Preface This manual is specially made for those who engage in automobile maintenance and repairing. Following general rules of system division of vehicles (engine, clutch, etc.), this manual adopts the division methods by major assembly. In order to describe all parts belonging to an assembly, assemblies are further divided into several parts.
00-1 General Contents page Guide on Using the Manual .......................................... 00-3 Engine .......................................................................... 00-5 Tightening Torque......................................................... 00-6 Sealant (FIPG) .............................................................
GENERAL GUIDE ON USING THE MANNUAL Guide on Using the Manual Grouping name Section Name Engine Front cover, Oil pump 00-2 Page 11-33 Maintaining Steps (1) Profile plots are provided for you to understand the installation of each component. (2) Use reference number of the parts to show operation steps, mark the parts that can not be used repeatedly (marked as N ) and the tightening torque.
OVERVIEW ENGINE 00-5 ENGINE MODEL VEHICLE MODEL HOVER CUV ENGINE MODEL DISPLACEMENT TYPE 4G64-D-Y7 2,351 ML FOUR CYLINDERS, IN-LINE, SOHC
OVERVIEW TIGHTENING TORQUE 00-6 Tightening Torque The common tightening torque is shown in the list. Tightening torque of special parts is shown at the beginning of each group. Tightening torque of bolts and nuts Diameter of bolt Torque (Kg. M) Bolt (with spring washer) Thread pitch Valve bolt M6 1.0 Head mark 4 Head mark 7 0.9 Head mark 10 1.3 Head mark 4 Head mark 7 1.1 M8 1.25 1.1 1.8 3.0 1.4 2.4 M10 M12 1.25 1.25 2.0 3.6 3.4 6.2 6.0 10.8 3.0 5.5 5.0 9.
OVERVIEW SEALANT(FIGP) 00-7 Sealant (FIPG) Sealant is used on many parts of the engine and gearbox. The using of sealant is for the purpose of adequately sealing, therefore, much attention should be paid to the dosage, position and the surface of sealant. Insufficient dosage of sealant may result in leakage, while superfluous dosage of sealant may result in the overflow of sealant and jam the passage of water or oil, or narrow the passage.
11-1 Engine Contents page General ........................................................................ 11-2 Specifications ............................................................... 11-3 Maintaining Standard ................................................... 11-3 Tightening Torque ........................................................ 11-5 Sealant ......................................................................... 11-7 Special Tools.........................................................
ENGINE SPECIFICATION 11-2 General Specifications Items 4G64 S4 MPI Type Number of Cylinders In-line OHV, SOHC 4 Combustion Chamber Single Pitch Roof Total Displacement ml Cylinder Bore mm 2,351 86.5 Stroke mm Compression Ratio 100.0 9.
ENGINE SPECIFICATION 11-3 Specifications Maintenance Standard Unit mm Items Standard Value Generator Convex value of tensioner arm 12 Toothed-belt Press-in value of tensioner arm (98~196N) 1 Height of cam Air intake 37.39 36.89 Air exhaust 36.83 36.33 Camshaft Cylinder Head Limit Value Shaft diameter 45.0 Planeness of Bottom Surface 0.03 0.2 Surface lapping limit*Total lapping of cylinder block and head * 0.2 Total height 119.9 120.
ENGINE SPECIFICATION 11-4 Items Standard Value Limit Value Axial clearance 0.05 0.18 0.25 Main shaft diameter 57 Connecting rod shaft diameter 45 Radial clearance of main shaft 0.02 0.04 0.1 Planeness of top surface 0.05 0.1 Top surface lapping limit*Total lapping * 0.2 Total Height 290 0.1 Minor diameter of cylinder hole 86.50 86.53 Cylinder Block Cylindricity of cylinder hole 0.
ENGINE SPECIFICATION 11-5 Tightening Torque Fastening Location Generator and Ignition System Fastening bolt of AC generator Stay bolt Pivot nut Crankshaft pulley bolt Spark plug Ignition coil bolt Timing toothed-belt Lower front cover of timing toothed-belt Tensioning pulley bolt Tensioning wheel arm bolt Automatic tensioning wheel bolt Central pulley bolt Tensioning wheel bracket Rear cover of timing toothed-belt Timing belt indicator Toothed-belt wheel of oil pump Crankshaft toothed-belt wheel bolt Te
11-6 ENGINE SPECIFICATION Fastening Location Front cover and oil pump Torque (Kg.M) Oil drain plug 4.5 Oil pan Oil suction filter bolt and nut 0.7 1.9 Oil pressure switch Pressure relief plug 1.0 4.5 Oil suction filter bracket bolt 1.9 Front cover bolt Plug 2.4 2.4 Flange bolt Oil pump cover bolt 3.7 1.6 Oil pump cover screw 1.0 Piston and connecting rod assembly Connecting rod nut 2.0 90 100 Crankshaft, cylinder block, flywheel and drive board Flywheel bolt 13.
ENGINE SPECIAL TOOLS 11-7 SPECIAL TOOLS Tools REF. NO.
ENGINE SPECIAL TOOLS 11-8 Tools REF. NO.
ENGINE SPECIAL TOOLS Tools REF. NO.
ENGINE AC GENERATOR AND IGNITIONSYSTEM 11-10 AC GENERATOR AND IGNITION SYSTEM DISASSEMBLY AND MOUNTING 7 5 8 23N.m 25N.m 10 4 11N.m 9 23N.m 11N.m 3 11 9 6 25N.m Disassembly Procedure E 1. driving belt 7. spark plug cable 2. water pump pulley 8. spark plug 3. 4. power steering pump pulley AC generator support 9. ignition coll 10. front top cover of timing toothed-belt 5. 6. AC generator crankshaft pulley 11.
ENGINE TIMING TOOTHED-BELT 11-11 NOTES FOR DISASSEMBLY A DISASSEMBLY OF CRANKSHAFT BOLT MD998781 (1) Fasten flywheel with special tools (2) Disassemble crankshaft bolt. 9EN0268 NOTES FOR MOUNTING MOUNTING OF CRANKSHAFT BOLT D MD998781 (1) Fasten flywheel with special tools. (2) Mount crankshaft bolt. 9EN0268 E 100N water pumo pulley ADJUST DRIVING BELT TENSION TO STANDARD VALUE WITH DEFLECTION INDICATOR OR TENSION GAUGE crankshaf STANDARD VALUE NEW BELT ...................................
ENGINE TIMING TOOTHED-BELT 11-12 TIMING TOOTHED-BELT DISASSEMBLY AND MOUNTING 11N.m 16 17 2 15 20 45N 8 19N 88N 19 18 12 14 48N. 13 3 162N.m 11 48N. 24N. 10 1 9 54N. 7 8.8N.m 6 11N.m 4 35N. 22N. 6EN1769 Disassembly Procudure 1. A H front lower cover of timing thoothed-belt 2. timing toothed-belt 3. temsioning pulley C D E 13. flange 4. tensioning arm G B F 5. automatic tensioner 6. centrual pulley E F 7. tensioning pulley bracket 8.
ENGINE TIMING TOOTHED-BELT WHEEL 11-13 NOTES FOR DISASSEMBLY DISASSEMBLY OF TIMING TOOTHED-BELT A (1) Record the rotation direction of toothed-belt for correct remounting. Notes: Adhering of water or grease to the toothed-belt will sharply shorten its service life. So, after disassembly, try your best to avoid the toothed-belt, toothed-belt wheel and tensioner from being contaminated and adhered by water or grease. No need to 6EN0662 clean these parts. Replace it if it is seriously contaminated.
11-14 ENGINE TIMING TOOTHED-BELT WHEEL In case water or grease is found on these parts, check the front cover oil-seal, camshaft oil-seal and water pump to see if there exist leakage. MD998785 6EN0636 F DISASSEMBLY OF BALANCING SHAFT TOOTHEDBELT WHEEL (1) Fasten balancing shaft toothed-belt wheel with the tools as shown in the figure. (2) Disassemble the balancing shaft toothed-belt wheel.
ENGINE TIMING TOOTHED-BELT WHEEL cracks canvas peel-off (2) There are cracks on the surface of back rubber; (3) There are cracks and peel-off on the surface of canvas (4) (5) There are cracks at the bottom of the tooth There are cracks on the side face of toothed-belt 11-15 side cracks crack at bottom of tooth 1EN0249 (6) The side face of toothed-belt is abnormally abraded.
ENGINE TIMING TOOTHED-BELT WHEEL 11-16 (3) The overhang length of measuring rod. Replace if not conform 12mm to standard. Standard value 12mm 6EN0161 (4) Measure the amount of displacement while pressing down the 98~196N rod displacement rod with a force of 98~196N. (5) Replace the automatic tensioner if the displacement of rod is at least 1mm lesser than the value as measured in item (3).
ENGINE TIMING TOOTHED-BELT WHEEL 11-17 TOOTHED-BELT WHEEL C (1) Fixup balancing shaft toothed-belt wheel with the tools as MD998785 shown in the figure. (2) Tighten the bolt to the specified torque. 6EN0636 MOUNTING OF TIMING TOOTHED-BELT B D (1) Align the marks of crankshaft toothed-belt wheel B and timing mark timing mark front cover balancing toothed-belt wheel separately. (2) Mount timing toothed-belt onto the crankshaft toothed-belt wheel B and balancing shaft toothed-belt wheel.
11-18 ENGINE TIMING TOOTHED-BELT E TIGHTENING OF CRANKSHAFT BOLT (1) Fixup flywheel with special tools; (2) Mount crankshaft bolt. MD998781 6EN0634 F MOUNTING OF OIL PUMP TOOTHED-BELT WHEEL (1) Insert cross point screwdriver into the plug hole on the left side of cylinder block to prevent balancing shaft from rotating. (2) Mount oil pump toothed-belt wheel. (3) Smear engine oil on the coupling face of nut and bearing. (4) Screw up the nut according to the specified torque.
ENGINE TIMING TOOTHED-BELT H timing mark 11-19 MOUNTING OF TIMING TOOTHED-BELT (1) Confirm the timing toothed-belt tensioner is properly mounted. (2) Align the timing mark on the camshaft toothed-belt wheel with the mark on the cylinder head. 6EN0673 (3) Align the timing mark on the crankshaft toothed-belt wheel with the mark on the front cover. timing mark 6EN0671 (4) Align the timing mark on the oil pump toothed-belt wheel with its accordant mark.
ENGINE TIMING TOOTHED-BELT 11-20 (8) Verify that all timing marks are in a line. MD998767 MD990685 (9) Remove the screwdriver inserted at step (5) and mount the plug. (10) Turn camshaft 1/4 circle counter-clockwise, then turn it clockwise until all timing marks come into line again. (11) Assemble the special tools socket wrench and torque wrench onto the tensioner pulley, then screw down the central bolt of tensioner pulley.
ENGINE FUEL OIL SYSTEM 11-21 FUEL SYSTEM DISASSEMBLY AND MOUNTING 19N.m 2 3 4 1 20N.m 12N.m 6 7 5 Disassembly Procedure 1. water pipe Notes for Mounting A Mounting of Fuel Distribution Assembly Before mounting fuel distribution assembly, carefully lubricate the matching face of the manifold or the O- 2. water pipe 3. 4. throttle body cushion 5. 6. cover cushion of the injector and the mounting hole, then insert the intake manifold. Finally, screw down the bolt accord- 7.
ENGINE INTAKE MANIFOLD 11-22 INTAKE MANIFOLD DISASSEMBLY AND MOUNTING 1 19N.m N 6 20N.m 20N.m 3 4 13N.m 13N.m 30N.m Disassembly Procedure 1. engine Link Ring 3. water Outlet B 5. intake manifold A 19N.m 2 2. engine Water Temperature Sensor 4. intake Manifold Bracket 6. intake Manifold Gasket NOTES FOR MOUNTING A APPLICATION OF SEALANT FOR ENGINE WATER TEMPERATURE SENSOR Sealant Specification: 3M Nut locking parts No.4171 or the equivalent.
ENGINE EXHAUST MANIFOLD & WATER PUMP 11-23 EXHAUST MANIFOLD, WATER PUMP DISASSEMBLY AND MOUNTING 6 45N.m 4 14N.m 29N.m N 11N.m 11 24N.m 5 49N.m 12 8 N N 13N.m 10 N 1 13 9 7 24N.m N 13 24N.m 13N.m 2 15 N 16 N 3 16 18 19 N 14N.m Disassembly Procedure 1. 2. oil level gauge oil level gauge tube 3. o-ring 4. 5. heat shield engine link ring 6. 7. oxygen sensor exhaust manifold 8. exhaust manifold gasket 9. water inlet 10. thermostat 11.
ENGINE EXHAUST MANIFOLD & WATER PUMP 11-24 NOTES FOR MOUNTING o-ring A MOUNTING OF O RING SEAL (1) Wet O ring seal with water in order to assemble. Notes: There shouldn t be any oil or lubricating grease on the surface of O ring seal. 6EN0594 squeeze out sealant of 3mm diameter B MOUNTING OF BYPASS WATERPIPE CONNECTOR Sealant Specification: Genuine MITSUBISHI brand parts No.MD970389 or the equivalent.
ENGINE ROCKER ARM AND CAMSHAFT 11-25 ROCKER ARM AND CAMSHAFT DISASSEMBLY AND MOUNTING 1 3 4 N 5 3.9N.m 6 7 N 8 31N.m 17 18N.m 16 10 9 16 16 14 16 21 11 13 11 18 11 13 13 11 13 15 22 12 12 12 Smear engine oil on all moving parts while mounting 12 N 19 6EN1762 1. air hose 2. PCV hose A A C C C 20 12. A rocker arm A 13. B rocker arm B 3. 4. pressure control valve pressure control valve gasket 5. oil filler cap 16. rocker arm C 6. 7.
ENGINE ROCKER ARM AND CAMSHAFT 11-26 NOTES FOR DISASSEMBLY A (1) Before disassemble the rocker arm and rocker shaft assembly, use the tools as shown in the figure to prevent hydraulic lifter from falling. MD998448 6AE0160 CHECK CAMSHAFT (1) Measure the height of camshaft Standard value and operating limit are as follows: Type 9EN0058 Air intake Air exhaust Standard value Limit value 37.39 36.83 36.89 36.
ENGINE ROCKER ARM AND CAMSHAFT MD998441 11-27 (3) Mount the special tool MD998441 onto the hydraulic lifter. (4) Use the special tool MD998442 to lightly expel the steel ball inside the lifter and make it move 5-10 strokes until it can move smoothly. Additionally, it can also eliminate resistance of the diesel oil plunger. Such operation can remove dirty oil.
11-28 ENGINE ROCKER ARM AND CAMSHAFT (9) Put the hydraulic lifter into vessel C, then use the special tool MD998442 MD998442 to lightly expel the steel ball inside the lifter. NOTES: Don t clean the hydraulic lifter in vessel C. Otherwise foreign body may enter the pressure chamber which is full of oil.
ENGINE ROCKER ARM AND CAMSHAFT 6EN1704 11-29 (19) Take the hydraulic lifter out of the vessel, stick it up straight with its plunger at the top, stably impel the plunger until it can t move any more. Check and compare the height difference between the plunger and the new hydraulic lifter. NOTES: If the hydraulic lifter becomes shorter, repeat step (15) to (19) and fully fill the hydraulic lifter with diesel oil. If it still becomes shorter after repetition of these steps, replace the hydraulic lifter.
ENGINE CYLINDER HEAD AND VALVE 11-30 CYLINDER HEAD AND VALVE DISASSEMBLY AND ASSEMBLY 2 78N.m thorough looseness 20N.m 90 +90 4 5 1 6 N 12 13 16 N 20 8 9 10 14 N 15 17 N 18 N 7 3 N N 19 11 All parts inside should be coated with enging oil in assembly 6EN1386 Disassembly Procedure A B D 1. cylinder head bolts C B B C B 2. 3. 4. 5. 6. 7. 8. 9. 10.
ENGINE CYLINDER HEAD AND VALVE 11-31 Notices after Disassembly MB991654 The disassembled parts should be sorted as per the cylinder number and the intake/exhaust parts. Dismantle of Cylinder head Bolts A (1) Loosen the bolts of each cylinder heads with SST. The looseness should be even and gradual.
ENGINE CYLINDER HEAD AND VALVE 11-32 identifi cation upper site of spring B Mount of Valve Spring (1) The valve spring shall be mounted in such way that the spring end with identification color faces the upper site of the valve spring. valve oil seal lower site of spring 6EN0437 C MD998772 (1) Mount of Valve Lock Clamp In case the valve spring is over compressed, it will contact the bottom of the valve spring and thus damage the valve oil seal.
ENGINE CYLINDER HEAD AND VALVE 11-33 (6) Mark a straight line with paint on the heads of cylinder head bolts and the cylinder head. (7) Tighten the cylinder head bolts by 90 in tightening order. (8) Tighten the bolts by another 90 , ensuring the paint marks on the heads of cylinder head bolts and the cylinder head should be in alignment. 90 Notice: If the screwing angle of the bolt is less than 90 , correct tightening moment cannot be expected.
11-34 ENGINE CYLINDER HEAD AND VALVE angle belwee cerrter line of spring and plun bine of subface Valve Spring (1) Measure the free spring height, in case it is less than the limit value, change the spring. Standard value: 51.0 mm free spring height Limit value: 50.0 mm (2) Measure the perpendicularity of the center line with the surface of the spring, if the gradient exceeds the limit, change the spring.
ENGINE CYLINDER HEAD AND VALVE 0.5 1mm 11-35 Main Points in Change of Valve Seat (1) Cut out part of the valve seat to be changed so as to thin and remove it. cut out 0.5 1mm 1EN0274 (2) Trim the valve seat holes on the cylinder head as per the outside diameter of the enlarged valve seat. Diameter of valve seat ring: height of valve seat ring Enlarged dimension: 0.30 34.435-34.455 Enlarged dimension: 0.60 34.735-34.755 Enlarged dimension: 0.30 31.935-31.955 Enlarged dimension: 0.60 32.
ENGINE CYLINDER HEAD AND VALVE 11-36 FRONT COVER, OIL PUMP, BALANCE SHAFT ,OIL PAN DISMANTLE AND ASSEMBLY 10N.m 1.0Kgft N 29 N 27 10 26 All inside parts should be coated with the engine oil N 24 24N.m 2.4Kgifm 23 N 22 15 18 16 N 28 N 17 25 19 10N.m 1.0Kgfm 19N.m 1.9Kgifm N 20 16N.m 1.7Kgfm 6 N 9 14 13 N 12 7 21 N 8 N 36N.m 3.7Kgfm 23N.m 2.4Kgfm 39N.m 4.0Kgfm 3 N 2 5 11 4 44N.m 4.5Kgfm 19N.m 1.9Kgfm 7N.m 0.7Kgfm Disassembly Process N A B C M L K J I 1. lubricating oil filter 2.
ENGINE CYLINDER HEAD AND VALVE 11-37 Main Points of Disassembly MD998727 Disassembly of Oil Sump A (1) Disassemble all of the bolts of oil sump. (2) Tap the SST into the clearance between the cylinder block and the oil sump. Notice: Do not replace the SST with screwdriver or chisel, otherwise the oil 6EN0698 MD998162 sump will deform and leak oil. Disassembly of Plug B (1) In case the plug is over tight, tap it lightly with hand hammer for two or three times, and it will become loose.
ENGINE CYLINDER HEAD AND VALVE 11-38 E Disassembly of Rear Bearing of Balancing Shaft (1) Tear down the rear bearing of the left balancing shaft from the MB991603 cylinder block with SST. Remark:The SST (MB991603) should be mounted in front of the cylinder block when dismantling the rear bearing of the left balancing shaft. MB998372 6EN0207 Main Points in Assembly A (1) (2) Mount of Rear Bearing of Right Balancing Shaft Coat the engine oil at the outside of the bearing.
ENGINE CYLINDER HEAD AND VALVE C (1) 11-39 Mount of Front Bearing of Balancing Shaft Mount the front bearing with SST. MD998705 MD998705 bearing cylinderblock 6EN1035 Mount of Front Cover D (1) Mount the SST on the front end of the crankshaft and coat the engine oil on the face of outer circumference of the SST, then mount on the front cover.
ENGINE CYLINDER HEAD AND VALVE 11-40 Mount of Oil Seal of Lubricating Pump F socket wrench oil seal (1) Press the oil seal into the front cover with the socket wrench. front cover Mount of Front Oil Seal of Crankshaft G (1) Mount the front oil seal of crankshaft on the front cover with socket oil seal SST.
ENGINE CYLINDER HEAD AND VALVE (2) 11-41 Tighten the flange bolt with specified torque and ensure the driven gear of oil pump is fastened on the left balancing shaft. 6EN0565 K MD998162 Mount of Plug (1) Mount the new O-ring in the grooves at the front cover. (2) Mount the plug with SST and tighten it to the specified torque. MD998783 6EN0909 L Mount of Oil Sump (1) Clean the matching face of the oil sump and the cylinder block thoroughly.
11-42 ENGINE CYLINDER HEAD AND VALVE N bracket side (1) (2) Mount of Oil Filter Clean the mounting face of the oil filter bracket. Coat the engine oil on the O-ring of oil filter. (3) Screw in the oil filter, when the O-ring contacts the mounting face, screw another 3/4 round (tightening moment: 1.4 kg.m) 6EN0591 Inspection Front Cover (1) Check whether the oil hole is blocked, and clean it where necessary.
ENGINE CYLINDER HEAD AND VALVE 11-43 DISASSEMBLY AND ASSEMBLY All inside parts must be coated with engine oil 6EN0526 Disassembly Procedure G 1. connecting rod nut A F E 2. connecting rod cap D E 4. piston and connecting rod cluster 5. connecting rod bearing C 6. first air ring 7. second air ring C B B A 3. connecting rod bearing 8. oil ring 9. piston pin 10. piston 11. connecting rod 12.
ENGINE CYLINDER HEAD AND VALVE 11-44 Main Points in Disassembly A cylinder No. (1) Mark the cylinder No. on the side face of the larger end of the connecting rod so as to ensure the correct assembly. (2) Put aside the dismantled connecting rod, connecting rod cap and connecting rod bearing in order as per the cylinder No. marked on. DEN0050 B Assembler for Piston Pin MD998780 Disassembly of Connecting Rod Cap Disassembly of Piston Pin conduit A=17.9mm pressing rod guide block B conduit A=18.
ENGINE CYLINDER HEAD AND VALVE 11-45 Main Points for Mount piston A (1) A Mount of Piston Pin Measure the following dimensions of the piston, piston pin and connecting rod; A) Length of inserting hole of the piston pin; B B) Width between the keyway C) Length of piston pin D) Width of smaller end of connecting rod.
ENGINE CYLINDER HEAD AND VALVE 11-46 (10) Check whether the piston can rotate freely. 6EN0 298 upper scraper blade main ring lower scraper blade Mount of oil ring B (1) Put the main ring of oil ring in the oil ring groove. Remark: 1. The scraper blade and the main ring has the specified upper./lower face. 2. The new main ring and scraper are colorful to identify its dimension. 6EN1019 Dimension Identification Color Standard value None 0.50mm larger Red 1.
ENGINE CYLINDER HEAD AND VALVE D upper scraper blade 11-47 Mount of Piston and Connecting Rod Cluster (1) Coat enough engine oil on the piston, air ring and oil ring. (2) Adjust the openings of the air ring and oil ring (scraper blade and the main ring) to the place shown in the figure. crankshaft pulley side lower balde openings of second and main rings (3) Rotate the crankshaft until the crank pin locates the position of the cylinder hole.
ENGINE CYLINDER HEAD AND VALVE 11-48 F cylinder No. Mount of Connecting Rod Cap (1) When mounting the connecting rod cap, align the marks made in disassembly well, if mounting the new member without mark, the anti-rotary gap shown in the figure should be mounted at the same side anti-rotary gap DEN0051 (2) Be sure the axial clearance at the larger end of connecting rod is suitable. Standard value: 0.10 0.25mm Limit value: 0.
ENGINE CYLINDER HEAD AND VALVE 11-49 Inspection Piston Ring (1) Check whether the piston ring has damage, over abrasion or breakage, if it has, change it, in the case of changing the piston, the piston ring needs to be changed too. (2) Check the clearance between the piston ring and the piston ring groove, if it is over large, change the piston ring or the both parts. 5EN0066 Standard value: 0.02 0.06mm Limit value: 0.
ENGINE CYLINDER HEAD AND VALVE 11-50 2 CRANKSHAFT, CYLINDER BLOCK AND 3 FLYWHEEL DISASSEMBLY AND ASSEMBLY 6 13 N 5 132N.m 11N.m 4 11N.m 8.8N.m 11 12 10 Smear the engine oil on all moving parts 9 8 7 Disassembly Procedure 1. flywheel bolt 2. flywheel 3. rear cover plate 4. bell jar E D 5. rear oil seal cap 6. oil seal C 7. main bearing cap bolt 25N.m+90 ~100 C B 8. main bearing cap B A 11. bearing on crankshaft 9. low bearing of crankshaft 10. crankshaft 12.
ENGINE CYLINDER HEAD AND VALVE 11-51 Inspection clearance gauge of plastic cord Measurement for Crankshaft Play (clearance gauge of plastic cord) (1) Clean the oil on the main journal and the inner race of bearing. (2) (3) Mount the crankshaft. Cut the clearance gauge of plastic cord in the length that is the same with the width of bearing, then put them on the crankshaft 6EN0703 journal and ensure them are parallel with the axial center line.
ENGINE CYLINDER HEAD AND VALVE 11-52 Re-boring of Cylinder Diameter (1) The diameter for the enlarged piston should be determined according to the max cylinder diameter. Identification of piston diameter dimension Plus 0.50 Plus 1.00 thrusting direction piston diameter 6EN0554 Identification mark 0.50 1.00 Remark: Dimension mark is printed on the top of piston.
ENGINE CYLINDER HEAD AND VALVE Mount of crankshaft bearing B (1) Select the bearing that meets the dimension of crankshaft main journal as per the form below. No.3 No.2 No.4 Combination of crankshaft main journal and main shaft aperture Crankshaft main journal Groups No.1 No.5 identification mark for dimension of main bearing No.3 No.4 No.5 identification mark of main bearing hole Identification color Diameter (mm) Yellow 56.994 57.000 None 56.988 56.994 White 56.982 56.
ENGINE CYLINDER HEAD AND VALVE 11-54 C Mount of Main Bearing Cap/ Main Bearing Bolt (1) Mount the main bearing cap with the arrow mark thereof directing to the side of timing toothed belt. (2) Be sure the length of bolt is less than the limit value before mounting the main bearing cap bolt. In case it is larger than the limit value, change the bolt. Limit value (A): 71.7 mm 9EN0477 (3) Coat the engine oil on the threaded part and seat face of the bolt.
ENGINE CYLINDER HEAD AND VALVE D 11-55 Mount of Oil Seal MD990938 MD998376 6EN0709 Mount of Rear Oil Seal Cover E Specified sealant Brand: Genuine Mitsubishi brand sealant MD970389 or the equivalents. Notice: (1) The rear oil seal cover should be mounted quickly on the condition the sealant is not dry ( 15 min). (2) Keep the sealing area free from the lubricant and coolant for 1 hours or so after the mount.
ENGINE AC GENERATOR 11-56 AC GENERATOR DISASSEMBLY AND ASSEMBLY 3 2 4 6 5 1 9 8 7 13 12 11 10 9EN0187 Disassembly Procedure A A 1. generator pulley A 2. 3. B rotor assembly rear bearing 4. 5. bearing block front bearing 6. 7. front cap stator assembly 8. retaining plate 9. adjustor and brush stand 10. brush 11. ring 12. rectifier assembly 13.
ENGINE AC GENERATOR 11-57 NOTES FOR DISASSEMBLY SEPARATION OF STATOR AND FRONT CAP (1) Insert the screwdriver into the gap between front cap and stator to separate the front cap from the stator. (2) If it is hard to separate them, lightly hit the front cap with a plastic hammer and prize it with screwdriver at the same time. NOTES: 6EN1774 Don't insert the screwdriver too deep lest the stator winding is damaged.
11-58 ENGINE AC GENERATOR STATOR (1) Conduct on stator examination over the stator and confirm whether the conduction exists with the lead-wire of the winding, if not, replace the stator assembly. 3EN0208 (2) Check the grounding of stator winding. Confirm whether conduction exists between the winding and stator iron core, if yes, replace the stator assembly.
ENGINE AC GENERATOR 11-59 BRUSH (1) If the brush is worn out to the wear limit line, replace brush by taking the following steps: wear limit line wite 9EN0192 (2) The brush may be taken off by burning off the soldering joint of the brush lead-wire. 9EN0193 (3) While mounting new brush, you should burn on the brush leadwire with the brush being pressed into the brush holder.
ENGINE STARTER 11-60 STARTER DISASS0.EMBLY AND ASSEMBLY 11 2 12 14 13 21 16 15 1 17 4 5 3 19 18 9 22 10 6 7 6EN1412 Disassembly Process 1. bolt A 2. magnet valve 12. washer B 13. plate 3. bolt B 4. bolt 5. rear carrier 6. brush holder 7. brush 8. rear bearing B 9. rotor 10. yoke assembly 11. washer A 14. ball 15. planetary gear 16. rod C C A A 17. snap spring 18. checking ring 19. free engine clutch 20. inner gear 21. planetary gear carrier 22.
ENGINE STARTER magnetic switch terminal S 11-61 ESSENTIALS FOR DISASSEMBLY A terminal B DISASSEMBLY OF MAGNET VALVE (1) Knock down exciting coil from terminal M of the magnet valve. terminal exciting coil wiring 6EN0616 B casing tube checking ring dinion snap spring clamp (1) C DISASSEMBLY OF ROTOR AND BALL Do not drop the ball mounted on the end of bearing while disassemble the rotor.
ENGINE STARTER 11-62 (2) Check the outside diameter of the . commutator Standard value: 29.4mm Limit value: 28.4mm 1EN0298 depth (3) Check the drop depth of mica between commutator separators. Standard value: 0.5mm brush holder mica Limit value: 0.2mm 1EN0296 BRUSH HOLDER (1) Check whether conduction exists between brush holder plate and brush holder, if not, it is normal.
ENGINE STARTER (3) new brush soft pigtail 11-63 While crumbing worn battery with a plier, be careful not to damage the soft pigtail. sodering (no soldering tin exposed on the surface of brush) (4) In order to make soldering tin easy to be adhered, scrape the soft pigtail end with a piece of sand paper. (5) Insert soft pigtail into the new brush hole and burn it on and be sure no soldering tin exposed on the surface of brush.
ENGINE THROTTLE BODY 11-64 THROTTLE BODDY DISASSEMBLY AND ASSEMBLY 6 1 2 4 N 2.9N.m 3.4N.m 3.4N.m 3 5 4.9N.m 6EN1782 Disassembly Procedure 1. holder 2. throttle position transducer 3. 4. idle air valve o-ring 5. 6. throttle body SAS speed adjusting screw SAS Remarks 1. SAS has been adjusted before leaving factory, so no adjustment is needed. 2. In case the fixed SAS is dismantled by chance, the speed adjusting screw of throttle should be fixed up again. 3.
