engine overhaul  - OUT
11F-1
GROUP 11F
ENGINE OVERHAUL
<4G69>
CONTENTS
GENERAL INFORMATION . . . . . . . .
11F-2
GENERAL SPECIFICATIONS . . . . . .
11F-2
SERVICE SPECIFICATIONS. . . . . . .
11F-3
REWORK DIMENSIONS . . . . . . . . . .
11F-5
TORQUE SPECIFICATIONS . . . . . . .
11F-5
SEALANTS . . . . . . . . . . . . . . . . . . . .
11F-8
SPECIAL TOOLS. . . . . . . . . . . . . . . .
11F-9
ALTERNATOR AND IGNITION
SYSTEM . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
EXHAUST MANIFOLD. . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
TIMING BELT. . . . . . . . . . . . . . . . . . .
11F-13
11F-13
11F-16
11F-16
11F-18
INLET MANIFOLD AND
WATER PUMP . . . . . . . . . . . . . . . . . . 11F-30
REMOVAL AND INSTALLATION . . . . . . . .
11F-30
ROCKER ARMS AND CAMSHAFT . . 11F-34
REMOVAL AND INSTALLATION . . . . . . . .
11F-34
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
11F-36
CYLINDER HEAD AND VALVES. . . . 11F-37
REMOVAL AND INSTALLATION . . . . . . . .
11F-37
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
11F-40
OIL PAN AND OIL PUMP. . . . . . . . . . 11F-43
REMOVAL AND INSTALLATION . . . . . . . .
11F-43
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
11F-51
PISTON AND CONNECTING ROD . . 11F-53
REMOVAL AND INSTALLATION . . . . . . . .
11F-53
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
11F-58
CRANKSHAFT AND
CYLINDER BLOCK . . . . . . . . . . . . . . 11F-60
REMOVAL AND INSTALLATION . . . . . . . .
11F-18
REMOVAL AND INSTALLATION . . . . . . . .
11F-60
INSPECTION . . . . . . . . . . . . . . . . . . . . . . .
11F-26
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
11F-64
FUEL AND EMISSION PARTS . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
11F-28
11F-28
11F-2
ENGINE OVERHAUL <4G69>
GENERAL INFORMATION
GENERAL INFORMATION
M1113000100534
VEHICLE AND ENGINE MODELS
Vehicle name
Vehicle
model
Engine model
Displacement Specification
mL
Outlander
CU5W
4G69-2
2,378
Single overhead camshaft, 16-valve
GENERAL SPECIFICATIONS
M1113000200791
Item
Specification
Type
In-line OHV, SOHC
Number of cylinders
4
Combustion chamber
Pent roof type
Total displacement cm3
2,378
Cylinder bore mm
87
Piston stroke mm
100
Compression ratio
9.5
Valve timing
Intake valve
Opens (BTDC)
10° <Low speed cam A>
12° <Low speed cam B>
24° <High speed cam>
Closes (ABDC)
42° <Low speed cam A>
44° <Low speed cam B>
68° <High speed cam>
Exhaust valve
Opens (BBDC)
58°
Closes (ATDC)
18°
Lubrication system
Pressure feed, full-flow filtration
Oil pump type
Involute gear type
11F-3
ENGINE OVERHAUL <4G69>
SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
M1113000300806
Item
Standard value
Limit
Auto tensioner rod length mm
3.8 − 4.5
−
Auto-tensioner rod projection length mm
12
−
Timing belt
Auto-tensioner rod pushed-in amount [When pushed with a 1.0 or less
force of 98 − 196 N] mm
−
Valve clearance mm
Intake
0.11
−
Exhaust
0.20
−
Low speed
cam A
33.84
Minimum 33.34
Low speed
cam B
37.35
Minimum 36.85
High speed 37.21
cam
Minimum 36.71
37.86
Minimum 37.36
45
−
Cylinder head flatness of gasket surface mm
Less than 0.03
0.2
Cylinder head grinding limit of gasket surface mm (Total
resurfacing depth of cylinder head and cylinder block)
−
0.2
Cylinder head overall height mm
120
−
Cylinder head bolt shank length mm
−
99.4
Valve thickness of valve head
(margin) mm
Intake
1.0
Minimum 0.5
Exhaust
1.2
Minimum 0.7
Valve overall height mm
Intake
111.33
Minimum 110.83
Exhaust
113.54
Minimum 113.04
6.0
−
Intake
0.02 − 0.04
0.10
Exhaust
0.04 − 0.06
0.15
43.5° − 44°
−
Intake
54.8
Minimum 53.8
Exhaust
56.1
Minimum 55.1
Valve spring load/installed height N/mm
267/44.2
−
Valve spring out-of-squareness
2° or less
4°
Valve seat valve contact width mm
0.9 − 1.3
−
Valve guide inside diameter mm
6.0
−
Valve guide projection from cylinder head upper surface
mm
14.0
−
Rocker arms and camshaft
Camshaft cam height mm
Intake
Exhaust
Camshaft journal outside diameter mm
Cylinder head and valves
Valve stem outside diameter mm
Valve thickness to valve guide
clearance mm
Valve face angle mm
Valve spring free length mm
11F-4
ENGINE OVERHAUL <4G69>
SERVICE SPECIFICATIONS
Item
Standard value
Limit
Intake
48.33
48.83
Exhaust
48.34
48.84
Drive gear
0.08 − 0.14
−
Driven gear
0.06 − 0.12
−
Dimension (Normal
temperature)
34.5 (1.358)
−
By-pass hole closing
temperature 97 to
103°C
40.0 (1.575)
−
78 or more
−
87
−
No. 1
0.03 − 0.07
0.1
No. 2
0.02 − 0.06
0.1
No. 1
0.15 − 0.30
0.8
No. 2
0.28− 0.43
0.8
Oil ring side rail
0.10 − 0.40
1.0
Piston pin outside 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 outside diameter mm
57.0
−
Crankshaft pin outside diameter mm
45.0
−
Oil clearance at crankshaft
journals mm
No. 1,2,4,5 journal
0.02 − 0.03
0.1
No. 3 journal
0.03 − 0.04
0.1
Bearing cap bolt shank length mm
−
71.1
Piston to cylinder clearance mm
0.02 − 0.04
−
Cylinder block flatness of gasket surface mm
0.05
0.1
Valve stem projection mm
Oil pan and oil pump
Oil pump side clearance mm
Oil cooler by-pass valve mm
Oil pressure at curb idle speed kPa
[oil temperature is 75 to 90°]
Piston and connecting rod
Piston outside diameter mm
Piston ring side clearance mm
Piston ring end gap mm
Crankshaft and cylinder block
Cylinder block grinding limit of gasket surface mm (Total
−
resurfacing depth of both cylinder head and cylinder block)
0.2
Cylinder block overall height mm
284
−
Cylinder block inside diameter mm
87.0
−
Cylindricity mm
0.01
−
11F-5
ENGINE OVERHAUL <4G69>
REWORK DIMENSIONS
REWORK DIMENSIONS
M1113024300413
Item
Standard value
Cylinder head And valves
Diameter of oversize valve seat ring hole in cylinder head
mm
Intake
Exhaust
Diameter of oversize valve guide hole in cylinder head mm
0.3 oversize
35.30 − 35.33
0.6 oversize
35.60 − 35.63
0.3 oversize
33.30 − 33.33
0.6 oversize
33.60 − 33.63
0.05 oversize
11.05 − 11.07
0.25 oversize
11.25 − 11.27
0.50 oversize
11.50 − 11.52
TORQUE SPECIFICATIONS
M1113023401971
Item
N⋅m
Alternator and ignition system
Auto-tensioner bracket bolt M10
44 ± 10
Auto-tensioner bracket bolt M8
22 ± 4
Camshaft position sensing cylinder bolt
22 ± 4
Camshaft position sensor bolt
11 ± 1
Camshaft position sensor support bolt
14 ± 1
Connector bracket bolt
11 ± 1
Crankshaft pulley bolt
25 ± 4
Alternator bolt
49 ± 9
Alternator pivot nut
44 ± 10
Idler pulley bolt
79 ± 5
Ignition coil bolt
10 ± 2
Oil level gauge guide bolt
13 ± 1
Spark plugs
25 ± 5
Water pump pulley bolt
8.8 ± 1.0
Exhaust manifold
Oxygen sensor
44 ± 5
Engine hanger bolt
24 ± 3
Exhaust manifold cover bolt
14 ± 1
Exhaust manifold bracket B bolt
59± 10
Exhaust manifold nut
49 ± 5
Exhaust manifold bracket A bolt
35 ± 6
Timing belt
Auto-tensioner bolt
23 ± 3
Camshaft sprocket bolt
89 ± 9
11F-6
ENGINE OVERHAUL <4G69>
TORQUE SPECIFICATIONS
Item
N⋅m
Counterbalance shaft sprocket bolt
45 ± 3
Crankshaft bolt
167
Crankshaft angle sensor bolt
8.5 ± 0.5
Engine support bracket bolt
49 ± 5
Generator bracket bolt
49 ± 9
Idler pulley bolt
35 ± 6
Oil pump sprocket nut
54 ± 4
Tensioner "B" bolt
19 ± 3
Tensioner arm bolt
21 ± 4
Tensioner pulley bolt
48 ± 5
Timing belt cover bolt M6 (Bolt, washer assembly)
9.0 ± 1.0
Timing belt cover bolt M6 (Flange bolt and nut)
11 ± 1
Timing belt cover bolt M8
14 ± 1
Fuel and emission parts
EGR valve bolt
24 ± 3
Injectors and delivery pipe bolt
11 ± 1
Solenoid valve bracket bolt
11 ± 1
Solenoid valve nut
9.0 ± 1.0
Throttle body bolt
19 ± 3
Vacuum pipe and hose bolt
11 ± 1
Inlet manifold and water pump
Detonation sensor
23 ± 2
Engine coolant temperature gauge unit
11 ± 1
Engine coolant temperature sensor
30 ± 9
Engine hanger bolt
24 ± 3
Harness bracket bolt
11 ± 1
Inlet manifold bolt
24 ± 3
Inlet manifold nut
20 ± 2
Inlet manifold stay bolt
31 ± 3
Manifold differential pressure sensor bolt
5.0 ± 1.0
Oil pressure switch
19 ± 3
Thermostat housing bolt
24 ± 4
Water inlet fitting bolt
13 ± 2
Water inlet pipe bolt
13 ± 2
Water outlet fitting bolt
13 ± 2
Water pump bolt
14 ± 1
Rocker arms and camshaft
Accumulator body bolt
44 ± 5
Oil feeder control valve bolt
11 ± 1
Rocker arms and rocker arm shaft bolt <exhaust side>
13 ± 1
11F-7
ENGINE OVERHAUL <4G69>
TORQUE SPECIFICATIONS
Item
N⋅m
Rocker arms and rocker arm shaft bolt <intake side>
31 ± 3
Nut
9.0 ± 1.0
Rocker cover bolt
3.5 ± 0.5
Taper plug
47 ± 7
Cylinder head and valves
Cylinder head bolt
78 ± 2 → 0 → 20 ± 2 → +90° →
+90°
Oil pan and oil pump
Drain plug
39 ± 5
Flange bolt
36 ± 3
Front case bolt
23 ± 3
Oil cooler by-pass valve
54 ± 5
Oil filter bracket bolt
19 ± 3
Oil pan bolt
9.0 ± 3.0
Oil pump cover bolt
17 ± 1
Oil pump cover screw
10 ± 2
Oil screen bolt
19 ± 3
Plug
23 ± 3
Relief plug
44 ± 5
Transmission stay bolt
22 ± 4
Piston and connecting rod
Connecting rod cap nut
20 ± 2 → +90° to 94°
Crankshaft and cylinder block
Bearing cap bolt
25 ± 2 → +90°
Bell housing cover bolt
9.0 ± 1.0
Drive plate bolt
132 ± 5
Flywheel bolt
132 ± 5
Oil seal case bolt
11 ± 1
Rear plate bolt
11 ± 1
11F-8
ENGINE OVERHAUL <4G69>
SEALANTS
SEALANTS
M1113000500725
Item
Specified sealant
Camshaft position sensor support*
Mitsubishi Genuine Part No. MD970389 or equivalent
Engine support bracket seal bolt
Mitsubishi Genuine Part No. MD970389 or equivalent
Engine coolant temperature sensor
3M ATD No.8660 or equivalent
Engine coolant temperature e gauge unit
3M Nut Locking Part No.4171 or equivalent
Water outlet fitting*
Mitsubishi Genuine Part No. MD970389 or equivalent
Thermostat housing*
Thermostat housing seal bolt
3M™ AAD Part No. 8672 or equivalent
Oil pressure switch
3M ATD No.8660 or equivalent
Oil pan*
Mitsubishi Genuine Part No. MD970389 or equivalent
Rear oil seal case*
NOTE: *: Part to be sealed with a form-in-place gasket (FIPG)
FORM-IN-PLACE GASKET (FIPG)
This engine has several areas where the
form-in-place gasket (FIPG) is used for sealing. To
ensure that the FIPG fully serves its purpose, it is
necessary to observe some precautions when applying it.
Bead size, continuity and location are of paramount
importance. Too thin a bead could cause leaks. Too
thick a bead, on the other hand, could be squeezed
out of location, causing blocking or narrowing of fluid
passages. To prevent leaks or blocking of passages,
therefore, it is absolutely necessary to apply the
FIPG evenly without a break, while observing the
correct bead size.
FIPG hardens as it reacts with the moisture in the
atmospheric air, and it is usually used for sealing
metallic flange areas.
REMOVAL OF FIPG SEALED PARTS
Parts sealed with a FIPG can be easily removed
without need for the use of a special method. In
some cases, however, the FIPG in joints may have to
be broken by tapping parts with a mallet or similar
tool. You can also tap a flat, thin gasket scraper into
the joint to break the FIPG, taking extreme care not
to damage the mating surfaces. The oil pan remover
(MD998727) is available as a special tool for removing the oil pan. The tool, however, must not be used
with an aluminum oil pan as it could damage the mating surfaces.
CLEANING FIPG APPLICATION
SURFACE
Thoroughly remove all substances deposited on the
FIPG application surface, using a gasket scraper or
wire brush. Make sure that the FIPG application surface is flat and smooth. Also make sure that the surface is free from oils, greases and foreign
substances. Do not fail to remove old FIPG that may
remain in the fastener fitting holes.
APPLICATION OF FIPG
Applied FIPG bead should be of the specified size
and free of any break. FIPG can be wiped away
unless it has completely hardened. Install the mating
parts in position while the FIPG is still wet (in less
than 15 minutes after application). Do not allow FIPG
to spread beyond the sealing areas during installation. Avoid operating the engine or letting oils or
water come in contact with the sealed area before a
time sufficient for FIPG to harden (approximately one
hour) has passed. FIPG application method may
vary from location to location. Follow the instruction
for each particular case described later in this manual.
11F-9
ENGINE OVERHAUL <4G69>
SPECIAL TOOLS
SPECIAL TOOLS
M1113000601769
Tool
Number
Name
Use
MD998781
Flywheel stopper
Supporting drive plate
MB991883
Flywheel stopper
Supporting flywheel
MB991398
Spark plug wrench
Removal and installation of
spark plug
MD998770
Oxygen sensor wrench
Removal and installation of
oxygen sensor
MD998778
Crankshaft sprocket
puller
Removal of crankshaft sprocket
MD998785
Sprocket stopper
Supporting counterbalance
shaft sprocket
MB990767
End yoke holder
Holding camshaft sprocket
when loosening or torquing bolt
MD998719
Pins
D998781
MB991883
B990767
D998719
11F-10
ENGINE OVERHAUL <4G69>
SPECIAL TOOLS
Tool
Number
Name
Use
MD998738
Adjusting screw
• Holding the auto-tensioner
• Timing belt tension
adjustment
MD998767
Tension pulley wrench
Adjustment of timing belt
tension
MD998012
Oil pressure switch
socket wrench
Removal and installation of oil
pressure switch <to cylinder
block>
MD998713
Camshaft oil seal
installer
Installation of camshaft oil seal
MB991654
Cylinder head bolt
wrench (12)
Removal and installation of
cylinder head bolt
MD998735
Valve spring compressor Compression of valve spring
MB991999
Valve steam seal
installer
D998738
D998767
D998713
B991654
B991999
Installation of valve steam seal
11F-11
ENGINE OVERHAUL <4G69>
SPECIAL TOOLS
Tool
Number
Name
Use
MD998162
Plug wrench
Removal and installation of
front case cap plug
MD998783
Plug wrench retainer
MD998371
Silent shaft bearing
puller
Removal of counterbalance
shaft front bearing
MD998372
Silent shaft bearing
puller
Removal of counterbalance
shaft rear bearing
MB991603
Bearing installer stopper Removal and installation of rear
bearing
MD998705
Silent shaft bearing
installer
Installation of counterbalance
shaft bearing
MD998285
Crankshaft front oil seal
guide
Installation of crankshaft front
oil seal
MD998375
Crankshaft front oil seal
installer
D998285
11F-12
ENGINE OVERHAUL <4G69>
SPECIAL TOOLS
Tool
D998776
Number
Name
Use
MD998780
Piston pin setting tool
Removal and installation of
piston pin
MB992010
Bolt guide
Removal and installation of
piston and connecting rod
assembly
MB990938
Handle
Installation of crankshaft rear oil
seal
MD998776
Crankshaft rear oil seal
installer
11F-13
ENGINE OVERHAUL <4G69>
ALTERNATOR AND IGNITION SYSTEM
ALTERNATOR AND IGNITION SYSTEM
REMOVAL AND INSTALLATION
M1113001001395
11 ± 1 N·m
10 ± 2 N·m
1
10
11 ± 1 N·m
13
25 ± 5 N·m
14
11
15
16
13 ± 1 N·m
12
11 ± 1 N·m
14 ± 1 N·m
2
22 ± 4 N·m
3
8
4
6
44 ± 10 N·m
8.8 ± 1.0 N·m
22 ± 4 N·m
25 ± 4 N·m
7
79 ± 5 N·m
49 ± 9 N·m
9
5
44 ± 10 N·m
AK301540AD
1.
2.
3.
4.
5.
6.
7.
8.
Removal steps
Oil level gauge
Oil level gauge guide
O-ring
Auto tensioner
Crankshaft pulley
Water pump pulley
Idler pulley
Connector bracket
9.
10.
<<A>> >>C<< 11.
12.
13.
14.
>>B<< 15.
<<B>> >>A<< 16.
Removal steps (Continued)
Alternator
Ignition coil
Spark plug
Connector bracket
Camshaft position sensor
O-ring
Camshaft position sensor support
Camshaft position sensing cylinder
11F-14
ENGINE OVERHAUL <4G69>
ALTERNATOR AND IGNITION SYSTEM
REMOVAL SERVICE POINT
<<A>> SPARK PLUG REMOVAL
INSTALLATION SERVICE POINT
>>A<< CAMSHAFT POSITION SENSING
CYLINDER INSTALLATION
<A/T>
MB991398
AK300130 AD
Using special tool Spark plug wrench (MB991398),
removal the spark plug.
<<B>> CAMSHAFT POSITION SENSING
CYLINDER REMOVAL
MD998781
AK300135 AG
<M/T>
MB991883
<A/T>
AK600660AB
MD998781
AK300135 AG
<M/T>
MB991883
AK600659AB
1. Using special tool Flywheel stopper (MD998781),
hold the drive plate.
• Flywheel stopper (MB991883)
• Flywheel stopper (MD998781)
2. Removal the camshaft position sensing cylinder.
1. Using special tool Flywheel stopper (MD998781),
hold the drive plate.
• Flywheel stopper (MB991883)
• Flywheel stopper (MD998781)
2. Tighten the camshaft position sensing cylinder to
the specified torque.
Tightening torque: 22 ± 4 N⋅m
11F-15
ENGINE OVERHAUL <4G69>
ALTERNATOR AND IGNITION SYSTEM
>>B<< CAMSHAFT POSITION SENSOR
SUPPORT INSTALLATION
>>C<< SPARK PLUG INSTALLATION
3 mm
MB991398
AK300130 AD
AK300004AE
1. Remove completely the FIPG remaining on the
camshaft position sensor support and cylinder
head.
2. Apply a 3 ± 1 mm diameter bead of FIPG to the
indicated surface of the camshaft position sensor
support.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
Using special tool Spark plug wrench (MB991398),
tighten the spark plug to the specified torque.
Tightening torque: 25 ± 5 N⋅m
11F-16
ENGINE OVERHAUL <4G69>
EXHAUST MANIFOLD
EXHAUST MANIFOLD
REMOVAL AND INSTALLATION
M1113004900747
14 ± 1 N·m
14 ± 1 N·m
4
7
49 ± 5 N·m
6
1
2
3
44 ± 5 N·m
24 ± 3 N·m
5
44 ± 5 N·m
8
35 ± 6 N·m
59 ± 10 N·m
AK303751AD
<<A>> >>B<<
<<A>> >>B<<
>>B<<
1.
2.
3.
4.
Removal steps
Engine hanger
Oxygen sensor
Oxygen sensor
Exhaust manifold cover
>>A<<
5.
6.
7.
8.
Removal steps (Continued)
Exhaust manifold bracket B
Exhaust manifold
Exhaust manifold gasket
Exhaust manifold bracket A
11F-17
ENGINE OVERHAUL <4G69>
EXHAUST MANIFOLD
REMOVAL SERVICE POINT
<<A>> OXYGEN SENSOR REMOVE
>>B<< EXHAUST MANIFOLD COVER /
OXYGEN SENSOR INSTALLATION
1. Install the exhaust manifold cover to the exhaust
manifold.
2. Temporarily tighten the exhaust manifold cover
bolt.
MD998770
AK300132AD
MD998770
Using special tool Oxygen sensor wrench
(MD998770), removal the oxygen sensor.
INSTALLATION SERVICE POINT
>>A<< EXHAUST MANIFOLD BRACKET
"B" INSTALLATION
AK300131
Check to ensure that the exhaust manifold bracket
"B" is in close contact with the exhaust manifold and
the cylinder block before tightening the respective
mounting bolts to the specified torque.
AK300132AD
3. Using special tool Oxygen sensor wrench
(MD998770), install both of the oxygen sensors to
the exhaust manifold.
NOTE: Do not remove the special tool after the
oxygen sensor is installed.
4. Tighten the exhaust manifold cover bolt to the
specified torque of 14 ± 1N⋅m.
5. Remove the special tool.
11F-18
ENGINE OVERHAUL <4G69>
TIMING BELT
TIMING BELT
REMOVAL AND INSTALLATION
M1113001901525
2
1
14 ± 1 N·m
6
5
48 ± 5 N·m
23 ± 3 N·m
7
11 ± 1 N·m
21 ± 4 N·m
14 ± 1 N·m
14
13
12
22
167 N·m
11 ± 1 N·m
3
9.0 ± 1.0 N·m
23
19
18
4
45 ± 3 N·m
26
49 ± 9 N·m
89 ± 9 N·m
25
21
20
49 ± 5 N·m
8
15
11
<<B>> >>H<<
<<C>> >>G<<
>>G<<
10
49 ± 9 N·m
8.5 ± 0.5 N·m
17
19 ± 3 N·m
54 ± 4 N·m
>>I<<
9
16
35 ± 6 N·m
<<A>> >>K<<
>>J<<
24
Removal steps
1. Connector bracket
2. Timing belt front upper cover
3. Timing belt front lower cover
4. Timing belt
5. Tensioner pulley
6. Tensioner arm
7. Auto-tensioner
8. Idler pulley
9. Bracket
10. Crankshaft angle sensor
11. Oil pump sprocket
12. Crankshaft bolt
13. Crankshaft pulley washer
AK301538 AC
Removal steps (Continued)
<<D>> >>G<< 14. Crankshaft sprocket
>>G<< 15. Crankshaft sensing blade
16. Tensioner "B"
<<E>> >>F<< 17. Timing belt "B"
<<F>> >>E<< 18. Counterbalance shaft sprocket
>>D<< 19. Spacer
<<G>> >>C<< 20. Crankshaft sprocket "B"
21. Crankshaft key
22. Generator bracket
>>B<< 23. Engine support bracket
24. Timing belt rear cover
<<H>> >>A<< 25. Camshaft sprocket bolt
26. Camshaft sprocket
11F-19
ENGINE OVERHAUL <4G69>
TIMING BELT
REMOVAL SERVICE POINTS
<<A>> TIMING BELT REMOVAL
<<C>> CRANKSHAFT BOLT LOOSENING
<M/T>
MB991883
AK600659AB
AK300133
<A/T>
CAUTION
Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and
tensioner must be washed or immersed in solvent. Replace parts if contaminated.If there is oil
or water on any part, check the front case oil
seals, camshaft oil seal, and water pump for
leaks.
1. Mark the belt running direction for reinstallation.
2. Loosen the tensioner pulley bolt, and then remove
the timing belt.
<<B>> OIL PUMP SPROCKET REMOVAL
1. Remove the plug on the left side of the cylinder
block.
MD998781
AK300135 AG
1. Install Flywheel stopper (MD998781) to hold the
drive plate or the flywheel.
• Flywheel stopper (MB991883)
• Flywheel stopper (MD998781)
2. Loosen and remove the crankshaft bolt and
washer.
<<D>> CRANKSHAFT SPROCKET
REMOVAL
AK300134
2. Insert a Phillips screwdriver (shank diameter 8
mm) through the plug hole to block the left
counterbalance shaft.
3. Loosen the nut, and then remove the oil pump
sprocket.
MD998778
AK300136 AD
1. Set special tool Crankshaft sprocket puller
(MD998778) as shown in the illustration.
2. Screw in the center bolt of the special tool to
remove the crankshaft sprocket.
11F-20
ENGINE OVERHAUL <4G69>
TIMING BELT
<<E>> TIMING BELT "B" REMOVAL
<<G>> CRANKSHAFT SPROCKET "B"
REMOVAL
AK300137
CAUTION
Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and
tensioner must be free from oil and water. These
parts should not be washed or immersed in solvent. Replace parts if contaminated.If there is oil
or water on each part, check the front case oil
seals, camshaft oil seal and water pump for
leaks.
MD998778
1. Set special tool Crankshaft sprocket puller
(MD998778) as shown in the illustration.
2. Screw in the center bolt of the special tool to
remove crankshaft sprocket "B."
<<H>> CAMSHAFT SPROCKET
REMOVAL
1. Mark the belt running direction for reinstallation.
2. Loosen the tensioner "B" bolt, and then remove
the timing belt "B."
<<F>> COUNTERBALANCE SHAFT
SPROCKET REMOVAL
AK300139AD
MB990767
MD998719
MD998785
AK300140 AD
1. Remove the camshaft sprocket.
2. Use the special tools to prevent the camshaft
sprocket from rotating.
• End yoke holder (MB990767)
• Pulley holder pin (MD998719)
AK300138 AD
1. Set special tool Sprocket stopper (MD998785) as
shown to prevent the counterbalance shaft
sprocket from turning together.
2. Loosen the bolt and remove the sprocket.
11F-21
ENGINE OVERHAUL <4G69>
TIMING BELT
INSTALLATION SERVICE POINTS
>>A<< CAMSHAFT SPROCKET INSTALLATION
>>C<< CRANKSHAFT SPROCKET "B"
INSTALLATION
Sprocket "B"
Crankshaft
MB990767
Degrease
Front case
MD998719
AK300141 AD
1. Use the special tools to prevent the camshaft
sprocket from rotating.
• End yoke holder (MB990767)
• Pulley holder pin (MD998719)
2. Tighten the camshaft sprocket bolt to the specified
torque.
Tightening torque: 89 ± 9 N⋅m
Clean and then degrease the front case of the front
case, crankshaft sprocket "B" and crankshaft surface
on which sprocket "B" is attached.
NOTE: Degreasing is necessary to prevent decrease
in the friction between contacting surfaces.
>>D<< SPACER INSTALLATION
Oil seal
>>B<< ENGINE SUPPORT BRACKET
INSTALLATION
AK301828AC
Counter
balance
shaft
Spacer
Chamfered
AK301298AD
1. Apply a thin coat of clean engine oil to the lip area
of the oil seal.
2. Install the spacer with the chamfered end facing
toward the oil seal.
AK300142
1. Remove thoroughly the old sealant remaining on
the indicated bolt and in its hole.
2. Coat the bolt with sealant, then install and tighten
it.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
Tightening torque: 49 ± 5 N⋅m
>>E<< COUNTERBALANCE SHAFT
SPROCKET INSTALLATION
MD998785
AK300138 AD
1. Install the counterbalance shaft sprocket and
screw on the bolt.
11F-22
ENGINE OVERHAUL <4G69>
TIMING BELT
2. Install special tool Sprocket stopper (MD998785)
as shown in the illustration to lock the
counterbalance shaft.
3. Tighten the bolt, and then remove the special tool.
Tightening torque: 45 ± 3 N⋅m
>>F<< TIMING BELT "B" INSTALLATION
4. Move tensioner "B" in the direction of the arrow
while lifting with your finger to give sufficient
tension to the tension side of timing belt. In this
condition, tighten the bolt to secure tensioner "B."
When the bolt is tightened, use care to prevent
the tensioner pulley shaft from turning with the
bolt. If the shaft is turned with the bolt, the belt will
be over tensioned.
Tightening torque: 19 ± 3 N⋅m
Timing
mark
Timing
mark
AK300143 AD
1. Align timing marks on the crankshaft sprocket "B"
and counterbalance shaft sprocket with the marks
on the front case.
2. Install the timing belt "B" on the crankshaft
sprocket "B" and counterbalance shaft sprocket.
There should be no slack on the tension side.
5. Check that timing marks on the sprockets are
aligned with the timing marks on the front case.
6. With your index finger, press the midway of span
on the tension side of timing belt "B." The bolt
must deflect 5 to 7 mm.
>>G<< CRANKSHAFT SENSING
BLADE/CRANKSHAFT
SPROCKET/CRANKSHAFT PULLEY
WASHER/CRANKSHAFT BOLT
INSTALLATION
Tensioner "B"
Center of
tensioner pulley
AK300146
Center of
bolt
AK300144 AD
Crankshaft
bolt
Sensing blade
Sprocket
3. Make sure that the tensioner pulley center and the
bolt center are positioned as shown in the
illustration.
Washer
Big chamfered side
AK300145
Crankshaft
Clean
Degrease
AK301075AD
1. Clean and then degrease the contacting surfaces
of the crankshaft sprocket, sensing blade and
crankshaft.
NOTE: Degreasing is necessary to prevent
decrease in the friction between contacting surfaces.
2. Clean the bolt hole in the crankshaft, the
crankshaft contacting surface of the crankshaft
sprocket, and the washer.
11F-23
ENGINE OVERHAUL <4G69>
TIMING BELT
3. Install the sensing blade and the crankshaft
sprocket to the crankshaft.
4. Apply a small amount of engine oil to the threads
and seating surface of the crankshaft bolt.
5. Install the washer to the crankshaft bolt with the
larger chamfered side toward the bolt head.
2. Install the oil pump sprocket.
3. Apply a thin coat of engine oil to the seating
surface of the nut.
4. Tighten the nut to the specified torque.
Tightening torque: 54 ± 5 N⋅m
>>I<< AUTO-TENSIONER INSTALLATION
<M/T>
MB991883
If the auto-tensioner rod is fully extended, reset it as
follows:
AK600660AB
<A/T>
AK300154
1. Clamp the auto-tensioner in a vise with soft jaws.
A
B
MD998781
AK300135 AG
6. Lock the drive plate or the flywheel using the
special tool Flywheel stopper.
• Flywheel stopper (MB991883)
• Flywheel stopper (MD998781)
7. Tighten the crankshaft bolt to the specified torque.
Tightening torque: 167 N⋅m
>>H<< OIL PUMP SPROCKET
INSTALLATION
AK301074AD
2. Push in the rod little by little with the vise until the
set hole A in the rod is aligned with hole B in the
cylinder.
3. Insert a wire (1.4 mm in diameter) into the set
holes. This auto-tensioner setting wire will be
used during timing belt alignment.
4. Unclamp the auto-tensioner from the vise.
AK301073
1. Insert a Phillips head screwdriver (shank diameter
8 mm) through the plug hole on the left side of the
cylinder block to block the left counterbalance
shaft.
AK301832
11F-24
ENGINE OVERHAUL <4G69>
TIMING BELT
CAUTION
Leave the wire installed in the auto-tensioner.
Timing mark
5. Install the auto-tensioner onto the front case and
tighten to the specified torque.
Tightening torque: 23 ± 3 N⋅m
>>J<< TENSIONER PULLEY
INSTALLATION
AK301076AD
3. Align the timing mark on oil pump sprocket with its
mating mark.
60 mm or more
Tensioner
pulley hole
AK300147AD
Set the tensioner pulley so that the holes for attaching a wrench may be positioned as shown in the illustration.
>>K<< TIMING BELT INSTALLATION
Timing mark
AK300148 AD
Counter
balance
shaft
AK301077 AD
4. Remove the plug on the cylinder block and insert
a Phillips head screwdriver (shank diameter 8
mm) through the hole.
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 to 25 mm, turn the
oil pump sprocket one turn and realign the timing
marks. then check to ensure that the screwdriver
can be inserted 60 mm or more. keep the
screwdriver inserted until the timing belt is
completely installed.
1. Align the timing mark on the camshaft sprocket
with the timing mark on the rocker cover.
MD998738
AK300151 AD
Timing mark
AK300149 AD
2. Align the timing mark on the crankshaft sprocket
with the timing mark on the front case.
5. Set the special tool Set screw (MD998738) as
shown and screw it in up to the position where the
wire inserted in the auto-tensioner when installing
it can be moved lightly.
6. Install the timing belt on the crankshaft sprocket,
oil pump sprocket, idler pulley, camshaft sprocket,
and tensioner pulley in that order.
ENGINE OVERHAUL <4G69>
TIMING BELT
11F-25
Auto tensioner
AK301295AD
7. Lift up the tensioner pulley in the direction of the
arrow and tighten the center bolt.
8. Check that all timing marks are aligned.
9. Remove the screwdriver inserted in step 5 and
install the plug.
10.Turn the crankshaft a quarter turn
counterclockwise. Then, turn it clockwise until the
timing marks are aligned again.
AK301836
14. The wire inserted at the auto-tensioner
installation is pulled out and then the special tool
Set screw (MD998738) is removed by hand.
15.Give two clockwise turns to the crankshaft. Wait
for 15 minutes, then proceed with the following
inspection steps.
AK300152
MD998767
AK300150 AD
11.Install special tool Tension pulley socket wrench
(MD998767), socket wrench and torque wrench,
onto the tensioner pulley, and loosen the
tensioner pulley center bolt.
NOTE: Use a torque wrench that can measure 0
to 5.0 N⋅m.
12.Torque to 3.5 N⋅m with the torque wrench.
13.Holding the tensioner pulley with special tool
Tension pulley socket wrench (MD998767) and
torque wrench, tighten the center bolt to
specification.
Tightening torque: 48 ± 5 N⋅m
16.Check to see whether the metal wire (inserted
when the auto-tensioner was installed) can be
removed without any resistance.
If the metal wire can be removed without any
resistance, it means that the belt has a proper
tension. Therefore, remove the metal wire. In this
condition, check that the rod protrusion of the
auto-tensioner is within the standard value.
Standard value: 3.8 − 4.5 mm
17.If the metal wire offers resistance when removed,
repeat the previous steps 10 through 15 until the
standard value is obtained as measured by the
rod projection of the auto-tensioner rod.
11F-26
ENGINE OVERHAUL <4G69>
TIMING BELT
INSPECTION
M1113002000481
TIMING BELT
Rubber exposed
Tooth missing and
canvas fiber exposed
AKX00751AD
AK202794
Replace the belt if any of the following conditions
exist:
1. Hardening of rubber backing.
Back side should be glossy without resilience and
leave no indent when pressed with fingernail.
Cracks
Cracks
7. Abnormal wear on teeth.
Initial stage:
Canvas worn (fluffy canvas fibers, rubbery
texture gone, white discoloration, canvas
texture indistinct)
Final stage:
Canvas worn, exposing rubber (tooth width
reduced)
8. Missing tooth.
AUTO-TENSIONER
Peeling of canvas
Cracks in sides
12 mm
Cracks in tooth roots
2.
3.
4.
5.
AK202793 AD
Cracks on rubber back.
Cracks or peeling of canvas.
Cracks at bottom of ribs.
Cracks on belt sides.
AK301307AD
1. Check for oil leaks. If oil leaks are evident, replace
the auto-tensioner.
2. Check the rod end for wear or damage and
replace the auto-tensioner if necessary.
3. Measure the rod protrusion. If it is out of
specification, replace the auto tensioner.
Standard value: 12 mm
Rounded edge
98 TO 196 N
Abnormal wear
(fluffy strand)
AK202795 AD
Movement
6. Abnormal wear of belt sides. Normal wear is
indicated if the sides are sharp as if cut by a knife.
Abnormal wear is indicated if the sides are
ragged.
AK301308AD
ENGINE OVERHAUL <4G69>
TIMING BELT
4. Press the rod with a force of 98 to 196 N and
measure the movement of the rod.
If the measured value is out of the standard value,
replace the auto-tensioner.
Standard value: 1.0 mm or less
11F-27
3. Measure the valve clearance marked with arrows
shown in the figure.
White arrow mark: When No.1 cylinder is on the
top dead center of compression stroke.
Black arrow mark: When No.4 cylinder is on the
top dead center of compression stroke.
VALVE CLEARANCE ADJUSTMENT
Perform the adjustment of the valve clearance in the
following procedure.
1. Remove the rocker cover.
Timing mark
AK300153
AK300148 AE
CAUTION
Rotate the crankshaft clockwise at any time.
2. Rotate crankshaft clockwise and then align the
timing mark on the camshaft sprocket with the
timing mark on the cylinder head. (Place No. 1
cylinder on the top dead center of compression
stroke.)
Intake valve side
No. 1 No. 2 No. 3 No. 4
Exhaust valve side
AK204362AE
4. Using a thickness gauge, adjust the clearance
between the valve shaft end and the adjusting
screw.
Standard value (in cold state):
Intake side: 0.11 mm
Exhaust side: 0.20 mm
NOTE: After the engine assembly is installed on
the vehicle, check the valve clearance again in
the engine warm-up state. Adjust if necessary.
5. Hold the adjusting screw not rotating through a
driver and then tighten the rock nut.
6. Rotate the crankshaft one time clockwise and
then align the timing mark with the timing mark on
the crankshaft sprocket. (Place No. 4 cylinder on
the top dead center of compression stroke.)
7. Adjust the valve clearance for the rest of the
valves.
8. Install the rocker cover.
11F-28
ENGINE OVERHAUL <4G69>
FUEL AND EMISSION PARTS
FUEL AND EMISSION PARTS
REMOVAL AND INSTALLATION
M1113002200720
19 ± 3 N·m
24 ± 3 N·m
13
12
11 ± 1 N·m
11
9
10
6
8
2
14
1
7
11 ± 1 N·m
3
5
11 ± 1 N·m
9.0 ± 1.0 N·m
4
AK400854AB
>>C<<
1.
2.
3.
4.
5.
6.
7.
Removal steps
Throttle body
Throttle body gasket
Vacuum pipe and hose
Solenoid valve
Solenoid valve bracket
Injector and delivery pipe
Insulator
>>B<<
>>A<<
8.
9.
10.
11.
12.
13.
14.
Removal steps (Continued)
Insulator
Injector
O-ring
Grommet
Delivery pipe
EGR valve
EGR gasket
11F-29
ENGINE OVERHAUL <4G69>
FUEL AND EMISSION PARTS
INSTALLATION SERVICE POINTS
>>A<< EGR VALVE INSTALLATION
CAUTION
Use care not to let engine oil enter the delivery
pipe.
1. Apply clean engine oil to the O-ring.
2. Insert the injector into the delivery pipe.
3. Make sure the injector rotates smoothly.
If not, remove the injector to check the O-ring for
damage, and replace the O-ring if necessary.
Then, reinstall the injector and check that it
rotates smoothly.
AK300578AD
Install a new gasket is positioned as shown in the
illustration.
>>B<< INJECTORS INSTALLATION
>>C<< THROTTLE BODY GASKET
INSTALLATION
Projection
AK300579AD
Install a new gasket so that the projection is positioned as shown in the illustration.
A
A
Inlet
manifold
Delivery pipe
Injector
AK300155AF
11F-30
ENGINE OVERHAUL <4G69>
INLET MANIFOLD AND WATER PUMP
INLET MANIFOLD AND WATER PUMP
REMOVAL AND INSTALLATION
M1113025500164
11 ± 1 N·m
9
5.0 ± 1.0 N·m
13
11 ± 1 N·m
13 ± 2 N·m
2
14
24 ± 4 N·m
16
24 ± 3 N·m
10
1
13 ± 2 N·m
11
7
12
11 ± 1 N·m
30 ± 9 N·m
24 ± 3 N·m
19 ± 3 N·m
18
15
11 ± 1 N·m
13 ± 2 N·m
5
11 ± 1 N·m
19
20 ± 2 N·m
6
17
23 ± 2 N·m
8
20
4
31 ± 3 N·m
3
14 ± 1 N·m
Removal steps
1. Water hose
2. Water hose
3. Water pump
4. Water pump gasket
>>H<< 5. O-ring
>>H<< 6. Water inlet pipe
>>H<< 7. O-ring
>>G<< 8. Inlet manifold stay
>>F<< 9. Engine coolant temperature gauge
unit
10. Water inlet fitting
>>E<< 11. Thermostat
AK403249 AB
Removal steps (Continued)
>>D<< 12. Thermostat housing
13. Manifold differential pressure
sensor
14. Inlet manifold
15. Inlet manifold gasket
16. Engine hanger
17. Detonation sensor
<<A>> >>C<< 18 Oil pressure switch
>>B<< 19. Engine coolant temperature sensor
>>A<< 20. Water outlet fitting
ENGINE OVERHAUL <4G69>
INLET MANIFOLD AND WATER PUMP
REMOVAL SERVICE POINT
<<A>> OIL PRESSURE SWITCH
REMOVAL
11F-31
>>B<< SEALANT APPLICATION TO
ENGINE COOLANT TEMPERATURE
SENSOR
MD998012
AK300156 AF
Using special tool Oil pressure switch wrench
(MD998012), removal the oil pressure switch.
INSTALLATION SERVICE POINTS
>>A<< WATER OUTLET FITTING INSTALLATION
3 mm
AK301336AD
1. Apply a 3 mm diameter bead of FIPG to the
indicated surface of the water outlet fitting.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
2. Install the housing quickly (within 15 minutes)
while the sealant is wet and tighten the bolts to the
specified torque.
Tightening torque: 13 ± 2 N⋅m
NOTE: . After installation, keep the sealed area away
from the coolant for approximately one hour.
AK300712 AB
CAUTION
When using a tool, avoid letting it touch the connector portion which is made of plastic.
1. Remove all old sealant remaining on the threads
of the coolant temperature sensor and in the
threaded hole in the thermostat housing.
2. Apply sealant to the coolant temperature sensor's
threads indicated in the drawing.
Specified sealant:
3M ATD Part No.8660 or equivalent
11F-32
ENGINE OVERHAUL <4G69>
INLET MANIFOLD AND WATER PUMP
>>C<< SEALANT APPLICATION TO OIL
PRESSURE SWITCH
2. Apply a 3 mm diameter bead of FIPG on the
indicated surface of the thermostat housing.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
AK300715 AB
1. Apply sealant to the threaded portion.
Specified Sealant:
3M ATD Part No.8660 or equivalent
MD998012
AK300157 AF
2. Using special tool Oil pressure switch wrench
(MD998012), tighten the oil pressure switch to the
specified torque.
Tightening torque: 19 ± 3 N⋅m
AK300158
3. Coat the bolt with sealant, then install and tighten
it.
Specified sealant:
3M Nut Locking Part No.4171 or equivalent
4. Install the housing quickly (within 15 minutes)
while the sealant is wet and tighten the bolts to the
specified torque.
Tightening torque: 24 ± 4 N⋅m
NOTE: After installation, keep the sealed area
away from the coolant for approximately one hour.
>>E<< THERMOSTAT INSTALLATION
Jiggle valve
>>D<< THERMOSTAT HOUSING
INSTALLATION
Thermostat
housing
AK400855AC
3 mm
AK301337AD
1. Remove all old FIPG remaining on the thermostat
housing and cylinder head.
1. Check that the rubber ring is undamaged and
seated correctly in the thermostat flange.
2. Install the thermostat as shown in the illustration.
The jiggle valve must be at the uppermost
position.
11F-33
ENGINE OVERHAUL <4G69>
INLET MANIFOLD AND WATER PUMP
>>F<< SEALANT APPLICATION TO
ENGINE COOLANT TEMPERATURE
GAUGE UNIT
>>G<< INLET MANIFOLD STAY
INSTALLATION
Inlet manifold
Cylinder block
AK301361AC
AK300711 AB
1. Remove all old sealant remaining on the threaded
hole in the coolant temperature gauge unit and
the thermostat housing.
NOTE: A new coolant temperature gauge unit is
coated with sealant. It does not require coating
with sealant before installation.
2. Apply sealant to the indicated threads of the
coolant temperature gauge unit.
Specified sealant:
3M Nut Locking Part No.4171 or equivalent
1. Install the inlet manifold stay and tighten the bolts
just finger tight.
2. Check to ensure that the stay is in close contact
with the bosses of the inlet manifold and cylinder
block.
3. First tighten the inlet manifold side bolts to the
specified torque, then the cylinder block side bolts
to the specified torque.
Tightening torque: 31 ± 3 N⋅m
>>H<< WATER INLET PIPE/O-RING
INSTALLATION
CAUTION
Keep the O-ring free of oil or grease.
O-ring
Water inlet pipe
AK301861AC
1. Attach a new O-ring to each end of the water inlet
pipe.
2. Wet the O-ring with water.
3. Insert the rear end of the pipe into the thermostat
housing.
11F-34
ENGINE OVERHAUL <4G69>
ROCKER ARMS AND CAMSHAFT
ROCKER ARMS AND CAMSHAFT
REMOVAL AND INSTALLATION
M1113005400875
5
Apply engine oil to
all moving parts
before installation.
3
4
31 ± 3 N·m
12
12
12
12
6
3.5 ± 0.5 N·m
8
9.0 ± 1.0 N·m
1
2
7
12
12
13 ± 1 N·m
12 12
11
18
13
13
13
16 17
12
15
13
13 16 17
13
10
13
12
14
13
15 12
13
13
16 17
12
20
13
15 12
13
16 17
12
26
13
15 12
27
13
47 ± 7 N·m
12
13
13
28
11 ± 1 N·m
19
21
22
23
24
25
44 ± 5 N·m
9
AK305650 AE
Removal steps
1. Breather hose
2. PCV hose
3. PCV valve
4. PCV valve gasket
5. Oil filler cap
6. Rocker cover
7. Rocker cover gasket
8. Oil seal
>>D<< 9. Oil seal
<<A>> >>C<< 10.Rocker arms and rocker arm shaft
(Intake side)
Removal steps (Continued)
<<A>> >>C<< 11. Rocker arms and rocker arm shaft
(Exhaust side)
12.Nut
>>B<< 13.Adjusting screw
14.Rocker arm shaft assembly (Intake
side)
15.Rocker arm "C"
16.Piston arm assembly
17.Rocker arm "D"
18.Rocker arm shaft (Exhaust side)
>>A<< 19.Oil feeder control valve
11F-35
ENGINE OVERHAUL <4G69>
ROCKER ARMS AND CAMSHAFT
Removal steps (Continued)
20.O-ring
21.Snap ring
22.Accumulator spring seat
23.Plunger spring
24.Accumulator plunger
25.Accumulator body
26.Taper plug
27.Oil feeder control valve filter
28.Camshaft
REMOVAL SERVICE POINT
<<A>> ROCKER ARMS AND ROCKER
ARM SHAFT REMOVAL
When the rocker arm is removed from the rocker
shaft, keep them with the tags that show the installation location for the reinstallation of the rocker arm,
the T-lever, the piston arm assembly and so on.
INSTALLATION SERVICE POINTS
>>A<< OIL FEEDER CONTROL VALVE
INSTALLATION
CAUTION
Do not reuse the O-ring.Install the O-ring after
wrap a tape not having adhesion (such as a seal
tape) round the notch on the oil passage of oil
feeder control valve to prevent it from damage.
The damaged O-ring may cause oil leakage.
>>B<< ADJUSTING SCREW
INSTALLATION
3 mm
AK301421 AD
Install provisionally the screw to rocker arm, insert it
so that end of the screw is flush with the edge of the
rocker arm or projects slightly 3 mm.
>>C<< ROCKER SHAFT
SPRING/ROCKER ARMS AND ROCKER
ARM SHAFT INSTALLATION
1. In accordance with the tags for the reinstallation,
install the rocker arm and so on to the rocker arm
shaft.
2. Install the rocker arm shaft with oil hole to the
lower (cylinder head) side.
Timing belt side
Tape
AK301422 AD
AK303651AE
1. Apply a little amount of engine oil to the O-ring of
oil feeder control valve.
2. Install the oil feeder control valve to the cylinder
head.
3. Tighten the oil feeder control valve to the specified
torque of 11 ± 1 N⋅m.
3. Install the rocker arm, rocker arm shaft assembly
and intake temporarily.
4. Install the rocker arm, rocker arm shaft assembly
and exhaust temporarily.
5. Confirm the each rocker arm and rocker arm shaft
assembly are in position and then tighten to the
specified torque.
Tightening torque
M6: 13 ± 1 N⋅m
M8: 31 ± 3 N⋅m
11F-36
ENGINE OVERHAUL <4G69>
ROCKER ARMS AND CAMSHAFT
>>D<< CAMSHAFT OIL SEAL
INSTALLATION
MD998713
INSPECTION
M1113005500496
CAMSHAFT
AK300160 AD
AK300161
1. Apply engine oil to the lip area of the oil seal and
the front end outside diameter of camshaft.
2. Using special tool Camshaft oil seal installer
(MD998713), install the camshaft oil seal.
Measure the cam height. If it is below the limit,
replace the camshaft.
A C B A C B A C B A C B
D D
D D
D D
D D
AK301488AD
Standard
value
Minimum
limit
A: Intake low speed
cam A
33.84 mm
33.34 mm
B: Intake low speed
cam B
37.35 mm
36.85 mm
C: Intake high speed
cam
37.21 mm
36.71 mm
D: Exhaust cam
37.86 mm
37.36 mm
11F-37
ENGINE OVERHAUL <4G69>
CYLINDER HEAD AND VALVES
CYLINDER HEAD AND VALVES
REMOVAL AND INSTALLATION
M1113006900806
78 ± 2 N·m → 0 N·m → 20 ± 2 N·m → +90˚ → +90˚
8
9
1
10
20
14
4
5
15
17
6
12
13
16
19
11
18
2
7
3
Apply engine oil to
all moving parts
before installation.
AK301262AE
Removal steps
<<A>> >>D<< 1. Cylinder head bolt
2. Cylinder head assembly
3. Cylinder head gasket
<<B>> >>C<< 4. Retainer lock
5. Valve spring retainer
>>B<< 6. Valve spring
7. Intake valve
<<B>> >>C<< 8. Retainer lock
9. Valve spring retainer
>>B<< 10.Valve spring
11. Exhaust valve
Removal steps (Continued)
>>A<< 12.Valve stem seal
13.Valve spring seat
>>A<< 14.Valve stem seal
15.Valve spring seat
16.Intake valve guide
17.Exhaust valve guide
18.Intake valve seat
19.Exhaust valve seat
20.Cylinder head
11F-38
ENGINE OVERHAUL <4G69>
CYLINDER HEAD AND VALVES
REMOVAL SERVICE POINTS
<<A>> CYLINDER HEAD BOLTS
REMOVAL
INSTALLATION SERVICE POINTS
>>A<< VALVE STEM SEAL INSTALLATION
MB991999
MB991654
AK300164 AF
AK300162 AD
Using special tool Cylinder head bolt wrench
(MB991654), loosen the cylinder head bolts. Loosen
each bolt evenly, little by little, by two or three steps.
<<B>> RETAINER LOCK REMOVAL
CAUTION
The special tool must be used to install the valve
stem seal. Improper installation could result in oil
leaking past the valve guide.
1. Install the valve spring seat.
2. Using special tool Valve stem seal installer
(MB991999), install a new valve stem seal.
MD998735
>>B<< VALVE SPRING INSTALLATION
Painted end
AK300163 AD
1. Set special tool Valve spring compressor
(MD998735) as illustrated to compress the valve
spring. Remove the retainer lock.
2. Relieve the spring tension and remove the valve,
retainer, spring, etc. Store removed valves,
springs, and other parts, tagged to indicate their
cylinder number and location for assembly.
AK300717AB
Install the valve spring with its identification color
painted end (larger pitch side) upward (toward the
valve spring retainer).
Identicifation:
<Intake> Light blue
<Exhaust> Orange
11F-39
ENGINE OVERHAUL <4G69>
CYLINDER HEAD AND VALVES
>>C<< RETAINER LOCK INSTALLATION
MD998735
MB991654
AK300165 AD
AK300163 AD
CAUTION
Do not compress the valve spring excessively. It
can damage the stem seal.
1. Set special tool Valve spring compressor
(MD998735) as illustrated to compress the valve
spring. Install the retainer locks.
2. Relieve the spring tension. Check that the retainer
locks are seated correctly.
>>D<< CYLINDER HEAD BOLT
INSTALLATION
Timing belt side
8
6
1
3
10
4
2
5
9
7
AK306004AC
3. Using special tool Cylinder head bolt wrench
(MB991654) tighten the bolts to the specified
torque, using the tightening sequence shown.
Tightening torque: 78 ± 2 N⋅m
4. Loosen all bolts fully in the reverse order of
tightening.
5. Retighten the loosened bolts to in the tightening
sequence shown.
Tightening torque: 20 ± 2 N⋅m
Shank length
AK300591AB
1. When the removed cylinder head bolts are to be
reused, check that the shank length of each bolt
meets the limit. If it exceeds the limit, replace the
bolts.
Limit: 99.4 mm
2. Apply engine oil to the thread of the bolts and to
the washers.
90˚
90˚
Paint mark
AK300166 AD
6. Make a paint mark across each bolt head and
cylinder head.
7. Tighten the cylinder head bolts 90 degrees in the
specified order.
11F-40
ENGINE OVERHAUL <4G69>
CYLINDER HEAD AND VALVES
CAUTION
• If the bolt is turned less than 90 degrees,
proper fastening performance may not be
achieved. Be careful to turn each bolt exactly
90 degrees.
• If the bolt is overtightened, loosen the bolt
completely and then retighten it by repeating
the tightening procedure from step 1.
8. Tighten the bolts another 90 degrees in the same
order as in step 7, and check that the paint marks
on the cylinder head bolt are aligned with the paint
marks on the cylinder head.
INSPECTION
M1113007000709
CYLINDER HEAD
VALVE
Contact
(Should be at
centre of face)
Margin
AK300593AB
1. Check the valve seat contact. Valve seat contact
should be uniform at the center of the valve face.
If incorrect, reface using a valve refacer.
2. If the margin is below the limit, replace the valve.
Standard value:
<Intake> 1.0 mm
<Exhaust> 1.2 mm
Minimum limit:
<Intake> 0.5 mm
<Exhaust> 1.0 mm
AK300167
1. Check the cylinder head gasket surface for
flatness by using a straight edge and feeler
gauge.
Standard value: 0.03 mm
Limit: 0.2 mm
2. If it exceeds the limit, correct to meet
specification.
Grinding limit: *0.2 mm
* Includes combined with cylinder block grinding.
Cylinder head height (Specification when
new): 120 mm
Total length
AK103808AC
3. Measure the valve's total length. If the
measurement is less than the limit, replace the
valve.
Standard value:
<Intake> 111.33 mm
<Exhaust> 113.54 mm
Minimum limit:
<Intake> 110.83 mm
<Exhaust> 113.04 mm
11F-41
ENGINE OVERHAUL <4G69>
CYLINDER HEAD AND VALVES
VALVE SPRING
VALVE SEAT
Valve stem
end
Out of square
Valve stem
projection
Free height
Spring
seating
surface
AK300596 AB
AK300718AB
1. Measure the free height of the spring. If it is less
than the limit, replace.
Standard value:
<Intake> 54.8 mm
<Exhaust> 56.1 mm
Minimum limit:
<Intake> 53.8 mm
<Exhaust> 55.1 mm
2. Measure the squareness of the spring. If it
exceeds the limit, replace.
Standard value: 2 degrees or less
Limit: 4 degrees
VALVE GUIDE
Assemble the valve, then measure the valve stem
projection between the end of the valve stem and the
spring seating surface. If the measurement exceeds
the specified limit, replace the valve seat.
Standard value:
<Intake> 48.33 mm
<Exhaust> 48.34 mm
Limit:
<Intake> 48.83 mm
<Exhaust> 48.84 mm
VALVE SEAT RECONDITIONING PROCEDURE
Intake side
0.9 – 1.3 mm
Exhaust side
0.9 – 1.3 mm
65˚
Valve
guide
65˚
20˚
10˚
43.5˚ – 44˚
AK300385AB
Stem diameter
AK300168 AE
Guide inside diameter
Measure the clearance between the valve guide and
valve stem. If it exceeds the limit, replace the valve
guide or valve, or both.
Standard value:
<Intake> 0.02 − 0.04 mm
<Exhaust> 0.04 − 0.06 mm
Limit:
<Intake> 0.10 mm
<Exhaust> 0.15 mm
1. Before correcting the valve seat, check for
clearance between the valve guide and valve and,
if necessary, replace the valve guide.
2. Using the seat grinder, correct to obtain the
specified seat width and angle.
3. After correcting the valve seat, lap the valve and
valve seat using lapping compound. Then, check
the valve stem projection.
11F-42
ENGINE OVERHAUL <4G69>
CYLINDER HEAD AND VALVES
VALVE SEAT REPLACEMENT PROCEDURE
VALVE GUIDE REPLACEMENT PROCEDURE
1. Using a press, remove the valve guide toward the
cylinder block.
0.5 – 1 mm
CAUTION
Do not install a valve guide of the same size
again.
Cut
0.5 – 1 mm
AK300719AB
1. Cut the valve seat from the inside to thin the wall
thickness. Then, remove the valve seat.
2. Rebore the valve guide hole of the cylinder head
so that it fits the press-fitted oversize valve guide.
Valve guide hole diameters
0.05 oversize 11.05 − 11.07 mm
0.25 oversize 11.25 − 11.27 mm
0.50 oversize 11.50 − 11.52 mm
Valve seat
height
14.0 mm
Oversize hole diameter
AK400856AB
AK300720AB
2. Rebore the valve seat hole in the cylinder head to
a selected oversize valve seat diameter.
Intake seat ring hole diameters
0.3 oversize: 35.30 − 35.33 mm
0.6 oversize: 35.60 − 35.63 mm
Exhaust seat ring hole diameters
0.3 oversize: 33.30 − 33.33 mm
0.6 oversize: 33.60 − 33.63 mm
3. Before fitting the valve seat, either heat the
cylinder head up to approximately 250°C or cool
the valve seat in liquid nitrogen, to prevent the
cylinder head bore from galling.
4. Using a valve seat cutter, correct the valve seat to
the specified width and angle.
See "VALVE SEAT RECONDITIONING
PROCEDURE" on the previous page.
3. Press-fit the valve guide until it protrudes 14.0 mm
from the cylinder head top surface as shown in
the illustration.
NOTE: When press-fitting the valve guide, work
from the cylinder head top surface.
NOTE: Pay attention to the difference in length of
the valve guides. (Intake side: 45.5 mm; exhaust
side: 50.5 mm)
NOTE: After installing the valve guides, insert new
valves in them to check for smooth operation.
11F-43
ENGINE OVERHAUL <4G69>
OIL PAN AND OIL PUMP
OIL PAN AND OIL PUMP
REMOVAL AND INSTALLATION
M1113008101348
<M/T>
29
27
30
Apply engine oil to
all moving parts
before installation.
20
31
19
10 ± 2 N·m
23 ± 3 N·m
28
25
54 ± 5 N·m
13
21
8
17 ± 1 N·m
7
15
19 ± 3 N·m
6
19 ± 3 N·m
22
24
14
23
26
18
12
11
10
16
9
17
23 ± 3 N·m
36 ± 3 N·m
23 ± 3 N·m
4
9.0 ± 3.0 N·m
44 ± 5 N·m
3
1
2
39 ± 5 N·m
22 ± 4 N·m
5
9.0 ± 3.0 N·m
AK400857 AB
>>M<<
>>L<<
<<A>> >>K<<
<<B>> >>K<<
<<C>> >>J<<
Removal steps
1. Drain plug
2. Drain plug gasket
3. Oil filter
4. Transmission stay
5. Oil pan lower
6. Oil pan upper
7. Oil screen
8. Oil screen gasket
9. Relief plug
10.Gasket
11. Relief spring
12.Relief plunger
13.Oil cooler by-pass valve <M/T>
14.Oil filter bracket
15.Oil filter bracket gasket
16.Plug
<<D>> >>I<<
>>H<<
>>G<<
>>G<<
>>F<<
>>E<<
>>D<<
<<E>> >>C<<
<<F>> >>B<<
<<F>> >>A<<
Removal steps (Continued)
17.O-ring
18.Flange bolt
19.Front case
20.Front case gasket
21.Oil pump cover
22.Oil pump driven gear
23.Oil pump drive gear
24.Crankshaft front oil seal
25.Oil pump oil seal
26.Counterbalance shaft oil seal
27.Counterbalance shaft, left
28.Counterbalance shaft, right
29.Counterbalance shaft, front bearing
30.Counterbalance shaft, rear bearing,
right
31.Counterbalance shaft, rear bearing, left
11F-44
ENGINE OVERHAUL <4G69>
OIL PAN AND OIL PUMP
<A/T>
28
26
29
Apply engine oil to
all moving parts
before installation.
19
30
18
10 ± 2 N·m
23 ± 3 N·m
27
24
20
17 ± 1 N·m
7
14
8
19 ± 3 N·m
6
19 ± 3 N·m
21
23
13
22
25
17
16
12
11
10
15
9
23 ± 3 N·m
36 ± 3 N·m
23 ± 3 N·m
4
9.0 ± 3.0 N·m
44 ± 5 N·m
3
1
2
22 ± 4 N·m
39 ± 5 N·m
9.0 ± 3.0 N·m
5
AK600666 AB
>>M<<
>>L<<
<<A>> >>K<<
<<B>> >>K<<
<<C>> >>J<<
<<D>> >>I<<
Removal steps
1. Drain plug
2. Drain plug gasket
3. Oil filter
4. Transmission stay
5. Oil pan lower
6. Oil pan upper
7. Oil screen
8. Oil screen gasket
9. Relief plug
10.Gasket
11. Relief spring
12.Relief plunger
13.Oil filter bracket
14.Oil filter bracket gasket
15.Plug
16.O-ring
17.Flange bolt
Removal steps (Continued)
>>H<< 18.Front case
19.Front case gasket
20.Oil pump cover
>>G<< 21.Oil pump driven gear
>>G<< 22.Oil pump drive gear
>>F<< 23.Crankshaft front oil seal
>>E<< 24.Oil pump oil seal
>>D<< 25.Counterbalance shaft oil seal
26.Counterbalance shaft, left
27.Counterbalance shaft, right
<<E>> >>C<< 28.Counterbalance shaft, front bearing
<<F>> >>B<< 29.Counterbalance shaft, rear bearing,
right
<<F>> >>A<< 30.Counterbalance shaft, rear bearing, left
11F-45
ENGINE OVERHAUL <4G69>
OIL PAN AND OIL PUMP
REMOVAL SERVICE POINTS
<<A>> OIL PAN LOWER REMOVAL
<<D>> FLANGE BOLT REMOVAL
CAUTION
Do not use a scraper or special tool MD998727 to
remove the oil pan.
Apply a wood block to the oil pan side and remove
the oil pan lower by tapping lightly on it with a plastic
hammer.
<<B>> OIL PAN UPPER REMOVAL
1. Remove all bolts.
AK300172
1. Remove the plug on the side of the cylinder block.
2. Insert a Phillips screwdriver (shank diameter 8
mm) into the plug hole to lock the counterbalance
shaft.
A
A
AK304400 AB
CAUTION
Do not use a scraper or special tool MD998727 to
remove the oil pan.
AK300173
2. Screw a bolt into hole A shown to remove the oil
pan.
3. Loosen the flange bolt.
<<C>> PLUG REMOVAL
<<E>> COUNTERBALANCE SHAFT
FRONT BEARING REMOVAL
MD998162
MD998783
AK300171 AD
Fit the teeth of the special tools in notches of the plug
as shown in the drawing and support the tool with the
special tool to loosen the plug.
• Plug wrench (MD998162)
• Plug wrench retainer (MD998783)
MD998371
AK300174 AD
CAUTION
Be sure to remove the front bearing first. If it has
not been removed, special tool Silent shaft bearing puller (MD998372) cannot be used for rear
balance shaft bearing removal.
Using special tool Silent shaft bearing puller
(MD998371), remove the counterbalance shaft front
bearing from the cylinder block.
11F-46
ENGINE OVERHAUL <4G69>
OIL PAN AND OIL PUMP
<<F>> COUNTERBALANCE SHAFT REAR
BEARING REMOVAL
INSTALLATION SERVICE POINTS
>>A<< LEFT COUNTERBALANCER
SHAFT REAR BEARING INSTALLATION
MB991603
MD998372
AK300175AD
1. Use the special tool Silent shaft bearing puller
(MD998372) to remove the counterbalancer shaft
rear bearings from the cylinder block.
MD998705
AK300177 AF
MB991603
MD998705
MB991603
Rear bearing
AK300619AG
MD998372
AK300176 AD
2. When removing the rear bearing of the left
counterbalancer shaft, install the special tool
Silent shaft bearing installer stopper (MB991603)
on the front of the cylinder block and use a special
tool Silent shaft bearing puller (MD998372) to pull
out the bearing.
1. Install special tool Silent shaft bearing installer
stopper (MB991603) to the cylinder block.
2. Apply engine oil to the rear bearing outer surface
and bearing hole in the cylinder block.
3. Using special tool Silent shaft bearing installer
(MD998705), install the rear bearing.
NOTE: The left rear bearing has no oil holes.
>>B<< RIGHT COUNTERBALANCER
SHAFT REAR BEARING INSTALLATION
MD998705(Guide pin)
AK300178 AD
1. Install the guide pin of the Silent shaft bearing
installer (MD998705) in the threaded hole of the
cylinder block as shown.
11F-47
ENGINE OVERHAUL <4G69>
OIL PAN AND OIL PUMP
Ratchet ball
>>C<< COUNTERBALANCE SHAFT
FRONT BEARING INSTALLATION
Oil hole
MD998705
Rear bearing right
AK300621AD
2. Align the ratchet ball of the special tool with the oil
hole in the rear bearing to install the bearing of the
special tool.
3. Apply engine oil to the bearing outer surface and
bearing hole in the cylinder block.
Rear bearing
installing portion
AK300623AF
1. Remove the rear bearing installing portion from
the special tool Silent shaft bearing installer
(MD998705).
MD998705
MD998705(Guide pin)
MD998705(Guide pin)
AK300179 AG
MD998705
AK300178 AD
2. Install the guide pin of the Silent shaft bearing
installer (MD998705) in the threaded hole of the
cylinder block as shown.
Ratchet ball
Oil hole
AK300622AG
4. Using special tool Silent shaft bearing installer
(MD998705), install the rear bearing. Make sure
that the oil hole of the bearing is aligned with the
oil hole of the cylinder block.
Front bearing right
AK304592AB
3. Align the ratchet ball of the special tool with the oil
hole in the rear bearing to install the bearing of the
special tool.
4. Apply engine oil to the front bearing outer surface
and bearing hole in the cylinder.
11F-48
ENGINE OVERHAUL <4G69>
OIL PAN AND OIL PUMP
>>E<< OIL PUMP OIL SEAL
INSTALLATION
MD998705
Socket wrench
Oil seal
Front case
MD998705(Guide pin)
AK300179 AG
AK301070AD
Using a suitable socket wrench, install the oil pump
oil seal into the front case.
>>F<< CRANKSHAFT FRONT OIL SEAL
INSTALLATION
MD998375
AK300624
5. Using special tool Silent shaft bearing installer
(MD998705), install the rear bearing. Make sure
that the oil hole of the bearing is aligned with the
oil hole of the cylinder block.
Oil seal
Front case
>>D<< COUNTERBALANCE SHAFT OIL
SEAL INSTALLATION
Socket wrench
Oil seal
Front case
AK301072AD
Using special tool Crankshaft front oil seal installer
(MD998375), install the crankshaft front oil seal into
the front case.
>>G<< OIL PUMP DRIVEN GEAR/OIL
PUMP DRIVE GEAR INSTALLATION
AK301071AD
Using a suitable socket wrench, install the counterbalance shaft oil seal into the front case.
Alignment
mark
AK300180 AD
Install the oil pump gears into the front case and
align the alignment marks.
11F-49
ENGINE OVERHAUL <4G69>
OIL PAN AND OIL PUMP
>>H<< OIL PUMP CASE INSTALLATION
>>I<< FLANGE BOLT INSTALLATION
MD998285
AK300181AD
1. Set special tool Crankshaft front oil seal guide
(MD998258) on the front end of crankshaft and
apply a thin coat of engine oil to the outer surface
of special tool.
2. Apply engine oil to the lip of the crankshaft front oil
seal.
AK300172
1. Insert a Phillips head screwdriver (shank diameter
8 mm) into the hole in the left side of the cylinder
block to lock the counterbalance shaft.
AK300183
MD998285
AK300182 AD
3. Install the front case carefully not to damage the
oil seal.
20 mm
22 mm
40 mm
2. Secure the oil pump driven gear onto the left
counterbalance shaft by tightening the flange bolt
to the specified torque.
Tightening torque: 36 ± 3 N⋅m
3. Pull out the screwdriver and screw in the plug.
>>J<< PLUG INSTALLATION
25 mm
32 mm
MD998162
AK301520AD
CAUTION
Carefully install the tightening bolts because of
the different length respectively.
4. Tighten all flange bolts to the specified torque.
Tightening torque: 23 ± 3 N⋅m
MD998783
AK300184 AD
1. Install a new O-ring to the groove of the front
case.
2. Install the plug to the front case.
3. Use the special tools to tighten the plug to the
specified torque.
• Plug wrench (MD998162)
• Plug wrench retainer (MD998783)
Tightening torque: 23 ± 3 N⋅m
11F-50
ENGINE OVERHAUL <4G69>
OIL PAN AND OIL PUMP
>>K<< OIL PAN UPPER/OIL PAN LOWER
INSTALLATION
CAUTION
Do not apply FIPG over remaining old FIPG.
Doing so could result in oil leakage.
1. Clean the gasket surfaces of the cylinder block
and oil pan.
Timing belt side
CAUTION
Do not apply FIPG over remaining old FIPG.
Doing so could result in oil leakage.
4. Thoroughly remove old FIPG from the gasket
surfaces of the oil pan upper and lower sections.
Timing belt side
Bolt hole
area
Bolt hole
area
Grooved area
Grooved
area
AK304401 AB
CAUTION
Too much FIPG will squeeze out, blocking coolant or oil passages, while too thin a bead could
result in leakage.
2. Apply a 4 mm diameter bead of FIPG to the flange
surface all around the oil pan.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
NOTE: In the grooved areas on the oil pan flange,
apply FIPG bead along the center of the groove.
AK304403 AB
CAUTION
Too much FIPG will squeeze out, blocking coolant or oil passages, while too thin a bead could
result in leakage.
5. Apply a 4 mm diameter bead of FIPG to the flange
surface all around the oil pan.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
NOTE: In the grooved areas on the oil pan flange,
apply FIPG bead along the center of the groove.
Timing belt side
9
8
5
4
12
M6 × 16
1
11
3
2
6
7
10
AK304404 AB
AK304402 AB
3. Install the shorter bolts in the locations indicated
in the drawing.
6. Install the oil pan lower section by tightening the
bolts in the indicated sequence.
ENGINE OVERHAUL <4G69>
OIL PAN AND OIL PUMP
11F-51
>>L<< DRAIN PLUG GASKET
INSTALLATION
Drain plug
General service tool
Oil pan
Gasket
Oil pan
side
AK300601AB
CAUTION
If the gasket is installed in the wrong direction,
oil leaks will occur.
Install the drain plug gasket in the direction shown.
>>M<< OIL FILTER INSTALLATION
1. Clean the installation surface of the filter bracket.
AK300186 AD
3. Using general service tool, Install the oil filter to
the bracket and tighten it to the specified torque.
Tightening torque
Part number MD356000 filter: 14 ± 2 N⋅m
Other Mitsubishi Genuine filter: 17 ± 3 N⋅m
4. If a torque wrench cannot be used use the
following procedure:
(1) Screw in the oil filter until its o-ring contacts
the oil filter bracket.
(2) Tighten the oil filter as follows:
Part number MD356000 filter: one turn
Other Mitsubishi Genuine filter: 3/4 turn
INSPECTION
M1113008200290
FRONT CASE
1. Check the oil passage for clogging. Clean if
necessary.
2. Check the left counterbalance shaft front bearing
for wear, damage and seizure. If the bearing is
damaged, replace the front case.
3. Check the front case for cracks and other
damage.
Replace cracked or damaged front case.
OIL SEAL
AK301069AD
2. Apply engine oil to the o-ring of the oil filter.
1. Check the oil seal lip for wear and damage.
Replace the oil seal if necessary.
2. Check the oil seal lip for deterioration. Replace
the oil seal if necessary.
11F-52
ENGINE OVERHAUL <4G69>
OIL PAN AND OIL PUMP
COUNTERBALANCE SHAFT
OIL COOLER BYPASS VALVE
L
AK300187
1. Check the oil holes for clogging and clean if
necessary.
2. Check the journal for seizure, damage and
contact with bearing. If there is anything wrong
with the journal, replace the counterbalance shaft,
bearing or front case assembly if required.
OIL PUMP
1. Assemble the oil pump gears to the front case and
rotate it to ensure smooth rotation with no
looseness.
2. Ensure that there is no ridge wear on the contact
surface between the front case and the gear
surface of the oil pump cover.
AK300188
3. Check the side clearance.
Standard value:
Drive gear 0.08 − 0.14 mm
Driven gear 0.06 − 0.12 mm
Valve
AK000032 AC
1. Make sure that valve moves smoothly.
2. Ensure that the dimension L measures the
standard value under normal temperature and
humidity.
Standard value: 34.5 mm
3. The dimension must be the standard value when
measured after the valve has been dipped in 97 to
103°C oil.
Standard value: 40.0 mm
11F-53
ENGINE OVERHAUL <4G69>
PISTON AND CONNECTING ROD
PISTON AND CONNECTING ROD
REMOVAL AND INSTALLATION
M1113008400885
6
7
8
10
4
9
12
11
5
Apply engine oil to
all moving parts
before installation.
3
2
1
20 ± 2 N·m → +90º to 94º
AK306012 AC
>>G<<
<<A>> >>F<<
>>D<<
<<B>> >>E<<
>>D<<
>>C<<
>>C<<
1.
2.
3.
4.
5.
6.
7.
Removal steps
Nut
Connecting rod cap
Connecting rod bearing
Piston and connecting rod assembly
Connecting rod bearing
Piston ring No. 1
Piston ring No. 2
Removal steps (Continued)
>>B<< 8. Oil ring
<<C>> >>A<< 9. Piston pin
10.Piston
11. Connecting rod
12.Bolt
11F-54
ENGINE OVERHAUL <4G69>
PISTON AND CONNECTING ROD
REMOVAL SERVICE POINTS
<<A>>CONNECTING ROD CAP
REMOVAL
<<C>> PISTON PIN REMOVAL
Guide A: 17.9 mm
Push
rod
Guide B
Cylinder
number
Guide A: 18.9 mm
Guide C
Guide A: 20.9 mm
AK202812 AB
Base
1. Mark the cylinder number on the side of the
connecting rod big end for correct reassembly.
2. Keep the removed connecting rods, caps, and
bearings in that order according to the cylinder
number.
<<B>> PISTON AND CONNECTING ROD
ASSEMBLY REMOVAL
MB992010
Guide A: 21.9 mm
AK301562 AB
The special tool Piston pin setting tool (MD998780),
consists of the elements shown in the drawing.
Push rod
Front mark
Crank pin
AK402310 AC
1. Not to damage the crank pin, attach a special tool
Bolt guide (MB992010), to the connecting rod
bolt.
2. Remove the piston and connecting rod assembly
from the cylinder block.
Front
mark
Guide C
Base
AK202781 AB
1. Insert the tool element, Push rod, into the piston
from the front mark side, then attach the element,
Guide C, to the push rod.
2. Place the piston and connecting rod assembly on
the element, Base, with the front mark facing up.
3. Use a press to remove the piston pin.
11F-55
ENGINE OVERHAUL <4G69>
PISTON AND CONNECTING ROD
NOTE: Keep the disassembled pistons, piston
pins and connecting rods cylinder by cylinder.
INSTALLATION SERVICE POINTS
6. Insert the tool element, Guide B, into the tool
element, Guide A, with having 2.75 mm of the
clearance "L" between the tool element, Guide A
and B.
>>A<< PISTON PIN INSTALLATION
Push rod
Timing belt side
Crankshaft
bore size mark
Piston pin
Front mark
No.1
No.2
No.3
No.4
AK301530 AD
1. When replacing a piston, check the cylinder bore
size mark stamped at the indicated location on the
cylinder block and select an appropriate
replacement piston using the following table.
Cylinder bore size mark
Piston size mark
I
A
II
No mark
III
C
2.
3.
4.
5.
NOTE: The piston size mark is located on the piston top surface.
Insert the tool element, Push rod, into the piston
pin and attach the element, Guide A, to the push
rod end.
Assemble the connecting rod with the piston with
their front marks facing in the same direction.
Apply engine oil to the outside surface of the
piston pin.
Insert the assembly of piston pin, Push rod, and
Guide A (put together in step 4.) into the piston
holes from the front mark side.
Front
mark
Guide A
Base
Guide B
AK202782 AB
7. Place the piston and connecting rod assembly
onto the element, Piston setting base, with the
front marks facing up.
8. Install the piston pin using a press. If the required
press force is less than the standard value,
replace the piston and piston pin assembly or the
connecting rod, or both.
Standard value: 7,350 − 17,100 N
L
AK301796
9. Check that the piston moves smoothly.
Guide B
Guide A
AK301480 AD
11F-56
ENGINE OVERHAUL <4G69>
PISTON AND CONNECTING ROD
>>B<< OIL RING INSTALLATION
1. Fit the oil ring spacer into the piston ring groove.
>>C<< PISTON RING NUMBER 2/PISTON
RING NUMBER 1 INSTALLATION
Side rail end
Piston ring
expander
AK300190 AD
Upper
side rail
Spacer
AK300191 AD
1. Using the piston ring expander, fit number 2 into
the number 2 groove of piston.
NOTE: Install piston rings with identification mark
facing up, to the piston crown side.
2. Install the number 1 piston ring in the same
manner as step 1.
Lower
side rail
AK300395AE
No.1
CAUTION
Do not use a piston ring expander when installing side rail.
2. Install the upper side rail.
To install the side rail, first fit one end of the rail
into the piston groove, then press the remaining
portion into position by hand. See illustration.
NOTE: The side rails and spacer may be installed
in either direction.
NOTE: New spacers and side rails are colored for
identification of their sizes.
Size
Identification color
Standard
None
0.50 mm oversize
diameter
Red
3. Install the lower side rail in the same manner as
described in step 2.
4. Make sure that the side rails move smoothly in
both directions.
No.2
AK301452AD
Identification mark
<Number 1 ring> 1R
<Number 2 ring> 2R
NOTE: Confirm the profile for No.1 and No.2 piston rings carefully. Install them correctly by careful
attention to the direction of top and bottom.
NOTE: The identification mark and the size mark
are stamped on the upper plane of the piston ring
(piston top side).
Size
Size mark
Standard
None
0.50 mm oversize
diameter
50
3. To prevent wrong installation, check the
identification mark of each piston ring. The
identification mark is stamped near the ring gap.
11F-57
ENGINE OVERHAUL <4G69>
PISTON AND CONNECTING ROD
>>D<< CONNECTING ROD BEARING
INSTALLATION
>>E<< PISTON AND CONNECTING ROD
INSTALLATION
Side rail
Locations of crankshaft pin diameter
marks
No. 1
No. 2
No. 3
No. 1
Side rail
No. 2
No. 4
AK202730 AB
AK304412 AB
1. Apply engine oil on the circumference of the
piston, piston rings, and oil ring.
2. Arrange the piston ring and oil ring gaps (side rail
and spacer) as shown in the illustration.
3. Rotate the crankshaft so that the crank pin is on
the center of the cylinder bore.
Identification
color position
Bolt
Identification
mark position
AK400858AC
1. Measure the crankshaft pin diameter and confirm
its classification from the following table. On a
crankshaft supplied as a service part,
identification marks of its pins are stamped at the
positions shown in the illustration.
Crankshaft pin outside
diameter
Connecting
rod bearing
Identification Size mm
mark
Identification
mark
I
44.995 − 45.000
1
II
44.985 − 44.995
2
III
44.980 − 44.985
3
MB992010
Connecting rod
AK402300AC
4. Not to damage the crank pin, attach a special tool
Bolt guide (MB992010), to the connecting rod
bolt.
2. If the crankshaft pin outside diameter identification
mark is "I," for example, select a bearing whose
identification mark is "1."
If there is no identification color paint on the
crankshaft, measure the pin outside diameter and
select a bearing appropriate for the measured
value.
3. Install the selected bearing in the big end and in
the cap of the connecting rod.
AK300192
5. Use suitable thread protectors on the connecting
rod bolts before inserting the piston and
connecting rod assembly into the cylinder block.
Care must be taken not to nick the crank pin.
6. Insert the piston and connecting rod assembly
into the cylinder with the front mark on the piston
crown pointing to the timing belt side.
11F-58
ENGINE OVERHAUL <4G69>
PISTON AND CONNECTING ROD
7. Using a suitable piston ring compressor tool,
install the piston and connecting rod assembly
into the cylinder block.
>>F<< CONNECTING ROD CAP
INSTALLATION
Cylinder
number
2. Before installing each nut, apply engine oil to the
threaded portion and bearing surface of the nut.
3. Loosely tighten each nut to the bolt.
4. Then tighten the nuts alternately to the specified
torque to install the cap properly.
Tightening torque: 20 ± 2 N⋅m
Paint
mark
90˚ to 94˚
Paint mark
Nut
Notches
AK300193 AD
1. Verifying the mark made during disassembly,
install the bearing cap to the connecting rod. If the
connecting rod is new with no index mark, make
sure that the bearing locking notches are on the
same side as shown.
AK300194
2. Make sure that the connecting rod big end side
clearance meets the specification.
Standard value: 0.10 − 0.25 mm
Limit: 0.4 mm
>>G<< CONNECTING ROD CAP NUT
TIGHTENING
1. The connecting rod bolts should be examined
before reuse. If the bolt threads are damaged, the
bolt should be replaced.
Hand-thread the nut to the full length of the bolt
threads. If the nut does not run down smoothly,
the bolt should be replaced.
Bolt
AK301477AD
5. Make a paint mark on the head of each nut.
6. Make a paint mark on the bolt end at the position
90 to 94 degrees from the paint mark made on the
nut in the direction of tightening the nut.
CAUTION
• If the nut is turned less than 90 degrees,
proper fastening performance may not be
achieved. Be careful to tighten the nut exactly
90 degrees.
• If the nut is overtightened (exceeding 94
degrees), loosen the nut completely and then
retighten it by repeating the tightening procedure from step 3.
7. Turn the nut 90 to 94 degrees and make sure that
the paint marks on the nut and bolt are aligned.
INSPECTION
M1113008500473
PISTON
Replace the piston if scratches or seizure is evident
on its surfaces (especially the thrust surface).
Replace the piston if it is cracked.
PISTON PIN
1. Insert the piston pin into the piston pin hole with
your thumb. You should feel a slight resistance.
Replace the piston pin if it can be easily inserted
or there is an excessive play.
2. The piston and piston pin must be replaced as an
assembly.
11F-59
ENGINE OVERHAUL <4G69>
PISTON AND CONNECTING ROD
PISTON RING
1. Check the piston ring for damage, excessive
wear, and breakage. Replace if defects are
evident. If the piston has been replaced, the
piston rings must also be replaced.
CRANKSHAFT PIN OIL CLEARANCE
<PLASTIGAGE METHOD>
1. Remove oil from the crankshaft pin and the
connecting rod bearing.
Plastigage
AK300196AE
AK300195
2. Check for clearance between the piston ring and
ring groove. If it exceeds the limit, replace the ring
or piston, or both.
Standard value:
<Number 1> 0.03 − 0.07 mm
<Number 2> 0.02 − 0.06 mm
Limit: 0.1 mm
2. Cut plastigage to the same length as the width of
the bearing and place it on the pin, parallel with its
axis.
3. Install the connecting rod cap carefully and tighten
the nuts to the specified torque.
4. Carefully remove the connecting rod cap.
Push in by
piston
Plastigage
AK300197AE
Piston ring
Piston ring gap
AK301481AD
3. Insert the piston ring into the cylinder bore. Force
the ring down with a piston, the piston crown
being in contact with the ring, to correctly position
it at right angles to the cylinder wall. Then,
measure the end gap with a feeler gauge.
If the ring gap is excessive, replace the piston
ring.
Standard value:
<Number 1> 0.15 − 0.30 mm
<Number 2> 0.28 − 0.43 mm
<Oil> 0.10 − 0.40 mm
Limit:
<Number 1, Number 2> 0.8 mm
<Oil> 1.0 mm
5. Measure the width of the plastigage at its widest
part by using a scale printed on the plastigage
package.
Standard value: 0.02 − 0.05 mm
Limit: 0.1 mm
11F-60
ENGINE OVERHAUL <4G69>
CRANKSHAFT AND CYLINDER BLOCK
CRANKSHAFT AND CYLINDER BLOCK
REMOVAL AND INSTALLATION
M1113008701986
CAUTION
On the flexible flywheel equipped engines, do not remove any of the bolts "A" of the flywheel shown
in the illustration. The balance of the flexible flywheel is adjusted in an assembled condition. Removing the bolt, therefore, can cause the flexible flywheel to be out of balance giving and resulting in
damage.
11 ± 1 N·m
13
6
12
7
9
21
132 ± 5 N·m
8
10
11
11 ± 1 N·m
132 ± 5 N·m
1
9.0 ± 1.0 N·m
20
4
19
2
18
5
A
3
17
16
14
15
>
<<A> >>F<< 1.
2.
3.
4.
5.
>
<<A> >>F<< 6.
7.
Removal steps
Flywheel bolt (M/T)
Adapter plate (M/T)
Flywheel (M/T)
Adapter plate (M/T)
Crankshaft bushing (M/T)
Drive plate bolt (A/T)
Adapter plate (A/T)
Apply engine oil to
all moving parts
before installation.
25 ± 2 N·m → +90˚
25 ± 2 N·m → +90˚
AK400859 AB
>>E<<
>>D<<
>>C<<
>>C<<
Removal steps (Continued)
8. Drive plate (A/T)
9. Crankshaft bushing (A/T)
10.Rear plate
11. Bell housing cover
12.Oil seal case
13.Oil seal
14.Bearing cap bolt (Head 17)
15.Bearing cap bolt (Head 14)
11F-61
ENGINE OVERHAUL <4G69>
CRANKSHAFT AND CYLINDER BLOCK
Removal steps (Continued)
>>C<< 16.Bearing cap
>>B<< 17.Crankshaft bearing (Lower)
18.Crankshaft
>>B<< 19.Crankshaft bearing (Upper)
>>A<< 20.Crankshaft thrust bearing
21 Cylinder block
REMOVE SERVICE POINTS
<<A>>DRIVE PLATE BOLT AND FLYWHEEL BOLT REMOVE
<M/T>
MB991883
Groove
AK301467AD
2. The thrust bearings must be installed with their
groove side toward the crankshaft web.
>>B<< CRANKSHAFT BEARING
INSTALLATION
When bearing replacement is required, select and
install the correct bearing by the following procedure.
Location of crankshaft journal
diameter marks
AK600659AB
<A/T>
No. 2
No. 1
No. 3
No. 4
MD998781
AK300135 AG
1. Lock the drive plate or the flywheel using the
special tool Flywheel stopper.
• Flywheel stopper (MB991883)
• Flywheel stopper (MD998781)
2. Remove the drive plate bolt or the flywheel bolt.
INSTALLATION SERVICE POINTS
>>A<< CRANKSHAFT THRUST BEARING
INSTALLATION
1. Install the two thrust bearings in the number 3
bearing bore in the cylinder block. For easier
installation, apply engine oil to the bearings; this
will help hold them in position.
No. 5
AK304413 AB
1. Measure the crankshaft journal diameter and
confirm its classification from the following table.
In the case of a crankshaft supplied as a service
part, identification marks of its journals are
stamped at the positions shown in the illustration.
Timing belt side
No. 1
No. 2 No. 3
No. 4
No. 5
Cylinder bore
indentification
mark
AK300198 AD
2. The cylinder block bearing bore diameter
identification marks are stamped at the position
shown in the illustration from left to right,
beginning at No.1.
11F-62
ENGINE OVERHAUL <4G69>
CRANKSHAFT AND CYLINDER BLOCK
Crankshaft journal outside diameter
Cylinder block
bearing bore
Identification mark Size mm
Identification mark Identification mark
Identification mark
0
1
0
1
2
1
2
3
2
0
2
1
1
3
2
2
4
3
0
3
2
1
4
3
2
5
4
56.994 − 57.000
0
56.988 − 56.994
1
56.982 − 56.988
2
Crankshaft bearing Crankshaft bearing
for No.3
>>C<< BEARING CAP/BEARING CAP
BOLT INSTALLATION
1. Install the bearing caps so that the arrow points to
the timing belt side.
Identification
color position
Identification
mark position
AK400858AC
For example, if the crankshaft journal outside diameter identification mark is "0" and cylinder block bearing bore identification mark is "1," select a bearing
whose identification mark is "2" for number 1, 2, 4
and 5, and a bearing whose identification mark is "1"
for number 3.
If there is no identification mark on the crankshaft,
measure the journal outside diameter and select a
bearing appropriate for the measured value.
Groove
Shank length
AK301471AD
2. Before installing the bearing cap bolts, check that
the shank length of each bolt meets the limit. If it
exceeds the limit, replace the bolt.
Limit: 71.1 mm
3. Apply engine oil to the threaded portion and
bearing surface of the bolt.
8
4
1
5
9
7
3
2
6
10
For upper
For lower
AK301466AD
3. Install the bearings having an oil groove to the
cylinder block.
4. Install the bearings having no oil groove to the
bearing cap.
Arrow
AK300199 AD
4. Tighten the bolts to the specified in the tightening
sequence shown.
Tightening torque: 25 ± 2 N⋅m
11F-63
ENGINE OVERHAUL <4G69>
CRANKSHAFT AND CYLINDER BLOCK
>>D<< OIL SEAL INSTALLATION
Paint mark
Paint mark
MB990938
MD998776
90˚
AK300200 AD
5. Make a paint mark on the head of each bolt.
6. Make a paint mark on the bearing cap 90 degrees
from the paint mark made on the bolt in the
direction of tightening the bolt.
CAUTION
• If the bolt is overtightened, loosen the bolt
completely and then retighten it by repeating
the tightening procedure from step 4.
• If the bolt is turned less than 90 degrees,
proper fastening performance may not be
achieved. Be sure to turn the bolt exactly 90
degrees.
7. Turn each bolt 90 degrees in the tightening
sequence specified in step 4, and make sure that
the paint marks on the bolt and cap are aligned.
AK300202 AD
Use the special tools to press-fit the rear oil seal in
the rear oil seal case.
• Handle (MB990938)
• Crankshaft rear oil seal installer (MD998776)
>>E<< SEALANT APPLICATION TO OIL
SEAL CASE
1. Remove completely old FIPG remaining on the
rear oil seal case and cylinder block.
AK300576AD
AK300201
8. Make sure that the crankshaft turns smoothly and
the end play is correct. If the end play exceeds the
limit, replace the number 3 crankshaft bearings.
Standard value: 0.05 − 0.25 mm
Limit: 0.40 mm
2. Apply a bead of FIPG to the surface of the rear oil
seal case as shown in the drawing.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
NOTE: Be sure to install the case quickly while the
sealant is wet (within 15 minutes).
3. Install the oil seal into the cylinder block after
applying an appropriate amount of engine oil to
the entire circumference of its lip portion.
4. Install the rear oil seal case by tightening its bolts
to 11 ± 1 N⋅m.
NOTE: After installation, keep the sealed area away
from the oil for approximately one hour.
11F-64
ENGINE OVERHAUL <4G69>
CRANKSHAFT AND CYLINDER BLOCK
>>F<< DRIVE PLATE BOLT AND
FLYWHEEL BOLT INSTALLATION
1. Using the special tool Flywheel stopper secure
the drive plate or the flywheel.
<M/T>
MB991883
INSPECTION
M1113008800474
CRANKSHAFT JOURNAL OIL
CLEARANCE <PLASTIGAGE METHOD>
1. Remove oil from the crankshaft journal and
crankshaft bearing.
2. Install the crankshaft.
Plastigage
AK600660AB
<A/T>
AK300203AE
3. Cut the plastigage to the same length as the width
of bearing and place it on journal in parallel with
its axis.
4. Install the crankshaft bearing cap carefully and
tighten the bolts to the specified torque.
5. Carefully remove the crankshaft bearing cap.
MD998781
AK300135 AG
2. Tighten the flywheel bolt to the specified torque of
132 ± 5 N⋅m.
Plastigage
AK300204 AE
6. Measure the width of the plastigage at its widest
part by using a scale printed on the plastigage
package.
Standard value:
No.1,2,4,5 journal: 0.02 − 0.03 mm
No.3 journal: 0.03 − 0.04 mm
Limit: 0.1 mm
11F-65
ENGINE OVERHAUL <4G69>
CRANKSHAFT AND CYLINDER BLOCK
CYLINDER BLOCK
BORING CYLINDER
Piston outside
diameter
AK403250
1. Visually check for scratches, rust, and corrosion.
Use also a flaw detecting agent for the check. If
defects are evident, correct or replace.
2. Using a straightedge and feeler gauge, check the
block top surface for warpage. Make sure that the
surface is free from gasket chips and other foreign
matter.
Standard value: 0.05 mm
Limit: 0.1 mm
3. If the distortion is excessive, correct within the
allowable limit or replace.
Grinding limit: 0.2 mm
*Includes/combined with cylinder head
grinding
Cylinder block height (when new):
290 mm
4. Check cylinder walls for scratches and seizure. If
defects are evident, replace or bore to oversize
and replace pistons and piston rings.
A
B
12mm
Center
Bottom
AK300206 AD
5. Using a cylinder gauge, measure the cylinder
bore and cylindrically. If worn badly, correct the
cylinder to an oversize and replace the piston and
piston rings. Measure at the points shown in the
illustration.
Standard value:
Cylinder inner diameter 87.0 mm
Cylindrically 0.01 mm or less
Thrust
direction
AK300577AC
AD
1. Oversize pistons to be used should be determined
on the basis of the largest bore cylinder.
Piston size identification
Size
Identification mark
0.50 mm oversize
diameter
50
NOTE: Size mark is stamped on the piston top.
2. Measure the outside diameter (OD) of the piston
to be used. Measure it in thrust direction as
shown.
3. Based on the measured piston OD, calculate the
boring finish dimension.
Boring finish dimension = Piston OD +
(clearance between piston OD and cylinder)
−0.02 mm (honing margin)
CAUTION
To prevent distortion that may result from temperature rise during honing, bore cylinders,
working from number 2 to number 4 to number 1
to number 3.
4. Bore all cylinders to the calculated boring finish
dimension.
5. Hone to the final finish dimension (piston OD +
clearance between piston OD and cylinder).
6. Check the clearance between the piston and
cylinder.
Clearance between piston and cylinder:
0.02 − 0.04 mm
NOTE: When boring cylinders, finish all of four
cylinders to the same oversize. Do not bore only
one cylinder to an oversize.
NOTES
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