.031) Oil ring Front wheel drive vehicle...
Page 302 mm (in.) Standard Limit Cylinder block 91.1 (3.587) Cylinder bore Flatness of gasket surface 0.05 (.002) Grinding limit of top surface “0.2 (.008) cylinder head and cylinder block Oil pump 0.35 (0138) Tip clearance 0.03 - 0.08 (0012 - .0031) Side clearance Body clearance 0.10 - 0.18 (0040 - .0070)
Page 303 Generator and drive belt Cooling fan bolt Fan pulley bolt Tensioner pulley nut SOHC DIAMANTE, DOHC SOHC MONTERO AND TRUCK Tensioner bracket bolt SOHC DIAMANTE SOHC MONTERO AND TRUCK Ml0 DOHC Idler pulley bolt SOHC MONTERO AND TRUCK DOHC Cooling fan bracket bolt Tensioner bracket stay bolt Generator pivot nut Generator brace bolt...
Page 304 Ignition system Center cover bolt Spark plug Distributor nut Ignition coil bolt SOHC MONTERO AND TRUCK DOHC Ignition power transistor bolt Crankshaft position sensor nut Timing belt - SOHC Engine support bracket bolt Ml0 Tensioner lock bolt riming belt - DOHC ‘51 rensioner pulley bolt dler pulley bolt...
Page 305 Exhaust manifold Oil level guide bolt gauge Heat protector bolt Engine hanger bolt SOHC DIAMANTE SOHC MONTERO AND TRUCK DOHC NON-TURBO Exhaust manifold nut SOHC DOHC NON-TURBO DOHC TURBO Heater pipe bolt SOHC MONTERO AND TRUCK pump bolt Turbocharger stay bolt pipe bolt Nater pipe eye bolt...
Page 306: Piston And Connecting Rod
11 E-22 Oil pan and oil pump Transmission stay bolt Oil pressure switch DIAMANTE AND 3000GT MONTERO AND TRUCK Oil pressure gauge unit DIAMANTE AND 3000GT MONTERO Oil cooler by-pass valve Oil filter bracket stay bolt (10x20) Oil filter bracket bolt DIAMANTE AND 3000GT MONTERO AND TRUCK mark 4 mark 7...
Page 307: Sealant
As required Rocker cover As required Bearing cap As required Oil pressure switch As required Oil pressure gauge unit As required Oil pan MITSUBISHI GENUINE Part No.MD970389 As required Oil seal case MITSUBISHI GENUINE Part No.MD970389 As required TSB Revision...
Page 308 11 E-24 SOHC engine only Leak-down tester Air bleed wire For SOHC engine only Camshaft oil seal installer ton and timing belt For SOHC engine only TSB Revision...
Page 309 Tools Tool Number and Supersession Application tool name Installation of crankshaft front oil seal Crankshaft front oil seal installer I I nstallation of crankshaft rear oil seal Use with MB990938, Crankshaft rear oil seal installer Pulley holding pins (2) Oil pan remover nstallation of valve stem seal Valve stem...
Page 310 11 E-26 seal installer compressor Installation of flywheel TSB Revision...
Page 311 GENERATOR AND DRIVE BELT REMOVAL AND INSTALLATION - SOHC for DIAMANTE 23 Nm 155 Nm 30 ft.lbs. Removal steps 14 Nm 2. Tensioner pulley 10 ft.lbs. 3. Adjusting bolt 4. Adjusting stud 5. Tensioner bracket 6. Pivot bolt 7. Generator 8.
Page 312 13 Nm 9 ftlbs. 13 Nm 9 ftlbs. 7 ftlbs. Removal steps 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.
Page 313 23 Nm 17 ft.lby 24 Nm 17 ftlbs. 24 Nm 17 ft.lbs. 45 Nm 33 ft.lbs. 50 Nm 36 klbs. 50 Nm Removal steps 2. Idler pulley 165 Nm 3. Tensioner pulley 4. Adjusting bolt 5. Adjusting stud 6. Tensioner bracket 7.
Page 314 REMOVAL SERVICE POINT CRANKSHAFT BOLT LOOSENING tool, hold the drive plate or flywheel. (1) Using the special INSTALLATION SERVICE POINT SOHC for DIAMANTE DRIVE BELT TENSION ADJUSTMENT DRIVE BELT - TENSION CHART Deflection Generator drive belt mm (in.) SOHC for 4.5 (.16-.20) 500 (110) 7 l.28)
Page 315 (3) If you use a tension gauge, tighten the adjusting bblt to adjust the belt tension to the specification shown in the chart. DOHC CRANKSHAFT BOLT TIGHTENING Install the crankshaft bolt. TSB Revision...
Page 316 INTAKE MANIFOLD PLENUM AND THROTTLE BODY REMOVAL AND INSTALLATION - SOHC for DIAMANTE 12 Nm 8 ft.lbs. 18 Nm 22 Nm 16 ftlbs. 3.6 ft.lbs. 13 ft.lbs. Removal steps 1. EGRpipe For California 2. Ignition coil 3. High tension cable 4.
Page 317 14 Nm 18 Nm 13 ft.lbs. 18 Nm 22 Nm 16 ft.lbs. Removal steps 1. EGR pipe For California 2. EGR pipe gasket 3. Intake inariifold plenum stay, rear 4. Intake manifold plenum stay, front 5. EGR valve 6. EGR valve gasket > For California 7.
Page 318 12 Nm 8 ft.lbs. 3 ftlbs. 22 Nm 16 ft.lbs. 13 ft.lbs. 13 ftlbs. 13 fklbs. Removal steps For California 2. Intake manifold plenum stay, rear 3. Intake manifold plenum stay, front 5. EGR valve For California 6. EGR valve gasket 7.
Page 319 13 ftlbs. 13 ft.lbs. 18 Nm 13 ftlbs. Removal steps 1. EGRpipe For California 2. EGR pipe gasket 3. Intake manifold plenum stay, rear 4. Intake manifold plenum stay, front 5. EGR valve For California 6. EGR valve aasket 7. Throttle bo?iy 8.
Page 320 INSPECTION EGR VALVE 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. Blow air in from one passage of the EGR to check its condition as follows.
Page 321 THROTTLE BODY DISASSEMBLY AND REASSEMBLY - SOHC for DIAMANTE, DOHC NON-TURBO 2.5 Nm 1.8 ft.lbs. Disassembly steps 2. Idle air control motor 3. Throttle body DISASSEMBLY AND REASSEMBLY - For VEHICLES with TRACTION CONTROL 3.5 Nm 2.5 ftlbs. 3.5 Nm 2.5 ft.lbs.
Page 322 DISASSEMBLY AND REASSEMBLY - DOHC TURBO Disassembly steps Up to 1992 models 3. Vacuum valve 4. Dash pot- From 1993 models 6. Idle air control motor 7. Throttle body DISASSEMBLY AND REASSEMBLY - SOHC for MONTERO and TRUCK 3.5 Nm 2.5 ftlbs.
Page 323 DISASSEMBLY SERVICE POINTS PEDAL POSITION SENSOR AND IDLE AIR CONTROL MOTOR REMOVAL (2) Do not clean the sensor and motor by dipping them into the solvent. Clean them with shop towel. (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.
Page 324 VACUUM VALVE - DOHC TURBO Up to 1992 models (2) Connect a hand vacuum pump to the black nipple of the vacuum valve. (3) With the other nipple closed by the finger, apply a negative pressure of 500 mmHg (19.7 in.Hg.) to make sure that the negative pressure is maintained.
Page 325 (3) Hold the idle air control motor as shown in the illustration, connect the negative 0 terminal of the power supply to and check each clip as described in the following steps, whether or not a vibrating feeling (a feeling of very slight vibration of the stepper motor) is generated as a result of the activation of the stepper motor.
Page 326 (3) Connect a circuit tester between 4 (ground) and 2 (output), or between 2 (output) and 1 (power). Then, make sure that Throttle position Ground the resistance changes smoothly when the throttle valve is slowly moved to the fully open position. (4) Check for continuity across terminals 3 (closed throttle position switch) and 4 (ground) with the throttle valve both fully closed and fully open.
Page 327 If there is no continuity with throttle valve fully closed, turn the throttle position sensor clockwise, and then check again. (5) If the above specifications are not met, replace TPS. INSTALLATION body as shown in the illustration. (2) Turn the accelerator pedal position sensor 90” clockwise to set it, and tighten the screws.
Page 328 IGNITION SYSTEM SOHC for DIAMANTE 25 Nm 18 ft.lbs. Removal steps 1. Spark plug cables 2. Spark plug 3. Distributor 4. O-ring TSB Revision...
Page 329 25 Nm 18 ft.lbs. Removal steps 1. Spark plug cables 2. Spark plugs 3. High tension cable 5. O-ring 6. Ignition coil...
Page 330 11 E-46 13 Nm 9 ft.lbs. Removal steps 2. Spark plug cables 3. Soark oluas 4. Ciamp’ From 1993 models 5. Ignition coil 6. Engine hanger power transistor- DIAMANTE 8. ignition power transistor _ 3000GT 9. Crankshaft position sensor- Up to 1992 models 10.
Page 331 ENGINE INSTALLATION SERVICE POINTS DISTRIBUTOR INSTALLATION - SOljC (1) Turn the crankshaft so that the No. 1 cylinder is at compression top dead center. (2) Align the distributor housing and gear mating marks. (3) With the stud located in the center of the adjusting slot at the distributor, install the distributor.
Page 332 TIMING BELT - SOHC REMOVAL AND INSTALLATION - DIAMANTE 26 Nm 19 ft.lbs. 80 ftlbs. Removal steps 2. 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.
Page 333: Timing Belt
SOHC 25 Nm 18 ft.lbs. 11 Nm 8 ftlbs. 19 ft.lbs. Removal steps 1. Access cover 2. Timing belt front upper cover, right 3. Timing belt front upper cover, left 4. Timing belt front lower cover 5. Flange 8. Tensioner spring 9.
Page 334 REMOVAL SERVICE POINTS TIMING BELT REMOVAL tion. NOTE 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 water pump for leaks.
Page 335 (7) Abnormal wear on teeth (8) Tooth missing and canvas fiber exposed. Rubber exposed Tooth missing and canvas fiber exposed INSTALLATION SERVICE POINTS CAMSHAFT SPROCKET BOLT INSTALLATION 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.
Page 336 11 E-52 crankshaft sprocket. (2) Install the timing belt on the crankshaft sprocket first and while keeping the belt tight on the tension side, install the belt on the left camshaft sprocket. (3) Then, install on the water pump pulley and on the right camshaft sprocket and finally on the timing belt tensioner.
Page 337 ENGINE SUPPORT BRACKET INSTALLATION in the illustration. ad ,I mark NOTE The bolt used at the location shown in the illustration is a reamer bolt (head mark “R”).
Page 338 TIMING BELT - DOHC REMOVAL AND INSTALLATION - Up to 1992 models 2 ft.lbs. 90 Nm 65 ftlbs. 49 Nm 35 ft.lbs. 30 ft.lbs. 55 Nm 40 ftlbs. Removal steps 11. Crankshaft sprocket 2. Timing belt front upper cover, right 3.
Page 339 2 ft.lbs. 2 klbs. 24 Nm 17 ft.lbs. 42 Nm 55 Nm 30 ft.lbs. 35 ft.lbs. 40 ft.lbs. Idler pulley 13. Idler pulley bracket 14. Crankshaft sprocket 15. Sensing plate 60 ft.lbs. 16. Washer Removal steps 18. Rocker cover gasket, A 19.
Page 340 REMOVAL SERVICE POINTS TIMING BELT REMOVAL tion. NOTE (1) Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be kept free from oil and water. Do not immerse parts in cleaning solvent.
Page 341 INSTALLATION SERVICE POINTS CAMSHAFT SPROCKET BOLT TIGHTENING when tightening the camshaft sprocket bolt. Tighten the bolt to the specified torque. ROCKER COVER INSTALLATION Specified sealant: 3M ATD Part No.8660 or equivalent. Apply sealant (2) Tighten the rocker cover bolts in the sequence shown in the illustration.
Page 342 11 E-58 DOHC (1) Using the special tool, line up the crankshaft sprocket timing marks, and then rotate the sprocket one tooth counterclockwise. (2) Line up the timing marks of the camshaft sprockets for left bank. (3) Using two wrenches, line up the timing marks of the camshaft sprockets for right bank.
Page 343 (6) Check that the timing marks of the camshaft sprockets for left bank are in alignment. Then install the timing belt on these sprockets and hold it with a paper clip at the positions shown in the illustration. (7) Install the timing belt on the idler pulley. (8) Install the timing belt on the crankshaft sprocket.
Page 344 Timing marks Timing marks (on right Camshaft sprocket (on left rocker cover) rocker cover) Timing mark (on sprocket) Auto tensioner Timing mark (on oil pump case) (on sprocket) Crankshaft sprocket ’ install the special tool and a torque wrench on the pull’ey. While holding the pulley with approximately 10 Nm (7 bolt to the specified torque.
Page 345 tensioner is within the standard limit. Standard value: 3.8 - 4.5 mm (.I50 - .I77 ‘in.) ENGINE SUPPORT BRACKET INSTALLATION in the illustration. NOTE ad mark The bolt used at the location shown in the illustration is a reamer bolt (head mark “R”).
Page 346 11 E-62 INTAKE MANIFOLD AND FUEL PARTS REMOVAL AND INSTALLATION - SOHC for DIAMANTE 8 ftlbs. 7 ftlbs. 19 Nm 14 ftlbs. Removal steps 2. Injector and fuel rail 3. insulator 5. O-ring 6. Insulator 11. O-ring 12. Fuel rail 16.
Page 347 Parts 14 ft.lbs. 30 Nm 22 c.lbs. 11 Nm 8 ftlbs. Removal steps 12. Heat pipe 1. Injector and fuel rail 2. Insulator 13. Heat pipe gasket 14. Water hose 4. O-ring 5. Insulator 7. O-ring 18. Water outlet fitting 8.
Page 348 19 Nm 14 ft.lbs. 8 ftlbs. 19 Nm 14 ft.lbs. 18 Nm 13 ft.lbs. --$j Removal steps 1. Injector harness 2. Injector and fuel rail 15. Intake manifold gasket 3. Insulator 5. O-ring 6. Insulator 19. Water hose Injector clip 20.
Page 349 Intake Manifold and Fuel Parts INSPECTION INJECTORS (1) Measure the resistance between the terminals of the injectors using a circuit tester. If the resistance is out of?he specification, replace the injector. Standard value: 13 - 16 R at 20°C (68°F) Non Turbo Turbo 2 - 3 IR at 20°C (68°F)
Page 350 DOHC INTAKE MANIFOLD INSTALLATION - (2) Tighten the nuts on the left bank to the specified torque. Then tighten the nuts on right bank to the specified torque. (3) Tighten the nuts on the left bank and those on the right 71 NO090 INSTALLATION OF INJECTOR lubricated with a drop of clean engine oil for easy...
Page 351 EXHAUST MANIFOLD REMOVAL AND INSTALLATION - SOHC for DIAMANTE 14 Nm 6 III 24 Nm 14 Nm 14 ft.lbs. Removal steps For M/l 2. Oil level gauge guide 3. O-ring 4. Heat protector For A/T 5. Engine hanger, right 20. Water pump 6.
Page 352 9 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 8. Heat protector, left 9. Bracket 10. Exhaust manifold, left 12. Water hose 13. Water hose A 14.
Page 353 14 10 1 ft. l b s. Nm 14 Nm 10 ft.lbs. 13 Nm 9 ft.lbs. 14 Nm 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.
Page 354 REMOVAL AND INSTALLATION - DOHC TURBO 14 Nm Removal steps 1. Oil level gauge 3. O-ring 17 ftlbs. 7. Water pump 8. Water pump gasket TSB Revision...
Page 355 44 ft.lbs. 31 Nm 14 Nm 43 ftlbs. 19. Turbocharger, right 9. Heat protector B 20. Turbocharger gasket Ring 11. Turbocharger stay 22. Oil return pipe, right 12. Exhaust fitting 23. Oil return pipe gasket 13. Exhaust fitting gasket 24. Exhaust manifold sta , right 14.
Page 356 14 Nm 8 klbs. 31 Nm 22 ftlbs. 25 Nm 18 ft.lbs. -9 27. Heat protector D 28. Exhaust fitting, left 29. Exhaust fitting gasket, left 30. Heat protector C 32. Oil return pipe gasket 33. Oil pipe 34. Water pipe 6, left 35.
Page 357 INSTALLATION SERVICE POINTS O-ring Water pump O-RING AND WATER PIPE INSTALLATION Caution Keep the O-ring free of oil or grease. Water in’let pipe EXHAUST MANIFOLD GASKET IDENTIFICATION - SOHC (1) Install gaskets with cylinder number 0, @ and @ embos- Cylinder No.
Page 358 11 E-74 LEFT EXHAUST MANIFOLD INSTALLATION - DOHC TURBO Tighten the nuts in the following order. (1) Tighten four nuts @ to 30 Nm (22 ft.lbs.). (2) -TT;.poranly 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.).
Page 359 TURBOCHARGER DISASSEMBLY AND REASSEMBLY Snap pin 2. Turbocharger waste gate actuator 3. Coupling 4. Turbine housing 7. 0-rina 8. Combressor cover INSPECTION TURBOCHARGER it operates freely. or blockage. (3) Clean the inlet section of the compressor cover with a rag. Inspect it for signs of contact with the compressor turbine.
Page 360 while aligning the dowel pin and the hole. Caution Use care not to damage the blades of the turbine wheel and compressor wheel. Chamfered assembly cover the hole. Caution Use care not to damage the blades of the turbine wheel.
Page 361 ROCKER ARMS ANI) CAMSHAFTS - SOHC REMOVAL AND INSTALLATION - DIAMANTE 7 ft.lbs. Removal steps cover 5. Distributor adaptor 6. O-ring...
Page 362 7 ft.lbs. 9 ft.lbs. ------d Removal steps 1 Oil filler 2. Oil filler tube 4. Gasket 7. Distributor adaptor O-ring...
Page 363 SOHC REMOVAL SERVICE POINT ROCKER ARM, SHAFT AND BEARING CAP REMOVAL (1) Install the special tools to the rocker arm to hold the lash adjuster. (2) Loosen the camshaft bearing cap bolt. Do not remove the bolts from the cap. (3) Remove the rocker arm, shaft and bearing cap as an assembly.
Page 364 (2) While lightly pushing down the inner steel ball using the small wire, move the plunger up and down four or five times to bleed air. Use of the Retainer facilitates the air bleeding of the rocker arm mounted type lash adjuster. (3) Remove the small wire and press the plunger.
Page 365 ROCKER ARM, SHAFT AND BEARING CAP INSTALLATION (1) Apply a minimum amount of the specified sealant on the four places of the cylinder head. NOTE Be sure the sealing agent does not swell out onto the cam journal surface of the cylinder head. If it swells out, immediately wipe it off before it can dry.
Page 366 11 E-82 Arrow mark (bearing cap) Rocker arm shaft assembly(B) Arrow mark (cylinder head) Timing belt side R o c k e r a r m s h a f t - - - - - assembly (A) Arrow mark-(bearing cap) (3) Tighten the bearing cap bolts to the specified torque.
Page 367 special tool and drive in the circular packing. NOTE Use of MD724328 spacer for transmission is recom- mended. Caution 0.5 mm (020 in.) The packing is overdriven if no spacer is fitted to the special tool. Spacer 7 ROCKER COVER INSTALLATION (1) Apply specified sealant on the area specified in the illustration.
Page 368 DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Bearing cap No.4 2. Rocker arm 3. Spring 4. Bearing cap No. 3 5. Bearing cap No. 2 8. Bearing cap No. 1 DISASSEMBLY SERVICE POINT rocker arm by a symbol. For example, put symbols as shown below. 1 IN: For No.1 cylinder intake TSB Revision...
Page 369 INSPECTION ROCKER ARM (1) Check the roller surface and replace the rocker arm if recesses, damage or heat seizure is observed. (2) Check roller rotation and replace the rocker arm if uneven rotation or roller backlash is observed. (3) Check the inside diameter and replace the rocker arm if damage or seizure is observed.
Page 370 as illustrated. The rocker arms are all 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 cap No.4...
Page 371 CAMSHAFTS, ROCKER ARMS AND BEARING CAPS - DOHC REMOVAL AND INSTALLATION 20 Nm Removal steps 1992 models adaptor-Up to - F r o m 1993 models 4. Bearing cap, front 5. Bearing cap, rear 6. Bearing cap No. 2 7. Bearing cap No. 4 8.
Page 372 INSPECTION CAMSHAFT Measure the cam height (longer diameter of the cam). If it exceeds the limit, replace the camshaft. Standard value: Up to 1992 models 35.49 mm (1.3972 in.) Intake side 35.20 mm (1.3858 in.) Exhaust side From 1993 models 34.91 mm (1.3744 in.) Intake side 34.91 mm (1.3744 in.)
Page 373 center. (2) Check that the rocker arm is installed correctly on the lash adjuster and valve. (3) Install the camshaft while noting the identification mark Identification mark (stamped on the hexagon section). Identification mark: Up to 1992 From 1993 models Turbo Intake side Exhaust side...
Page 374 amshafts, Rocker Arms and Bearing Caps - DOHC C A M S H A F T O I L S E A L oil seal. C I R C U L A R P A C K I N G TSB Revision...
Page 375 CYLINDER HEAD AND VALVE - SOHC REMOVAL AND INSTALLATION 80 ft.lbs. Removal steps 1. Valve spring 2. Exhaust valve 3. Valve stem seal 4. Valve spring seat 5. Valve stem seal 6. Valve spring retainer 6. Valve spring seat 7. Inlet valve guide 8.
Page 376 11 E-92 REMOVAL SERVICE POINTS PRECAUTION FOR REMOVED PARTS number and intake/exhaust. CYLINDER HEAD BOLT REMOVAL Loosen evenly, little by little. RETAINER LOCK REMOVAL Revision...
Page 377 INSPECTION CYLINDER HEAD using a straightedge in the directions of A through G shown in the illustration. 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.) block.
Page 378 VALVE SPRINGS than the limit, replace. Standard value: SOHC 49.8 mm (1.961 in.) DOHC up to 1992 models 45.2 mm (1.780 in.) From 1993 models 46.4 mm (1.827 in.) Limit: SOHC 48.8 mm (1.921 in.) 1 EN0264 DOHC up to 1992 models 44.2 mm (1.740 in.) From...
Page 379 (4) Check the valve seat sinkage. The valve seat sinkage can be determined by measuring the valve spring’s installed height. (If the valve seat sinkage is great, the valve seat’s installed height also is great.) If the valve spring’s installed height exceeds the service limit, replace the insert with an oversize part as described height below.
Page 380 11 E-96 SOHC NOTE Do not install a valve guide of the same size again. (4) Using the special tool, press-fit the valve guide, working from the cylinder head top surface. (5) After installing valve guides, insert new valves in them to check for sliding condition.
Page 381 SOHC Caution Identification mark Do not apply sealant to the cylinder head gasket. Identification mark: TRUCK CYLINDER HEAD BOLT INSTALLATION 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 AND VALVES - DOHC REMOVAL OF INSTALLATION Non-turbo 80 ft.lbs. Turbo 90 ft.lbs. Removal steps 2. Washer 12. Exhaust valve 3. Cylinder head assembly 4. Cylinder head gasket 14. Valve spring seat 5. Retainer lock 6. Valve spring retainer 16.
Page 383 REMOVAL SERVICE POINTS Loosen evenly, little by little. (1) Using the special tool, compress the spring. (2) Remove the retainer locks. (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...
Page 384 ENGINE CYLINDER HEAD Cylinder head height (when new): 131.9 - 132.1 mm (5.193 - 5.201 in.) INSTALLATION SERVICE POINTS VALVE STEM SEAL INSTALLATION (2) Using the special tool, install a new stem seal to the valve guide. Valve Caution seat Do not reuse removed valve stem seal.
Page 385 CYLINDER HEAD GASKET IDENTIFICATION Identification mark Non-turbo Turbo 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 Exhaust side...
Page 386 OIL PAN AND OIL PUMP REMOVAL AND INSTALLATION - DIAMANTE and 3000GT 23 Nm 17 ft.lbs. 24 Nm 17 ftlbs. 55 Nm 75 Nm 54 ft.lbs. 7 ft.lbs. 14 Nm 33 ft.lbs. 40 Nm 29 ft.lbs. 4 ft.lbs. Removal steps 16.
Page 387 Pump Bolt with head mark “4” 24 Nm 17 ft.lbs. Bolt with head mark “7” 14 Nm 10 ft.lbs. 55 Nm 7 ft.lbs. 55 Nm 40 ft.lbs. 14 Nm 11 ft.lbs. 14 ft.lbs. 7 ft.lbs. 45 Nm 33 ft.lbs. 40 Nm 29 ft.lbs.
Page 388 REMOVAL SERVICE POINT O I L P A N R E M O V A L cylinder block. to remove it. OUTER ROTOR / INNER ROTOR REMOVAL reference in reassembly. INSPECTION OIL PUMP Standard value: 0.03 - 0.08 mm (.0012 - .0031 in.) (2) Check the side clearance.
Page 389 OIL COOLER BYPASS VALVE (2) Ensure that the dimension L measures the standard value under normal temperature and humidity. Dimension L: 34.5 mm (1.358 in.) (3) The dimension 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 INNER ROTOR / OUTER ROTOR INSTALLATION...
Page 390 (2) Apply a 4 mm (.I6 in.) diameter bead of sealant to the oil pan flange. See “Form In-Place Gasket” in introduction. Specified sealant: Mitsubishi Genuine Part No. MD970389 equivalent (3) The oil pan should be installed within 15 minutes after the application of sealant.
Page 391 (1) Install the drain plug gasket as illustrated. 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.
Page 392 PISTON AND CONNECTING REMOVAL AND INSTALLATION Removal steps 1. Nut 3. Connecting rod bearing (lower) 5. Connecting rod bearing (upper) 6. Piston rina No.? 7. Piston rini No.2 8. Oil ring 9. Piston pin 0. Piston 2. Bolt TSB Revision...
Page 393 REMOVAL SERVICE POINTS CONNECTING ROD CAP REMOVAL (1) Mark the cylinder big end for correct reassembly. (2) Keep the removed connecting rods, caps, and bearings in order according to the cylinder number.. Piston pin setting tool MIT21 6941 Item No. Part No. Description Base Piston Support...
Page 394 ENGINE INSPECTION PISTON (1) Replace the piston if scratches or seizure is evident on its surfaces (especially the thrust surface). Replace the piston if it is cracked. PISTON PIN (1) Insert the piston pin into the piston pin hole with a thumb. You should feel a slight resistance.
Page 395 CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE METHOD) The crankshaft oil clearance can be measured easily by using a plastic gauge, as follows: the crankshaft pin and the 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 pin in parallel with its axis.
Page 396 (3) Place the base on 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 connecting rod.
Page 397 PISTON RING NO.2 / PISTON RING NO.1 INSTALLATION (1) Using a piston ring expander, fit No.2 and then No.1 piston ring into position. NOTE 1. Note the difference in shape between No.1 and No.2 piston rings. 2. Install piston rings No.1 and No.2 with their side having marks facing up (on the piston crown side.) PISTON AND CONNECTING ROD INSTALLATION Upper side...
Page 398 CONNECTING ROD CAP INSTALLATION rod by checking with the alignment marks marked during disassembly. If a new connecting rod is used which has no Cylinder No. alignment mark, position the notches for locking the bearing on the same side. Notches (2) Check if the thrust clearance in the connecting rod big end is correct.
Page 399 1 l’E415 CRANKSHAFT, FLYWHEEL AND DRIVE PLATE REMOVAL AND INSTALLATION 23 Nm 17 ftlbs. 54 ft.lbs. 75 Nm 54 ft.lbs. SOHC 79 Nm 57 ft.lbs. 35 ft.lbs. DOHC - 93 Nm Removal steps 1. Flywheel For MIT 2. Ball bearing 3.
Page 400 INSPECTION CRANKSHAFT If the oil clearance exceeds the limit, replace the bearing, and crankshaft if necessary. (1) Measure the outside diameter of the journals and the inside diameter of the crankshaft bearings. If the difference between them (oil clearance) exceeds the limit, replace the crankshaft bearing and, if necessary, crankshaft.
Page 401 Drive Plate INSPECTION CYLINDER BLOCK for scratches, rust, and corrosion. Use also a flaw detecting agent for the check. If defects are evident, correct, or replace. 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 (.0039 in.) limit or replace.
Page 402 Caution To prevent distortion that may result from temperature rise during honing, bore cylinders in the order of No.2, (5) Hone to the final finish dimension (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 - m m (-0004 - .0016 in.)
Page 403 CRANKSHAFT BEARING (UPPER) / THRUST BEARING A / THRUST BEARING B / CRANKSHAFT BEARING (LOWER) INSTALLATION 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.
Page 404 BEARING CAP / BEARING BOLT INSTALLATION (1) Attach the bearing cap on the cylinder block as shown in the illustration. (2) Tighten the bearing cap bolts to the specified torque in the sequence shown in the illustration. (3) Check that the crankshaft rotates smoothly. Cylinder (4) Check the end plate.
Page 405 CRANKSHAFT REAR OIL SEAL INSTALLATION seal into the oil seal case. OIL SEAL CASE INSTALLATION Sealing agent Specified sealant: MITSUBISHI GENUINE Part No. MD970389 or equivalent (2) Apply a small amount of engine oil to the entire circuinfer- cylinder block.
Page 406 BRACKET REMOVAL AND INSTALLATION - DIAMANTE and 3000GT 30 ft.lbs. Removal steps 1. Engine support bracket, right 2. Engine support bracket, left REMOVAL AND INSTALLATION - MONTERO and TRUCK 30 ft.lbs. 25 Nm 18 ft.lbs. Removal steps 2. Roll stopper bracket, rear...
Page 407 ENGINE <1993> CONTENTS INTAKE MANIFOLD ......................BRACKET PISTON AND CONNECTING ROD ....103 CRANKSHAFT, FLYWHEEL AND DRIVE PLATE ............110 ROCKER ARMS AND CAMSHAFT ....CYLINDER HEAD AND VALVES ......SEALANT ..............EXHAUST MANIFOLD AND SERVICE SPECIFICATIONS ..................WATER PUMP SPECIAL TOOLS ............
Page 408 4G6 ENGINE <1993> - General Information GENERAL INFORMATION ENGINE SECTIONAL VIEW - SOHC 8 VALVE 6EN0629 TSB Revision...
Page 409 4G6 ENGINE <1993> - General Information 6EN0630 TS8 Revision...
Page 410 4G6 ENGINE <1993> - General Information ENGINE SECTIONAL VIEW - SOHC 16 VALVE 6EN0616 TSB Revision...
Page 411 TSB Revision...
Page 412 ENGINE SECTIONAL VIEW - DOHC TSB Revision...
Page 414 ENGINE LUBRICATION SYSTEM - SOHC 8 VALVE Rocker shaft Oil pump ENGINE LUBRICATION SYSTEM - SOHC 16 VALVE Crankshaft Oil pump...
Page 415 ENGINE LUBRICATION SYSTEM - DOHC Camshaft , Oil cooler ‘Crankshaft Relief valve Oil pumr ‘Silent shaft ENGINE LUBRICATION SYSTEM - DOHC-TURBO From thermostat case Oil filter To wate Oil jet Crankshaft Oil pump ’ ‘ S i l e n t s h a f t...
Page 416 GENERAL SPECIFICATIONS Specifications In-line OHV, SOHC Number of cylinders Combustion chamber Total displacement 1,997 (121.9) Cylinder bore mm (in.) 85 (3.35) Piston stroke mm (in.) 88 (3.46) Compression ratio Valve timing Opens BTDC 11” Closes ABDC 53” Exhaust valve BBDC Opens 63”...
Page 417 1 TFk-l- 1 Items Specifications In-line OHV, SOHC Number Combustion chamber 2,350 (143.4) mm (in.) 8 6 . 5 ( 3 . 4 1 ) Cylinder bore mm (in.) Piston stroke Compression ratio Valve timing Intake valve Opens BTDC Closes ABDC Exhaust valve BBDC...
Page 418 Specifications Items In-line OHV, SOHC Number of cylinders Combustion chamber 2,350 (143.4) Total displacement 86.5 (3.41) mm (in.) Cylinder bore 100 (3.94) mm (in.) Piston stroke Compression ratio Valve timing intake valve 18” BTDC Opens 58” ABDC Closes Exhaust valve 58”...
Page 419 Items Specifications In-line OHV, OHC Number of cylinders Combustion chamber Total displacement 1,997 (121.9) Cylinder bore mm (in.) 85 (3.35) Piston stroke mm (in.) 88 (3.46) Compression ratio ECLIPCE-Turbo Valve timing Intake valve 16” Opens BTDC 21” 26” 21” 48” Closes ABDC 43”...
Page 420 SERVICE SPECIFICATIONS mm (in.) L i m i t Standard Cylinder head - SOHC 8 VALVE 0.2 (.008) 0.05 (.0020) Flatness of gasket surface Grinding limit of gasket surface cylinder block. 89.9 - 90.1 (3.508 - 3.547) Overall height Oversize rework dimensions of valve guide hole (both intake and exhaust) 0.05 (002) 0.25 (.OlO)
Page 421 mm (in.) Limit Standard Cylinder head - DOHC Flatness of gasket surface 0.2 (.008) 0.05 (.0020) Grinding limit of gasket surface cylinder block Flatness of manifold mounting surface 0.15 (.0059) 0.3 LO1 2) 131.9-132.1 (5.193-5.201) Overall height Oversize rework dimensions of valve guide hole (both intake and exhaust) 0.05 (.002) 0.25 (.OlO)
Page 422 mm (in.) Limit Standard Rocker arm - SOHC 8 VALVE I.D. 18.91 - 18.93 (.7445- .7453) Rocker arm-to-shaft clearance 0.1 (.004) 0.01 - 0.04 (.0004- .0016) Rocker arm - SOHC 16 VALVE I.D. 20.02 - 20.04 i.7882 - .7890) Rocker arm-to-shaft clearance 0.02 - 0.05 (.0008 - .0020) 0.1 i.004) Lash adjuster...
Page 423 mm (in.) Standard Limit Valve - SOHC 16 VALVE Overall length Intake 112.3 (4.421) Exhaust 114.1 (4.492) Stem diameter Intake 5.97 - 5.98 i.2350 - .2354) Exhaust 5.95 - 5.97 (.2343 - .2350) Face angle 45” - 45”30’ Thickness of valve head (margin) Intake 0.5 (.020) Exhaust...
Page 424 mm (in.) Limit Standard Valve guide- SOHC 8 VALVE Overall length Intake 47 (1.85) Exhaust 52 (2.05) I.D. 8.00 - 8.02 (3150 - .3157) O.D. 13.06 - 13.07 (5142 - .5146) Service size 0.05 (.002), 0.25 (.OlO), 0.50 (.020) oversize Press-in temperature Room temperature Valve guide - SOHC 16 VALVE...
Page 425 mm (in.) Standard Limit Piston - DOHC O.D. Non-turbo 84.97 - 85.00 (3.3453 - 3.3465) Turbo Piston to cylinder clearance Non-turbo 0.02 -0.04 (0008 - .0016) Turbo 0.03 -0.05 (0012 - .0020) Service size 0.25 LOlO), 0.50 (.020), 0.75 (.030), 1 .OO (.039) over size Piston ring - SOHC End gap...
Page 426 mm (in.) Limit Standard Crankshaft 0.05 - 0.25 (0020 - .0098) 0.4 (.016) End play Journal O.D. 56.98 - 57.00 (2.2433 - 2.2441) 44.98 - 45.00 (1.7709 - 1.7717) Pin O.D. Out-of-roundness and taper of journal and pin Max. 0.01 (.0004) Concentricity of journal Max.
Page 427 TORQUE SPECIFICATIONS Generator and ignition system Cooling fan Fan clutch Water pulley pump Generator mounting bolt Generator brace bolt Generator pivot nut Crankshaft pulley bolt Spark plug Ignition coil bolt Distributor nut Center cover bolt Power transistor bolt Timing belt dler pulley bolt - SOHC dler pulley bolt - DOHC ingine support bracket bolt...
Page 428 Intake manifold Intake manifold bolt and nut Intake manifold bolt (Ml 0) and nut (Ml 0) - DOHC Intake manifold stay bolt - SOHC Intake manifold stay bolt - DOHC Intake manifold plenum bolt and nut Intake manifold plenum stay bolt Water outlet fitting bolt Engine coolant temperature gauge unit Engine coolant temperature sensor...
Page 429 Rocker arms and camshaft Rocker cover bolt - SOHC Rocker cover bolt - DOHC Bearing cap bolt - SOHC Bearing cap bolt - DOHC Rocker shaft bolt Oil delivery body Cylinder head and valves Cylinder head bolt 20 + 114 turns 14.5 + 114 turr Front case, silent shaft and oil pan Drain plug...
Page 430 Rocker cover Semi-circular packing As required As required Engine support bracket bolt As required Oil pan gasket MITSUBISHI GENUINE PART As required Water outlet fitting MITSUBISHI GENUINE PART Engine coolant temperature gauge unit As required As required Engine coolant temperature sensor...
Page 431 SPECIAL TOOLS Use with M IT304204 Use with MIT304204 Crankshaft front oil seal installer TSB Revision...
Page 432 Application Supersession Number and Tool tool name Air bleeding of lash adjuster For SOHC engine only Air bleed of lash adjuster Air bleed wire Supporting of the lash adjuster to prevent it from falling when rocker shaft assembly is Lash adjuster removed or installed holder (8) For SOHC engine only...
Page 433 tool name compressor Crankshaft rear oil seal installer Removal and installation of piston pin Piston pin setting tool Supporting flywheel and drive plate TSB Revision...
Page 434 11 F-28 GENERATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION - SOHC 8 VALVE 25 Nm 18 ftlbs, 14 Nm 11 Nm 8 ftlbs. 25 N’m 18 ft.lbs. 8 ft.lbs. Removal steps 2. Cooling fan 3. Fan clutch 4. Water pump pulley 5.
Page 435 Generator and Ignition System REMOVAL AND INSTALLATION - SOHC 16 VALVE 25 ‘Nm 18 ft.lbs. 14 Nm 17 ftlbs. Removal steps 2. Water pump pulley 3. Power steering pump pulley 4. Generator brace 5. Generator 6. Crankshaft pulley 7. Spark plug cable 8.
Page 436 REMOVAL AND INSTALLATION - DOHC 2 ft.lbs.- 25 Nm 18 ft.lbs. 19 Nm 14 ft.lbs. 23 Nm 17 ft.lbs. 11 Nm 24 Nm 8 ft.lbs. 17 ft.lbs. 17 klbs. 7. Center cover 2. Water pump pulley 8. Spark plug cable 3.
Page 437 INSTALLATION SERVICE POINTS DISTRIBUTOR INSTALLATION (1) Turn the crankshaft so that the No. 1 cylinder is at top dead center. (2) Align the distributor housing and gear mating marks. (2) Install the distributor to the engine while aligning the fine cut (groove or projection) of the distributor’s installation flange with the center of the distributor installation stud.
Page 438 ADJUSTER TYPE clockwise to increase the belt tension and turn 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-type belt 7.0 - 10.0 mm (.28 - .39 in.) When using tension gauge for V-ribbed belt only.
Page 439 TIMING BELT REMOVAL AND INSTALLATION - SOHC 8 VALVE 90 Nm 35 ft.lbs. 14 Nm 55 km 35 ft.lbs. 40 ft.lbs. 87 ft.lbs. Removal steps 1. Timing belt front upper cover 2. Timing belt front lower cover 6. Oil pump sprocket 8.
Page 440 11 F-34 REMOVAL AND INSTALLATION - SOHC 16 VALVE 15 I&.,“=. ..- .-mm-... Removal steps 1. Timing belt front cover 2. Timing be lower cover 5. Tensioner arm 6. Auto tensioner Idler pulley 11. Flange 12. Tensioner “B” Spacer 16. Crankshaft sprocket “B Camshaft sprocket bolt 19.
Page 441 1 TF45 REMOVAL AND INSTALLATION - DOHC 2.2 ft.1 33 ftlbs. Removal steps 14 ft.lbs. 1. Timing belt front upper cover 2. Timing belt front lower cover 5. Tensioner arm 7. Idler pulley 40 ft.lbs. 87 ft.lbs. 12. Tensioner “B” 16.
Page 442 11 F-36 REMOVAL SERVICE POINTS TIMING BELT REMOVAL (1) Mark the belt running direction for reference in reinstalla- tion. NOTE 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.
Page 443 CRANKSHAFT BOLT LOOSENING CRANKSHAFT SPROCKET REMOVAL TIMING BELT “9” REMOVAL (1) Make a mark on the back of the timing belt indicating the direction of rotation so, it may be reassembled in the same 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...
Page 444 11 F-38 CAMSHAFT SPROCKET BOLT LOOSENiNG CAMSHAFT SPROCKET BOLT LOOSENING (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.
Page 445 (6) Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife. Roundededge Abnormal wear (Fluffy strand) (7) Abnormal wear on teeth. (8) Missing tooth. Rubber exposed Tooth missing and canvas fiber exposed AUTO TENSIONER (1) Check the auto tensioner for possible leaks and replace as...
Page 446 INSTALLATION SERVICE POINTS CAMSHAFT SPROCKET TIGHTENING CAMSHAFT SPROCKETS TIGHTENING 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. (1) Coat the bolts illustrated with sealant before tightening. Specified sealant:...
Page 447 Apply sealant PACKING Specified sealant: 3M ATD Part No. 8660 or equiva- lent Apply sealant Cylinder head TSB Revision...
Page 448 11 F-42 ENGINE <1993> SEALANT APPLICATION ON ROCKER COVER Apply sealant to the areas indicated in the illustration. Specified sealant: 3M ATD Part No. 8660 or equivalent Apply sealant SPACER INSTALLATION Install the spacer with the chamfered end toward the oil seal.
Page 449 TIMING, BELT “B” INSTALLATION (1) Align timing marks on the crankshaft sprocket “B” and silent shaft sprocket with the marks on the front case respectively. (2) Install the timing belt “B” on the crankshaft sprocket “B” and silent shaft sprocket. There should be no slack on the tension side.
Page 450 OIL PUMP SPROCKET INSTALLATION (1) Insert a Phillips screwdriver [shank diameter 8 mm (.31 in.) shaft] through the plug hole on the left side of the cylinder block to block the left silent shaft. (2) Install the oil pump sprocket. (3) Apply a proper amount of engine oil to the bearing surfaces of the nuts.
Page 451 (6) Install the auto tensioner to front case and tighten to the specified torque. Caution Leave the wire installed in the auto tensioner. TENSIONER PULLEY INSTALLATION (1) Install the tensioner pulley in such direction that its two small holes are arranged vertically. TIMING BELT INSTALLATION (1) Check that the timing belt tensioner has been installed in position.
Page 452 (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 correctly aligned.
Page 453 11 F-47 belt (11 )Hold the center of the tension side span of the timing (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.
Page 454 (6) Install the timing belt on the crankshaft sprocket, idler pulley, camshaft sprocket, and tensioner pulley in that order. (7) Lift up the tensioner pulley in the direction of arrow and tighten the center bolt. (8) Check to see that all timing marks are lined up. (9) Remove the screwdriver inserted in step (5) and fit the plug.
Page 455 Camshaft sprocket (1) Turn the two sprockets so that their dowel pins are located on top. Then, align the timing marks facing each other with Intake Dowel the top surface of the cylinder head. When you let go of the exhaust camshaft sprocket, it will rotate one tooth in the counterclockwise direction.
Page 456 (5) Thread the timing belt over the intake side camshaft sprocket and fix it at indicated position by a clip. (6) Thread the timing belt over the exhaust side sprocket, aligning the timing marks with the cylinder head top surface using two wrenches.
Page 457 Wrench, on the tensioner pulley, 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.). wrench. torque wrench, tighten the center bolt to specification.
Page 458 Fuel and Emission Control Parts FUEL AND EMISSION CONTROL PARTS REMOVAL AND INSTALLATION - SOHC for GALANT/EXPO/EXP LRV 9 ftlbs. 22 Nm 16 ft.lbs. 6 ft.lbs. Removal steps 2. Throttle body gasket 3. EGR valve 4. EGR valve gasket 5. EGR temp sensor - For California 6.
Page 459 REMOVAL AND INSTALLATION - SOHC for TRUCK 12 Nm 9 ft.lbs. 16 ft.lbs. Removal steps 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.
Page 460 REMOVAL AND INSTALLATION - DOHC 12 Nm 9 ft.lbs. 19 Nm 14 ft.lbs. 19 Nm 14 ftlbs. 22 Nm Removal steps 1. Throttle body stay 2. Throttle body 3. Throttle body gasket 4. EGR valve 5. EGR valve gasket 6. EGR temp sensor - For California 7.
Page 461 1 l,F-55 Fuel and Emission Control Parts INSPECTION EGR VALVE (1) Check EGR valve for sticking or carbon deposits. If such conditions exist, clean or replace EGR valve. (2) Connect a hand vacuum pump to the nipple of EGR valve and plug other nipple.
Page 462 11 F-56 (2) Install injector top end into fuel rail. Be careful not to damage the O-ring during installation. lubricated with a drop of clean engine O-ring to aid in installation.
Page 463 1 ‘IF-57 THROTTLE BODY DISASSEMBLY AND REASSEMBLY SOHC - TRUCK - Federal Disassembly steps 2. Speed control motor 3. Throttle valve set screw SOHC - TRUCK - California SOHC - GALANT Disassembly steps 3.5 Nm 2. Idle air control motor 3.
Page 464 SOHC - EXPO/EXPO LRV Disassembly steps 1. Accelerator wire bracket 3. Idle air control motor 4. Throttle valve set screw 5. Throttle body Disassembly steps 1. Dash pot 2. Hose 3. Vacuum valve 6. Idle position switch 7. Adjusting nut 8.
Page 465 DISASSEMBLY SERVICE POINTS THROTTLE POSITION SENSOR AND IDLE AIR CONTROL MOTOR REMOVAL (1) Do not disassemble the sensor and motor. (2) Do not immerse solvent to clean the sensor and motor. Clean them with shop towel. (1) Do not remove the throttle valve. (2) Check if the vacuum port or passage is clogged.
Page 466 11 F-60 (3) Holding the idle air control motor as shown in the illustration, connect the negative 0 terminal of the power supply to each clip as described in the following steps, and check whether or not a vibrating feeling (a feeling of very slight vibration of the stepper motor) is generated as a result of the activation of the stepper motor.
Page 467 REASSEMBLY SERVICE POINTS SOHC FOR EXPO (1) Install the throttle position sensor to the throttle body as shown in the illustration. (2) Turn the throttle position sensor 90” counterclockwise to set it in position and tighten the screws. (3) Connect the circuit tester between @ (ground) and @ (output), or between @ (output) and @ (power).
Page 468 (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, Throttle position sensor power make sure that the resistance changes smoothly when the Ground throttle valve is slowly moved to the fully open position.
Page 469 INTAKE MANIFOLD REMOVAL AND INSTALLATION - SOHC - 8 VALVE 8 ft.lbs. Removal steps 1. Water hose 2. Water hose 5. Water outlet fitting 7. Thermostat 8. Thermostat housing 9. Gasket 11. Intake manifold plenum 12. Intake manifold plenum gasket 13.
Page 470 13 Nm 9 ft.lbs. 24 Nm 22 ftlbs. - 4 11 Nm 13 ft.lbs. 31 ium 22 ft.lbs. Removal steps 1. Water hose 2. Water hose 6. Thermostat 7. Water outlet fitting 9. Intake manifold stay TSB Revision...
Page 471 REMOVAL AND INSTALLATION - DOHC (To oil cooler) @ Removal steps 1. Water hose 2. Water hose 3. Water hose (turbo) 20 ftlbs. 4. Water hose (turbo) 7. Water outlet fitting 8. Gasket 9. Thermostat 11. Gasket 12. Intake manifold stay 14.
Page 472 WATER OUTLET FITTING GASKET INSTALLATION (FOR RUBBER COATED METAL GASKET ONLY) facing up (toward the water outlet fitting side). Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent diameter bead sealant SEALANT APPLICATION TO WATER OUTLET...
Page 473 11 F-67 SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE GAUGE UNIT Specified sealant: 3M ATD Part No. 8660 or equivalent TSB Revision...
Page 474 EXHAUST MANIFOLD AND WATER PUMP REMOVAL AND INSTALLATION - SOHC 8 VALVE 14 Nm 22 ft.lbs. 18 Nm 13 ft.lbs. 14 Nm Removal steps 2. Oil level gauge 4. Heat protector 5. Engine hanger 6. Exhaust manifold 7. Exhaust manifold gasket 11.
Page 475 Exhaust Manifold and Water Pump 14 Nm 10 ft.uM. 28 Nm 14 Nm Removal steps 2. Oil level gauge 3. Oil level gauge guide 4. O-ring 5. Heat protector 6. Heat protector 7. Engine hanger 8. Exhaust manifold 9: Exhaust manifold gasket 12.
Page 476 Exhaust Manifold and Water Pump 45 Nm 33 ft.lbs. 14 Nm 60 Nm 43 ft.lbs. 14 Nm 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.
Page 477 Exhaust Manifold and ‘Water Pump 14 Nm 10 ftlbs. 60 Nm 24 Nm 7 ft.lbs. - 1 2 Removal steps 16. Oil pipe 1. Oil level gauge 17. Water pipe “A” 2. Oil level gauge guide 18. Turbocharger 3. O-ring 19.
Page 478 INSTALLATION SERVICE POINT O-ring 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. Revision...
Page 479 TURBOCHARGER DISASSEMBLY AND REASSEMBLY Disassembly steps Inspection of turbocharger waste gate actuator operation 1. Snap pin 2. Turbochargerwaste gate actuator 7. Compressor cover TSB Revision...
Page 480 11 F-74 INSPECTION es for TURBINE HOUSING (1) Check the housing for traces of contact with the turbine wheel, cracks due to overheating, pitching, deformation and other damage. Replace with a new turbine housing if cracked. (2) Operate the turbocharger waste gate valve lever manually to check that the gate can be opened and closed smoothly.
Page 481 11 F-75 TURBINE HOUSING INSTALLATION (1) Install the turbine housing in relation to the dowel pin. Caution Use care not to damage the blades of turbine wheel. COUPLING INSTALLATION (1) Install the coupling and tighten to specified torque. Coupling TURBOCHARGER WASTE GATE ACTUATOR OPERATION INSPECTION to the actuator and make sure that the rod moves.
Page 482 Rocker Arms Camshaft ROCKER ARMS AND CAMSHAFT REMOVAL AND INSTALLATION - SOHC 8 VALVE 4 ft.lbs. 20 Nm 14 ft.lbs. 24 Nm 17 ft.lbs.- Removal steps 1. Breather hose 2. P.C.V. hose Oil filter cap Rocker cover Gasket Semi-circular packin Rocker arms and rot er shafts Rear bearing cap Rocker arm D...
Page 483 Removal steps 1. Breather hose 2. P.C.V. hose 3. Oil filler cap 4. Rocker cover 5. Rocker cover gasket 6. Oil seal 11. Rocker arm A 12. Rocker arm B 13. Rocker arm shaft (Intake side) 15. Rocker arm C 18.
Page 484 20 Nm 14 ftlbs: 11 Nm 8 ft.lbs. Removal steps 9. Rocker arm 11. Oil delivery body TSB Revision...
Page 485 REMOVAL SERVICE POINT ROCKER ARMS AND ROCKER ARM SHAFTS REMOVAL (1) Before removing rocker arms and shafts assembly, install the special tool as illustrated to prevent adjuster from dropping. INSPECTION CAMSHAFT (1) Measure the cam height. SOHC mm (in.) Limit Identification mark Standard value Intake...
Page 486 Roller LASH ADJUSTER LEAK DOWN TEST Caution 1. The lash adjuster is a precision part. Keep it free from dust and other foreign matter. 2. Do not disassemble lash adjuster. 3. When cleaning lash adjuster, use clean diesel fuel only. (2) While lightly pushing down inner steel ball using the small wire, move the plunger up and down four or five times to bleed air.
Page 487 (4) After air bleeding, set lash adjuster on the special tool (Leak Division = 1 mm t.04 in.) down tester M D998440). (5) After plunger has gone down somewhat (2 - .5 mm), measure time taken for it to go down 1 mm. Replace if measured time is out of specification.
Page 488 Rocker Arms and Camshaft ROCKER SHAFTS INSTALLATION the notch on the shaft faces up, and insert the installation bolt without tightening it. Front bearing cap Wave (1) Install the wave washer in correct direction as shown. washer side rocker arm CAMSHAFT BEARING CAPS IDENTIFICATION Rocker cover mounting bolt hole...
Page 489 LASH ADJUSTER INSTALLATION (1) Immerse the lash adjuster in clean diesel fuel. (2) Using a small wire, move the plunger up and down 4 or 5 times while pushing down lightly on the check ball in order to bleed out the air. (3) Insert the lash adjuster to rocker arm, being careful not to spill the diesel fuel.
Page 490 11 F-84 Apply sealant Specified sealant:...
Page 491 CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION - SOHC - 8VALVE Removal steps 2. Cylinder head assembly 4. Retainer lock 5. Valve spring retainer 7. Intake valve 8. Retainer lock 9. Valve spring retainer 11. Exhaust valve 13. Valve spring seat 15.
Page 492 Removal steps 2. Cylinder head assembly 3. Cylinder head gasket 5. Valve spring retainer 7. Intake valve 9. Valve spring retainer 11. Exhaust valve 13. Valve spring seat 15. Valve spring seat 16. Intake valve guide 17. Exhaust valve guide Intake valve seat 19.
Page 493 Removal steps 2. Cylinder head assembly 5. Valve spring retainer 7. Intake valve 9. Valve spring retainer 13. Valve spring seat 15. Valve spring seat 16. Intake valve guide 17. Exhaust valve guide 18. Intake valve seat 19. Exhaust valve seat 20.
Page 494 ENGINE <1993> - Cylinder Head and Valves REMOVAL SERVICE POINTS PRECAUTION FOR REMOVED PARTS (1) Keep removed parts in order according to the cylinder number and intake/exhaust. CYLINDER HEAD BOLTS REMOVAL (1) &sing the 12 mm - 12 points socket wrench, loosen the cylinder head bolts.
Page 495 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 Grinding limit: mm (.008 in.) Cylinder head height (Specification when new): SOHC - 8VALVE 89.9 - 90.1 mm (3.539 - 3.547 in.) SOHC - 16VALVE 119.9 - 120.1 mm (4.720 - 4.728 in.) DOHC 131.9 - 132.1 mm (5.193 - 5.201 in.) VALVE using valve refacer.
Page 497 Valves Head and (2) Measure the squareness of the spring and, if the limit is exceeded, replace. Standard value: SOHC 2” or less DOHC 1.5” or less Limit: Max. 4” VALVE GUIDE stem. If the limit is exceeded, replace the valve guide or valve, or both.
Page 498 Cylinder Head and Valves (2) Rebore the valve seat hole in the cylinder head to a selected oversize valve seat diameter. Seat ring hole diameter: See “Service Specifications” on page llF-14. (3) Before fitting the 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.
Page 499 toward the spring retainer. Identification color bottom end of retainer to be in contact with, and damage, the stem seal.
Page 500 11 F-94 Identification mark Identification mark: ................63 .
Page 501 Front Case, Silent Shaft and Oil Pan FRONT CASE, SILENT SHAFT AND OIL PAN REMOVAL AND INSTALLATION 2 1 17Nm 24 ft.lbs. 27 ft.lbs. 40 ft.lbs. 17 ft.lbs. 55 km. NOTE Removal steps 19. Oil filter bracket 1. Oil filter 20.
Page 502 11 F-96 REMOVAL SERVICE POINTS OIL PAN REMOVAL (2) Drive in the service tool between the cylinder block and oil pan. NOTE Never use a screwdriver or chisel, instead of the service tool, as a deformed oil pan flange will result in oil leakage. 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.
Page 503 LEFT SILENT SHAFT REAR BEARING REMOVAL Using the special tool, remove the left silent shaft rear bearing from the cylinder block. Using the special tool, remove the right silent shaft rear bearing from the cylinder block. INSPECTION FRONT CASE (2) Check left silent shaft front bearing section for wear, damage and seizure.
Page 504 11 F-98 Front Case, Silent Shaft and Oil Pan OIL PUMP to ensure smooth rotation with no looseness. (2) Ensure that there is no ridge wear on the contact surface between the front case and the gear surface of the oil pump cover.
Page 505 11 F-99 OIL PUMP DRIVEN GEAR / OIL PUMP DRIVE GEAR INSTALLATION (1) Apply’ engine oil amply to the gears and line up the alignment marks. SEALANT APPLICATION TO OIL PRESSURE GAUGE UNIT switch using the special tool. Specified sealant: 3M ATD Part No. 8660 or equivalent Caution 2.
Page 506 LEFT SILENT SHAFT REAR BEARING INSTALLATION (1) Install the special tool (GUIDE PLATE) tool to the cylinder block. (2) Apply engine oil to the rear bearing 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.
Page 507 Front Case, Silent Shaft and Oil Pan (2) Install the front case assembly through a new front case gasket and temporarily tighten the flange bolts (other than those for tightening the filter bracket). FLANGE BOLT INSTALLATION (1) Insert a Phillips screwdriver into a hole in the left side of the cylinder block to lock the silent shaft.
Page 508 (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.
Page 509 PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION Removal steps TSB Revision...
Page 510 REMOVAL SERVICE POINTS CONNECTING ROD CAP REMOVAL (1) Mark the cylinder number on the side of the connecting rod big end for correct reassembly. number (2) Keep the removed connecting rods, caps, and bearings in order according to the cylinder number. Piston pin setting tool MIT216941 Description...
Page 511: Inspection Piston/Pin/Ring
INSPECTION PISTON (1) Replace the piston if scratches or seizure is evident on its surfaces (especially the thrust surface). Replace the piston if it is cracked. PISTON PIN (1) Insert the piston pin into the piston pin hole with a thumb. You should feel a slight resistance.
Page 512 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 bearing and place it on crankshaft pin in parallel with its axis. (3) Install the connecting rod cap carefully and tighten the bolts to specified torque.
Page 513 (3) Place the base on press support blocks. (4) Slide the piston pin over the threaded end of the press pin, Press pin -8 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 connecting rod.
Page 514 PISTON RING NO. 2 / PISTON RING NO. 1 INSTALLATION and then No. 1 piston ring into position. NOTE piston rings. (2) Install piston rings No. 1 and No. 2 with their side having marks facing up (on the piston crown side). DOHC Non-turbo Turbo...
Page 515 CONNECTING ROD BEARINGS INSTALLATfON bearings for assembly according to identification co’tors for the crankshaft. Connecting rod bearing Crank pin O.D. identification color identification mark Yellow None White CONNECTING ROD CAP INSTALLATION bearing cap to the connecting rod. If the connecting rod is Cylinder No.
Page 516 CRANKSHAFT, FLYWHEEL AND DRIVE PLATE 98 ft.lbs. REMOVAL AND INSTALLATION 98 ft.lbs. 135 Nm Removal steps 2. Flywheel 3. Drive plate bolt - 1 8 4. Adapter plate 5. Drive plate SOHC - 1 GVALVE AA 7. Adapter plate 8. Drive plate 9.
Page 517 1 IF4 11 INSPECTION CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE METHOD) bearing. (2) Install the crankshaft. (3) Cut the plastic gauge to the same length as the width of bearing and place it on journal in parallel with its axis. (4) Install the crankshaft bearing cap carefully and tighten the bolts to specified torque.
Page 518 BORING CYLINDER (1) Oversize pistons to be used should be determined on the basis of the largest bore cylinder. Piston size identification Thrust direction Piston O.D. NOTE Size mark is stamped on piston top. (2) Measure outside diameter of piston to be used. Measure it in thrust direction as shown.
Page 519 Crankshaft, Flvvvheel and Drive Plate REASSEMBLY SERVICE POINTS CRANKSHAFT BEARING INSTALLATION bearing for assembly according to the identification color for the crankshaft and the identification mark stamped on the cylinder block. Crankshaft bearing Identification mark for Journal OD identification cylinder block bearing mark section ID color...
Page 520 Standard value: 0.05 - 0.25 mm (.0020 - .0098 in.) Limit: 0.4 mm (.016 in.) SEALANT APPLICATION TO OIL SEAL CAqE Specified sealant: Mitsubishi Genuine Part No. MD970389 or equiva- lent TSB Revision...
Page 521 BRACKET Rear wheel drive and four wheel drive 1. Engine support bracket, right 2. Engine support bracket, left 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.
Page 522 NOTES...

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4g3 4g6 4g9 6g7

Mitsubishi 4G1 Service Manual

Introduction

Engine Model Table

Special Tool Note

Torque References

Table of Contents

Engine

Engine 4G93

Quick Links

Chapters

Summary of Contents for Mitsubishi 4G1

Page 3: Table Of Contents

Page 6: Engine Model Table

Page 7: Special Tool Note

Page 8: Form-In-Place Gasket

Page 19: Crankshaft, Flywheel And Drive Plate

Page 22: Generator And Ignition System

Page 27: Water Pump

Page 30: Fuel And Emission Parts

Page 38: Rocker Arms And Camshaft

Page 47: Front Case And Oil Pump

Page 64: General Information

Page 67: General Specifications

Page 72: Timing Belt

Page 73: Bracket

Page 78: Generator And Ignition System

Page 94: Exhaust Manifold And Water Pump

Page 125: Intake Manifold

Page 160: Removal And Installation

Page 170: Fuel And Emission Control Parts

Page 260: Exhaust Manifold

Page 268: Front Case And Oil Pump

Page 285: Contents Intake Manifold

Page 288: General Information

Page 296: General Specifications

Page 306: Piston And Connecting Rod

Page 307: Sealant

Page 333: Timing Belt

Page 511: Inspection Piston/Pin/Ring

This manual is also suitable for:

Mitsubishi 4G1 Service Manual

Introduction

Engine Model Table

Special Tool Note

Torque References

Table of Contents

Engine

Engine 4G93

Quick Links

Chapters

Related Manuals for Mitsubishi 4G1

Summary of Contents for Mitsubishi 4G1

This manual is also suitable for:

Table of Contents