11-1
ENGINE
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . 2
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . 31
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 3
WATER PUMP AND WATER HOSE . . . . . 34
Service Specifications . . . . . . . . . . . . . . . . . . . . . . 3
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . 5
ROCKER ARMS AND CAMSHAFT . . . . . . 37
New Tightening Method by Use of Bolts
to Be Tightened in Plastic Area . . . . . . . . . . . . 9
CYLINDER HEAD AND VALVES . . . . . . . . 43
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FRONT CASE, COUNTERBALANCE
SHAFT AND OIL PAN . . . . . . . . . . . . . . . . . 51
Form-In-Place Gasket . . . . . . . . . . . . . . . . . . . . 10
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 11
ALTERNATOR AND IGNITION SYSTEM . 14
TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . 15
FUEL AND EMISSION CONTROL PARTS 27
SECONDARY AIR SYSTEM AND INTAKE
MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
PISTON AND CONNECTING ROD . . . . . . 59
CRANKSHAFT AND FLYWHEEL . . . . . . . . 67
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . 73
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . 75
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . 79
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . 83
11-2
ENGINE – General Information
GENERAL INFORMATION
Descriptions
Specifications
Type
In-line OHV, SOHC
Number of cylinders
4
Combustion chamber
Pentroof + curved top piston type
Total displacement dm3
1,997
Cylinder bore mm
85.0
Piston stroke mm
88.0
Compression ratio
8.8
Valve timing
Intake valve
Exhaust valve
Opens (BTDC)
21°
Closes (ABDC)
59°
Opens (BBDC)
58°
Closes (ATDC)
18°
Lubrication system
Pressure feed, full-flow filtration
Oil pump type
Involute gear type
11-3
ENGINE – Specifications
SPECIFICATIONS
SERVICE SPECIFICATIONS
Items
Standard value
Limit
Auto-tensioner rod projection length mm
12
–
Auto-tensioner rod pushed-in amount [when pushed with a force of 98
– 196 N] mm
1.0 or less
–
Intake
35.79
35.29
Exhaust
35.49
34.99
26
–
Cylinder head flatness of gasket surface mm
Less than 0.05
0.2
Cylinder head grinding limit of gasket surface mm
Total resurfacing depth of both cylinder head and cylinder block
–
0.2
Cylinder head overall height mm
131.9 – 132.1
–
Cylinder head bolt shank length mm
–
Maximum 99.4
Intake
1.0
0.5
Exhaust
1.5
1.0
Intake
109.5
109.0
Exhaust
109.7
109.2
Intake
0.02 – 0.05
0.10
Exhaust
0.05 – 0.09
0.15
Valve face angle
45° – 45.5°
–
Valve spring free length mm
48.3
47.3
Valve spring load/installed height N/mm
294/40.0
–
Valve spring out-of-squareness
1.5° or less
Maximum 4°
Valve seat contact width mm
0.9 – 1.3
–
Valve guide inner diameter mm
6.6
–
Valve guide projection from cylinder head upper surface mm
20.5
–
Valve stem projection mm
Intake
49.20
49.70
Exhaust
48.40
48.90
0.05 O.S.
12.05 – 12.07
–
0.25 O.S.
12.25 – 11.27
–
0.50 O.S.
12.50 – 12.52
–
Timing belt
Rocker arms and camshaft
Camshaft cam height mm
Camshaft journal outer diameter mm
Cylinder head and valves
Valve thickness of valve head (margin) mm
Overall valve length mm
Valve thickness to valve guide clearance
mm
Oversize rework dimensions of valve guide
hole mm
11-4
ENGINE – Specifications
Items
Standard value
Limit
0.3 O.S.
35.30 – 35.33
–
0.6 O.S.
35.60 – 35.63
–
0.3 O.S.
33.30 – 33.33
–
0.6 O.S.
33.60 – 33.63
–
Drive gear
0.08 – 0.14
–
Driven gear
0.06 – 0.12
–
78 or more
–
85.0
–
No. 1 ring
0.04 – 0.075
–
No. 2 ring
0.02 – 0.06
–
No. 1 ring
0.25 – 0.35
0.8
No. 2 ring
0.40 – 0.55
0.8
Oil ring
0.10 – 0.40
1.0
Piston pin outer diameter mm
21.0
–
Piston pin press-in load N (Room temperature)
7,350 – 17,200
–
Crankshaft pin oil clearance mm
0.02 – 0.05
0.1
Connecting rod big end side clearance mm
0.10 – 0.25
0.4
Crankshaft end play mm
0.05 – 0.25
0.40
Crankshaft journal outer diameter mm
57.0
–
Crankshaft pin outer diameter mm
44.0
–
Crankshaft journal oil clearance mm
0.02 – 0.04
0.1
Bearing cap bolt shank length mm
–
Maximum 71.1
Piston to cylinder clearance mm
0.02 – 0.04
–
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 inner diameter mm
85.0
–
Cylinder block cylinder mm
0.01
–
100
113.3
Intake oversize rework dimensions of valve
guide hole mm
Exhaust oversize rework dimensions of
valve guide hole mm
Front case and oil pan
Oil pump side clearance mm
Oil pressure at curb idle speed kPa [Oil temperature is 75 to 90°C]
Piston and connecting rod
Piston outer diameter mm
Piston ring side clearance mm
Piston ring end gap mm
Crankshaft and flywheel
Turbocharger
Waste gate actuator operation check kPa
11-5
ENGINE – Specifications
Items
Standard value
Limit
Rotor coil resistance Ω
Approx. 3 – 5
–
Protrusion length of brush mm
–
2
Commutator runout mm
0.05
0.1
Commutator outer diameter mm
32.0
31.4
Commutator undercut mm
0.5
–
Alternator
Starter motor
TORQUE SPECIFICATIONS
Items
Nm
Alternator and ignition system
Oil level gauge guide
13
Water pump pulley
9
Alternator brace (Alternator side)
21
Alternator brace (Tightened with water pump)
23
Alternator pivot bolt
44
Crankshaft pulley
25
Center cover
3
Spark plug
25
Ignition coil
10
Timing belt
Timing belt cover (Flange bolt)
11
Timing belt cover (Washer bolt)
9
Power steering pump bracket
49
Tensioner pulley
49
Tensioner arm
24
Auto tensioner
24
Idler pulley
48
Crank angle sensor
9
Oil pump sprocket
54
Camshaft bolt
118
Tensioner “B”
19
Counterbalance shaft sprocket
45
11-6
ENGINE – Specifications
Items
Nm
Rocker cover
3.5
Engine support bracket
49
Camshaft sprocket bolt
88
Timing belt rear right cover
11
Timing belt rear left upper cover
11
Fuel and emission control parts
Throttle body
18
Fuel pressure regulator
9
Delivery pipe
11
Vacuum tank bracket
9
Solenoid valve bracket
9
Solenoid valve
9
Vacuum hose and vacuum pipe
11
Secondary air intake manifold
Heat protector
13
Vacuum hose and vacuum pipe
11
Air pipe (Heat protector side)
13
Air pipe (Cam position sensor side)
11
Air pipe (Eye bolt)
49
Air pipe (Control valve side)
24
Air control valve
21
Air control valve bracket
24
Intake manifold stay
30
Intake manifold (M8)
19
Intake manifold (M10)
35
Exhaust manifold
Engine hanger
12
Heat protector (Turbocharger side)
14
Oxygen sensor
54
Exhaust fitting bolt
59
Exhaust fitting nut
59
Air outlet fitting
19
11-7
ENGINE – Specifications
Items
Nm
OIl return pipe (Turbocharger side)
9
Oil return pipe (Oil pan side – Head mark 7)
9
Oil return pipe (Oil pan side – Head mark 10)
13
Oil pipe
11
Oil pipe eye bolt (Cylinder head side)
16
Oil pipe eye bolt (Turbocharger side)
30
Water pipe
11
Water pipe eye bolt
41
Exhaust manifold (M8)
29
Exhaust manifold (M10)
49
Exhaust manifold (Turbocharger side)
59
Water pump and water hose
Water temperature sensor
29
Water temperature gauge unit
11
Water inlet fitting
24
Water outlet fitting (M6)
10
Water outlet fitting (M8)
13
Thermostat housing
24
Thermostat housing (Clamp)
11
Water inlet pipe (Cylinder block)
13
Water inlet pipe (Outlet fitting)
10
Water pump
14
Knock sensor
22
Rocker arms and camshaft
Camshaft position sensor
9
Camshaft position sensor cover
10
Camshaft position sensing cylinder
21
Camshaft position sensing support
13
Camshaft bearing cap
20
Oil delivery body
11
Cylinder head and valves
Cylinder head bolt [Tighten to 78 Nm and then completely before tightening to final torque
specification]
20 ! 90° + 90°
11-8
Items
ENGINE – Specifications
Nm
Front case and oil pan
Drain plug
39
Oil pan
7
Oil screen
19
Buffle plate
22
Oil pressure switch
10
Oil cooler by-pass valve
54
Relief plug
44
Plug
24
Front case
24
Oil pump cover (Screw)
10
Oil pump cover (Bolt)
16
Piston and connecting rods
Connecting rod nut
20 + 90° to 94°
Crankshaft and flywheel
Flywheel bolt
132
Rear plate
11
Bell housing cover
9
Oil seal case
11
Beam bearing cap bolt
25 + 90°
Check valve
32
Throttle body
Throttle position sensor
3.5
Idle speed control body assembly
3.5
Turbocharger
Waste gate actuator
11
11-9
ENGINE – Specifications
NEW TIGHTENING METHOD – BY USE OF BOLTS TO BE TIGHTENED IN
PLASTIC AREA
A new type of bolts, to be tightened in plastic area, is currently used some parts of the engine. The
tightening method for the bolts is different from the conventional one. Be sure to observe the method
described in the text when tightening the bolts.
Service limits are provided for the bolts. Make sure that the service limits described in the text are strictly
observed.
D
D
Areas where the bolts are in use:
(1) Cylinder head bolts
(2) Main bearing cap bolts
(3) Connecting rod cap bolts
Tightening method
After tightening the bolts to the specified torque, tighten them another 90° or 180° (twice 90°). The
tightening method varies on different areas. Observe the tightening method described in the text.
SEALANTS
Item
Specified sealant
Quantity
Engine support bracket bolt
3MTM AAD Part No. 8672 or equivalent
As required
Semi-circular packing
3MTM AAD Part No. 8672 or equivalent
As required
Rocker cover
3MTM AAD Part No. 8672 or equivalent
As required
Oil return pipe gasket
3MTM AAD Part No. 8731 or equivalent
As required
Thermostat housing
Mitsubishi Genuine Part No. MD970389 or
equivalent
As required
Water outlet fitting
Mitsubishi Genuine Part No. MD970389 or
equivalent
As required
Engine coolant temperature gauge unit
3MTM AAD Part No. 8672 or equivalent
As required
Engine coolant temperature sensor
3MTM AAD Part No. 8731 or equivalent
As required
Cam position sensor support
Mitsubishi Genuine Part No. MD970389 or
equivalent
As required
Oil pressure switch
3MTM AAD Part No. 8672 or equivalent
As required
Oil pan
Mitsubishi Genuine Part No. MD970389 or
equivalent
As required
Oil seal case
Mitsubishi Genuine Part No. MD970389 or
equivalent
As required
11-10
ENGINE – Specifications
FORM-IN-PLACE GASKET
The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket
fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead
size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick
a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the
fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to
apply the gasket evenly without a break, while observing the correct bead size.
The FIPG used in the engine is a room temperature vulcanisation (RTV) type and is supplied in a 100-gram
tube (Part No. MD970389). Since the RTV hardens as it reacts with the moisture in the atmospheric
air, it is normally used in the metallic flange areas. The FIPG, Part No. MD970389, can be used for
sealing both engine oil and coolant, while Part No. MD997110 can only be used for engine oil sealing.
Disassembly
The parts assembled with the FIPG can be easily disassembled without use of a special method. In
some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking
with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the
joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.
For removal of the oil pan, the special tool “Oil Pan Remover” (MD998727) is available. Be sure to use
the special tool to remove the oil pan.
Surface Preparation
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure
that there are no oils, greases and foreign substances deposited on the application surfaces. Do not
forget to remove the old sealant remained in the bolt holes.
Form-in-Place Gasket Application
When assembling parts with the FIPG, you must observe some precautions, but the procedures is very
simple as in the case of a conventional precut gasket.
Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the
bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is
hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When
the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do
not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time
(about one hour) has passed after installation is completed.
The FIPG application procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.
ENGINE – Special Tools
SPECIAL TOOLS
Tool
Number
Name
Use
MD998781
Flywheel stopper
Holding of flywheel and drive plate
MD998778
Crankshaft
sprocket puller
Removal of crankshaft sprocket
MD998719
Pulley holder pin
Holding camshaft sprocket
MB990767
Crankshaft pulley
holder
MD998785
Sprocket stopper
Holding silent shaft sprocket
MD998767
Tensioner puller
socket wrench
Adjustment of timing belt tension
MD998738
Set screw
MD998713
Camshaft oil seal
installer
Installation of camshaft oil seal
MD998442
Lash adjuster wire
Air bleeding of lash adjuster
11-11
11-12
Tool
ENGINE – Special Tools
Number
Name
Use
MB991654
Cylinder head bolt
wrench (12)
Removal and installation of cylinder head bolt
MD998772
Valve spring
compressor
Removal and installation of valve and related
parts
MD998735
Valve spring
compressor
MD998737
Valve stem seal
installer
Installation of valve stem seal
MD998727
Oil pan remover
Removal of oil pan
MD998162
Plug wrench
Removal and installation of front case cap plug
Use with MD998783.
MD998783
Plug wrench
retainer
Removal and installation of front case cap plug
MD998371
Silent shaft bearing
puller
Removal of counterbalance shaft front bearing
MD998372
Silent shaft bearing
puller
Removal of counterbalance shaft rear bearing
ENGINE – Special Tools
Tool
11-13
Number
Name
Use
MB991603
Silent shaft bearing
puller stopper
Guide stopper for removal and installation of
counterbalance shaft rear bearing
Use with MD998372.
MD998705
Silent shaft bearing
installer
Installation of counterbalance shaft front and
rear bearing
MD998375
Crankshaft
front
seal installer
Installation of crankshaft front oil seal
MD998285
Crankshaft front oil
seal guide
Guide for installation of crankshaft front oil seal
Use with MD998375.
MD998780
Piston setting tool
Removal and installation of piston pin
MB990938
Handle
Installation of crankshaft rear oil seal
MD998776
Crankshaft rear oil
seal installer
11-14
ENGINE – Alternator and Ignition System
ALTERNATOR AND IGNITION SYSTEM
REMOVAL AND INSTALLATION
9
3 Nm
10 Nm
1
10
2
11
15
12
25 Nm
16
14
13 Nm
44 Nm
4
7
3
13
6
21 Nm
5
23 Nm
9 Nm
25 Nm
Removal steps
1. Oil level gauge
2. O-ring
3. Oil level gauge guide
4. O-ring
5. Water pump pulley
6. Alternator brace
7. Alternator
8. Crankshaft pulley
8
9.
10.
11.
12.
13.
14.
15.
16.
Center cover
Spark plug cable
Ignition coil
Spark plug
Breather hose
PCV hose
PCV valve
PCV valve gasket
11-15
ENGINE – Timing Belt
TIMING BELT
REMOVAL AND INSTALLATION
11 Nm
23
7
1
26
8
22
49 Nm
24
2
24 Nm
25
9
30
11 Nm
11 Nm
13
3.5 Nm
24 Nm
14
27
31
118 Nm
9 Nm
49 Nm
3
4
30 Nm
6
18 19
45 Nm
29
5
19 Nm
32
28
21
88 Nm
15
48 Nm
10
AA" "LA
"KA
"JA
AB" "IA
AC" "HA
AD"
11
16
12
20
17
49 Nm
9 Nm
54 Nm
Removal steps
1. Timing belt front upper cover
2. Timing belt front center cover
3. Rubber plug
4. Timing belt front lower cover
5. Power steering pump bracket
6. Timing belt
7. Tensioner pulley
8. Tensioner arm
9. Auto tensioner
10. Idler pulley
11. Crank angle sensor
12. Oil pump sprocket
13. Crankshaft sprocket bolt
14. Crankshaft sprocket
15. Crankshaft sensing blade
16. Tensioner B
AE" "GA 17.
AF" "FA 18.
"EA 19.
AG"
20.
21.
22.
"DA 23.
24.
25.
"CA 26.
"BA 27.
AH" "AA 28.
29.
30.
31.
32.
Timing belt B
Counterbalance shaft sprocket
Crankshaft spacer
Crankshaft sprocket B
Crankshaft key
Oil filler cap
Rocker cover
Rocker cover gasket A
Rocker cover gasket B
Semi-circular packing
Engine support bracket
Camshaft sprocket bolt
Camshaft sprocket
Timing belt rear right cover
Timing belt rear left upper cover
Timing belt rear left lower cover
11-16
ENGINE – Timing Belt
REMOVAL SERVICE POINTS
AA" TIMING BELT REMOVAL
(1) If the timing belt is to be reused, chalk an arrow mark
on the back surface of the belt so that the belt can be
reinstalled in the same direction.
(2) Place the exhaust camshaft sprocket in a position where
the timing mark for No. 1 cylinder is positioned about
one tooth before the top dead center of the compression
stroke.
Timing mark
Caution
The camshaft sprocket on the exhaust side can turn
very easily because of the valve spring tension. Use
care not to allow your fingers to get caught by the
sprocket.
(3) Loosen the lock nut of the tensioner pulley, then remove
the timing belt.
AB" OIL PUMP SPROCKET REMOVAL
(1) Remove the plug on the left side of cylinder block.
(2) Insert a screwdriver (shank diameter 8 mm) to block the
counterbalance shaft.
(3) Remove the nut.
(4) Remove the oil pump sprocket.
AC" CRANKSHAFT BOLT LOOSENING
(1) Hold the drive plate with the special tool as shown.
(2) Remove the crankshaft bolt.
AD" CRANKSHAFT SPROCKET REMOVAL
If it is difficult to remove the sprocket, use the special tool.
ENGINE – Timing Belt
11-17
AE" TIMING BELT “B” REMOVAL
Make a mark on the back of the timing belt indicating the
direction of rotation so it may be reassembled in the same
direction if it is to be reused.
6EN1322
MD998785
NOTE
(1) Water or oil on the belt shortens its life drastically, so
the removed timing belt, sprocket, and tensioner must
be free from oil and water. These parts should not be
washed. Replace parts if seriously contaminated.
(2) If there is oil or water on each part check front case
oil seals, camshaft oil seal and water pump for leaks.
AF" COUNTERBALANCE SHAFT SPROCKET
REMOVAL
(1) Set the special tool as shown to prevent the
counterbalance shaft sprocket from turning together.
(2) Loosen the bolt and remove the sprocket.
AG" CRANKSHAFT SPROCKET “B” REMOVAL
If it is difficult to remove the sprocket, use the special tool.
AH" CAMSHAFT SPROCKET BOLT LOOSENING
Use a wrench to hold the hexagonal part of the camshaft,
and then remove the camshaft sprocket mounting bolt.
INSTALLATION SERVICE POINTS
"AA CAMSHAFT SPROCKET BOLT TIGHTENING
Using a wrench, hold the camshaft at its hexagon and tighten
the bolt to the specification.
11-18
ENGINE – Timing Belt
"BA ENGINE SUPPORT BRACKET INSTALLATION
Coat the bolts illustrated with sealant before tightening.
Specified sealant: 3MTM AAD Part No. 8672 or equivalent
"CA SEALANT APPLICATION TO SEMI-CIRCULAR
PACKING
Specified sealant: 3MTM AAD Part No. 8672 or equivalent
10 mm
10 mm
Semicircular
packing
Cylinder head
11-19
ENGINE – Timing Belt
"DA SEALANT APPLICATION TO ROCKER COVER
Apply sealant to the areas indicated in the illustration.
Specified sealant: 3MTM AAD Part No. 8672 or equivalent
Apply sealant
10 mm
10 mm
10 mm
Apply sealant
10 mm
Apply sealant
Apply sealant
"EA SPACER INSTALLATION
Install the spacer with the chamfered end toward the oil seal.
Sharp
edge
Counterbalance
shaft
MD998785
"FA COUNTERBALANCE SHAFT SPROCKET
INSTALLATION
(1) Install the counterbalance shaft sprocket and screw the
bolt.
(2) Install special tool MD998785 as shown in the illustration
to lock the counterbalance shaft.
(3) Tighten the bolt, and then remove the special tool.
11-20
Timing
marks
(on front
case)
ENGINE – Timing Belt
Timing
marks
"GA TIMING BELT “B” INSTALLATION
(1) Align timing marks on the crankshaft sprocket “B” and
counterbalance shaft sprocket with the marks on the front
case respectively.
(2) Install the timing belt “B” on the crankshaft sprocket “B”
and counterbalance shaft sprocket. There should be no
slack on the tension side.
(3) Make sure that the relationship between the tensioner
pulley center and the bolt center is as shown in the
illustration.
(4) Move the tensioner “B” in the direction of arrow while
lifting with a finger to give a sufficient tension to the tension
side of timing belt. In this condition, tighten bolt to secure
tensioner “B”. When the bolt is tightened, use care to
prevent shaft from turning together. If shaft is turned
together, belt will be overtensioned.
(5) Check to ensure that timing marks on sprockets and front
case are in alignment.
(6) Press with index finger the center of span on the tension
side of timing belt “B”. The bolt must deflect 5 – 7 mm.
"HA CRANKSHAFT BOLT TIGHTENING
(1) Using the special tool, hold the flywheel or drive plate.
(2) Install the crankshaft pulley in position.
ENGINE – Timing Belt
11-21
"IA OIL PUMP SPROCKET INSTALLATION
(1) Insert a Phillips screwdriver (shank diameter 8 mm shaft)
through the plug hole on the left side of the cylinder
block to block the left counterbalance shaft.
(2) Install the oil pump sprocket.
(3) Apply a proper amount of engine oil to the bearing surfaces
of the nuts.
(4) Tighten the nuts to the specified torque.
6EN0564
"JA AUTO TENSIONER INSTALLATION
(1) If the auto tensioner rod is in its fully extended position,
reset it as follows.
(2) Clamp the auto-tensioner in the vise with soft jaws.
(3) Push in the rod little by little with the vise until the set
hole A in the rod is aligned with the hole B in the cylinder.
A
B
(4) Insert a wire (1.4 mm in diameter) into the set holes.
(5) Unclamp the auto tensioner from the vise.
(6) Install the auto tensioner to front case and tighten to
the specified torque.
Caution
Leave the wire installed in the auto tensioner.
"KA TENSIONER PULLEY INSTALLATION
Install the tensioner pulley in such direction that its two small
holes are arranged vertically.
Small holes
6EN1323
11-22
ENGINE – Timing Belt
"LA TIMING BELT INSTALLATION
(1) Place the exhaust side camshaft sprocket in a position
where its timing mark is one tooth offset from the timing
mark on the rocker cover in the counterclockwise direction.
Timing mark
NOTE
Even if the timing marks on the sprocket and the rocker
cover are brought into alignment, the exhaust camshaft
is forced back by the valve spring tension. It is stabilized
at a position one tooth before the timing mark.
(2) Align the timing mark on the intake side camshaft sprocket
with that on the rocker cover.
Timing mark
NOTE
Even if the timing marks on the sprocket and the cover
are brought into alignment, the intake camshaft is forced
to turn one tooth in the clockwise direction by the valve
spring tension and stabilized there.
(3) Place the timing mark on the crankshaft sprocket one
tooth this side from the mated timing mark as in the case
of the camshaft sprocket.
(4) Align the timing mark on oil pump sprocket with its mating
mark.
Oil pump
sprocket
timing marks
6EN1327
Plug
Screwdriver
6EN1026
(5) Remove the plug on cylinder block and insert a Phillips
screwdriver (shank diameter 8 mm) through the hole
(Engine with counterbalance shafts).
If it can be inserted as deep as 60 mm or more, the
timing marks are correctly aligned. If the inserted depth
is only 20 – 25 mm, turn the oil pump sprocket one turn
and realign timing marks. Then check to ensure that the
screwdriver can be inserted 60 mm or more. Keep the
screwdriver inserted until installation of timing belt is
finished.
ENGINE – Timing Belt
11-23
(6) Remove the Phillips screwdriver. Place the oil pump
sprocket in a position where its timing mark is one tooth
offset from the mated timing mark in the counterclockwise
direction.
Timing mark
6EN1327
(7) Fit the timing belt over the exhaust side camshaft sprocket,
and secure it at the illustrated position using a paper
clip.
(8) Turn the intake side camshaft sprocket as shown to a
position where its timing mark is one tooth offset from
the mated timing mark in the counterclockwise direction.
Then, fit the timing belt over the sprocket and secure
it with a paper clip.
NOTE
The intake camshaft will be turned a little clockwise by
the valve spring tension and stabilized in position even
if the belt is clipped at one tooth offset position.
(9) Check to ensure that the timing marks on the intake
camshaft sprocket side are in alignment when the exhaust
camshaft sprocket is turned clockwise to align the timing
marks.
Timing mark
NOTE
The timing belt span between the intake and exhaust
sprockets will have 17 cogs.
(10)Fit the timing belt over the idler pulley, oil pump sprocket
and crankshaft sprocket in this order.
NOTE
Be careful that the belt does not become slack.
Crankshaft
sprocket
Oil pump
sprocket
11-24
ENGINE – Timing Belt
(11)Fit the timing belt over the tensioner pulley.
NOTE
When fitting the timing belt over the tensioner pulley,
turn the intake side camshaft sprocket a little
counterclockwise, as this will facilitate the work.
Crankshaft
sprocket
MD998767
(12)Turn the crankshaft pulley a little in the illustrated direction
to pull up the timing belt at the idler pulley side.
(13)Check to ensure that the timing marks on the crankshaft
sprocket, oil pump sprocket and exhaust camshaft
sprocket are all offset one tooth from the corresponding
timing marks in the counterclockwise direction.
(14)Using the special tool, turn the tensioner pulley in the
illustrated direction to strain the timing belt. Then, secure
the tensioner temporarily by tightening the retaining bolt
lightly.
NOTE
There must be no slack in the timing belt between the
intake and exhaust camshafts.
(15)Turn the crankshaft to align the timing mark with the mark
for No. 1 cylinder top dead center in the compression
stroke.
MD998738
(16)Set the special tool 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.
ENGINE – Timing Belt
11-25
(17)Loosen the retaining bolt of the tensioner pulley.
Caution
Loosening the retaining bolt can cause the intake
and exhaust camshafts to turn, resulting in slackened
timing belt. Use care that the timing belt does not
come off the sprockets at this time.
MD998767
(18)Pull up the slack of the timing belt by turning the tensioner
in illustrated direction using the special tool and a torque
wrench (0 – 5 Nm).
(19)From this position, turn back the tensioner until the torque
wrench reading becomes 3.5 Nm, then secure it by
tightening the retaining bolt.
(20)Remove the special tool attached in step (16).
(21)Rotate the crankshaft clockwise 2 turns. Then, leave it
intact 15 minutes.
(22)Check to see that the wire inserted when installing the
auto-tensioner can be pulled out lightly. If it can be pulled
out lightly, the timing belt is being tensioned properly.
If so, remove the wire. In addition, check that the rod
protrusion from the auto-tensioner meets the standard
value, which is also an indication of properly tensioned
timing belt.
Standard value: 3.8 – 4.5 mm
(23)If the wire cannot be removed with a light force, repeat
steps (16) through (21) until the proper belt tensioner
is obtained.
INSPECTION
TIMING BELT
Replace belt if any of the following conditions exist.
(1) Hardening of back rubber.
Back side is glossy without resilience and leaves no indent
when pressed with fingernail.
(2)
(3)
(4)
(5)
Cracks
Cracks
Cracks
Cracks
on rubber back.
or peeling of canvas.
on rib root.
on belt sides.
11-26
ENGINE – Timing Belt
(6) Abnormal wear of belt sides. The sides are normal if
they are sharp as if cut by a knife.
(7) Abnormal wear on teeth.
(8) Missing tooth.
12 mm
AUTO TENSIONER
(1) Check the auto tensioner for possible leaks and replace
as necessary.
(2) Check the rod end for wear or damage and replace as
necessary.
(3) Measure the rod protrusion. If it is out of specification,
replace the auto tensioner.
Standard value: 12 mm
(4) Press the rod with a force of 98 to 196 N and measure
its protrusion.
(5) If the measured value is 1 mm or more shorter than the
value obtained in step (3), replace the auto tensioner.
98 to 196 N
Movement
11-27
ENGINE – Fuel and Emission Control Parts
FUEL AND EMISSION CONTROL PARTS
REMOVAL AND INSTALLATION
11 Nm
11
11 Nm
3
1
18 Nm
12
9
10
9 Nm
8
6
5
4
14
7
2
15
16
9 Nm
13
Removal steps
1. Throttle body
"CA 2. Throttle body gasket
3. Fuel return pipe
"BA 4. Fuel pressure regulator
5. O-ring
6. Insulator
7. Insulator
"AA 8. Injector
9.
10.
11.
12.
13.
14.
15.
16.
O-ring
Grommet
Delivery pipe
Vacuum hose and vacuum pipe
Vacuum tank
Vacuum tank bracket
Solenoid valve
Solenoid valve bracket
11-28
ENGINE – Fuel and Emission Control Parts
INSTALLATION SERVICE POINTS
"AA INJECTORS INSTALLATION
(1) Before installing an injector, the rubber O-ring must be
lubricated with a drop of clean engine oil to aid in
installation.
(2) Install injector top end. Be careful not to damage O-ring
during installation.
Grommet
O-ring
1EN0388
"BA FUEL PRESSURE REGULATOR INSTALLATION
(1) Apply a small amount of new engine oil to the O-ring.
Insert the fuel pressure regulator into the delivery pipe
being careful not to damage the O-ring.
Caution
Be sure not to let engine oil get into the delivery
pipe.
(2) Check that the fuel pressure regulator turns smoothly.
If it does not turn smoothly, the O-ring may be trapped.
Remove the fuel pressure regulator and check the O-ring
for damage, and then re-insert it into the delivery pipe
and check once again.
Projection
"CA GASKET INSTALLATION
Position the projection as shown in the illustration.
11-29
ENGINE – Secondary Air System and Intake Manifold
SECONDARY AIR SYSTEM AND INTAKE MANIFOLD
REMOVAL AND INSTALLATION
5
21 Nm
4
21 Nm
24 Nm
6
11 Nm
35 Nm
3
24 Nm
2
7
10
11 Nm
49 Nm
13 Nm
35 Nm
35 Nm
1
19 Nm
9
11
8
30 Nm
Removal steps
1. Exhaust manifold heat protector
2. Vacuum hose and vacuum pipe
"BA 3. Air pipe assembly
4. Air control valve gasket
5. Air control valve assembly
6. Engine hanger
"AA 7.
8.
9.
10.
11.
Air control valve bracket
Intake manifold stay
Alternator brace stay
Intake manifold
Intake manifold gasket
11-30
ENGINE – Secondary Air System and Intake Manifold
INSTALLATION SERVICE POINTS
(1)
(2)
"AA AIR CONTROL VALVE BRACKET INSTALLATION
(1) Attach the air control valve bracket and the engine hanger
to the intake manifold using bolts and nuts with which
the intake manifold is also installed to the engine.
(2) Tighten the bolts and nuts to the specified torque in the
sequence given in the illustration.
(3)
(3)
(4)
(2)
(1)
"BA AIR PIPE ASSEMBLY INSTALLATION
(1) Install the air pipe assembly to the exhaust manifold and
to the air control valve and secure it provisionally by
tightening the fasteners handtight.
(2) Tighten the fasteners to the specified torque in the
sequence given in the illustration.
11-31
ENGINE – Exhaust Manifold
EXHAUST MANIFOLD
REMOVAL AND INSTALLATION
16 Nm
19
59 Nm
1
18
12 Nm
11 Nm
29 Nm
30 Nm
14
15
49 Nm
10 Nm
13
41 Nm
12
4
16
10 Nm
5
59 Nm
14 Nm
59 Nm
11
17
41 Nm
8
7
3
2
54 Nm
19 Nm
10
9
9 Nm
6
Head mark 7: 9 Nm
Head mark 10: 13 Nm
Removal steps
1. Engine hanger
2. Turbocharger heat protector
3. Oxygen sensor
4. Exhaust fitting
5. Exhaust fitting gasket
6. Air outlet fitting
"CA 7. Air outlet fitting gasket
8. Oil return pipe
"BA 9. Gasket
"BA 10. Oil return pipe gasket
(Oil pan side)
11. Oil return pipe gasket
(Turbocharger side)
12. Turbocharger assembly
13. Turbocharger gasket
14. Oil pipe
15. Water pipe
16. Water pipe
17. Turbocharger
"AA 18. Exhaust manifold
19. Exhaust manifold gasket
11-32
ENGINE – Exhaust Manifold
INSTALLATION SERVICE POINTS
3
1
4
7
5
9
"AA EXHAUST MANIFOLD INSTALLATION
Tighten the exhaust manifold mounting nuts to the specified
torque in the sequence given in the illustration.
6
8
2
Timing belt side
Oil pan
Silicon print
"BA GASKET / OIL RETURN GASKET INSTALLATION
EVOLUTION IV AND V
Install the gasket with the silicon-printed side toward the oil
pan and with the tabbed end directed as shown.
Oil return
pipe gasket
EVOLUTION VI
(1) Install the gasket with the tabbed end directed as shown.
Timing belt side
Oil pan
Oil return
pipe gasket
Oil pan
Oil return
pipe
(2) Apply sealant to both sides of the oil return pipe gasket
and leave it for 20 minutes to dry before installing. Tighten
the mounting bolts to the specified torque.
Specified sealant:
3MTM AAD Part No. 8731 or equivalent
Gasket
NOTE
If mounting bolts with head mark 7 have been used,
be sure to replace them with bolts having head mark
10.
ENGINE – Exhaust Manifold
11-33
"CA GASKET INSTALLATION
Position the projection as shown in the illustration.
Projection
11-34
ENGINE – Water Pump and Water Hose
WATER PUMP AND WATER HOSE
REMOVAL AND INSTALLATION <EVOLUTION VI>
11
1
10 Nm
2
4
8
13 Nm
7
9.8 Nm
24 Nm
11 Nm
12
13
29 Nm
24 Nm
5
6
11 Nm
9
10
16
22 Nm
15
14
14 Nm
Removal steps
1. Water hose
2. Water hose
3. Water hose
4. Water hose
"EA 5. Water temperature sensor
"DA 6. Water temperature gauge unit
7. Thermostat
8. Water outlet fitting
9.
10.
"AA 11.
"AA 12.
"AA 13.
14.
15.
16.
Thermostat housing
Thermostat housing gasket
O-ring
Water inlet pipe
O-ring
Water pump
Water pump gasket
Knock sensor
3
11-35
ENGINE – Water Pump and Water Hose
REMOVAL AND INSTALLATION <EVOLUTION IV or V>
13 Nm
24 Nm
13 Nm
11
8
1
24 Nm
9
4
12
7
6
2
10
11 Nm
5
13
29 Nm
16
22 Nm
15
14 Nm
14
Removal steps
1. Water hose
2. Water hose
3. Water hose
4. Water hose
"EA 5. Water temperature sensor
"DA 6. Water temperature gauge unit
7. Water inlet fitting
8. Thermostat
"CA
"BA
"AA
"AA
"AA
9.
10.
11.
12.
13.
14.
15.
16.
Water outlet fitting
Thermostat housing
O-ring
Water inlet pipe
O-ring
Water pump
Water pump gasket
Knock sensor
3
11-36
ENGINE – Water Pump and Water Hose
INSTALLATION SERVICE POINTS
Water pipe
"AA WATER PIPE / O-RING INSTALLATION
Wet the O-ring (with water) to facilitate assembly.
Caution
Keep the O-ring free of oil or grease.
O-ring
6EN0594
"BA THERMOSTAT HOUSING INSTALLATION
Apply 3 mm diameter of form-in-place gasket (FIPG) to the
location shown in the illustration.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or equivalent
"CA WATER OUTLET FITTING INSTALLATION
Apply 3 mm diameter of form-in-place gasket (FIPG) to the
location shown in the illustration.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or equivalent
"DA SEALANT APPLICATION TO ENGINE COOLANT
TEMPERATURE GAUGE UNIT
(1) When reusing the gauge unit, clean its thread.
(2) Apply the specified sealant to the thread.
Specified sealant:
3MTM AAD Part No. 8672 or equivalent
9EN0092
"EA SEALANT APPLICATION TO ENGINE COOLANT
TEMPERATURE SENSOR
(1) When reusing the sensor, clean its thread.
(2) Apply the specified sealant to the thread.
Specified sealant:
3MTM AAD Part No. 8731 or equivalent
9EN0091
11-37
ENGINE – Rocker Arms and Camshaft
ROCKER ARMS AND CAMSHAFT
REMOVAL AND INSTALLATION
8
11
20 Nm
3
21 Nm
4
14
13
10 Nm
9
6
12
13 Nm
2
1
10
5
15
9 Nm
11 Nm
7
18
16
17
Apply engine oil to all
moving parts before
installation.
"FA
"EA
"DA
"CA
"CA
Removal steps
1. Cam position sensor
2. O-ring
3. Cam position sensor support cover
4. Cam position sensor support
gasket
5. Cam position sensing cylinder
6. Cam position sensor support
7. Camshaft oil seal
8. Camshaft bearing cap rear right
9. Camshaft bearing cap rear left
"CA
"CA
"CA
"CA
"CA
"BA
10.
11.
12.
13.
14.
15.
16.
"AA 17.
18.
Camshaft bearing
Camshaft bearing
Camshaft bearing
Camshaft bearing
Camshaft bearing
Camshaft
Rocker arm
Lash adjuster
Oil delivery body
cap
cap
cap
cap
cap
front
No. 5
No. 2
No. 3
No. 4
11-38
ENGINE – Rocker Arms and Camshaft
INSTALLATION SERVICE POINTS
"AA LASH ADJUSTER INSTALLATION
Caution
If the lash adjuster is re-used, clean the lash adjuster.
Fit the lash adjuster onto rocker arm without allowing diesel
fuel to spill out.
Camshaft sprocket side
Slit
"BA CAMSHAFT INSTALLATION
(1) Apply engine oil to the journals and cams of the camshafts.
Install the camshafts on the cylinder head.
Use care not to confuse the intake camshaft with the
exhaust one. The intake camshaft has a slit on its rear
end for driving the crankshaft position sensor.
Intake side
camshaft
Dowel pin
Cam number
Symbol identifying
intake or exhaust
Timing belt side
(2) Install the crankshaft sprocket B or spacer and flange
to one end of the crankshaft, and turn the crankshaft
until the timing marks are lined up, setting No. 1 cylinder
to the TDC.
(3) Set the camshafts so that their dowel pins are positioned
at top.
"CA BEARING CAP INSTALLATION
(1) According to the identification mark stamped on the top
of each bearing cap, install the caps to the cylinder head.
Only “L” or “R” is stamped on front bearing cap. Cap
No. is stamped on No. 2 to No. 5 bearing caps. Rear
bearing cap has no stamping.
I: For intake camshaft side
E: For exhaust camshaft side
(2) Tighten the bearing caps in the order shown two to three
times by torquing progressively.
Tighten to the specification in the final sequence.
(3) Check to ensure that the rocker arm is positioned correctly
on the lash adjuster and valve stem end.
11-39
ENGINE – Rocker Arms and Camshaft
"DA CAMSHAFT OIL SEAL INSTALLATION
(1) Apply engine oil to lib area of the oil seal and the front
end outside diameter of the camshaft.
(2) Using special tool install the camshaft oil seals.
MD998713
"EA CAMSHAFT POSITION SENSOR SUPPORT
INSTALLATION
Apply 3 mm diameter of form-in-place gasket (FIPG) to the
location shown in the illustration.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or equivalent
"FA CAMSHAFT POSITION SENSING CYLINDER
INSTALLATION
(1) Set the No. 1 cylinder to the compression top dead center
position (so that dowel pin of the exhaust camshaft is
at the top).
(2) Install the camshaft position sensing cylinder so that the
white paint mark is facing in the direction shown in the
illustration.
Paint mark
Camshaft
position
sensor
INSPECTION
CAMSHAFT
Measure the cam height.
Roller
Tip
Item
Standard value mm
Limit mm
Intake
35.79
35.29
Exhaust
35.49
34.99
ROCKER ARM
(1) Check the roller surface. If any dents, damage or seizure
is evident, replace the rocker arm.
(2) Check rotation of the roller. If it does not rotate smoothly
or if looseness is evident, replace the rocker arm.
(3) Check the inside diameter. If damage or seizure is evident,
replace the rocker arm.
11-40
ENGINE – Rocker Arms and Camshaft
LASH ADJUSTER
Caution
(1) The lash adjusters are precision-engineered
mechanisms. Do not allow them to become
contaminated by dirt or other foreign substances.
(2) Do not attempt to disassemble the lash adjusters.
(3) Use only fresh diesel fuel to clean the lash adjusters.
Outside
cleaning
A
Inside
cleaning
B
Filling with
diesel fuel
(1) Prepare three containers and approximately five liters
of diesel fuel. Into each container, pour enough diesel
fuel to completely cover a lash adjuster when it is standing
upright. Then, perform the following steps with each lash
adjuster.
C
(2) Place the lash adjuster in container A and clean its outside
surface.
NOTE
Use a nylon brush if deposits are hard to remove.
Diesel
fuel
(3) While gently pushing down the internal steel ball using
wire (0.5 mm in diameter) or special tool MD998442,
move the plunger through 5 to 10 strokes until it slides
smoothly. In addition to eliminating stiffness in the plunger,
this operation will remove dirty oil.
MD998442
Diesel fuel
Caution
The steel ball spring is extremely weak, so the lash
adjuster’s functionality may be lost if the air bleed
wire is pushed in hard.
NOTE
If the plunger remains stiff or the mechanism appears
otherwise abnormal, replace the lash adjuster.
ENGINE – Rocker Arms and Camshaft
11-41
(4) Removal the lash adjuster from the container. Then, push
down the steel ball gently and push the plunger to eliminate
diesel fuel from the pressure chamber.
MD998442
Caution
Make sure the oil hole in the side of the body is pointing
toward container A. Do not point the oil hole at yourself
or other people.
Diesel fuel
(5) Place the lash adjuster in container B. Then, gently push
down the internal steel ball using wire (0.5 mm in diameter)
or special tool MD998442 and move the plunger through
5 to 10 strokes until it slides smoothly. This operation
will clean the lash adjuster’s pressure chamber.
MD998442
Diesel fuel
Caution
The steel ball spring is extremely weak, so the lash
adjuster’s functionality may be lost if the air bleed
wire is pushed in hard.
(6) Remove the lash adjuster from the container. Then, push
down the steel ball gently and push the plunger to eliminate
diesel fuel from the pressure chamber.
MD998442
Caution
Make sure the oil hole in the side of the body is pointing
toward container A. Do not point the oil hole at yourself
or other people.
Diesel fuel
(7) Place the lash adjuster in container C. Then, gently push
down the internal steel ball using wire (0.5 mm in diameter)
or special tool MD998442.
MD998442
Diesel fuel
Caution
Do not use container C for cleaning. If cleaning is
performed in container C, foreign matter could enter
the pressure chamber when chamber is filled with
diesel fuel.
(8) Stand the lash adjuster with its plunger at the top, then
push the plunger downward firmly until it moves through
its greatest possible stroke. Return the plunger slowly,
then release the steel ball and allow the pressure chamber
to fill with diesel fuel.
MD998442
Diesel fuel
11-42
ENGINE – Rocker Arms and Camshaft
(9) Remove the lash adjuster from the container, then stand
the lash adjuster with its plunger at the top. Push the
plunger firmly and check that it does not move. Also,
check that the lash adjuster’s height matches that of a
new lash adjuster.
NOTE
If lash adjuster contracts, perform the operations (7)
through (9) again to fill it with diesel fuel completely.
Replace the lash adjuster if it still contracts after performing
these steps.
(10)Stand the lash adjuster upright to prevent diesel fuel from
spilling out. Do not allow the lash adjuster to become
contaminated by dirt or other foreign matter. Fit the lash
adjuster onto the engine as soon as possible.
11-43
ENGINE – Cylinder Head and Valves
CYLINDER HEAD AND VALVES
REMOVAL AND INSTALLATION
Apply engine oil to all
moving parts before
installation.
78 Nm → Loosen completely → 20 Nm + 90_ + 90_
1
8
9
14
10
20
4
5
12
15
17
6
13
16
19
11
18
7
2
3
Removal steps
AA" "DA 1. Cylinder head bolt
2. Cylinder head assembly
3. Cylinder head gasket
AB" "CA 4. Retainer lock
5. Valve spring retainer
"BA 6. Valve spring
7. Intake valve
AB" "CA 8. Retainer lock
9. Valve spring retainer
"BA 10. Valve spring
AC"
11.
"AA 12.
13.
"AA 14.
15.
16.
17.
18.
19.
20.
Exhaust valve
Valve stem seal
Valve spring seat
Valve stem seal
Valve spring seat
Intake valve guide
Exhaust valve guide
Intake valve seat
Exhaust valve seat
Cylinder head
11-44
ENGINE – Cylinder Head and Valves
REMOVAL SERVICE POINTS
MB991654
PRECAUTION FOR REMOVED PARTS
Keep removed parts in order according to the cylinder number
and intake/exhaust.
AA" CYLINDER HEAD BOLTS REMOVAL
Using the special tool, loosen the cylinder head bolts. Loosen
evenly, little by little.
AB" RETAINER LOCK REMOVAL
Store removed valves, springs and other parts, tagged to
indicate their cylinder No. and location for reassembly.
MD998772
MD998735
AC" VALVE HANDLING PRECAUTIONS
(1) Sodium reacts violently with water or moisture generation
heat and liberating hydrogen. It must be handled with
utmost care because otherwise the following dangerous
conditions may result:
Loss of eyesight if sodium gets in eyes.
Burns if soduim contact skin.
Fire hazard.
(2) Handling of Soduim-filled Exhaust Valves
Soduim-filled exhaust valves are not dangerous and may
be handled in the same way as ordinary valves unless
they are broken.
Never try to break the valves and expose soduim to the
air. When worn exhaust valves are to be discarded, have
them disposed of by a salvage company equipped with
special disposal system, notifying them that the valves
contain soduim.
Should the exhaust valves be broken, neutralize soduim
using the method described below, and discard the valves
in the same way as ordinary valves.
ENGINE – Cylinder Head and Valves
11-45
(3) How to Neutralize Sodium
Place a container filled with more than 10 liters of water
in a well ventilated large space.
Wear rubber gloves and goggles, and carefully take out
broken valves from the cylinder head.
Put a broken valve in the water-filled container and quickly
get away from the container at least 2 or 3 m.
Caution
1. Valves must be neutralized one at a time.
2. Put a valve in the container only after soduim
in the preceding one has completely reacted with
water.
Keep fire away from the container during the
neutralization. The resulting hydrogen gas is highly
explosive.
When the reaction has finished (there is no more
generation of hydrogen gas), take the valves out of the
container with large tweezers or the like.
NOTE
The reaction occurs when water enters the cavity in the
valve. Hydrogen gas may be trapped inside the valve,
temporarily blocking the water passage. In such a case,
wait until hydrogen gas in released and remaining soduim
reacts with water.
After the neutralization of soduim, water in the container
contains soduim hydroxide and is highly alkaline. The
water solution should be disposed of according to local
regulations.
Caution
1. Do not let the solution contact the eyes or the
skin.
2. Should it get in the eyes, immediately flush them
with clean water thoroughly, and receive medical
attention. When it contacts the skin, wash with
ample amounts of clean water.
INSTALLATION SERVICE POINTS
MD998737
"AA VALVE STEM SEAL INSTALLATION
(1) Install the valve spring seat.
(2) The special tool must be used to install the valve stem
seal. Improper installation could result in oil leaks past
the valve guide.
Caution
Do not reuse removed valve stem seals.
11-46
ENGINE – Cylinder Head and Valves
"BA VALVE SPRING INSTALLATION
Direct the valve spring end with identification color toward
the spring retainer.
"CA RETAINER LOCK INSTALLATION
The valve spring, if excessively compressed, causes the
bottom end of the retainer to be in contact with, and damage,
the stem seal.
MD998772
MD998735
"DA CYLINDER HEAD BOLT INSTALLATION
(1) When installing the cylinder head bolts, check that the
shank length of each bolt meets the limit. If the limit is
exceeded, replace the bolt.
Limit: Max. 99.4 mm
(2) Apply engine oil to the bolt threads and to the washers.
Shank length
6EN0782
Timing belt side
(3) Using the special tool (MB991654) and according to the
tightening sequence, tighten the bolts to the specified
torque.
Tightening torque: 78 Nm
(4) Loosen all bolts fully.
(5) Retighten the loosened bolts to a torque of 20 Nm in
the specified tightening sequence.
ENGINE – Cylinder Head and Valves
11-47
(6) Make paint marks on the cylinder head bolt heads and
cylinder head.
(7) Give a 90° turn to the cylinder head bolts in the specified
tightening sequence.
(8) Give another 90° turn to the cylinder head bolts and make
sure that the paint mark on the head of each cylinder
head bolt and that on the cylinder head are on the same
straight line.
90°
90°
Paint mark
6AE0297
Caution
1. If the bolt is turned less than 90°, proper fastening
performance may not be expected. When
tightening the bolt, therefore, be careful to give
a sufficient turn to it.
2. If the bolt is overtightened, loosen the bolt
completely and then retighten it by repeating the
tightening procedure from step (1).
INSPECTION
CYLINDER HEAD
(1) Check the cylinder head gasket surface for flatness by
using a straightedge and thickness gauge.
Standard value: 0.05 mm
Limit: 0.2 mm
(2) If the service limit is exceeded, correct to meet
specification.
9EN0064
Grinding limit: *0.2 mm
* Includes combined with cylinder block grinding.
Cylinder head height (Specification when new):
131.9 – 132.1 mm
11-48
ENGINE – Cylinder Head and Valves
VALVE
(1) Check the valve face for correct contact. If incorrect, reface
using a valve refacer. Valve seat contact should be
maintained uniform at the center of valve face.
(2) If the margin exceeds the service limit, replace the valve.
Item
Standard value mm
Limit mm
Intake
1.0
0.5
Exhaust
1.5
1.0
(3) Measure valve’s total length. If measurement is less than
specified, replace the valve.
Item
Standard value mm
Limit mm
Intake
109.5
109.0
Exhaust
109.7
109.2
VALVE SPRING
(1) Measure the free height of spring and, if it is smaller
than the limit, replace.
Out of
square
Free
height
Standard value mm
Limit mm
48.3
47.3
(2) Measure the squareness of the spring and, if the limit
is exceeded, replace.
1EN0264
Standard value
Limit
1.5°
4°
VALVE GUIDE
Measure the clearance between the valve guide and valve
stem. If the limit is exceeded, replace the valve guide or
valve, or both.
Valve
guide
Item
Standard value mm
Limit mm
Intake
0.02 – 0.05
0.10
Exhaust
0.05 – 0.09
0.15
11-49
ENGINE – Cylinder Head and Valves
Valve stem end
Valve stem
projection
Spring seating
surface
VALVE SEAT
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.
Item
Standard value mm
Limit mm
Intake
49.20
49.70
Exhaust
48.40
48.90
DEN0212
VALVE SEAT RECONDITIONING PROCEDURE
0.9 – 1.3 mm
43.5° – 44°
(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 (refer to VALVE SEAT in INSPECTION).
6EN0491
VALVE SEAT REPLACEMENT PROCEDURE
0.5 – 1 mm
(1) Cut the valve seat to be replaced from the inside to thin
the wall thickness. Then, remove the valve seat.
0.5 – 1 mm
(2) Rebore the valve seat hole in the cylinder head to a
selected oversize valve seat diameter.
Valve seat ring hole diameter
Height of
seat ring
Item
Intake
Exhaust
Oversize I.D.
1EN0275
Standard value mm
0.30 O.S.
35.30 – 35.33
0.60 O.S.
35.60 – 35.63
0.30 O.S.
33.30 – 33.33
0.60 O.S.
33.60 – 33.63
(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”.
11-50
ENGINE – Cylinder Head and Valves
VALVE GUIDE REPLACEMENT PROCEDURE
(1) Force the valve guide out toward the cylinder block using
a press.
(2) Machine the valve guide hole in the cylinder head to
the size of the oversize valve guide to be installed.
Caution
Do not use the valve guide of the same size as the
removed one.
Valve gauge hole diameters in cylinder head
Item
Standard value mm
0.05 O.S.
12.05 – 12.07
0.25 O.S.
12.25 – 12.27
0.50 O.S.
12.50 – 12.52
(3) Press-fit the valve guide until it protrude specified value
19.5 mm as shown in the illustration.
Caution
1. Press the valve guide from the cylinder head top
surface.
2. Valve guide for intake valve and that for exhaust
valve are different in length. (45.5 mm for intake
valve; 50.5 mm for exhaust valve)
Protrusion
1EN0106
(4) After the valve guide has been installed, insert a new
valve to check for smooth sliding motion.
11-51
ENGINE – Front Case, Counterbalance Shaft and Oil Pan
FRONT CASE, COUNTERBALANCE SHAFT AND OIL PAN
REMOVAL AND INSTALLATION
10 Nm
Apply engine oil to all
moving parts before
installation.
29
31
8
28
20
30
24 Nm
10 Nm
7
25
54 Nm
21
15
27
22 Nm
9
19
16 Nm
14
6
24
18
16
13
12
11
18 Nm
17
24 Nm
26
23
36 Nm
5
19 Nm
19 Nm
4
24 Nm
10
44 Nm
22
2
39 Nm
1
7 Nm
3
Removal steps
1. Drain plug
"NA 2. Drain plug gasket
"MA 3. Oil filter
AA" "LA 4. Oil pan
5. Oil screen
6. Oil screen gasket
7. Buffle plate
"IA 8. Oil pressure switch
9. Oil cooler by-pass valve
10. Relief plug
11. Relief plug gasket
12. Relief spring
13. Relief plunger
14. Oil filter bracket
15. Oil filter bracket gasket
AB" "KA 16. Plug
17. O-ring
AC" "JA 18. Flange bolt
"HA 19. Front case
20. Front case gasket
21. Oil pump cover
"GA 22. Oil pump driven gear
"GA 23. Oil pump drive gear
"FA 24. Crankshaft oil seal
"EA 25. Oil pump oil seal
"DA 26. Counterbalance shaft oil seal
27. Counterbalance shaft left
28. Counterbalance shaft right
AD" "CA 29. Counterbalance shaft front bearing
AE" "BA 30. Counterbalance shaft rear bearing
left
AE" "AA 31. Counterbalance shaft rear bearing
right
11-52
ENGINE – Front Case, Counterbalance Shaft and Oil Pan
REMOVAL SERVICE POINTS
MD998727
AA" OIL PAN REMOVAL
(1) Remove all oil pan bolts.
(2) Drive in the special tool between the cylinder block and
oil pan.
NOTE
Never use a screwdriver or chisel, instead of the service
tool, as a deformed oil pan flange will result in oil leakage.
6EN0698
MD998162
AB" PLUG REMOVAL
(1) Fit special tool MD998162 on the plug, and then hold
it in position with special tool MD998783.
(2) Loosen the plug.
(3) Remove the special tools MD998783 and MD998162 and
then the plug.
MD998783
AC" FLANGE BOLT REMOVAL
(1) Remove the plug on the side of cylinder block.
(2) Insert a Phillips screwdriver (shank diameter 8 mm) into
the plug hole to lock the counterbalance shaft.
Plug
Screwdriver
6EN1026
(3) Loosen the flange bolt.
6EN0565
AD" COUNTERBALANCE SHAFT FRONT BEARING
REMOVAL
Using the special tool, remove the counterbalance shaft front
bearing from the cylinder block.
NOTE
Be sure to remove the front bearing first.
If it has not been removed, the Rear Bearing Puller cannot
be used.
ENGINE – Front Case, Counterbalance Shaft and Oil Pan
11-53
AE" COUNTERBALANCE SHAFT REAR BEARING
REMOVAL
Using the special tool, remove the left counterbalance shaft
rear bearing from the cylinder block.
MB991603
NOTE
When removing the left counterbalance shaft rear bearing,
install the special tool (MB991603) in front of the cylinder
block.
INSTALLATION SERVICE POINTS
"AA RIGHT COUNTERBALANCE SHAFT REAR
BEARING INSTALLATION
(1) Apply engine oil to the outer surface of bearing.
(2) Using special tools, install right rear bearing. Make sure
that oil hole of bearing is aligned with oil hole of cylinder
block.
MD998705
6EN1034
"BA LEFT COUNTERBALANCE SHAFT REAR
BEARING INSTALLATION
(1) Install the special tool (Guide Plate) to the cylinder block.
(2) Apply engine oil to the rear bearing outer circumference
and bearing hole in the cylinder block.
(3) Using the special tool, install the rear bearing.
MB991603
NOTE
The left rear bearing has no oil holes.
Rear bearing
MB991603
MD998705
6EN0557
11-54
ENGINE – Front Case, Counterbalance Shaft and Oil Pan
"CA COUNTERBALANCE SHAFT FRONT BEARING
INSTALLATION
Using special tools, install front bearing.
MD998705
MD998705
Bearing
Cylinder block
6EN1035
"DA COUNTERBALANCE SHAFT OIL SEAL
INSTALLATION
Using a suitable socket wrench, install the counterbalance
shaft oil seal into the front case.
"EA OIL PUMP OIL SEAL INSTALLATION
Using a suitable socket wrench, install the oil pump oil seal
into the front case.
"FA CRANKSHAFT FRONT OIL SEAL INSTALLATION
Using the special tool, install the crankshaft front oil seal
into the front case.
ENGINE – Front Case, Counterbalance Shaft and Oil Pan
11-55
"GA OIL PUMP DRIVEN GEAR / OIL PUMP DRIVE
GEAR INSTALLATION
Apply engine oil amply to the gears and line up the alignment
marks.
"HA FRONT CASE ASSEMBLY INSTALLATION
(1) Set the special tool on the front end of crankshaft and
apply a thin coat of engine oil to the outer circumference
of the special tool to install the front case.
(2) Install the front case assembly through a new front case
gasket and temporarily tighten the flange bolts (other
than those for tightening the filter bracket).
"IA SEALANT APPLICATION TO OIL PRESSURE
SWITCH
Coat the threads of switch with sealant and install the switch
using the special tool.
Specified sealant: 3MTM AAD Part No. 8672 or equivalent
Caution
(1) Keep the end of the thread portion clear or sealant.
(2) Avoid an overtightening.
"JA FLANGE BOLT INSTALLATION
(1) Insert a Phillips screwdriver into a hole in the left side
of the cylinder block to lock the silent shaft.
6EN0564
11-56
ENGINE – Front Case, Counterbalance Shaft and Oil Pan
(2) Secure the oil pump driven gear onto the left
counterbalance shaft by tightening the flange bolt to
specified torque.
MD998162
"KA PLUG INSTALLATION
(1) Install a new O-ring to the groove of the front case.
(2) Install the plug to the front case.
(3) Fit the special tool MD998162 on the plug, and then
hold it in position with special tool MD998783.
(4) Tighten the plug to the specified torque.
(5) Remove the special tools MD998783 and MD998162.
MD998783
"LA OIL PAN INSTALLATION
(1) Clean both mating surfaces of oil pan and cylinder block.
(2) Apply a 4 mm wide bead of sealant to the entire
circumference of the oil pan flange.
Specified sealant:
Mitsubishi Genuine
equivalent
Bolt hole
portion
Part
No.
MD970389
or
Groove
portion
6EN0213
NOTE
1. Be sure to install the oil pan quickly while the sealant
is wet (within 15 minutes).
2. After installation, keep the sealed area away from
the oil and coolant for approx. one hour.
(3) Note the difference in bolt lengths at the location shown.
ENGINE – Front Case, Counterbalance Shaft and Oil Pan
Bracket side
11-57
"MAOIL FILTER INSTALLATION
(1) Clean the installation surfaces of the filter bracket.
(2) Apply engine oil to the O-ring of the oil filter.
(3) Screw the oil filter in until the O-ring contacts the bracket.
Then tighten 3/4 turn (tightening torque: 16 Nm).
6EN0591
"NA DRAIN PLUG GASKET INSTALLATION
Caution
Fitting the gasket in a wrong way will result in oil leakage.
Drain plug
Install the drain plug gasket in the direction shown.
Gasket
Oil pan
Oil pan
side
INSPECTION
FRONT CASE
(1) Check oil holes for clogging and clean if necessary.
(2) Check the left counterbalance shaft front bearing section
for wear, damage and seizure. If there is anything wrong
with the section, replace the front case.
(3) Check the front case for cracks and other damage.
Replace cracked or damaged front case.
OIL SEAL
(1) Check the oil seal lip for wear and damage. Replace
oil seal if necessary.
(2) Check the oil seal lip for deterioration. Replace oil seal
if necessary.
11-58
ENGINE – Front Case, Counterbalance Shaft and Oil Pan
COUNTERBALANCE SHAFT
(1) Check oil holes for clogging.
(2) Check journals for seizure, damage and contact with
bearing. If there is anything wrong with the journal, replace
the counterbalance shaft, bearing or front case assembly.
OIL COOLER BY-PASS VALVE (ENGINE WITH AIR
COOLING TYPE OIL COOLER)
(1) Make sure that the valve moves smoothly.
(2) Ensure that the dimension (L) measures the standard
valve under normal temperature and humidity.
Standard value (L): 34.5 mm
Valve
(3) The dimension must be the standard value when
measured after the valve has been dipped in 100°C oil.
Standard value (L): 40 mm or more
OIL PUMP
(1) Assemble the oil pump gear 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.
(3) Check the side clearance.
Standard value:
Drive gear
Driven gear
0.08 – 0.14 mm
0.06 – 0.12 mm
11-59
ENGINE – Piston and Connecting Rod
PISTON AND CONNECTING ROD
REMOVAL AND INSTALLATION
6
7
8
Apply engine oil to all
moving parts before
installation.
4
10
12
9
11
5
3
2
20 Nm + 90_ to 94_
1
"GA
AA" "FA
"EA
"DA
"CA
Removal steps
1. Connecting rod nut
2. Connecting rod cap
3. Connecting rod bearing
4. Piston and connecting rod assembly
5. Connecting rod bearing
6. Piston ring No. 1
"CA 7. Piston ring No. 2
"BA 8. Oil ring
AB" "AA 9. Piston pin
10. Piston
11. Connecting rod
12. Bolt
11-60
ENGINE – Piston and Connecting Rod
REMOVAL SERVICE POINTS
AA" CONNECTING ROD CAP REMOVAL
(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 order according to the cylinder number.
AB" PISTON PIN REMOVAL
(1) Insert the special tool, Push Rod, into the piston from
the side on which the front mark is stamped in the piston
head, and attach the guide C to the push rod end.
(2) Place the piston and connecting rod assembly on the
special tool, Piston Pin Setting Base, with the front mark
facing upward.
(3) Using a press, remove the piston pin.
NOTE
Keep the disassembled pistons, piston pins and
connecting rods in order according to the cylinder number.
ENGINE – Piston and Connecting Rod
11-61
INSTALLATION SERVICE POINTS
"AA PISTON PIN INSTALLATION
(1) Measure the following dimensions of the piston, piston
pin and connecting rod.
A: Piston pin insertion hole length
B: Distance between piston bosses
C: Piston pin length
D: Connecting rod small end width
(2) Obtain dimension L (to be used later) from the above
measurements by using by following formula.
L =
(A – C) – (B – D)
2
(3) Insert the special tool, Push Rod, into the piston pin and
attach the guide A to the push rod end.
(4) Assemble the connecting rod in the piston with their front
marks facing the same direction.
(5) Apply engine oil to the entire periphery of the piston pin.
(6) Insert the piston pin, push rod and guide A assembly
having assembled in step (3) from the guide A side into
the piston pin hole on the front marked side.
3 mm + L
(7) Screw the guide B into the guide A until the gap between
both guides amounts to the value L obtained in step
(2) plus 3 mm.
(8) Place the piston and connecting rod assembly onto the
piston setting base with the front marks directed upward.
(9) Press-fit the piston pin using a press.
If the press-fitting force required is less than the standard
value, replace the piston and piston pin set or/and the
connecting rod.
Standard value: 7,350 – 17,200 N
11-62
ENGINE – Piston and Connecting Rod
(10)Check that the piston moves smoothly
Upper
side rail
Spacer
Lower side rail
6EN1237
"BA OIL RING INSTALLATION
(1) Fit the oil ring spacer into the piston ring groove.
NOTE
1. The side rails and spacer may be installed in either
direction.
2. New spacers and side rails are colored for
identification of their sizes.
Size
Identification color
Standard
None
0.50 mm oversize
Red
1.00 mm oversize
Yellow
(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 finger. See illustration.
Use of ring expander to expand the side rail end gap
can break the side rail, unlike other piston rings.
Side rail gap
Caution
Do not use piston ring expander when installing side
rail.
1EN0269
(3) Install the lower side rail in the same procedure as
described in step (2).
(4) Make sure that the side rails move smoothly in either
direction.
11-63
ENGINE – Piston and Connecting Rod
"CA PISTON RING NO. 2 / PISTON RING NO. 1
INSTALLATION
(1) Using piston ring expander, fit No. 2 and then No. 1 piston
ring into position.
NOTE
1. The ring end is provided with identification mark.
Identification mark
Identification mark
Side mark
No. 1
No. 2
Item
Identification mark
No. 1 ring
1R
No. 2 ring
2R
2. Install piston rings with identification mark facing up,
to the piston crown side.
3. Size marks on position rings are as follows.
Size
Size mark
Standard
None
0.50 mm oversize
50
1.00 mm oversize
100
9EN0524
"DA PISTON AND CONNECTING ROD ASSEMBLY
INSTALLATION
(1) Liberally coat engine oil on the circumference of the piston,
piston ring, and oil ring.
(2) Arrange the piston ring and oil ring gaps (side rail and
spacer) as shown in the figure.
(3) Rotate the crankshaft so that crank pin is on the center
of cylinder bore.
Timing belt side
(4) Use suitable thread protectors on the connecting rod bolts
before inserting piston and connecting rod assembly into
the cylinder block.
Care must be taken not to nick the crank pin.
(5) Using a suitable piston ring compressor tool, install the
piston and connecting rod assembly into the cylinder block.
"EA CONNECTING ROD BEARINGS INSTALLATION
When the bearing needs replacing, select and install a proper
bearing by the following procedure.
(1) Measure the crankshaft pin diameter and confirm its
classification from the following table. In the case of a
crankshaft supplied as a service part, identification colors
of its pins are painted at the positions shown in the
illustration.
11-64
ENGINE – Piston and Connecting Rod
(2) The connecting rod bearing identification mark is stamped
at the position shown in the illustration.
Crankshaft pin
Classification
Identification mark
Connecting rod bearing
Identification mark
Identification
color
O. D. mm
Identification
mark
Thickness mm
Production part
Service
part
1
None
Yellow
44.995 – 45.000
0
1.483 – 1.487
2
None
None
44.985 – 44.995
1
1.487 – 1.491
3
None
White
44.980 – 44.985
2
1.491 – 1.495
Connecting rod I.D.: 48.000 – 48.015 mm
(3) Select a proper bearing from the above table on the basic
of the identification data confirmed under items (1) and
(2).
[Example]
If the measured value of a crankshaft pin outer diameter
is 44.996 mm, the pin is classified as “1” in the table.
In case the crankshaft is also replaced by a spare part,
check the identification colors of the pins painted on the
new crankshaft. If the color is yellow, for example, the
pin is classified as “1”. In the above cases, select the
connection rod bearing having identification mark “0”.
"FA CONNECTING ROD CAP INSTALLATION
(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 come on the same side as shown.
(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
ENGINE – Piston and Connecting Rod
11-65
"GA CONNECTING ROD CAP NUT INSTALLATION
Caution
If the cylinder head has been installed before installing
the connecting rod cap nut, be sure to remove the spark
plugs.
Paint mark
90° to 94°
Paint
mark
Nut
Bolt
6AE0298
(1) Since the connecting rod cap bolts and nuts are torqued
using the plastic area tightening method, the bolts should
be examined BEFORE reuse. If the bolt threads are
“necked down”, the bolt should be replaced.
Necking can be checked by running a nut with fingers
to the full length of the bolt threads. If the nut does not
run down smoothly, the bolt should be replaced.
(2) Before installation of each nut, apply engine oil to the
thread portion and bearing surface of the nut.
(3) Install each nut to the bolt and tighten it with fingers.
Then tighten the nuts alternately to install the cap properly.
(4) Tighten the nuts to a torque of 20 Nm.
(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° from the paint mark made on the nut in the direction
of tightening the nut.
(7) Give a 90° to 94° turn to the nut and make sure that
the paint mark on the nut and that on the bolt are in
alignment.
Caution
1. If the nut is turned less than 90°, proper fastening
performance may not be expected. When
tightening the nut, therefore, be careful to give
a sufficient turn to it.
2. If the nut is overtightened (exceeding 94°), loosen
the nut completely and then retighten it by
repeating the tightening procedure from step (1).
INSPECTION
PISTON RING
(1) Check the piston ring for damage, excessive wear, and
breakage and replace if defects are evident. If the piston
has been replaced with a new one, the piston rings must
also be replaced with new ones.
(2) Check for the clearance between the piston ring and
ring groove. If the limit is exceeded, replace the ring or
piston, or both.
Standard value:
No. 1 ring 0.04 – 0.075 mm
No. 2 ring 0.02 – 0.06 mm
Limit: 0.1 mm
11-66
ENGINE – Piston and Connecting Rod
(3) Install the piston ring into the cylinder bore. Force it down
with a piston, its 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:
No. 1 ring 0.25 – 0.35 mm
No. 2 ring 0.40 – 0.55 mm
Oil ring
0.10 – 0.40 mm
Limit:
No. 1, No. 2 ring 0.8 mm
Oil ring 1.0 mm
CRANKSHAFT PIN OIL CLEARANCE
(PLASTIC GAUGE METHOD)
(1) Remove oil from the crankshaft pin and connecting rod
bearing.
(2) Cut the Plastigage to the same length as the width of
the bearing and place it on the crankshaft pin in parallel
with its axis.
Plastigage
(3) Install the connecting rod cap carefully and tighten the
nuts to specified torque.
(4) Carefully remove the connecting rod cap.
(5) Measure the width of the Plastigage at its widest part
by using a scale printed on the Plastigage package.
Standard value: 0.03 – 0.05 mm
Limit: 0.1 mm
11-67
ENGINE – Crankshaft and Flywheel
CRANKSHAFT AND FLYWHEEL
REMOVAL AND INSTALLATION
2
3
1
15
6
5
132 Nm
4
11 Nm
9 Nm
11 Nm
11 Nm
14
12
13
11
32 Nm
10
9
Apply engine oil to all
moving parts before
installation.
8
25 Nm + 90_
7
"EA
"DA
"CA
"CA
Removal steps
1. Flywheel bolt
2. Flywheel
3. Rear plate
4. Bell housing cover
5. Oil seal case
6. Oil seal
7. Beam bearing cap bolt
8. Beam bearing cap
"BA 9.
10.
"BA 11.
"AA 12.
13.
14.
15.
Crankshaft bearing lower
Crankshaft
Crankshaft bearing upper
Crankshaft thrust bearing
Check valve
Oil jet
Cylinder block
11-68
ENGINE – Crankshaft and Flywheel
INSTALLATION SERVICE POINTS
"AA CRANKSHAFT THRUST BEARING INSTALLATION
(1) Install the two thrust bearing 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.
(2) The thrust bearings must be installed with their groove
side toward the crankshaft web.
Groove
Identification color of crankshaft journal
Bearing bore size
identification mark
No. 1
No. 2 No. 3
No. 4
No. 5
Bearing bore
identification
mark
Cylinder inner
diameter size
mark
Bottom of
cylinder block
Rear face of
cylinder block
"BA CRANKSHAFT BEARING INSTALLATION
(1) From the following table, select a bearing whose size
is appropriate for the crankshaft journal outside diameter.
11-69
ENGINE – Crankshaft and Flywheel
Crankshaft journal outside diameter
Cylinder block bearing bore
Crankshaft bearing
Identification color
Size mm
Identification mark
Identification mark or color
Yellow
56.994 – 57.000
0
0 or Black
1
1 or Green
2
2 or Yellow
0
1 or Green
1
2 or Yellow
2
3 or None
0
2 or Yellow
1
3 or None
2
4 or Blue
None
56.988 – 56.994
White
56.982 – 56.988
For example, if the crankshaft journal outside diameter
ID color is “yellow” and cylinder block bearing bore ID
mark is “1”, select a bearing whose ID mark is “1”.
If there is no ID color paint on the crankshaft, measure
the journal outside diameter and select a bearing
appropriate for the measured value.
Crankshaft bearing size
identification mark or color
Identification
mark or color
(2) Install the bearings having an oil groove to the cylinder
block.
(3) Install the bearings having no oil groove to the bearing
cap.
Groove
Upper
Lower
"CA BEARING CAP / BEARING CAP BOLT
INSTALLATION
(1) Install the bearing caps so the arrow points to the timing
belt side.
(2) Before installing the bearing cap bolts, check that the
shank length of each bolt meets the limit. If the limit is
exceeded, replace the bolt.
Limit: Max. 71.1 mm
Shank length
9EN0477
(3) Apply engine oil to the threaded portion and bearing
surface of the bolt.
11-70
ENGINE – Crankshaft and Flywheel
(4) Tighten the bolts to 25 Nm in the specified tightening
sequence.
Arrow mark
Paint mark
Paint mark
90°
6AE0299
(5) Make a paint mark on the head of each bolt.
(6) Make a paint mark on the bearing cap at the position
90° from the paint mark made on the bolt in the direction
of tightening the bolt.
(7) According to the specified tightening sequence, give a
90° turn to each bolt and make sure that the paint mark
on the bolt and that on the cap are in alignment.
Caution
If the bolt is turned less than 90°, proper fastening
performance may not be expected. When tightening
the bolt, therefore, be careful to give a sufficient turn
to it.
(8) After installing the bearing caps, make sure that the
crankshaft turns smoothly and the end play is correct.
If the end play exceeds the limit, replace No. 3 crankshaft
bearings.
Standard value: 0.05 – 0.25 mm
Limit: 0.4 mm
"DA OIL SEAL INSTALLATION
Using the special tool, knock the oil seal into the oil seal
case.
ENGINE – Crankshaft and Flywheel
11-71
"EA SEALANT APPLICATION TO OIL SEAL CASE
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or equivalent
NOTE
(1) Be sure to install the case quickly while the sealant is
wet (within 15 minutes).
(2) After installation, keep the sealed area away from the
oil and coolant for approx. one hour.
INSPECTION
Plastigage
CRANKSHAFT OIL CLEARANCE (PLASTIGAGE
METHOD)
(1) Remove oil from the crankshaft journal and the crankshaft
bearing.
(2) Install the crankshaft.
(3) Cut the Plastigage to the same length as the width of
the bearing and place it on the journal in parallel with
its axis.
(4) Install the crankshaft bearing cap carefully and tighten
the bolts to the specified torque.
(5) Carefully remove the crankshaft bearing cap.
(6) Measure the width of the Plastigage at its widest part
by using a scale printed on the Plastigage package.
Standard value: 0.02 – 0.04 mm
Limit: 0.1 mm
Plastigage
CYLINDER BLOCK
(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): 284 mm
(4) Check cylinder walls for scratches and seizure. If defects
are evident, correct (bored to oversize) or replace.
11-72
ENGINE – Crankshaft and Flywheel
(5) Using cylinder gauge, measure the cylinder bore and
cylindricity. If worn badly, correct cylinder to an oversize
and replace piston and piston rings. Measure at the points
shown in illustration.
Standard value:
Cylinder I.D. 85.00 – 85.03 mm
Cylindricity 0.01 mm or less
BORING CYLINDER
(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 O.S.
50
1.00 O.S.
100
NOTE
Size mark is stamped on the piston top.
(2) Measure outside diameter of piston to be used. Measure
it in thrust direction as shown.
(3) Based on the measured piston O.D. calculate boring finish
dimension.
Boring finish dimension = Piston O.D. + (clearance
between piston O.D. and cylinder) – 0.02 mm
(honing margin)
(4) Bore all cylinders to the calculated boring finish dimension.
Caution
To prevent distortion that may result from temperature
rise during honing, bore cylinders, working from No.
2, No. 4, No. 1 to No. 3.
(5) Hone to final finish dimension (piston O.D. + clearance
between piston O.D. and cylinder).
(6) Check clearance between piston and cylinder.
Clearance between piston and cylinder:
0.02 – 0.04 mm
NOTE
When boring cylinders, finish all of four cylinders to same
oversize. Do not bore only one cylinder to an oversize.
11-73
ENGINE – Throttle Body
THROTTLE BODY
DISASSEMBLY AND REASSEMBLY
6
7
4
5
3.5 Nm
1
2
3
3.5 Nm
Disassembly steps
AA" "AA 1. Throttle position sensor (with builtin closed throttle position switch)
2. Idle speed control body assembly
3. O-ring
AB"
4. Throttle body
5. Fixed SAS
6. Speed adjusting screw
8. O-ring
NOTE
1. The fixed SAS and the speed adjusting screw are
correctly adjusted at the factory and should not be
removed.
2. If the fixed SAS should happen to have been
removed, carry out fixed SAS adjustment.
3. If the speed adjusting screw should happen to have
been removed, carry out speed adjusting screw
adjustment.
11-74
ENGINE – Throttle Body
DISASSEMBLY SERVICE POINTS
AA" THROTTLE POSITION SENSOR AND IDLE AIR
CONTROL MOTOR REMOVAL
(1) Do not disassemble the sensor and motor.
(2) Do not immerse solvent to clean the sensor and motor.
Clean then with shop towel.
AB" THROTTLE BODY REMOVAL
(1) Do not remove the throttle body.
(2) Check if the vacuum port or passage is clogged. Use
compressed air to clean the vacuum passage.
REASSEMBLY SERVICE POINT
"AA THROTTLE POSITION SENSOR INSTALLATION
(1) Install the throttle position sensor to the throttle body
as shown in the diagram.
Throttle position sensor
(2) Turn throttle position sensor 90° clockwise to set it, and
tighten screws.
TPS power supply
TPS output
Earth
Idle position switch
(3) Check the continuity between terminal No. 3 (Idle throttle
position switch) and No. 4 (Earth).
Throttle valve condition
Continuity
Fully closed
Conductive
Fully open
No conductive
If there is no continuity with the throttle valve fully closed,
turn the throttle position sensor counterclockwise, and
then check again.
11-75
ENGINE – Turbocharger
TURBOCHARGER
DISASSEMBLY AND REASSEMBLY
7
8
6
5
3
4
11 Nm
2
1
Disassembly steps
D Inspection of turbocharger waste gate
actuator operation
1. Snap pin
2. Waste gate actuator
"EA 3. Coupling
"FA
"DA 4.
AA" "CA 5.
AB" "BA 6.
7.
"AA 8.
Turbine housing
Snap ring
Turbine wheel assembly
Compressor cover
O-ring
11-76
ENGINE – Turbocharger
DISASSEMBLY SERVICE POINTS
AA" SNAP RING REMOVAL
Lay the unit with the compressor cover side facing down
and using snap ring pliers, remove the compressor cover
attaching snap ring.
Caution
When removing the snap ring, hold it with fingers to
prevent it from springing away.
Snap ring
AB" TURBINE WHEEL ASSEMBLY REMOVAL
Remove the turbine wheel assembly, striking the
circumference of the compressor cover with a plastic hammer.
The turbine wheel assembly may be a little hard to remove
due to an O-ring put on the outer circumference.
Turbine
wheel
assembly
CLEANING
(1) Use a clean cleaning oil commercially available. Do not
use corrosive cleaning oils as they could damage to some
parts.
(2) Use a plastic scraper or hard brush to clean aluminum
parts.
REASSEMBLY SERVICE POINTS
"AA O-RING INSTALLATION
Apply a light coat of engine oil to a new O-ring and fit in
the turbine wheel assembly groove.
O-ring
Dowel pin hole
Dowel pin
Caution
When installing the O-ring, use care not to damage it.
A damaged O-ring causes oil leaks.
"BA TURBINE WHEEL ASSEMBLY
(1) Apply a light coat of engine oil to the periphery of the
O-ring.
(2) Install the turbine wheel assembly to the compressor cover
in relation to the dowel pin.
Caution
Use care not to damage the blades of turbine wheel
and compressor wheel.
ENGINE – Turbocharger
Snap ring
Chamfered
edge
11-77
"CA SNAP RING INSTALLATION
Lay the assembly with the compressor cover facing down
and fit the snap ring.
Caution
Fit the snap ring with its chamfered side facing up.
Turbine wheel
assembly
Compressor
cover
"DA TURBINE HOUSING INSTALLATION
Install the turbine housing in relation to the dowel pin.
Caution
Use care not to damage the blades of turbine wheel.
Dowel pin
Dowel pin hole
"EA COUPLING INSTALLATION
Install the coupling and tighten to the specified torque.
Coupling
"FA WASTE GATE ACTUATOR OPERATION CHECK
Using a tester, apply a pressure of approx. 100.0 kPa to
the actuator and make sure that the rod moves.
Caution
Do not apply a pressure of more than 113.3 kPa to the
actuator. Otherwise, diaphragm may be damaged. Never
attempt to adjust the waste gate valve.
Traces of contact
INSPECTION
TURBINE HOUSING
(1) Check the housing for traces of contact with the turbine
wheel, cracks due to overheating, pitching, deformation
and other damage. Replace with a new turbine housing
if cracked.
(2) Operate the waste gate valve lever manually to check
that the gate can be operated and closed smoothly.
11-78
ENGINE – Turbocharger
Oil passage
Turbine wheel
Compressor
wheel
Water passage
COMPRESSOR COVER
Check the compressor cover for traces of contact with the
compressor wheel and other damage.
TURBINE WHEEL ASSEMBLY
(1) Check the turbine and compressor wheel blades for bend,
burr, damage, corrosion and traces of contact on the
back side and replace if defective.
(2) Check the oil passage of the turbine wheel assembly
for deposit and clogging.
(3) In the case of water cooled type, check also the water
passage for deposit and clogging.
(4) Check the turbine wheel and compressor wheel for light
and smooth turning.
11-79
ENGINE – Alternator
ALTERNATOR
DISASSEMBLY AND REASSEMBLY
1
4
3
5
6
7
2
12
10
9
8
14
13
11
AA"
AB"
Disassembly steps
1. Front bracket assembly
2. Alternator pulley
"BA 3. Rotor
4. Rear bearing
5. Bearing retainer
6. Front bearing
7. Front bracket
AC"
8.
9.
AC" "AA 10.
11.
12.
13.
14.
Stator
Plate
Regulator assembly
Brush
Slinger
Rectifier
Rear bracket
11-80
ENGINE – Alternator
DISASSEMBLY SERVICE POINTS
AA" FRONT BRACKET ASSEMBLY REMOVAL
Insert a flat tip screwdrivers or the like in the clearance between
the front bracket assembly and stator core, to pry open and
separate the stator and front bracket.
Caution
Do not insert the screwdriver too far, or the stator coil
gets damaged.
AB" ALTERNATOR PULLEY REMOVAL
Face pulley side upward, fix the rotor with a work bench
and remove the pulley.
Caution
Use care not to damage the rotor.
Soldered
AC" STATOR / REGULATOR ASSEMBLY REMOVAL
(1) Unsolder the stator with a soldering iron (180 to 250
W). Complete this work within four seconds not to transfer
heat to the diode.
(2) When removing rectifier from the regulator assembly,
remove the soldered sections to rectifier.
Caution
1. Use care to make sure that the heat of the soldering
iron is not transmitted to the diodes for a long
period.
2. Use care that no undue force is exerted to the
lead wires of the diodes.
REASSEMBLY SERVICE POINTS
Wire
"AA REGULATOR ASSEMBLY INSTALLATION
After installing the regulator assembly, insert a wire into the
hole provided on the rear bracket while pressing in the brush
to fix the brush.
NOTE
The brush is fixed when a wire is inserted, making rotor
installation easier.
Rear bracket
Brush
Wire
ENGINE – Alternator
Wire
11-81
"BA ROTOR INSTALLATION
After installing the rotor, remove the wire used to fix the brush.
INSPECTION
ROTOR CHECK
(1) Check the continuity between the rotor coil slip rings,
and replace the rotor if the resistance value is not at
the standard value.
Standard value: 3 – 5 Ω
(2) Check the continuity between the slip ring and core, and
if there is continuity, replace the rotor.
STATOR CHECK
(1) Check the continuity between the coil leads, and if there
is continuity, replace the stator.
(2) Check the continuity between the coil and core, and if
there is continuity, replace the stator.
11-82
ENGINE – Alternator
RECTIFIERS CHECK
(1) Inspect the (+) heat sink by checking the continuity
between the (+) heat sink and stator coil lead wire
connection terminal using a tester probe.
If there is a continuity at both, the diode is short circuited,
so replace the rectifier.
(2) Inspect the (–) heat sink by checking the continuity
between the (–) heat sink and stator coil lead wire
connection terminal using a tester probe.
If there is a continuity at both, the diode is short circuited,
so replace the rectifier.
(3) Check the diode trio by connecting an ohmmeter to both
ends of each diode and check the continuity of the three
diodes.
If there is a continuity at both ends, or if there is no
continuity, the diode is damaged so replace the recitifier.
BRUSH CHECK
(1) Measure the length of the brush protrusion shown in the
illustration, and replace the brush if the measured value
is below the limit value.
Protrusion
length
Limit: 2 mm or less
Soldered
(2) The brush can be removed if the solder of the brush
lead wire is removed.
(3) When installing a new brush, insert the brush into the
holder as shown in the illustration, and then solder the
lead wires.
11-83
ENGINE – Starter Motor
STARTER MOTOR
DISASSEMBLY AND REASSEMBLY
3
14
15
17
19
2
13
12
16
18
22
21
5
20
23
4
1
9
11
6
8
7
10
AA"
AB"
AB"
Disassembly steps
1. Cover
2. Screw
3. Magnetic switch
4. Screw
5. Through
6. Rear bracket
7. Brush holder
8. Brush
9. Rear bearing
10. Armature
11. Yoke assembly
12. Ball
13.
14.
15.
16.
17.
AC" "AA 18.
AC" "AA 19.
20.
21.
22.
23.
Packing A
Packing B
Plate
Planetary gear
Lever
Snap ring
Stop ring
Overrunning clutch
Internal gear
Planetary gear holder
Front bracket
11-84
Magnetic
switch
ENGINE – Starter Motor
DISASSEMBLY SERVICE POINTS
“S” terminal
“B” terminal
AA" MAGNETIC SWITCH REMOVAL
Disconnect field coil wire from “M” terminal of magnetic switch.
“M” terminal
Field coil wire
AB" ARMATURE / BALL REMOVAL
Caution
When removing the armature, take care not to lose the
ball (which is used as a bearing) in the armature end.
AC" SNAP RING / STOP RING REMOVAL
(1) Press stop ring off snap ring with a suitable socket.
Socket
Stop ring
Armature
Pinion gear
Overrunning
clutch
(2) Remove snap ring with snap ring pliers and then remove
stop ring and overrunning clutch.
Snap ring
Snap ring pliers
Pinion gear
Overrunning
clutch
Armature
STARTER MOTOR PARTS CLEANING
(1) Do not immerse parts in cleaning solvent. Immersing the
yoke and field coil assembly and/or armature will damage
insulation. Wipe motor assembly with a cloth only.
(2) Do not immerse drive unit in cleaning solvent. Overrunning
clutch is pre-lubricated at the factory and solvent will wash
lubrication from clutch.
(3) The drive unit may be cleaned with a brush moistened
with cleaning solvent and wiped dry with a cloth.
ENGINE – Starter Motor
11-85
REASSEMBLY SERVICE POINTS
"AA STOP RING / SNAP RING INSTALLATION
Using a suitable pulling tool, pull overrunnig clutch stop ring
over snap ring.
Stop ring
Stop ring
Overrunning
clutch
Snap ring
INSPECTION
COMMUTATOR CHECK
(1) Place the armature in a pair of “V” blocks and check
the runout with a dial indicator.
Standard value: 0.05 mm
Limit: 0.1 mm
(2) Measure the commutator outer diameter.
Standard value: 32.0 mm
Limit: 31.4 mm
(3) Check the undercut depth between segments.
Undercut
Standard value: 0.5 mm
Segment
Mica
Brush holder
BRUSH HOLDER CHECK
Check the continuity between brush holder plate and brush
holder.
If there is no continuity, the brush holder is in order.
11-86
ENGINE – Starter Motor
OVERRUNING CLUTCH CHECK
(1) While holding clutch housing, rotate the pinion. Drive
pinion should rotate smoothly in one direction, but should
not rotate in opposite direction. If clutch does not function
properly, replace overrunnig clutch assembly.
(2) Inspect pinion for wear or burrs. If pinion is worn or burred,
replace overrunning clutch assembly. If pinion is damaged,
also inspect ring gear for wear or burrs.
Free
Lock
FRONT AND REAR BRACKET BUSHING CHECK
Inspect bushing for wear or burrs. If bushing is worn or burred,
replace front bracket assembly or rear bracket assembly.
BRUSH AND SPRING REPLACEMENT
(1) Brushes that are worn beyond wear limit line, or oil-soaked,
should be replaced.
(2) When replacing ground brush, slide the brush from brush
holder by prying retaining spring back.
Wear limit line
Growler
ARMATURE TEST
ARMATURE COIL SHORT-CIRCUIT TEST
(1) Place armature in a growler.
(2) Hold a thin steel blade parallel and just above while rotating
armature slowly in growler. A shorted armature will cause
blade to vibrate and be attracted to the core. Replace
shorted armature.
ARMATURE COIL EARTH TEST
Check the insulation between each commutator segment and
armature coil core.
If there is no continuity, the insulation is in order.
ENGINE – Starter Motor
11-87
ARMATURE COIL OPEN-CIRCUIT INSPECTION
Check the continuity between segments. If there is continuity,
the coil is in order.