Workshop Manual L200
11A-2
ENGINE <4G6>
CONTENTS
11109000399
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3
Lash Adjuster Check . . . . . . . . . . . . . . . . . . . . . . . . 14
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 3
CAMSHAFT OIL SEAL . . . . . . . . . . . . . . . . . . . . 16
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OIL PAN, OIL SCREEN . . . . . . . . . . . . . . . . . . . . 19
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . 21
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 7
TIMING BELT, TIMING BELT B . . . . . . . . . . . . 26
Drive Belt Tension Check and Adjustment . . . . . 7
Ignition Timing Check and Adjustment . . . . . . . 10
Idle Speed Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Idle Mixture Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Compression Pressure Check . . . . . . . . . . . . . . . . 12
Manifold Vacuum Check . . . . . . . . . . . . . . . . . . . . . 13
CRANKSHAFT FRONT OIL SEAL . . . . . . . . . . 32
CRANKSHAFT REAR OIL SEAL . . . . . . . . . . . 35
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 37
ENGINE <4G6> – General Information/Service Specifications
GENERAL INFORMATION
11A-3
11100010322
Items
4G63
4G64
Total displacement m
1,997
2,351
Bore × Stroke mm
85.0 x 88.0
86.5 x 100.0
Compression ratio
9.5
9.5
Combustion chamber
Pentroof type
Pentroof type
Camshaft arrangement
SOHC
SOHC
Intake
8
8
Exhaust
8
8
Opening
BTDC 11_
BTDC 18_
Closing
ABDC 53_
ABDC 58_
Opening
BBDC 63_
BBDC 58_
Closing
ATDC 21_
ATDC 18_
Fuel system
Electronic control
multipoint fuel
injection
Electronic control
multipoint fuel
injection
Rocker arm
Roller type
Roller type
Auto-lash adjuster
Equipped
Equipped
Number of valve
Intake
Valve timing
Exhaust
SERVICE SPECIFICATIONS
Items
Alternator drive
belt
tension
Tension N
Deflection
(Reference
value) mm
Power steering
oil pump
um drive
belt tension
Tension N
Deflection
(Reference
value) mm
11100030342
Standard value
Limit
When checked
294 – 490
–
When a used belt is installed
343 – 441
–
When a new belt is installed
490 – 686
–
When checked
7.0 – 9.0
–
When a used belt is installed
7.5 – 8.5
–
When a new belt is installed
5.5 – 7.5
–
When checked
294 – 490
–
When a used belt is installed
343 – 441
–
When a new belt is installed
490 – 686
–
When checked
5.5 – 7.5
–
When a used belt is installed
6.0 – 7.0
–
When a new belt is installed
4.0 – 6.0
–
11A-4
ENGINE <4G6> – Service Specifications
Items
Standard value
Limit
When checked
355 – 445
–
When a used belt is installed
355 – 445
–
When a new belt is installed
530 – 620
–
When checked
6.0 – 7.0
–
When a used belt is installed
6.0 – 7.0
–
When a new belt is installed
4.5 – 5.5
–
Basic ignition timing
5_ BTDC ± 2_
–
Idle speed r/min
750 ± 100
–
CO contents %
0.5 or less
–
HC contents ppm
100 or less
–
4G63
1,270
min. 960
4G64
1,320
min. 1,000
Compression pressure difference of all cylinder kPa
–
max. 100
Intake manifold vacuum kPa
min. 60
–
Cylinder head bolt shank length mm
–
99.4
Auto-tensioner push rod movement mm
Within 1.0
–
Timing belt tension torque Nm (Reference value)
3.5
–
Auto tensioner rod protrusion mm
2.5 – 3.0
–
A/C compressor drive belt
tension
Tension N
Deflection
(Reference
value) mm
Compression pressure
(250 – 400 r/min) kPa
ENGINE <4G6> – Sealant/Special Tools
SEALANT
11100050218
Item
Specified sealant
Oil pan
MITSUBISHI
GENUINE
MD970389 or equivalent
Remark
PART
Semi-drying sealant
SPECIAL TOOLS
Tool
11A-5
11100060310
Number
Name
MB991502
MUT-II
sembly
MD998738
MB990767
MD998719
MD998754
or
Use
D
D
Checking the idle speed
Erasing of diagnosis code
Adjusting screw
D
D
Holding the auto tensioner
Timing belt tension adjustment
End yoke holder
Holding the camshaft sprocket
sub
as-
Crankshaft pulley
holder pin
MD998713
Camshaft oil seal
installer
Press-in of the camshaft oil seal
MD998727
Oil pan remover
Removal of the oil pan
MD998781
Fly wheel stopper
Securing the flywheel <M/T> or drive plate
<A/T>
11A-6
Tool
ENGINE <4G6> – Special Tools
Number
Name
Use
MD998776
Crankshaft rear oil
seal installer
Press-fitting the crankshaft rear oil seal
MB990938
Handle
Press-fitting the crankshaft rear oil seal
MD998747
Crankshaft pulley
holder
Supporting of crankshaft sprocket
MD998375
Crankshaft front oil
seal installer
Press-fitting the crankshaft front oil seal
MD998767
Tension pulley
socket wrench
Timing belt tension adjustment
11A-7
ENGINE <4G6> – On-vehicle Service
ON-VEHICLE SERVICE
Tension gauge
11100090326
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. In addition, press this
section with a force of 98 N and check that the amount of
belt deflection is at the standard value.
Standard value:
98 N
Alternator
pulley
Crankshaft pulley
Water
pump
pulley
Tension N
294 – 490
Deflection (Reference value) mm
7.0 – 9.0
ALTERNATOR DRIVE BELT TENSION ADJUSTMENT
1. Loosen the nut of the alternator pivot bolt.
2. Loosen the lock bolt.
3. Use the adjusting bolt to adjust the belt tension and belt
deflection to the standard values.
Standard value:
Items
When a used
belt is installed
When a new
belt is installed
Tension N
343 – 441
490 – 686
Deflection (Reference 7.5 – 8.5
value) mm
5.5 – 7.5
4. Tighten the nut of the alternator pivot bolt.
Adjusting
bolt
Lock bolt
Tightening torque: 22 Nm
5. Tighten the lock bolt.
Tightening torque: 22 Nm
6. Tighten the adjusting bolt.
Tightening torque: 9.8 Nm
11A-8
ENGINE <4G6> – On-vehicle Service
Power
steering
oil pump
pulley
98 N
Deflection
Water pump
pulley
Crankshaft
pulley
Standard value:
A
B
POWER STEERING OIL PUMP DRIVE BELT TENSION
CHECK AND ADJUSTMENT
11100110145
1. Use a belt tention 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).
In addition, press this section with a force of 98 N and
check that the amount of belt deflection is at the standard
value.
Items
When
checked
When a
used belt is
intalled
When a new
belt is
installed
Tension N
294 – 490
343 – 441
490 – 686
Deflection
(Reference
value) mm
5.5 – 7.5
6.0 – 7.0
4.0 – 6.0
2. If the tension or deflection is outside the standard value,
adjust by the following procedure.
(1) Loosen power steering oil pump fixing bolts A and
B.
(2) Move power steering oil pump tension belt moderately
and adjust tension.
(3) Tighten fixing bolts A and B.
Tightening torque: 22 Nm
(4) Check the belt deflection amount and tension, and
readjust if necessary.
Caution
Check after turning the crankshaft once or more
clockwise (right turn).
11A-9
ENGINE <4G6> – On-vehicle Service
Tension pulley
Crankshaft
pulley
98 N
Deflection
Standard value:
A/C compressor pulley
Tension pulley
Crankshaft
pulley
AIR CONDITIONER COMPRESSOR DRIVE BELT
TENSION CHECK AND ADJUSTMENT
11100100135
1. Use a belt tention 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).
In addition, press this section with a force of 98 N and
check that the amount of belt deflection is at the standard
value.
Adjusting bolt
Fixing nut
A/C compressor
pulley
Items
When
checked
When a
used belt is
intalled
When a new
belt is
installed
Tension N
355 – 445
355 – 445
530 – 620
Deflection
(Reference
value) mm
6.0 – 7.0
6.0 – 7.0
4.5 – 5.5
2. If the tension or deflection is outside the standard value,
adjust by the following procedure.
(1) Loosen tension pulley fixing nut.
(2) Adjust belt tension with adjusting bolt.
(3) Tighten fixing nut.
(4) Check the belt deflection amount and tension, and
readjust if necessary.
Caution
Check after turning the crankshaft once or more
clockwise (right turn).
11A-10
ENGINE <4G6> – On-vehicle Service
IGNITION TIMING CHECK AND ADJUSTMENT
11100170167
1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Insert a paper clip into the noise filter connector (1 pin)
as shown in the illustration at left.
3. Connect a primary-voltage-detection type of tachometer
to the paper clip.
Noise filter
connector
NOTE
Do not use the MUT-II.
If tested with the MUT-II connected to the diagnosis
connector, the ignition timing will not be the basic timing
but be ordinary timing.
4. Set up a timing light.
5. Start the engine and run at idle.
6. Check that engine idle speed is within the standard value.
Standard value: 750 ± 100 r/min
Ignition timing adjustment
connector (brown)
7. Turn the ignition switch to OFF.
8. Remove the waterproof connector from the ignition timing
adjustment connector (brown).
9. Connect the jumper wire with the clip to the ignition timing
adjustment terminal, and earth this to the body as
illustrated.
NOTE
Earthing this terminal sets the engine to the basic ignition
timing.
Jumper wire
10. Start the engine and run it at idle.
To retard
11. Check that basic ignition timing is within the standard
value.
Standard value: 5_ BTDC±2_
12. If not within the standard value, loosen distributor fixing
bolts and adjust by rotating distributor body.
13. Tighten mounting bolts after adjusting.
To advance
Tightening torque: 12 Nm
14. Stop the engine, remove the jumper wire from the ignition
timing adjustment connector (brown), and return the
connector to its original condition.
15. Start the engine and check that ignition timing at the
standard value.
Standard value: Approx. 10_ BTDC
NOTE
1. Ignition timing is variable within about ± 7_, even
under normal operating.
2. And it is automatically further advanced by about
5_ from 10_ BTDC at higher altitudes.
ENGINE <4G6> – On-vehicle Service
11A-11
16. Attach a sealing tape to the fixing bolt and nut only for
vehicles for Switzerland.
NOTE
Sealing tape is attached to all new vehicles.
IDLE SPEED CHECK
11100190330
1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Check the basic ignition timing. Adjust if necessary.
Standard value: 5_ BTDC±2_
3. After turning the ignition switch to OFF, connect the MUT-II
to the diagnosis connector.
4. Start the engine and run it at idle.
5. Run the engine at idle for 2 minutes.
6. Check the idle speed.
Curb idle speed: 750±100 r/min
NOTE
The idle speed is controlled automatically by the idle speed
control (ISC) system.
7. If the idle speed is outside the standard value, inspect
the MPI components by referring to GROUP 13A –
Troubleshooting.
IDLE MIXTURE CHECK
11100210265
1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Check that the basic ignition timing is within the standard
value.
Standard value: 5_ BTDC±2_
3. Turn the ignition switch to OFF and connect the MUT-II
to the diagnosis connector.
4. Start the engine and run it at 2,500 r/min for 2 minutes.
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. If there is a deviation from the standard value, check
the following items:
D Diagnosis output
D Closed-loop control (When the closed-loop control
is normal, the output signal of the oxygen sensor
changes between 0–400 mV and 600–1,000 mV
at idle.)
11A-12
ENGINE <4G6> – On-vehicle Service
D
D
D
D
D
D
Fuel pressure
Injector
Ignition coil, spark plug cable, spark plug
Leak in the EGR system and in the EGR valve
Evaporative emission control system
Compression pressure
NOTE
Replace the three way catalyst when the CO and HC
contents are not within the standard value, even though
the result of the inspection is normal on all items.
Distributor 4
pin connector
COMPRESSION PRESSURE CHECK
11100260352
1. Before inspection, check that the engine oil, starter and
battery are normal. In addition, set the vehicle to the
pre-inspection condition.
2. Disconnect the spark plug cables.
3. Remove all of the spark plugs.
4. Disconnect the distributor connector.
NOTE
Doing this will prevent the engine-ECU from carrying out
ignition and fuel injection.
5. Cover the spark plug hole with a shop towel etc., and
after the engine has been cranked, check that no foreign
material is adhering to the shop towel.
Compression gauge
Caution
1. Keep away from the spark plug hole when
cranking.
2. If compression is measured with water, oil, fuel,
etc., that has come from cracks inside the cylinder,
these materials will become heated and will gush
out from the spark plug hole, which is dangerous.
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):
4G63: 1,270 kPa
4G64: 1,320 kPa
Limit (at engine speed of 250–400 r/min):
4G63: min. 960 kPa
4G64: min. 1,000 kPa
ENGINE <4G6> – On-vehicle Service
11A-13
8. Measure the compression pressure for all the cylinders,
and check that the pressure differences of the cylinders
are below the limit.
Limit: max. 100 kPa
9. If there is a cylinder with compression or a compression
difference that is outside the limit, pour a small amount
of engine oil through the spark plug hole, and repeat
the operations in steps (7) and (8).
(1) If the compression increases after oil is added, the
cause of the malfunction is a worn or damaged piston
ring and/or cylinder inner surface.
(2) If the compression does not rise after oil is added,
the cause is a burnt or defective valve seat, or pressure
is leaking from the gasket.
10. Connect the distributor connector.
11. Install the spark plugs and spark plug cables.
12. Use the MUT-II to erase the diagnosis codes.
NOTE
This will erase the problem code resulting from the
distributor connector being disconnected.
Vacuum gauge
MANIFOLD VACUUM CHECK
11100270270
1. Start the engine and allow it to warm up until the
temperature of the engine coolant reaches 80 to 95_C.
2. Connect a tachometer.
3. Attach a three-way union to the vacuum hose between
the fuel pressure regulator and the air intake plenum,
and connect a vacuum gauge.
4. Start the engine and check that idle speed is within
specification. Then read off the vacuum gauge.
Standard value: min. 60 kPa
11A-14
ENGINE <4G6> – On-vehicle Service
LASH ADJUSTER CHECK
Good
MAX
MIN
11100290214
NOTE
Soon after the engine is started or while it is running, abnormal
noise (clattering) which may be attributed to the adjuster
sounds but does not stop. In this case, check the following.
1. Check the engine oil, and refil or replace oil if necessary.
NOTE
1. If the oil amount is small, air will be sucked from
the oil strainer and mixed in the oil passage.
2. If the oil amount is excessive, the oil will be stirred
by the crank and mixed with a large amount of air.
3. Air and oil can not be separated easily in the
deteriorated oil, and the amount of air mixed in the
oil increases.
High
pressure
chamber
If such mixed-in air enters the high pressure chamber
in the lash adjuster, the air in the high-pressure chamber
will be compressed while the valve is opened, the lash
adjuster will be excessively compressed and abnormal
noise will be produced when the valve is closed.
This is the same phenomenon which occurs when the
valve clearance is improperly adjusted to be excessively
large.
However, it will return to be normal if the air entrapped
in the adjuster is released in this case.
2. Start the engine, and slowly race* it several times (10
times or less).
If the abnormal noise is eliminated by racing the engine,
it means that the air is released from the high-pressure
chamber of the lash adjuster and the function of the lash
adjuster is returned to normal.
* Gradually increase the engine speed from the idle
speed to 3,000 r/min (for 30 seconds), and then
gradually slow down the engine to the idling speed
(for 30 seconds).
NOTE
1. If the vehicle is parked on a slope for a long time,
the oill will be sometimes reduced in the lash adjuster,
and air will enter the high-pressure chamber when
the engine is started.
2. After the vehicle is parked for a long time, the oil
will go out of the oil passage. Since it takes a little
time to supply oil to the lash adjuster, air sometimes
enters the high-pressure chamber.
ENGINE <4G6> – On-vehicle Service
Exhaust valve side
Intake valve side
11A-15
3. If any abnormal noise is not eliminated by racing, check
the lash adjuster.
(1) Stop the engine.
(2) Set the engine so that cylinder No. 1 is positioned
at the top dead centre of the compression.
(3) Press the rocker arm at the area indicated by the
white arrow mark to check whether the rocker arm
is lowered or not.
(4) Slowly turn the crankshaft 360 degrees clockwise.
(5) In the same procedure as step (3), check the rocker
arm at the area indicated by the black arrow mark.
(6) If the rocker arm is easily lowered when the section
directly above the lash adjuster of the rocker arm
is pressed, the lash adjuster is defective, so replace
it.
Moreover, if it is felt to be so hard that the rocker
arm is not lowered when it is pressed, the lash adjuster
is normal. Check for other causes of the abnormality.
For Y-formed rocker arm at the exhaust valve side,
if one lash adjuster is defective and the other is normal,
it is impossible to press the rocker arm. In this case,
remove the lash adjuster and carry out the leak down
test.
NOTE
1. A leak down test can be performed to accurately
determine whether the lash adjuster is defective or
not.
2. For the procedures for the leak down test and air
bleeding of the lash adjuster, refer to the Engine
Workshop Manual.
11A-16
ENGINE <4G6> – Camshaft Oil Seal
CAMSHAFT OIL SEAL
11200190272
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Distributor Removal and Installation
10 – 12 Nm
6
Lip
5
6
2
10 Nm
Engine oil
88 Nm
4
3
24 Nm
10 – 12 Nm
1
Removal steps
1. Ignition coil
2. Timing belt upper cover assembly
3. Distributor bracket
"CA 4. Camshaft sprocket spacer
AA" "BA 5. Camshaft sprocket
AB" "AA 6. Camshaft oil seal
REMOVAL SERVICE POINTS
AA" CAMSHAFT SPROCKET REMOVAL
1. Rotate the crankshaft in the forward (right) direction and
align the timing mark.
Timing mark
Camshaft
sprocket
Timing
mark
Cord
Camshaft
sprocket
Timing belt lower cover
Caution
The crankshaft must always be rotated in the forward
direction only.
2. Tie the camshaft sprocket and timing belt with a cord
so that the position of the camshaft sprocket will not move
with respect to the timing belt.
ENGINE <4G6> – Camshaft Oil Seal
11A-17
3. Insert the special tool into the rubber plug hole in the
timing belt cover assembly rear and turn it gently. Stop
turning the special tool when it can no longer be turned
gently.
MD998738
NOTE
This work will make the end of the special tool touch
the tensioner arm. So the auto tensioner will stop and
the timing belt tension will not vary.
4. Use the special tool to remove the camshaft sprocket
with the timing belt attached.
Caution
After removing the camshaft sprocket, be sure not
to rotate the crankshaft.
MB990767
MD998719 or
MD998754
Camshaft
sprocket
Oil seal
Lip
section
(–) screwdriver
AB" CAMSHAFT OIL SEAL REMOVAL
1. Make a notch in the oil seal lip section with a knife, etc.
2. Cover the end of a (–) screwdriver with a rag and insert
into the notched section of the oil seal, and lever out
the oil seal to remove it.
Caution
Be careful not to damage the camshaft and the cylinder
head.
Camshaft
Lip
MD998713
INSTALLATION SERVICE POINTS
"AA 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.
"BA CAMSHAFT SPROCKET INSTALLATION
1. Use the special tool to stop the camshaft sprocket from
turning, and then install the camshaft sprocket bolt.
2. Remove the special tool from the rubber plug hole.
3. Remove the cord which binds the camshaft sprocket and
timing belt.
MB990767
MD998719 or
MD998754
Camshaft
sprocket
11A-18
ENGINE <4G6> – Camshaft Oil Seal
"CA CAMSHAFT SPROCKET SPACER INSTALLATION
Align the mating marks on the camshaft sprocket and the
camshaft sprocket spacer (groove), and then install them.
Mating marks
11A-19
ENGINE <4G6> – Oil Pan, Oil Screen
OIL PAN AND OIL SCREEN
11200250185
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Under Cover Removal and Installation
D Engine Oil Draining and Refilling
(Refer to GROUP 12 – On-vehicle Service.)
4
Front of
engine
4.0 mm
Groove
Bolt
hole
3
6
Sealant:
MITSUBISHI GENUINE PART No.
MD970389 or equivalent
5 <4G63>
5 <4G64>
10 – 12 Nm
1
9 Nm
18 Nm
7 Nm
39 Nm
Removal steps
1. Drain plug
"BA 2. Drain plug gasket
3. Bell housing cover
2
4
AA" "AA 4. Oil pan
5. Oil screen
6. Gasket
11A-20
MD998727
ENGINE <4G6> – Oil Pan, Oil Screen
MD998727
REMOVAL SERVICE POINT
AA" OIL PAN REMOVAL
After removing the oil pan mounting bolts, remove the oil
pan with the special tool and a brass bar.
Caution
Perform this slowly to avoid deformation of the oil pan
flange.
INSTALLATION SERVICE POINTS
"AA OIL PAN INSTALLATION
1. Remove sealant from oil pan and cylinder block mating
surfaces.
2. Degrease the sealant-coated surface and the engine
mating surface.
3. Apply the specified sealant around the gasket surface
of oil pan.
Specified sealant: MITSUBISHI GENUINE PART No.
MD970389 or equivalent
NOTE
The sealant should be applied in a continuous bead
approximately 4 mm in diameter.
Front
4. Assemble oil pan to cylinder block within 15 minutes after
applying the sealant.
Caution
After installing the oil pan, wait at least 1 hour before
starting the engine.
M6 x 8
Be careful when installing, as the bolts indicated in the
illustration have different lengths from the other bolts.
"BA DRAIN PLUG GASKET INSTALLATION
Install the drain plug gasket in the direction so that it faces
as shown in the illustration.
Oil pan side
Drain plug
gasket
INSPECTION
D
D
D
11200260041
Check oil pan for cracks.
Check oil pan sealant-coated surface for damage and
deformation.
Check oil screen for cracked, clogged or damaged wire
net and pipe.
11A-21
ENGINE <4G6> – Cylinder Head Gasket
CYLINDER HEAD GASKET
11200400351
REMOVAL AND INSTALLATION
Pre-removal Operation
D Engine Coolant Draining
(Refer to GROUP 14 – On-vehicle Service.)
D Fuel Line Pressure Releasing
(Refer to GROUP 13A – On-vehicle Service.)
D Battery Removal
D Air Cleaner Assembly Removal
(Refer to GROUP 15.)
D Distributor Removal
Post-installation Operation
D Distributor installation
D Air Cleaner Assembly installation
(Refer to GROUP 15.)
D Battery Installation
D Engine Coolant Refilling
(Refer to GROUP 14 – On-vehicle Service.)
D Accelerator Cable Adjustment
(Refer to GROUP 17 – On-vehicle Service.)
D Throttle Cable Adjustment
(Refer to GROUP 23 – On-vehicle Service.)
14
1
12 Nm
13
5 Nm
12
10
19
2
16 Nm
8
6
3
17
20
9
7
11
4
18
16
50 Nm
5
15
17
Removal steps
1. Accelerator cable connection
2. Throttle cable connection <A/T>
3. Brake booster vacuum hose connection
4. Ignition coil connector
5. Engine coolant temperature sensor
connector
6. Noise filter connector
7. Power transistor connector
8. Injector connectors
9. Capacitor connector
10. Throttle position sensor connector
11. Idle speed control servo connector
12. Engine coolant temperature gauge
unit connector
13. Engine coolant temperature switch
connector <A/T>
14. Spark plug cable
15. Vacuum hose connection
16. Radiator upper hose connection
17. Water hose connections
18. Fuel return hose connection
19. High-pressure fuel hose connection
20. Front exhaust pipe connection
11A-22
ENGINE <4G6> – Cylinder Head Gasket
2.9 – 3.4 Nm
27
<Cold engine>
78 Nm 0 Nm 20 Nm
+90_ +90_
22 Nm
29
21
10 – 12 Nm
26
10 Nm
25
30
23
88 Nm
24 Nm
24
28
22
10 – 12 Nm
12 – 15 Nm
21. Power steering pump mount
bracket
22. Ignition coil
23. Timing belt upper cover assembly
24. Distributor bracket
"DA 25. Camshaft sprocket spacer
AA" "CA 26.
27.
28.
AB" "BA 29.
"AA 30.
Camshaft sprocket
Rocker cover
Intake manifold stay
Cylinder head assembly
Cylinder head gasket
ENGINE <4G6> – Cylinder Head Gasket
11A-23
REMOVAL SERVICE POINTS
AA" CAMSHAFT SPROCKET REMOVAL
1. Rotate the crankshaft in the forward (right) direction and
align the timing mark.
Timing mark
Camshaft
sprocket
Timing
mark
Caution
The crankshaft must always be rotated in the forward
direction only.
2. Tie the camshaft sprocket and timing belt with a cord
so that the position of the camshaft sprocket will not move
with respect to the timing belt.
Cord
Camshaft
sprocket
Timing belt lower cover
3. Insert the special tool into the rubber plug hole in the
timing belt cover assembly rear and turn it gently. Stop
turning the special tool when it can no longer be turned
gently.
MD998738
NOTE
This work will make the end of the special tool touch
the tensioner arm. So the auto tensioner will stop and
the timing belt tension will not vary.
4. Use the special tool to remove the camshaft sprocket
with the timing belt attached.
Caution
After removing the camshaft sprocket, be sure not
to rotate the crankshaft.
MB990767
MD998719 or
MD998754
Camshaft
sprocket
Intake side Front of engine
4
2
Exhaust side
6
9
7
8
10
5
1
3
AB" CYLINDER HEAD ASSEMBLY REMOVAL
Loosen the bolts in 2 or 3 steps in order of the numbers
shown in the illustration, and remove the cylinder head
assembly.
Caution
Because the plug guides cannot be replaced by
themselves, be careful not to damage or deform the plug
guides when removing the cylinder head bolts.
11A-24
ENGINE <4G6> – Cylinder Head Gasket
INSTALLATION SERVICE POINTS
Identification mark
"AA CYLINDER HEAD GASKET INSTALLATION
1. Wipe off all oil and grease from the gasket mounting
surface.
2. Install the gasket to the cylinder block with the identification
mark facing upwards.
"BA CYLINDER HEAD ASSEMBLY INSTALLATION
1. When installing the cylinder head bolts, the length below
the head of the bolts should be within the limit.
If it is outside the limit, replace the bolts.
(Engine oil)
Limit (A): 99.4 mm
2. Apply a small amount of engine oil to the thread section
and the washer of the cylinder head bolt.
3. Tighten the bolts by the following procedure.
Intake side Front of engine
Step
4
2
6
9
7
8
10
5
1
3
Operation
Remarks
1
Tighten to 78 Nm.
Carry out in the order
shown in the illustration.
2
Fully loosen.
Carry out in the reverse
order of that shown in the
illustration.
3
Tighten to 20 Nm.
Carry out in the order
shown in the illustration.
4
Tighten 90_ of a turn.
In the order shown in the
illustration. Mark the head
of the cylinder head bolt
and cylinder head by paint.
5
Tighten 90_ of a turn.
In the order shown in the
illustration. Check that the
painted mark of the head
bolt is lined up with that of
the cylinder head.
Exhaust side
Step 4
90_
Painted mark
Step 5
90_
Painted mark
Caution
1. Always make a tightening angle just 90_. If it is less
than 90_, the head bolt will be loosened.
2. If it is more than 90_, remove the head bolt and repeat
the procedure from step 1.
ENGINE <4G6> – Cylinder Head Gasket
11A-25
"CA CAMSHAFT SPROCKET INSTALLATION
1. Use the special tool to stop the camshaft sprocket from
turning, and then install the camshaft sprocket bolt.
2. Remove the special tool from the rubber plug hole.
3. Remove the cord which binds the camshaft sprocket and
timing belt.
MB990767
MD998719 or
MD998754
Camshaft
sprocket
"DA CAMSHAFT SPROCKET SPACER INSTALLATION
Align the mating marks on the camshaft sprocket and the
camshaft sprocket spacer (groove), and then install them.
Mating marks
11A-26
ENGINE <4G6> – Timing Belt, Timing Belt B
TIMING BELT, TIMING BELT B
11200430336
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Engine Coolant Draining and Refilling
(Refer to GROUP 14 – On-vehicle Service.)
D Cooling Fan Removal and Installation
(Refer to GROUP 14.)
D Distributor Removal and Installation
9
7
10 – 12 Nm
3
4
8
24 Nm
19 Nm
1
24 Nm
10 – 12 Nm
2
9 Nm
6
5
25 Nm
Removal steps
1. Ignition coil
2. Crankshaft pulley
3. Timing belt upper cover assembly
4. Distributor bracket
5. Timing belt lower cover assembly
"EA D Timing belt tension adjustment
AA" "DA 6.
AB" "CA 7.
"BA D
8.
AB" "AA 9.
Auto tensioner
Timing belt
Timing belt B tension adjustment
Timing belt B tensioner
Timing belt B
ENGINE <4G6> – Timing Belt, Timing Belt B
11A-27
REMOVAL SERVICE POINTS
Timing marks
AA" AUTO TENSIONER REMOVAL
1. Turn the crankshaft clockwise (right turn) to align each
timing marks and to set the No. 1 cylinder to compression
top dead centre.
Caution
Never turn the crankshaft anticlockwise.
2. Remove the auto tensioner.
Auto
tensioner
Timing marks
Timing mark
Crankshaft sprocket
AB" TIMING BELT/TIMING BELT B REMOVAL
Caution
If the belt is to be re-used, chalk the belt with an arrow
indicating the clockwise direction of rotation.
Silent shaft sprocket
Belt tension side
Timing
marks
Timing
marks
INSTALLATION SERVICE POINTS
"AA TIMING BELT B INSTALLATION
1. Ensure that crankshaft sprocket ”B” timing marks and
the silent shaft sprocket timing marks are aligned.
2. Fit timing belt ”B” over crankshaft sprocket B and the
silent shaft sprocket. Ensure that there is no slack in
the belt.
Crankshaft
sprocket B
Centre of
tension
pulley
Centre of
mounting bolt
"BA TIMING BELT B TENSION ADJUSTMENT
1. Temporarily fix the timing belt ”B” tensioner such that
the centre of the tensioner pulley is to the left and above
the centre of the installation bolt, and temporarily attach
the tensioner pulley so that the flange is toward the front
of the engine.
11A-28
ENGINE <4G6> – Timing Belt, Timing Belt B
Shaft
2. Holding the timing belt ”B” tensioner up with your finger
in the direction of the arrow, apply pressure on the timing
belt so that the tension side of the belt is taut. Now tighten
the bolt to fix the tensioner.
19 Nm
Caution
When tightening the bolt, ensure that the tensioner
pulley shaft does not rotate with the bolt. Allowing
it to rotate with the bolt can cause excessive tension
of the bolt.
3. To ensure that the tension is correct, depress the belt
(point A) with a finger. Adjust the belt tension if it is
incorrect.
A
Centre of
tensioner
pulley
Standard value: 5 – 7 mm
Centre of
installation
bolt
Timing marks
Camshaft sprocket
"CA TIMING BELT INSTALLATION
1. Check that the timing marks of the camshaft sprocket,
crankshaft sprocket and oil pump sprocket are all aligned.
Tensioner
pulley
Timing marks
Crankshaft
sprocket
Oil pump
sprocket
Timing marks
60 mm
8 mm
Plug
Screwdriver
Silent
shaft
Cylinder
block
2. After aligning the timing marks on the oil pump sprocket,
remove the cylinder block plug and insert a Phillips
screwdriver with a diameter of 8 mm, and check to be
sure that the screwdriver goes in 60 mm or more. If the
screwdriver will only go in 20 – 25 mm before striking
the silent shaft, turn the sprocket once, realign the timing
mark and check that the screwdriver goes in 60 mm or
more. The screwdriver should not be taken out until the
timing belt is installed.
ENGINE <4G6> – Timing Belt, Timing Belt B
Camshaft sprocket
Idler pulley
11A-29
3. Install the timing belt by the following procedure.
(1) Place the timing belt onto the tensioner pulley and
crankshaft sprocket, and hold it with your left hand
so that it doesn’t slip.
(2) While pulling the timing belt with your right hand,
place it onto the oil pump sprocket.
(3) Place the timing belt onto the idler pulley and camshaft
sprocket.
(4) Push the tensioner pulley in the direction shown by
the arrow to apply tension to the timing belt, and
then tighten the tensioner pulley fixing bolt.
Tensioner
pulley
Crankshaft
sprocket
Oil pump sprocket
"DA AUTO TENSIONER INSTALLATION
1. While holding the auto-tensioner by hand, press the end
of the rod against a metal surface (such as the cylinder
block) with a force of 98 – 196 Nm and measure how
far the rod is pushed in.
98 – 196 Nm
A
B
Amount
pushed in
Auto tensioner
Push rod
Standard value: Within 1 mm
A: Length when no force is applied
B: Length when force is applied
A – B: Amount pushed in
2. If it is not within the standard value, replace the auto
tensioner.
Plug
Plain washer
Dolly blocks
3. Place two dolly blocks in a vice as shown in the illustration,
and then place the auto tensioner in the vice.
Caution
(1) Place the auto tensioner perpendicular to the jaws
of the vice.
(2) If there is a plug at the base of the auto tensioner,
insert a plain washer onto the end of the auto
tensioner to protect the plug.
11A-30
ENGINE <4G6> – Timing Belt, Timing Belt B
Pin hole A
Pin hole B
4. Slowly compress the push rod of the auto tensioner until
pin hole A in the push rod is aligned with pin hole B
in the cylinder.
Caution
Never compress the push rod too fast, or the push
rod may be damaged.
5. Insert the setting pin into the pin holes once they are
aligned.
NOTE
If replacing the auto tensioner, the pin will already be
inserted into the pin holes.
6. Install the auto tensioner to the engine.
Tensioner
arm
Caution
Do not remove the setting pin from the auto tensioner.
Auto
tensioner
MD998738
Push rod
7. Remove the rubber plug from the timing belt cover
assembly rear. Then screw in the special tool by hand
until the tensioner arm is touching the auto tensioner
push rod.
Caution
Do not use a spanner or the similar tool to turn the
special tool, otherwise, the auto tensioner setting pin
may be broken. Turn the special tool by hand only.
ENGINE <4G6> – Timing Belt, Timing Belt B
48 Nm
Tension
direction
11A-31
"EA TIMING BELT TENSION ADJUSTMENT
1. Turn the crankshaft 1/4 of a revolution in the anticlockwise
direction, then turn it in the clockwise direction until the
timing marks are aligned.
2. Loosen the tension 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
timing belt.
Standard value: 3.5 Nm <Timing belt tension torque>
MD998767
Caution
When tightening the fixing bolt, make sure that the
tension pulley does not turn with the bolt.
3. Remove the setting pin that has been inserted into the
auto tensioner, and then remove the special tool.
4. Turn the crankshaft two turns clockwise, and wait for
approximately 15 minutes.
5. Insert the special tool again and turn it by hand until
the end of the special tool touches the tensioner arm.
MD998738
Push rod
6. Once the end touches, keep turning the special tool until
the auto tensioner push rod retracts and the tensioner
arm contacts the auto tensioner cylinder.
Tensioner arm
Caution
Turn the special tool slowly 1/4 of a turn at a time.
Screw in
Auto
tensioner
cylinder
7. Check that the amount by which the special tool has
been screwed in is within the standard value range.
Standard value: 2.5 – 3 turns
8. Remove the special tool and install the rubber plug.
11A-32
ENGINE <4G6> – Crankshaft Front Oil Seal
CRANKSHAFT FRONT OIL SEAL
11200340226
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Timing Belt, Timing Belt B Removal and Installation
(Refer to P.11A-26.)
Crankshaft
4
3
2
4
1
Engine oil
108 – 127 Nm
Removal steps
AA" "BA 1. Crankshaft sprocket
"BA 2. Flange
"BA 3. Crankshaft sprocket B
"AA 4. Crankshaft front oil seal
ENGINE <4G6> – Crankshaft front oil seal
11A-33
REMOVAL SERVICE POINT
MD998747
AA" CRANKSHAFT SPROCKET REMOVAL
1. Temporarily install the crankshaft pulley, and then use
the V-ribbed belt and the special tool to stop the crankshaft
pulley from turning.
Caution
(1) Do not use the vehicle’s V-ribbed belt, or the belt
may be damaged.
(2) Do not use a damaged V-ribbed belt.
V-ribbed belt
2. Loosen the crankshaft sprocket bolt, and then remove
the sprocket.
INSTALLATION SERVICE POINTS
MD998375
Crankshaft
sprocket
Flange
Crankshaft
sprocket B
Crankshaft
"AA CRANKSHAFT FRONT OIL SEAL INSTALLATION
1. Apply engine oil to the entire circumference of the oil
seal lip.
2. Press-fit the oil seal until it is flush with the front case.
"BA CRANKSHAFT SPROCKET B/FLANGE/
CRANKSHAFT SPROCKET INSTALLATION
1. Install the crankshaft sprocket B, flange and the crankshaft
sprocket so that they face as shown in the illustration.
11A-34
ENGINE <4G6> – Crankshaft front oil seal
2. Temporarily install the crankshaft pulley, and then use
the V-ribbed belt and the special tool to stop the crankshaft
pulley from turning.
MD998747
V-ribbed belt
Caution
(1) Do not use the vehicle’s V-ribbed belt, or the belt
may be damaged.
(2) Do not use a damaged V-ribbed belt.
3. Tighten the crankshaft sprocket bolt to the specified
torque.
Tightening torque: 108 – 127 Nm
11A-35
ENGINE <4G6> – Crankshaft Rear Oil Seal
CRANKSHAFT REAR OIL SEAL
11200370232
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Transmission Assembly Removal and Installation
<2WD> (Refer to GROUP 22, 23.)
D Transmission and Transfer Assembly Removal and
Installation <4WD> (Refer to GROUP 22.)
6
<M/T>
127 – 137 Nm
Crankshaft
1
Engine oil
6
2
<A/T>
127 – 137 Nm
3
4
5
4
Removal steps
<M/T>
D Clutch cover and clutch disc
AA" "BA 1. Flywheel bolt
2. Flywheel
"AA 6. Crankshaft rear oil seal
<A/T>
AA" "BA 3. Drive plate bolt
4. Adaptor plate
5. Drive plate
"AA 6. Crankshaft rear oil seal
11A-36
ENGINE <4G6> – Crankshaft Rear Oil Seal
REMOVAL SERVICE POINT
AA" FLYWHEEL BOLT <M/T>/DRIVE PLATE BOLT
<A/T> REMOVAL
MD998781
INSTALLATION SERVICE POINTS
"AA CRANKSHAFT REAR OIL SEAL INSTALLATION
1. Apply a small amount of engine oil to the entire
circumference of the oil seal lip.
2. Tap in the oil seal as shown in the illustration.
MB990938
MB998776
"BA DRIVE PLATE BOLT <A/T>/FLYWHEEL BOLT
<M/T> INSTALLATION
Use the special tool to install the drive bolt and flywheel bolt.
11A-37
ENGINE <4G6> – Engine Assembly
ENGINE ASSEMBLY
11200100350
REMOVAL AND INSTALLATION
Pre-removal Operation
D Hood Removal (Refer to GROUP 42.)
D Fuel Line Pressure Releasing
(Refer to GROUP 13A – On-vehicle Service.)
D Air Cleaner and Air Intake Hose Removal
(Refer to GROUP 15.)
D Battery Removal
D Radiator Removal (Refer to GROUP 14.)
D Transmission Assembly Removal <2WD>
(Refer to GROUP 22, 23.)
D Transmission and Transfer Assembly Removal
<4WD> (Refer to GROUP 22.)
1
12 Nm
Post-installation Operation
D Transmission and Transfer Assembly Installation
<4WD> (Refer to GROUP 22.)
D Transmission Assembly Installation <2WD>
(Refer to GROUP 22, 23.)
D Radiator Installation (Refer to GROUP 14.)
D Battery Installation
D Air Cleaner and Air Intake Hose installation
(Refer to GROUP 15.)
D Hood Installation (Refer to GROUP 42.)
D Drive Belt Tension Adjustment (Refer to P. 11A-7.)
D Accelerator Cable Adjustment
(Refer to GROUP 17 – On-vehicle Service.)
D Throttle Cable Adjustment <A/T>
(Refer to GROUP 23 – On-vehicle Service.)
13
5 Nm
12
10
2
17
16 Nm
8
6
15
3
9
18
7
11
4
16
5
15
Removal steps
1. Accelerator cable connection
2. Throttle cable connection <A/T>
3. Brake booster vacuum connection
4. Ignition coil connector
5. Engine coolant temperature sensor
connector
6. Noise filter connector
7. Power transistor connector
8. Injector connectors
9. Capacitor connector
10. Throttle position sensor connector
50 Nm
14
11. Idle speed control servo connector
12. Engine coolant temperature gauge
unit connector
13. Engine coolant temperature switch
connector <A/T>
14. Vacuum hose connection
15. Water hose connections
16. Fuel return hose connection
17. High-pressure fuel hose connection
18. Front exhaust pipe connection
11A-38
ENGINE <4G6> – Engine Assembly
16
24 Nm
39 Nm
15
14 Nm
19
20
22 Nm
9.8 Nm
24
25
18
17
34 Nm
25
26
AA"
AA"
15.
16.
17.
18.
19.
Drive belt (for Power steering)
Power steering oil pump assembly
Drive belt (for A/C)
A/C compressor assembly
Engine oil pressure switch connector
20. Alternator connector
24. Heat protector
25. Engine support front insulator attaching bolt
AB" "AA 26. Engine assembly
ENGINE <4G6> – Engine Assembly
11A-39
REMOVAL SERVICE POINTS
AA" POWER STEERING OIL PUMP ASSEMBLY AND
A/C COMPRESSOR ASSEMBLY REMOVAL
1. Remove the oil pump and A/C compressor (with the hose
attached).
2. Suspend the removed oil pump (by using wire or similar
material) at a place where no damage will be caused
during removal/installation of the engine assembly.
AB" ENGINE ASSEMBLY REMOVAL
1. Check that all cables, hoses, harness connectors, etc.
are disconnected from the engine.
2. Lift the chain block slowly to remove the engine assembly
upward from the engine compartment.
INSTALLATION SERVICE POINT
"AA ENGINE ASSEMBLY INSTALLATION
Install the engine assembly. When doing so, check carefully
that all pipes and hoses are connected, and that none are
twisted, damaged, etc.
NOTES
11B-2
ENGINE <4D5> – General Information
GENERAL INFORMATION
11100010339
Items
4D56
Total displacement m
2,477
Bore x Stroke mm
91.1 x 95.0
Compression ratio
21
Combustion chamber
Vortex chamber type
Camshaft arrangement
SOHC
Number of valve
Valve timing
Intake
4
Exhaust
4
Intake
Opening BTDC 20_, Closing ABDC 49_
Exhaust
Opening BBDC 55_, Closing ATDC 22_
Fuel system
Distribution type injection pump
Rocker arm
Roller type
Adjusting screw
Elephant foot type
11B-3
ENGINE <4D5> – Service Specifications/Sealants
SERVICE SPECIFICATIONS
Items
11100030359
Standard value
Limit
When checked
245 – 441
–
When a used belt is installed
294 – 392
–
When a new belt is installed
392 – 588
–
When checked
12.0 – 17.0
–
When a used belt is installed
13.0 – 16.0
–
When a new belt is installed
10.0 – 13.0
–
When checked
294 – 490
–
When a used belt is installed
343 – 441
–
When a new belt is installed
490 – 686
–
When checked
8.0 – 12.0
–
When a used belt is installed
9.0 – 11.5
–
When a new belt is installed
6.0 – 8.0
–
When checked
320 – 400
–
When a used belt is installed
320 – 400
–
When a new belt is installed
480 – 560
–
When checked
6.0 – 7.0
–
When a used belt is installed
6.0 – 7.0
–
When a new belt is installed
4.5 – 5.5
–
Valve clearance (at hot) mm
0.25
–
Injection timing (Value indicated on dial gauge mm)
9_ ATDC (1 ± 0.03)
–
Idle speed r/min
750 ± 100
–
Idle up engine speed for ABS r/min
1,900 ± 100
–
Compression pressure kPa
3,040
Min. 2,200
Compression pressure difference of all cylinder (at engine speed of 280
r/min) kPa
–
Max. 300
Timing belt tension mm
4–5
–
Timing belt B tension mm
4–5
–
Alternator drive belt
tension (for each
belt))
Tension N
Deflection
(Reference
value)) mm
Power steering oil
pump drive belt tenten
sion
Tension N
Deflection
(Reference
value)) mm
A/C
compressor
drive
belt tension
Tension N
Deflection
(Reference
value)) mm
SEALANTS
11100050270
Items
Specified sealant
Remarks
Oil pan
MITSUBISHI GENUINE PART
MD970389 or equivalent
Semi-drying sealant
Semi-circular packing and rocker
cover seal, and cylinder head seal
3M ATD Part No. 8660 or equivalent
11B-4
ENGINE <4D5> – Special Tools
SPECIAL TOOLS
Tool
11100060327
Number
Name
Use
MD998384
Prestroke measuring adapter
Adjustment of the injection timing
MD998721
Crankshaft pulley
holder
Holding the crankshaft pulley
MB990767
End yoke holder
Holding the camshaft sprocket
MD998719
Crankshaft pulley
holder pin
MD998381
Camshaft oil seal
installer
Installing the camshaft oil seal
MD998727
Oil pan remover
Removal of oil pan
MD998051
Cylinder head bolt
wrench
Removal and installation of the cylinder head
bolt
MD998382
Crankshaft front oil
seal installer
Installing the crankshaft front oil seal
MD998383
Crankshaft front oil
seal guide
ENGINE <4D5> – Special Tools/On-vehicle Service
Tool
Alternator
pulley
Number
Name
Use
MD998781
Flywheel stopper
Securing the flywheel
MD998376
Crankshaft rear oil
seal installer
Press-fitting the crankshaft rear oil seal
Water pump
pulley
98 N
Crankshaft
pulley
11B-5
ON-VEHICLE SERVICE
11100090333
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. In addition, press this
section with a force of 98 N and check that the amount of
belt deflection is at the standard value.
Standard value (for each belt):
Tension N
245 – 441
Deflection (Reference value) mm
12.0 – 17.0
11B-6
ENGINE <4D5> – On-vehicle Service
ALTERNATOR DRIVE BELT TENSION ADJUSTMENT
1. Loosen the nut of the alternator pivot bolt.
2. Loosen the lock bolt.
3. Use the adjusting bolt to adjust the belt tension and belt
deflection to the standard values.
Lock bolt
Adjusting
bolt
Standard value (for each belt):
Pivot bolt
Items
When a used
belt is installed
When a new belt
is installed
Tension N
294 – 392
392 – 588
Deflection (Reference
value) mm
13.0 – 16.0
10.0 – 13.0
4. Tighten the nut of the alternator pivot bolt.
Tightening torque: 44 Nm
5. Tighten the lock bolt.
Tightening torque: 22 Nm
6. Tighten the adjusting bolt.
Tightening torque: 9.8 Nm
Power
steering
oil pump
pulley
Water pump
pulley
Crankshaft
pulley
98 N
Deflection
POWER STEERING OIL PUMP DRIVE BELT TENSION
CHECK AND ADJUSTMENT
11100110152
1. Use a belt tention 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).
In addition, press this section with a force of 98 N and
check that the amount of belt deflection is at the standard
value.
Standard value:
Items
When
checked
When a used
belt is intalled
When a new
belt is installed
Tension N
294 – 490
343 – 441
490 – 686
Deflection
(Reference
value) mm
8.0 – 12.0
9.0 – 11.5
6.0 – 8.0
11B-7
ENGINE <4D5> – On-vehicle Service
2. If the tension or deflection is outside the standard value,
adjust by the following procedure.
(1) Loosen power steering oil pump fixing bolts A, B and
C.
(2) Adjust the amount of belt deflection using adjusting
bolt D.
(3) Tighten fixing bolts A, B and C.
A
C
B
Tightening torque: 22 Nm
(4) Check the belt deflection amount and tension, and
readjust if necessary.
Caution
Check after turning the crankshaft once or more
clockwise (right turn).
Tension pulley
Crankshaft
pulley
98 N
Deflection
Standard value:
A/C compressor pulley
Tension pulley
Crankshaft
pulley
AIR CONDITIONER COMPRESSOR DRIVE BELT
TENSION CHECK AND ADJUSTMENT
11100100142
1. Use a belt tention 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).
In addition, press this section with a force of 98 N and
check that the amount of belt deflection is at the standard
value.
Adjusting bolt
Fixing nut
A/C
compressor
pulley
Items
When
checked
When a used
belt is intalled
When a new
belt is installed
Tension N
320 – 400
320 – 400
480 – 560
Deflection
(Reference
value) mm
6.0 – 7.0
6.0 – 7.0
4.5 – 5.5
2. If the tension or deflection is outside the standard value,
adjust by the following procedure.
(1) Loosen tension pulley fixing nut.
(2) Adjust belt tension with adjusting bolt.
(3) Tighten fixing nut.
11B-8
ENGINE <4D5> – On-vehicle Service
(4) Check the belt deflection amount and tension, and
readjust if necessary.
Caution
Check after turning the crankshaft once or more
clockwise (right turn).
Timing marks
Timing marks
VALVE CLEARANCE CHECK AND
ADJUSTMENT
11100150109
1. Start the engine and allow it to warm up until the engine
coolant temperature reaches 80 to 90 _C.
2. Remove the timing belt upper cover.
3. Remove the rocker cover.
4. Align the camshaft sprocket timing marks and set the
No. 1 cylinder at top dead centre.
Camshaft
sprocket
Crankshaft
pulley
Caution
The crankshaft should always be turned in a clockwise
direction.
5. Measure the valve clearance at the places indicated by
arrows in the illustration.
Standard value: 0.25 mm
Adjusting
screw
Pad
Thickness gauge
NOTE
Insert the thickness gauge from the centre of the cylinder
head towards the outside so that it doesn’t touch the
pad.
ENGINE <4D5> – On-vehicle Service
Thickness gauge
11B-9
6. If the clearance is outside the standard value, loosen
the lock nut of the rocker arm and adjust by turning the
adjusting screw while using a thickness gauge to measure
the clearance.
7. Tighten the lock nut while holding the adjusting screw
with a screwdriver so that it doesn’t turn.
8. Turn the crankshaft 360_ clockwise to bring No. 4 cylinder
to the top dead centre position.
9. Measure the valve clearances at the places indicated
by arrows in the illustration. If the clearance is not within
the standard value, repeat steps 7 and 8 above.
10. Apply specified sealant to the section of the semi-circular
packing shown in the illustration.
Cylinder head
10 mm
Specified sealant: 3M ATD Part No. 8660 or equivalent
11. Install the rocker cover.
12. Install the timing belt upper cover.
10 mm
Semi circular packing
INJECTION TIMING CHECK AND
ADJUSTMENT
Accelerator lever
11100180023
1. Warm up the engine and then check to be sure that
the fast idle lever is separated from the throttle lever.
2. Remove all of the glow plugs.
3. Remove the timing belt upper cover.
Fast idle lever
Timing marks Timing marks
Camshaft
sprocket
Crankshaft
pulley
4. Align the timing marks of the camshaft sprocket and set
the No. 1 cylinder to the top dead centre position.
11B-10
ENGINE <4D5> – On-vehicle Service
5. Remove the timing check plug at the rear of the injection
pump.
Timing check plug
Push rod
Nut
MD998384
6. Before installation of special tool, make sure that push
rod is protruding by 10 mm. Protrusion of push rod can
be adjusted with an inner nut.
7. Connect the dial gauge to the special tool.
10 mm
8. Install the special tool to the check plug at the rear of
the injection pump.
MD998384
Approx. 30_
9. Turn the crankshaft clockwise to move the No. 1 cylinder
approximately 30_ before compression top dead centre.
10. Set the needle of the dial gauge to 0.
11. Check that the needle doesn’t move even if the crankshaft
is turned slightly (2 – 3_) in both clockwise and
anti-clockwise direction.
NOTE
If the needle moves, the notch is not positioned properly,
so once again move the No. 1 cylinder approximately
30_ before compression top dead centre.
1 ± 0.03 mm
12. Turn the crankshaft clockwise to align the No. 1 cylinder
to 9_ ATDC.
13. Check that the value indicated on the dial gauge is at
the standard value.
Standard value: 1 ± 0.03 mm
Set to 9_ ATDC
ENGINE <4D5> – On-vehicle Service
Injection pipe
union nuts
(4 places)
Nuts (2 places)
Bolts (2 places)
1 ± 0.03 mm or more
Front
view
14. If the needle is outside the standard value, adjust the
injection timing by the following procedure.
(1) Loosen the injection pipe union nuts (4 places) on
the injection pump. (Do not remove the union nuts.)
Caution
When loosening the nuts, hold the delivery valve
holders with a spanner so that they don’t turn
at the same time.
(2) Loosen the upper mounting nuts and the lower
mounting bolts of the injection pump. (Do not remove
the nut and bolt.)
(3) Tilt the injection pump to the left and right and adjust
the needle on the dial gauge so that the display value
is uniform.
(4) Provisionally tighten the mounting nut and bolt of
the injection pump.
(5) Repeat steps 9 – 13 to check if the adjustment has
been made correctly.
1 ± 0.03 mm of less
Injection pipe
union nuts
(29 Nm)
Nuts
(19 Nm)
11B-11
Bolts
(24 Nm)
(6) Tighten the mounting nuts and bolts to the specified
torque.
(7) Tighten the injection pump union nuts to the specified
torque.
Caution
When tightening the nuts, hold the delivery valve
holders with a spanner so that they don’t turn
at the same time.
15. Remove the special tool.
16. Install a new gasket to the timing check plug.
17. Tighten the timing check plug to the specified torque.
Gasket N
Timing
check plug
(17 Nm)
IDLE SPEED CHECK AND ADJUSTMENT
11100190347
NOTE
Check that the injection timing is normal
1. Before inspection, set the vehicle to the pre-inspection
condition.
11B-12
ENGINE <4D5> – On-vehicle Service
2. Connect the speedometer to the injection nozzle or the
injection pipe.
Caution
When the speedometer is connected to the injection
pipe, the pipe mounting clamps should all be removed.
Speedometer
3. Start the engine and run it at idle.
4. Check the idle speed.
Standard value: 750 ± 100 r/min
Injection
nozzle
5. If not within the standard value, loosen idle adjusting
screw lock nut and adjust the idle speed by rotating
adjusting screw. And tighten locking nut.
Accelerator lever
Locking
nut
Idle speed
adjusting screw
IDLE-UP MECHANISM CHECK AND
ADJUSTMENT-FOR A/C
11100230032
Refer to GROUP 55 – On-vehicle Service.
IDLE-UP MECHANISM CHECK AND
ADJUSTMENT-FOR ABS
11100230025
1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Inspect and adjust the idle speed.
3. Disconnect the vacuum hose (for anti-skid brakes: blue
stripe) from the idle-up actuator.
4. Connect a hand vacuum pump to the nipple of the removed
vacuum hose.
5. Connect the speedometer.
6. Start the engine and run it at idle.
ENGINE <4D5> – On-vehicle Service
11B-13
7. Check the engine speed when a negative pressure of
87 kPa is applied.
Lock nut
Adjusting
screw
Standard value: 1,900 ± 100 r/min
8. If the engine speed is outside the standard value, loosen
the lock nut on the actuator rod and adjust by turning
the adjusting screw.
9. Tighten the lock nut while making sure that the adjusting
screw doesn’t turn.
COMPRESSION PRESSURE CHECK
11100260369
1. Before inspection, check that the engine oil, starter and
battery are normal. In addition, set the vehicle to the
pre-inspection condition.
2. Remove all of the glow plugs.
Caution
Be careful not to subject the glow plugs to any shocks.
Fuel cut
solenoid valve
Fuel cut valve
controller
3. Disconnect the fuel cut solenoid valve connector or fuel
cut valve controller.
NOTE
Doing this will prevent carrying out fuel injection.
4. Cover the glow plug hole with a shop towel etc., and
after the engine has been cranked, check that no foreign
material is adhering to the shop towel.
Caution
1. Keep away from the glow plug hole when cranking
2. If compression is measured with water, oil, fuel,
etc., that has come from cracks inside the cylinder,
these materials will become heated and will gush
out from glow plug hole, which is dangerous.
11B-14
ENGINE <4D5> – On-vehicle Service
Compression gauge
5. Set compression gauge to one of the glow plug holes.
6. Crank the engine and measure the compression pressure.
Standard value (at engine speed of 280 r/min):
3,040 kPa
Limit (at engine speed of 280 r/min): min. 2,200 kPa
7. Measure the compression pressure for all the cylinders,
and check that the pressure differences of the cylinders
are below the limit.
Limit: max 300 kPa
8. If there is a cylinder with compression or a compression
difference that is outside the limit, pour a small amount
of engine oil through the glow plug hole, and repeat the
operations in steps (6) and (7).
(1) If the compression increses after oil is added, the
cause of the malfunction is a worn or damaged piston
ring and/or cylinder inner surface.
(2) If the compression does not rise after oil is added,
the cause is a burnt or defective valve seat, or pressure
is leaking from the gasket.
9. Connect the fuel cut solenoid valve connector or fuel
cut valve controller connector.
10. Install the glow plugs.
Tightening torque: 18 Nm
TIMING BELT TENSION ADJUSTMENT
11100280136
1. Remove timing belt upper cover.
2. Turn the crankshaft in the clockwise direction and check
the timing belt around its entire circumference for
abnormalities.
Timing marks
3. Align the timing marks on the sprockets with the timing
marks on the front upper case.
Caution
When aligning the timing mark, be sure not to turn
the crankshaft in the counterclockwise direction as
this can cause improper belt tension.
Timing marks
ENGINE <4D5> – On-vehicle Service
11B-15
4. Loosen the tensioner pivot side bolt 1 turn and slot side
bolt 1 or 2 turns.
Slot side
bolt
Pivot side
bolt
5. Turn the crankshaft clockwise and stop at the second
lobe of the camshaft sprocket.
6. First tighten tensioner slot side bolt, and then tighten
pivot side bolt to the specified torque.
Camshaft sprocket
Tightening torque: 25 Nm
2 teeth
7. Turn the crankshaft anti-clockwise to align the timing
marks.
8. Push down belt at a point halfway with a forefinger to
check that tension of belt is up to standard value.
Standard value: 4 – 5 mm
9. Mount the timing belt upper cover.
Timing marks
TIMING BELT “B” TENSION ADJUSTMENT
11100280143
1. Remove timing belt upper cover.
2. Turn the crankshaft in the clockwise direction and check
the timing belt around its entire circumference for
abnormalities.
3. Align the timing marks on the sprockets with the timing
mark on the front upper case.
Timing marks
Caution
When aligning the timing mark, be sure not to turn
the crankshaft in the counterclockwise direction as
this can cause improper belt tension.
11B-16
ENGINE <4D5> – On-vehicle Service
4. Remove the access cover.
Access cover
Pivot
side
bolt
Slot
side
nut
Access cover
Guide
5. Loosen the tensioner pivot side bolt 1 mm and slot side
nut 1 or 2 turns.
6. First tighten tensioner slot side nut, and then tighten pivot
side bolt to the specified torque.
Tightening torque:
Pivot side bolt 24 Nm
Slot side nut 25 Nm
7. Install the access cover while sliding the front lower cover
down along the two guides.
8. Install the timing belt upper cover.
ENGINE <4D5> – Crankshaft Pulley
CRANKSHAFT PULLEY
11B-17
11200160242
REMOVAL AND INSTALLATION
Pre-removal Operation
D Under Cover Removal
Post-installation Operation
D Drive Belt Tension Adjustment (Refer to P.11B-5.)
D Under Cover Installation
167 – 186 Nm
3
2
5
4
25 Nm
1
Removal steps
1. Drive belt (for A/C)
2. Drive belt (for power steering)
3. Drive belt (for alternator)
AA" "AA 4. Crankshaft pulley (for power steering
or A/C)
5. Crankshaft pulley
REMOVAL SERVICE POINT
AA" CRANKSHAFT PULLEY REMOVAL
INSTALLATION SERVICE POINT
"AA CRANKSHAFT PULLEY INSTALLATION
MD998721
11B-18
ENGINE <4D5> – Camshaft and Camshaft Oil Seal
CAMSHAFT AND CAMSHAFT OIL SEAL
11200190289
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Intercooler Removal and Installation <4WD>
(Refer to GROUP 15.)
5.9 Nm
4
5
2
5
3
Sealant:
3M ATD Part No. 8660 or equivalent
4
34 – 39 Nm
Lip
7
19 – 21 Nm
8
34 – 39 Nm
9
9
10
19 – 21 Nm
9
Cam section
and journal
section
9
7
10
6
Engine oil
1
64 – 74 Nm
9.8 – 12 Nm
AA" "DA
AB" "CA
AC" "BA
"AA
Camshaft removal steps
1. Timing belt upper cover assembly
2. Breather hose connection
3. Boost hose connection <4WD>
4. Rocker cover
5. Semi-circular packing
6. Camshaft sprocket
7. Camshaft oil seal
8. Rocker arm and shaft assembly
9. Camshaft bearing cap
10. Camshaft
Camshaft oil seal removal steps
1. Timing belt upper cover assembly
AA" "DA 6. Camshaft sprocket
AB" "CA 7. Camshaft oil seal
ENGINE <4D5> – Camshaft and Camshaft Oil Seal
Timing marks
11B-19
REMOVAL SERVICE POINTS
AA" CAMSHAFT SPROCKET REMOVAL
1. Rotate crankshaft clockwise (to the right) and align timing
marks.
Caution
Never turn the crankshaft anticlockwise.
No. 1 T.D.C
Timing belt
Cord
2. Tie the camshaft sprocket and timing belt together with
cord so that timing mark is not maladjusted.
Camshaft
sprocket
3. Use the special tool to stop the camshaft sprocket from
turning, and then remove the camshaft sprocket with the
timing belt still attached.
MB990767
Caution
Do not rotate crankshaft after removing camshaft
sprocket.
MD998719
Lip
section
Oil
seal
(–) screwdriver
AB" CAMSHAFT OIL SEAL REMOVAL
1. Make a notch in the oil seal lip section with a knife, etc.
2. Cover the end of a (–) screwdriver with a rag and insert
into the notched section of the oil seal, and lever out
the oil seal to remove it.
Caution
Be careful not to damage the camshaft and the cylinder
head.
Camshaft
AC" ROCKER ARM AND SHAFT ASSEMBLY REMOVAL
Loosen the rocker arm and shaft assembly mounting bolt,
and then remove the rocker arm and shaft assembly with
the bolt still attached.
Caution
Never disassemble the rocker arm and shaft assembly.
11B-20
ENGINE <4D5> – Camshaft and Camshaft Oil Seal
INSTALLATION SERVICE POINTS
Cap No.
"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. However,
no numbers are embossed on bearing caps 1 and 5.
"BA ROCKER ARM AND SHAFT ASSEMBLY
INSTALLATION
1. Install the rocker arm and shaft assembly to the bearing
caps.
2. Set the washer so that it faces in the direction shown
in the illustration, and then install the bolt.
3. Check the valve clearance and adjust if necessary. (Refer
to P.11B-8.)
Chamfer
MD998381
Camshaft
"CA CAMSHAFT OIL SEAL INSTALLATION
1. Apply a small amount of engine oil to the entire
circumference of the oil seal lip and camshaft.
2. Use the special tool to tap in the oil seal.
NOTE
The oil seal should be tapped in until the distance from
the end of the camshaft to the end of the oil seal is
as shown in the illustration.
Oil seal
"DA CAMSHAFT SPROCKET INSTALLATION
1. Use the special tool in the same way as during removal
to stop the camshaft sprocket from turning, and then
tighten the bolt to the specified torque.
Tightening torque: 64 – 67 Nm
2. Remove the cord which binds the camshaft sprocket and
timing belt.
11B-21
ENGINE <4D5> – Oil Pan and Oil Screen
OIL PAN AND OIL SCREEN
11200250192
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Under Cover Removal and Installation
D Engine Oil Draining and Supplying
(Refer to GROUP 12 – On-vehicle Service.)
Front of
engine
6
Groove
5 <2WD>
<4WD> 5
φ 4.0 mm
4
Bolt
hole
6
Sealant:
MITSUBISHI GENUINE Part No.
MD970389 or equivalent
19 Nm
19 Nm
3
39 Nm
1
6.9 Nm
4
2
Removal steps
1. Drain plug
"BA 2. Drain plug gasket
3. Oil return hose connection
MD998727
MD998727
AA" "AA 4. Oil pan
5. Oil screen
6. Gasket
REMOVAL SERVICE POINT
AA" OIL PAN REMOVAL
1. Remove oil pan bolts.
2. Tap the special tool in between the oil pan and cylinder
block.
3. Slide the special tool by tapping it at an angle to remove
the oil pan.
11B-22
ENGINE <4D5> – Oil Pan and Oil Screen
Caution
The use of a screwdriver or chisel in place of the
special tool can damage the gasket seat surface and
cause oil leakage.
INSTALLATION SERVICE POINTS
"AA OIL PAN INSTALLATION
1. Remove sealant from oil pan and cylinder block mating
surfaces.
2. Degrease the sealant-coated surface and the engine
mating surface.
3. Apply the specified sealant around the gasket surface
of oil pan.
Specified sealant:
MITSUBISHI GENUINE PART No. MD970389 or
equivalent
NOTE
The sealant should be applied in a continuous bead
approximately 4 mm in diameter.
4. Assemble oil pan to cylinder block within 15 minutes after
applying the sealant.
Caution
After installing the oil pan, wait at least 1 hour before
starting the engine.
"BA DRAIN PLUG GASKET INSTALLATION
Install a new gasket in the direction so that it faces as shown
in the illustration.
Oil pan side
Drain plug
gasket
INSPECTION
D
D
D
11200260041
Check oil pan for cracks.
Check oil pan sealant-coated surface for damage and
deformation.
Check oil screen for cracked, clogged or damaged wire
net and pipe.
11B-23
ENGINE <4D5> – Cylinder Head Gasket
CYLINDER HEAD GASKET
11200400368
REMOVAL AND INSTALLATION
Pre-removal Operation
D Intake and Exhaust Manifold Removal
(Refer to GROUP 15.)
D Timing Belt Removal (Refer to P.11B-26.)
D Engine Coolant Draining
(Refer to GROUP 14 – On-vehicle Service.)
Post-installation Operation
D Timing Belt Installation (Refer to P.11B-26.)
D Intake and Exhaust Manifold Installation
(Refer to GROUP 15.)
D Fuel Line Air Bleeding
(Refer to GROUP 13E – On-vehicle Service.)
D Engine Coolant Filling
(Refer to GROUP 14 – On-vehicle Service.)
5.9 Nm
10
29 Nm
4.9 Nm
9
29 Nm
5
4.9 Nm
3
113 – 123 Nm
2
22 Nm
11
4.9 Nm
29 Nm
22 Nm
6
9
10 mm
7
12
13
10 mm
1
24 Nm
10
8
4
14
Sealant:
3M ATD Part No. 8660 or
equivalent
Removal steps
1. Engine coolant temperature switch
connector (for A/C)
2. Engine coolant temperature gauge
unit and sensor connector
3. Glow plug terminal
AA" "CA 4. Radiator upper hose
AB" "DA 5. Fuel injection pipe
6. Heater hose or water by-pass hose
connection
7.
8.
9.
10.
11.
12.
Fuel hose connection
Earth cable connection
Rocker cover
Semi-circular packing
AC"
Power steering oil pump assembly
Power steering oil pump bracket
bolt
AD" "BA 13. Cylinder head assembly
"AA 14. Cylinder head gasket
11B-24
ENGINE <4D5> – Cylinder Head Gasket
REMOVAL SERVICE POINTS
AA" RADIATOR UPPER HOSE DISCONNECTION
After making mating marks on the radiator upper hose and
the hose clamp, disconnect the radiator upper hose.
Delivery holder
AB" FUEL INJECTION PIPE REMOVAL
When loosening nuts at both ends of injection pipe, hold
the delivery holder (for pump side) and the injection nozzle
assembly (for nozzle side) with wrench and loosen nut.
Caution
After disconnecting the injection pipe, plug the opening
so that no foreign particles get inside the pump or into
the injection nozzle.
Nut
AC" POWER STEERING OIL PUMP REMOVAL
Remove the power steering oil pump from the bracket 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.
AD" CYLINDER HEAD ASSEMBLY REMOVAL
Use the special tool to tighten each bolt 2 – 3 times in the
order shown in the illustration.
MD998051
Front
ENGINE <4D5> – Cylinder Head Gasket
INSTALLATION SERVICE POINTS
Identification mark
Rank A
B
11B-25
"AA CYLINDER HEAD GASKET INSTALLATION
1. Wipe off any oil or grease from the gasket mounting
surface.
2. Check the rank from the number of identification holes
on the cylinder head gasket that was removed, and select
a cylinder head gasket of the same rank.
C
D
E
Identification
holes
NOTE
The ranks are listed in the parts catalogue.
3. Place the cylinder head gasket on top of the cylinder
block so that the identification mark is facing upwards
as in the illustration.
"BA CYLINDER HEAD INSTALLATION
Use the special tool to tighten each bolt 2 – 3 times in the
order shown in the illustration.
MD998051
Head bolt
washer
Caution
The head bolt washer should be installed so that the
burred side is facing upwards.
Burred
side
Front
"CA RADIATOR UPPER HOSE CONNECTION
To reuse the radiator upper hose, align the mating marks
that were made during removal, and then install the hose
clamp.
"DA FUEL INJECTION PIPE INSTALLATION
When tightening the nuts at both ends of the fuel injection
pipe, hold the delivery holder (for pump side) and the injection
nozzle assembly (for nozzle side) with a wrench, and tighten
the nuts to the specified torque.
11B-26
ENGINE <4D5> – Timing Belt and Timing B
TIMING BELT AND TIMING BELT B
11200430343
REMOVAL AND INSTALLATION
Pre-removal Operation
D Cooling Fan Removal (Refer to GROUP 14.)
1
Post-installation Operation
D Cooling Fan Installation (Refer to GROUP 14.)
D Engine Adjustment (Refer to P.11B-5.)
6
25 Nm
7
8
9
25 Nm
9.8 – 12 Nm
4
5
3
16
9.8 – 12 Nm
25 Nm
167 – 186 Nm
25 Nm
14
15
24 Nm
13
12
10
2
11
Removal steps
1. Timing belt front upper cover
2. Tension pulley bracket (for A/C)
3. Crankshaft pulley (for power steering
and A/C)
AA" "CA 4. Crankshaft pulley
5. Timing belt front lower cover
AB" "BA 6. Timing belt
7. Tensioner spacer
8. Tensioner spring
9.
10.
11.
AC" "AA 12.
13.
14.
15.
16.
Timing belt tensioner assembly
Crankshaft sprocket
Flange
Timing belt B
Gasket
Tensioner spacer B
Tensioner spring B
Timing belt tensioner B
ENGINE <4D5> – Timing Belt and Timing Belt B
11B-27
REMOVAL SERVICE POINTS
AA" CRANKSHAFT PULLEY REMOVAL
1. Position the No. 1 cylinder at compression TDC and
remove the crankshaft pulley.
NOTE
The No. 1 cylinder is at compression TDC when the marks
are aligned as shown in the figure.
Timing marks
2. Use the special tool to keep crankshaft from turning and
remove the bolts.
MD998721
Tilt to water pump side
Tensioner
mounting
bolt A
AB" TIMING BELT REMOVAL
1. When reinstalling timing belt, mark an arrow at the belt
to show rotation direction.
2. Loosen the tensioner mounting bolt A and B.
3. Push timing belt tensioner to water pump side and tighten
the tensioner mounting bolt A and B. Secure so that
tensioner will not move back.
Tensioner
mounting
bolt B
Water pump
Tensioner
mounting
bolt
Tensioner
mounting nut
AC" TIMING BELT B REMOVAL
1. When reinstalling timing belt ”B”, mark an arrow at the
belt to show rotation direction.
2. Loosen the tensioner mounting bolt and nut.
3. Push timing belt tensioner to water pump side and tighten
the tensioner mounting bolt and nut. Secure so that
tensioner will not move back.
INSTALLATION SERVICE POINTS
Timing mark
"AA TIMING BELT B INSTALLATION
1. Align the timing marks of the 3 sprockets.
2. When reusing timing belt ”B”, make sure the arrow mark
is pointing in the same direction as when the belt was
removed.
Tensioner
Timing marks
Timing belt
11B-28
ENGINE <4D5> – Timing Belt and Timing Belt B
3. Install timing belt B and make sure there is no deflection
on the tension side.
Timing mark
Tensioner
24 Nm
A
Tension side
Timing marks
25 Nm
Timing belt
Counterbalance
shaft sprocket
4. Press the deflection side of timing belt B (indicated by
arrow (A)) with the hand and fully stretch the tensioner
side.
5. Make sure that the timing marks are aligned.
6. Loosen the tensioner mounting bolt and nut so that only
the pressure of the spring is applied to timing belt B.
7. Tighten the tensioner mounting bolt and nut, tightening
the nut first. If the bolt is tightened first, the tensioner
will move and tension the belt.
8. Press in the direction of the arrow in the figure with the
index finger to check the amount of deflection.
Standard value: 4 – 5 mm
Belt deflection
Crankshaft
sprocket “B”
Tension
side
Water pump
Tension side
"BA TIMING BELT INSTALLATION
1. Align the timing marks of the 3 sprockets.
2. When reusing timing belt, make sure the arrow mark is
pointing in the same direction as when the belt was
removed.
3. Install the timing belt to the crankshaft sprocket, to injection
pump sprocket, to tensioner and to camshaft sprocket
in that order. Being careful not to allow deflection on
the tension side of the timing belt.
Caution
1. Engage the belt on the various sprockets while
maintaining tension on the belt of tension side.
2. Align the injection pump sprocket with the timing
mark, hold the sprocket so that is does not turn
and engage the belt.
ENGINE <4D5> – Timing Belt and Timing Belt B
4. Loosen the tensioner mounting bolts and apply tension
with the spring.
5. Turn the crankshaft clockwise and stop at the second
lobe of the camshaft sprocket.
Camshaft sprocket
2 teeth
A
11B-29
Belt deflection Tensioner
mounting bolt
Caution
1. When turning the crankshaft in item (5), strictly
observe the specified amount of rotation (2 teeth
on the camshaft sprocket) in order to apply a
constant force to the tension side of the belt.
2. Do not turn the crankshaft counterclockwise.
3. Do not touch the belt during adjustment.
6. Make sure that the part indicated by arrow A does not
float upward.
7. Tighten the tensioner mounting bolts, starting with the
bolt in the elongated hole. If the lower bolt is tightened
first, belt tension will become too tight.
Tensioner
Tensioner
mounting bolt
Amount of belt deflection
8. Turn the crankshaft anticlockwise and align the timing
mark. Next, make sure that the timing marks of all
sprockets are aligned.
9. Press on the centre of the bolt with an index finger to
check the amount of deflection.
Standard value: 4 – 5 mm
"CA CRANKSHAFT PULLEY INSTALLATION
Using the special tool to install the crankshaft pulley as same
as removal procedure.
11B-30
ENGINE <4D5> – Crankshaft Front Oil Seal
CRANKSHAFT FRONT OIL SEAL
11200340233
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Timing Belt and Timing Belt “B” Removal and
Installation (Refer to P.11B-26.)
(Engine oil)
2
1
Removal steps
1. Crankshaft sprocket B
AA" "AA 2. Oil seal
REMOVAL SERVICE POINT
Oil seal
Lip
portion
Screwdriver
AA" OIL SEAL REMOVAL
1. Cut out a portion in the crankshaft oil seal lip.
2. Cover the tip of a screwdriver with a cloth and apply
it to the cutout in the oil seal to pry off the oil seal.
Caution
Be careful not to damage the crankshaft and front
case.
Camshaft
Oil seal
Crankshaft
MD998382 MD998383
(Apply oil to outer surface)
INSTALLATION SERVICE POINT
"AA OIL SEAL INSTALLATION
Apply engine oil to the outside of the special tool (MD998383)
and to the oil seal lip, and use the special tool to press-fit
the oil seal.
11B-31
ENGINE <4D5> – Crankshaft Rear Oil Seal
CRANKSHAFT REAR OIL SEAL
11200370249
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Oil Pan Removal and Installation (Refer to P.11-21.)
D Transmission Assembly Removal and Installation
(Refer to GROUP 22, 23.)
127 – 137 Nm
5
6
127 – 137 Nm
1
2
8
7
4
Removal steps
AA" "CA 1. Flywheel assembly <M/T>
AA" "CA 2. Adaptor plate <A/T>
3. Drive plate <A/T>
4. Crankshaft adaptor <A/T>
5.
6.
"BA 7.
"AA 8.
3
Oil seal case
Gasket
Oil separator
Oil seal
REMOVAL SERVICE POINT
AA" FLYWHEEL <M/T>/ADAPTOR PLATE <A/T>
REMOVAL
Use the special tool to secure the flywheel or adaptor plate
and remove the bolt.
MD998781
INSTALLATION SERVICE POINTS
"AA OIL SEAL INSTALLATION
MD998376
11B-32
Oil seal case
ENGINE <4D5> – Crankshaft Rear Oil Seal
Oil separator
"BA OIL SEPARATOR INSTALLATION
Install the oil separator in such a way that its oil hole come
at the case bottom (indicated by an arrow in the illustration).
Oil hole
Oil pan mounting surface
"CA FLYWHEEL <M/T>/ADAPTOR PLATE <A/T>
INSTALLATION
Use the special tool in the same way as during removal to
stop the flywheel or adaptor plate assembly from turning,
and then tighten the bolt to the specified torque.
Tightening torque: 127 – 137 Nm
11B-33
ENGINE <4D5> – Engine Assembly
ENGINE ASSEMBLY
11200100367
REMOVAL AND INSTALLATION
Pre-removal Operation
D Hood Removal (Refer to GROUP 42.)
D Intercooler Removal <4WD> (Refer to GROUP 15.)
D Air Cleaner and Air Intake Hose Removal
(Refer to GROUP 15.)
D Brake Master Cylinder Heat Protector Removal
<4WD>
D Battery Removal
D Radiator Removal (Refer to GROUP 14.)
D Transmission Assembly Removal <2WD>
(Refer to GROUP 22.)
D Transmission and Transfer Assembly Removal
<4WD> (Refer to GROUP 22, 23.)
4
Post-installation Operation
D Transmission and Transfer Assembly Installation
<4WD> (Refer to GROUP 22, 23.)
D Transmission Assembly Installation <2WD>
(Refer to GROUP 22.)
D Radiator Installation (Refer to GROUP 14.)
D Battery installation
D Brake Master Cylinder Heat Protector Installation
<4WD>
D Air Cleaner and Air Intake Hose Installation
(Refer to GROUP 15.)
D Intercooler Installation <4WD>
(Refer to GROUP 15.)
D Hood Installation (Refer to GROUP 42.)
D Drive Belt Tension Adjustment (Refer to P.11B-5.)
D Accelerator Cable Adjustment
(Refer to GROUP 17 – On-vehicle Service.)
D Throttle Cable Adjustment <A/T>
(Refer to GROUP 23 – On-vehicle Service.)
5
6
4.9 Nm
8.8 Nm
7
8
3
9
2
12 Nm
1
5
10
16 Nm
14 13 12
11
Removal steps
1. Engine coolant temperature sensor
and gauge unit connector
2. Earth cable connector
3. Glow plug terminal
4. Earth cable connector
5. Vacuum hose connection (for A/C)
6. Vacuum hose connection (for ABS)
7. Brake booster vacuum hose
connection
8. Accelerator cable connection
6
9. Heater hose connections
10. Throttle cable connection <A/T>
11. Fuel cut solenoid valve or fuel cut
valve controller connector
12. Revolution pick-up sensor connector
13. Lever (throttle) position switch
connector
14. Engine coolant temperature switch
connector (for A/C)
11B-34
ENGINE <4D5> – Engine Assembly
16
22 Nm
22 Nm
15
23
44 Nm
21
30 Nm
14 Nm
22
19
20
22 Nm
18
24
25
17
9.8 Nm
26
34 Nm
25
AA"
AA"
15.
16.
17.
18.
19.
Drive belt (for Power steering)
Power steering oil pump assembly
Drive belt (for A/C)
A/C compressor assembly
Engine oil pressure switch
connector
20. Alternator connector
21.
22.
23.
24.
25.
Engine oil cooler hose connection
Fuel hose connections
Front exhaust pipe connection
Heat protector
Engine support front insulator
attaching bolt
AB" "AA 26. Engine assembly
ENGINE <4D5> – Engine Assembly
11B-35
REMOVAL SERVICE POINTS
AA" POWER STEERING OIL PUMP ASSEMBLY AND
A/C COMPRESSOR ASSEMBLY REMOVAL
1. Remove the oil pump and A/C compressor (with the hose
attached).
2. Suspend the removed oil pump (by using wire or similar
material) at a place where no damage will be caused
during removal/installation of the engine assembly.
AB" ENGINE ASSEMBLY REMOVAL
1. Check that all cables, hoses, harness connectors, etc.
are disconnected from the engine.
2. Lift the chain block slowly to remove the engine assembly
upward from the engine compartment.
INSTALLATION SERVICE POINT
"AA ENGINE ASSEMBLY INSTALLATION
Install the engine assembly. When doing so, check carefully
that all pipes and hoses are connected, and that none are
twisted, damaged, etc.
NOTES
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