Page 1 11109000276 ENGINE <4G6> ..........
Page 2: Table Of Contents
11A-2 ENGINE <4G6> CONTENTS 11109000603 Lash Adjuster Check ......GENERAL INFORMATION ....
Page 3: General Information
11A-3 ENGINE <4G6> - General Information/Service Specifications GENERAL INFORMATION 11100010469 Items 4G63 Total displacement mL 1,997 Bore ´ Stroke mm 85.0 ´88.0 Compression ratio 10.0 Combustion chamber Pentroof type Camshaft arrangement SOHC Intake Number of valve Exhaust Opening BTDC 11_...
Page 4: Special Tools
11A-4 ENGINE <4G6> - Service Specifications/Sealants/Special Tools Items Standard value Limit Idle speed r/min 750 ± 100 CO contents % 0.5 or less HC contents ppm 100 or less Compression pressure (250 - 400 r/min) kPa 1,400 Min. 1,060 Compression pressure difference of all cylinder kPa Max.
Page 5 11A-5 ENGINE <4G6> - Special Tools Tool Number Name MD998713 Camshaft oil seal Press-in of the camshaft oil seal installer MD998443 Auto-lash adjuster Supporting of auto-lash adjuster holder MD998727 Oil pan remover Removal of oil pan MD998781 Flywheel stopper Securing the flywheel...
Page 6: On-Vehicle Service
11A-6 ENGINE <4G6> - On-vehicle Service ON-VEHICLE SERVICE Alternator pulley Water pump 11100090432 pulley DRIVE BELT TENSION CHECK AND ADJUSTMENT ALTERNATOR DRIVE BELT TENSION CHECK Use a belt tension gauge to check that the belt tension is at the standard value at a point half-way between the two pulleys as shown in the illustration.
Page 7: Ignition Timing Check
11A-7 ENGINE <4G6> - On-vehicle Service POWER STEERING OIL PUMP AND AIR CONDITIONER <Vehicles without A/C> Oil pump pulley COMPRESSOR DRIVE BELT TENSION CHECK AND ADJUSTMENT 11100130127 98 N 1. Use a belt tension gauge to check that the belt tension is at the standard value at a point half-way between the two pulleys (indicated by an arrow in the illustration).
Page 8: Idle Speed Check
11A-8 ENGINE <4G6> - On-vehicle Service 7. Check that basic ignition timing is within the standard value. Standard value: 5_ BTDC±2_ 8. If the basic ignition timing is outside the standard value, inspect the MPI system while referring to GROUP 13A - Troubleshooting.
Page 9: Compression Pressure Check
11A-9 ENGINE <4G6> - ENGINE <4G6> - On-vehicle Service On-vehicle Service 5. Set the CO, HC tester. 6. Check the CO contents and the HC contents at idle. Standard value CO contents: 0.5% or less HC contents: 100 ppm or less 7.
Page 10: Manifold Vacuum Check
11A-10 ENGINE <4G6> - On-vehicle Service 6. Set compression gauge to one of the spark plug holes. 7. Crank the engine with the throttle valve fully open and measure the compression pressure. Standard value (at engine speed of 250 - 400 r/min):...
Page 11: Lash Adjuster Check
11A-11 ENGINE <4G6> - On-vehicle Service LASH ADJUSTER CHECK 11100290344 If an abnormal noise (knocking) that seems to be coming from the lash adjuster is heard after starting the engine and does not stop, carry out the following check. NOTE...
Page 12 11A-12 ENGINE <4G6> - On-vehicle Service (3) Carry out lash adjuster simple check. (Refer to P.11A-13.) If any of the rocker arms can be pushed down easily during the lash adjuster simple check, replace the corresponding lash adjusters. If the lash adjuster simple check has been carried...
Page 13 11A-13 ENGINE <4G6> - On-vehicle Service <LASH ADJUSTER SIMPLE CHECK> 1. Stop the engine. 2. Remove the rocker cover. 3. Set the No.1 cylinder to the compression top dead centre position. 4. Check the rocker arms indicated by white arrows in the illustration by the procedures given below.
Page 14 11A-14 ENGINE <4G6> - ENGINE <4G6> - On-vehicle Service On-vehicle Service 1. Check the engine oil and replenish or replace the oil if necessary. NOTE (1) If there is a only small amount of oil, air will be drawn in through the oil screen and will get into the oil passage.
Page 15: Crankshaft Pulley
11A-15 ENGINE <4G6> - Crankshaft Pulley CRANKSHAFT PULLEY 11200160303 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Under Cover Removal Drive Belt Tension Adjustment (Refer to P.11A-6.) Under Cover Installation 25 Nm Removal steps 1. Drive belt (Power steering and 2. Drive belt (Alternator) A/C) 3.
Page 16: Camshaft And Camshaft Oil Seal
11A-16 ENGINE <4G6> - Camshaft and Camshaft Oil Seal CAMSHAFT AND CAMSHAFT OIL SEAL 11200190418 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Air Cleaner Removal and Installation Timing Belt Removal and Installation (Refer to P.11A-26.) Relay Box Removal and Installation 10 Nm (f 3 ±...
Page 17 11A-17 ENGINE <4G6> - Camshaft and Camshaft Oil Seal REMOVAL SERVICE POINTS AA" CAMSHAFT SPROCKET REMOVAL MB990767 MD998719 or MD998754 AB" ROCKER ARM AND SHAFT ASSEMBLY REMOVAL MD998443 Before removing the rocker arm and shaft assembly, install the special tools as shown in the illustration so that the lash adjusters will not fall out.
Page 18 11A-18 ENGINE <4G6> - Camshaft and Camshaft Oil Seal "BA CAMSHAFT OIL SEAL INSTALLATION 1. Apply engine oil to the camshaft oil seal lip. 2. Use the special tool to press-fit the camshaft oil seal. MD998713 "CA CAMSHAFT SPROCKET INSTALLATION...
Page 19: Oil Pan
11A-19 ENGINE <4G6> - Oil Pan OIL PAN 11200280207 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Oil Draining and Supplying (Refer to GROUP Front Exhaust Pipe Removal and Installation (Refer 12 - On-vehicle Service.) to GROUP 15.) Oil Level Gauge Removal and Installation f 4 ±...
Page 20: Crankshaft Oil Seal
11A-20 ENGINE <4G6> - Crankshaft Oil Seal CRANKSHAFT OIL SEAL 11200310135 REMOVAL AND INSTALLATION <M/T> 127 - 137 Nm 127 - 137 Nm <A/T> <A/T> <M/T> Crankshaft Crankshaft (Engine oil: bolt washer (Engine oil: surface) bolt wash- er surface) Lip section...
Page 21 11A-21 ENGINE <4G6> - Crankshaft Oil Seal REMOVAL SERVICE POINTS <M/T> AA" TRANSMISSION ASSEMBLY REMOVAL <M/T>: Refer to GROUP 22. Flywheel Caution Do not remove the flywheel mounting bolt shown by the arrow. If this bolt Is removed, the flywheel will become Bolt out of balance and damaged.
Page 22: Cylinder Head Gasket
11A-22 ENGINE <4G6> - Cylinder Head Gasket CYLINDER HEAD GASKET 11200400542 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Fuel Discharge Prevention (Refer to GROUP 13A Thermostat Case Assembly Installation (Refer to - On-vehicle Service.) GROUP 14 - Water Hose and Water Pipe.)
Page 23 11A-23 ENGINE <4G6> - Cylinder Head Gasket 10 Nm <Cold engine> 78 Nm ® 0 Nm ® 20 Nm ® + 90_ ® + 90_ 3.4 Nm (Engine oil) 49 Nm 24 Nm 44 Nm 34 Nm 31 Nm 12. Radiator upper hose connection 21.
Page 24 11A-24 ENGINE <4G6> - Cylinder Head Gasket REMOVAL SERVICE POINTS AA" POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL Remove the power steering oil pump and bracket assembly from the engine with the hose attached. NOTE Place the removed power steering oil pump in a place where it will not be a hindrance when removing and installing the cylinder head assembly, and tie it with a cord.
Page 25 11A-25 ENGINE <4G6> - Cylinder Head Gasket 4. Tighten the bolts by the following procedure. Intake side Front of engine Step Operation Remarks Tighten to 78 Nm. Carry out in the order shown in the illustration. Fully loosen. Carry out in the reverse order of that shown in the illustration.
Page 26: Timing Belt
11A-26 ENGINE <4G6> - Timing Belt TIMING BELT 11200430473 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Crankshaft Pulley Removal and Installation (Refer to P.11A-15.) Engine Mount Bracket Removal and Installation (Refer to GROUP 32 - Engine Mounting.) 48 Nm 10 - 12 Nm...
Page 27 11A-27 ENGINE <4G6> - Timing Belt REMOVAL SERVICE POINT Timing mark (Top Timing mark of cylinder head) Camshaft sprocket AA" TIMING BELT REMOVAL 1. Turn the crankshaft clockwise (right turn) to align each timing mark and to set the No. 1 cylinder at compression top dead centre.
Page 28 11A-28 ENGINE <4G6> - Timing Belt 4. Once the holes are aligned, insert the set pin. Set pin NOTE When replacing the auto tensioner with a new part, the pin will be in the auto tensioner. 5. Install the auto tensioner to the engine.
Page 29 11A-29 ENGINE <4G6> - Timing Belt "CA TIMING BELT TENSION ADJUSTMENT 50 Nm 1. After turning the crankshaft 1/4 of a revolution in the anticlockwise direction, turn it in the clockwise direction until the timing marks are aligned. Tension 2. Loosen the tension pulley fixing bolt, and then use the...
Page 30: Timing Belt B
11A-30 ENGINE <4G6> - Timing Belt B TIMING BELT B 11200460106 REMOVAL AND INSTALLATION 19 Nm 108 - 127 Nm Removal steps 1. Timing belt (Refer to P.11A-26.) 4. Timing belt B tensioner AA" "CA 2. Crankshaft sprocket AB" "AA 5. Timing belt B "BA 3.
Page 31 11A-31 ENGINE <4G6> - Timing Belt B INSTALLATION SERVICE POINTS Counterbalance shaft sprocket Belt tension side "AA TIMING BELT B INSTALLATION, ADJUSTMENT 1. Install timing belt “B” by the following procedure. (1) Ensure that crankshaft sprocket “B” timing mark and...
Page 32 11A-32 ENGINE <4G6> - Timing Belt B "CA CRANKSHAFT SPROCKET INSTALLATION Crankshaft MD998719 or MD998754 sprocket NOTE Apply the minimum amount of engine oil to the bearing surface and thread of the crankshaft bolt. MB990767...
Page 33: Engine Assembly
11A-33 ENGINE <4G6> - Engine Assembly ENGINE ASSEMBLY 11200090015 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Fuel Discharge Prevention (Refer to GROUP 13A Thermostat Case Assembly Installation (Refer to - On-vehicle Service.) GROUP 14 - Water Hose and Water Pipe.)
Page 34 11A-34 ENGINE <4G6> - Engine Assembly 49 Nm 57 Nm* 98 Nm 13. Drive belt (Alternator) 22. Camshaft position sensor connector 14. Drive belt (Power steering and 23. Detonation sensor connector A/C) AC" D Transmission assembly AA" 15. Power steering oil pump and AD"...
Page 35 11A-35 ENGINE <4G6> - Engine Assembly REMOVAL SERVICE POINTS AA" POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL Remove the power steering oil pump and bracket assembly from the engine with the hose attached. NOTE Place the removed power steering oil pump in a place where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord.
Page 36 11A-36 ENGINE <4G6> - Engine Assembly INSTALLATION SERVICE POINTS "AA ENGINE ASSEMBLY INSTALLATION Install the engine assembly, checking that the cables, hoses, and harness connectors are not clamped. "BA ENGINE MOUNT STOPPER INSTALLATION Engine side Clamp the engine mount stopper so that the arrow points Dynamic damper in the direction as shown in the diagram.
Page 37 11B-1 ENGINE <6A1> CONTENTS 11109000610 GENERAL INFORMATION ....CRANKSHAFT PULLEY ....SERVICE SPECIFICATIONS .
Page 38: General Information
11B-2 ENGINE <6A1> - General Information/Service Specifications GENERAL INFORMATION 11100010452 Items 6A13 Total displacement mL 2,498 Bore ´ Stroke mm 81.0 ´ 80.8 Compression ratio Combustion chamber Pentroof type Camshaft arrangement SOHC Intake Number of valve Exhaust Opening BTDC 15_ Intake ABDC 53_ Closing...
Page 39: Special Tools
Timing belt tension torque Nm Auto-tensioner rod protrusion amount mm 3.8 - 4.5 SEALANTS 11100050379 Items Specified sealants Remarks Oil pan MITSUBISHI GENUINE PART Semi-drying sealant MD970389 or equivalent Flywheel bolt or drive plate bolt 3M Stud Locking 4170 or equivalent SPECIAL TOOLS 11100060464...
Page 40 11B-4 ENGINE <6A1> - Special Tools Tool Number Name MD998443 Auto-lash adjuster Supporting of auto-lash adjuster holder MD998713 Camshaft oil seal Press-in of the camshaft oil seal installer MD998776 Crankshaft rear oil Press-in of the crankshaft rear oil seal seal installer MB990938 Handle Press-in of the crankshaft rear oil seal...
Page 41: On-Vehicle Service
11B-5 ENGINE <6A1> - Special Tools/On-vehicle Service Tool Number Name MB991453 Engine hanger Supporting the engine assembly during assembly removal and installation of the transmission ON-VEHICLE SERVICE Alternator pulley 11100090425 Tension pulley DRIVE BELT TENSION CHECK AND ADJUSTMENT ALTERNATOR DRIVE BELT TENSION CHECK Use a belt tension gauge to check that the belt tension is at the standard value at a point half-way between the two pulleys as shown in the illustration.
Page 42: Ignition Timing Check
11B-6 ENGINE <6A1> - On-vehicle Service POWER STEERING OIL PUMP AND AIR CONDITIONER Power steering COMPRESSOR DRIVE BELT TENSION CHECK AND oil pump pulley ADJUSTMENT 11100130134 1. Use a belt tension gauge to check that the belt tension is at the standard value at a point half-way between the two pulleys (indicated by an arrow in the illustration).
Page 43: Idle Speed Check
11B-7 ENGINE <6A1> - On-vehicle Service 9. Press the MUT-II clear key (Select a forced driving cancel mode) to release the Actuator test. Caution If the test is not cancelled, a forced driving will continue for 27 minutes. Driving under this condition may damage the engine.
Page 44: Compression Pressure Check
11B-8 ENGINE <6A1> - On-vehicle Service 5. Set the CO, HC tester. 6. Check the CO contents and the HC contents at idle. Standard value CO contents: 0.2% or less HC contents: 100 ppm or less 7. If there is a deviation from the standard value, check the following items: Diagnosis output Closed-loop control (When the closed-loop control...
Page 45: Manifold Vacuum Check
11B-9 ENGINE <6A1> - On-vehicle Service 6. Set compression gauge to one of the spark plug holes. Compression gauge 7. Crank the engine with the throttle valve fully open and measure the compression pressure. Standard value (at engine speed of 250 - 400 r/min): 1,177 kPa Limit (at engine speed of 250 - 400 r/min): Min.
Page 46: Lash Adjuster Check
11B-10 ENGINE <6A1> - On-vehicle Service LASH ADJUSTER CHECK 11100290337 If an abnormal noise (knocking) that seems to be coming from the lash adjuster is heard after starting the engine and does not stop, carry out the following check. NOTE (1) The abnormal noise which is caused by a problem with the lash adjusters is generated after the engine is started, and will vary according to the engine speed.
Page 47 11B-11 ENGINE <6A1> - On-vehicle Service (3) Carry out lash adjuster simple check. (Refer to P.11B-12.) If any of the rocker arms can be pushed down easily during the lash adjuster simple check, replace the corresponding lash adjusters. If the lash adjuster simple check has been carried out but all lash adjusters are normal (if none of the rocker arms could be pushed down easily), check for some other cause of the problem.
Page 48 11B-12 ENGINE <6A1> - On-vehicle Service <LASH ADJUSTER SIMPLE CHECK> 1. Stop the engine. 2. Remove the rocker cover. Timing belt side 3. Set the No.1 cylinder to the compression top dead centre position. 4. Check the rocker arms indicated by white arrows in the illustration by the procedures given below.
Page 49 11B-13 ENGINE <6A1> - ENGINE <6A1> - On-vehicle Service On-vehicle Service 1. Check the engine oil and replenish or replace the oil if necessary. NOTE (1) If there is a only small amount of oil, air will be drawn in through the oil screen and will get into the oil passage.
Page 50: Crankshaft Pulley
11B-14 ENGINE <6A1> - Crankshaft Pulley CRANKSHAFT PULLEY 11200160310 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Under Cover Removal Drive Belt Tension Adjustment (Refer to P.11B-5.) Under Cover Installation (Engine oil) 177 - 186 Nm Removal steps 1. Drive belt (Power steering oil AA"...
Page 51: Camshaft And Camshaft Oil Seal
11B-15 ENGINE <6A1> - Camshaft and Camshaft Oil Seal CAMSHAFT AND CAMSHAFT OIL SEAL 11200220124 REMOVAL AND INSTALLATION <Front bank> Pre-removal and Post-installation Operation Engine Coolant Draining and Refilling (Refer to Timing Belt Removal and Installation (Refer to GROUP 14 - On-vehicle Service.) P.11B-26.) Air Intake Hose Assembly Removal and Installation Drive Belt Tension Adjustment (Refer to P.11B-5.)
Page 52 11B-16 ENGINE <6A1> - Camshaft and Camshaft Oil Seal <Rear bank> Pre-removal and Post-installation Operation Air Intake Plenum Removal and Installation Distributor Removal and Installation (Refer to GROUP 15.) (Refer to GROUP 16.) Timing Belt Removal and Installation Drive Belt Tension Adjustment (Refer to P.11B-5.) (Refer to P.11B-26.) Apply engine oil to all sliding parts when...
Page 53 11B-17 ENGINE <6A1> - Camshaft and Camshaft Oil Seal AB" CAMSHAFT SPROCKET REMOVAL MB990767 MD998715 AC" ROCKER ARM AND SHAFT ASSEMBLY REMOVAL 1. Install the special tools as shown in the illustration so that the lash adjusters will not fall out. MD998443 2.
Page 54 11B-18 ENGINE <6A1> - Camshaft and Camshaft Oil Seal "CA CAMSHAFT SPROCKET INSTALLATION Use the special tool to stop the camshaft sprocket from turning in the same way as was done during removal, and then tighten the bolts to the specified torque. Tightening torque: 88 Nm "DA RADIATOR LOWER HOSE/RADIATOR UPPER HOSE CONNECTION...
Page 55: Oil Pan
Starter Motor Removal and Installation Oil Level Gauge Removal and Installation Front Exhaust Pipe Removal and Installation (Refer to GROUP 15.) Bolt Groove hole Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent 7 Nm 39 Nm 7 Nm 7 Nm 44 Nm 44 Nm...
Page 56 11B-20 ENGINE <6A1> - Oil Pan REMOVAL SERVICE POINT MD998727 MD998727 AA" LOWER OIL PAN/UPPER OIL PAN REMOVAL After removing the oil pan mounting bolts, remove the oil pan with the special tool and a brass bar. Caution Perform this slowly to avoid deformation of the oil pan flange.
Page 57: Crankshaft Oil Seal
11B-21 ENGINE <6A1> - Crankshaft Oil Seal CRANKSHAFT OIL SEAL 11200310142 REMOVAL AND INSTALLATION <M/T> Crankshaft (Engine oil: bolt wash- er surface) <A/T> Crankshaft (Engine oil: bolt washer surface) Sealant: 3M Stud Locking 4170 or equivalent <M/T> Lip section <A/T> 93 - 103 Nm Lip section Engine oil...
Page 58 11B-22 ENGINE <6A1> - Crankshaft Oil Seal REMOVAL SERVICE POINTS <M/T> AA" TRANSMISSION ASSEMBLY REMOVAL <M/T>: Refer to GROUP 22. Flywheel Caution Do not remove the flywheel mounting bolt shown by the arrow. If this bolt Is removed, the flywheel will become Bolt out of balance and damaged.
Page 59 11B-23 ENGINE <6A1> - Crankshaft Oil Seal "CA CRANKSHAFT FRONT OIL SEAL INSTALLATION 1. Apply a small amount of engine oil to the entire Crankshaft circumference of the oil seal lip. MD998717 2. Tap the oil seal unit it is flush with the oil seal case. MD998717 Oil seal...
Page 60: Cylinder Head Gasket
11B-24 ENGINE <6A1> - Cylinder Head Gasket CYLINDER HEAD GASKET 11200400559 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Refilling (Refer to Fuel Discharge Prevention (Refer to GROUP 13A GROUP 14 - On-vehicle Service.) - On-vehicle Service.) Air Intake Hose Assembly Removal and Installation Front Exhaust Pipe Removal and Installation (Refer Radiator Assembly Removal and Installation (Refer...
Page 61 11B-25 ENGINE <6A1> - Cylinder Head Gasket REMOVAL SERVICE POINT Exhaust side <Front bank side> AA" CYLINDER HEAD BOLT REMOVAL Loosen the bolts in 2 or 3 steps in order of the numbers shown in the illustration, and remove the cylinder head Front of assembly.
Page 62: Timing Belt
11B-26 ENGINE <6A1> - Timing Belt TIMING BELT 11200430480 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation Drive Belt Tension Adjustment (Refer to P.11B-5.) Crankshaft Pulley Removal and Installation Alternator Removal and Installation (Refer to GROUP 16.) 3 Nm 44 Nm 12 Nm...
Page 63 11B-27 ENGINE <6A1> - Timing Belt REMOVAL SERVICE POINT AA" TIMING BELT REMOVAL 1. Align each of the timing marks. Tensioner pulley Timing marks 2. Loosen the centre bolt of the tension pulley and remove the timing belt. Caution (1) If the timing belt is to be reused, use chalk to Timing belt mark it with an arrow on its flat side indicating the turning direction.
Page 64 11B-28 ENGINE <6A1> - Timing Belt "BA TIMING BELT INSTALLATION Rocker cover Rocker cover 1. Check that the timing marks of the both camshaft sprockets and the crankshaft sprocket are aligned. NOTE Camshaft In this condition, the No.1 cylinder will be in the sprocket compression top dead centre position.
Page 65 11B-29 ENGINE <6A1> - Timing Belt "CA TIMING BELT TENSION ADJUSTMENT MD998767 1. After turning the crankshaft 1/4 of a revolution in the Tension direction anticlockwise direction, turn it in the clockwise direction until the timing marks are aligned. 2. Loosen the tensioner pulley fixing bolt, and then use the special tool and a torque wrench to tighten the fixing bolt to the specified torque while applying tension to the Tensioner...
Page 66: Engine Assembly
11B-30 ENGINE <6A1> - Engine Assembly ENGINE ASSEMBLY 11200100558 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Fuel Discharge Prevention (Refer to GROUP 13A Front Exhaust Pipe Installation (Refer to GROUP - On-vehicle Service.) 15.) Under Cover Removal Radiator Installation (Refer to GROUP 14.) Hood Removal (Refer to GROUP 42.) Air Cleaner Installation Air Cleaner Removal...
Page 67 11B-31 ENGINE <6A1> - Engine Assembly 12 Nm 12 Nm 39 Nm 35 Nm 67 Nm 57 Nm 98 - 118 Nm* 25. Drive belt (Alternator) AD" "CA 32. Engine mount bracket 26. Drive belt (Power steering and "BA 33. Engine mount stopper A/C) AE"...
Page 68 11B-32 ENGINE <6A1> - Engine Assembly REMOVAL SERVICE POINTS AA" POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL Remove the power steering oil pump and bracket assembly from the engine with the hose attached. NOTE Place the removed power steering oil pump in a place where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord.
Page 69 11B-33 ENGINE <6A1> - Engine Assembly INSTALLATION SERVICE POINTS "AA ENGINE ASSEMBLY INSTALLATION Install the engine assembly, checking that the cables, hoses, and harness connectors are not clamped. "BA ENGINE MOUNT STOPPER INSTALLATION Engine side Clamp the engine mount stopper so that the arrow points Dynamic damper in the direction as shown in the diagram.
Page 70 NOTES...
Page 71 11C-1 ENGINE <4D6> CONTENTS 11109000627 GENERAL INFORMATION ....CRANKSHAFT PULLEY ....SERVICE SPECIFICATIONS .
Page 72: General Information
11C-2 ENGINE <4D6> - General Information/Service Specifications GENERAL INFORMATION 11100010476 Items 4D68 Total displacement mL 1,998 Bore ´ Stroke mm 82.7 ´ 93.0 Compression ratio 22.4 Combustion chamber Vortex chamber type Camshaft arrangement SOHC Number of valve Intake Exhaust Valve timing Intake Opening BTDC 20_...
Page 73: Sealants
5 - 7 SEALANTS 11100050362 Items Specified sealants Remarks Oil pan MITSUBISHI GENUINE PART Semi-drying sealant MD970389 or equivalent Semi-circular packing and rocker 3M ATD Part No.8660 or equivalent cover seal, and cylinder head seal Flywheel bolt or adapter plate bolt...
Page 74: Special Tools
11C-4 ENGINE <4D6> - Special Tools SPECIAL TOOLS 11100060471 Tool Number Name MB991502 MUT-II sub Idle speed check assembly MB998720 Prestroke Adjustment of the injection timing measuring adapter MB990767 End yoke holder Holding the camshaft sprocket MD998719 Crankshaft pulley holder pin MD998754 Crankshaft pulley holder pin...
Page 75 11C-5 ENGINE <4D6> - Special Tools Tool Number Name MD998382 Crankshaft front oil Installing the crankshaft front oil seal seal installer MD998383 Crankshaft front oil seal guide MD998781 Flywheel stopper Securing the flywheel <M/T> or drive plate <A/T> GENERAL Engine lifter Supporting the engine assembly during SERVICE removal and installation of the transmission...
Page 76: On-Vehicle Service
11C-6 ENGINE <4D6> - ENGINE <4D6> - On-vehicle Service On-vehicle Service ON-VEHICLE SERVICE 11100090449 DRIVE BELT TENSION CHECK AND ADJUSTMENT ALTERNATOR DRIVE BELT TENSION CHECK Use a belt tension gauge to check that the belt tension is Water pump at the standard value at a point half-way between the two pulley Alternator pulley...
Page 77 11C-7 ENGINE <4D6> - On-vehicle Service POWER STEERING OIL PUMP DRIVE BELT TENSION Power steering CHECK AND ADJUSTMENT 11100110183 oil pump pulley 1. Check the tension by pulling or pushing at the centre of the belt between pulleys with a force of 98 N as shown in the figure.
Page 78: Valve Clearance Check And Adjustment
11C-8 ENGINE <4D6> - On-vehicle Service COMPRESSOR DRIVE BELT TENSION CHECK AND A/C compressor pulley ADJUSTMENT 11100100203 1. Check the tension by pulling or pushing at the centre of the belt between pulleys with a force of 98 N as shown in the figure.
Page 79 11C-9 ENGINE <4D6> - On-vehicle Service 6. Measure the valve clearance in the places indicated by arrows in the illustration. Arrow A: When the No.1 cylinder is at compression top dead centre Arrow B: When the No.4 cylinder is at compression top dead centre Timing belt...
Page 80: Injection Timing Check And Adjustment
11C-10 ENGINE <4D6> - On-vehicle Service 8. Tighten the lock nut while holding the adjusting screw with a screwdriver so that it doesn’t turn. 9. Turn the crankshaft one full revolution to align the crankshaft pulley timing mark. 10. Adjust the remaining valves by the same procedure as in steps 7.
Page 81 11C-11 ENGINE <4D6> - On-vehicle Service 7. Turn the crankshaft clockwise to move the No.1 cylinder approximately 30_ before compression top dead centre. 8. Set the needle of the dial gauge to 0. 9. Check that the needle doesn’t move even if the crankshaft Set to 0 is turned slightly (2 - 3_) in both clockwise and anti-clockwise direction.
Page 82: Idle Speed Check
11C-12 ENGINE <4D6> - On-vehicle Service IDLE SPEED CHECK 11100350073 NOTE Check that the injection timing is normal, and then perform this check. 1. Before inspection, set the vehicle to the pre-inspection condition. 2. Connect the MUT-II to the diagnosis connector. 3.
Page 83: Timing Belt Tension Adjustment
11C-13 ENGINE <4D6> - On-vehicle Service 5. Set compression gauge to one of the glow plug holes. 6. Crank the engine and measure the compression pressure. Compression gauge Standard value: 3,500 kPa (at engine speed of 280 r/min) Limit: Min. 2,560 kPa (at engine speed of 280 r/min) 7.
Page 84 11C-14 ENGINE <4D6> - On-vehicle Service 5. Turn the crankshaft anti-clockwise by 1/2 the width of a camshaft sprocket tooth in order to take up the slack in the idler pulley belt (the side where the belt is slack). 1/2 the width of a tooth Timing mark...
Page 85: Crankshaft Pulley
11C-15 ENGINE <4D6> - Crankshaft Pulley CRANKSHAFT PULLEY 11200160327 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Under Cover Removal Drive Belt Tension Adjustment (Refer to P.11C-6.) Under Cover Installation 25 Nm Removal steps 1. Drive belt (Power steering) 3. Drive belt (Alternator) 2.
Page 86: Camshaft And Camshaft Oil Seal
11C-16 ENGINE <4D6> - Camshaft and Camshaft Oil Seal CAMSHAFT AND CAMSHAFT OIL SEAL 11200190425 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Timing Belt Removal and Installation (Refer to P.11C-26.) Air Pipe A Removal and Installation Vacuum Pump Removal and Installation (Refer to GROUP 14.) 6 Nm Lip section...
Page 87 11C-17 ENGINE <4D6> - Camshaft and Camshaft Oil Seal REMOVAL SERVICE POINT MB990767 AA" CAMSHAFT SPROCKET REMOVAL MD998719 or MD998754 INSTALLATION SERVICE POINTS Camshaft sproket side "AA CAMSHAFT BEARING CAP INSTALLATION The cap numbers are embossed on the top surface of the bearing caps, so install in the order of the numbers.
Page 88: Oil Pan
BOLT IDENTIFICATION f4 ± 1 mm Bolt Groove hole A: 6 ´ 8 mm B: 6 ´ 10 mm Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent 29 - 34 Nm 9 Nm Washer assembled bolt 9 Nm Flange bolt 10 Nm...
Page 89 11C-19 ENGINE <4D6> - Oil Pan REMOVAL SERVICE POINT MD998727 MD998727 AA" OIL PAN REMOVAL After removing the oil pan mounting bolts, remove the oil pan with the special tool and a brass bar. Caution Perform this slowly to avoid deformation of the oil pan flange.
Page 90: Crankshaft Oil Seal
11C-20 ENGINE <4D6> - Crankshaft Oil Seal CRANKSHAFT OIL SEAL 11200310159 REMOVAL AND INSTALLATION <M/T> 127 - 137 Nm <A/T> 127 - 137 Nm (Engine oil) 108 - 127 Nm Crankshaft Crankshaft (Engine oil: bolt washer (Engine oil: surface) bolt washer surface) Lip section Lip section...
Page 91 11C-21 ENGINE <4D6> - Crankshaft Oil Seal REMOVAL SERVICE POINT <M/T> AA" TRANSMISSION ASSEMBLY REMOVAL <M/T>: Refer to GROUP 22. Flywheel Caution Do not remove the flywheel mounting bolt shown by the arrow. If this bolt Is removed, the flywheel will become Bolt out of balance and damaged.
Page 92 11C-22 ENGINE <4D6> - Crankshaft Oil Seal "CA CRANKSHAFT FRONT OIL SEAL INSTALLATION Oil seal Front Crankshaft 1. Apply a small amount of engine oil to the entire lower case circumference of the oil seal lip. 2. Tap the oil seal unit it is flush with the oil seal case. MD998382 MD998383...
Page 93: Cylinder Head Gasket
11C-23 ENGINE <4D6> - ENGINE <4D6> - Cylinder Head Gasket Cylinder Head Gasket CYLINDER HEAD GASKET 11200400566 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Coolant Draining and Refilling Timing Belt Removal and Installation (Refer to GROUP 14 - On-vehicle Service.) (Refer to P.11C-26.) Air Pipe A Removal and Installation Thermostat Case Assembly Removal and Installation...
Page 94 11C-24 AA" FUEL INJECTION PIPE REMOVAL When loosening nuts at injection pipe ends, hold the nut at other side (delivery holder nut for pump side, nozzle holder nut at nozzle side) with wrench. Caution After disconnecting the injection pipe, plug the opening so that no foreign particles get inside the pump or into the injection nozzle.
Page 95 11C-25 ENGINE <4D6> - Cylinder Head Gasket 4. Tighten the bolts by the following procedure. Intake side Front of engine Step Operation Remarks Tighten to 88 Nm. Carry out in the order shown in the illustration. Fully loosen. Carry out in the reverse order of that shown in the illustration.
Page 96: Timing Belt
11C-26 ENGINE <4D6> - Timing Belt TIMING BELT 11200430497 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Crankshaft Pulley Removal and Installation (Refer to P.11C-15.) Engine Mount Bracket Removal and Installation (Refer to GROUP 32.) 10 - 12 Nm 9 Nm 10 - 12 Nm 19 Nm 25 Nm...
Page 97 11C-27 ENGINE <4D6> - Timing Belt REMOVAL SERVICE POINTS AA" TIMING BELT FRONT UPPER COVER INSTALLATION Attach protective tape to the engine mount bracket, and then remove the timing belt front upper cover. Protective tape AB" TIMING BELT REMOVAL Timing marks 1.
Page 98 11C-28 ENGINE <4D6> - Timing Belt Timing marks INSTALLATION SERVICE POINTS "AA TIMING BELT INSTALLATION Injection 1. Ensure that the timing marks of the camshaft sprocket, pump sprocket the injection pump sprocket, the crankshaft sprocket, and Camshaft sprocket the oil pump sprocket are all aligned. Timing mark Timing mark Oil pump...
Page 99 11C-29 ENGINE <4D6> - Timing Belt 6. Using the index finger, press between the camshaft sprocket and the injection pump sprocket, and check whether or not the amount of flexion is within the standard value range. Injection Camshaft Standard value: 4 - 5 mm pump sprocket sprocket...
Page 100: Timing Belt B
11C-30 ENGINE <4D6> - Timing Belt B TIMING BELT B 11200460113 REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Crankshaft Pulley Removal and Installation Timing Belt Removal and Installation (Refer to P.11C-15.) (Refer to P.11C-26.) Engine Mount Bracket Removal and Installation (Refer to GROUP 32.) 48 Nm 19 Nm...
Page 101 11C-31 ENGINE <4D6> - Timing Belt B AB" TIMING BELT B REMOVAL Caution If the timing belt “B” is to be re-used, use chalk to mark (on its flat side) an arrow indicating the clockwise direction. INSTALLATION SERVICE POINTS Counter balance shaft sprocket Belt tension side "AA TIMING BELT B INSTALLATION Crankshaft...
Page 102 11C-32 ENGINE <4D6> - Timing Belt B "BA CRANKSHAFT SPROCKET INSTALLATION 1. Apply as little engine oil as possible to the seat and the thread of the crankshaft bolt. 2. Secure the crankshaft sprocket in the same way as during removal, and then tighten the bolt to the specified torque.
Page 103: Engine Assembly
11C-33 ENGINE <4D6> - Engine Assembly ENGINE ASSEMBLY 11200100565 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Hood Removal (Refer to GROUP 42.) Front Exhaust Pipe Installation Air Cleaner Assembly Removal (Refer to GROUP 15.) Engine Coolant Draining Under Cover Installation Radiator Assembly Removal (Refer to GROUP 14.) Radiator Assembly Installation Under Cover Removal...
Page 104 11C-34 ENGINE <4D6> - Engine Assembly 22 Nm 39 Nm 29 - 34 Nm 12 Nm 57 Nm* 98 Nm 18. Heater hose connection AC" D Transmission assembly AD" "CA 27. Engine mount bracket 19. Drive belt (Power steering) 20. Drive belt (A/C) "BA 28.
Page 105 11C-35 ENGINE <4D6> - Engine Assembly REMOVAL SERVICE POINTS AA" POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL Remove the power steering oil pump and bracket assembly from the engine with the hose attached. NOTE Place the removed power steering oil pump in a place where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord.
Page 106 11C-36 ENGINE <4D6> - Engine Assembly INSTALLATION SERVICE POINTS "AA ENGINE ASSEMBLY INSTALLATION Install the engine assembly, checking that the cables, hoses, and harness connectors are not clamped. "BA ENGINE MOUNT STOPPER INSTALLATION Engine side Clamp the engine mount stopper so that the arrow points Dynamic damper in the direction as shown in the diagram.

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