Manual de Taller Mitsubishi 4g64
September 1, 2022 | Author: Anonymous | Category: N/A
Short Description
Download Manual de Taller Mitsubishi 4g64...
Description
11A-0-1
ENGINE 4G6 SERIES CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-0-3 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-4 NEW TIGHTENING METHOD BY USE USE OF B BOL OLTS TS TO BE TIGHTENE TIGHTENED D IN PLASTIC PLASTIC AREA . . 11A-1-9 1A-1-9 SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-9 FORM-IN-PLACE GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-10 2. SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-2-1 3. ALTERNATOR AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 11A-3-1 3a. INTAKE MANIFOLD (GDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-3a-1 4. TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-4-1 4a. EXHAUST MANIFOLD (GDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-4a-1 5. FUEL AND EMISSION CONTROL PARTS . . . . . . . . . . . . . . . . . . . . . . 11A-5-1 5a. FUEL PARTS (GDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-5a-1 6. WATER PUMP AND INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . 11A-6-1 6a. WATER PUMP AND WATER HOSE (GDI) . . . . . . . . . . . . . . . . . . . . . 11A-6a-1 7. EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-7-1 8. ROCKER ARMS AND CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-8-1 8a. ROCKER ARMS AND CAMSHAFTS (GDI) . . . . . . . . . . . . . . . . . . . 11A-8a-1 9. CYLINDER HEAD AND VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-9-1 10. FRONT CASE, COUNTERBALANCE COUNTERBALANCE SHAFTS SHAFTS AND OIL PAN PAN 11A-10-1 11. PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-11-1 12. CRAN CRANKS KSH HAFT AFT, FLYWHEE HEEL AND AND DRI RIV VE PLATE . . . . . . . . . . . . . 11A-1 -12 2-1
E Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
Downloaded from www.Manualslib.com manuals search engine
11A-0-2 NOTES
E Mitsubishi Motors Corporation
Dec. 1996
PWEE9616
Downloaded from www.Manualslib.com manuals search engine
4G6 4G 6 EN ENGI GINE NE - General Informatio Information n
11A-0-3
GENERAL INFORMA INFORMATION TION SOHC-4G63 Descriptions
Specifications
Type
In-line OHV, SOHC
Number of cylinders
4
Combustion chamber
Pentroof type
Total displacement dm3
1,997
Cylinder bore mm
85.0
Piston stroke mm
88.0
Compression ratio
10
Valve timing
Intake valve
Exhaust valve
Opens (BTDC)
18_
Closes (ABDC)
58_
Opens (BBDC)
58_
Closes (ATDC)
18_
Lubrication system
Pressure feed, full-flow filtration
Oil pump type
Involute gear type
SOHC-4G64 Descriptions
Specifications
Type
In-line OHV, SOHC
Number of cylinders
4
Combustion chamber
Pentroof type
Total displacement dm3
2,351
Cylinder bore mm
86.5
Piston stroke mm
100.0
Compression ratio
10
Valve timing
Intake valve
Exhaust valve
Opens (BTDC)
16_
Closes (ABDC)
53_
Opens (BBDC)
50_
Closes (ATDC)
16_
Lubrication system
Pressure feed, full-flow filtration
Oil pump type
Involute gear type
E Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
Downloaded from www.Manualslib.com manuals search engine
11A-0-4
4G6 4G 6 EN ENGI GINE NE - General Informatio Information n
GDIt Descriptions
Specifications
Type
In-line OHV, SOHC
Number of cylinders
4
Combustion chamber
Pentroof + curved top piston type
Total displacement dm3
2,351
Cylinder bore mm
86.5
Piston stroke mm
100.0
Compression ratio
11.5
Valve timing
Intake valve
Exhaust valve
Opens (BTDC)
16_
Closes (ABDC)
60_
Opens (BBDC)
56_
Closes (ATDC)
16_
Lubrication system
Pressure feed, full-flow filtration
Oil pump type
Involute gear type
NOTE GDI is a tradem trademark ark of Mitsub Mitsubish ishii Motors Motors Cor Corpora poratio tion. n.
E Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
Downloaded from www.Manualslib.com manuals search engine
4G6 4G 6 ENG NGIN INE E - Specifications
11A-1-1
1. SPECIFICATIONS SPECIFICATIONS SERVICE SPECIFICA SPECIFICATIONS TIONS Items
Standard value
Limit
Auto-tensioner rod projection length mm
12
-
Auto-tensioner rod pushed-in amount [when pushed with a force of 98
1.0 or less
-
Intake
37.39
36.89
Exhaust
37.14
36.64
Intake
37.39
36.89
Exhaust
36.83
36.33
Lash adjuster leak down time [diesel fuel at 15 - 20_C] seconds/mm
3 - 20/1.0
-
Camshaft journal outer diameter mm
45
-
Intake
35.79
35.29
Exhaust
37.14
36.64
Lash adjuster leak down time [diesel fuel at 15 - 20_C] seconds/mm
3 - 20/1.0
-
Camshaft journal outer diameter mm
26
-
Cylinder head flatness of gasket surface mm
Less than 0.05
0.2
Cylinder head grinding limit of gasket surface mm Total resurfacing depth of both cylinder head and cylinder block
-
0.2
Cylinder head overall height mm
SOHC
120
-
GDI
132
-
-
Maximum 99.4
Intake
1.0
0.5
Exhaust
1.2
0.7
Intake
1.0
0.5
Exhaust
1.5
1.0
Intake
112.30
111.80
Exhaust
114.11
113.61
Intake
105.5
105.0
Exhaust
105.7
105.2
6.0
-
Timing belt
- 196 N] mm Rocker arms and camshaft Camshaft cam height mm
4G63 SOHC
4G64 SOHC
Rocker arms and camshaft (GDI)
Camshaft cam height mm
Cylinder head and valves
Cylinder head bolt shank length mm Valve alve thic thickn knes ess s of valv valve e head head (m (mar argi gin) n) mm
GDI
Valve overall height mm
SOHC SOHC
SOHC
GDI
Valve stem outer diameter mm E Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
Downloaded from www.Manualslib.com manuals search engine
11A-1-2
4G6 4G 6 ENG NGIN INE E - Specifications
Items Valve alve thic thickne kness ss to valve valve guid guide e clearan clearance ce mm
SOHC SOHC
GDI
Standard value
Limit
Intake
0.02 - 0.05
0.10
Exhaust
0.03 - 0.07
0.15
Intake
0.02 - 0.05
0.10
Exhaust
0.05 - 0.09
0.15
Valve face angle mm
45_ - 45.5_
-
SOHC
51.0
50.0
GDI
48.3
47.3
SOHC
267/44.2
-
GDI
294/40.0
-
SOHC
2_ or less
Maximum 4_
GDI
1.5_ or less
Maximum 4_
0.9 - 1.3
-
SOHC
6.0
-
GDI
6.6
-
14.0
-
19.5
-
49.30
49.80
Intake
49.20
49.70
Exhaust
48.40
48.90
Oversize Oversi ze rework rework dim dimens ension ions s of valve valve guide guide 0.05 Oversize diameter hole (SOHC) mm 0.25 Oversize diameter
11.05 - 11.07
-
11.25 - 11.27
-
0.50 Oversize diameter
11.50 - 11.52
-
Oversi Ove rsize ze rework rew ork dim dimens ension ions s of valve valve guide guide 0.05 Oversize diameter hole (GDI) mm 0.25 Oversize diameter
12.05 - 12.07 12.25 - 12.27
-
0.50 Oversize diameter
12.50 - 12.52
-
.3 Oversize diameter Int Intake ake ove oversi rsize ze rew rework ork dimens dimension ions s of valve valve 0 .3 seat hole (SOHC) mm 0.6 Oversize diameter
34.30 - 34.33
-
34.60 - 34.63
-
.3 Oversize diameter Int Intake ake ove oversi rsize ze rew rework ork dimens dimension ions s of valve valve 0 .3 seat hole (GDI) mm 0.6 Oversize diameter
35.30 - 35.33
-
35.60 - 35.63
-
.3 Oversize diameter Exhaustt oversi Exhaus oversize ze rew rework ork dimens dimension ions s of 0 .3 valve seat hole (SOHC) mm 0.6 Oversize diameter
34.30 - 34.33
-
34.60 - 34.63
-
Exhaustt oversi Exhaus oversize ze rew rework ork dimens dimension ions s of 0 .3 .3 Oversize diameter valve seat hole (GDI) mm 0.6 Oversize diameter
33.30 - 33.33
-
33.60 - 33.63
-
Valve spring free length mm
Valve spring load/installed height N/mm
Valve spring out-of-squareness
Valve seat valve contact width mm
Valve guide inner diameter mm
Valve guide projection from cylinder head SOHC upper surface mm GDI
Valve stem projection mm
S OHC SO GDI
E Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
Downloaded from www.Manualslib.com manuals search engine
4G6 4G 6 ENG NGIN INE E - Specifications Items
11A-1-3
Standard value
Limit
Drive gear
0.08 - 0.14
-
Driven gear
0.06 - 0.12
-
78 or more
-
4G63
85.0
-
4G64
86.5
-
No. 1
0.02 - 0.06
0.1
No. 2
0.02 - 0.06
0.1
No. 1
0.25 - 0.35
0.8
No. 2
0.40 - 0.55
0.8
Oil ring side rail
0.10 - 0.40
1.0
Piston pin outer diameter mm
22.0
-
Piston pin press-in load N (Room temperature)
7,350 - 17,200
-
Crankshaft pin oil clearance mm
0.02 - 0.05
0.1
Connecting rod big end side clearance mm
0.10 - 0.25
0.4
Crankshaft end play mm
0.05 - 0.25
0.40
Crankshaft journal outer diameter mm
57.0
-
Crankshaft pin outer diameter mm
45.0
-
Crankshaft journal oil clearance mm
0.02 - 0.04
0.1
Bearing cap bolt shank length mm
-
Maximum 71.1
Piston to cylinder clearance mm Cylinder block flatness of gasket surface mm
0.02 - 0.04 0.05
0.1
Cylinder block grinding limit of gasket surface mm Total resurfacing depth of both cylinder head and cylinder block
-
0.2
4G63
284
-
4G64
290
-
4G63
85.0
-
4G64
86.5
-
0.01
-
Front case, counterbalance shaft and oil pan
Oil pump side clearance mm
Oil pressure at curb idle speed kPa [Oil temperature is 75 to 90_C] Piston and connecting rod
Piston outer diameter mm
Piston ring side clearance mm
Piston ring end gap mm
Crankshaft, flywheel and drive plate
Cylinder block overall height mm
Cylinder block inner diameter mm
Cylindricity mm
E Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
Downloaded from www.Manualslib.com manuals search engine
11A-1-4
4G6 4G 6 ENG NGIN INE E - Specifications
TORQUE SPECIFICA SPECIFICATIONS TIONS Items
Nm
Alternator and ignition system Water pump pulley
9
Adjusting bolt
10
Lock bolt
22
Alternator brace
23
Alternator pivot nut
44
Crankshaft pulley
25
Ignition coil (Multipoint fuel injection)
10
Spark plug
25
Distributor (Carburetor)
12
Camshaft position sensing cylinder (Multipoint fuel injection)
22
Camshaft position sensor support (Multipoint fuel injection)
14
Camshaft position sensor (Multipoint fuel injection)
10
Oil level gauge guide
13
Idler pulley bracket (M8) (Vehicle for Hong Kong)
22
Idler pulley bracket (M10) (Vehicle for Hong Kong)
49
Idler pulley (Vehicle for Hong Kong)
49
Intake manifold (GDI) Vacuum pipe and hose (Flange bolt)
11
Vacuum pipe and hose (Bolt, washer assembly)
8.8
Solenoid valve
8.8
Vacuum pipe
11
Throttle body
11
Intake manifold stay (M6)
8.8
Intake manifold stay (M8)
30
Air intake plenum resonator (Flange bolt)
11
Air intake plenum resonator (Bolt, washer assembly)
8.8
EGR valve
23
EGR valve support
23
Intake manifold
19
Timing belt Timing belt cover flange bolt E Mitsubishi Motors Corporation
Aug. 1999
11 PWEE9616-B
Revised
Downloaded from www.Manualslib.com manuals search engine
4G6 4G 6 ENG NGIN INE E - Specifications
11A-1-5
Items
Nm
Timing belt cover washer bolt
9
Power steering bracket
49
Crankshaft angle sensor (Multipoint fuel injection)
9
Tensioner arm
22
Tensioner puller
48
Auto tensioner
23
Idler pulley
35
Engine support bracket
49
Oil pump sprocket
54
Crankshaft bolt
118
Tensioner “B”
18
Counterbalance shaft sprocket
45
Camshaft sprocket bolt
88
Exhaust manifold (GDI) Exhaust manifold cover
13
Exhaust manifold (M10)
49
Exhaust manifold (M8)
29
Engine hanger
11
Fuel and emission parts Carburetor (Carburetor)
17
Fuel vapor separator (Carburetor)
23
Throttle body (Multipoint fuel injection) EGR valve (Except General Export)
18 22
Injectors and delivery pipe (Multipoint fuel injection)
12
Fuel pressure regulator (Multipoint fuel injection)
9
Fuel part (GDI) Fuel low pressure pipe (M6)
8.8
Fuel low pressure pipe (M8)
18
Fuel pump return nipple
8.8
Clamp A
8.8
Fuel pipe bracket
11
Fuel feed pipe
11
E Mitsubishi Motors Corporation
Aug. 1999
PWEE9616-B
Revised
Downloaded from www.Manualslib.com manuals search engine
11A-1-6
4G6 4G 6 ENG NGIN INE E - Specifications
Items
Nm
Fuel pump
4.9 ® 17 ± 2
Harness bracket
8.8
Fuel return pipe
11
Fuel high pressure regulator
18
Fuel pressure sensor
18
Pump camshaft case
23
Injector holder
22
Delivery pipe and injector assembly
11
Engine hanger
11
Water pump and intake manifold Engine coolant temperature sensor
29
Engine coolant temperature gauge unit
11
Water inlet fitting
13
Thermostat housing
24
Water inlet pipe
13
Water pump
14
Oil level gauge guide
14
Intake manifold stay
31
Intake manifold
19
Engine hanger
11
Detonation sensor (Multipoint fuel injection)
23
Water pump and water hose (GDI) Engine coolant temperature sensor
29
Engine coolant temperature gauge unit
11
Water inlet fitting
12
Water outlet fitting
12
Thermostat housing
23
Water inlet pipe
12
Water pump
13
Knock sensor
22
Exhaust manifold Exhaust manifold cover
E Mitsubishi Motors Corporation
13
Aug. 1999
PWEE9616-B
Revised
Downloaded from www.Manualslib.com manuals search engine
4G6 4G 6 ENG NGIN INE E - Specifications
11A-1-7
Items
Nm
Heat protector
13
Exhaust manifold (M8)
29
Exhaust manifold (M10)
49
Water outlet fitting
13
Rocker arms and camshaft Rocker cover
3.4
Rocker arm shaft
31
Rocker arms and camshafts (GDI) Camshaft position sensor
8.8
Cover
9.8
Camshaft position sensing cylinder
21
Camshaft position sensing support
13
Beam camshaft cap
20
Cylinder head and valves Cylinder head bolt [Tighten to 78 Nm and then completely completely loosen before finally tightening with above proce procedure.] dure.]
20 + 90_ + 90_
Front case, counterbalance shaft and oil pan Drain plug
39
Oil pan
6.9
Oil level sensor (For Europe)
8.8
Stiffener (For Europe)
21
Oil screen
18
Oil pressure switch (4G63)
19
Oil pressure switch (4G64)
9.8
Relief plug
44
Oil filter bracket
18
Plug
23
Flange bolt
36
Oil pump cover bolt
16
Oil pump cover screw
9.8
Front case
23
Transmission stay (GDI engine)
21
Oil level gauge guide
12
E Mitsubishi Motors Corporation
Aug. 1999
PWEE9616-B
Revised
Downloaded from www.Manualslib.com manuals search engine
11A-1-8
4G6 4G 6 ENG NGIN INE E - Specifications
Items
Nm
Oil pan lower
6.9
Baffle plate
6.9
Oil pan upper
6.9
Piston and connecting rod Connecting rod cap
20 + 90_ ® 100_
Crankshaft, flywheel and drive plate Flywheel bolt
132
Drive plate bolt
132
Rear plate
11
Bell housing cover
8.8
Oil seal case bolt
11
Bearing cap bolt
25 + 90_ ® 100_
E Mitsubishi Motors Corporation
Aug. 1999
PWEE9616-B
Revised
Downloaded from www.Manualslib.com manuals search engine
4G6 4G 6 ENG NGIN INE E - Specifications
11A-1-9
NEW TIGH NEW TIGHTE TENI NING NG ME METH THOD OD - BY US USE E OF BOL BOLTS TS TO BE TI TIGH GHTEN TENED ED IN PLASTIC PLASTI C AREA A new type of bolts, to be tightened in plastic area, is currently used some parts of the engine. The tig tighte htenin ning g method method for the bolts bolts is differ different ent from the con conven ventio tional nal one. Be sure sure to observ observe e the method method described in the text when tightening the bolts. Service limits are provided for the bolts. Make sure that the service limits described in the text are strictly observed. D
D
Area Areas s wher where e the the bolt bolts s are in use: use: (1) Cylinde Cylinderr head head bolts bolts (2) (2) Main Main beari bearing ng ca cap p bolts bolts (3) Connec Connectin ting g rod cap bolts bolts Tightenin Tightening g method method After tightening the bolts to the specified torque, tighten them another 90_ or 180_ (twice 90_). The tig tighte htenin ning g method method var varies ies on differ different ent are areas. as. Observ Observe e the tig tighte htenin ning g method method descri described bed in the text. text.
SEALANTS Item
Specified sealant
Quantity
Cam position sensor support
Mitsubishi Genuine Part No. MD970389 or equivalent
As required
En Engi gine ne cool coolan antt te temp mper erat atur ure e se sens nsor or
3M Nut Nut Lock Lockin ing g Pa Part rt No. No. 4171 4171 or equi equiva vale lent nt
As requ requir ired ed
Engi Engine ne co cool ola ant temp temper erat atur ure e ga gau uge uni nitt Thermostat case
3M ATD Part Part No. 86 8660 60 or eq equi uiva vale len nt Mitsubishi Genuine Part No. MD970389 or equivalent
As req equi uire red d As required
Water outlet fitting
Mitsubishi Genuine Part No. MD970389 or equivalent
As required
Beam camshaft cap
Mitsubishi Genuine Part No. MD970389 or equivalent
As required
Cylinder head
Mitsubishi Genuine Part No. MD970389 or equivalent
As required
Oil pressure switch
3M ATD Part No. 8660 or equivalent
As required
Oil pan
Mitsubishi Genuine Part No. MD970389 or
As required
equivalent Oil seal case
E Mitsubishi Motors Corporation
Mitsubishi Genuine Part No. MD970389 or equivalent
Aug. 1998
PWEE9616-A
As required
Added
Downloaded from www.Manualslib.com manuals search engine
11A-1-10
4G6 4G 6 ENG NGIN INE E - Specifications
FORM-IN-PLAC FORM-I N-PLACE E 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 bea bead, d, on the the other other hand, hand, co coul uld d be sq sque ueez ezed ed out out of lo loca cati tion on,, ca caus usin ing g block blocking ing or narro narrowi wing ng of th the e fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to apply app ly the gasket gasket evenly evenly without without a break, break, whi while le obse observi rving ng the correc correctt bead bead size. size. The FIPG used in the engine is a room temperature vulcanisation (RTV) type and is supplied in a 100-gram tube tub e (Part (Part No. MD970389) MD970389).. Since Since the RTV hardens hardens as it reacts reacts with with the moisture moisture in the atmospher atmospheric ic air air, it is norm normal ally ly used used in the the meta metall llic ic flang flange e are areas as.. Th The e FI FIPG, PG, Part Part No. No. MD970 MD97038 389, 9, ca can n be used used fo forr sealing both engine oil and coolant, while Part No. MD997110 can only be used for engine oil sealing.
Disassembly The Th e part parts s asse assemb mble led d wi with th the the FIPG FIPG ca can n be eas easil ily y disas disasse semb mbled led wi with thout out use use of a sp spec ecia iall meth method od.. In some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking wi with th a mall mallet et or si simi milar lar tool. tool. A flat flat and thin gask gasket et sc scrap raper er may may be lig light htly ly hamm hammer ered ed in betw betwee een n th the e joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces. For removal of the oil pan, the special tool “Oil Pan Remover” (MD998727) is available. Be sure to use the special tool to remove the oil pan. Surface Preparation Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure thatt there tha there are no oils, oils, grease greases s and foreign foreign substance substances s deposit deposited ed on the applica applicatio tion n surfac surfaces. es. Do not forget for get to remove remove the old sealant sealant remained remained in the bolt holes. holes. Form-in-Place Gasket Application When assembling parts with the FIPG, you must observe some precautions, but the procedures is very simple as in the case of a conventional precut gasket. Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is hard hardene ened. d. Whil While e the the FIPG FIPG is stil stilll mois moistt (i (in n less less than than 15 mi minu nute tes) s),, mount mount th the e part parts s in posit positio ion. n. When When the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time (about (ab out one hour) hour) has passed passed after after instal installat lation ion is comple completed ted.. The FIPG applica applicatio tion n procedur procedure e may vary vary on differ different ent area areas. s. Observ Observe e the procedu procedure re descri described bed in the textt when tex when applyin applying g the FIPG.
E Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
Downloaded from www.Manualslib.com manuals search engine
4G6 4G 6 EN ENGI GINE NE (E- W) - Special Tools
11A-2-1
2. SPECIAL TOOLS Tool
Number
Name
Use
MB990767
Crankshaft pulley holder
Holding camshaft sprocket Use with MD998719.
MD990938
Handle
Installation of crankshaft rear oil seal Use with MD998776.
MB991603
Silent shaft bearing puller stopper
Guide stopper for removal and installation of counterbalance shaft rear bearing Use with MD998372.
MB991654
Cylinder head bolt wrench (12)
Removal and installation of cylinder head bolt
MD99 9981 816 62
Plug Plug wren enc ch
Remov emoval al and in inst stal alla lati tio on of fron ontt case case cap cap pl plug ug Use with MD998783.
MD99 9982 828 85
Cran anks ksha hafft fr fron ontt oi oill seal guide
Guide for instal Guide installat lation ion of cra cranks nkshaf haftt fro front nt oil sea seall Use with MD998375.
MD998371
Silent shaft bearing puller
Removal of counterbalance shaft front bearing
MD998372
Silent shaft bearing puller
Removal of counterbalance shaft rear bearing
MD998375
Crankshaft
Installation of crankshaft front oil seal
seal installer
E Mitsubishi Motors Corporation
Dec. 1996
PWEE9616
front
Downloaded from www.Manualslib.com manuals search engine
11A-2-2 Tool
E Mitsubishi Motors Corporation
4G6 4G 6 EN ENGI GINE NE (E- W) - Special Tools Number
Name
Use
MD99 MD 9984 8440 40
Le Leak ak down down te test ster er
Leak Leak down down test test of la lash sh ad adju just ster er
MD998441
Lash adjuster retainer
Air bleeding of lash adjuster
MD99 MD 9984 8442 42
La Lash sh adju adjust ster er wire wire
Ai Airr bl blee eedi ding ng of la lash sh ad adju just ster er
MD998443
Lash adjuster holder
Retain Reta iner er for for ho hold ldin ing g la lash sh adju adjust ster er in rock rocker er arm arm at time of removal and installation of rocker shaft assembly
MD998705
Silent shaft bearing installer
Installation of counterbalance shaft front and rear bearing
MD998713
Camshaft oil seal installer
Installation of camshaft oil seal
MD99 9987 871 19
Pull Pulley ey ho hold lder er pi pin n
Hol oldi ding ng cam camshaf shaftt spro procket cket Use with MB990767.
MD998727
Oil pan remover
Removal of oil pan
MD998735
Valve spring compressor
Removal and installation of valve and related parts
Dec. 1996
PWEE9616
Downloaded from www.Manualslib.com manuals search engine
4G6 4G 6 EN ENGI GINE NE (E- W) - Special Tools Tool
E Mitsubishi Motors Corporation
11A-2-3
Number
Name
Use
MD998738
Set screw
Adjustment of timing belt tension
MD998767
Tensioner puller socket wrench
Adjustment of timing belt tension
MD998772
Valve spring compressor
Removal and installation of valve and related parts
MD998774
Valve stem installer
seal
Installation of valve stem seal
MD998775
Valve stem installer
seal
Installation of valve stem seal
MD998776
Crankshaft rear oil seal installer
Installation of crankshaft rear oil seal Use with MB990938.
MD998778
Crankshaft sprocket puller
Removal of crankshaft sprocket
MD99 MD 9987 8780 80
Pist Piston on sett settin ing g to tool ol
Remo Remova vall an and d in inst stal alla lati tion on of pi pist ston on pi pin n
MD99 MD 9987 8781 81
Flyw Flywhe heel el st stop oppe perr
Hold Holdin ing g of flyw flywhe heel el and and driv drive e pl plat ate e
Aug. 1998
PWEE9616-A
Revised
Downloaded from www.Manualslib.com manuals search engine
11A-2-4 Tool
E Mitsubishi Motors Corporation
4G6 4G 6 EN ENGI GINE NE (E- W) - Special Tools Number
Name
Use
MD998783
Plug wrench retainer
Removal and installation installation of front case case cap plug
MD99 MD 9987 8785 85
Sp Spro rock cket et st stop oppe perr
Hold Holdin ing g sile silent nt shaf shaftt spro sprock cket et
Aug. 1998
PWEE9616-A
Added
Downloaded from www.Manualslib.com manuals search engine
4G6 4G 6 ENG NGIINE (E- W) - Alte Alternat rnator or and Igni Ignition tion System
11A-3-1
3. ALTERNA ALTERNATOR TOR AND IGNITION IGNITION SYSTEM SYSTEM REMOVAL REMOV AL AND INST INSTALLA ALLATION TION
8
6 12 Nm
7
25 Nm
10 4
10 Nm
9
3 44 Nm
22 Nm
24 Nm
2 5
9 Nm
25 Nm
1
Removal steps Removal 1. Drive belt 2. Water pump pulley 3. Alternator brace 4. Alternator 5. Crankshaft Crankshaft pulley 6. Spark plug cable 7. Spark plug cable 8. High tension "BA 9. Distribut Distributor or assembly 10. O-ring
E Mitsubishi Motors Corporation
Dec. 1996
PWEE9616
Downloaded from www.Manualslib.com manuals search engine
11A-3-2
4G6 4G 6 ENG NGIINE (E- W) - Alte Alternat rnator or and Igni Ignition tion System
REMOVAL REMOV AL AND INST INSTALLA ALLATION TION
10 Nm
7
10 Nm
6 9 25 Nm
10
8 11
4 22 Nm 10 Nm
3 14 Nm 44 Nm
r 22 Nm
24 Nm
2 5
9 Nm
25 Nm
1
Removal steps Removal 1. Drive belt 2. Water pump pulley 3. Alternator brace 4. Alternator 5. Crankshaft Crankshaft pulley 6. Spark plug cable
E Mitsubishi Motors Corporation
Dec. 1996
7. 8. 9. "AA 10. 11.
PWEE9616
Ignition coil assembly Spark plug Camshaft posit Camshaft position ion sensor sensor Camshaft position sensing support Camshaft Camshaft posit position ion sensing sensing cylinder cylinder
Downloaded from www.Manualslib.com manuals search engine
4G6 4G 6 ENG NGIINE (E- W) - Alte Alternat rnator or and Igni Ignition tion System
11A-3-3
REMOVAL REMOV AL AND INST INSTALLA ALLATION TION (GDI)
9.8 Nm
11 25 Nm
12
49 Nm
6
7 9.8 Nm
1
8.8 Nm
22 Nm 23 Nm
4
5 13 Nm
8 9
2
49 Nm
3
25 Nm
10 49 Nm 22 Nm
Removal steps Removal 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Drive belt 5. Water pump pulley 6. Alternator 7. Alternator brace
E Mitsubishi Motors Corporation
Aug. 1999
8. Idler pulley brack bracket et (Vehicle for Hong Kong) 9. Idler pulley (Vehicle for Hong Kong) 10. Crankshaft Crankshaft pulley 11. Ignition coil 12. Spark plug
PWEE9616-B
Revised
Downloaded from www.Manualslib.com manuals search engine
11A-3-4
4G6 4G 6 ENG NGIINE (E- W) - Alte Alternat rnator or and Igni Ignition tion System INSTALLA INST ALLATION TION SERVICE POINTS "AA CAMS CAMSHAFT HAFT POSITIO POSITION N SENSOR SENSOR SUPPORT SUPPORT INSTALLATION (1 (1)) Appl Apply y a 3 mm bead bead of fo form rm-i -inn-pla place ce gask gasket et (FIP (FIPG) G) to the area shown.
Specified sealant: Mit its subi ubishi shi Genui nuine equivalent
Part art
No. No.
MD9 MD970389 389
or
"BA DISTRIBUT DISTRIBUTOR OR ASSEMBLY ASSEMBLY INSTALLA INSTALLATION TION (1 (1)) Turn urn the the cr crank anksh shaf aftt to bri bring ng No. No. 1 cy cyli linde nderr to th the e to top p dead dea d center center on compres compressio sion n str stroke oke.. (2) Align Align the mating mating marks marks on the distribut distributor or housing housing with that of the coupling key.
Stud bolt
E Mitsubishi Motors Corporation
Aug. 1998
(3 (3)) Inst In stal all l the the bolt di dist stri ribu buto torr asse as mbly ly on the e engin eng ine e whil wh ile ewith al align ignin ing g the stud used forsemb securin sec uring g th the distribu distr ibutor tor the slot in the mounting flange of the distributor.
PWEE9616-A
Added
Downloaded from www.Manualslib.com manuals search engine
4G6 4G 6 EN ENGI GINE NE (E- W) - Inta Intake ke Mani Manifold fold (GDI)
11A-3a-1
3a.. INTAKE 3a INTAKE MANIFO MANIFOLD LD (GDI) (GDI) REMOVAL REMOV AL AND INST INSTALLA ALLATION TION (SP (SPACE ACE WAGON)
8.8 Nm
8.8 Nm
3
2
11 Nm
11 Nm 8.8 Nm
16 14
4
11 Nm
12 5 11
13
7 1
23 Nm
17
23 Nm
6 8.8 Nm
19 Nm
18
15
10
11 Nm
19
30 Nm 19 Nm
9 8.8 Nm 30 Nm
8
Removal steps Removal 1. Vacuum pipe and hose (1999 model vehicles for Hong Kong) 2. Solenoi Solenoid d valve valve (1999 (1999 model model vehicles for Hong Kong) 3. Vacuum pipe and hose (Vehicle (Vehicles s for Europe and 2000
"DA 7. Thrott Throttle le body gasket "CA 8. Intake Intake manifold manifold stay "BA 9. Air intake intake plenum resonato resonatorr 10. Gasket 11. Water hose 12. EGR valve 13. Gasket
model vehicles 4. Solenoid valve for Hong Kong) (Vehicle (Vehicles s for Europe and 2000 model vehicles for Hong Kong) 5. Vacuum pipe 6. Throttle body
"AA 15. 14. EGR Hose support clamp "AA 16. Gasket 17. Gasket 18. Intake manifold manifold 19. Gasket
E Mitsubishi Motors Corporation
Aug. 1999
PWEE9616-B
Revised
Downloaded from www.Manualslib.com manuals search engine
11A-3a-2
4G6 4G 6 EN ENGI GINE NE (E- W) - Inta Intake ke Mani Manifold fold (GDI)
REMOVAL REMOV AL AND INST INSTALLA ALLATION TION (GALAN (GALANT) T)
8.8 Nm 8.8 Nm
1 2 8 11 Nm
9 11 23 Nm
3 4
13
19 Nm
23 Nm
5 10 14
15
12 16 7
19 Nm 30 Nm
11 Nm 8.8 Nm
6
Removal steps Removal 1. Vacuum pipe and hose 2. Solenoid valve 3. Throttle body
9. EGR valve 10. Gasket "AA 11. Hose clamp clamp
"C A 5. DA 4. Intake Thrott Thtake rottle lemanifold bodyold gasket " In manif stay "BA 6. Air intake intake plenum resonato resonatorr 7. Gasket 8. Water Water hose E Mitsubishi Motors Corporation
Aug. 1999
"A A 13. AA 12. Gasket EGR support " 14. Gasket 15. Intake manifold manifold 16. Gasket PWEE9616-B
Revised
Downloaded from www.Manualslib.com manuals search engine
4G6 4G 6 EN ENGI GINE NE (E- W) - Inta Intake ke Mani Manifold fold (GDI) Intake manifold side Cylinder Cylind er head side
Hose clamp
11A-3a-3
INSTALLA INST ALLATION TION SERVICE POINTS "AA EG EGR R SUPPO SUPPORT RT / HOSE HOSE CLAMP CLAMP / GASKE GASKET T INSTALLATION (1) Instal Installl the gasket, gasket, EGR support support and hose clamp to the cy cyli linde nderr head head in th that at or order der and ti tigh ghte ten n th the e fa fast sten eners ers temporarily. (2) Instal Installl the EGR support support assembl assembly y to the intake intake manifol manifold d wi with th the the gask gasket et at atta tach ched ed on th the e mati mating ng su surf rfac ace, e, and and ti tigh ghte ten n the fasten fasteners ers to the specif specified ied torque torque.. (3 (3)) Tig ight hten en th the e fa fast stene eners rs on th the e cy cyli lind nder er head head si side de to th the e specified speci fied torque. torque. "BA AIR INTAKE INTAKE PLENUM RESONATOR RESONATOR INSTALLATION (1) Install Install the mounting bolts bolts on the throttle body side without without fail.
"CA INT INTAKE AKE MANIFOLD STA STAY INSTALLA INSTALLATION TION (1) Tigh (1) Tighte ten n th the e fa fast sten ener ers s to the the sp spec ecif ifie ied d to torq rque ue af afte terr confirming confir ming that the intake manifold stay is in close contact contact wi with th the the ai airr int intak ake e pl plenu enum m resona resonato torr and th the e cy cyli linde nderr block.
Intake manifold stay
Air intake plenum resonator
"DA THROTTLE BODY GASKET INSTALLA INSTALLATION TION (1) Positi Position on the projec projectio tion n as shown shown in the ill illust ustrat ration ion..
Projection
E Mitsubishi Motors Corporation
Aug. 1999
PWEE9616-B
Added
Downloaded from www.Manualslib.com manuals search engine
4G6 4G 6 ENG NGIINE (E- W) - Timing Belt
11A-4-1
4. TIMING TIMING BELT BELT REMOVAL REMOV AL AND INST INSTALLA ALLATION TION (SOHC)
20 45 Nm
18 45 Nm
17
16
14
15
23
18 Nm
5
88 Nm
13 19
22 7
21 9 Nm
22 Nm
1
48 Nm 49 Nm
49 Nm
6
14 Nm
4
3
12 8 23 Nm
9
10
11
54 Nm
35 Nm 118 118 Nm
11 Nm
2
9 Nm
Removal steps Removal 1. Timing belt front upper cover 2. Timing Timing belt front lower cover 3. Power steering steering bracket bracket 4. Crankshaft Crankshaft position position sensor sensor (Multipoint (Mult ipoint fuel injection) injection) AA" "KA 5. Timing Timing belt "JA 6. Tensioner pulley 7. Tensioner arm "IA 8. Auto tensio tensioner ner 9. Idler pulley AC" "HA 10. Oil pump sprocket AD" "GA 11. 11. Crankshaft bolt
E Mitsubishi Motors Corporation
Aug. 1999
AE"
12. Crank Crankshaft shaft sprocket sprocket 13. Flange (Multipoi (Multipoint nt fuel injection) injection) 14. Flange (Carburetor) 15. Tensioner Tensioner “B” AF" "FA 16. Timing Timing belt “B” AG" "EA 17. Counterbal Counterbalance ance shaft shaft sproc sprocket ket "DA 18. Spacer AH" 19. Crank Crankshaft shaft sprocket sprocket “B” "CA 20. Engine support support brack bracket et AI" "AA 21. Camshaft Camshaft sprocket sprocket bolt 22. Camshaft sprocket sprocket 23. Timing belt rear cover
PWEE9616-B
Revised
Downloaded from www.Manualslib.com manuals search engine
11A-4-2
4G6 4G 6 ENG NGIINE (E- W) - Timing Belt
REMOVAL REMOV AL AND INST INSTALLA ALLATION TION (GDI) 21 25
22
1
3.4 Nm
6 7
48 Nm
23
26 24
27
23 Nm
8 2
23 Nm
12
11 Nm
13
31
11 Nm
118 118 Nm 11 Nm
49 Nm
32
9 Nm
5 30
45 Nm
18
3
17
4
18 Nm
88 Nm
28
15
29
10 33 20
48 Nm
8.8 Nm
19 14 9
16
49 Nm
11 54 Nm
AB"
AC" AD" AE" AF" AG"
Removal steps Removal 1. Front upper cover 2. Front lower cover 3. Power steering steering pump bracket stay 4. Power steering steering bracket bracket "LA 5. Timing Timing belt "JA 6. Tensioner pulley 7. Tensioner arm "IA 8. Auto tensio tensioner ner 9. Idle pulley 10. Crankshaft Crankshaft position position sensor sensor "HA 11. Oil pump sprocket "GA 12. Crankshaft Crankshaft bolt 13. Cran Crankshaf kshaftt sprocket sprocket 14. Flange 15. Tensioner B "FA 16. Timing belt B "EA 17. Count Counterbal erbalance ance shaft sprocket sprocket
E Mitsubishi Motors Corporation
Aug. 1999
"DA 18. Spacer 19. Crank Crankshaft shaft sprocket sprocket B 20. Crankshaft Crankshaft key 21. Breather Breather hose 22. PCV hose 23. PCV valve 24. PCV valve valve gasket gasket 25. Oil filler cap 26. Rocker cover 27. Rocker Rocker cover gasket "CA 28. Engine support support brack bracket et AJ" "BA 29. Camshaft Camshaft sprocket sprocket bolt 30. Camshaft sprocket sprocket 31. Timing belt rear right cover 32. Timing belt rear left upper cover 33. Timing belt rear left lower cover AH"
PWEE9616-B
Revised
Downloaded from www.Manualslib.com manuals search engine
4G6 4G 6 ENG NGIINE (E- W) - Timing Belt
11A-4-3
REMOVAL REMOV AL SERV SERVICE ICE POINTS AA" TIMING BELT BELT REMOVAL REMOVAL (1) Mark Mark belt belt running running direct direction ion for reinsta reinstallat llation. ion. NOTE (1 (1)) Wate Waterr or oi oill on th the e belt belt sh shor orte ten n it its s life life dr dras asti tica call lly y, so the removed timing belt, sprocket, and tensioner must be free from oil and water. These parts should not be washed. Replace parts if seriously contaminated. (2) If there is oil or water on each part, check check front front case oil seals, camshaft oil seal and water pump for leaks.
AB" TIMING BELT BELT REMOVAL REMOVAL (1 (1)) If the timi timing ng belt is to be reused, reused, chalk chalk an arrow arrow mark on the back surface of the belt so that the belt can be reinst reinstall alled ed in the same same direct direction ion.. (2) Place the exhaust exhaust camshaft sprocket sprocket in a position where where the the timi timing ng mark mark fo forr No. No. 1 cy cyli lind nder er is posi positi tion oned ed about about one tooth before the top dead center of the compression stroke.
Caution D The camshaf camshaftt sprocket sprocket on the exhaust side side can turn turn ve very ry ea easi sily ly beca becaus use e of the the va valv lve e spri spring ng
Timing mark
tension. Use care not to allow your fingers to get caught caug ht by the sprocket sprocket.. (3) Loosen the lock nut of the tensioner pulley, pulley, then remove the timing timing belt. belt.
AC" OIL PUMP SPROCKET SPROCKET REMOV REMOVAL (1 (1)) Remo Remove ve th the e pl plug ug on th the e le left ft si side de of cy cylin linde derr block block.. (2) Insert Insert a screwd screwdriv river er (shank diamete diameterr 8 mm) to block block the counterbalan count erbalance ce shaft. shaft. (3 (3)) Remo Remove ve th the e nut. nut. (4) Remove Remove the oil pump sprock sprocket. et.
E Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
Downloaded from www.Manualslib.com manuals search engine
11A-4-4
4G6 4G 6 ENG NGIINE (E- W) - Timing Belt AD" CRANKSHAFT BOLT LOOSENING (1 (1)) Hold Hold the the dr driv ive e pl plat ate e wi with th the the sp spec ecia iall to tool ol as sh show own. n. (2) Remove Remove the cranks crankshaf haftt bolt. bolt.
AE" CRANKSHAFT SPROCKET REMOVAL REMOVAL (1 (1)) If it is dif diffi ficu cult lt to remov remove e th the e sp spro rock cket et,, use use th the e sp spec ecia iall tool.
AF" TIMI TIMING NG BELT BELT “B” REMOV REMOVAL (1 (1)) Make Make a ma mark rk on th the e back back of th the e ti timi ming ng belt belt in indi dica cati ting ng the direction of rotation so it may be reassembled in the same direction if it is to be reused.
6EN1322
MD998785
E Mitsubishi Motors Corporation
Aug. 1998
NOTE (1) Water Water or oil on the belt shorten shortens s its life drastical drastically ly,, so the removed timing belt, sprocket, and tensioner must be free from oil and water. These parts should not be washed. Replace parts if seriously contaminated. (2) If there is oil or water on each part check check front case oil seals, camshaft oil seal and water pump for leaks.
AG" COUNTERB COUNTERBALANCE ALANCE SHAFT SPROCKET SPROCKET REMOVAL (1) Set the special tool as shown to prevent the counterbalanc counte rbalance e shaft sprocket from turning together. together. (2) Loosen Loosen the bolt bolt and remove remove the sprocket sprocket..
PWEE9616-A
Revised
Downloaded from www.Manualslib.com manuals search engine
4G6 4G 6 ENG NGIINE (E- W) - Timing Belt
11A-4-5
AH" CRANKSHAFT SPROCKET “B” REMOVAL REMOVAL (1 (1)) If it is dif diffi ficu cult lt to remov remove e th the e sp spro rock cket et,, use use th the e sp spec ecia iall tool.
AI" CAMSHAFT SPROCKET BOLT BOLT LOOSENIN LOOSENING G (1) Using the special tools tools shown in the illustration, illustration, lock the camshaft camsh aft sprocket sprocket in position. position. (2) Loosen Loosen the camshaf camshaftt bolt. bolt.
AJ" CAMSHAFT SPROCKET BOLT BOLT LOOSENING LOOSENING (1) Use a wrench wrench to hold the hexagonal hexagonal part of the camshaft, camshaft, and then then remove remove the camsha camshaft ft sprock sprocket et mounti mounting ng bolt. bolt.
INSTALLA INST ALLATION TION SERVICE POINTS "AA CAMSHAFT SPROCKET BOLT BOLT TIGHTENING (1) Using the special tools tools shown in the illustration, illustration, lock the camshaft camsh aft sprocket sprocket in position. position. (2) Tighten Tighten the camshaft camshaft sprocket bolt to the specified torque. torque.
"BA CAMSHAFT SPROCKET BOLT BOLT TIGHTENING (1) Using Using a wre wrench nch,, hold hold the camshaf camshaftt at its hexagon hexagon and tig tighte hten n the bolt bolt to the specif specifica icatio tion. n.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
Downloaded from www.Manualslib.com manuals search engine
11A-4-6
4G6 4G 6 ENG NGIINE (E- W) - Timing Belt "CA ENGINE SUPPORT BRACKET INSTALLA INSTALLATION TION (1) Coat Coat the bolts bolts ill illust ustrat rated ed with with sealant sealant before tig tighte htening ning..
Specified sealant: 3M ATD Part No. 8660 or equivalent
"DA SP SPACER ACER INSTALLATION INSTALLATION (1 (1)) Inst Instal alll the the sp spac acer er wi with th th the e ch cham amfe fere red d end end to towa ward rd th the e oil seal.
Sharp edge
Counterbalance shaft
"EA COUNTERB COUNTERBALANCE ALANCE SHAFT SPROCKET SPROCKET INSTALLATION MD998785
Timing marks (onfront case)
Timing marks
(1) Instal Installl the counte counterbal rbalanc ance e shaft shaft sprock sprocket et and screw screw the bolt. (2) Install Install special tool MD998785 MD998785 as shown in the illustration illustration to lock lock the counte counterbal rbalanc ance e shaft. shaft. (3) Ti Tight ghten en the bolt, bolt, and then remove remove the special special tool. tool.
"FA TIMING BELT BELT “B” INSTALLA INSTALLATION TION (1) Align Align timing timing marks on the cranksha crankshaft ft sprock sprocket et “B” and counterbalanc counte rbalance e shaft sprocket sprocket with the marks on the front case respectively. respectively. (2) Instal Installl the timing timing belt “B” on the cranksha crankshaft ft sprock sprocket et “B” and counterbalance shaft sprocket. There should be no slack on the tension side.
(3) Make Make sure sure that that the relations relationship hip betwee between n the tensio tensioner ner pull pulley ey ce cent nter er an and d th the e bo bolt lt ce cent nter er is as sh show own n in th the e illustration.
Mitsubishi Motors Corporation
Aug. 1998
E Mitsubishi Motors Corporation
Aug. 1998
PWEE9616 A
Downloaded from www.Manualslib.com manuals search engine
Revised
4G6 4G 6 ENG NGIINE (E- W) - Timing Belt
11A-4-7
(4 (4)) Move Move the te tens nsion ioner er “B” in the dir direc ecti tion on of arrow arrow while while lift li fting ing wi with th a fi finge ngerr to give give a su suff ffic icien ientt te tens nsion ion to the te tens nsion ion side of timing belt. In this condition, tighten bolt to secure tens tension ioner er “B”. “B”. When When th the e bolt bolt is ti tight ghten ened, ed, use ca care re to preven pre ventt sh shaft aft from from turnin turning g togeth together er.. If sh shaft aft is turned turned together toge ther,, belt will be overtens overtensione ioned. d.
(5) Check to ensure ensure that timing marks marks on sprockets sprockets and front case are in alignment. (6) Press with index index finger the center center of span on the tension si side de of timi timing ng belt “B”. “B”. The bolt bolt must defl deflec ectt 5 - 7 mm.
"GA CRANKSHAFT BOLT TIGHTENING (1) Using Using the special special tool, tool, hold the flywheel flywheel or drive drive plate. (2) Instal Installl the cranks crankshaft haft pulley pulley in positio position. n.
"HA OIL PUMP SPROCKET INSTALLATION INSTALLATION (1) Insert a Phillips screwdriver screwdriver (shank (shank diameter 8 mm shaft) thro throug ugh h th the e pl plug ug ho hole le on th the e le left ft si side de of th the e cy cyli lind nder er block bloc k to block block the left counterbal counterbalance ance shaft. (2) Instal Installl the oil pump sprocket sprocket.. (3)) Appl (3 Apply y a prop proper er amou amount nt of en engi gine ne oi oill to th the e be bear arin ing g su surf rfac aces es of the nuts. (4) Tighten ighten the nuts nuts to the specif specified ied torque. torque. 6EN0564
"IA AUTO TENSIONER INSTALLA INSTALLATION TION
B
(1) If the aut auto o tensione tensionerr rod is in its fully fully extended extended position, position, reset res et it as fol follow lows. s. (2 (2)) Cl Clam amp p the autoauto-te tens nsion ioner er in the vi vise se wi with th so soft ft ja jaws ws.. (3 (3)) Push Push in the rod little little by little little with the vi vise se until until the set
A
hole A in the rod is aligned with the hole B in the cylinder.
6AE0049
E Mitsubishi Motors Corporation
Aug. 1998
PWEE9616 A
Downloaded from www.Manualslib.com manuals search engine
Revised
11A-4-8
4G6 4G 6 ENG NGIINE (E- W) - Timing Belt (4 (4)) Inse Insert rt a wi wire re (1.4 mm in di diam amet eter er)) int into o th the e se sett holes holes.. (5) Unclam Unclamp p the auto tensio tensioner ner from the vise.
6AE0050
(6 (6)) Inst Instal alll the the auto auto te tens nsio ioner ner to fr front ont ca case se and ti tight ghten en to the specified specified torque. torque.
Caution D Le Leave ave the wire wire instal installed led in the auto tensione tensionerr.
6EN0350
"JA TENSIONE TENSIONER R PULLEY INSTALLA INSTALLATION TION (1) Instal Installl the tensioner tensioner pulley pulley in such such direct direction ion that its two small holes are arranged arranged vertically vertically..
Small holes 6EN1323
"KA TIMING BELT BELT INSTALLA INSTALLATION TION (1) Check that that the timing belt tensioner tensioner and spring have been instal ins talled led in positi position. on. (See (See "JA) (2) Align timing timing mark on camshaft camshaft sprocket with timing timing mark on cylind cylinder er head. head.
(3) Align timing timing mark on crankshaft sprocket sprocket with timing timing mark on front front case. case.
E Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Downloaded from www.Manualslib.com manuals search engine
Revised
4G6 4G 6 ENG NGIINE (E- W) - Timing Belt
11A-4-9
(4) Align the timing timing mark on oil pump sprocket with with its mating mark.
Oil pump sprocket timingmarks
6EN1327
Plug Screwdriver
(5) Remove Remove the plug on cylind cylinder er block and insert insert a Philli Phillips ps sc scre rewd wdriv river er (s (sha hank nk di diam amet eter er 8 mm) mm) th thro rough ugh th the e hole hole (Engine with counterbalanc counterbalance e shafts). shafts). If it can be inserted as deep as 60 mm or more, the timing marks are correctly aligned. If the inserted depth is only 20 - 25 mm, turn the oil pump sprocket one turn and realign timing marks. Then check to ensure that the screwdriver can be inserted 60 mm or more. Keep the sc scre rewd wdriv river er in inse sert rted ed unti untill in inst stall allat atio ion n of ti timi ming ng belt belt is finished.
6EN1026
(6) Instal Ins tall tim ing belt on cranks haft t sprock spr pulley pul ley,l, the camsha camtiming shaft ft sprock spr ocket, et,the andcrankshaf tensio tensioner ner pulley pulocket, leyet, in idler that that order.
(7) Lift Lift up the tens tensione ionerr pulley in the direct direction ion of arrow arrow and tig tighte hten n the center center bolt. bolt. (8 (8)) Chec Check k that that al alll ti timi ming ng mark marks s ar are e line lined d up. up. (9) Remove Remove the screwdr screwdrive iverr insert inserted ed in step (5) and fit the plug. (10)Giv (10 )Give e the cra cranks nkshaf haftt a quarter quarter counte countercl rclock ockwis wise e turn. turn. Then, Then, turn it clockwise until the timing marks are lined up again.
6EN0899
(1 (11)Ins 1)Insta tall ll the the sp spec ecia iall to tools ols,, Sock Socket et Wrenc Wrench h and and Torque orque Wrench, on the tensioner pulley, and loosen the tensioner pulley center bolt.
MD998767
NOTE If the specia speciall tool tool is not availab available, le, use a commer commercia cially lly avail availab able le to torqu rque e wr wren ench ch th that at is ca capa pabl ble e of meas measur urin ing g 0 - 5 Nm.
6EN0900
(12)Torque to 3.5 Nm with the torque wrench. (13)Hol (13 )Holding ding the tensio tensioner ner pulley pulley with with the specia speciall tool tool and torque tor que wrench, wrench, tig tighte hten n the center center bolt to specif specifica icatio tion. n.
E Mitsubishi Motors Corporation
Aug. 1998
Downloaded from www.Manualslib.com manuals search engine
PWEE9616-A
Revised
11A-4-10
4G6 4G 6 ENG NGIINE (E- W) - Timing Belt (14)Aft (14 )After er giving giving two clockw clockwise ise turns turns to the cranks crankshaf haft, t, let it alone alone fo forr appro approx. x. 15 mi minu nute tes. s. Then, Then, make su sure re th that at the auto auto tensio tensioner ner settin setting g wire wire moves moves freely freely.. NOTE If the wire does not move freely, repeat step (10) above untilil it moves unt moves freely freely.. (15)Rem (15 )Remove ove the auto auto tensio tensioner ner settin setting g wire. wire.
(16)Mea (16 )Measur sure e the distan distance ce “A” (betwe (between en the tensio tensioner ner arm and auto auto tensio tensioner ner body). body).
St Stan anda dard rd value value:: 3.8 3.8 - 4.5 4.5 mm
Timing mark
"LA TIMING BELT BELT INSTALLA INSTALLATION TION (1) Place Place the exhaust exhaust side side camsha camshaft ft sprock sprocket et in a positi position on where its timing mark is one tooth offset from the timing mark ma rk on th the e ro rock cker er co cove verr in th the e co count unterc ercloc lockw kwis ise e di dire rect ctio ion. n. NOTE Even if the timing marks on the sprocket and the rocker cover are brought into alignment, the exhaust camshaft is forced back by the valve spring tension. It is stabilized at a position one tooth before the timing mark.
Timing mark
(2) Align the timing timing mark on the intake side side camshaft camshaft sprocket sprocket with that on the rocker cover. NOTE Even if the timing marks on the sprocket and the cover are brought into alignment, the intake camshaft is forced to turn one tooth in the clockwise direction by the valve spring tension and stabilized there.
(3 (3)) Pl Plac ace e the the ti timi ming ng mark mark on th the e cr cran anks kshaf haftt sp spro rock cket et one one tooth this side from the mated timing mark as in the case of the camshaf camshaftt sprock sprocket. et.
E Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Downloaded from www.Manualslib.com manuals search engine
Added
4G6 4G 6 ENG NGIINE (E- W) - Timing Belt
11A-4-11
(4) Align the timing timing mark on oil pump sprocket with with its mating mark.
Oil pump sprocket timingmarks
6EN1327
Plug Screwdriver
(5) Remove Remove the plug on cylind cylinder er block and insert insert a Philli Phillips ps sc scre rewd wdriv river er (s (sha hank nk di diam amet eter er 8 mm) mm) th thro rough ugh th the e hole hole (Engine with counterbalanc counterbalance e shafts). shafts). If it can be inser inserte ted d as deep deep as 60 mm or more, more, th the e timing marks are correctly aligned. If the inserted depth is only 20 - 25 mm, turn the oil pump sprocket one turn and realign timing marks. Then check to ensure that the screwdriver can be inserted 60 mm or more. Keep the sc scre rewd wdriv river er in inse sert rted ed unti untill in inst stall allat atio ion n of ti timi ming ng belt belt is finished.
6EN1026
(6 (6)) Remo Re move ve in th the ea position Phil Philli lips ps where sc scre rewd wdri rive ver r. Pl Plac ace e th the e one oi oill pump pu mp sprocket its timing mark is tooth offset from the mated timing mark in the counterclockwise direction.
Timing mark
6EN1327
(7 (7)) Fi Fitt the the timi timing ng belt belt over over th the e exha exhaus ustt si side de ca cams mshaf haftt sp sproc rocke ket, t, and and se secu cure re it at th the e il illu lust strat rated ed posit positio ion n usin using g a paper paper clip.
(8 (8)) Turn urn the the in inta take ke si side de ca cams mshaf haftt sp spro rock cket et as sh show own n to a positi pos ition on where where its timing timing mark mark is one tooth off offset set from the mated timing mark in the counterclockwise direction. Then Th en,, fit fit th the e ti timi ming ng belt belt over over th the e sp spro rock cket et and se secu cure re it with a paper clip. NOTE The intake camshaft will be turned a little clockwise by the valve spring tension and stabilized in position even if the belt is cli clipped pped at one tooth offset offset positi position. on.
E Mitsubishi Motors Corporation
Aug. 1998
Downloaded from www.Manualslib.com manuals search engine
PWEE9616-A
Added
11A-4-12
4G6 4G 6 ENG NGIINE (E- W) - Timing Belt (9 (9)) Chec Check k to ensu ensure re th that at th the e ti timi ming ng mark marks s on th the e int intak ake e camshaft sprocket side are in alignment when the exhaust camshaft sprocket is turned clockwise to align the timing marks.
17 cogs
NOTE The Th e timi timing ng belt belt sp span an betwe between en th the e in inta take ke and and exhau exhaust st sprock spr ockets ets will will have have 17 cogs. cogs.
Timing mark
(10)Fit the timing belt over the idler pulley, oil pump sprocket and cranks crankshaf haftt sprock sprocket et in thi this s order order. NOTE Be careful that the belt does not become slack.
Crankshaft sprocket
Oil pump sprocket
(1 (11)Fit 1)Fit the timing timing belt over the tensione tensionerr pulley pulley.. NOTE When Wh en fitt fittin ing g th the e ti timi ming ng belt belt over over th the e te tens nsion ioner er pulle pulley y, turn the intake side camshaft sprocket a little countercloc count erclockwise kwise,, as this will facilitate facilitate the work.
Crankshaft sprocket
MD998767
(12)Turn the crankshaft pulley a little in the illustrated direction to pull up the timing belt at the idler pulley side. (13)Check to ensure that the timing marks on the crankshaft sp spro rock cket et,, oi oill pu pump mp sp spro rock cket et an and d ex exha haus ustt ca cams msha haft ft sprocket are all offset one tooth from the corresponding timing timin g marks in the counterclock counterclockwise wise direction.
(14)Usi (14 )Using ng the specia speciall tool, tool, turn turn the tensioner tensioner pulley pulley in the illustrated direction to strain the timing belt. Then, secure the tensioner temporarily by tightening the retaining bolt lightly. NOTE There must be no slack in the timing belt between the intake and exhaust camshafts. camshafts. (15)Turn the crankshaft to align the timing mark with the mark for for No. No. 1 cy cyli linde nderr to top p dead dead ce cent nter er in th the e co comp mpre ress ssio ion n stroke.
E Mitsubishi Motors Corporation
Aug. 1998
Downloaded from www.Manualslib.com manuals search engine
PWEE9616-A
Added
4G6 4G 6 ENG NGIINE (E- W) - Timing Belt
MD998738
11A-4-13
(16)Set the special tool as shown and screw it in up to the positi pos ition on where where the wire wire insert inserted ed in the auto-t auto-tens ensione ionerr when whe n ins instal talling ling it can be moved moved lig lightl htly y.
(17)Loo (17 )Loosen sen the retain retaining ing bolt bolt of the tensio tensioner ner pulley pulley..
Caution D Loosening the the retaining bolt can cause cause the intake and an d ex exha haus ustt ca cams msha haft fts s to tu turn rn,, resu result ltin ing g in slack sla ckene ened d timing timing belt. belt. Use care that that the timing timing belt does not come off the sprockets at this time.
MD998767
(18)Pull up the slack of the timing belt by turning turning the tensioner tensioner in illustrated direction using the special tool and a torque wren wrench ch (0 - 5 Nm). Nm). (19)From this position, turn back the tensioner until the torque wren wrench ch re read adin ing g be beco come mes s 3. 3.5 5 Nm, Nm, th then en se secu cure re it by tightening tight ening the retaining retaining bolt. (20)Rem (20 )Remove ove the specia speciall tool tool att attach ached ed in step step (16). (16). (21)Rot (21 )Rotate ate the cranks crankshaf haftt clockw clockwise ise 2 turns. turns. Then, Then, leave leave it intact intact 15 minute minutes. s. (22)Check to see that the wire inserted when installing the auto-tensioner can be pulled out lightly. If it can be pulled out lightl lightly y, the timing timing belt belt is being being tensio tensioned ned properl properly y. If so so,, re remo move ve th the e wi wire re.. In addit additio ion, n, ch chec eck k th that at th the e ro rod d protru pro trusio sion n from from the auto-t auto-tens ension ioner er meets meets the standa standard rd value, which is also an indication of properly tensioned timing timin g belt.
St Stan anda dard rd value value:: 3.8 3.8 - 4.5 4.5 mm (23)If the wire cannot be removed with a light force, repeat steps ste ps (16) (16) through through (21) until until the proper proper belt belt tensio tensioner ner is obtaine obtained. d.
INSPECTION TIMING BELT BELT Replac Rep lace e belt if any of the fol follow lowing ing condit condition ions s exist. exist. (1) Hardeni Hardening ng of back back rubber rubber.. Back is glossy withou t resilience resilience and leaves no indent indent when side pressed withwithout fingernail.
E Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Downloaded from www.Manualslib.com manuals search engine
Added
11A-4-14
4G6 4G 6 ENG NGIINE (E- W) - Timing Belt (2) (3) (4 (4)) (5)
Cracks Cracks Cracks Cracks Cr Crac acks ks Cracks Cracks
on rubber rubber back. or peeling peeling of canvas canvas.. on ri rib b ro root ot.. on belt belt sides. sides.
(6 (6)) Abnor Abnorma mall wear wear of belt belt si side des. s. The The si side des s ar are e norm normal al if they are sharp as if cut by a knife.
(7) Missin Abnorma Abnsing ormal l wear wea (8) Mis g tooth. too th. r on teeth.
12 mm
AUTO TENSIONER TENSIONER (1) Check Check the auto auto tensio tensioner ner for possible possible leaks and replace replace as necessary. necessary. (2 (2)) Chec Check k the the ro rod d end end fo forr wear wear or dama damage ge and re repl plac ace e as necessary. (3) Measur Measure e the rod protrus protrusion. ion. If it is out of specif specifica icatio tion, n, replace replac e the auto tensioner. tensioner. Standard value: 12 mm
6EN0161
98 to 196 N
Movement
6EN1033
(4 (4)) Pres Press s the rod wi with th a fo forc rce e of 98 to 196 N and meas measure ure its protru protrusion. sion. (5) If the measured measured value value is 1 mm or more shorter shorter than the value val ue obtaine obtained d in step step (3), (3), replac replace e the auto auto tensio tensioner ner..
E Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Downloaded from www.Manualslib.com manuals search engine
Added
4G6 4G 6 EN ENGI GIN NE (E- W) - Exha Exhaust ust Mani Manifold fold (GDI)
11A-4a-1
4a. EXHAUST MANIFOLD (GDI) REMOVAL REMOV AL AND INST INSTALLA ALLATION TION
11 Nm
29 Nm
5 4
49 Nm
29 Nm
3
13 Nm
49 Nm 13 Nm
2
Removal steps Removal 1. Exhaust Exhaust manifold manifold 2. Exhaust manifold 3. Exhaust Exhaust manifold manifold 4. Exhaust manifold 5. Engine hanger hanger
cover (Veh (Vehicle icle for Europe) Europe) (Vehicl (Vehicle e for Europ Europe) e) (Vehicl (Vehicle e for Hong Kong) gaske gaskett
1
E Mitsubishi Motors Corporation
Aug. 1998
Downloaded from www.Manualslib.com manuals search engine
PWEE9616-A
Added
4G6 4G 6 EN ENGI GIN NE (E- W) - Fuel and Emis Emission sion Contro Controll Part Parts s
5. FUEL AND EMISSION CONTROL PARTS REMOVAL REMOV AL AND INST INSTALLA ALLATION TION
17 Nm
5
22 Nm
2 6
23 Nm
4
7 8
1 3
Removal steps Removal 1. Fuel hose 2. Fuel hose 3. Fuel vapor separato separatorr 4. Water hose 5. Carburetor 6. Gasket 7. EGR valve (For GCC) 8. Gasket Gasket (For GCC)
11A-5-1
E Mitsubishi Motors Corporation
Dec. 1996
Downloaded from www.Manualslib.com manuals search engine
PWEE9616
11A-5-2
4G6 4G 6 EN ENGI GIN NE (E- W) - Fuel and Emis Emission sion Contro Controll Part Parts s
REMOVAL REMOV AL AND INST INSTALLA ALLATION TION
View more...
Comments
