11A-1
ENGINE
CONTENTS
11109000276
ENGINE <4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A
ENGINE <6A1> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B
ENGINE <4D6> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11C
11A-3
ENGINE <4G6> - General Information/Service Specifications
GENERAL INFORMATION
11100010469
Items
4G63
Total displacement mL
Bore ´ Stroke mm
Compression ratio
Combustion chamber
Camshaft arrangement
1,997
85.0 ´88.0
10.0
Pentroof type
SOHC
Intake
8
Number of valve
Exhaust
8
Opening
Closing
Opening
Closing
BTDC 11_
ABDC 53_
BBDC 63_
ATDC 21_
Intake
Valve timing
Exhaust
Fuel system
Electronically controlled multipoint fuel injection
Rocker arm
Roller type
Equipped
Auto-lash adjuster
SERVICE SPECIFICATIONS
11100030489
Items
Standard value
294-490
Limit
When checked
-
-
-
-
-
-
-
-
-
-
-
-
-
-
When a used belt is installed
343-441
Tension N
Alternator drive
belt
When a new belt is installed
When checked
490-686
7.7-12.3
tension
Deflection
(Reference
value) mm
When a used belt is installed
When a new belt is installed
When checked
8.4-10.6
5.9-7.7
392-588
When a used belt is installed
When a new belt is installed
When checked
441-539
Tension N
Power steering
oil pump and
A/C compressor
drive belt
637-833
11.7-15.3
12.5-14.3
8.8-11.0
tension
Deflection
mm
When a used belt is installed
When a new belt is installed
Basic ignition timing
Ignition timing
5_ BTDC±2_
Approx. 10_BTDC
11A-4
ENGINE <4G6> - Service Specifications/Sealants/Special Tools
Items
Standard value
Limit
Idle speed r/min
750 ± 100
-
CO contents %
0.5 or less
-
HC contents ppm
100 or less
-
Compression pressure (250-400 r/min) kPa
Compression pressure difference of all cylinder kPa
Intake manifold vacuum kPa
Cylinder head bolt shank length mm
Auto-tensioner push rod movement mm
Timing belt tension torque Nm (Reference value)
Auto-tensioner rod protrusion amount mm
Timing belt B tension mm
1,400
Min. 1,060
-
Max. 100
-
Min. 69
-
99.4
Within 1
3.5
-
-
-
-
3.8 - 4.5
5 - 7
SEALANTS
11100050201
Items
Specified sealants
3M ATD Part No.8660 or equivalent
Remarks
Rocker cover and cylinder head
Semi-circular packing
-
Oil pan
Thermostat case
MITSUBISHI
GENUINE
PART Semi-drying sealant
MD970389 or equivalent
Flywheel bolt
3M Stud Locking 4170 or equivalent
-
SPECIAL TOOLS
11100060457
Tool
Number
Name
Use
MB991502
MUT-II sub assem-
bly
D
D
Checking the idle speed
Erasing diagnosis code
MB990767
End yoke holder
D
D
Holding the camshaft sprocket
Holding the crankshaft sprocket
MD998719 or Crankshaft pulley
MD998754 holder pin
D
D
Holding the camshaft sprocket
Holding the crankshaft sprocket
11A-5
ENGINE <4G6> - Special Tools
Tool
Number
Name
Use
MD998713
Camshaft oil seal Press-in of the camshaft oil seal
installer
MD998443
MD998727
MD998781
MD998776
MB990938
MD998767
Auto-lash adjuster Supporting of auto-lash adjuster
holder
Oil pan remover
Flywheel stopper
Removal of oil pan
Securing the flywheel
Crankshaft rear oil Press-in of the crankshaft rear oil seal
seal installer
Handle
Press-in of the crankshaft rear oil seal
Tension
pulley Timing belt tension adjustment
socket wrench
Engine lifter
GENERAL
SERVICE
TOOL
Supporting the engine assembly during
removal and installation of the transmission
MZ203827
MB991453
Engine hanger
assembly
11A-6
ENGINE <4G6> - On-vehicle Service
Alternator pulley
Water pump
pulley
ON-VEHICLE SERVICE
11100090432
DRIVE BELT TENSION CHECK AND
ADJUSTMENT
ALTERNATOR DRIVE BELT TENSION CHECK
Use a belt tension gauge to check that the belt tension is
at the standard value at a point half-way between the two
pulleys as shown in the illustration. In addition, press this
section with a force of 98 N and check that the amount of
belt deflection is at the standard value.
Crankshaft pulley
Standard value:
Tension N
294-490
7.7-12.3
Deflection (Reference value) mm
ALTERNATOR DRIVE BELT TENSION ADJUSTMENT
1. Loosen the nut of the alternator pivot bolt.
2. Loosen the lock bolt.
3. Use the adjusting bolt to adjust the belt tension and belt
deflection to the standard values.
Standard value:
Adjusting bolt
Lock bolt
Items
When a used
belt is installed
When a new
belt is installed
Tension N
343-441
490-686
5.9-7.7
Deflection (Reference 8.4-10.6
value) mm
4. Tighten the nut of the alternator pivot bolt.
Tightening torque: 44 Nm
5. Tighten the lock bolt.
Tightening torque: 22 Nm
6. Tighten the adjusting bolt.
Tightening torque: 10 Nm
11A-7
ENGINE <4G6> - On-vehicle Service
POWER STEERING OIL PUMP AND AIR CONDITIONER
COMPRESSOR DRIVE BELT TENSION CHECK AND
<VehicleswithoutA/C>
Oilpumppulley
ADJUSTMENT
11100130127
98 N
1. Use a belt tension gauge to check that the belt tension
is at the standard value at a point half-way between the
two pulleys (indicated by an arrow in the illustration).
In addition, press this section with a force of 98 N and
check that the amount of belt deflection is at the standard
value.
B
A
Crankshaft
pulley
Tensionerpulley
Standard value:
Items
When
checked
When a
used belt is
installed
When a new
belt is
installed
<VehicleswithA/C>
Oil pump pulley
98 N
Tension N
392-588
441-539
637-833
8.8-11.0
Tensioner
pulley
Deflection
(Reference
value) mm
11.7-15.3
12.5-14.3
A
B
Crankshaft
pulley
A/C
compressor
pulley
2. If the tension or deflection is outside the standard value,
adjust by the following procedure.
(1) Loosen tensioner pulley fixing nut A.
(2) Adjust the amount of belt deflection using adjusting
bolt B.
(3) Tighten fixing nut A.
Tightening torque: 25 Nm
(4) Check the belt deflection amount and tension, and
readjust if necessary.
Caution
Check after turning the crankshaft once or more
clockwise (right turn).
IGNITION TIMING CHECK
11100170297
1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Connect the MUT-II to the diagnosis connector.
3. Set up a timing light.
4. Start the engine and run at idle.
5. Check that engine idle speed is within the standard value.
Standard value: 750 ± 100 r/min
6. Select No.17 of the MUT-II Actuator test.
11A-8
ENGINE <4G6> - On-vehicle Service
7. Check that basic ignition timing is within the standard
value.
Standard value: 5_ BTDC±2_
8. If the basic ignition timing is outside the standard value,
inspect the MPI system while referring to GROUP 13A
- Troubleshooting.
9. Press the MUT-II clear key (Select a forced driving cancel
mode) to release the Actuator test.
Caution
If the test is not cancelled, a forced driving will
continue for 27 minutes. Driving under this condition
may damage the engine.
10. Check that ignition timing is at the standard value.
Standard value: approx. 10_BTDC
NOTE
1. Ignition timing is variable within about ± 7_, even
under normal operating.
2. And it is automatically further advanced by about
5_ from standard value at higher altitudes.
IDLE SPEED CHECK
11100350066
1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Turn the ignition switch to OFF and connect the MUT-II
to the diagnosis connector.
3. Check the basic ignition timing.
Standard value: 5_ BTDC±2_
4. Run the engine at idle for 2 minutes.
5. Check the idle speed. Select item No. 22 and take a
reading of the idle speed.
Standard value: 750 ± 100 r/min
NOTE
The idle speed is controlled automatically by the idle speed
control (ISC) system.
6. If the idle speed is outside the standard value, inspect
the MPI components by referring to GROUP 13A -
Troubleshooting.
IDLE MIXTURE CHECK
11100210418
1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Turn the ignition switch to OFF and connect the MUT-II
to the diagnosis connector.
3. Check that the basic ignition timing is within the standard
value.
Standard value: 5_ BTDC±2_
4. Run the engine at 2,500 r/min for 2 minutes.
11A-9
ENGINE <4G6> - On-vehicle Service
5. Set the CO, HC tester.
6. Check the CO contents and the HC contents at idle.
Standard value
CO contents: 0.5% or less
HC contents: 100 ppm or less
7. If there is a deviation from the standard value, check
the following items:
D
D
Diagnosis output
Closed-loop control (When the closed-loop control
is normal, the output signal of the oxygen sensor
changes between 0-400 mV and 600-1,000 mV
at idle.)
D
D
D
D
D
D
Fuel pressure
Injector
Ignition coil, spark plug cable, spark plug
Leak in the EGR system and in the EGR valve
Evaporative emission control system
Compression pressure
NOTE
Replace the three way catalyst when the CO and HC
contents are not within the standard value, even though
the result of the inspection is normal on all items.
COMPRESSION PRESSURE CHECK
11100260499
1. Before inspection, check that the engine oil, starter and
battery are normal. In addition, set the vehicle to the
pre-inspection condition.
2. Disconnect the spark plug cables.
3. Remove all of the spark plugs.
4. Disconnect the crank angle sensor connector.
NOTE
Doing this will prevent the engine-ECU from carrying out
ignition and fuel injection.
5. Cover the spark plug hole with a shop towel etc., and
after the engine has been cranked, check that no foreign
material is adhering to the shop towel.
Caution
1. Keep away from the spark plug hole when
cranking.
2. If compression is measured with water, oil, fuel,
etc., that has come from cracks inside the cylinder,
these materials will become heated and will gush
out from the spark plug hole, which is dangerous.
11A-10
ENGINE <4G6> - On-vehicle Service
6. Set compression gauge to one of the spark plug holes.
7. Crank the engine with the throttle valve fully open and
measure the compression pressure.
Standard value (at engine speed of 250-400 r/min):
1,400 kPa
Compression gauge
Limit (at engine speed of 250-400 r/min):
Min. 1,060 kPa
8. Measure the compression pressure for all the cylinders,
and check that the pressure differences of the cylinders
are below the limit.
Limit: Max. 100 kPa
9. If there is a cylinder with compression or a compression
difference that is outside the limit, pour a small amount
of engine oil through the spark plug hole, and repeat
the operations in steps 7 and 8.
(1) If the compression increases after oil is added, the
cause of the malfunction is a worn or damaged piston
ring and/or cylinder inner surface.
(2) If the compression does not rise after oil is added,
the cause is a burnt or defective valve seat, or pressure
is leaking from the gasket.
10. Connect the crank angle sensor connector.
11. Install the spark plugs and spark plug cables.
12. Use the MUT-II to erase the diagnosis codes.
NOTE
This will erase the diagnosis code resulting from the crank
angle sensor connector being disconnected.
MANIFOLD VACUUM CHECK
11100270409
Vacuum gage
1. Start the engine and allow it to warm up until the
temperature of the engine coolant reaches 80 to 95_C.
2. Connect a tachometer.
3. Attach a three-way union to the vacuum hose between
the fuel pressure regulator and the air intake plenum,
and connect a vacuum gauge.
4. Start the engine and check that idle speed is within
standard value. Then read off the vacuum gauge.
Limit: Min. 69 kPa
11A-11
ENGINE <4G6> - On-vehicle Service
LASH ADJUSTER CHECK
11100290344
If an abnormal noise (knocking) that seems to be coming
from the lash adjuster is heard after starting the engine and
does not stop, carry out the following check.
NOTE
(1) The abnormal noise which is caused by a problem
with the lash adjusters is generated after the engine
is started, and will vary according to the engine speed.
However, this noise is not related to the actual engine
load.
Because of this, if the noise does not occur
immediately after the engine is started, if it does not
change in accordance with the engine speed, or if
it changes in accordance with the engine load, the
source of the noise is not the lash adjusters.
(2) If there is a problem with the lash adjusters, the noise
will almost never disappear, even if the engine has
been run at idle to let it warm up.
The only case where the noise might disappear is
if the oil in the engine has not been looked after
properly and oil sludge has caused the lash adjusters
to stick.
1. Start the engine.
2. Check that the noise occurs immediately after the engine
is started, and that the noise changes in accordance
with changes in the engine speed.
If the noise does not occur immediately after the engine
is started, or if it does not change in accordance with
the engine speed, the problem is not being caused y
the lash adjusters, so check for some other cause of
the problem. Moreover, if the noise does not change in
accordance with the engine speed, the cause of the
problem is probably not with the engine. (In these cases,
the lash adjusters are normal.)
3. While the engine is idling, check that the noise level does
not change when the engine load is varied (for example,
by shifting from N ® D).
If the noise level changes, the cause of the noise is
probably parts striking because of worn crankshaft
bearings or connecting rod bearings. (In such cases, the
lash adjusters are normal.)
4. After the engine has warmed up, run it at idle and check
if any noise can be heard.
If the noise has become smaller or has disappeared,
the cause of the noise was probably that oil sludge had
caused the lash adjusters to become stuck. If this
happens, carry out the following check. If the noise level
does not change, go to step 5.
(1) Let the engine cool down sufficiently.
(2) Turn the crankshaft two full revolutions.
11A-12
ENGINE <4G6> - On-vehicle Service
(3) Carry out lash adjuster simple check. (Refer to
P.11A-13.)
D
If any of the rocker arms can be pushed down
easily during the lash adjuster simple check,
replace the corresponding lash adjusters.
D
If the lash adjuster simple check has been carried
out but all lash adjusters are normal (if none of
the rocker arms could be pushed down easily),
check for some other cause of the problem.
NOTE
You can check whether the lash adjusters are normal
or not by carrying out a leak-down test. (Refer to
the Engine Workshop Manual.)
Caution
Make sure that the air has been fully bled before
installation of a new lash adjuster. (Refer to the
Engine Workshop Manual.)
5. Bleed the air from the lash adjusters. (Refer to P.11A-13.)
6. If the noise does not disappear even after the air has
been bled from the lash adjusters, carry out the following
check.
Carry out lash adjuster simple check. (Refer to P.11A-13.)
D
If one of the rocker arms can be pushed down easily
during the lash adjuster simple check, replace the
corresponding lash adjuster.
If two or more of the rocker arms can be pushed
down easily during the lash adjuster simple check,
the cause may be that the oil passage to the cylinder
head is blocked.
D
Check for blockages in the oil passage, and clear
the blockages if any are found. If there are no
blockages, replace the lash adjusters.
If the lash adjuster simple check has been carried
out but all lash adjusters are normal (if none of the
rocker arms could be pushed down easily), check
for some other cause of the problem.
D
NOTE
You can check whether the lash adjusters are normal
or not by carrying out a leak-down test. (Refer to the
Engine Workshop Manual.)
Caution
Make sure that the air has been fully bled before
installation of a new lash adjuster. (Refer to the Engine
Workshop Manual.)
7. Start the engine and check that the abnormal noise has
disappeared. If necessary, bleed the air from the lash
adjusters. (Refer to P.11A-13.)
11A-13
ENGINE <4G6> - On-vehicle Service
<LASH ADJUSTER SIMPLE CHECK>
1. Stop the engine.
2. Remove the rocker cover.
3. Set the No.1 cylinder to the compression top dead centre
position.
4. Check the rocker arms indicated by white arrows in the
illustration by the procedures given below.
<Checking an intake-side rocker arm>
Check whether the rocker arm moves downwards when
the part of the rocker arm which touches the top of the
lash adjuster is pushed.
D
If the rocker arm moves down easily when it is pushed,
make a note of which is the corresponding lash
adjuster.
If the rocker arm feels extremely stiff when it is pushed
and does not move down, the lash adjuster is normal,
so check for some other cause of the problem.
D
<Checking an exhaust-side rocker arm>
NOTE
It will not be possible to depress the Y-shaped rocker
arm at the exhaust valve side if one lash adjuster is
defective but the other one is normal. In such cases,
carry out the following procedure using a thickness gauge.
(1) Check that a thickness gauge with a thickness of
0.1 - 0.2 mm can be inserted easily between the
valve and the lash adjuster.
(2) If the thickness gauge can be inserted easily, make
a note of which is the corresponding lash adjuster.
(3) If the thickness gauge cannot be inserted easily, the
lash adjuster is normal, so check for some other cause
of the problem.
5. Slowly turn the crankshaft 360_ in the clockwise direction.
6. Check the rocker arms indicated by black arrows in the
illustration in the same way as explained in step 4.
<LASH ADJUSTER AIR BLEEDING>
NOTE
(1) If the vehicle is parked on a slope for a long period
of time, the amount of oil inside the lash adjuster
will decrease, and air may get into the high pressure
chamber when starting the engine.
(2) After parking the vehicle for long periods, the oil drains
out of the oil passage, and it takes time for the oil
to be supplied to the lash adjuster, so air can get
into the high pressure chamber.
(3) If either of the above situations occur, the abnormal
noise can be eliminated by bleeding the air from inside
the lash adjusters.
11A-14
ENGINE <4G6> - On-vehicle Service
1. Check the engine oil and replenish or replace the oil
if necessary.
NOTE
(1) If there is a only small amount of oil, air will be drawn
in through the oil screen and will get into the oil
passage.
(2) If the amount of oil is greater than normal, then the
oil will being mixed by the crankshaft and a large
amount of air may get mixed into the oil.
(3) If the oil is degenerated, air and oil will not separate
easily in oil, and the amount of air mixed into the
oil will increase.
Good
(4) If the air which has been mixed in with the oil due
to any of the above reasons gets into the high pressure
chamber of the lash adjuster, the air inside the high
pressure chamber will be compressed when the valve
is open and the lash adjuster will over-compress,
resulting in abnormal noise when the valve closes.
This is the same effect as if the valve clearance is
adjusted to be too large by mistake. If the air inside
the lash adjusters is then released, the operation
of the lash adjusters will return to normal.
High
pressure
chamber
2. Run the engine at idle for 1 - 3 minutes to let it warm
up.
Drive pattern for air bleeding
Gradually open the
throttle valve.
Close the throttle
valve.
3. With no load on the engine, repeat the drive pattern shown
in the illustration at left and check if the abnormal noise
disappears. (The noise should normally disappear after
10 - 30 repetitions, but if there is no change in the noise
level after 30 repetitions or more, the problem is probably
not due to air inside the lash adjusters.)
Approx.
3,000 r/min.
Idle speed
15
seconds
15
seconds
4. After the noise has disappeared, repeat the drive pattern
shown in the illustration at left a further 5 times.
5. Run the engine at idle for 1 - 3 minutes and check that
the noise has disappeared.
Once
11A-15
ENGINE <4G6> - Crankshaft Pulley
CRANKSHAFT PULLEY
11200160303
REMOVAL AND INSTALLATION
Pre-removal Operation
Post-installation Operation
D
Under Cover Removal
D
Drive Belt Tension Adjustment (Refer to P.11A-6.)
D
Under Cover Installation
2
3
25 Nm
1
Removal steps
1. Drive belt (Power steering and
A/C)
2. Drive belt (Alternator)
3. Crankshaft pulley
11A-16
ENGINE <4G6> - Camshaft and Camshaft Oil Seal
CAMSHAFT AND CAMSHAFT OIL SEAL
REMOVAL AND INSTALLATION
11200190418
Pre-removal and Post-installation Operation
D
D
Air Cleaner Removal and Installation
Timing Belt Removal and Installation (Refer to
P.11A-26.)
D
Relay Box Removal and Installation
10 Nm
5
1
2
(f 3 ± 1 mm)
4
3.4 Nm
14 Nm
Sealant:
MITSUBISHI GENUINE PART
MD970389 or equivalent
3
22 Nm
8
5
28-34 Nm
Lipsection
9
11
10
5
6
12
Cam section and
journal section
88 Nm
12
8
7
Engine oil
Removal steps
1. Control harness connection
2. Spark plug cable
"BA 8. Camshaft oil seal
9. Spark plug guide oil seal
3. PCV hose connection
4. Rocker cover
AB" "AA 10. Rocker arm and shaft assembly
(intake side)
5. Camshaft position sensor support
6. Camshaft position sensing cylinder
AA" "CA 7. Camshaft sprocket
AB" "AA 11. Rocker arm and shaft assembly
(exhaust side)
12. Camshaft
11A-17
ENGINE <4G6> - Camshaft and Camshaft Oil Seal
REMOVAL SERVICE POINTS
AA" CAMSHAFT SPROCKET REMOVAL
MB990767
MD998719 or
MD998754
AB" ROCKER ARM AND SHAFT ASSEMBLY
REMOVAL
MD998443
Before removing the rocker arm and shaft assembly, install
the special tools as shown in the illustration so that the lash
adjusters will not fall out.
INSTALLATION SERVICE POINTS
"AA ROCKER ARM AND SHAFT ASSEMBLY
INSTALLATION
1. Temporarily tighten the rocker shaft with the bolt so that
all rocker arms on the inlet valve side do not push the
valves.
2. Fit the rocker shaft spring from the above and position
it so that it is right angles to the plug guide.
NOTE
Install the rocker shaft spring before installing the rocker
arm and rocker arm shaft on the exhaust side.
3. Remove the special tool for fixing the lash adjuster.
4. Confirm that the rocker shaft notch is in the direction
shown in the diagram.
11A-18
ENGINE <4G6> - Camshaft and Camshaft Oil Seal
"BA CAMSHAFT OIL SEAL INSTALLATION
1. Apply engine oil to the camshaft oil seal lip.
2. Use the special tool to press-fit the camshaft oil seal.
MD998713
"CA CAMSHAFT SPROCKET INSTALLATION
Use the special tool to stop the camshaft sprocket from turning
in the same way as was done during removal, and then tighten
the bolts to the specified torque.
11A-19
ENGINE <4G6> - Oil Pan
OIL PAN
11200280207
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D
Engine Oil Draining and Supplying (Refer to GROUP
D
Front Exhaust Pipe Removal and Installation (Refer
to GROUP 15.)
12 - On-vehicle Service.)
D
Oil Level Gauge Removal and Installation
5
f 4 ± 1 mm
Bolt
Groove
hole
5
3
Sealant:
MITSUBISHI GENUINE PART
MD970389 or equivalent
4
7 Nm
2
9 Nm
1
9 Nm
Removal steps
1. Drain plug
"AA 2. Drain plug gasket
3. Bell housing cover
4. Oil level sensor
5. Oil pan
AA"
REMOVAL SERVICE POINT
MD998727
MD998727
AA" OIL PAN REMOVAL
After removing the oil pan mounting bolts, remove the oil
pan with the special tool and a brass bar.
Caution
Perform this slowly to avoid deformation of the oil pan
flange.
INSTALLATION SERVICE POINT
"AA DRAIN PLUG GASKET INSTALLATION
Install the drain plug gasket in the direction so that it faces
as shown in the illustration.
Oil pan side
Drain plug
gasket
11A-20
ENGINE <4G6> - Crankshaft Oil Seal
11200310135
REMOVAL AND INSTALLATION
<M/T>
127-137 Nm
7
9
8
11
12
127-137 Nm
<A/T>
6
2
8
4
10
1
<A/T>
Crankshaft
<M/T>
5
3
Crankshaft
(Engine oil:
boltwasher
surface)
12
5
(Engineoil:
bolt wash-
er surface)
Lip section
Lip section
9
10
Sealant: 3M Stud locking 4170 or equivalent
Engine oil
Crankshaft front oil seal removal
steps
Crankshaft rear oil seal removal
steps
D Timing belt (Refer to P.11A-26.)
D Crank angle sensor
(Refer to GROUP 16.)
1. Crankshaft sprocket
2. Flange
D Oil pan (Refer to P.11A-19.)
D Transmission assembly
D Clutch cover and disc <M/T>
6. Crankshaft bushing
AA"
AB" "BA 7. Plate <M/T>
3. Crankshaft sprocket B
4. Key
AB" "BA 8. Adapter plate
AB" "BA 9. Flywheel <M/T>
AB" "BA 10. Drive plate <A/T>
AB" "BA 11. Adapter plate <M/T>
"AA 12. Crankshaft rear oil seal
"CA 5. Crankshaft front oil seal
11A-21
ENGINE <4G6> - Crankshaft Oil Seal
REMOVAL SERVICE POINTS
<M/T>
AA" TRANSMISSION ASSEMBLY REMOVAL
<M/T>:
Refer to GROUP 22.
Flywheel
Caution
Do not remove the flywheel mounting bolt shown by the
arrow. If this bolt Is removed, the flywheel will become
out of balance and damaged.
Bolt
<A/T>:
Refer to GROUP 23.
AB" PLATE <M/T>/ADAPTER PLATE/FLYWHEEL
<M/T>/DRIVE PLATE <A/T> REMOVAL
Use the special tool to secure the flywheel or drive plate,
and remove the bolts.
MD998781
INSTALLATION SERVICE POINTS
"AA CRANKSHAFT REAR OIL SEAL INSTALLATION
Crankshaft
rear oil seal
Crankshaft
1. Apply a small mount of engine oil to the entire
circumference of the oil seal lip.
2. Install the oil seal by tapping it as far as the chamfered
position of the oil seal case as shown in the illustration.
MD990938
MD998776
"BA DRIVE PLATE <A/T>/FLYWHEEL <M/T>/ADAPTER
PLATE/PLATE <M/T> INSTALLATION
1. Clean off all sealant, oil and other substances which are
adhering to the threaded bolts, crankshaft thread holes
and the flywheel or drive plate.
2. Apply oil to the bearing surface of the flywheel or drive
plate bolts.
3. Apply oil to the crankshaft thread holes.
4. Apply sealant to the threaded mounting holes.
Specified sealant: 3M Stud locking 4170 or equivalent
5. Use the special tool to hold the flywheel or drive plate
in the same manner as removal, and install the bolt.
"CA CRANKSHAFT FRONT OIL SEAL INSTALLATION
1. Apply a small amount of engine oil to the entire
circumference of the oil seal lip.
2. Press-fit the oil seal unit it is flush with the oil seal case.
11A-22
ENGINE <4G6> - Cylinder Head Gasket
CYLINDER HEAD GASKET
REMOVAL AND INSTALLATION
Pre-removal Operation
11200400542
Post-installation Operation
D
D
D
Fuel Discharge Prevention (Refer to GROUP 13A
D
D
D
Thermostat Case Assembly Installation (Refer to
- On-vehicle Service.)
GROUP 14 - Water Hose and Water Pipe.)
Engine Oil Supplying (Refer to GROUP 12 -
On-vehicle Service.)
Engine Oil Draining (Refer to GROUP 12
On-vehicle Service.)
-
Thermostat Case Assembly Removal (Refer to
GROUP 14 - Water Hose and Water Pipe.)
Accelerator Cable Adjustment (Refer to GROUP
17 - On-vehicle Service.)
Delivery pipe
O-ring
1
9
10
10
Engine oil
7
5
2
8
6
4
3
11
Removal steps
1. Accelerator cable connection
2. Vacuum hose connection
3. Brake booster vacuum hose
connection
4. Vacuum hose connection
5. Throttle position sensor connector
6. Idle speed control connector
7. Injector connector
8. Purge control solenoid valve
connector
9. EGR solenoid valve connector
"CA 10. High-pressure fuel hose connection
11. Fuel return hose connection
11A-23
ENGINE <4G6> - Cylinder Head Gasket
10 Nm
15
14
<Cold engine>
78 Nm ® 0 Nm ® 20 Nm ® + 90_ ® + 90_
16
3.4 Nm
27
12
(Engine oil)
26
17
19
28
13
29
22
49 Nm
18
20
21
24
24 Nm
44 Nm
25
34 Nm
23
31 Nm
12. Radiator upper hose connection
13. PCV hose
21. Heater hose connection
22. Thermostat case assembly
23. Water hose connection
24. Power steering oil pump and
bracket assembly
14. Ignition coil connector
15. Ignition coil assembly
16. Breather hose
AA"
17. Engine coolant temperature sensor
connector
25. Front exhaust pipe connection
26. Rocker cover
18. Engine coolant temperature gauge
unit connector
D Timing belt (Refer to P.11A-26.)
AB" "BA 27. Cylinder head bolt
28. Cylinder head assembly
19. Camshaft position sensor
20. Water hose connection
"AA 29. Cylinder head gasket
11A-24
ENGINE <4G6> - Cylinder Head Gasket
REMOVAL SERVICE POINTS
AA" POWER STEERING OIL PUMP AND BRACKET
ASSEMBLY REMOVAL
Remove the power steering oil pump and bracket assembly
from the engine with the hose attached.
NOTE
Place the removed power steering oil pump in a place where
it will not be a hindrance when removing and installing the
cylinder head assembly, and tie it with a cord.
AB" CYLINDER HEAD BOLT REMOVAL
Intake side
Front of engine
Loosen the bolts in 2 or 3 steps in order of the numbers
shown in the illustration, and remove the cylinder head
assembly.
3
1
5
7
10
9
8
6
2
4
Caution
Because the plug guides cannot be replaced by
themselves, be careful not to damage or deform the plug
guides when removing the cylinder head bolts.
Exhaust side
INSTALLATION SERVICE POINTS
"AA CYLINDER HEAD GASKET INSTALLATION
1. Wipe off all oil and grease from the gasket mounting
surface.
2. Install so that the shapes of the cylinder head holes match
the shapes of the respective cylinder head gasket holes.
"BA CYLINDER HEAD BOLT INSTALLATION
Head bolt
1. When installing the cylinder head bolts, the length below
the head of the bolts should be within the limit.
If it is outside the limit, replace the bolts.
Burred side
Headbolt
(Engine
oil)
washer
Limit (A): 99.4 mm
A
Cylinder
head
2. The head bolt washer should be installed with the burred
side caused by tapping out facing upwards.
3. Apply a small amount of engine oil to the thread section
and the washer of the cylinder head bolt.
11A-25
ENGINE <4G6> - Cylinder Head Gasket
4. Tighten the bolts by the following procedure.
Intake side
Front of engine
Step
1
Operation
Remarks
Tighten to 78 Nm.
Carry out in the order
shown in the illustration.
8
6
4
1
2
3
5
9
7
2
Fully loosen.
Carry out in the reverse
order of that shown in the
illustration.
10
3
4
Tighten to 20 Nm.
Carry out in the order
shown in the illustration.
Exhaust side
Tighten 90_ of a turn.
In the order shown in the
illustration. Mark the head
of the cylinder head bolt
and cylinder head by paint.
Step 4
Step 5
90_
90_
5
Tighten 90_ of a turn.
In the order shown in the
illustration. Check that the
painted mark of the head
bolt is lined up with that of
the cylinder head.
Painted mark
Painted mark
Caution
1. Always make a tightening angle just 90_. If it is less
than 90_, the head bolt will be loosened.
2. If it is more than 90_, remove the head bolt and repeat
the procedure from step 1.
"CA HIGH-PRESSURE FUEL HOSE INSTALLATION
1. Apply a small amount of new engine oil to the O-ring.
Caution
Do not let any engine oil get into the delivery pipe.
2. While turning the high-pressure fuel hose to the right
and left, install the delivery pipe, while being careful not
to damage the O-ring. After installing, check that the hose
turns smoothly.
3. If the hose does not turn smoothly, the O-ring is probably
being clamped. Disconnect the high-pressure fuel hose
and check the O-ring for damage. After this, re-insert
the delivery pipe and check that the hose turns smoothly.
11A-26
ENGINE <4G6> - Timing Belt
TIMING BELT
11200430473
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D
Crankshaft Pulley Removal and Installation (Refer
to P.11A-15.)
Engine Mount Bracket Removal and Installation
(Refer to GROUP 32 - Engine Mounting.)
D
3
1
48 Nm
5
10-12 Nm
4
24 Nm
9 Nm
2
Removal steps
1. Timing belt upper cover
2. Timing belt lower cover
"CA D Timing belt tension adjustment
AA" "BA 3. Timing belt
4. Tension pulley
"AA 5. Auto tensioner
11A-27
ENGINE <4G6> - Timing Belt
Timing mark (Top
of cylinder head)
REMOVAL SERVICE POINT
AA" TIMING BELT REMOVAL
Timing mark
Camshaft sprocket
1. Turn the crankshaft clockwise (right turn) to align each
timing mark and to set the No. 1 cylinder at compression
top dead centre.
Timing mark
Timing mark
Timing mark
Caution
Oil pump
sprocket
The crankshaft should always be turned only
clockwise.
Crankshaft
sprocket
2. Loosen the tension pulley centre bolt.
3. Move the tension pulley to the water pump side, and
then remove the timing belt.
Caution
If the timing belt is to be re-used, use chalk to mark
(on its flat side) an arrow indicating the clockwise
direction.
Centre bolt
INSTALLATION SERVICE POINTS
"AA AUTO TENSIONER INSTALLATION
98N - 196N
1. Apply 98 - 196 N force to the auto tensioner by pressing
it against a metal (cylinder block, etc.), and measure the
movement of the push rod.
B
Movement
Push rod
A
Standard value: Within 1 mm
A: Length when it is free (not pressed)
B: Length when it is pressed
A - B: Movement
Auto tensioner
2. If it is out of the standard value, replace the auto tensioner.
3. Use a press or vice to gently compress the auto tensioner
push rod until pin hole A of the push rod and pin hole
B of the tensioner cylinder are aligned.
A
B
Caution
If the compression speed is too fast, the rod may
become damaged, so be sure to carry out this
operation slowly.
11A-28
ENGINE <4G6> - Timing Belt
4. Once the holes are aligned, insert the set pin.
Set pin
NOTE
When replacing the auto tensioner with a new part, the
pin will be in the auto tensioner.
5. Install the auto tensioner to the engine.
"BA TIMING BELT INSTALLATION
Timing mark (Top
of cylinder head)
Timing mark
Camshaft sprocket
1. Align the timing marks on the camshaft sprocket,
crankshaft sprocket and oil pump sprocket.
Timing mark
Timing mark
Timing mark
Oil pump
sprocket
Crankshaft
sprocket
2. After aligning the timing mark on the oil pump sprocket,
remove the cylinder block plug and insert a Phillips
screwdriver with a diameter of 8 mm, and check to be
sure that the screwdriver goes in 60 mm or more. If
the screwdriver will only go in 20 - 25 mm before striking
the counterbalance shaft, turn the sprocket once, realign
the timing mark and check that the screwdriver goes in
60 mm or more. The screwdriver should not be taken
out until the timing belt is installed.
60 mm or
more
8 mm
Plug
Screwdriver
Counter-
balance
shaft
Cylinder
block
3. Install the belt to the crankshaft sprocket, oil pump
sprocket and camshaft sprocket in that order, so that
there is no slackness in the belt tension.
Caution
Fixing bolt
Pin hole
If the timing belt is re-used, install so that the arrow
marked on it at time of removal is pointing in the
clockwise direction.
Belt tension side
4. Set the tension pulley so that the pin holes are at the
top, press the tension pulley lightly against the timing
belt, and then provisionally tighten the fixing bolt.
5. Adjust the timing belt tension.
Belt tension side
11A-29
ENGINE <4G6> - Timing Belt
"CA TIMING BELT TENSION ADJUSTMENT
50 Nm
1. After turning the crankshaft 1/4 of a revolution in the
anticlockwise direction, turn it in the clockwise direction
until the timing marks are aligned.
2. Loosen the tension pulley fixing bolt, and then use the
special tool and a torque wrench to tighten the fixing
bolt to the specified torque while applying tension to the
timing belt.
Tension
direction
MD998767
Standard value: 3.5 Nm <Timing belt tension torque>
Caution
When tightening the fixing bolt, make sure that the
tension pulley does not turn with the bolt.
3. Turn the crankshaft two revolutions in the clockwise
direction so that the timing marks are aligned. After leaving
it for 15 minutes, measure the amount of protrusion of
the auto tensioner.
A
Standard value (A): 3.8 - 4.5 mm
4. If the amount of protrusion is outside the standard value,
repeat the operation in steps (1) to (3).
5. Check again to be sure that the timing marks of each
sprocket are aligned.
Auto tensioner
11A-30
ENGINE <4G6> - Timing Belt B
TIMING BELT B
11200460106
REMOVAL AND INSTALLATION
5
1
19 Nm
4
3
2
108 - 127 Nm
Removal steps
1. Timing belt (Refer to P.11A-26.)
4. Timing belt B tensioner
AB" "AA 5. Timing belt B
AA" "CA 2. Crankshaft sprocket
"BA 3. Flange
REMOVAL SERVICE POINTS
AA" CRANKSHAFT SPROCKET REMOVAL
Crankshaft
sprocket
MD998719 or MD998754
MB990767
AB" TIMING BELT B REMOVAL
Caution
If timing belt “B” is to be re-used, use chalk to mark
it with an arrow on its flat side indicating the turning
direction (to the right).
11A-31
ENGINE <4G6> - Timing Belt B
INSTALLATION SERVICE POINTS
"AA TIMING BELT B INSTALLATION, ADJUSTMENT
Counterbalance shaft sprocket
Belt tension side
1. Install timing belt “B” by the following procedure.
(1) Ensure that crankshaft sprocket “B” timing mark and
the counterbalance shaft sprocket timing mark are
aligned.
Timing marks
Timing
marks
(2) Fit timing belt “B” over crankshaft sprocket “B” and
the counterbalance shaft sprocket. Ensure that there
is no slack in the belt.
Crankshaft
sprocket B
2. Adjust the tension of timing belt “B” by the following
procedure.
(1) Temporarily fix the timing belt “B” tensioner such that
the centre of the tensioner pulley is to the left and
above the centre of the installation bolt, and
temporarily attach the tensioner pulley so that the
flange is toward the front of the engine.
Centre of
tensioner
pulley
Centre of installation
bolt
(2) Holding the timing belt “B” tensioner up with your
finger in the direction of the arrow, place pressure
on the timing belt so that the tension side of the
belt is taut. Now tighten the bolt to fix the tensioner.
Shaft
Caution
When tightening the bolt, ensure that the tensioner
pulley shaft does not rotate with the bolt. Allowing
it to rotate with the bolt can cause excessive
tension on the belt.
3. To ensure that the tension is correct, depress the belt
(point A) with a finger. If not, adjust.
A
Standard value: 5 - 7 mm
Centre of
tensioner
pulley
Centre of
installation
bolt
"BA FLANGE INSTALLATION
When installing, make sure the direction is correct. See figure.
Crankshaft
Crankshaft
sprocket “B”
Crankshaft
sprocket
Flange
11A-32
ENGINE <4G6> - Timing Belt B
"CA CRANKSHAFT SPROCKET INSTALLATION
Crankshaft
sprocket
MD998719 or MD998754
NOTE
Apply the minimum amount of engine oil to the bearing surface
and thread of the crankshaft bolt.
MB990767
11A-33
ENGINE <4G6> - Engine Assembly
ENGINE ASSEMBLY
11200090015
REMOVAL AND INSTALLATION
Pre-removal Operation
Post-installation Operation
D
Fuel Discharge Prevention (Refer to GROUP 13A
- On-vehicle Service.)
D
Thermostat Case Assembly Installation (Refer to
GROUP 14 - Water Hose and Water Pipe.)
Engine Coolant Supplying
D
D
Engine Coolant Draining
D
D
Thermostat Case Assembly Removal (Refer to
GROUP 14 - Water Hose and Water Pipe.)
Front Exhaust Pipe Removal (Refer to GROUP 15.)
Hood Removal (Refer to GROUP 42.)
Under Cover Removal
Accelerator Cable Adjustment (Refer to GROUP
17 - On-vehicle Service.)
D
D
D
D
D
D
Front Exhaust Pipe Installation (Refer to GROUP
15.)
D
D
D
Hood Installation (Refer to GROUP 42.)
Under Cover Installation
Radiator Assembly Removal (Refer to GROUP 14.)
Air Cleaner Removal
Radiator Assembly Installation (Refer to GROUP
14.)
D
Air Cleaner Installation
1
O-ring
Delivery pipe
10
9
10
7
5
Engine oil
8
2
12
6
4
3
11
Removal steps
1. Accelerator cable connection
2. Vacuum hose connection
3. Brake booster vacuum hose con-
nection
4. Vacuum hose connection
5. Throttle position sensor connector
6. Idle speed control connector
7. Injector connector
8. Purge control solenoid valve con-
nector
9. EGR solenoid valve connector
"DA 10. High-pressure fuel hose connection
11. Fuel return hose connection
12. PCV hose connection
11A-34
ENGINE <4G6> - Engine Assembly
15
26
23
20
22
49 Nm
21
16
19
17
18
14
13
57 Nm*
24
25
25
98 Nm
13. Drive belt (Alternator)
22. Camshaft position sensor connector
23. Detonation sensor connector
D Transmission assembly
14. Drive belt (Power steering and
A/C)
AC"
AA"
15. Power steering oil pump and
bracket assembly
AD" "CA 24. Engine mount bracket
"BA 25. Engine mount stopper
AE" "AA 26. Engine assembly
AB"
16. A/C compressor
17. Alternator connector
18. Oil pressure switch connector
19. Heater hose connection
Caution
Mounting locations marked by * should be provisionally
tightened, and then fully tightened after placing the vehicle
horizontally and loading the full weight of the engine on
the vehicle body.
20. Engine coolant temperature gauge
unit connector
21. Engine coolant temperature sensor
connector
11A-35
ENGINE <4G6> - Engine Assembly
REMOVAL SERVICE POINTS
AA" POWER STEERING OIL PUMP AND BRACKET
ASSEMBLY REMOVAL
Remove the power steering oil pump and bracket assembly
from the engine with the hose attached.
NOTE
Place the removed power steering oil pump in a place where
it will not be a hindrance when removing and installing the
engine assembly, and tie it with a cord.
AB" A/C COMPRESSOR REMOVAL
Disconnect the A/C compressor connector and remove the
compressor from the compressor bracket with the hose still
attached.
NOTE
Place the removed A/C compressor where it will not be a
hindrance when removing and installing the engine assembly,
and tie it with a cord.
AC" TRANSMISSION ASSEMBLY REMOVAL
<M/T>
<M/T>:
Refer to GROUP 22.
Caution
Flywheel
Do not remove the flywheel mounting bolt shown by the
arrow. If this bolt Is removed, the flywheel will become
out of balance and damaged.
Bolt
<A/T>:
Refer to GROUP 23.
AD" ENGINE MOUNT BRACKET REMOVAL
MZ203827
1. Support the engine with a garage jack.
2. Remove the special tool which was attached when the
transmission assembly was removed.
3. Hold the engine assembly with a chain block or similar
tool.
4. Place a garage jack against the engine oil pan with a
piece of wood in between, jack up the engine so that
the weight of the engine is no longer being applied to
the engine mount bracket, and then remove the engine
mount bracket.
MB991453
AE" ENGINE ASSEMBLY REMOVAL
After checking that all cables, hoses and harness connectors,
etc., are disconnected from the engine, lift the chain block
slowly to remove the engine assembly upward from the engine
compartment.
11A-36
ENGINE <4G6> - Engine Assembly
INSTALLATION SERVICE POINTS
"AA ENGINE ASSEMBLY INSTALLATION
Install the engine assembly, checking that the cables, hoses,
and harness connectors are not clamped.
"BA ENGINE MOUNT STOPPER INSTALLATION
Engine side
Clamp the engine mount stopper so that the arrow points
in the direction as shown in the diagram.
Dynamic damper
Arrow
Engine
mount
stopper
Engine mount bracket
"CA ENGINE MOUNT BRACKET INSTALLATION
1. Place a garage jack against the engine oil pan with a
piece of wood in between, and install the engine mount
bracket while adjusting the position of the engine.
2. Support the engine with the garage jack.
3. Remove the chain block and support the engine assembly
with the special tool.
"DA HIGH-PRESSURE FUEL HOSE INSTALLATION
1. Apply a small amount of new engine oil to the O-ring.
Caution
Do not let any engine oil get into the delivery pipe.
2. While turning the high-pressure fuel hose to the right
and left, install it to the delivery pipe, while being careful
not to damage the O-ring. After installing, check that the
hose turns smoothly.
3. If the hose does not turn smoothly, the O-ring is probably
being clamped. Disconnect the high-pressure fuel hose
and check the O-ring for damage. After this, re-insert
the delivery pipe and check that the hose turns smoothly.
11B-1
ENGINE <6A1>
CONTENTS
11109000610
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CRANKSHAFT PULLEY . . . . . . . . . . . . . . . . . . . 14
CAMSHAFT AND CAMSHAFT OIL SEAL . . . 15
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CRANKSHAFT OIL SEAL . . . . . . . . . . . . . . . . . . 21
CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . 24
TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 30
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 5
Drive Belt Tension Check and Adjustment . . . . . . 5
Ignition Timing Check . . . . . . . . . . . . . . . . . . . . . . . . . 6
Idle Speed Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Idle Mixture Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Compression Pressure Check . . . . . . . . . . . . . . . . . 8
Manifold Vacuum Check . . . . . . . . . . . . . . . . . . . . . . 9
Lash Adjuster Check . . . . . . . . . . . . . . . . . . . . . . . . 10
11B-2
ENGINE <6A1> - General Information/Service Specifications
GENERAL INFORMATION
11100010452
Items
6A13
Total displacement mL
Bore ´ Stroke mm
Compression ratio
Combustion chamber
Camshaft arrangement
Intake
2,498
81.0 ´ 80.8
9.5
Pentroof type
SOHC
12
Number of valve
Exhaust
12
Opening
Closing
Opening
Closing
BTDC 15_
ABDC 53_
BBDC 53_
ATDC 15_
Intake
Valve timing
Exhaust
Fuel system
Electronically controlled multipoint fuel injection
Rocker arm
Roller type
Equipped
Auto-lash adjuster
SERVICE SPECIFICATIONS
11100030496
Items
Standard value
294-490
Limit
When checked
-
-
-
-
-
-
-
-
-
-
-
-
-
-
When a used belt is installed
343-441
Tension N
Alternator drive
belt
When a new belt is installed
When checked
490-686
9.0-13.0
tension
Deflection
(Reference
value) mm
When a used belt is installed
When a new belt is installed
When checked
10.0-12.0
6.8-8.0
490-686
When a used belt is installed
When a new belt is installed
When checked
539-637
Tension N
Power steering
oil pump and
A/C compressor
drive belt
784-980
11.0-15.0
12.0-14.0
8.0-12.0
Deflection
(Reference
value) mm
tension
When a used belt is installed
When a new belt is installed
Basic ignition timing
Ignition timing
5_ BTDC±3_
Approx. 7° BTDC
11B-3
ENGINE <6A1> - Service Specifications/Sealants/Special Tools
Items
Standard value
Limit
Idle speed r/min
650 ± 100
-
CO contents %
0.2 or less
-
HC contents ppm
100 or less
-
Compression pressure (250-400 r/min) kPa
Compression pressure difference of all cylinder kPa
Intake manifold vacuum kPa
Cylinder head bolt shank length mm
Auto-tensioner push rod movement mm
Timing belt tension torque Nm
Auto-tensioner rod protrusion amount mm
1177
Min. 875
-
Max. 98
-
Min. 60
-
96.4
Within 1
3
-
-
-
3.8 - 4.5
SEALANTS
11100050379
Items
Specified sealants
MITSUBISHI GENUINE
Remarks
PART Semi-drying sealant
Oil pan
MD970389 or equivalent
Flywheel bolt or drive plate bolt
3M Stud Locking 4170 or equivalent
-
SPECIAL TOOLS
11100060464
Tool
Number
Name
Use
MB991502
MB990767
MD998719
MD998715
MUT-II sub
Engine idle speed check
Erasing diagnosis code
assembly
End yoke holder
D
D
Holding the camshaft sprocket
Holding the crankshaft pulley
Crankshaft pulley
holder pin
Crankshaft pulley
holder pin
11B-4
ENGINE <6A1> - Special Tools
Tool
Number
Name
Use
MD998443
Auto-lash adjuster
holder
Supporting of auto-lash adjuster
MD998713
MD998776
MB990938
MD998767
MD998717
MD998727
MD998781
Camshaft oil seal
installer
Press-in of the camshaft oil seal
Press-in of the crankshaft rear oil seal
Press-in of the crankshaft rear oil seal
Timing belt tension adjustment
Press-in of the crankshaft front oil seal
Removal of oil pan
Crankshaft rear oil
seal installer
Handle
Tension pulley
socket wrench
Crankshaft front
oil seal installer
Oil pan remover
Flywheel stopper
Engine lifter
Securing the flywheel <M/T> or drive plate
<A/T>
GENERAL
SERVICE
TOOL
Supporting the engine assembly during
removal and installation of the transmission
MZ203827
11B-5
ENGINE <6A1> - Special Tools/On-vehicle Service
Tool
Number
Name
Use
MB991453
Engine hanger
assembly
Supporting the engine assembly during
removal and installation of the transmission
Alternator pulley
ON-VEHICLE SERVICE
11100090425
Tension pulley
DRIVE BELT TENSION CHECK AND
ADJUSTMENT
ALTERNATOR DRIVE BELT TENSION CHECK
Use a belt tension gauge to check that the belt tension is
at the standard value at a point half-way between the two
pulleys as shown in the illustration. In addition, press this
section with a force of 98 N and check that the amount of
belt deflection is at the standard value.
Crankshaft pulley
Standard value:
Tension N
294-490
9.0-13.0
Deflection (Reference value) mm
ALTERNATOR DRIVE BELT TENSION ADJUSTMENT
1. Loosen the tension pulley fixing nut.
2. Use the adjusting bolt to adjust the belt tension or
deflection to the standard value.
Adjusting bolt
Fixing nut
Standard value:
Items
When a used
belt is installed
When a new
belt is installed
Tension N
343-441
490-686
6.8-8.0
Deflection (Reference 10.0-12.0
value) mm
3. Tighten the fixing nut.
Tightening torque: 49 Nm
Caution
Turn the crankshaft one full rotation or more clockwise
before this check.
11B-6
ENGINE <6A1> - On-vehicle Service
POWER STEERING OIL PUMP AND AIR CONDITIONER
COMPRESSOR DRIVE BELT TENSION CHECK AND
ADJUSTMENT
Power steering
oil pump pulley
11100130134
1. Use a belt tension gauge to check that the belt tension
is at the standard value at a point half-way between the
two pulleys (indicated by an arrow in the illustration).
In addition, press this section with a force of 98 N and
check that the amount of belt deflection is at the standard
value.
A
A/C compressor
pulley
Crankshaft
pulley
Standard value:
B
Items
When
checked
When a
used belt is
installed
When a new
belt is
installed
Tension N
490 - 686
539 - 637
784 - 980
8.0-12.0
Deflection
(Reference
value) mm
11.0 - 15.0
12.0 - 14.0
2. If the tension or deflection is outside the standard value,
adjust by the following procedure.
(1) Loosen tensioner pulley fixing nut A.
(2) Adjust the amount of belt deflection using adjusting
bolt B.
(3) Tighten fixing nut A.
Tightening torque: 49 Nm
(4) Check the belt deflection amount and tension, and
readjust if necessary.
Caution
Check after turning the crankshaft once or more
clockwise (right turn).
IGNITION TIMING CHECK
11100170280
1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Connect the MUT-II to the diagnosis connector.
3. Set up a timing light.
4. Start the engine and run at idle.
5. Check that engine idle speed is within the standard value.
Standard value: 650 ± 100 r/min
6. Select No.17 of the MUT-II Actuator test.
7. Check that basic ignition timing is within the standard
value.
Standard value: 5_ BTDC±3_
8. If the basic ignition timing is outside the standard value,
inspect the MPI system while referring to GROUP 13A
- Troubleshooting.
11B-7
ENGINE <6A1> - On-vehicle Service
9. Press the MUT-II clear key (Select a forced driving cancel
mode) to release the Actuator test.
Caution
If the test is not cancelled, a forced driving will
continue for 27 minutes. Driving under this condition
may damage the engine.
10. Check that ignition timing is at the standard value.
Standard value: approx. 7_BTDC
NOTE
1. Ignition timing is variable within about ± 7_, even
under normal operating.
2. And it is automatically further advanced by about
5_ from standard value at higher altitudes.
IDLE SPEED CHECK
11100350059
1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Turn the ignition switch to OFF and connect the MUT-II
to the diagnosis connector.
3. Check the basic ignition timing. Adjust if necessary.
Standard value: 5_ BTDC±3_
4. Run the engine at idle for 2 minutes.
5. Check the idle speed. Select item No. 22 and take a
reading of the idle speed.
Curb idle speed: 650 ± 100 r/min
NOTE
The idle speed is controlled automatically by the idle speed
control (ISC) system.
6. If the idle speed is outside the standard value, check
the MPI components by referring to GROUP 13A -
Troubleshooting.
IDLE MIXTURE CHECK
1110020401
1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Turn the ignition switch to OFF and connect the MUT-II
to the diagnosis connector.
3. Check that the basic ignition timing is within the standard
value.
Standard value: 5_ BTDC±3_
4. Run the engine at 2,500 r/min for 2 minutes.
11B-8
ENGINE <6A1> - On-vehicle Service
5. Set the CO, HC tester.
6. Check the CO contents and the HC contents at idle.
Standard value
CO contents: 0.2% or less
HC contents: 100 ppm or less
7. If there is a deviation from the standard value, check
the following items:
D
D
Diagnosis output
Closed-loop control (When the closed-loop control
is normal, the output signal of the oxygen sensor
changes between 0-400 mV and 600-1,000 mV
at idle.)
D
D
D
D
D
D
Fuel pressure
Injector
Ignition coil, spark plug cable, spark plug
Leak in the EGR system and in the EGR valve
Evaporative emission control system
Compression pressure
NOTE
Replace the three way catalyst when the CO and HC
contents are not within the standard value, even though
the result of the inspection is normal on all items.
COMPRESSION PRESSURE CHECK
11100260482
1. Before inspection, check that the engine oil, starter and
battery are normal. In addition, set the vehicle to the
pre-inspection condition.
2. Disconnect the spark plug cables.
3. Remove all of the spark plugs.
4. Disconnect the crank angle sensor connector.
Crank angle
sensor connector
NOTE
Doing this will prevent the engine-ECU from carrying out
ignition and fuel injection.
5. Cover the spark plug hole with a shop towel etc., and
after the engine has been cranked, check that no foreign
material is adhering to the shop towel.
Caution
1. Keep away from the spark plug hole when
cranking.
2. If compression is measured with water, oil, fuel,
etc., that has come from cracks inside the cylinder,
these materials will become heated and will gush
out from the spark plug hole, which is dangerous.
11B-9
ENGINE <6A1> - On-vehicle Service
6. Set compression gauge to one of the spark plug holes.
7. Crank the engine with the throttle valve fully open and
measure the compression pressure.
Compression gauge
Standard value (at engine speed of 250-400 r/min):
1,177 kPa
Limit (at engine speed of 250-400 r/min):
Min. 875 kPa
8. Measure the compression pressure for all the cylinders,
and check that the pressure differences of the cylinders
are below the limit.
Limit: Max. 98 kPa
9. If there is a cylinder with compression or a compression
difference that is outside the limit, pour a small amount
of engine oil through the spark plug hole, and repeat
the operations in steps 7 and 8.
(1) If the compression increases after oil is added, the
cause of the malfunction is a worn or damaged piston
ring and/or cylinder inner surface.
(2) If the compression does not rise after oil is added,
the cause is a burnt or defective valve seat, or pressure
is leaking from the gasket.
10. Connect the crank angle sensor connector.
11. Install the spark plugs and spark plug cables.
12. Use the MUT-II to erase the diagnosis codes.
NOTE
This will erase the diagnosis code resulting from the crank
angle sensor connector being disconnected.
MANIFOLD VACUUM CHECK
11100270393
Vacuum gauge
Fuel pressure regulator
1. Start the engine and allow it to warm up until the
temperature of the engine coolant reaches 80 to 95_C.
2. Connect a tachometer.
3. Attach a three-way union to the vacuum hose between
the fuel pressure regulator and the air intake plenum,
and connect a vacuum gauge.
4. Start the engine and check that idle speed is within the
standard value. Then read off the vacuum gauge.
Limit: Min. 60 kPa
11B-10
ENGINE <6A1> - On-vehicle Service
LASH ADJUSTER CHECK
11100290337
If an abnormal noise (knocking) that seems to be coming
from the lash adjuster is heard after starting the engine and
does not stop, carry out the following check.
NOTE
(1) The abnormal noise which is caused by a problem
with the lash adjusters is generated after the engine
is started, and will vary according to the engine speed.
However, this noise is not related to the actual engine
load.
Because of this, if the noise does not occur
immediately after the engine is started, if it does not
change in accordance with the engine speed, or if
it changes in accordance with the engine load, the
source of the noise is not the lash adjusters.
(2) If there is a problem with the lash adjusters, the noise
will almost never disappear, even if the engine has
been run at idle to let it warm up.
The only case where the noise might disappear is
if the oil in the engine has not been looked after
properly and oil sludge has caused the lash adjusters
to stick.
1. Start the engine.
2. Check that the noise occurs immediately after the engine
is started, and that the noise changes in accordance
with changes in the engine speed.
If the noise does not occur immediately after the engine
is started, or if it does not change in accordance with
the engine speed, the problem is not being caused y
the lash adjusters, so check for some other cause of
the problem. Moreover, if the noise does not change in
accordance with the engine speed, the cause of the
problem is probably not with the engine. (In these cases,
the lash adjusters are normal.)
3. While the engine is idling, check that the noise level does
not change when the engine load is varied (for example,
by shifting from N ® D).
If the noise level changes, the cause of the noise is
probably parts striking because of worn crankshaft
bearings or connecting rod bearings. (In such cases, the
lash adjusters are normal.)
4. After the engine has warmed up, run it at idle and check
if any noise can be heard.
If the noise has become smaller or has disappeared,
the cause of the noise was probably that oil sludge had
caused the lash adjusters to become stuck. If this
happens, carry out the following check. If the noise level
does not change, go to step 5.
(1) Let the engine cool down sufficiently.
(2) Turn the crankshaft two full revolutions.
11B-11
ENGINE <6A1> - On-vehicle Service
(3) Carry out lash adjuster simple check. (Refer to
P.11B-12.)
D
If any of the rocker arms can be pushed down
easily during the lash adjuster simple check,
replace the corresponding lash adjusters.
If the lash adjuster simple check has been carried
out but all lash adjusters are normal (if none of
the rocker arms could be pushed down easily),
check for some other cause of the problem.
D
NOTE
You can check whether the lash adjusters are normal
or not by carrying out a leak-down test. (Refer to
the Engine Workshop Manual.)
Caution
Make sure that the air has been fully bled before
installation of a new lash adjuster. (Refer to the
Engine Workshop Manual.)
5. Bleed the air from the lash adjusters. (Refer to P.11B-12.)
6. If the noise does not disappear even after the air has
been bled from the lash adjusters, carry out the following
check.
Carry out lash adjuster simple check. (Refer to P.11B-12.)
D
If one of the rocker arms can be pushed down easily
during the lash adjuster simple check, replace the
corresponding lash adjuster.
If two or more of the rocker arms can be pushed
down easily during the lash adjuster simple check,
the cause may be that the oil passage to the cylinder
head is blocked.
D
Check for blockages in the oil passage, and clear
the blockages if any are found. If there are no
blockages, replace the lash adjusters.
If the lash adjuster simple check has been carried
out but all lash adjusters are normal (if none of the
rocker arms could be pushed down easily), check
for some other cause of the problem.
D
NOTE
You can check whether the lash adjusters are normal
or not by carrying out a leak-down test. (Refer to the
Engine Workshop Manual.)
Caution
Make sure that the air has been fully bled before
installation of a new lash adjuster. (Refer to the Engine
Workshop Manual.)
7. Start the engine and check that the abnormal noise has
disappeared. If necessary, bleed the air from the lash
adjusters. (Refer to P.11B-12.)
11B-12
ENGINE <6A1> - On-vehicle Service
<LASH ADJUSTER SIMPLE CHECK>
1. Stop the engine.
2. Remove the rocker cover.
Timing belt side
3. Set the No.1 cylinder to the compression top dead centre
position.
4. Check the rocker arms indicated by white arrows in the
illustration by the procedures given below.
<Checking an intake-side rocker arm>
Check whether the rocker arm moves downwards when
the part of the rocker arm which touches the top of the
lash adjuster is pushed.
D
If the rocker arm moves down easily when it is pushed,
make a note of which is the corresponding lash
adjuster.
If the rocker arm feels extremely stiff when it is pushed
and does not move down, the lash adjuster is normal,
so check for some other cause of the problem.
D
<Checking an exhaust-side rocker arm>
NOTE
It will not be possible to depress the Y-shaped rocker
arm at the exhaust valve side if one lash adjuster is
defective but the other one is normal. In such cases,
carry out the following procedure using a thickness gauge.
(1) Check that a thickness gauge with a thickness of
0.1 - 0.2 mm can be inserted easily between the
valve and the lash adjuster.
(2) If the thickness gauge can be inserted easily, make
a note of which is the corresponding lash adjuster.
(3) If the thickness gauge cannot be inserted easily, the
lash adjuster is normal, so check for some other cause
of the problem.
5. Slowly turn the crankshaft 360_ in the clockwise direction.
6. Check the rocker arms indicated by black arrows in the
illustration in the same way as explained in step 4.
<LASH ADJUSTER AIR BLEEDING>
NOTE
(1) If the vehicle is parked on a slope for a long period
of time, the amount of oil inside the lash adjuster
will decrease, and air may get into the high pressure
chamber when starting the engine.
(2) After parking the vehicle for long periods, the oil drains
out of the oil passage, and it takes time for the oil
to be supplied to the lash adjuster, so air can get
into the high pressure chamber.
(3) If either of the above situations occur, the abnormal
noise can be eliminated by bleeding the air from inside
the lash adjusters.
11B-13
ENGINE <6A1> - On-vehicle Service
1. Check the engine oil and replenish or replace the oil
if necessary.
NOTE
(1) If there is a only small amount of oil, air will be drawn
in through the oil screen and will get into the oil
passage.
(2) If the amount of oil is greater than normal, then the
oil will being mixed by the crankshaft and a large
amount of air may get mixed into the oil.
(3) If the oil is degenerated, air and oil will not separate
easily in oil, and the amount of air mixed into the
oil will increase.
Good
(4) If the air which has been mixed in with the oil due
to any of the above reasons gets into the high pressure
chamber of the lash adjuster, the air inside the high
pressure chamber will be compressed when the valve
is open and the lash adjuster will over-compress,
resulting in abnormal noise when the valve closes.
This is the same effect as if the valve clearance is
adjusted to be too large by mistake. If the air inside
the lash adjusters is then released, the operation
of the lash adjusters will return to normal.
High
pressure
chamber
2. Run the engine at idle for 1 - 3 minutes to let it warm
up.
Drive pattern for air bleeding
Gradually open the
throttle valve.
Close the throttle
valve.
3. With no load on the engine, repeat the drive pattern shown
in the illustration at left and check if the abnormal noise
disappears. (The noise should normally disappear after
10 - 30 repetitions, but if there is no change in the noise
level after 30 repetitions or more, the problem is probably
not due to air inside the lash adjusters.)
Approx.
3,000 r/min.
Idle speed
15
seconds
15
seconds
4. After the noise has disappeared, repeat the drive pattern
shown in the illustration at left a further 5 times.
5. Run the engine at idle for 1 - 3 minutes and check that
the noise has disappeared.
Once
11B-14
ENGINE <6A1> - Crankshaft Pulley
CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
Pre-removal Operation
11200160310
Post-installation Operation
Drive Belt Tension Adjustment (Refer to P.11B-5.)
Under Cover Installation
D
Under Cover Removal
D
D
(Engine oil)
3
1
4
5
177-186 Nm
2
Removal steps
1. Drive belt (Power steering oil
pump, or A/C compressor and
power steering oil pump)
AA" "AA 3. Crankshaft bolt
4. Washer
5. Crankshaft pulley
2. Drive belt (Alternator)
REMOVAL SERVICE POINT
AA" CRANKSHAFT BOLT REMOVAL
MB990767
MD998719
INSTALLATION SERVICE POINT
"AA CRANKSHAFT BOLT INSTALLATION
When installing the crankshaft bolt, apply the minimum amount
of engine oil to the bearing surface and thread of the bolt.
11B-15
ENGINE <6A1> - Camshaft and Camshaft Oil Seal
CAMSHAFT AND CAMSHAFT OIL SEAL
11200220124
REMOVAL AND INSTALLATION
<Front bank>
Pre-removal and Post-installation Operation
D
Engine Coolant Draining and Refilling (Refer to
D
D
Timing Belt Removal and Installation (Refer to
GROUP 14 - On-vehicle Service.)
P.11B-26.)
D
Air Intake Hose Assembly Removal and Installation
Drive Belt Tension Adjustment (Refer to P.11B-5.)
Apply engine oil to all
sliding parts when
installing.
6
3
4
1
3.4 Nm
5
2
7
10
22 Nm
(Engine oil)
28 - 34 Nm
12
24 Nm
5
11
9
13
8
88 Nm
Removal steps
AA" "DA 1. Radiator upper hose connection
AA" "DA 2. Radiator lower hose connection
3. Blow-by hose connection
AB" "CA 8. Camshaft sprocket
"BA 9. Camshaft oil seal
10. Engine hanger
4. PCV hose connection
11. Thrust case
5. Vacuum hose connection
AC"
12. Rocker arm and shaft assembly
6. Spark plug cable
"AA 13. Camshaft
7. Rocker cover
11B-16
ENGINE <6A1> - Camshaft and Camshaft Oil Seal
<Rear bank>
Pre-removal and Post-installation Operation
D
Air Intake Plenum Removal and Installation
D
D
Distributor Removal and Installation
(Refer to GROUP 16.)
Drive Belt Tension Adjustment (Refer to P.11B-5.)
(Refer to GROUP 15.)
D
Timing Belt Removal and Installation
(Refer to P.11B-26.)
Apply engine oil to all
sliding parts when
installing.
6
1
7
3.4 Nm
2
28 - 34 Nm
12
9
8
13
88 Nm
Removal steps
1. Breather hose connection
2. Blow-by hose connection
6. Spark plug cable
AB" "CA 8. Camshaft sprocket
"BA 9. Camshaft oil seal
AC"
12. Rocker arm and shaft assembly
7. Rocker cover
"AA 13. Camshaft
REMOVAL SERVICE POINTS
AA" RADIATOR UPPER HOSE/RADIATOR LOWER
HOSE DISCONNECTION
After making mating marks on the radiator hose and the hose
clamp, disconnect the radiator hose.
11B-17
ENGINE <6A1> - Camshaft and Camshaft Oil Seal
AB" CAMSHAFT SPROCKET REMOVAL
MB990767
MD998715
AC" ROCKER ARM AND SHAFT ASSEMBLY
REMOVAL
1. Install the special tools as shown in the illustration so
that the lash adjusters will not fall out.
MD998443
2. Loosen the rocker arm and shaft assembly mounting bolt,
and then remove the rocker arm and shaft assembly with
the bolt still attached.
Caution
Never disassemble the rocker arm and shaft
assembly.
INSTALLATION SERVICE POINTS
<Front bank side>
<Rear bank side>
"AA CAMSHAFT INSTALLATION
Set the camshaft dowel pins so that they are in the position
shown in the illustration.
Approx.
Approx.
Caution
35_
35_
Do not mistake the camshafts for the front bank and the
rear bank. The camshaft for the rear bank has a slit with
a width of approximately 4 mm on its rear end.
Dowel
pin
Dowel
pin
"BA CAMSHAFT OIL SEAL INSTALLATION
<Rear bank side>
<Front bank side>
1. Apply engine oil to the camshaft oil seal lip.
2. Use the special tool to press-fit the camshaft oil seal.
MD991559
MD998713
MD998713
11B-18
ENGINE <6A1> - Camshaft and Camshaft Oil Seal
"CA CAMSHAFT SPROCKET INSTALLATION
Use the special tool to stop the camshaft sprocket from turning
in the same way as was done during removal, and then tighten
the bolts to the specified torque.
Tightening torque: 88 Nm
"DA RADIATOR LOWER HOSE/RADIATOR UPPER
HOSE CONNECTION
1. Insert each hose as far as the projection of the water
inlet fitting.
2. Align the mating marks on the radiator hose and hose
clamp, and then connect the radiator hose.
Caution
Be sure to install the clamp as far as the old clamp
position.
11B-19
ENGINE <6A1> - Oil Pan
OIL PAN
11200280214
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D
Engine Oil Draining and Supplying (Refer to GROUP
D
D
Under Cover Removal and Installation
Starter Motor Removal and Installation
12 - On-vehicle Service.)
D
D
Oil Level Gauge Removal and Installation
Front Exhaust Pipe Removal and Installation (Refer
to GROUP 15.)
5
Bolt
Groove
hole
3
5
Sealant:
MITSUBISHI GENUINE PART
MD970389 or equivalent
7 Nm
1
39 Nm
7 Nm
4
2
7 Nm
3
44 Nm
44 Nm
7 Nm
Removal steps
1. Drain plug
2. Drain plug gasket
3. Lower oil pan
4. Cover
5. Upper oil pan
"AA
AA"
AA"
11B-20
ENGINE <6A1> - Oil Pan
REMOVAL SERVICE POINT
MD998727
MD998727
AA" LOWER OIL PAN/UPPER OIL PAN REMOVAL
After removing the oil pan mounting bolts, remove the oil
pan with the special tool and a brass bar.
Caution
Perform this slowly to avoid deformation of the oil pan
flange.
INSTALLATION SERVICE POINT
"AA DRAIN PLUG GASKET INSTALLATION
Install the drain plug gasket in the direction so that it faces
as shown in the illustration.
Oil pan side
Drain plug
gasket
11B-21
ENGINE <6A1> - Crankshaft Oil Seal
CRANKSHAFT OIL SEAL
11200310142
REMOVAL AND INSTALLATION
<M/T>
Crankshaft
(Engine oil:
bolt wash-
er surface)
5
4
3
8
2
1
<A/T>
Crankshaft
(Engine oil:
bolt washer
surface)
10
9
8
7
6
Sealant: 3M Stud Locking
4170 or equivalent
<M/T>
5
11
Lip section
<A/T>
11
93 - 103 Nm
10
Lip section
7
Engine oil
Crankshaft front oil seal removal
steps
Crankshaft rear oil seal removal
steps
D Timing belt (Refer to P.11B-26.)
D Crank angle sensor
AA"
D Transmission assembly
D Clutch cover and disc <M/T>
(Refer to GROUP 16.)
AB" "BA 6. Plate <M/T>
AB" "BA 7. Adapter plate
AB" "BA 8. Flywheel <M/T>
1. Crankshaft sprocket
2. Crankshaft sensing blade
3. Crankshaft spacer
AB" "BA
9. Adapter plate <M/T>
4. Key
AB" "BA 10. Drive plate <A/T>
"CA 5. Crankshaft front oil seal
"AA 11. Crankshaft rear oil seal
11B-22
ENGINE <6A1> - Crankshaft Oil Seal
REMOVAL SERVICE POINTS
<M/T>
AA" TRANSMISSION ASSEMBLY REMOVAL
<M/T>:
Refer to GROUP 22.
Flywheel
Caution
Do not remove the flywheel mounting bolt shown by the
arrow. If this bolt Is removed, the flywheel will become
out of balance and damaged.
Bolt
<A/T>:
Refer to GROUP 23.
AB" PLATE <M/T>/ADAPTER PLATE/FLYWHEEL
<M/T>/DRIVE PLATE <A/T> REMOVAL
Use the special tool to secure the flywheel or drive plate,
and remove the bolts.
MD998781
INSTALLATION SERVICE POINTS
"AA CRANKSHAFT REAR OIL SEAL INSTALLATION
Crankshaft
rear oil seal
Crankshaft
1. Apply a small mount of engine oil to the entire
circumference of the oil seal lip.
2. Install the oil seal by tapping it as far as the chamfered
position of the oil seal case as shown in the illustration.
MD990938
MD998776
"BA DRIVE PLATE <A/T>/FLYWHEEL <M/T>/ADAPTER
PLATE/PLATE <M/T> INSTALLATION
1. Clean off all sealant, oil and other substances which are
adhering to the threaded bolts, crankshaft thread holes
and the flywheel or drive plate.
2. Apply oil to the bearing surface of the flywheel or drive
plate bolts.
3. Apply oil to the crankshaft thread holes.
4. Apply sealant to the threaded mounting holes.
Specified sealant: 3M Stud locking 4170 or equivalent
5. Use the special tool to hold the flywheel or drive plate
in the same manner as removal, and install the bolt.
11B-23
ENGINE <6A1> - Crankshaft Oil Seal
"CA CRANKSHAFT FRONT OIL SEAL INSTALLATION
1. Apply a small amount of engine oil to the entire
circumference of the oil seal lip.
2. Tap the oil seal unit it is flush with the oil seal case.
Crankshaft
MD998717
MD998717
Oil seal
11B-24
ENGINE <6A1> - Cylinder Head Gasket
CYLINDER HEAD GASKET
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
11200400559
D
Engine Coolant Draining and Refilling (Refer to
D
D
D
D
Fuel Discharge Prevention (Refer to GROUP 13A
GROUP 14 - On-vehicle Service.)
- On-vehicle Service.)
D
D
Air Intake Hose Assembly Removal and Installation
Radiator Assembly Removal and Installation (Refer
to GROUP 14 - Radiator.)
Front Exhaust Pipe Removal and Installation (Refer
to GROUP 15.)
Thermostat Case Assembly Removal and Installation
(Refer to GROUP 14 - Water Hoses and Pipes.)
Water Inlet Pipe Removal and Installation (Refer to
GROUP 14 - Water Hoses and Pipes.)
D
Air Intake Plenum and Intake Manifold Removal and
Installation (Refer to GROUP 15 - Air Intake Plenum.)
Engine Cover Removal and Installation
Drive Belt Tension Adjustment (Refer to P.11B-5.)
Timing Belt Removal and Installation (Refer to
P.11B-26.)
D
D
D
5
5
3
2
1
6
3.4 Nm
4
2
3.4 Nm
(Engine oil)
20 Nm ® + 120_ ® + 120_
10
9
20 Nm ® + 120_ ® + 120_
9
(Engine oil)
4
11
10 - 12 Nm
11
7
8
35 Nm
Removal steps
1. PCV hose connection
7. Idler pulley
2. Blow-by hose connection
3. Breather hose connection
4. Vacuum hose connection
5. Spark plug cable
8. Timing belt rear centre cover
AA" "BA 9. Cylinder head bolt
10. Cylinder head assembly
"AA 11. Cylinder head gasket
6. Rocker cover
11B-25
ENGINE <6A1> - Cylinder Head Gasket
REMOVAL SERVICE POINT
<Front bank side>
<Rear bank side>
Exhaust side
Exhaust side
AA" CYLINDER HEAD BOLT REMOVAL
Loosen the bolts in 2 or 3 steps in order of the numbers
shown in the illustration, and remove the cylinder head
assembly.
Front of
engine
Intake side
Identification mark
INSTALLATION SERVICE POINTS
"AA CYLINDER HEAD GASKET INSTALLATION
1. Wipe off all oil and grease from the gasket mounting
surface.
2. Install the gasket to the cylinder block with the identification
mark facing upwards.
"BA CYLINDER HEAD BOLT INSTALLATION
Head bolt
1. When installing the cylinder head bolts, the length below
the head of the bolts should be within the limit.
If it is outside the limit, replace the bolts.
Burred side
(Engine
oil)
Head bolt
washer
A
Limit (A): 96.4 mm
Cylinder
head
2. The head bolt washer should be installed with the burred
side caused by tapping out facing upwards.
3. Apply a small amount of engine oil to the thread section
and the washer of the cylinder head bolt.
Exhaust side
Intake side
4. Install the bolts by the following procedure.
(1) Tighten the bolts to 20 Nm in the sequence shown
in the illustration.
<Front bank side>
<Rear bank side>
(2) From the position in (1) above, turn each bolt a further
120_ in the same sequence.
Front of
engine
(3) Turn each bolt a further 120_ in the same sequence.
Caution
1) If the tightening angle is less than 120_, that
bolt will not be sufficiently tight.
2) If a bolt is tightened by more than the specified
angle, loosen the bolts and repeat the
procedure from step (1).
Exhaust side
11B-26
ENGINE <6A1> - Timing Belt
TIMING BELT
11200430480
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D
D
D
Under Cover Removal and Installation
Crankshaft Pulley Removal and Installation
Alternator Removal and Installation
(Refer to GROUP 16.)
D
Drive Belt Tension Adjustment (Refer to P.11B-5.)
3 Nm
1
9
44 Nm
12 Nm
10
3
7
8
10 - 12 Nm
6
4
10 - 12 Nm
24 Nm
5
35 Nm
24 Nm
22 Nm
11
2
14
13
10 - 12 Nm
12
Removal steps
1. Engine cover
9. Timing belt cover (front, upper
right)
2. Engine mount stay
3. Power steering hose clamp bolt
4. Crank angle sensor mounting bolt
5. Oil level gauge assembly
6. Engine hanger
7. Tension pulley bracket assembly
8. Tensioner bracket
10. Timing belt cover (front, upper left)
11. Timing belt cover (front, lower)
12. Flange
"CA
D
Timing belt tension adjustment
AA" "BA
13. Timing belt
"AA
14. Auto tensioner
11B-27
ENGINE <6A1> - Timing Belt
REMOVAL SERVICE POINT
AA" TIMING BELT REMOVAL
1. Align each of the timing marks.
Tensioner
pulley
Timing
marks
2. Loosen the centre bolt of the tension pulley and remove
the timing belt.
Caution
(1) If the timing belt is to be reused, use chalk to
mark it with an arrow on its flat side indicating
the turning direction.
Timing belt
(2) If the timing belt is to be re-used, be careful not
to damage the teeth of the timing belt against
the edges of the camshaft sprocket when
removing the timing belt.
INSTALLATION SERVICE POINTS
"AA AUTO TENSIONER INSTALLATION
98 N - 196 N
1. Apply 98 - 196 N force to the auto tensioner by pressing
it against a metal (cylinder block, etc.), and measure the
movement of the push rod.
B
A
Movement
Standard value: Within 1 mm
A: Length when it is free (not pressed)
B: Length when it is pressed
A - B: Movement
Push rod
Auto tensioner
2. If it is out of the standard value, replace the auto tensioner.
3. Use a press or vice to gently compress the auto tensioner
push rod until pin hole A of the push rod and pin hole
B of the tensioner cylinder are aligned.
A
B
Caution
If the compression speed is too fast, the rod may
become damaged, so be sure to carry out this
operation slowly.
4. Once the holes are aligned, insert the set pin.
Set pin
NOTE
When replacing the auto tensioner with a new part, the
pin will be in the auto tensioner.
5. Install the auto tensioner to the engine.
11B-28
ENGINE <6A1> - Timing Belt
"BA TIMING BELT INSTALLATION
Rocker cover
Rocker cover
1. Check that the timing marks of the both camshaft
sprockets and the crankshaft sprocket are aligned.
NOTE
Camshaft
sprocket
In this condition, the No.1 cylinder will be in the
compression top dead centre position.
Camshaft
sprocket
Timing
marks
Crank-
shaft
sprocket
Tension side A
Tension side B
2. Install the timing belt so that there is no slackness on
the tension sides of the belt (A, B, C and D).
Caution
Be careful not to damage the teeth of the timing belt
against the edges of the camshaft sprocket when
installing the timing belt.
Rear
Tension side C
Tension side D
bank
NOTE
side
camshaft
sprocket
If reusing the old timing belt, install it so that the arrow
made on the belt during removal is pointing in the direction
of rotation (clockwise).
3. Set the tensioner pulley so that the pin holes are at the
bottom, press the tensioner pulley lightly against the timing
belt, and then provisionally tighten the fixing bolt.
Pin holes
Fixing bolt
4. Apply force to the rear bank side camshaft sprocket in
the direction of the arrow to apply tension to the tension
sides (A, B, C and D), and check that all of the timing
marks are aligned at this time.
11B-29
ENGINE <6A1> - Timing Belt
"CA TIMING BELT TENSION ADJUSTMENT
MD998767
1. After turning the crankshaft 1/4 of a revolution in the
anticlockwise direction, turn it in the clockwise direction
until the timing marks are aligned.
Tension direction
2. Loosen the tensioner pulley fixing bolt, and then use
the special tool and a torque wrench to tighten the fixing
bolt to the specified torque while applying tension to the
timing belt.
Tensioner
pulley
Standard value: 3 Nm <Timing belt tension torque>
48 Nm
Caution
When tightening the fixing bolt, make sure that the
tensioner pulley does not turn with the bolt.
3. Turn the crankshaft two revolutions in the clockwise
direction, and after leaving it for 5 minutes or more, check
if the set pin of the auto tensioner can be removed and
inserted easily.
NOTE
If the set pin cannot be inserted easily, the auto tensioner
is good. Check if the amount of protrusion of the auto
tensioner rod is within the standard value.
A
Standard value (A): 3.8 - 4.5 mm
If the amount of protrusion is outside the standard value,
repeat the procedure in steps 1 to 3
4. Check to be sure that the timing marks of each sprocket
are aligned.
11B-30
ENGINE <6A1> - Engine Assembly
ENGINE ASSEMBLY
11200100558
REMOVAL AND INSTALLATION
Pre-removal Operation
Post-installation Operation
D
Fuel Discharge Prevention (Refer to GROUP 13A
- On-vehicle Service.)
D
Front Exhaust Pipe Installation (Refer to GROUP
15.)
D
D
D
D
D
D
D
D
Under Cover Removal
D
D
D
D
D
D
Radiator Installation (Refer to GROUP 14.)
Air Cleaner Installation
Hood Removal (Refer to GROUP 42.)
Air Cleaner Removal
Hood Installation (Refer to GROUP 42.)
Under Cover Installation
Radiator Removal (Refer to GROUP 14.)
Front Exhaust Pipe Removal (Refer to GROUP 15.)
Engine Cover Removal
Drive Belt Tension Adjustment (Refer to P.11B-5.)
Accelerator Cable Adjustment (Refer to GROUP
17 - On-vehicle Service.)
Battery Removal
Engine Coolant Draining
D
D
D
Engine Cover Installation
Battery Installation
Engine Coolant Supplying
1
6
7
5
18 Nm
4
8
18
3
9
17
2
10
22
23
24
19
20
11
16
21
9
12
O-ring
19
14
15
Engine oil
13
Removal steps
1. Accelerator cable connection
2. Capacitor connector
13. Power steering oil pressure switch
connector
3. Vacuum hose connection
4. TPS connector
14. Oil pressure harness connector
15. Thermo switch connector
16. Crank angle sensor connector
17. Brake booster vacuum hose con-
nection
5. Accelerator pedal position sensor
connector <TCL>
6. ISC connector
7. Control harness connector
8. Distributor connector
9. Vacuum hose connection
18. Fuel return hose connection
"DA 19. High-pressure fuel hose connection
20. Earth cable connection
10. Engine coolant temperature sensor
connector
21. Control harness connector
22. Front harness connector
23. Purge control solenoid valve
connector
11. Engine coolant temperature gauge
unit connector
12. Injector connector
24. EGR solenoid valve connector
11B-31
ENGINE <6A1> - Engine Assembly
30
12 Nm
28
27
27
12 Nm
27
39 Nm
25
34
26
29
35 Nm
31
67 Nm
32
33
57 Nm
33
98 - 118 Nm*
25. Drive belt (Alternator)
AD" "CA 32. Engine mount bracket
"BA 33. Engine mount stopper
AE" "AA 34. Engine assembly
26. Drive belt (Power steering and
A/C)
27. Clamp bolt (Power steering hose
and pipe)
Caution
AA"
AB"
28. Power steering oil pump assembly
29. A/C compressor
Mounting locations marked by * should be
provisionally tightened, and then fully tightened
after placing the vehicle horizontally and loading
the full weight of the engine on the vehicle
body.
30. Heater hose connection
D Transmission assembly
31. Engine mount stay
AC"
11B-32
ENGINE <6A1> - Engine Assembly
REMOVAL SERVICE POINTS
AA" POWER STEERING OIL PUMP AND BRACKET
ASSEMBLY REMOVAL
Remove the power steering oil pump and bracket assembly
from the engine with the hose attached.
NOTE
Place the removed power steering oil pump in a place where
it will not be a hindrance when removing and installing the
engine assembly, and tie it with a cord.
AB" A/C COMPRESSOR REMOVAL
Disconnect the A/C compressor connector and remove the
compressor from the compressor bracket with the hose still
attached.
NOTE
Place the removed A/C compressor where it will not be a
hindrance when removing and installing the engine assembly,
and tie it with a cord.
AC" TRANSMISSION ASSEMBLY REMOVAL
<M/T>
<M/T>:
Refer to GROUP 22.
Caution
Flywheel
Do not remove the flywheel mounting bolt shown by the
arrow. If this bolt Is removed, the flywheel will become
out of balance and damaged.
<A/T>:
Refer to GROUP 23.
Bolt
AD" ENGINE MOUNT BRACKET REMOVAL
MZ203827
1. Support the engine with a garage jack.
2. Remove the special tool which was attached when the
transmission assembly was removed.
3. Hold the engine assembly with a chain block or similar
tool.
4. Place a garage jack against the engine oil pan with a
piece of wood in between, jack up the engine so that
the weight of the engine is no longer being applied to
the engine mount bracket, and then remove the engine
mount bracket.
MB991453
AE" ENGINE ASSEMBLY REMOVAL
After checking that all cables, hoses and harness connectors,
etc., are disconnected from the engine, lift the chain block
slowly to remove the engine assembly upward from the engine
compartment.
11B-33
ENGINE <6A1> - Engine Assembly
INSTALLATION SERVICE POINTS
"AA ENGINE ASSEMBLY INSTALLATION
Install the engine assembly, checking that the cables, hoses,
and harness connectors are not clamped.
"BA ENGINE MOUNT STOPPER INSTALLATION
Engine side
Clamp the engine mount stopper so that the arrow points
in the direction as shown in the diagram.
Dynamic damper
Arrow
Engine
mount
stopper
Engine mount bracket
"CA ENGINE MOUNT BRACKET INSTALLATION
1. Place a garage jack against the engine oil pan with a
piece of wood in between, and install the engine mount
bracket while adjusting the position of the engine.
2. Support the engine with the garage jack.
3. Remove the chain block and support the engine assembly
with the special tool.
"DA HIGH-PRESSURE FUEL HOSE INSTALLATION
1. Apply a small amount of new engine oil to the O-ring.
Caution
Do not let any engine oil get into the delivery pipe.
2. While turning the high-pressure fuel hose to the right
and left, install it to the delivery pipe, while being careful
not to damage the O-ring. After installing, check that the
hose turns smoothly.
3. If the hose does not turn smoothly, the O-ring is probably
being clamped. Disconnect the high-pressure fuel hose
and check the O-ring for damage. After this, re-insert
the delivery pipe and check that the hose turns smoothly.
11C-1
ENGINE <4D6>
CONTENTS
11109000627
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CRANKSHAFT PULLEY . . . . . . . . . . . . . . . . . . . 15
CAMSHAFT AND CAMSHAFT OIL SEAL . . . 16
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CRANKSHAFT OIL SEAL . . . . . . . . . . . . . . . . . . 20
CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . 23
TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
TIMING BELT B . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 33
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6
Drive Belt Tension Check and Adjustment . . . . . . 6
Valve Clearance Check and Adjustment . . . . . . . . 8
Injection Timing Check and Adjustment . . . . . . . . 10
Idle Speed Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Compression Pressure Check . . . . . . . . . . . . . . . . 12
Timing Belt Tension Adjustment . . . . . . . . . . . . . . . 13
11C-2
ENGINE <4D6> - General Information/Service Specifications
GENERAL INFORMATION
11100010476
Items
4D68
Total displacement mL
Bore ´ Stroke mm
Compression ratio
Combustion chamber
Camshaft arrangement
1,998
82.7 ´ 93.0
22.4
Vortex chamber type
SOHC
Number of valve
Intake
4
Exhaust
Intake
4
Valve timing
Opening
Closing
Opening
Closing
BTDC 20_
ABDC 48_
Exhaust
BBDC 54_
ATDC 22_
Fuel system
Rocker arm
Distribution type injection pump
Roller type
Adjusting screw
Elephant foot type
SERVICE SPECIFICATIONS
11100030502
Items
Standard value
343 - 490
Limit
Alternator
drive belt
tension
Tension N
When checked
-
-
-
-
-
When a used belt is installed
When a new belt is installed
392 - 490
490 - 588
Deflection
(Reference
value) mm
Centre of belt
When checked
8.0 - 10.0
8.0 - 9.4
between alternator
When a used belt is
installed
pulley and water
pump pulley
When a new belt is
installed
7.0 - 8.0
-
Centre of belt
between crankshaft
pulley and alternator
pulley
When checked
7.9 - 9.9
7.9 - 9.2
-
-
When a used belt is
installed
When a new belt is
installed
6.8 - 7.9
-
11C-3
ENGINE <4D6> - Service Specifications/Sealants
Items
Standard value
Limit
Power
Tension N
When checked
294 - 490
343 - 441
490 - 686
12.6 - 16.3
13.4 - 15.3
10.0 - 12.6
392 - 588
441 - 539
637 - 833
9.2 - 12.0
9.8 - 11.2
7.0 - 8.6
0.35
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
steering oil
pump drive
belt tension
When a used belt is installed
When a new belt is installed
When checked
Deflection
mm
When a used belt is installed
When a new belt is installed
When checked
A/C com-
pressor
drive belt
tension
Tension N
When a used belt is installed
When a new belt is installed
When checked
Deflection
mm
When a used belt is installed
When a new belt is installed
Intake valve
Valve clearance (at hot)
mm
Exhaust valve
0.45
Injection timing (Dial gauge display value mm)
1 ± 0.03
(10_ATDC)
Idle speed r/min
800 ± 30
-
Compression pressure kPa
3,500
-
Min. 2,560
Max. 300
Compression pressure difference of all cylinder
(at engine speed of 280 r/min) kPa
Cylinder head bolt shank length mm
Timing belt deflection mm
-
99.4
4 - 5
5 - 7
-
-
Timing belt B deflection mm
SEALANTS
11100050362
Items
Specified sealants
Remarks
Oil pan
MITSUBISHI GENUINE PART
MD970389 or equivalent
Semi-drying sealant
Semi-circular packing and rocker 3M ATD Part No.8660 or equivalent
cover seal, and cylinder head seal
Flywheel bolt or adapter plate bolt
3M Stud Locking 4170 or equivalent
-
11C-4
ENGINE <4D6> - Special Tools
SPECIAL TOOLS
11100060471
Tool
Number
Name
Use
MB991502
MUT-II sub
assembly
Idle speed check
MB998720
MB990767
MD998719
MD998754
MD998364
MD998727
MD998776
MB990938
Prestroke
Adjustment of the injection timing
Holding the camshaft sprocket
measuring adapter
End yoke holder
Crankshaft pulley
holder pin
Crankshaft pulley
holder pin
Camshaft oil seal Installing the camshaft oil seal
installer
Oil pan remover
Removal of oil pan
Crankshaft rear oil Press-in of the crankshaft rear oil seal
seal installer
Handle
11C-5
ENGINE <4D6> - Special Tools
Tool
Number
Name
Use
MD998382
Crankshaft front oil Installing the crankshaft front oil seal
seal installer
MD998383
MD998781
Crankshaft front oil
seal guide
Flywheel stopper
Engine lifter
Securing the flywheel <M/T> or drive plate
<A/T>
GENERAL
SERVICE
TOOL
Supporting the engine assembly during
removal and installation of the transmission
MZ203827
MB991453
Engine hanger as-
sembly
11C-6
ENGINE <4D6> - On-vehicle Service
ON-VEHICLE SERVICE
11100090449
DRIVE BELT TENSION CHECK AND
ADJUSTMENT
ALTERNATOR DRIVE BELT TENSION CHECK
Use a belt tension gauge to check that the belt tension is
at the standard value at a point half-way between the two
pulleys as shown in the illustration. In addition, press this
section with a force of 98 N and check that the amount of
belt deflection is at the standard value.
A
Water pump
pulley
Alternator
pulley
Standard value:
Tension N
343 - 490
8.0 - 10.0
7.9 - 9.9
B
Deflection (Reference
value) mm
Portion A
Portion B
Crankshaft
pulley
ALTERNATOR DRIVE BELT TENSION ADJUSTMENT
1. Loosen the nut of the alternator pivot bolt.
2. Loosen the lock bolt.
Adjusting bolt
3. Use the adjusting bolt to adjust the belt tension and belt
deflection to the standard values.
Lock
bolt
Standard value:
Items
When a
used belt is
installed
When a new
belt is
installed
Pivot bolt
Tension N
392 - 490
8.0 - 9.4
490 - 588
7.0 - 8.0
Deflection
(Reference
value) mm
Portion A
Portion B
7.9 - 9.2
6.8 - 7.9
4. Tighten the lock bolt.
Tightening torque: 23 Nm
5. Tighten the nut of the alternator pivot bolt.
Tightening torque: 44 Nm
6. Tighten the adjusting bolt.
Tightening torque: 10 Nm
Caution
Check after turning the crankshaft once or more
clockwise (right turn).
11C-7
ENGINE <4D6> - On-vehicle Service
POWER STEERING OIL PUMP DRIVE BELT TENSION
CHECK AND ADJUSTMENT
Power steering
oil pump pulley
11100110183
1. Check the tension by pulling or pushing at the centre
of the belt between pulleys with a force of 98 N as shown
in the figure. Measure drive belt deflection amount.
Standard value:
Items
When
checked
When a
used belt is
installed
When a new
belt is
installed
Water pump
pulley
Tension N
294 - 490
343 - 441
490 - 686
Deflection
(Reference
value) mm
12.6 - 16.3
13.4 - 15.3
10.0 - 12.6
2. If the tension is outside the standard value, adjust by
the following procedure.
A
Oil pump
(1) Loosen oil pump fixing bolts A and B. Check that
the slide bushing at the place where bolt B was
installed is touching the A/C bracket and that there
is no looseness in the oil pump mounting.
B
(2) While holding a bar or similar tool against the oil
pump body, apply a suitable amount of force to the
belt with your hand to adjust the tension of the belt.
(3) Tighten oil pump fixing bolts A and B in that order.
Tightening torque: 39 Nm
(4) Check the belt tension, and readjust if necessary.
Caution
Check after turning the crankshaft once or more
clockwise (right turn).
11C-8
ENGINE <4D6> - On-vehicle Service
COMPRESSOR DRIVE BELT TENSION CHECK AND
ADJUSTMENT
A/C compressor
pulley
A
11100100203
1. Check the tension by pulling or pushing at the centre
of the belt between pulleys with a force of 98 N as shown
in the figure. Measure drive belt deflection amount.
Standard value:
Items
When
checked
When a
used belt is
installed
When a new
belt is
installed
Crankshaft
pulley
B
Tension N
392 - 588
9.2 - 12.0
441 - 539
9.8 - 11.2
637 - 833
7.0 - 8.6
Deflection
(Reference
value) mm
2. If the tension is outside the standard value, adjust by
the following procedure.
(1) Loosen tensioner pulley fixing nut A.
(2) Adjust the belt tension using adjusting bolt B.
(3) Tighten fixing nut A.
Tightening torque: 25 Nm
(4) Check the belt frequency, tension or deflection, and
readjust if necessary.
Caution
Check after turning the crankshaft once or more
clockwise (right turn).
VALVE CLEARANCE CHECK AND
ADJUSTMENT
11100150130
1. Start the engine and allow it to warm up until the engine
coolant temperature reaches 80 to 95 _C.
2. Remove the timing belt upper cover.
3. Remove the rocker cover.
4. Remove the glow plug plate and all of the glow plugs.
5. Turn the crankshaft clockwise to align the crankshaft pulley
timing mark and to set the No.1 cylinder or No.4 cylinder
to the compression top dead centre position.
Camshaft
sprocket
Timing
marks
Timing marks
NOTE
Aligning the camshaft sprocket timing mark will set the
No.1 cylinder to the compression top dead centre position.
If the crankshaft is turned one more full revolution from
this position, the No.4 cylinder will be set to the
compression top dead centre position.
Crankshaft
pulley
11C-9
ENGINE <4D6> - On-vehicle Service
6. Measure the valve clearance in the places indicated by
arrows in the illustration.
Arrow A: When the No.1 cylinder is at compression top
dead centre
Arrow B: When the No.4 cylinder is at compression top
dead centre
Timing
belt
side
Standard value:
When warm
0.35 mm
When cold (NOTE)
0.25 mm
A
B
Intake
Exhaust
0.45 mm
0.35 mm
NOTE
(1) When inserting the thickness gauge, press the pad
from the opposite side using a flat-tipped screwdriver
or similar tool to make a gap for the thickness gauge
to be inserted.
Adjusting
screw
Pad
Thickness gauge
Flat-tipped
screwdriver
(2) If you attempt to insert the thickness gauge without
using a flat-tipped screwdriver to make a gap, the
pad will become tilted as shown in the illustration,
and it will not be possible to insert the thickness gauge.
Thickness
gauge
Pad
7. If the clearance is outside the standard value, loosen
the lock nut and turn the adjusting screw while using
a thickness gauge to adjust the clearance.
Thickness
gauge
11C-10
ENGINE <4D6> - On-vehicle Service
8. Tighten the lock nut while holding the adjusting screw
with a screwdriver so that it doesn’t turn.
9. Turn the crankshaft one full revolution to align the
crankshaft pulley timing mark.
10. Adjust the remaining valves by the same procedure as
in steps 7. - 9. above.
11. Install the glow plugs and the glow plug plate.
12. Install the rocker cover.
13. Install the timing belt upper cover.
INJECTION TIMING CHECK AND
ADJUSTMENT
11100180054
1. Remove all of the glow plugs.
2. Remove the timing belt upper cover.
3. Align the timing marks of the camshaft sprocket and set
the No.1 cylinder to the top dead centre position.
Camshaft
sprocket
Timing
marks
Timing marks
Crankshaft
pulley
4. Remove the timing check plug at the rear of the injection
pump.
Timing check plug
5. Install the special tool to the timing check plug hole at
the rear of the injection pump.
6. Connect the dial gauge to the special tool.
Dial gauge
MD998720
11C-11
ENGINE <4D6> - On-vehicle Service
7. Turn the crankshaft clockwise to move the No.1 cylinder
approximately 30_ before compression top dead centre.
8. Set the needle of the dial gauge to 0.
9. Check that the needle doesn’t move even if the crankshaft
is turned slightly (2 - 3_) in both clockwise and
anti-clockwise direction.
Set to 0
Approx.
30
NOTE
_
If the needle moves, the notch is not positioned properly,
so once again move the No.1 cylinder approximately 30_
before compression top dead centre.
Timing mark
10. Turn the crankshaft clockwise to align the No.1 cylinder
to 10_ ATDC.
11. Check that the value indicated on the dial gauge is at
the standard value.
Set to 10_
ATDC
1 ± 0.03 mm
Standard value: 1 ± 0.03 mm
12. If the value is outside the standard value, adjust the
injection timing by the following procedure.
(1) Loosen the injection pipe union nuts (4 places) on
the injection pump. (Do not remove the union nuts.)
Caution
When loosening the nuts, hold the delivery valve
holders with a spanner so that they don’t turn
at the same time.
Bolts
(2) Loosen the upper mounting nuts and the lower
mounting bolts of the injection pump. (Do not remove
the nut and bolt.)
Nuts
(3) Tilt the injection pump to the left or right and adjust
the needle on the dial gauge so that the display value
is uniform.
When the value is
1 ± 0.03 mm or more
(4) Provisionally tighten the mounting nuts and bolts of
the injection pump.
(5) Repeat steps 7 - 12 to check if the adjustment has
been made correctly.
(6) Tighten the mounting nuts and bolts securely.
(7) Tighten the injection pump union nuts securely.
When the value
is 1 ± 0.03 mm
or less
Caution
When tightening the nuts, hold the delivery valve
holders with a spanner so that they don’t turn
at the same time.
13. Remove the special tool.
14. Install a new gasket to the timing check plug.
15. Tighten the timing check plug securely.
11C-12
ENGINE <4D6> - On-vehicle Service
IDLE SPEED CHECK
11100350073
NOTE
Check that the injection timing is normal, and then perform
this check.
1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Connect the MUT-II to the diagnosis connector.
3. Start the engine and check that the idle speed is at the
standard value.
Standard value: 800 ± 30 r/min
4. If the idle speed is not at the standard value, refer to
GROUP 13E - Troubleshooting.
COMPRESSION PRESSURE CHECK
11100260505
1. Before inspection, check that the engine oil, starter motor
and battery are normal. In addition, set the vehicle to
the pre-inspection condition.
2. Remove the glow plug plate and all of the glow plugs.
3. Disconnect the fuel cut solenoid valve connector.
NOTE
Doing this will prevent carrying out fuel injection.
4. Cover the glow plug hole with a shop towel etc., and
after the engine has been cranked, check that no foreign
material is adhering to the shop towel.
Fuel cut solenoid
valve connector
Caution
1. Keep away from the glow plug hole when cranking.
2. If compression is measured with water, oil, fuel,
etc,. that has come from cracks inside the cylinder,
these materials will become heated and will gush
out from glow plug hole, which is dangerous.
11C-13
ENGINE <4D6> - On-vehicle Service
5. Set compression gauge to one of the glow plug holes.
6. Crank the engine and measure the compression pressure.
Compression gauge
Adapter
Standard value:
3,500 kPa (at engine speed of 280 r/min)
Limit: Min. 2,560 kPa (at engine speed of 280 r/min)
7. Measure the compression pressure for all cylinders, and
check that the pressure differences of the cylinders are
below the limit.
Limit: Max. 300 kPa
8. If there is a cylinder with compression or a compression
difference that is outside the limit, pour a small amount
of engine oil through the glow plug hole, and repeat the
operations in steps 6 and 7.
(1) If the compression increases after oil is added, the
cause of the malfunction is a worn or damaged piston
ring and/or cylinder inner surface.
(2) If the compression does not rise after oil is added,
the cause is a burnt or defective valve seat, or pressure
is leaking from the gasket.
9. Connect the fuel cut solenoid valve connector.
10. Install the glow plugs and the glow plug plate.
TIMING BELT TENSION ADJUSTMENT
11100280174
There are two timing belts: one is the timing belt for the
valve timing, and the other is the timing belt B for driving
the right-side counterbalance shaft.
1. Remove the timing belt upper cover.
2. Remove the glow plug plate and all of the glow plugs.
3. Turn the crankshaft clockwise and check that there is
nothing wrong with the timing belt. Replace the belt if
necessary.
4. Turn the crankshaft clockwise to set the No.1 cylinder
to the compression top dead centre position.
Timing marks
11C-14
ENGINE <4D6> - On-vehicle Service
5. Turn the crankshaft anti-clockwise by 1/2 the width of
a camshaft sprocket tooth in order to take up the slack
in the idler pulley belt (the side where the belt is slack).
1/2 the
width of
a tooth
Timing mark
Timing mark
6. Loosen the timing belt tensioner mounting bolt by 1/4
- 1/3 a turn, and use the force of the tensioner spring
to apply tension to the belt.
7. Turn the crankshaft anti-clockwise again by the width
of three camshaft sprocket teeth.
Width
of 2-1/2
teeth
Timing mark
1/2 the
width of
a tooth
Timing mark
8. Securely tighten the timing belt tensioner mounting bolt.
9. Turn the crankshaft clockwise to align the timing mark.
10. Press the belt at the point between the camshaft sprocket
and the injection pump sprocket with your index finger
to check the belt deflection.
Deflection
Camshaft
sprocket
Standard value: 4.0 - 5.0 mm
11. Install the timing belt upper cover.
12. Install the glow plugs and the glow plug plate.
Injection
pump
sprocket
11C-15
ENGINE <4D6> - Crankshaft Pulley
CRANKSHAFT PULLEY
11200160327
REMOVAL AND INSTALLATION
Pre-removal Operation
Post-installation Operation
D
Under Cover Removal
D
D
Drive Belt Tension Adjustment (Refer to P.11C-6.)
Under Cover Installation
4
3
1
25 Nm
2
Removal steps
1. Drive belt (Power steering)
2. Drive belt (A/C)
3. Drive belt (Alternator)
4. Crankshaft pulley
11C-16
ENGINE <4D6> - Camshaft and Camshaft Oil Seal
CAMSHAFT AND CAMSHAFT OIL SEAL
REMOVAL AND INSTALLATION
11200190425
Pre-removal and Post-installation Operation
D
Timing Belt Removal and Installation
(Refer to P.11C-26.)
Air Pipe A Removal and Installation
Vacuum Pump Removal and Installation
(Refer to GROUP 14.)
D
D
6 Nm
1
Lip section
5
3
2
19 - 21 Nm
27 - 31 Nm
27 - 31 Nm
8
7
19 - 21 Nm
6
7
Cam section
and journal
section
7
19 - 21 Nm
5
4
8
Engine oil
88 Nm
Removal steps
1. Breather hose connection
2. Control harness
"CA 5. Camshaft oil seal
"BA 6. Rocker arm and shaft assembly
"AA 7. Camshaft bearing cap
8. Camshaft
3. Rocker cover
AA" "DA 4. Camshaft sprocket
11C-17
ENGINE <4D6> - Camshaft and Camshaft Oil Seal
REMOVAL SERVICE POINT
AA" CAMSHAFT SPROCKET REMOVAL
MB990767
MD998719 or
MD998754
INSTALLATION SERVICE POINTS
"AA CAMSHAFT BEARING CAP INSTALLATION
Camshaft sproket
side
The cap numbers are embossed on the top surface of the
bearing caps, so install in the order of the numbers. However,
no numbers are embossed on bearing caps 1 and 5.
Cap No.
"BA ROCKER ARM AND SHAFT ASSEMBLY
INSTALLATION
1. Install the rocker arm and shaft assembly to the bearing
caps.
2. Set the rocker arm springs into the bearing cap indents.
3. Check the valve clearance and adjust if necessary.
(Refer to P.11C-8.)
Indent
Bearing cap
"CA CAMSHAFT OIL SEAL INSTALLATION
Oil seal
1. Apply a small amount of engine oil to the entire
circumference of the oil seal lip and camshaft.
2. Use the special tool to tap in the oil seal.
Camshaft
NOTE
The oil seal should be tapped in until the distance from
the end of the camshaft to the end of the oil seal is
as shown in the illustration.
MD998364
5.5 mm
"DA CAMSHAFT SPROCKET INSTALLATION
Use the special tool to stop the camshaft sprocket from turning
in the same way as was done during removal, and then tighten
the bolts to the specified torque.
Tightening torque: 88 Nm
11C-18
ENGINE <4D6> - Oil Pan
OIL PAN
11200280221
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D
Under Cover Removal and Installation
Front Exhaust Pipe Removal and Installation
(Refer to GROUP 15.)
D
D
Engine Oil Level Gauge Removal and Insertion
D
Engine Oil Draining and Refilling
(Refer to GROUP 12 - On-vehicle Service.)
BOLT IDENTIFICATION
7
B
7
A
B
f4 ± 1 mm
Groove
Bolt
hole
B
B
B
´
A: 6 8 mm
´
B: 6 10 mm
Sealant:
MITSUBISHI GENUINE PART
MD970389 or equivalent
29 - 34 Nm
9 Nm
5
6
4
3
2
Washer assembled bolt
9 Nm
7
Flange bolt
10 Nm
39 Nm
1
7 Nm
Removal steps
1. Drain plug
5. Bell housing cover
6. Oil level sensor
7. Oil pan
"AA
2. Drain plug gasket
3. Oil filter
AA"
4. Engine oil cooler pipe connection
11C-19
ENGINE <4D6> - Oil Pan
REMOVAL SERVICE POINT
MD998727
MD998727
AA" OIL PAN REMOVAL
After removing the oil pan mounting bolts, remove the oil
pan with the special tool and a brass bar.
Caution
Perform this slowly to avoid deformation of the oil pan
flange.
INSTALLATION SERVICE POINT
"AA DRAIN PLUG GASKET INSTALLATION
Install the drain plug gasket in the direction so that it faces
as shown in the illustration.
Oil pan side
Drain plug
gasket
11C-20
ENGINE <4D6> - Crankshaft Oil Seal
11200310159
REMOVAL AND INSTALLATION
<M/T>
9
127 - 137 Nm
10
6
11
7
<A/T>
5
4
3
127 - 137 Nm
2
1
6
8
10
(Engine oil)
108 - 127 Nm
Crankshaft
Crankshaft
(Engine oil:
bolt washer
surface)
5
11
(Engine oil:
bolt washer
surface)
Lip section
Lip section
9
Engine oil
Sealant: 3M Stud Locking 4170 or equivalent
Crankshaft front oil seal removal
steps
Crankshaft rear oil seal removal
steps
D
D
AA"
D
D
Timing belt (Refer to P.11C-26.)
Crank angle sensor
Transmission assembly
Clutch cover and disc <M/T>
AB" "BA
AB" "BA
AB" "BA
AB" "BA
(Refer to GROUP 16.)
6. Adapter plate
7. Flywheel <M/T>
8. Drive plate <A/T>
9. Adapter plate <M/T>
10. Crankshaft bushing
11. Crankshaft rear oil seal
1. Crankshaft sprocket
2. Flange
3. Crankshaft sprocket B
4. Key
"CA
"AA
5. Crankshaft front oil seal
11C-21
ENGINE <4D6> - Crankshaft Oil Seal
REMOVAL SERVICE POINT
<M/T>
AA" TRANSMISSION ASSEMBLY REMOVAL
<M/T>:
Refer to GROUP 22.
Flywheel
Caution
Do not remove the flywheel mounting bolt shown by the
arrow. If this bolt Is removed, the flywheel will become
out of balance and damaged.
Bolt
<A/T>:
Refer to GROUP 23.
AB" ADAPTER PLATE/FLYWHEEL <M/T>/DRIVE
PLATE <A/T> REMOVAL
Use the special tool to secure the flywheel or drive plate,
and remove the bolts.
MD998781
INSTALLATION SERVICE POINTS
"AA CRANKSHAFT REAR OIL SEAL INSTALLATION
Crankshaft
rear oil seal
Crankshaft
1. Apply a small mount of engine oil to the entire
circumference of the oil seal lip.
2. Install the oil seal by tapping it as far as the chamfered
position of the oil seal case as shown in the illustration.
MD990938
MD998776
"BA DRIVE PLATE <A/T>/FLYWHEEL <M/T>/ADAPTER
PLATE INSTALLATION
1. Clean off all sealant, oil and other substances which are
adhering to the threaded bolts, crankshaft thread holes
and the flywheel or drive plate.
2. Apply oil to the bearing surface of the flywheel or drive
plate bolts.
3. Apply oil to the crankshaft thread holes.
4. Apply sealant to the threaded mounting holes.
Specified sealant: 3M Stud locking 4170 or equivalent
5. Use the special tool to hold the flywheel or drive plate
in the same manner as removal, and install the bolt.
11C-22
ENGINE <4D6> - Crankshaft Oil Seal
"CA CRANKSHAFT FRONT OIL SEAL INSTALLATION
Oil seal
Front
lower
case
Crankshaft
1. Apply a small amount of engine oil to the entire
circumference of the oil seal lip.
2. Tap the oil seal unit it is flush with the oil seal case.
MD998382
MD998383
11C-23
ENGINE <4D6> - Cylinder Head Gasket
CYLINDER HEAD GASKET
11200400566
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D
D
D
Engine Coolant Draining and Refilling
(Refer to GROUP 14 - On-vehicle Service.)
Air Pipe A Removal and Installation
(Refer to GROUP 15 - Intercooler.)
Vacuum Pump Removal and Installation
(Refer to GROUP 14.)
D
D
Timing Belt Removal and Installation
(Refer to P.11C-26.)
Thermostat Case Assembly Removal and Installation
(Refer to GROUP 14 - Water Hoses and Pipes.)
6 Nm
1
3
2
16
27 - 31 Nm
O-ring
27 - 31 Nm
19 - 21 Nm
27 - 31 Nm
13 Nm
Engine oil
12 - 15 Nm
7
5
16
9
18
6
10
88 Nm ® 0 Nm ® 39 Nm ® + 90_ ® + 90_
11
12
19
8
15
14
4
9 Nm
20
29 Nm
44 Nm
17
13
10 - 12 Nm
24 Nm
Removal steps
1. Breather hose connection
2. Control harness
12. Brake booster vacuum hose
connection
3. Rocker cover
13. Timing belt rear centre cover
14. Front exhaust pipe connection
15. Oil return pipe connection
16. Oil level gauge guide assembly
17. Alternator brace
AA" "DA
4. Fuel injection pipe
5. Camshaft bearing cap
6. Glow plug plate
"CA
7. Rocker arm and shaft assembly
8. Fuel return hose connection
AB" "BA
18. Cylinder head bolt
19. Cylinder head assembly
20. Cylinder head gasket
9. Water temperature sensor connector
10. Vacuum air temperature sensor
connector
"AA
11. Engine coolant temperature gauge
unit connector
11C-24
AA" FUEL INJECTION PIPE REMOVAL
When loosening nuts at injection pipe ends, hold the nut
at other side (delivery holder nut for pump side, nozzle holder
nut at nozzle side) with wrench.
Caution
After disconnecting the injection pipe, plug the opening
so that no foreign particles get inside the pump or into
the injection nozzle.
AB" CYLINDER HEAD BOLT REMOVAL
Intake side
Front of engine
Loosen the bolts in 2 or 3 steps in order of the numbers
shown in the illustration, and remove the cylinder head
assembly.
3
1
5
7
10
9
8
6
2
4
Exhaust side
INSTALLATION SERVICE POINTS
"AA CYLINDER HEAD GASKET INSTALLATION
1. Wipe off all oil and grease from the gasket mounting
surface.
2. Check the number of identification holes on the cylinder
head gasket that was removed, and select a cylinder
head gasket with the same number of identification holes.
3. Place the cylinder head gasket on top of the cylinder
block so that the identification mark is facing upwards
as shown in the illustration.
Identification mark
Identification holes
"BA CYLINDER HEAD BOLT INSTALLATION
Head bolt
1. When installing the cylinder head bolts, the length below
the head of the bolts should be within the limit.
If it is outside the limit, replace the bolts.
Burred side
Headbolt
(Engine
oil)
washer
Limit (A): 119.7 mm
A
Cylinder
head
2. The head bolt washer should be installed with the burred
side caused by tapping out facing upwards.
3. Apply a small amount of engine oil to the thread section
and the washer of the cylinder head bolt.
11C-25
ENGINE <4D6> - Cylinder Head Gasket
4. Tighten the bolts by the following procedure.
Intake side
Front of engine
Step
1
Operation
Remarks
Tighten to 88 Nm.
Carry out in the order
shown in the illustration.
8
6
4
1
2
3
5
9
7
2
Fully loosen.
Carry out in the reverse
order of that shown in the
illustration.
10
3
4
Tighten to 39 Nm.
Carry out in the order
shown in the illustration.
Exhaust side
Tighten 90_ of a turn.
In the order shown in the
illustration. Mark the head
of the cylinder head bolt
and cylinder head by paint.
Step 4
Step 5
90_
90_
5
Tighten 90_ of a turn.
In the order shown in the
illustration. Check that the
painted mark of the head
bolt is lined up with that of
the cylinder head.
Painted mark
Painted mark
Caution
(1) Always make a tightening angle just 90_. If it is less
than 90_, the head bolt will be loosened.
(2) If it is more than 90_, remove the head bolt and repeat
the procedure from step 1.
"CA ROCKER ARM AND SHAFT ASSEMBLY
INSTALLATION
1. Install the rocker arm and shaft assembly to the bearing
caps.
2. Set the rocker arm springs into the bearing cap indents.
3. Check the valve clearance and adjust if necessary.
(Refer to P.11C-8.)
Indent
Bearing cap
"DA FUEL INJECTION PIPE INSTALLATION
Fuel injection pipe
Nut
When tightening the nuts at both ends of the fuel injection
pipe, hold the delivery holder (for pump side) and the fuel
injection nozzle assembly (for nozzle side) with a wrench,
and tighten the nuts to the specified torque.
Nozzle holder
11C-26
ENGINE <4D6> - Timing Belt
TIMING BELT
11200430497
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D
Crankshaft Pulley Removal and Installation
(Refer to P.11C-15.)
Engine Mount Bracket Removal and Installation
(Refer to GROUP 32.)
D
3
10 - 12 Nm
7
9 Nm
10 - 12 Nm
1
19 Nm
25 Nm
10 - 12 Nm
4
6
10 - 12 Nm
2
5
9 Nm
10 - 12 Nm
23 Nm
Removal steps
1. Water pump pulley
5. Timing belt front lower cover
6. Injection pump bracket stay
2. A/C tension pulley assembly
3. Timing belt front upper cover
4. Timing belt front centre cover
AA"
"BA
AB" "AA
D
Timing belt tension adjustment
7. Timing belt
11C-27
ENGINE <4D6> - Timing Belt
REMOVAL SERVICE POINTS
AA" TIMING BELT FRONT UPPER COVER
INSTALLATION
Attach protective tape to the engine mount bracket, and then
remove the timing belt front upper cover.
Protective tape
AB" TIMING BELT REMOVAL
Timing marks
1. Align the timing marks.
2. Loosen the installation bolt of the timing belt tensioner.
3. Move the timing belt tensioner downward and loosely
tighten the bolt so that the tensioner doesn’t return; then
remove the timing belt.
Caution
If the timing belt is to be re-used, use chalk to mark
(on its flat side) an arrow indicating the clockwise
direction.
Thread diameter ´
length ´ pitch (mm)
Move to the bottom
of the slot.
11C-28
ENGINE <4D6> - Timing Belt
INSTALLATION SERVICE POINTS
Timing marks
"AA TIMING BELT INSTALLATION
Injection
pump
sprocket
1. Ensure that the timing marks of the camshaft sprocket,
the injection pump sprocket, the crankshaft sprocket, and
the oil pump sprocket are all aligned.
Camshaft sprocket
Timing mark
Timing mark
Oil pump
sprocket
Crankshaft
sprocket
2. Move the timing belt tensioner downward and loosely
tighten the bolt so that the tensioner doesn’t return.
3. Install the timing belt onto the crankshaft sprocket, the
timing belt idler, the camshaft sprocket, the injection pump
sprocket, and the oil pump sprocket in that order.
Move to the
bottom of the slot.
Caution
If the timing belt is reused, install so that the arrow
marked on it at the time of removal is pointing in
the clockwise direction.
"BA TIMING BELT TENSION ADJUSTMENT
1. Turn the crankshaft anti-clockwise by a distance
equivalent to 1/2 tooth of the camshaft sprocket in order
to correct looseness at the timing belt idler side.
1/2 tooth
Timing mark
Timing mark
2. Loosen (by 90_ to 120_ turn) the tensioner installation
bolt previously secured provisionally, taking advantage
of the force of the tensioner spring to provide tension
to the belt.
3. In addition, turn the crankshaft anti-clockwise by a distance
equivalent to 2-1/2 teeth.
Timing mark
4. Tighten the timing belt tensioner to the specified torque.
2-1/2 teeth
Tightening torque: 48 Nm
5. Turn the crankshaft clockwise and align the timing mark.
Timing mark
11C-29
ENGINE <4D6> - Timing Belt
6. Using the index finger, press between the camshaft
sprocket and the injection pump sprocket, and check
whether or not the amount of flexion is within the standard
value range.
Injection
pump
sprocket
Camshaft
sprocket
Standard value: 4 - 5 mm
11C-30
ENGINE <4D6> - Timing Belt B
TIMING BELT B
11200460113
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D
Crankshaft Pulley Removal and Installation
D
Timing Belt Removal and Installation
(Refer to P.11C-26.)
(Refer to P.11C-15.)
D
Engine Mount Bracket Removal and Installation
(Refer to GROUP 32.)
1
48 Nm
4
19 Nm
5
108 - 127 Nm
3
2
(Engine oil)
Removal steps
1. Idler pulley
4. Timing belt tensioner
AB" "AA 5. Timing belt B
AA" "BA 2. Crankshaft sprocket
3. Flange
REMOVAL SERVICE POINTS
AA" CRANKSHAFT SPROCKET REMOVAL
Crankshaft
sprocket
MB991385
MB991367
11C-31
ENGINE <4D6> - Timing Belt B
AB" TIMING BELT B REMOVAL
Caution
If the timing belt “B” is to be re-used, use chalk to
mark (on its flat side) an arrow indicating the clockwise
direction.
INSTALLATION SERVICE POINTS
"AA TIMING BELT B INSTALLATION
Counter balance shaft sprocket
Belt tension side
Crankshaft
sprocket B
1. Install the timing belt “B” by the following procedure.
(1) Ensure that crankshaft sprocket “B” timing mark and
the counterbalance shaft sprocket timing mark are
aligned.
(2) Fit timing belt “B” over crankshaft sprocket “B” and
the counterbalance shaft sprocket. Ensure that there
is no slack in the belt.
Timing mark
2. Adjust timing belt “B” by the following procedure,
(1) Temporarily fix the timing belt “B” tensioner such that
the centre of the tensioner pulley is to the left and
above the centre of the installation bolt, and
temporarily attach the tensioner pulley so that the
flange is toward the front of the engine.
Centre of
tensioner
pulley
Centre of
installation bolt
(2) Holding the timing belt “B” tensioner up with your
finger in the direction of the arrow, place pressure
on the timing belt so that the tension side of the
belt is taut. Now tighten the bolt to fix the tensioner.
Caution
When tightening the bolt, ensure that the tensioner
pulley shaft does not rotate with the bolt. Allowing
it to rotate with the bolt can cause excessive
tension of the belt.
Shaft
(3) Check to ensure that when centre of span on tension
side is depressed with index finger in direction of
arrow, tension of belt is up to specification.
Centre
of pulley
Standard value: 5 - 7 mm
Centre of installation bolt
11C-32
ENGINE <4D6> - Timing Belt B
"BA CRANKSHAFT SPROCKET INSTALLATION
1. Apply as little engine oil as possible to the seat and the
thread of the crankshaft bolt.
2. Secure the crankshaft sprocket in the same way as during
removal, and then tighten the bolt to the specified torque.
Tightening torque: 108 - 127 Nm
11C-33
ENGINE <4D6> - Engine Assembly
ENGINE ASSEMBLY
11200100565
REMOVAL AND INSTALLATION
Pre-removal Operation
Post-installation Operation
D
D
D
D
D
D
Hood Removal (Refer to GROUP 42.)
Air Cleaner Assembly Removal
D
Front Exhaust Pipe Installation
(Refer to GROUP 15.)
Engine Coolant Draining
D
D
Under Cover Installation
Radiator Assembly Installation
(Refer to GROUP 14.)
Radiator Assembly Removal (Refer to GROUP 14.)
Under Cover Removal
Front Exhaust Pipe Removal (Refer to GROUP 15.)
D
D
Engine Coolant Supplying
Accelerator Cable Adjustment
(Refer to GROUP 17 - On-vehicle Service.)
Air Cleaner Assembly Installation
D
D
Hood Installation (Refer to GROUP 42.)
1
2
7
3
8
13
12
10
11
4
17
5
9
14
6
15
16
Removal steps
1. Vacuum hose connection
2. Vacuum air temperature sensor con-
nector
10. Pump revolution sensor connector
11. Timing control valve connector
12. Solenoid-type spill valve connector
13. Fuel cut solenoid valve connector
14. Injection rate correction resistor con-
nector
3. Brake booster vacuum hose connec-
tion
4. Alternator connector
5. Oil pressure switch connector
6. Engine oil level sensor connector
7. Glow plug connector
8. Engine coolant temperature sensor
connector
15. Injection timing correction resistor con-
nector
16. Crank angle sensor connector
17. Fuel temperature sensor connector
9. Engine coolant temperature gauge
unit connector
11C-34
ENGINE <4D6> - Engine Assembly
18
25
29
22 Nm
19
21
20
39 Nm
29 - 34 Nm
22
23
24
12 Nm
26
57 Nm*
27
28
28
98 Nm
18. Heater hose connection
19. Drive belt (Power steering)
20. Drive belt (A/C)
AC"
D Transmission assembly
AD" "CA 27. Engine mount bracket
"BA 28. Engine mount stopper
AE" "AA 29. Engine assembly
21. Oil pump brace
AA"
22. Power steering oil pump and bracket
assembly
23. A/C compressor
24. Engine oil cooler pipe connection
25. Fuel hose connection
26. Clamp bolt (Power steering hose and
pipe)
Caution
AB"
Mounting locations marked by * should be
provisionally tightened, and then fully tightened
after placing the vehicle horizontally and loading
the full weight of the engine on the vehicle
body.
11C-35
ENGINE <4D6> - Engine Assembly
REMOVAL SERVICE POINTS
AA" POWER STEERING OIL PUMP AND BRACKET
ASSEMBLY REMOVAL
Remove the power steering oil pump and bracket assembly
from the engine with the hose attached.
NOTE
Place the removed power steering oil pump in a place where
it will not be a hindrance when removing and installing the
engine assembly, and tie it with a cord.
AB" A/C COMPRESSOR REMOVAL
Disconnect the A/C compressor connector and remove the
compressor from the compressor bracket with the hose still
attached.
NOTE
Place the removed A/C compressor where it will not be a
hindrance when removing and installing the engine assembly,
and tie it with a cord.
AC" TRANSMISSION ASSEMBLY REMOVAL
<M/T>
<M/T>:
Refer to GROUP 22.
Caution
Do not remove the flywheel mounting bolt shown by the
arrow. If this bolt Is removed, the flywheel will become
out of balance and damaged.
Flywheel
Bolt
<A/T>:
Refer to GROUP 23.
AD" ENGINE MOUNT BRACKET REMOVAL
MZ203827
1. Support the engine with a garage jack.
2. Remove the special tool which was attached when the
transmission assembly was removed.
3. Hold the engine assembly with a chain block or similar
tool.
4. Place a garage jack against the engine oil pan with a
piece of wood in between, jack up the engine so that
the weight of the engine is no longer being applied to
the engine mount bracket, and then remove the engine
mount bracket.
MB991453
AE" ENGINE ASSEMBLY REMOVAL
After checking that all cables, hoses and harness connectors,
etc., are disconnected from the engine, lift the chain block
slowly to remove the engine assembly upward from the engine
compartment.
11C-36
ENGINE <4D6> - Engine Assembly
INSTALLATION SERVICE POINTS
"AA ENGINE ASSEMBLY INSTALLATION
Install the engine assembly, checking that the cables, hoses,
and harness connectors are not clamped.
"BA ENGINE MOUNT STOPPER INSTALLATION
Engine side
Clamp the engine mount stopper so that the arrow points
in the direction as shown in the diagram.
Dynamic damper
Arrow
Engine
mount
stopper
Engine mount bracket
"CA ENGINE MOUNT BRACKET INSTALLATION
1. Place a garage jack against the engine oil pan with a
piece of wood in between, and install the engine mount
bracket while adjusting the position of the engine.
2. Support the engine with the garage jack.
3. Remove the chain block and support the engine assembly
with the special tool.
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