Service manual

ManualsBrandsMitsubishi ManualsAutomotive4G6 Series 1992

Table Of Contents

BACKUP

Service

Manual

ENGINE

GROUP INDEX

1992

1993

Introduction

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

FOREWORD

The information contained in this service manual

has been prepared for the professional automotive

technician involved in daily repair operations. In-

formation in this manual is divided into groups by

engine models. Each group is further divided to

address individual components within the group.

These groups contain general information, specifica-

tion, removal and installation, disassembly and

reassembly procedures for the components. The

first page of each group contains an alphabetical

index to assist in finding the location of the

component. The information, descriptions and spe-

cifications were in effect at the time this manual

was released.

WE SUPPORT

VOLUNTARY TECHNICIAN

CERTIFICATION THROUGH

National

lnstit~te

for

AUTOMOTIVE

SERVICE

EXCELLENCE

Engine

4G1l

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4G33

. . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . .

4G6

<1992>>

. . . . . . . . . . . . . . . . . . . . . . . .

4G99

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...*..

6G77

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4G6

<1993>>

. . . . . . . . . . . . . . . . . . . . . . . .

CCT

Mitsubishi Motors Co[poration reserves the right to make changes

dew?

or to make addltlons to or improvements in its products

WIthout

impoang

any obligations upon itself to install them on its products

previously manufactured.

1992

Mitsubishi Motors Corporation

Printed in Japan

Summary of content (522 pages)

PAGE 1
BACKUP Service Manual ENGINE GROUP INDEX 1992 - 1993 Introduction FOREWORD ............................ Engine The information contained in this service manual has been prepared for the professional automotive technician involved in daily repair operations. Information in this manual is divided into groups by engine models. Each group is further divided to address individual components within the group.
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PAGE 3
INTRODUCTION :, CONTENTS ENGINE MODEL TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 EXPLANATION OF MANUAL CONTENTS . . . . . . . . 2 FORM-IN-PLACE GASKET . . . . . . . . . . . . . . . . . ..I................ 6 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Form-In-Place Gasket Application ._...................... 6 Surface Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2 INTRODUCTION EXPLANATION OF MANUAL CONTENTS Maintenance and Servicing Procedures (1) A diagram of the component parts is provided near the front of each section in order to give the reader a better understanding of the installed condition of component parts. (2) The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures; the symbol m indicates a non-reusable part; the tightening torque is provided where applicable.
PAGE 5
INTRODUCTION 3 Indicates the section title. Denotes non-reusable This number corresponds to the number appearing in “Removal steps”, “Disassembly steps”, “lnstallation steps” or “Reassembly steps” I Operating procedures, cautions, etc. on removal, installation, disassembly and reassembly are described.
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4 INTRODUCTION ENGINE MODEL TABLE - 1992 Engine Series, 4Gl 4G3 4G6 4G9 6G7 4693 1.8 (1 IO) In-line, SOHC E$po LRV 6672 3.0 (I 83) 6O”V. SOHC (per bank) bgmante, h&ntero, Truck 6G72 3.0 (183) 6O”V. DOHC (per bank) Diamante, 3000GT 6G72 Turbo 3.0 (183) 6O“V. DOHC (per bank) 4 3000GT .K c: 2.4(146) In-line, SOHC 4 E$po-LRV. Expo 4G93 1.8 (1 IO) In-line, SOHC 4 @age, Expo LRV 6672 3.0 (I 83) 6O”V. SOHC (per bank) 2 Diamante, Mhtero, Truck 6672 3.
PAGE 7
INTRODUCTION 6 . SPECIAL TOOL NOTE 1 Please refer to the special tool cross reference chart which is located in the service manual at the beginning of each group, for a cross reference from the MMC special tool number to the special tool number that is iiS *‘l available in your market. *.j, “...!: ‘/’ l” TORQUE REFERENCES General tightening torque is as shown in the following table. The specific part tightening torque is shown at the beginning of each group.
PAGE 8
INTRODUCTION FORM-IN-PLACE GASKET The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the fluid feed line.
PAGE 9
4G15 CONTENTS BRACKET ................................................................ CRANKSHAFT, FLYWHEEL AND DRIVE PLATE ........................................................ CYLINDER HEAD AND VALVES ........................ EXHAUST MANIFOLD AND WATER PUMP .................................................... FRONT CASE AND OIL PUMP ............................ FUEL AND EMISSION PARTS ............................ GENERAL INFORMATION ................................ GENERAL SPECIFICATIONS ..............
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IlA-2 4Gl ENGINE - General Information GENERAL INFQRMATION ENGINE SECTIONAL VIEW 3 1 EN0086 TSB Revision
PAGE 11
4Gl ENGINE - General Information TSB Revision 1
PAGE 12
VA-4 4Gl ENGINE - General Information UBRICATION SYSTEM 0’ t7; ii I 1 TSB Revision ‘ZP : ii OTJ 09
PAGE 13
4Gl ENGINE - General Specifications GENERAL SPECIFICATIONS Items Specifications We Number of cylinders Combustion chamber Total displacement cm3 (cu.in.) Cylinder bore mm (in.) Piston stroke mm (in.) Compression ratio Valve timing ( ): Camshaft identification mark Intake valve Opens BTDC Closes ABDC Exhaust valve BBDC Opens Closes ATDC Lubrication system Oil pump type Cooling system Water pump type EGR valve Injector type and number Injector identification No.
PAGE 14
1 IA-6 4Gl ENGINE - Service Specifications SERVICE SPECIFICATIONS “” Items Standard value Limit d.05 (.0020) 0.2(.008) "0.2 (.008) Cylinder head Flatness of gasket surface Grinding limit of gasket surface t Total resurfacing depth of both cylinder head and cylinder block Overall height Oversize rework dimensions of valve guide hole (both intake and exhaust) 0.05 (.002) 0.25(.010) 0.50 (.020) Oversize rework dimensions of intake valve seat ring hole (primary) 0.3 (.012) 0.6(.
PAGE 15
4Gl ENGINE - Service Specifications mm (in.) .,_ Items Valve spring Free height Intake Exhaust -oad/installed height Intake Exhaust 3ut-of-squareness halve guide 3verall length Intake Exhaust .D. I.D. ;ervice size ‘Tess-in temperature lalve seat ;eat angle lalve contact width Gnkage iervice size ,-i , -7, ,i ,,- < 100.75 (3.9665) 101.05 (3.9783) 6.57 - 6.58 (2587 - .2591) 6.53 - 6.55 (2571 - .2579) 45” - 45”30’ 1 .o (.039) 1.5 l.059) 0.5 (020) 1 .o (.039) 0.02 - 0.05 (0008 - .0020) 0.05 - 0.09 (.
PAGE 16
IIA-8 4Gl ENGINE - Service Specifications mm (in.) Items Standard value Limit Piston 75.48 - 75.50 (2.9716 - 2.9724) 0.02 - 0.04 (0008 - .0016) 0.25 t.01). 0.50 (.02), 0.75 (.03), 1 .OO (.04) oversize O.D. Piston-to-cylinder clearance Service size Piston ring End gap No. 1 ring No. 2 ring Oil ring Ring-to-ring groove clearance 0.20 - 0.40 l.0079 - .0157) 0.20 - 0.35 (.0079 - .0138) 0.20 - 0.70 LOO79 - .0276) 0.8 (.031) 0.8 f.031) 1 .o i.039) No. 1 ring No. 2 ring Service size 0.03 - 0.07 (.
PAGE 17
4Gl ENGINE - Service Specifications rn:fq, (in, i ,I :, i / Items Standard value Oil pump Tip clearance Side clearance Body clearance 0.03 - 0.08 LOOI 2 - .0031) 0.04-0.10(.0016-.0039) O.lO-0.18(.0039-.0071) Drive belt deflection New belt Used belt 5.5 -7.0 (.22 - .28) 8.0 (.32) Injector Coil resistance fI? 13 - 16 at 20°C (68°F) Throttle position sensor Resistance kR 3.5-6.
PAGE 18
1 IA-IO 4Gl ENGINE - Torque Specifications TORQUE SPECIFICATIONS Nm - ftlbs.
PAGE 19
461 ENGINE - Torque Specifications / Sealant _ .” .c Nm ft.lbs.‘, I. ‘-,.‘.,; $8; Cylinder head and valves Cylinder head bolt 73 53 Front case and oil pump Oil pan drain plug Oil pan bolt Oil screen bolt Oil relief valve plug Front case bolt Oil pump cover screw 40 7 19 45 I4 IO 29 5 14 33 11 8 Piston and connecting rod Connecting rod cap nut 20 + I/4 turns 14.
PAGE 20
1 IA-12 4Gl ENGINE - Special Tools SPECIAL TOOLS Tool MD99801 1 Crankshaft rear oil seal installer MD99801 I-01 Installation of crankshaft rear oil seal MD998713-01 Installation of camshaft oil seal Crankshaft front oil seal installer MD99871 3 Camshaft oil seal ,.i ..
PAGE 21
4Gl ENGINE - Special Tools Valve stem seal compressor Flywheel stopper 1 TSB Revision
PAGE 22
1 IA-14 4Gl ENGINE - Generator and Ignition System _, * GENERATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION 12 Nm 9 ftJp3. 7 23 Nm Ji 14 Nm 10 ft.lbs. ” Rm/b=I n \! I 24Nr;l 17 ft.lbs. 9Nm I 85 Nm 81 ft.lbs. Removal steps 1, Oil level gauge 2. Oil level gauge guide 3. O-ring +C4 4. Drive belt 5. Water pump pulley 6. Generator brace 7. Generator (IA!) +B4 8. Crankshaft bolt 9. Special washer IO. Crankshaft pulley 11. Damper pulley 12. Spark plug cable 13. Spark plug *A4 ‘ll. ;.s;;$butor .
PAGE 23
461 ENGINE - Generator and Ignition System REMOVAL SERVICE POINT OAo CRANKSHAFT BOLT REMOVAL (I) Using the special tool, hold the drive plate or flywheel. (2) Remove the crankshaft bolt. INSTALLATION SERVICE POINTS r)A4 DISTRIBUTOR ASSEMBLY INSTALLATlOy / (1) Turn the crankshaft to bring the No. I cylinder piston to the top dead center on compression stroke. (2) Align the mating mark on thedistributor housing with that on the coupling key.
PAGE 24
4Gl ENGINE - Generator and Ignition System 6EN059E (2) Or using a tension gauge, adjust the tension to the standard value. Standard value: New belt 5 0 0 - 700 N (116 - 154 Ibs.) Used belt 400 N (88 Ibs.) (3) Tighten the lock bolt to the specified torque. (4) Tighten the nut for pivot bolt to th$ specified torque.
PAGE 25
461 ENGINE - Timing Belt TIMING BELT REMOVAL AND INSTALLATION 2bnhll 17 ft.lbs. I 7 8 d Removal steps 1. Timing belt upper cover 2. Timing belt lower cover @I$ eC4 3. Timing belt 4. Engine support bracket, left 5. Tensioner spring +B4 6. Tensioner 7. Crankshaft sprocket OBO 8. Flange $I$ *A4 9. Camshaft sprocket bolt 10.
PAGE 26
461 ENGINE - Timing B e l t REMOVAL SERVICE POINTS ~ OAo TIMING BELT REMOVAL (1) Mark belt running direction for reference in reinstallation. (2) Loosen the tensioner bolts and move the tensioner toward the water pump. (3) Remove the timing belt. NOTE (1) Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be kept free from oil and water. Do not immerse parts in cleaning solvent.
PAGE 27
461 ENGINE - Timing Belt (2) Cracks on rubber back (3) Cracks or peeling of canvas (4) Cracks on rib root (5) Cracks on belt sides Peeling Cracks 1 EN024E (6) Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife.
PAGE 28
11 A-20 4Gl ENGINE - Timing Belt I)cg TIMING BELT INSTALLATION (1) Align the timing marks on the camshaft sprocket and the crankshaft sprocket with their timing marks. (2) Set the timing belt first on crankshaft sprocket and then keeping the tension side belt tight, set on the camshaft sprocket. 4 1 EN033 (3) Loosen the tensioner mounting bolts @ and 0. (4) Check that the belt completely meshes with the sprocket.
PAGE 29
4Gl ENGINE - Timina Belt (5) Turn the crankshaft clockwise by 3 crankshaft s@Cxket I teeth. (6) Tighten bolt @ first and then bolt 0. If bolt @ is tightened first, the tensioner will turn together with the bolt, resulting in an overtensioned belt. 1 ENOOOE \ il (7) Check the belt tension. Hold the tensioner and ‘timing belt together by hand and give the belt a slight thumb pressure at a point level with tensioner center.
PAGE 30
IIA-22 461 ENGINE - Fuel and Emission Parts FUEL AND EMISSION PARTS REMOVAL AND INSTALLATION 19 Nm ;; 14 ft.lbs. Removal steps 1. Throttle body 2. Gasket 3. Injectors and fuel rail 4. Insulator eB4 ;. Fuw&ressure regulator 7: Insulator *A4 8. Injector clip *A4 9. Injector 10. O-ring 11. Grommet 12. Fuel rail 13. EGR valve (For California) 14.
PAGE 31
461 ENGJNE - Fuel and Emission Parts INSPECTION ‘,.$ ::. INJECTORS ‘I’:. ,L (1) Using an ohmmeter (circuit tester), test for, cont$u~ty, between terminals of injector; the circuit should be closed. If failure is detected, replace the injector. Standard value: 13 - 16 Cn [at 20°C (68”F)l 6FU192C EGR VALVE (1) Check the EGR valve for sticking or carbon deposits. If such conditions exist, clean or replace the EGR valve.
PAGE 32
1 M-24 4Gl ENGINE - Throttle Body THROTTLE BODY DISASSEMBLY AND REASSEMBLY Up to 1992 models 1 2Nm 1.4 ftlbs. Disassembly steps 4ArJ bA4 1. Throttle position sensor 2. Idle speed control motor 3. Throttle valve set screw 4. Throttle body 6FU1292 From 1993 models “p 2Nm 1.4 ft.lbs. Disassembly steps 8:; I)A4 I. Throttle position sensor 2. Idle arr control motor 3. O-ring 4. Throttle body 4BO 5.
PAGE 33
461 ENGINE - Throttle Bodv DISASSEMBLY SERVJCE POINTS 6Ab THROTTLE POSITION SENSOR AND IDLE SPEED CONTROL MOTOR / IDLE AIR CONTROL IMOTOR REMOVAL (1) DO not disassemble the sensor and motor. (2) DO not immerse in solvent the sensor and motor to clean. Clean them with shop towel. aB0 THROlTLE BODY REMOVAL (1) Do not remove the throttle valve. (2) Check if the vacuum port or passage is clogged. Use compressed air to clean the vacuum passage.
PAGE 34
llA-26 4Gl ENGINE - Intake Manifold INTAKE MANIFOLD REMOVAL AND INSTALLATION 14 Nm IO ft.lbs. A* 8Nm Gft.!bs. -18Nm / 13 ft.lbs. 18Nm 13 ftlbs. Removal steps I. Water hose eC4 2. Engine coolant temperature gauge unit eB4 3. Engine coolant temperature sensor *AiJ 4. Thermoswitch For AIT 5. Water outlet fitting 6. Water outlet fitting gasket 7. Thermostat 8. Outer cable bracket 9. Inner cable bracket k:E 10. Engine hanger 11. Thermostat housing 12. Intake manifold stay 13.
PAGE 35
4Gl ENGINE - Intake Manifold INSTALLATION SERVICE POINTS #A4 SEALANT APPLICATION TO THERM0,-(” .SWIT& *f. ‘; , : i’<, ‘* ; * Sealant Specified sealant: 3M Nut Locking Part No. 4171 or equivalent lEN033E I)B4 SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE GAUGE UNIT Specified sealant: 3M ATD Part No. 8660 or equivalent Sealant 9EN009; I)c4 SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE SENSOR Specified sealant: 3M Nut Locking Part No.
PAGE 36
1 IA-28 461 ENGINE - Exhaust Manifold and Water Pump* EXHAUST MANIFOLD AND WATER PUMP REMOVAL AND INSTALLATION 14 Nm 10 ft.lbs. 30 Nm 22 ft.lbs. 1 7 - 9Nm’ 7 klbs. 14 Nm 10 ftlbs. Removal steps 1. Exhaust manifold cover “A” 2. Oxygen sensor - [1992,1993 (FED) models1 3. Engine hanger 4. Exhaust manifold 5. Exhaust manifold cover “B” 6. Exhaust manifold gasket 7. Water hose +A4 8. Water inlet pipe *AC 9. O-ring 10. Water pump 11.
PAGE 37
4Gl ENGINE - Exhaust Manifold and Water Pump O-ring I Water inlet pipe Water INSTALLATION SERVICE POINT I)A4 WATER PIPE / O-RING INSTALLATION.‘ pump .‘ ) & p :. (1) Wet the O-ring (with water) to facilitateFas-6embly.
PAGE 38
1 IA-30 461 ENGINE - Rocker Arms and Camshaft ‘_ ROCKER ARMS AND CAMSHAFT REMOVAL AND INSTALLATION 1 I 1.8Nm 1.3ft.lbs. 32 Nm 23 ft.lbs. Removal steps 1. Breather hose 2. PCV hose 3. Rocker cover 4. Rocker cover gasket )C4 5. Oil seal eB4 6. Rocker arm and rocker arm shaft #Bd 7. Rocker arm and rocker arm shaft 8. Rocker arm “D” 9. Wave washer 10. Spacer 11. Rocker arm “C” 12. Rocker arm shaft (exhaust side) 13. Rocker arm “B” 14. Rocker arm spring 15. Rocker arm “A” 16.
PAGE 39
461 ENGINE - Rocker Arms and Camshaft qfq/&&l INSPECTION CAMSHAFT (1) Measure the cam height. Standard value: 38.78 mti (1.5268 ‘in.) Intake 3 9 . 1 0 m m (1.53& Sii.) Exhaust Limit: 38.28 mm (1.5071 in.) Intake 38.60 mm (1.5197 in.) Exhaust .:_j * ” , 1 EN009s ROCKER ARM l Check the roller surface. If any dents, damage or seizure is evident, replace the rocker arm. l Check rotation of the roller. If it does not rotate smoothty or if looseness is evident, replace the rocker arm.
PAGE 40
1 IA-32 4Gl ENGINE - Rocker Arms and Camshaft Exhaust 1 VALVE CLEARANCE ADJUSTMENT ~ (1) Position the No. 1 cylinder at the top dead center on compression stroke. (2) Adjust the valve clearance at the points shown in the illustration. Exhaust 3 Intake 1 Intake 2 lEN015t (3) Loosen the adjusting screw locknut’. (4) Using a feeler gauge, adjust the valve clearance by turning the adjusting screw. Standard value: on cold engine 0.07 mm (.0028 in.) Up to 1992 models Intake 0.09 mm (.0035 in.
PAGE 41
4Gl ENGINE - Cylinder Head and Valves CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION 73 Nm 53 ft.lbs. 2- Removal steps (JAI) #E4 1. Cylinder head bolt 2. Cylinder head, valve assembly I)D4 3. Cylinder head gasket (IBI) #Q 4. Retainer lock 5. Valve spring retainer #B4 6. Valvespring 7. Intake valve (primary) 8. intake valve (secondary) (IBM) bC4 9. Retainer lock 10. Valve spring retainer +B4 11. Valve spring 12. Exhaust valve $I$ #A4 13. Valve stem seal 14. Valve spring seat @I$ #A4 15.
PAGE 42
1 IA-34 461 ENGINE - Cvlinder Head and Valves REMOVAL SERVICE POINTS j (IAN CYLINDER HEAD BOLT REMOVAL OBo RETAINER LOCK REMOVAL (1) Store the removed valves, springs and other parts, tagged to indicate their cylinder No. and location to aid reassembly. $0 VALVE STEM SEAL REMOVAL (1) Do not reuse removed valve stem seals. i: ;". INSPECTION ., CYLINDER HEAD (1) Check the cylinder head gasket &$-face for flatness by using a straightedge and thicknessygauge. Standard value: 0.05 mm (.0020 jn.) Limit: 0.
PAGE 43
4Gl ENGINE - Cylinder Head and Valves 6EN054: Free height 1 EN0264 I VALVE (1) Check the valve face for correct contact. If incorrect, reface using valve refacer. Valve should“ma,ke a uniform contact with the seat at the center of valve ‘face. (2) If the margin is smaller than the ser@cefimit, replace the valve. Standard value: 1.0 mm (.039 in.) Intake 1.5 mm (.059 in.) Exhaust Limit: Intake 0.5 mm (.020 in.) 1.0 mm (.039 in.
PAGE 44
1 IA-36 4Gl ENGINE - Cylinder Head and Valves VALVE SEAT REPLACEMENT PROCEDURE (1) Cut the valve seat to be replaced from the inside to thin the wall thickness. Then, remove the valve seat. 0.5 - 1 mm f.02 - .04 in.) 0.5- 1 mm (.02 - .04 in.) Oversize I.D. I 1 EN0275 (2) Rebore the valve seat hole in cylinder head to a selected oversize valve seat diameter.
PAGE 45
4Gl ENGINE - Cylinder Head and Valves +B4 VALVE SPRING INSTALLATION I Spring retainer Painted end (1) ~.s$~~;~ valve spring with the painted end on the rocker _ Stem seal Spring seat 6EN043i I)c4 RETAINER LOCK INSTALLATION (1) The valve spring, if excessively compressed, causes the bottom end of retainer to be in contact with, and damage, the stem seal.
PAGE 46
1 IA-38 461 ENGINE - Cvlinder Head and Valves TSB Revision
PAGE 47
4Gl ENGINE - Front Case and Oil Pump FRONT CASE AND OIL PUMP REMOVAL AND INSTALLATION 45 Nm 33 ft.lbs. I 7 Removal steps eD4 1. Oil filter 2. Drain plug 3. Drain plug gasket QAI$~C~ 4. Oil pan 5. Oil screen 6. Oil screen gasket 7. Relief plug 8. Gasket 9. Relief spring 10. Relief plunger +B4 11. Oil seal 12. Front case 13. Front case gasket 14. Oil pump cover @I) +A4 15. Outer rotor @I) +A4 16.
PAGE 48
1 IA-40 4Gl ENGINE - Front Case and Oil Puma, REMOVAL SERVICE POINTS 1 OAo OIL PAN REMOVAL (1) Knock the special tool deeply between the oil pan and the cylinder block. (2) Hitting the side of the special tool, slide the special tool along the oil pan to remove it. OBo OUTER ROTOR / INNER ROTOR REMOVAL (I) Make alignment marks on the outer and inner rotors for reference in reassembly. lEN008t INSPECTION .? OIL PUMP (1) Check the tip clearance. Standard value: 0.03 - 0.08 mm (.00?2 - .0031 in.
PAGE 49
4Gl ENGINE - Front Case and Oil Pump INSTALLATION SERVICE POINTS I)A4 INNER ROTOR / OUTER ROTOR INSTALLATION (1) Install the outer rotor in the same direction as before noting the mark put at the time of removal. Apply engine oil to the entire rotor surface. I lEN00801 eB4 MD998305 n’ \ CRANKSHAFT FRONT OIL SEAL INSTALLATION (1) Set the special tool on the crankshaft front end and apply engine oil to its outer circumference.
PAGE 50
4Gl ENGINE - Front Case and Oil Puma I)c4 O I L P A N I N S T A L L A T I O N (1) Scrape clean or wire brush all gask{t surfaces removing all loose material. (2) Apply a 4 mm (16 in.) diameter beid of sealant to the oil pan flange. .F 1 Specified sealant: Mitsubishi Genuine Part No. ‘%lD970389 or equivai. lent (3) The oil pan should be installed within 15 minutes after the application of sealant. 4 mm (.I 6 in.
PAGE 51
yl&g .. 4Gl ENGINE - Piston and Connecting Rod PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION Removal steps OAo $1 k khecting rod cap 3. Connecting rod bearing *iI4 4. Piston and connecting rod 5. Connecting rod bearing eC4 6. Piston ring No. 1 eC4 7. Piston ring No. 2 I)B4 8. Oil ring oBoeA 9. Piston pin 10. Piston 11. Connecting rod 12. Bolt ‘.
PAGE 52
IlA-44 4Gl ENGINE - Piston and Connecting Rod DISASSEMBLY ,SERVlCE POINT6 OAo CONNECTING ROD CAP REMOVAL ylinder No. (1) Mark the cylinder number on the side of the connecting rod big end for correct reassembly. DENOOM Piston pin setting tool MIT21 6941 7EN042E Press pin $Mgg , Piston pin h Front mark (IBM PISTON PIN REMOVAL Item No. Part No.
PAGE 53
INSPECTION PISTON RING (1) Check for side clearance. If the limit is exceeded, replace the ring or piston, or both. 5EN0066 Standard value: 0.03 - 0.07 mm (A012 - .0028 h.) No. 1 0.02 - 0.08 mm (&IO8 - .0024.‘in.) No. 2 Limit: 0.1 mm (.004 in.) (2) insert the piston ring into the cylinder bore. Force the ring down with a piston, the piston crown being in contact with the ring, to correctly position it at right angles to the cylinder wall. Then, measure the end gap with a thickne$s gauge.
PAGE 54
11 A-46 4Gl ENGINE - Piston and Connecting Rod REASSEMBLY SERVICE POINTSI)A4 PISTON PIN INSTALLATION ,’ (I) Thread the stop screw and lock nut asiembly into the base. Fit the correct piston support on the top of the base. Insert the press pin, threaded end up, into t?re hole in the piston support until the press pin touches e stop screw. (2) Using the graduations on the press n, adjust the stop screw to the correct depth of 49 mm (1.93 in.) 7EN0421 (3) Place the base on the press support blocks.
PAGE 55
4Gl ENGINE - Piston and Connecting Rod *6+ OIL RING INSTALLATION (1) Fit the oil ring spacer into the piston ring groove. NOTE The side rails and spacer may be installed in either direction. 1 EN027;I Side rail gap 1 EN026E (2) Install the upper side rail. To install the side rail, first fit one end of the rail into the piston groove, then press the remaining portion into position by finger. See illustration. Caution Do not use piston ring expander when installing the side rail.
PAGE 56
IlA-48 461 ENGINE - Piston and Connecting R o d Timing belt c3 side (3) Rotate crankshaft so that the crank pi^n is on the center of the cylinder bore. (4) Use suitable thread protectors on theconnecting rod bolts before inserting piston and connecting rod assembly into the cylinder block. Care must be taken not to nick the crank pin. (5) Using a suitable piston ring compressor. tool, install the piston and connecting rod assembly ir#o the cylinder block.
PAGE 57
461 ENGINE - Crankshaft, Flywheel and Drive Plate CRANKSHAFT, FLYWHEEL AND DRIVE PLATE REMOVAL AND INSTALLATION ., 135.Nm .Y fths- 11 Nm 8 ft.lbs. 8 Al, I f L 19 Nm l4 fi*‘bfm 184% 3 \ 135Nm - 6 ft.lbk. 53 Nm 38 ft.lbs. Removal steps 1. Flywheel bolt For MIT 2. Flywheel 3. Drive plate bolt 4. Adaptor plate 5. Drive plate 6. Adaptor plate 7. Crankshaft bushing 8. Rear plate 9. Bell housing cover 10. Oil seal case 11. Oil seal case gasket *Cl4 12. Rear oil seal 13. Bearing cap bolt *C4 14.
PAGE 58
1 IA-50 461 ENGINE - Crankshaft, Flywheel and Drive Plate rr, INSPECTION CRANKSHAFT JOURNAL OIL CLEARANCE (PLASTIC GAUGE METHOD) (1) Remove oil from the crankshaft journal and the crankshaft bearing. (2) Install the crankshaft. (3) Cut the plastic gauge to the same length as the width of bearing and place it on the journal in parallel with its axis. 6EN055C (4) Install the crankshaft bearing cap carefully and tighten the bolts to the specified torque. (5) Carefully remove the crankshaft bearing cap.
PAGE 59
4Gl ENGINE - Crankshaft, Flywheel and Drive Plate BORING CYLINDER (1) Oversize pistons to be used should be determined on the basis of the largest bore cylinder. Piston size identification Thrust direction 6EN055 Identification Size 0.50 mm (.02 in.) O.S. 0.75 mm (.03 in.) OS. 1 .OO mm (.04 in.) OS. 0.25 0.50 0.75 I- 1 .oo NOTE Size mark is stamped on the piston top. (2) Measure outside diameter of piston to be used. Measure it in thrust direction as shown. (3) Based on the measured piston O.D.
PAGE 60
11 A-52 401 ENGINE - Crankshaft, Flywheel and Drive Pla$ I)c4 INSTALLATION OF BEARING CAP (1) Install according to the front mark end cap No. NO174 Timing belt side Cap No. 1 EN017E (2) After installing the bearing caps, make sure that the crankshaft turns smoothly and the end play is correct. If the end play exceeds the limit, replace crankshaft bearings. Standard value: 0.05 - 0.18 mm (.0020 - .0071 in.) Limit: 0.3 mm (.012 in.
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l.lA-53 4Gl ENGINE - Bracket BRACKET REMOVAL AND INSTALLATION 65 Nm 47 ft.lbs. 2 60 Nm 44 ft.1bs.h 36 Nm 26 ft.lbs. /--+GFL yy 1 120 Nm 67 ftlbs. ‘\ Removal steps 1. Exhaust pipe support bracket 2. Engine support bracket, front 3. Roll stopper bracket, front 4.
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NOTES
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ENGINE 4637 CONTENTS BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT, FLYWHEEL AND DRIVE PLATE . . .._..............._...._.............................. CYLINDER HEAD AND VALVES f....................... EXHAUST MANIFOLD AND WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT CASE, OIL PUMP AND OIL PAN . . . . . . . . FUEL AND EMISSION PARTS . . . .
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IIB-2 4G3 ENGINE - General Information GENERAL INFORMATION ENGINE SECTIONAL VIEW 3ENOO86 1 TSB Revision I
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4G3 ENGINE - General Information I pqJp3 3EN0087 \ TSB Revision
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IIB-4 4G3 ENGINE - General Information JBRICATION SYSTEM 3LUOO20 TSB Revision
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4G3 ENGINE - General Specifications ptgpg GENERAL SPECIFICATIONS Description Specifications Type Number of cylinders Combustion chamber Total displacement cm3 (cu. in.) mm (in.) Cylinder bore Piston stroke mm (in.
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IIB-6 4G3 ENGINE - Service Specifications 7 SERVICE SPECIFICATIONS mm (in.) Limit Standard Cylinder head Flatness of gasket surface Grinding limit of gasket surface * Total resurfacing depth of both cylinder head and cylinder block Overall height Oversize rework dimensions of valve guide hole (both intake and exhaust) 0.05 (002) 0.25 (.OlO) 0.50 (020) Oversize rework dimensions of intake valve seat ring hole 0.30 (012) 0.60 (024) Oversize rework dimensions of exhaust valve seat ring hole 0.30 (012) 0.
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463 ENGINE - Service Specifications mm (in.) Standard Limit I c’:,; ,. *‘:’ ;, :,i :; . . .-y >,-; ,. Valve Overall length Intake Exhaust Stem diameter Intake Exhaust Face angle Thickness of valve head (margin) Intake Exhaust Stem-to-guide clearance Intake Exhaust 1.2 (.047) 1.5 (.059) 0.7 (.028) 1 .o i.039) 0.03 - 0.06 (0012 - .0024) 0.05 - 0.09 (.0020 - .0035) 0.10 (.0039) 0.15 c.qaq$l) , Valve spring Free height Load/installed height Out-of-squareness 49.2 (1.937) 31 O/37.3 (68/l .469) Max.
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463 ENGINE - Service SDecifications mm (in.) Standard Limit Silent shaft Journal diameter Right(front) (rear) Left (front) (rear) Oil clearance Right(front) (rear) Left Ifrar$) r 0.02 0.05 0.02 0.05 Piston O.D. Piston-to-cylinder clearance Service size 80.57 - 80.60 (3.1720 - 3.1732) 0.02 - 0.04 (.0008 - .0016) 0.25 (.Ol), 0.50 (.02), 0.75 (.03), 1 .OO (.04) oversize 38.96 - 38.98 (1.5339 - 1.5346) 35.95 - 35.97 (1.4154 - 1.4161) 18.47 - 18.48 (.7272 - .7276) 35.95 - 35.97 (I .4154- 1.4161) - 0.06 (.
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463 ENGINE - Service Specifications Crankshaft End play Journal O.D. Pin O.D. Out-of-roundness and taper of journal and pin Oil clearance of journal Oil clearance of pin Journal undersize 0.25 (.OlO) U.S. 0.50 (.020) U.S. 0.75 (.030) U.S. Pin undersize 0.25 (.OlO) U.S. 0.50 (020) U.S. 0.75 (.030) U.S. Standard Limit 0.05-0.18(.0020-.0071) 57 (2.24) 45 (1.77) Within 0.01 (0004) 0.3 (;012~ :, .’ ,/ * ,‘/~ 0.02-0.05 (.0008- .0020) 0.02 - 0.05 (.0008 - .0020) 0.10 (.0039) 0.10 (.0039) 56.74 - 56.75 (2.
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IIB-10 4G3 ENGINE - Torque Specifications TORQUE SPECIFICATIONS Nm ft.lbs.
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4G3 ENGINE - Torque Specifications Rocker cover bolt Camshaft bearing cap bolt (M8) Camshaft bearin Oil pressure gauge unit Oil filter bracket Oil pan drain plug Oil pan bolt Oil screen nut Oil pump cover bolt Oil pump driven gear bolt Oil relief valve plug 3ear plate bolt 3ell housing cover bolt 3il seal case bolt 3earing cap bolt 53 38 3racket Exhaust pipe support bracket 3011 stopper bracket, front 3011 stopper bracket, rear Ingine support bracket, right 36 65 120 65 26 47 87 47 [ TSB Revision
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IIB-12 4G3 ENGINE - Sealant SEALANT Specified sealant Engine coolant temperature sensor Engine coolant temperature gauge unit Semi-circular packing Oil pan Oil pressure gauge unit Oil pressure switch 3M Nut Locking Part No. 4171 or equivalent 3M ATD Part No. 8660 or equivalent 3M ATD Part No. 8660 or equivalent MITSUBISHI GENUINE Part MD970389 or equivalent 3M ATD Part No. 8660 or equivalent 3M ATD Part No.
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463 ENGINE - Special Tools SPECIAL TOOLS r00i Number and tool name Supersession MB990767 Lns”, yo!; holder MB990767-01 Holdingcamshaft sprocket when loosening Use with MIT308239 or torquing bolt. Application .
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IIB-14 463 ENGINE - Special Tools Leak-down tester Air bleed wire MD998713 Camshaft oil seal installer M D9987 13-O 1 Installation of camshaft oil seal MD998719 Pulley holding pins (2) M IT308239 Holding camshaft sprocket when loosening or torquing bolt _ M D998727 Oil pan remover M D998728 Valve stem seal installer Removal of oil pan MD998728-01 1 TSB Revision Installation of valve stem seal I
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463 ENGINE - Special Tools Removal of crankshaft sprocket 1 TSB Revision
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IIB-16 4G3 ENGINE - Generator and Ignition System GENERATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION 25 Nm - 18 ft.lbs. 23 Nm @- 17 ft.lbs. 14 ilm 10 ft.lbs. I 19 Nm 14 ft.lbs. 7 9Nm 7 ftlbs. 12 Nm 9 ft.lbs. 17’Nm 12 ft.lbs. 17 Nm 12 ft.lbs. Removal steps +B4 1. Drive belt 2. Water pump pulley 3. Generator brace 4. Generator 5. Damper pulley 6. Adapter 7. Crankshaft pulley 8. Spark plug cable 9. Spark plug 10. Distributor 11.
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4G3 ENGINE - Generator and Ignition System INSTALLATION SERVICE POINTS I)Ag DISTRIBUTOR INSTALLATION (1) Turn the crankshaft so that the I&. 1 cylinder is at to; dead center. (2) Align the distributor housing and gear mating marks. 3EN022~ (3) Install the distributor to the engine while aligning the fine cut (groove or projection) of the distributor’s installation flange with the center of the distributor installation stud.
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IIB-18 4G3 ENGINE - Timing Belt TIMING BELT REMOVAL AND INSTALLATION 36Nm l5 26 ft.lbs. I 37 Nm 27 ft.lbs. 12 I 13 I Removal steps 1. Timing belt front upper cover 2. Timing belt front lower cover (IAO eH4 3. Timing belt #G4 4. Tensioner #G4 5. Tensioner spring 461) +F4 6. Oil pump sprocket (I$$ +E4 7. Crankshaft bolt 8. Crankshaft sprocket 9. Flange 10. Tensioner “B” OEo *II4 11. Timing belt “6” (IFI) eC4 12. Silent shaft sprocket *B4 13. Spacer 14. Crankshaft sprocket “B” SO 15.
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463 ENGINE - Timing Belt REMOVAL SERVICE POINTS qA0 TIMING BELT REMOVAL (1) Mark the belt running direction for reference -in reihstallation. aB0 OIL PUMP SPROCKET REMOVAL (1) Remove the plug on the left side of the cylinder block. (2) Insert a Phillips screwdriver [shank diameter 8 mm (31 in.)] to block the left silent shaft. (3) Remove the nuts. (4) Remove the oil pump sprocket. @r) CRANKSHAFT BOLT LOOSENING (1) Using the special tool, hold the drive plate or flywheel. (2) Remove the crankshaft bolt.
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IIB-20 4G3 ENGINE - Timing B e l t OF0 SILENT SHAFT SPROCKET REMOVAL *i -, OGo CRANKSHAFT SPROCKET “B’ REMOVAL QHo CAMSHAFT SPROCKET BOLT LOOSENING INSPECTION - \ 000 00B & 8EN006E (2) (3) (4) (5) Cracks B TIMING BELT / TIMING BELT “B” ditions exist. Replace belt if any of the following ide is glossy without (1) Hardening of back rubber - the ba resilience and leaves no indent whe pressed with fingerk nail.
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463 ENGINE - Timing Belt (6) Abnormal wear of belt sides. The sides are normal )’ if they are sharp as if cut by a knife. Rounded edge / Abnormal wear (Fluffy strand) 8EN0067 (7) Abnormal wear in teeth (8) Missing tooth Rubber exposed Tooth missing and canvas 8EN006E INSTALLATION SERVICE POINTS I)A4 CAMSHAFT SPROCKET BOLT INSTALLATION, #B4 SPACER INSTALLATION (1) Install the spacer with the chamfered end toward the oil seal.
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11 B-22 4G3 ENGINE - Timing Belt I)04 TIMING BELT “B” INSTALLABON (1) Align the timing marks on the crankshaft sprocket “B” and silent shaft sprocket with the marks on the front case respectively. (2) Install the timing belt “B” on the crankshaft sprocket “B” and silent shaft sprocket. There should be no slack on the tension side. (3) Make sure that the relationship between the tensioner pulley center and the bolt center’ is as shown in the illustration.
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463 ENGINE - Timinn Belt IT&23 I)F4 OIL PUMP SPROCKET INSTALLATION Y--l Screwdriver 6R? ” ’ ” (1) Insert a Phillips screwdriver [shank diameter 8 mm (31 in.)] through the plug hole on the left side of the cylinder block to block the left silent shaft. (2) Install the oil pump sprocket. (3) Tighten the nuts to the specified torque. 3EN0231 I)Gg TENSIONER / TENSIONER SPRING INSTALLATION (1) Hook the tensioner spring ends to the water pump body and tensioner bracket.
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11 B-24 4G3 ENGINE - Timing Belt (2) Align the timing mark on the oil pump sprocket with its mating mark. (3) Remove the plug on the cylinder block and insert a Phillips screwdriver [shank diameter 8 mm (.31 in.)] through the hole. If it can be inserted as deep ‘8s 60 mm (2.4 in.) or more, the timing marks are correctly *lioned. If the inserted depth is only 20 to 25 mm (8 to 1 .Odn.), turn the oil pump sprocket one turn and realign the timing marks.
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4G3 ENGINE - Timing Belt (8) Tighten the tensioner attaching nut, then tighten ‘the tensioner attaching bolt. Caution If the bolt is tightened first, tensioner turns as the bolt is tightened, resulting in an excessive belt tension. (9) Hold the center of the tension side span of the timing belt (between the camshaft and oil pump sprockets) between your thumb and index finger as shown. Then, make sure that the clearance between the belt back surface and cover is standard value. Standard value: 12 mm (.
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11 B-26 4G3 ENGINE - Fuel and Emission Parts FUEL AND EMISSION PARTS REMOVAL AND INSTALLATION - 12 Nm 9 ft.lbs. ‘2 4 I ;.: L . 3 19 Nm 14ftJbs. 22 Nm 16 ft.lbs. Removal steps 1. Throttle body assembly 2. Gasket 3. Injector and fuel rail #B4 4. Fuel pressure regulator 5. O-ring 6. Fuel rail 7. Insulator 8. Insulator *A4 9. Injector 10. G-ring 11.
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4G3 ENGINE - Fuel and Emission Parts INSPECTION Yrm7 . . -’ ,. x,r, INJECTORS (1) Using an ohmmeter (circuit tester), test for con&uity between terminals of injector; the circuit should be closed. If failure is detected, replace the injector. Standard value: 13 - 16 n at 20°C (68°F) 6FU192C EGR VALVE (1) Check EGR valve for sticking or carbon deposits. If such conditions exist clean or replace EGR valve. (2) Connect a hand vacuum pump to the nipple of EGR valve and plug the other nipple.
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11 B-28 4G3 ENGINE - Throttle Body THROTTLE BODY DISASSEMBLY AND REASSEMBLY Disassembly steps (I$! #A4 1. Throttle position sensor 2. Idle speed control motor 3. Throttle valve set screw 4. Throttle body OBO 6FU1292 DISASSEMBLY SERVICE POINTS (IAI) THRO-ITLE POSITION SENSOR AND IDLE SPEED CONTROL MOTOR REMOVAL(1) Do not disassemble the sensor an8 motor. (2) Do not immerse in solvent the sensor and motor. Clean them with shop towel.
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4G3 ENGINE - Throttle Bodv QBo THROlTLE BODY REMOVAL (1) Do not remove the throttle valve (2) Check if the vacuum port or b&sage is clog&~& ‘&e compressed air to clean the vacuum passage. Throttle position sensor power supply \ Ground / REASSEMBLY SERVICE POINT I)A4 THROlTLE POSITION SENSOR INSTALLATION (1) Check correct installation of the throttle position sensor.
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11 B-30 463 ENGINE - Intake Manifold INTAKE MANIFOLD REMOVAL AND INSTALLATION 19 Nm 14ft.lbs. 18 Nm 13 ftlbs. 1 5 I 18N‘m 13 ft.lbs. 22’Nm 16 ftlbs. Removal steps 1. Water hose “A” 2. Water hose “B” eB4 3. Engine coolant temperature gauge unit #A4 4. Engine coolant temperature sensor 5. Water outlet fitting 6. Water outlet fitting gasket 7. Thermostat 8. Intake manifold plenum stay 9. Intake manifold plenum IO. Intake manifold plenum gasket 11. Intake manifold stay 12. Engine hanger 13.
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463 ENGINE - Intake Manifold INSTALLATION SERVICE POlNTS I)A4 SEALANT APPLICATION TO EyGlNE Coo&ANT TEMPERATURE SENSOR Specified sealant: 3M Nut Locking Part No. 4171 or equivalent ZEN0219 r)64 SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE GAUGE UNIT Specified sealant: 3M ATD Part No.
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11 B-32 463 ENGINE - Exhaust Manifold and Water Pump EXHAUST MANIFOLD AND WATER PUMP REMOVAL AND INSTALLATION 30 Nm 14 Nm 10 ft.lbs. 14 Nm 10 ft.lbs. Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Exhaust manifold cover “A” 5. Engine hanger 6. Exhaust manifold 7. Exhaust manifold gasket 8. Exhaust manifold cover “B” #A4 9. Water inlet pipe 10. O-ring 11. Water pump 12.
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4G3 O-ring ENGINE - Exhaust Manifold and Water Pump 1 INSTALLATION SERVICE POINT Water pump \ I)A4 WATER INLET PIPE INSTALLATION (with water) to facilitate assembly.” -’ (1) Wet the 0- ring .
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IIB-34 / 4G3 ENGINE - Rocker Arms and Camshaft ROCKER ARMS AND CAMSHAFT REMOVAL AND INSTALLATION 20 Nm 14 ft.lbs. 11 Nm 8 ft.lbs. + 6 Removal steps 1. Breather hose 2. P.C.V. hose 3. Oil seal 4. Rocker cover 5. Gasket 6. Rocker arm and rocker shaft 7. Rear camshaft bearing cap 8. Rocker arm +E4 9. Wave washer *DC 10. Camshaft bearing cap No. 4 11. Rocker shaft spring eD4 12. Camshaft bearing cap No. 3 +D4 13. Camshaft bearing cap No. 2 #C4 14. Right rocker shaft eC4 15. Left rocker shaft 16.
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4G3 ENGINE - Rocker Arms and Camshaft: REMOVAL SERVICE POINT ’ QAQ ROCKER ARM AND ROCKkR SHAFT REMOVAL (1) Mark lash adjusters for installation in the same position. (2) Remove the lash adjuster holders and the lash adjusters. INSPECTION CAMSHAFT (1) Measure the cam height. Standard value: 35.91 mm (j.4138 in.) Limit: 35.41 mm (1.3941 in.) ROCKER ARM (1) Visually check the roller and replace if dent, damage, or seizure is evident. (2) Check roller for smooth rotation.
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11 B-36 463 ENGINE - Rocker Arms and Camshaft (1) Immerse the lash adjuster in cleati diesel fuel. (2) While lightly pushing down inner steel ball using a small wire, move the plunger up and do9 four or five times to bleed air. Use of the Retainer facilitates the aitbleeding of the rocker arm mounted type lash adjuster. i (3) Remove the small wire and press thdplunger. If the plunger is hard to be pushed in, the lash ad&ster is normal.
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4G3 ENGINE - Rocker Arms and Camshaft #B4 LASH ADJUSTER IiUSTALLATlON (1) Dip the lash adjuster in clean diesel fuel. (2) While using a small wire to lightly press the check ball downward, move the plunger up and down four or five times to bleed out the air. 6EN0421 MD99?443-01 (3) Insert the lash adjuster to the rocker arm, being careful not to spill the diesel fuel.
PAGE 100
11 B-38 4G3 ENGINE - Rocker Arms and Camshaft +E4 WAVE WASHER INSTALLATIdN Install the wave washer in correct ‘direction as shown.
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4G3 ENGINE - Cylinder Head and Valves CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION 2 Removal steps (IA~J *E4 1. Cylinder head bolt 2. Cylinder head assembly +ll4 3. Cylinder head gasket OBrJ eC4 4. Retainer lock 5. Valve spring retainer I)B4 6. Valve spring 7. Intake valve (IBI) I)CC 8. Retainer lock 9. Valve spring retainer I)B4 10. Valve spring 11. Exhaust valve (IQ) I)A4 12. Valve stem seal 13. Valve spring seat OCrJ I)A4 14. Valve stem seal 15. Valve spring seat 16. Intake valve guide 17.
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IIB-40 463 ENGINE - Cylinder Head and Valves REMOVAL SERVICE POINTS : OAr) CYLINDER HEAD BOLT REMqVAL (1) Using the special tool, loosen the cylinder head bolts Loosen evenly, little by little. 3EN0185 @s> RETAINER LOCK REMOVAL (1) Store removed valves, springs and other parts, tagged to indicate their cylinder No. and location to aid reassembly. @I) VALVE STEM SEAL REMOVAL (1) Do not reuse removed valve stem seals.
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4G3 ENGINE - Cylinder Head and’valves VALVE (1) Check the valve face for correct contact. If incorrect, reface using a valve refacer. Valve should make a uniform contact with the seat at the center of valve face. (2) If the margin is smaller than the service limit, replace the I ,’ I valve. n Standard value: 1.2 mm (047 in.) Intake 1.5 mm (.059 in.) Exhaust I 6EN054i ! Free height 1 EN0264 Limit: 0.7 mm (028 in.) Intake 1.0 mm (039 in.
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116-42 463 ENGINE - Cylinder Head and Valves VALVE SEAT REPLACEMENT PROCEDURE 0.5 - 1 mm (.02 - .04 in,) (1) Cut the valve seat to be replaced from the inside to thin the wall thickness. Then, remove the valve seat. (2) Rebore the valve seat hole in the cylinder head to a selected oversize valve seat diameter. Seat hole diameter: See “Service Specifications” in page 11 B-6. 0.5-I mm (.02 - .04 in.
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463 ENGINE - Cylinder Head and Valves I)64 VALVE SPRING INSTALLATION (1) Install the valve spring with the painted end on’the.I rocker ’;i .i arm side. Spring retainer Identification color Stem seal Spring seat I)c4 RETAINER LOCK INSTALLATION (1) The valve spring, if excessively compressed, causes the bottom end of retainer to be in contact with, and damage, the stem seal.
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11 B-44 4G3 ENGINE - Cylinder Head and Valves 3EN018E .
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463 ENGINE - Front Case, Oil Pump and Oil Pan FRONT CASE, OIL PUMP AND OIL PAN REMOVAL AND INSTALLATION 4 24 17 Nm 191) Ihc I --16 .ft.lbs. -- 45’Nm 33 ftlbs. Removal steps )M4 1 Oil filter #L4 2. Oil pressure switch eK4 3. Oil pressure gauge unit 4. Oil filter bracket 5. Gasket 6. Drain plug 7 Drain plug gasket 51 n3t-l Y’Y .-v -. -..r--.. 9. Oil screen 10. Oil screen gasket 11. Oil pump cover 12. Oil pump oil seal _-. 3. Oil pump cover gasket 4. Flange bolt 5. Oil pump driven gear 6.
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11 B-46 463 ENGINE - Front Case, Oil Pump and Oil Pan -11 General General ------service tool I REMOVAL SERVICE POINTS OAo OIL PAN REMOVAL :’ (1) Knock the special tool deeply between the oil pan and the cylinder block. (2) Hitting the side of the special tool, slide the special tool along the oil pan to remove it. (80 FLANGE BOLT REMOVAL (1) When loosening the oil pump driven gear flange bolt, first insert a Phillips screwdriver [shank diameter 8 mm (32 in.
PAGE 109
4G3 ENGINE - Front Case, Oil Pump and Oil Pan INSPECTION 3EN0165 SILENT SHAFT (1) Check oil holes for clogging. (2) Check journal for seizure, damage, and contact with bearing. If there is anything wrong with the journal, replace the silent shaft, bearing or front case assembly. ’ (3) Check the silent shaft oil clearance. If the clearance is excessive due to wear, replace the silent shaft bearing, silent shaft or front case assembly. Standard: Right Front 0.02 - 0.06 mm (.OOOS - .0024 in.) Rear 0.05 - 0.
PAGE 110
II B-48 4G3 ENGINE - Front Case, Oil Puma and Oil Pan (4) Set the special tool on the guide pints and drive the bearing into the cylinder block. 3EN017C +c4 CRANKSHAFT OIL SEAL INSTALLATION (1) Using the special tool, install the crankshaft oil seal into the front case. I)D4 Sotket wrench SILENT SHAFT OIL SEAL INSTALLATION (1) Using a socket wrench, press-in the silent shaft oil seal into the front case. nt case 3EN019.
PAGE 111
4G3 ENGINE - Front Case, Oil Pump and Oil Pan I)F4 OIL PUMP DRIVEN GEAR / OIL PUMP DRIVE INSTALLATION GEAR (1) install the oil pump drive gear and driven gear to the front case, lining up the timing marks. Lubricate the gears with engine oil. #G4 FLANGE BOLT INSTALLATION (1) Insert a Phillips screwdriver [shank diameter 8 mm (32 in.) into the plug hole on the left side of cylinder block to block the silent shaft, then tighten the flange bolt.
PAGE 112
IIB-50 463 ENGINE - Front Case, Oil Pump and Oil Pan, +J4 O I L P A N I N S T A L L A T I O N (1) Clean mating surfaces of both oil pan and cylinder block. (2) Apply a 4 mm (.I6 in.) diameter beqd of sealant to the oil pan flange. ri , Specified sealant: MITSUBISHI GENUINE Part “No. MD970389 or equivalent (3) The oil pan should be installed withi; 15 minutes after the application of sealant.
PAGE 113
4G3 ENGINE - Front Case, Oil Pump and Oil Pan I)M4 OIL FILTER INSTALLATION (1) Clean the installation surface of the filter bracket side. (2) Apply engine oil to the 0-ririg of ihe, bil filter: ‘,*“” ; ’ (3) Screw the oil filter on until the O-ring contacts the base. Then tighten one turn.
PAGE 114
11 B-52 4G3 ENGINE - Piston and Connecting Rod PISTON AND CONNECTING ROD REMOVAL AND IhJSTALLATlON 6 7 8 Removal steps 1. Nut c$Ar) I)E4 2. Connecting rod cap 3. Connecting rod bearing *II4 4. Piston and connecting rod 5. Connecting rod bearing )Cg 6. Piston ring No. 1 eC4 7. Piston ring No. 2 )BC 8. Oil ring c)Brj +A4 9. Piston pin 10. Piston 11. Connecting rod 12.
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463 ENGINE - Piston and Connecting Rod REMOVAL SERVICE POINTS OAo CONNECTING ROD CAP REMOVAL (1) Mark the cylinder number on the side of the connecting rod big end for correct reassembly. inder No. DENOOM Rear support . OBo PISTON PIN REMOVAL m Anvil Stop plug rernked ’ (1) Remove the piston and connecting rod using the special tools (MD998184-01). (2) Assemble set components on a press, with the press plates under the base.
PAGE 116
11 B-54 4G3 ENGINE - Piston and Connecting Rod INSPECTION PISTON (1) Replace the piston if scratches or seizure is evident on its surfaces (especially the thrust surfa$e). Replace the piston if it is cracked. ? PISTON PIN ; (1) Insert the piston pin into the piston #in hole with a thumb. You should feel a slight resistance. Replace the piston pin if it can be easily inserted or there it an excessive play. (2) The piston and piston pin must be replaced as an assembly.
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463 ENGINE - Piston and Connecting Rod REASSEMBLY SERVICE POINTS I)A4 PISTON PIN INSTALLATION (1) Install the piston and connecting rod as follows, using the special tools (MD9981 84-01). (2) Thread the stop plug approximately half way into the bottom of the receiving tube. (3) Select the piston pin guide that will pass through the piston and the connecting rod. Install spring, spacer, and guide into the receiving tube.
PAGE 118
11 B-56 4G3 ENGINE - Piston and Connecting Rod (2) To install the side rail, first place~_one end in the gap between the groove and the spac&. While holding the end firmly, press the portion to be inserted with finger as illustrated until the side rail is in i position. Endof side rail Caution Do not use piston ring expander td install the side rail. 1 EN0269 \ 7EN045i I)c4 PISTON RING NO. 2 / P I S T O N R I N G N O . 1 _. INSTALLATION (I) Using a piston ring expander, fit No. 2and then No.
PAGE 119
463 ENGINE - Piston and Connecting Rod #E4 CONNECTING ROD CAP INSTALLATION (I) Verifying the mark made during disassembly ins@4 the bearing cap to the connecting r’od. If the con&c&$/?&! is new with no index mark, make sure that the bearing locking notches come on the same side as shown. Notches DEN0051 (2) Make sure that connecting rod big end side clearance meets the specification. Standard value: 0.10 - 0.25 mm (.0039 - .0098 in.) Limit: 0.4 mm I.016 in.
PAGE 120
II B-58 463 ENGINE - Crankshaft, Flywheel and Drive Plate CRANKSHAFT, FLYWHEEL AND DRIVE PLATE REMOVAL AND INSTALLATION 135 Nm 88 ftlbs. I Il’Nm 8 ftlbs. t \ 9Nm 7 ft.lbs. \ 135 Nm 98 ft.lbs. b 6 38 ft.lbs. Removal steps 1. Flywheel bolt For MIT 2. Flywheel 3. Drive plate bolt 4. Adaptor plate For AIT 5. Drive plate 6. Crankshaft bushinn 7. Rear plate -’ 8. Bell housing cover 9. Oil seal case 10. Gasket *C4 11. Oil seal 12. Bearing cap bolt eB4 13. Bearing cap *A4 14. Crankshaft bearing, lower 15.
PAGE 121
4G3 ENGINE - Crankshaft, Flywheel and Drive Plate INSPECTION CRANKSHAFT JOURNAL OIL CLEARANCE (PiASTIC GAUGE METHOD) (1) Remove oil from crankshaft journal and crankshaft bearing. (2) install the crankshaft. (3) Cut the plastic gauge to the same length as the width of bearing and place it on journal in parallel with its axis. 6EN055C 1 (4) Install the crankshaft bearing cap carefully and tighten the bolts to the specified torque. (5) Carefully remove the crankshaft bearing cap.
PAGE 122
11 B-60 463 ENGINE - Crankshaft, Flywheel and Drive Plate CYLINDER BORING (1) Oversize pistons to be used should be determined on the basis of the largest bore cylinder. . Piston size identification ’ I Size Piston O.D. “A” 6EN0554 0.25 mm (.Ol in.) O.S. 0.50 mm (.02 in.) O.S. 0.75 mm (.03 in.) O.S. 1.00 mm (.04 in.) O.S. I Ideitification m a r k 1 ‘. ‘” 0.25 0.50 0.75 1 .oo NOTE Size mark is stamped on the piston top. (2) Measure outside diameter of piston to be used.
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4G3 ENGINE - Crankshaft, Flywheel and Drive Plate I)B4 BEARING CAP INSTALLATION Cao No. (1) Install according to the front mark and cap No. i Timing belt side - Cap No. Front a mark 3EN013E (2) After installing the bearing caps, make sure that the crankshaft turns smoothly and the end play is correct. If the end play exceeds the limit, replace the crankshaft bearings. Standard value: 0.05 - 0.18 mm (.0020 - .0071 in.) Limit: 0.3 mm’ (.012 in.
PAGE 124
MB-62 463 ENGINE - Bracket BRACKET REMOVAL AND INSTALLATION 65 Nm 47 ft.lbs. 120 Nm 67 ft.lbs. 65’Nm 47 ftlbs. 1. Exhaust pipe support bracket 2. Engine support bracket, right 3. Roll stopper bracket, front 4.
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ENGINE 4G61, 4663, 4664 <1992> CONTENTS BRACKET . . . . . . . . . . . . . . . . . . . . .,. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 CAMSHAFTS AND ROCKER ARMS - DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 CRANKSHAFT, FLYWHEEL AND DRIVE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 CYLINDER HEAD AND VALVES - SOHC . . . . . . . .
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IIC-2 466 ENGINE <1992> - General Information GENERAL INFQRMATION I ENGINE SECTIONAL VIEW - SOHC 6EN0313 TSB Revision .
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4G6 ENGINE <1992> - General Information 6EN0314 TSB Revision I
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IIC-4 466 ENGINE <1992> - General Information ,NGlNE SECTIONAL VIEW - DOHC TSB Revision
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6EN0244 TSB Revision \
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IIC-6 466 ENGINE <1992> - General Information ENGINE LUBRICATION SYSTEM - SOHC Rocker shaft \ Camshaft Oil pressure switch \ rankshaft 6LUOO39 ENGINE LUBRICATION SYSTEM - DOHC Camshaft Oil cooler Oil cooler by-pass valve Silent shaft&I) lressure switch Crankshaft Oil puml ’ I1 t- A/ ‘Silent shaft 6LUOO55 TSB Revision I -
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4G6 ENGINE <1992> - General Information ENGINE LUBRICATION SYSTEM DOHC-TURBO - To turbocharger Camshaft ee Silent shaft From thermostat case n Oil filter K Oil cooler / \ To water inlet41 pipe i I EIe + I! IJ , Key= Oil pressure sw&h Oil pump / -7 (k,/ ‘Silent shaft Crankshaft 6LUOW6 1 TSB Revision 1
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IIC-8 -4G6 ENGINE <1992> - General Specifications GENERAL SPECIFICATIONS 4G63 SOHC Type In-line OHV, SOHC 4 Compact type 1,997 (121.9) 85 (3.35) 88 (3.46) 8.5 Number of cylinders Combustion chamber Total displacement cm3 (cu. in.) Cylinder bore mm (in.) Piston stroke mm (in.
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4G6 ENGINE <1992> - General Specifications 1 TG9 4661 DOHC Type In-line OHV, DOHC 4 Number of cylinders Combustion chamber cm3 (cu. in.) Total displacement Cylinder bore mm (in.
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IIC-10 4G6 ENGINE <1992> - Service Specifications SERVICE SPECIFICATIONS mm (in.) Cylinder head - SOHC Flatness of gasket surface Grinding limit of gasket surface * Total resurfacing depth of both cylinder head and cylinder block. Overall height Oversize rework dimensions of valve guide hole (both intake and exhaust) 0.05 (.002) 0.25 (.OlO) 0.50 (.020) Oversize rework dimensions of intake valve seat ring hole 0.30 f.012) 4G63 4G64 0.
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466 ENGINE <1992> - Service Specification3 IWwl mm (in.) Standard Camshaft - SOHC Identification mark: D Cam height Identification mark: AR Cam height ., ;J’ _. Intake Exhaust 42.40 (1.6693) 42.40 (1.6693) 41’.90 (1.6496) 41.90 (1.6496) Intake Exhaust 44.53 (1.7531) 44.53 (1.7531) 44.03 (1.7335) 44.03 (1.7335) NOTE: The camshaft identification mark is stamped on the rear end of the camshaft. Fuel pump driving cam diameter Journal diameter Oil clearance 38 (1.50) 33.94 - 33.95 (1.3362 - 1.
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IIC-12 466 ENGINE c1992> - Service Specifications mm (in.) Limit Standard Valve - SOHC Overall length Intake Exhaust Stem diameter Face angle Thickness of valve head (margin) Stem-to guide clearance Valve - DOHC Overall length Stem diameter Face angle Thickness of valve head (margin) Stem-to guide clearance 4663 4664 4G63 4664 Intake Exhaust F i 0.7 (02%) 1.5 (.059) Intake Exhaust 1.2 (047) 2.0 (.079) Intake Exhaust 0.02 - 0.06 (.OOO%- .0024) 0.05 - 0.09 (0020 - .
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4G6 ENGINE <1992> - Service Snebifications mm (in.) Standard Valve guide - DOHC Overall length Limit 45.5 (1.791) 50.5 (1.988) 6.60 - 6.62 (.2598 - .2606) 12.06 - 12.07 (.4748 - .4752) 0.05 (.002), 0.25 (.OlO), 0.50 (.020) over size Room temperature I.D. O.D. Service size Press-in temperature Va Ive seat Seat angle Valve contact width Sinkage Service size 43”30’ - 44” 0.9 - 1.3 (.035 - .051) 0.2 (.OO%) 0.3 (.012), 0.6 (.024) over size Silent shaft Journal diameter 41.96 - 41.98 (1.6520 - 1.6528) 40.
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466 ENGINE <1992> - Service Specifications mm (in.) Piston ring - SOHC End gap Ring-to-ring groove clearance Standard Limit No. 1 ring No. 2 ring 4663 4664 Oil ring 0.25 - 0.40 LOO98 - .0157) 0.8 (031) 0.20 - 0.35 LOO79 - .0138) 0.20 - 0.40 LOO79 - .0157) 0.20 - 0.70 LOO79 - .0276) 0.8 (.031) 0.8 (.031) 1 .o (.039) No. 1 ring No. 2 ring 0.03 - 0.07 LOOI 2 - .0028) 0.02 - 0.06 (.OOO% - .0024) 0.25 (.OlO), 0.50 (.020), 0.75 (.030), 1 .OO (.039) over size 0.1 (.004) 0.1 (004) No. 1 ring No.
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466 ENGINE t1992> - Service Sbecifications .’ mm (ir _’ Standard Cylinder block Cylinder I.D. 4G61 4663 4664 82.30 - 82.33 (3.2402 - 3.2413) 85.00 - 85.03 (3.3465 - 3.3476) 86.50 - 86.53 (3.4055 - 3.4067) 0.05 (0020) Flatness of gasket surface Grinding limit * Total resurfacing depth of both cylinder head and cylinder block. Overall height 4G61 4663 4G64 274.9 - 275.1 (10.823 - 10.831) 283.9-284.1 (11.177-11.185) 289.9-290.1 (11.413-11.421) Oil pump Side clearance Drive gear Driven gear 0.08 - 0.
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IIC-16 4G6 ENGINE <1992> - Torque Specifications TORQUE SPECIFICATIONS Generator and ignition system - SOHC Cooling fan bolt Water pump pulley bolt - Engine without cooling fan Water pump pulley bolt - Engine with cooling fan Generator brace bolt Generator mounting bolt Generator pivot nut Crankshaft pulley bolt Spark plug Distributor nut Nm ft.1b.s.
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IIC-17 4G6 ENGINE <1992> - Toraue SDecifications Nm ftlbs. Fuel and emission parts EGR valve bolt Throttle body stay nut - DOHC Throttle body bolt - SOHC Throttle body bolt - DOHC Fuel pressure regulator bolt Fuel rail bolt 19 19 12 19 9 12 14 14 9 14 7 9 Throttle body Throttle position sensor bolt Idle speed control motor bolt Idle air control motor bolt 2 3.5 3.5 1.4 2.5 2.
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IIC-18 466 ENGINE <1992> - Torque Specifications ftlbs.
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1 IC-19 4G6 ENGINE <1992> - Torque Specifications / Sealant Bracket Left and right engine support bracket bolt Roll stopper bracket bolt, front Roll stopper bracket bolt, rear Engine support bracket bolt, front Exhaust pipe support bracket bolt Nm ft.lbs.
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11 c-20 466 ENGINE <1992> - Special Tools SPECIAL TOOLS Tool Number and tool name Supersession Application MB990767 End yoke holder Use with MD9987 19 M 8990767-01 Use with MIT308239 Holding camshaft spr&ket when loosening or torquing bolt.
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4G6 ENGINE <1992> - Special Tools MD998713 Camshaft oil seal installer MD998713-01 MD99871 9 Pulley holding pins (2) M IT308239 Removal of oil pan MD998727 Oil pan remover MD998729 Valve stem seal installer Holding camshaft sprocket when loosening or torquing bolt For SOHC engine only MD998729-01 TSB Revision Installation of valve stem seal For SOHC engine only
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IIC-22 4G6 ENGINE <1992> - Special Tools Holding silent shaft sprocket M D998779 Sprocket stopper MD998780 Piston pin setting tool M IT2 16941 MD998781 Flywheel stopper TSB Revision Removal and installation of piston pin Holding flywheel
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466 ENGINE <1992> - Generator and Ignition System - SOHC 1 IC-23 GENERATOR AND IGNITION SYSTEM - SOHC REMOVAL AND INSTALLATION 25 Nm 14 Nm lOft.lbs. -1 0Q I 23 Nm !!!?a R W D 17 ft.lbs. I 14 Nm 10 ftlbs. I 24 Nm 17 ftlbs. 4 5 I 9 Nm** 7 ftlbs. 11 Nm*** 8 ft.lbs. Removal steps *B4 1. Drive belt 2. Cooling fan*** 3. Fan clutch*** 4. Water pump pulley” 5. Water pump pulley 6. Generator brace 7. Generator 8. Crankshaft pulley 9. Spark plug cable 10. Spark plug 11. High tension cable *A4 12.
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1 IC-24 466 E N G I N E <1992> - Generator and Ignition System - SOHC INSTALLATION SERVICE ,POINTS r)A4 DISTRIBUTOR INSTALLATION (1) Align the marks put at the time of disassembly, and install the gear to the distributor shaft. (2) When aligning the driven gear’s mating mark and the housing’s mating marks, make the combination so that notch “A” at the shaft end is at the position shown in the figure, and then align the spring pin holes and drive in a new spring pin.
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4G6 ENGINE <1992> - Generator and Ignition Svstem - SOHC Water pulley Crankshaft pulley 6EN0593 /‘, Water pump pulley 1 ICE-25 BRACE BOLT TYPE (1) Move the generator to adjust the belt deflection to the standard value. Standard value: V-ribbed type belt New belt 7.5 - 9.0 mm (.30 - .35 in.) Used belt 8.0 mm (.32 in.) V-type belt 7.0 - 10.0 mm (.28 - .39 in.) When using a tension gauge for V-ribbed belt only. Standard value: New belt 500 - 700 N (110 - 154 Ibs.) Used belt 400 N (88 Ibs.
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11 C-26 4G6 ENGINE <1992> - Generator and Ignition System - DOHC GENERATOR AND IGNITION SYSTEM - DOHC REMOVAL AND INSTALLATION 18 ft.lbs. 19 Nm 14 ftlbs. 5 23 Nm I 14 Nm 10 ft.lbs. 24 Nm 17 ftlbs. I 11 11 Nm 8 ft.lbs. 24 Nm 17 ftlbs. Removal steps eB4 1. Drive belt 2. Water pump pulley 3. Water pump pulley (For driving power steering pump) 4. Generator brace 5. Generator 6. Crankshaft pulley 7. Center cover 8.-Spark plug cable 9. Spark plug 10. Ignition coil 11. Ignition power transistor #A4 12.
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466 ENGINE <1992> - Generator and Ignition System - DOHC IIC-27 INSTALLATION SERVICE POINTS #A4 CRANKSHAFT POSITION INSTALLATION (1) Turn the crankshaft so that the No. 1 cylinder is at top dead center. (2) Align the punch mark on the crankshaft position sensor housing with the notch in the plate. (3) Install the crankshaft position sensor on the cylinder head. eB4 DRIVE BELT TENSION ADJUSTMENT Refer to “I)B4 DRIVE BELT TENSION ADJUSTMENT” on page 11 C-24.
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11 C-28 4G6 ENGINE <1992> - Timing Belt - SOHC TIMING BELT - SOHC REMOVAL AND INSTALLATION 18 EE Nm 1” . . . . . 40 ft.lbs. i” F 87 ---ft.lbs. --~~~ Removal steps 1. Timing belt front upper cover 2. Timing belt front lower cover (IAI) eH4 3. Timing belt #Gg 4. Tensioner spring *Gg 5. Tensioner QBg eF4 6. Oil pump sprocket 81: $E4 7. Crankshaft bolt 8. Crankshaft sprocket 9. Flange 10. Tensioner “B” c$ErJ eD4 11. Timing belt “B” (IFI) #C4 12. Silent shaft sprocket, right #B4 13. Spacer 14.
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4G6 ENGINE <1992> - Timing Belt - S O H C IIC-29 REMOVAL SERVICE POINTS QAo TIMING BELT REMOVAL (1) Mark the belt running direction for reference in reinstallation. NOTE (1) Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and water. These parts should not be washed. Replace parts if seriously contaminated.
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4G6 ENGINE <1992> - Timing Belt - SOHC (IF0 SILENT SHAFT SPROCKET REMOVAL QGt) CRANKSHAFT SPROCKET “B” REMOVAL aHo CAMSHAFT SPROCKET BOLT REMOVAL INSPECTION TIMING BELT Replace belt if any of the following conditions exist. (1) Hardening of back rubber - the back side is glossy without resilience and leaves no indent when pressed with fingernail. \ 00 B 000 & 8EN006Z (2) (3) (4) (5) Peeling Cracks Cracks 1 EN0249 1 TSB Revision Cracks Cracks Cracks Cracks on rubber back. or peeling of canvas.
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4G6 ENGINE <1992> - Timing Belt - SOHC 1 IC-31 (6) Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife. Roundededge Abnormal wear (Fluffy strand) 8EN006; (7) Abnormal wear on teeth. (8) Missing tooth.
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11 C-32 466 ENGINE <1992> - Timing Belt - S O H C +D4 TIMING BELT “B” ‘INSTALLATION (1) Align timing marks on the crankshaft sprocket “B” and silent shaft sprocket with the marks on the front case respectively. (2) Install the timing belt “B” on the crankshaft sprocket “B” and silent shaft sprocket. There should be no slack on the tension side. (3) Make sure that the relationship between the tensioner pulley center and the bolt center is as shown in the illustration. Center of yx \ tensioner m P,...
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1 IC-33 4G6 ENGINE <1992> - Timing Belt - SOHC I)F4 OIL PUMP SPROCKET INSTALLATION (1) Insert a Phillips screwdriver [shank diameter 8 mm (31 in.)] through the plug hole on the left side of the cylinder block to block the left silent shaft. (2) Install the oil pump sprocket. (3) Apply an appropriate amount of engine oil to the bearing surface of the nut. (4) Tighten the nut to the specified torque.
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IIC-34 4G6 ENGINE <1992> - Timing Belt - SOHC 6EN0563 6EN0564 (3) Remove the plug on the cylinder block and insert a Phillips screwdriver [shank diameter 8 mm (.31 in.) ] through the hole (Engine with silent shafts). If it can be inserted as deep as 60 mm (2.4 in.) or more, the timing marks are correctly aligned. If the inserted depth is only 20 - 25 mm (.8 - 1.0 in.), turn the oil pump sprocket one turn and realign the timing marks. Then check to ensure that the screwdriver can be inserted 60 mm (2.
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4G6 ENGINE <1992> - Timinn Belt - SOHC 1 tc-35 (8) Tighten the tensioner attaching bolt, then tighten the tensioner spacer. Caution If the tensioner spacer is tightened first, the tensioner turns as the tensioner spacer is tightened, resulting in an excessive belt tension. i - (9) Hold the center of the tension side span of the timing belt (between the camshaft and oil pump sprockets) between your thumb and index finger as shown.
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WC-36 4G6 ENGINE <1992> - Timing Belt - DOHC TIMING BELT - DOHC REMOVAL AND INSTALLATION 3Nm 2.2 ft.lbs. -fl *? A 24 I '25 e 1 87ft.lbs. NO TE * : Engine without silent shafts ** Engine with silent shafts TSB Revision Removal steps 1. Timing belt front upper cover 2. Timing belt front lower cover (IAIJ eK4 3. Timing belt eJ4 4. Tensioner pulley 5. Tensioner arm #I4 6. Auto tensioner 7. Idler pulley (~Brj +H4 8. Oil pump sprocket $I$ eG4 9. Crankshaft sprocket bolt 10. Crankshaft sprocket 11.
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466 ENGINE <1992> - Timing ,Felt - DOHC IIC-37 REMOVAL SERVICE POINTS OAi) TIMING BELT REMOVAL (1) Make a mark on the back of the timing belt indicating the direction of rotation so that it may be reassembled in the same direction if it is to be reused. NOTE (1) Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and water. These parts should not be washed. Replace parts if seriously contaminated.
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1 IC-38 4G6 ENGINE <1992> - Timing Belt - DOHC OF0 QGo SILENT SHAFT SPROCKET REMOVAL CRANKSHAFT SPROCKET “B” REMOVAL (IHO CAMSHAFT SPROCKET REMOVAL (1) Using a wrench, hold the camshaft at its hexagon (between the No. 2 and No. 3 journals) and remove the camshaft sprocket bolt. Caution Locking the camshaft sprocket with a tool damages the sprocket. (2) Remove the camshaft sprockets. INSPECTION TIMING BELTS Refer to “INSPECTION” on page 1 IC-29.
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4G6 ENGINE <1992> - Timina Belt - D O H C IX-39 AUTO TENSIONER (1) Check the auto tensioner for possible leaks and replace as necessary. (2) Check the rod end for wear or damage and replace as necessary. (3) Measure the rod protrusion. If it is out of specification, replace the auto tensioner. Standard value: 12 mm (.47 in.) 12mm ( 47 in.) a 0 1 0 0 ‘il; 6EN0161 I (4) Clamp the auto tensioner in a vise with soft jaws. Caution The plug protrudes at the bottom of the auto tensioner.
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11 c-40 4G6 ENGINE <1992> - Timing Belt - DOHC I)B4 SEALANT APPLICATION ON SEMI-CIRCULAR PACKING Specified sealant: 3M ATD Part No. 8660 or equivalent Apply sealant ‘: ::.:.. . . -.-.*...a. . . . . . . . . . . . . . . . ....::::::::.:.:.:.:.:.:.. ..*.-.-.*,*.d 1 DEN0052 3EN0044 ec4 SEALANT APPLICATION ON ROCKER COVER Apply sealant to the areas indicated in the illustration. Specified sealant: 3M ATD Part No. 8660 or equivalent Apply sealant I IOmm f.39 in.
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4G6 ENGINE <1992> - Timing Belt - D O H C 1 x-47 I)04 SPACER INSTALLATION (ENGINE WITH SILENT SHAFTS) Refer to “eB4 SPACER INSTALLATION” on page 11 C-31. r)E$ SILENT SHAFT SPROCKET INSTALLATION I)F+ TIMING BELT “B” INSTALLATION (ENGINE WITH SILENT SHAFTS) Refer to Page 11 C-32. Note that the timing mark locations differ from those on the single camshaft engine. I)G+ CRANKSHAFT BOLT INSTALLATION (1) Using the special tool, hold the drive plate or flywheel. (2) Install the crankshaft bolt.
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11 C-42 466 ENGINE <1992> - Timing Belt - DOHC 1)14 AUTO TENSIONER INSTALLATION (1) If the auto tensioner rod is in its fully extended position, reset it as follows. (2) Clamp the auto-tensioner in the vise with soft jaws. Caution The plug protrudes at the bottom of the auto tensioner. Insert a plain washer as illustrated to prevent the plug from being in direct contact with the vise.
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466 ENGINE <1992> - Timina Belt - D O H C r)K4 Camshaft sprocket 1 IC-43 TIMING BELT INSTALLATION (I) Turn the two sprockets so that their dowel pins are located on top. Then, align the timing marks facing each other with the top surface of the cylinder head. When you let go of the exhaust camshaft sprocket, it will rotate one tooth in the counterclockwise direction. This should be taken into account when installing the timing belt on the sprockets.
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4G6 ENGINE <1992> - Timing Belt - DOHC. (5) Thread the timing belt over the intake side camshaft sprocket and fix it at indicated position by a clip. (6) Thread the timing belt over the exhaust side sprocket, while aligning the timing marks with the cylinder head top surface using two wrenches. (7) Fix the belt at indicated position by a clip. (8) Thread the timing belt over the idler pulley, the oil pump sprocket, the crankshaft sprocket and the tensioner pulley in the order shown.
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4G6 ENGINE <1992> - Timing Belt - DOHC IIC-45 (14)lnstall the special tools, Socket Wrench and Torque Wrench, on the tensioner pulley, and loosen the tensioner pulley center bolt. NOTE If the special tool is not available, use a commercially available torque wrench that is capable of measuring 0 - 3 Nm (0 - 2.2 ftlbs.). (15)Torque to 2.6 - 2.8 Nm (1.88 - 2.03 ft.lbs.) with the torque wrench.
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11 C-46 4G6 ENGINE <1992> - Fuel and Emission Control Parts FUEL AND EMISSION CONTROL PARTS REMOVAL AND INSTALLATION - SOHC for GALANT/EXPO P- I 4 12 Nm 9 ft.lbs 7 12 Nm 9 ftlbs. 9Nm 7 ft.lbs. P 6 19 Nm 14 klbs. Removal steps I. Throttle body 2. Throttle body gasket 3. EGR valve 4. EGR valve gasket 5. Injectors and fuel rail 6. Insulator 7. Fuel pressure regulator #B4 8. O-ring 9. Insulator #A4 IO. Injectors 11. O-ring 12. Grommet 13.
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466 ENGINE <1992> - Fuel and Emission Control Parts IIC-47 REMOVAL AND INSTALLATION - SOHC for TRUCK 12 Nm 9 ft.lbs. I - - - - 5 12 Nm 9 ft.lbs. 9Nm 7 ft.lbs. 19Nm 14 ft.lbs. Removal steps 1. Throttle body 2. Throttle body gasket 3. EGR valve 4. EGR valve gasket 5. Injectors and fuel rail 6. Insulator 7. Fuel pressure regulator )B4 8. O-ring 9. Insulator *AC 10. injectors 11. O-ring 12. Grommet 13.
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11 C-48 4G6 ENGINE <1992> - Fuel and Emission Control Parts IEMOVAL AND INSTALLATION - DOHC 12 Nm 9 ft.lbs. 19 Nm 14 ftlbs. 8 19Nm 14 ft.lbs. Removal steps 1. Throttle body stay 2. Throttle body 3. Throttle body gasket 4. EGR valve 5. EGR valve gasket 6. Injectors and fuel rail 7. Insulator 8. Fuel pressure regulator $B4 9. O-ring 10. Insulator )A4 II. Injectors 12. O-ring 13. Grommet 14.
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466 ENGINE <1992> - Fuel and Emission Control Parts IX-49 INSPECTION EGR VALVE (1) Check EGR valve for sticking or carbon deposits. If such conditions exist, clean or replace EGR valve. (2) Connect a hand vacuum pump to the nipple of EGR valve and plug other nipple. (3) Apply a vacuum of 500 mmHg (19.7 in. Hg) to make sure that a vacuum is maintained. If there is a leak, replace the EGR valve. In addition, check the valve for its opening and closing by applying and removing a vacuum.
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11 c-50 4G6 ENGINE <1992> - Throttle Body THROTTLE BODY DISASSEMBLY AND REASSEMBLY SOHC for EXPO Disassembly steps 1. Accelerator wire bracket @8 *A4 2. Throttle position sensor 3. Idle air control motor 4. Throttle valve set screw 5. Throttle body OBO 1.4 ft.lbs. 6FU1657 SOHC for GALANT/TRUCK 3.5 Nm 2.5 ft.lbs. 2Nm 1.4 ft.lbs. Disassembly steps $@ *A4 1. Throttle position sensor 2. Idle speed control motor 3. Throttle valve set screw 4.
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4G6 ENGINE <1992> - Throttle Body IIC-51 DOHC 2Nm 1.4ft.lbs. 5 Disassembly steps (IAI) *AC I. Throttle position sensor 2. Idle air control motor (stepper motor) OAO 3. Closed throttle position switch 4. Adjusting nut 5.
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11 C-52 4G6 ENGINE <1992> - Throttle Bodv DISASSEMBLY SERVICE POINTS QAo THROTTLE POSITION SENSOR AND IDLE AIR/ SPEED CONTROL MOTOR REMOVAL (1) Do not disassemble the sensor and motor. (2) Do not immerse the sensor and motor in cleaning solvent. Clean them with shop towel. ~BI) THROTTLE BODY REMOVAL (1) Do not remove the throttle valve. (2) Check if the vacuum port or passage is clogged. Use compressed air to clean the vacuum passage.
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4G6 ENGINE <1992> - Throttle Bodv 7FUO295 position sensor connector 6FU125i Idle speed control (3) Holding the idle air control motor as shown in the illustration, connect the negative 0 terminal of the power supply to each clip as described in the following steps, and check whether or not a vibrating feeling (a feeling of very slight vibration of the stepper motor) is generated as a result of the activation of the stepper motor.
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1 IC-54 466 ENGINE <1992> - Throttle Body REASSEMBLY SERVICE POINTS I)A4 THROTTLE POSITION SENSOR INSTALLATlON SOHC FOR EXPO (1) Install the throttle position sensor to the throttle body as shown in the illustration. (2) Turn the throttle position sensor 90” counterclockwise to set it in position and tighten the screws.
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466 ENGINE <1992> - Throttle Bodv IlC-55 (2) Turn the throttle position sensor 90” clockwise to set it and tighten the screws. I Throttle position sensor power round (3) Connect a circuit tester between @ (ground) and @ (output), or between @ (output) and @ (power). Then, make sure that the resistance changes smoothly when the throttle valve is slowly moved to the fully open position.
PAGE 180
11 C-56 466 ENGINE <1992> - Intake Manifold INTAKE MANIFOLD REMOVAL AND INSTALLATION - SOHC (RWD) 18 Nm 13 ftlbs. (FWD) 9 18 Nm .- ._... 14ttlbs. \ \ “w-4 ‘\ 30 Nm 22 ft.lbs. T34 18 Nrn 13 ftlbs. u wrn Ilklm 8 ftlbs. 18 Nm 13 ftlbs. 13 ftlbs. 11 2iNm 16 ft.lbs. Removal steps 1. Water hose 2. Water hose efl4 3. Engine coolant temperature gauge unit *Cg 4. Engine coolant temperature sensor 5. Water outlet fitting eB4 6. Gasket 7. Thermostat 8. Intake manifold plenum stay 9.
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IIC-57 4G6 ENGINE <1992> - Intake Manifold {EMOVAL AND INSTALLATION - DOHC (TO turbocharger) ;Xzr, ,, Nm 4 i - 8 ft.lbs. eg Li (To oil cooler) Q d Removal steps 1. Water hose 2. Water hose 3. Water hose (turbo) 4. Water hose (turbo) *DC 5. Engine coolant temperature gauge unit #Q 6. Engine coolant temperature sensor 7. Water outlet fitting +fl4 8. Gasket 9. Thermostat 10. Thermostat case 11. Gasket 20 ftlbs. 12. Intake manifold stay +A4 13. Intake manifold 14.
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11 C-58 4G6 ENGINE <1992> - Intake Manifold INSTALLATION SERVICE POINTS *A4 INTAKE MANIFOLD INSTALLATION - DOHC (1) Tighten the intake manifold bolts. Note that the bolts installed at the locations indicated in the illustration are tightened to a different torque. 6lNOO49 eB4 WATER OUTLET FITTING GASKET INSTALLATION (FOR RUBBER COATED METAL GASKET ONLY) (1) Install the water outlet fitting gasket with its “UP” mark facing up (toward the water outlet fitting side).
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4G6 ENGINE <1992> - Exhaust Manifold and Water Pumn EXHAUST MANIFOLD AND WATER PUMP REMOVAL AND INSTALLATION - SOHC 14 Nm* 10 ftlbs. 18 Nm 13 ft.lbs. 14 Nm 10 ft.lbs. 24Nm 17 ft.lbs. Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Heat protector 5. Engine hanger 6. Exhaust manifold 7. Exhaust manifold gasket #A4 8. Water inlet pipe +A4 9. O-ring 10. Water pump 11.
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11 C-60 466 ENGINE <1992> - Exhaust Manifold and Water Pump IEMOVAL AND INSTALLATION - DOHC FOR NON-TURBO 28 Nm 20 ftlbs. I 14 Nm 10 ft.lbs. 10 ft.lbs. 4 60 Nm 43 ftlbs. 14 Nm 10 ft.lbs. 4 24 Nm 17 ft.lbs. Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Heat protector “A” 5. Heat protector “B” 6. Engine hanger 7. Exhaust manifold 8. Exhaust manifold gasket +A4 9. Water inlet pipe )A4 10. O-ring 11. Water pump 12.
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4G6 ENGINE <1992> - Exhaust Manifold and Water Pump 1 X-61 IEMOVAL AND INSTALLATION - DOHC TURBO 43Nm 31 ft.lbs. 14 Nm 60 43 - 11 Nm 8 ftlbs. 14 Nm 10 ft.lbs. 16 43Nm 6 24 Nm 17 ft.lbs. 9Nm 7 ft.lbs. Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Heat protector “A” 5. Heat protector “B” 6. Exhaust fitting 7. Gasket 8. Air outlet fitting 9. Gasket I 0. Water pipe “B” 11. Oil return pipe 12. Gasket 13. Turbocharger assembly 14. Gasket TSB Revision 15. Ring 16. Oil pipe 17.
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11 C-62 4G6 ENGINE <1992> - Exhaust Manifold and Water Pump INSTALLATION SERVICE POINT I)A4 WATER PIPE/O-RING INSTALLATION O-ring (1) Wet the O-ring (with water) to facilitate assembly Caution Keep the O-ring free of oil or grease.
PAGE 187
4G6 ENGINE <1992> - Turbocharger 1 K-63 TURBOCHARGER DISASSEMBLY AND REASSEMBLY Disassembly steps inspection of turbocharger waste gate W4 actuator operation 1. Snap pin 2. Turbocharger waste gate actuator +E4 3. Coupling *DC 4. Turbine housing *C4 5. Snap ring eB4 6. Turbine wheel assembly 7. Compressor cover +A4 8.
PAGE 188
11 C-64 4G6 ENGINE <1992> - Turbocharger INSPECTION 6lN0055 Comr, whekl 3EN020E TURBINE HOUSING (1) Check the housing for traces of contact with the turbine wheel, cracks due to overheating, pitching, deformation and other damage. Replace with a new turbine housing if cracked. (2) Operate the waste gate valve lever manually to check that the gate can be opened and closed smoothly. COMPRESSOR COVER (1) Check the compressor cover for traces of contact with the compressor wheel and other damage.
PAGE 189
4G6 ENGINE <1992> - Turbocharger 11 C-65 eD4 TURBINE HOUSING INSTALLATION (1) Install the turbine housing on the compressor cover while aligning the dowel pin with the dowel pin hole. Caution Use care not to damage the blades of the turbine wheel. I)E4 COUPLING INSTALLATION (1) Install the coupling and tighten it to the specified torque. Coupling eF4 WASTE GATE ACTUATOR OPERATION CHECK (1) Using a tester, apply a pressure of approx. 72 kPa (10.3 psi) to the actuator and make sure that the rod moves.
PAGE 190
llC=66 4G6 ENGINE <1992> - Rocker Arms and Camshaft - SOHC ROCKER ARMS AND CAMSHAFT - SOHC REMOVAL AND INSTALLATION Q-----7 nemoval steps 1. Breather hose 2. P.C.V. hose 3. Packing 4. Oil seal 5. Rocker cover 6. Gasket eG4 7. Semi-circular packing 8. Rocker arms and rocker shafts 9. Rear bearing cap eC4 10. Rocker arm D 11. Spring v-EC 12. Rocker arm D *Dir 13. Bearing-cap No. 4 ‘34 14. Rocker arm C C4 15. arm C _^ Rocker ^ rq I/. Beanng cap No. 3 I;4 18. arm D .- Rocker C4 +04 +C4 eC4 20.
PAGE 191
- - - F&l~lluC /1663\ _ Rack r Arms I ‘K-67 and Camshaft - SOW REMOVAL SERVICE POINT (IAO ROCKER ARM AND CAMSHAFT REMOVAL MD998443-01 I (1) Before removing rocker arms and shafts assembly, install the special tool as illustrated to prevent adjuster from dropping. 6EN056E INSPECTION CAMSHAFT (1) Measure the cam height 1 Identification mark (Standard value D: Intake Exhaust AR: Intake Exhaust 42.40 42.40 44.53 44.53 (1.6692) (1.6692) (1.7531) (1.7531) 1 Limit 41.90 41.90 44.03 44.03 I (1.6496) (1.
PAGE 192
IIC-68 4G6 ENGINE <1992> - Rocker Arms and Camshaft - SOHC (1) Immerse the lash adjuster in clean diesel fuel. (2) While lightly pushing down the inner steel ball using a small wire, move the plunger up and down four or five times to bleed air. Use of the retainer facilitates the air bleeding of a rocker arm mounted type lash adjuster. (3) Remove the small wire and press the plunger. If the plunger is hard to be pushed in, the lash adjuster is normal.
PAGE 193
4G6 ENGINE <1992> - Rocker Arms and Camshaft - SOHC I)B+ Wave washer 11 C-69 WAVE WASHER INSTALLATION (1) Install the wave washer in the correct direction as shown. side rocker arm - 6EN057Z identification b Timing belt side No. 1 No. 2 No. 1 No. 2 I)c4 ROCKER ARM IDENTIFICATION Identification mark: 1 - 3 for No. 1 and 3 cylinders No. 3 No. 4 2-4 N o . 3 No. 4 6EN055e Rocker cover mounting bolt hole FroAt mark ’ Identification mark No. 2 No. 3 for No. 2 and 4 cylinders No.
PAGE 194
4G6 ENGINE <1992> - Rocker Arms and Camshaft - SOHC I)F4 CAMSHAFT OIL SEAL INSTALLATION I)G4 Apply sealant DEN0052 IOmm Semi-circular packing Gasket r$ of cvlinder head 6EN042 TSB Revision SEMI-CIRCULAR PACKING INSTALLATION Specified sealant: 3M ATD Part No.
PAGE 195
4G6 ENGINE <1992> - Camshafts and Rocker Arms - DOHC 1 IC-71 CAMSHAFTS AND ROCKER ARMS - DOHC REMOVAL AND INSTALLATION 6 20 Nm 14 t=t.lbs.- 11 Nm 8 ftlbs. Removal steps fiC4 1. Bearing cap rear #Q 2. Bearing cap front +04 3. Camshaft oil seal #C4 4. Bearing cap No. 5 eC4 5. Bearing cap No. 2 eC4 6. Bearing cap No. 4 eC4 7. Bearing cap No. 3 eB4 8. Camshaft 9. Rocker arm *A4 10. Lash adjuster 11.
PAGE 196
11 C-72 4G6 ENGINE <1992> - Camshafts and Rocker Arms - DOHC INSPECTION CAMSHAFT (1) Measure the cam height. Identification mark Standard value Limit 35.49 (1.3972) 35.20 (1.3858) 34.99 (1.3776) 34.70 (I .3661) 35.49 35.20 (1.3972) (1.3858) 34.99 34.70 (1.3776) (1.3661) 35.91 (1.3744) 34.41 (1.3547) Intake AD I3.CF.F Exhaust 2 E.F Roller Tip I 6EN018! Scale = 1 mm (.039 in.) M[ \ The camshaft identification mark is stamped on the rear end of camshaft.
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4G6 ENGINE <1992> - Camshafts and Rocker Arms - DOHC I)64 INSTALLATION OF CAMSHAFT (1) Apply engine oil to journals and cams of the camshafts. (2) Install the camshafts on the cylinder head. Use care not to confuse the intake camshaft with the exhaust one. The intake camshaft has a slit on its rear end for driving the crankshaft position sensor.
PAGE 198
11 c-74 4G6 ENGINE <1992> - Cylinder Head and Valves - SOHC CYLINDER HEAD AND VALVES - SOHC REMOVAL AND INSTALLATION 95 Nm 69 fklbs. --1 0 1 e--2 III184 RI7 v Removal steps (IA~J I)E4 ;. C&i;;;; head bolt 3: Cylinder head assembly $04 4. Gasket @I$ I)C4 5. Retainer lock 6. Valve spring retainer $64 7. Valve spring 8. Intake valve QBr) SC4 9. Retainer lock 10. Valve spring retainer I)B+ 11. Valve spring 12. Exhaust valve (A@ #A4 13. Valve stem seal 14. Valve spring seat (10) +A4 15.
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4G6 ENGINE <1992> - Cvlinder Head and Valves - SOHC IIC-75 REMOVAL SERVICE POINTS PRECAUTION FOR REMOVED PARTS (1) Keep removed parts in order according to the cylinder number and intake/exhaust. OAo CYLINDER HEAD BOLT REMOVAL (1) Using the special tool, loosen the cylinder head bolts. Loosen evenly, little by little. tJB0 RETAINER LOCK REMOVAL (1) Using the special tool, compress the spring. (2) Remove the retainer locks. Keep removed parts in order according to the cylinder number and intake/exhaust.
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1 IC-76 466 ENGINE <1992> - Cvlinder Head and Valves - SOHC INSPECTION CYLINDER HEAD (1) Check the cylinder head gasket surface for flatness by using a straightedge in the directions of A through G shown in the illustration. Standard value: 0.05 mm (JO20 in.) Limit: 0.2 mm (008 in.) (2) If the service limit is exceeded, correct to meet the specification. Grinding limit: “0.2 mm (008 in.) Caution * Total resurfacing depth of both cylinder head and cylinder block.
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4G6 ENGINE <1992> - Cylinder Head and Valves - SOHC IIC-77 VALVE SEAT RECONDITIONING PROCEDURE (1) Before correcting the valve seat, check for clearance between the valve guide and valve and, if necessary, replace the valve guide. (2) Using the special tool or seat grinder, correct to obtain the specified seat width and angle. (3) After correction, valve and valve seat should be lapped with a lapping compound. 6EN049 VALVE SEAT REPLACEMENT PROCEDURE 0.5 - 1 mm (.020- ,039 in.
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1 IC-78 466 ENGINE <1992> - Cylinder Head and Valves - SOHC INSTALLATION SERVICE POINTS I)A4 VALVE STEM SEAL INSTALLATION MD998729-01 (1) Install the valve spring seat. 4-l 5ENOOl E 1 (2) Using the special tool, install a new stem seal to the valve guide. Caution Do not reuse the valve stem seal. 61 ; I)& VALVE SPRING INSTALlATlON (I) Direct the valve spring end with identification color end toward the spring retainer.
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4G6 ENGINE <1992> - Cylinder Head and Valves - SOHC IIC-79 I)D4 CYLINDER HEAD GASKET IDENTIFICATION Identification mark Identification mark: 4663 . . . . . 63 4664 . . . . . 64 Caution Do not apply sealant to cylinder head gasket. 6EN054 5 I)E4 CYLINDER HEAD BOLT INSTALLATION (=I (1) Tighten the cylinder head bolts in the sequence shown. Each bolt should be tightened in two to three steps, torquing progressively. Tighten to the specified torque in the final sequence.
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11 C-80 466 ENGINE <1992> - Cylinder Head and Valves - DOHC CYLINDER HEAD AND VALVES - DOHC REMOVAL AND INSTALLATION Removal steps OArJ )E4 1. Cylinder head bolt 2. Washer 3. Cylinder head assembly )D4 4. Gasket (IBM *Cc 5. Retainer lock 6. Valve spring retainer 7. Valve spring 8. Intake valve 9. Retainer lock 10. Valve spring retainer II. Valve spring 12. Exhaust valve 13. Valve stem seal 14. Valve spring seat 15. Valve stem seal 6. Valve spring seat 17. Intake valve guide 18. Exhaust valve guide 19.
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4G6 ENGINE <1992> - Cylinder Head and Valves - DOHC 1 W-81 REMOVAL SERVICE POINTS OAo CYLINDER HEAD BOLT REMOVAL (1) Using the special tool, loosen the cylinder head bolts. Loosen evenly, little by little. OBo RETAINER LOCK REMOVAL MD998735-01 (1) Using the special tool, compress the spring. (2) Remove the retainer locks. Keep removed parts in order according to the cylinder number and intake/exhaust. ($0 VALVE STEM SEAL REMOVAL (1) Do not reuse the stem seals.
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11 C-82 4G6 ENGINE <1992> - Cylinder Head and Valves - DOHC CYLINDER HEAD Cylinder head height (when new): 131.9 - 132.1 mm (5.193 - 5.201 in.) VALVE Margin: Intake 1.0 mm (.039 in.) Exhaust I.5 mm (.059 in.) Limit: Intake 0.7 mm (.028 in.) Exhaust 1.0 mm (.039 in.) VALVE SPRING Free height: 48.3 mm (1.902 in.) Limit: 47.4 mm (I.866 in.) Squareness: 1.5” or less Limit: Max. 4” VALVE GUIDE Valve guide to valve stem clearance: Intake 0.02 - 0.05 mm (.OOOS - .0020 in.) Exhaust 0.05 - 0.09 mm (.0020 - .
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4G6 ENGINE <1992> - Cylinder Head and Valves - DOHC 1 IC-83 VALVE SEAT REPLACEMENT PROCEDURE (1) Refer to Page 1 IC-77 noting that the only difference is in the reboring size. Intake valve seat hole diameter 0.3 mm (.012 in.) O.S. . . . . . . . . . . . . . . . . . . . . 35.30- 35.33 mm (1.3898 - I .3909 in.) 0.6 mm (.024 in.) O.S. . . . . . . . . . . . . . . . . . . . . 35.60 - 35.63 mm (1.4016- 1.4028 in.) Exhaust valve seat hole diameter 0.3 mm (.012 in.) O.S. . . . . . . . . . . . . . . . . . . . . 33.
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11 C-84 4G6 ENGINE <1992> - Cylinder Head and Valves - DOHC I)& RETAINER LOCK INSTALLATION (1) Using the special tool, compress the valve spring and insert the retainer lock into position. I)D4 CYLINDER HEAD GASKET IDENTIFICATION Identification mark: I6 4661 2 0 4663 6EN0209 #Eg CYLINDER HEAD BOLT INSTALLATION a Camshaft sprocket side i 6 6 b 6 6 (1) Tighten the cylinder head bolts in the sequence shown. Each bolt should be tightened in two to three steps, torquing progressively.
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4G6 ENGINE <1992> - Front Case, Silent Shaft and Oil Pan 1 X-85 FRONT CASE, SILENT SHAFT AND OIL PAN REMOVAL AND INSTALLATION 22 ** 24 Nm **** 40 ftlbs. Removal steps 1. Oil filter 2. Oil cooler bolt*** 3. Oil cooler*** 4. Drain plug 5. Drain plug gasket (IAO+N~ 6. Oil pan 7. Oil screen 8. Oil screen gasket OBrJ )EC 9. Flange nut 10. Oil pump sprocket** @IQ )MCl 1. Plug 12. O-ring @IQ )L~I 13. Flange bolt 14. Oil filter bracket 15. Oil filter bracket gasket *KC 16. Front case 17. Front case gasket 18.
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IIC-86 466 ENGINE <1992> - Front Case, Silent Shaft and Oil Pan 19=-Q& 2ow 33 Nm -189 24 ft.lbs. 1 m5\ ? ? 45 Nm 33 ft.lbs. : ***** 55 Nm 40 ft.lbs. 1. Oil cooler by-pass valve***** +G4 2. Oil pressure switch eF4 3. Oil pressure gauge unit ;. pm :55 Nm 40 ft.lbs. $04 I)D4 eC4 *Bg NOTE * : DOHC ** : Engine with silent shafts *** : Engine with turbocharger **** : Engine without silent shafts *****: Engine with air-cooling type oil cooler 6: Relief spring 7. Relief plunger 8. Oil filter bracket 9.
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4G6 ENGINE <1992> - Front Case, Silent Shaft and Oil Pan 1 IC-87 REMOVAL SERVICE POINTS aA OIL PAN REMOVAL Service tool : (1) Remove the all oil pan bolts. (2) Drive in the service tool between the cylinder block and oil pan. NOTE Never use a screwdriver or chisel, instead of the service tool, as a deformed oil pan flange will result in oil leakage. OlLO583 OlLO584 (IBI) FLANGE NUT REMOVAL Engine with silent shafts (ENGINE WITH SILENT SHAFTS) (1) Remove the plug on the side of the cylinder block.
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4G6 ENGINE <1992> - Front Case, Silent Shaft and Oil Pan (2) Remove the oil pump sprocket nut. Engine with silent shafts OEo SILENT SHAFT FRONT BEARING REMOVAL (ENGINE WITH SILENT SHAFTS) Using the special tool, remove the silent shaft front bearing from the cylinder block. NOTE Be sure to remove the front bearing first. If it has not been removed, the Rear Bearing Puller cannot be used.
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4G6 ENGINE <1992> - Front Case, Silent Shaft and Oil Pan I Engine with silent shafts I DEN0711 IIC-89 SILENT SHAFT (ENGINE WITH SILENT SHAFTS) (1) Check oil holes for clogging. (2) Check journal for seizure, damage and contact with bearing. If there is anything wrong with the journal, replace silent shaft, bearing or front case assembly. (3) Check the silent shaft oil clearance. If the clearance is excessively due to wear, replace the silent shaft bearing, silent shaft or front case assembly.
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IIC-90 4G6 ENGINE <1992> - Front Case, Silent Shaft and Oil Pan I)64 OIL PUMP OIL SEAL INSTALLATION 6EN0494I 6EN0494 CRANKSHAFT FRONT OIL SEAL INSTALLATION I)c4 (1) Using the special tool, install the crankshaft front oil seal into the front case. I)D4 OIL PUMP DRIVEN GEAR / OIL PUMP DRIVE GEAR INSTALLATION (I) Apply engine oil amply to the gears and line up the alignment marks.
PAGE 215
4G6 ENGINE <1992> - Front Case, Silent Shaft and Oil Pan I)F~I IIC-91 SEALANT APPLICATION TO OIL PRESSURE GAUGE UNIT (1) Coat the threads of the oil pressure gauge unit with sealant and install the unit using the special tool. Specified sealant: 3M ATD Part No. 8660 or equivalent Caution 1. Keep the end of threaded portion clear of sealant. 2. Avoid an overtightening.
PAGE 216
IIC-92 4G6 ENGINE <1992> - Front Case. Silent Shaft and Oil Pan (3) Using the special tool, install the rear bearing. NOTE The left rear bearing has no oil holes. Engine with silent shafts 6EN0578 +Jg SILENT SHAFT FRONT BEARING INSTALLATION (ENGINE WITH SILENT SHAFTS) (1) Using the special tools, install the front bearing.
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4G6 ENGINE <1992> - Front Case, Silent Shaft and Oil Pan r IIC-93 (3) Mount the oil filter bracket with oil filter bracket gasket. Then, install the four bolts with washers. (4) Tighten the bolts to the specification. NOTE (1) The bolt marked with *I in the illustration differs in tightening torque. (2) The bolt marked with “2 in the illustration is for engine without silent shafts only. = Bolt length Imm (in.
PAGE 218
IIC-94 4G6 ENGINE <1992> - Front Case, Silent Shaft and Oil Pan I)N4 OIL PAN INSTALLATION (1) Clean both mating surface of the oil pan and the cylinder block. (2) Apply a 4 mm (.I6 in.) wide bead of sealant to the entire circumference of the oil pan flange. Specified sealant: MITSUBISHI GENUINE PART No. MD970389 or equivalent (3) The oil pan should be installed in 15 minutes after the application of sealant. 6FNn71R (4) Note that the bolts at the location shown are different in length from the others.
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4G6 ENGINE <1992> - Piston and Connecting Rod 1 IC-95 PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION 6 7 8 ?4 9 ll- Removal steps 1. Nut (IAO )E4 2. Connecting rod cap 3. Connecting rod bearing eD4 4. Piston and connecting rod assembly 5. Connecting rod bearing eC4 6. Piston ring No. 1 +C4 7. Piston ring No. 2 #B4 8. Oil ring QBo *AC 9. Piston pin IO.
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466 ENGINE <1992> - Piston and Connecting Rod 11 C-96 REMOVAL SERVICE POINTS aA0 CONNECTING ROD CAP REMOVAL number (1) Mark the cylinder number on the side of the connecting rod big end for correct reassembly. (2) Keep the removed connecting rods, caps, and bearings in order according to the cylinder number. cJB0 PISTON PIN REMOVAL ‘iston pin setting 001 MIT216941 Item No. Part No.
PAGE 221
4G6 ENGINE <1992> - Piston and Connectina Rod lW97 INSPECTION PISTON (1) Replace the piston if scratches or seizure is evident on its surfaces (especially the thrust surface). Replace the piston if it is cracked. PISTON PIN (1) Insert the piston pin into the piston pin hole with a thumb. You should feel a slight resistance. Replace the piston pin if it can be easily inserted or there is an excessive play. (2) The piston and piston pin must be replaced as an assembly.
PAGE 222
11 C-98 4G6 ENGINE <1992> - Piston and Connecting Rod (3) Install the connecting rod cap carefully and tighten the bolts to the specified torque. (4) Carefully remove the connecting rod cap. (5) Measure the width of the plastic gauge at its widest part by using a scale printed on the plastic gauge package. Standard value: 0.02 - 0.05 mm (0008 - .0020 in.) Limit: 0.1 mm (.004 in.
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4G6 ENGINE <1992> - Piston and Connecting Rod m-99 (8) Check that the piston moves smoothly. 6EN0298 I)B4 OIL RING INSTALLATION (1) Fit the oil ring spacer into the piston ring groove. NOTE The side rails and spacer may be installed in either direction. 6EN058E Side rail gap d-, 1 EN026 - (2) Install the upper side rail. To install the side rail, first fit one end of the rail into the piston groove, then press the remaining portion into position by finger. See illustration.
PAGE 224
IIC-100 4G6 ENGINE <1992> - Piston and Connecting Rod DOHC Non-turbo Turbo 6EN0497 I)D4 PISTON AND CONNECTING ROD INSTALLATION (1) Liberally coat engine oil on the circumference of the piston, piston ring, and oil ring. (2) Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in the figure. No. 1 a / pulley side No. 2 ring gap and spacer gap ‘Lower rail 6EN0549 Timing belt side, -*ront;r’ (3) Rotate the crankshaft so that the crank pin is on the center of the cylinder bore.
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4G6 ENGINE <1992> - Piston and Connecting Rod TSB Revision 1 IC-101
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IIC-102 4G6 ENGINE <1992> - Crankshaft, Flywheel and Drive Plate CRANKSHAFT, FLYWHEEL AND DRIVE PLATE 135 Nm 2 98ftJbs. I I REMOVAL AND INSTALLATION 11 Nm 8 ft.lbs. 18 27 ml19 98 ft.lbs. 17 6I **5*3 II 1 ** 135 Nm 98 ftlbs. Removal steps I, Flywheel bolt 2. Flywheel 3. Ball bearing* 4. Drive plate bolt** 5. Adapter plate** 6. Drive plate** 7. Crankshaft bushing** 8. Drive plate bolt 9. Adapter plate 10. Drive plate 11. Crankshaft bushing 12. Drive plate bolt* 13. Adapter plate* 14.
PAGE 227
4G6 ENGINE <1992> - Crankshaft, Flywheel and Drive Plate 1 x-103 INSPECTION CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE METHOD) (1) Remove oil from the crankshaft journals and crankshaft bearings. (2) Install the crankshaft. (3) Cut the plastic gauge to the same length as the width of the bearing and place it on the journal in parallel with its axis. 6EN055C (4) Install the crankshaft bearing cap carefully and tighten the bolts to the specified torque. (5) Carefully remove the crankshaft bearing cap.
PAGE 228
IIC-104 4G6 ENGINE <1992> - Crankshaft. Flvwheel and Drive Plate (4) Check cylinder walls for scratches and seizure. If defects are evident, correct (rebore to an oversize) or replace. (5) Using a cylinder gauge, measure the cylinder bore and cylindricity. If worn badly, correct the cylinder to an oversize and replace the piston and piston rings. Measure at the points shown in illustration. Standard value: Cylinder I.D. 4661 82.30 - 82.33 mm (3.2402 - 3.2413 in.) 4663 85.00 - 85.03 mm (3.3465 - 3.3476 in.
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4G6 ENGINE <1992> - Crankshaft, Flywheel and Drive Plate IIC-105 INSTALLATION SERVICE POINTS I)A4 CRANKSHAFT BEARING IDENTIFICATION Grooveless Upper bearing (for No. 1,2.4,5) Lower bearing (for No. 1.2.4.5) Upper and lower bearings (for No. 3) (1) The upper bearings (on the cylinder block side) for Nos. 1,2, 4 and 5 journals are provided with oil groove. (2) The lower bearings (on the cap side) for Nos. 1, 2, 4 and 5 journals are not provided with oil groove. (3) No.
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IIC-106 4G6 ENGINE <1992> - Crankshaft, Flywheel and Drive Plate I)c4 OIL SEAL INSTALLATION I 1 MD998376-01 DEN0052 I)D4 OIL SEPARATOR INSTALLATION Oil separator Oil seal case \0 0 (1) Force the oil separator into the oil seal case so that the oil hole in the separator is directed downward (arrow in illustration).
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1 I-C-I 07 4G6 ENGINE <1992> - Bracket BRACKET Rear wheel drive and four wheel drive 33 ft.lbs. I, 2. Engine support bracket, right Engine support bracket, left 45 Nm 33 ft.lbs. / 2 6EN350 Front wheel drive and all wheel drive I I. 2. 3. 4. Roll stopper bracket, front Engine support bracket, front Exhaust pipe support bracket Roll stopper bracket, rear TSB Revision 4 I 120 N, 87 ftlbs.
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NOTES
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IID-I ENGINE 4G93 CONTENTS CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE PLATE ........................ CYLINDER HEAD AND VALVES ........................ EXHAUST MANIFOLD ........................................ FRONT CASE AND OIL PUMP ............................ FUEL AND EMISSION PARTS ............................ GENERAL INFORMATION ................................ GENERAL SPECIFICATIONS ............................ 47 32 28 36 20 2 5 GENERATOR AND IGNITION SYSTEM ........
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llD-2 4G9 ENGINE - General Information GENERAL INFORMATION ENGINE SECTIONAL VIEW 9EN0104 TSB Revision
PAGE 235
4G9 ENGINE - General Information llD-3 ru-l- 9EN0105 TSB Revision
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11D-4 4G9 ENGINE - General Information UBRICATION SYSTEM 9EN0106 TSB Revision
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469 ENGINE - General Specifications 11D-5 GENERAL SPECIFICATIONS Description Specifications Type Number of cylinders Combustion chamber Total displacement cm3 (cu. in.) Cylinder bore mm (in.) Piston stroke mm (in.
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llD-6 469 ENGINE - Service Specifications SERVICE SPECIFICATIONS mm (in.) Items Standard value Limit 0.03 LOOI 2) 0.2 (.008) “0.2 (008) Cylinder head Flatness of gasket surface Grinding limit of gasket surface * Total resurfacing depth of both cylinder head and cylinder block Overall height Oversize rework dimensions of valve guide hole (both intake and exhaust) 0.05 (002) O.S. 0.25 (.OlO) 0.s. 0.50 (.020) O.S. Oversize rework dimensions of valve seat ring hole Intake 0.3 (.012) O.S. 0.6 (.024) O.S.
PAGE 239
11D-7 469 ENGINE - Service Specifications mm (in.) Items Standard value Limit 50.9 (2.004) 220/44.2 (49/l .74) Less than 2” 49.9 (1.965) Valve spring Free height Load/installed height Out of squareness N/mm (Ibs./in.) Valve guiide Length Intake Exhaust I.D. O.D. Service size Press-in temperature 45.5 (1.791) 50.5 (1.988) 6.00 - 6.01 (2362 - .2366) 11.055 - 11.065 (.4350 - .4356) 0.05 (.002), 0.25 (.Ol), 0.50 (.
PAGE 240
llD-8 4GS ENGINE - Service Specifications mm (in.) Items Standard value Limit Crankshaft End play Journal O.D. Pin O.D. Out-of-roundness and taper of journal and pin Oil clearance of journal Oil clearance of pin 0.05 - 0.25 (0020 - .0098) 49.982 - 49.994 (1.9678 - 1.9683) 44.980-44.995 (1.7709- 1.7715) 0.003 (.OOOl) 0.02 - 0.04 (.0008 - .0016) 0.02 - 0.05 (.0008- .0020) 0.4 (016) Cylinder block I.D.
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‘llD-9 4GS ENGINE - Torque Specifications TORQUE SPECIFICATIONS Nm ft.lbs.
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IID-IO 4G9 ENGINE - Torque Specifications / Sealant Nm ft.1b.G. 12 14 10 20 + 114 turns + 1/4turns 9 10 7 14.5 + 114 turns + 114 turns Front case and oil pump Drain plug Oil pan mounting bolt Oil screen Relief plug Oil pump case mounting bolt Oil pump case cover mounting bolt 40 7 19 45 14 10 29 5 14 33 10 7 Piston and connecting rod Connecting rod cap nut 20 + l/4 turns 14.
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4G9 ENGINE - Smcial Tools SPECIAL TOOLS Tool Application Number and tool name Supersession M B990767 6;: vo:; holder MB990767-01 Holdingcamshaft sprocket when loosening Use with MIT308239 or torqurng bolt MD998719 / 0 ‘3 MB990938-01 Installation of crankshaft rear oil seal MD99871 3 Camshaft oil seal installer MD99871 3-01 Installation of camshaft oil seal MD99871 6 Crankshaft wrench MD99871 6-01 Turning crankshaft MD9987 17 Crankshaft front oil seal installer MD99871 7-01 Installation o
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llD-12 4G9 ENGINE - Special Tools Number Tool MD998776 Crankshaft rear oil seal installer Use with MB990938 Cl 6 IN ame I Use of crankshaft rear oil seal Use with MB990938-01 MIT216941 MD998780 Piston pin setting tool Removal and installation of piston pin IJB Holding flywheel TSB Revision I ,’
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469 ENGINE - Generator and Ignition System 11043 GENERATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION 12Nm 9 ftlbs. i I 185 Nm 134ftlbs. I 8 33 ft.lbs. Removal steps I. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Drive belt 5. Generator brace 6. Generator 7. Crankshaft bolt 8. Crankshaft pulley 9. Spark plug cable 0. Spark plug I. Distributor 2.
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llD-14 469 ENGINE - Generator and Ignition System REMOVAL SERVICE POINT aA CRANKSHAFT BOLT LOOSENING (1) Using the special tool, hold the drive plate on flywheel. (2) Remove the crankshaft bolt. INSTALLATION SERVICE POINTS I)A4 DISTRIBUTOR ASSEMBLY INSTALLATION (1) Turn the crankshaft to bring No. 1 cylinder to the top dead center on compression stroke. (2) Align the mating marks on the distributor housing with that of the coupling key.
PAGE 247
4G9 ENGINE - Generator and Ignition System IOON llD-1’5 A Generator 9ENOOOl (2) Clru~ing a tension gauge, adjust the tension to the standard Standard value: New belt 500 - 700 N (110 - 154 Ibs.) Used belt 400 N (88 Ibs.) (3) Tighten the lock bolt to the specified torque. (4) Tighten the nut for pivot bolt to the specified torque.
PAGE 248
469 ENGINE - Thing Belt llD-16 TIMING BELT REMOVAL AND INSTALLATION 90 Nm 65 ft.lbs. 6 1 Removal steps 1. Flange 2. Timing belt upper cover 3. Timing belt lower cover (IAO #C4 4. Timing belt eB4 5. Tensioner +B4 6. Tensioner spring 7. Crankshaft sprocket (IBIJ *A4 8. Camshaft sprocket bolt 9.
PAGE 249
469 ENGINE - Timing Belt 11D-17 REMOVAL SERVICE POINTS (IA~) TIMING BELT REMOVAL (1) Mark the belt running direction for reference in installation. (2) Back off the tensioner spring mounting bolt three turns. (3) Pinching the end of the tensioner spring on the tensioner side with pliers, unhook it from the bracket hook on the tensioner to free the tensioner spring. (4) Loosen the tensioner mounting bolt and remove the timing belt.
PAGE 250
llD-18 469 ENGINE - Timing Belt (6) Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife. Rounded edge (Fluffy strand) 8EN0067 (7) Abnormal wear on teeth. (8) Missing tooth. Rubber exposed Tooth missing and canvas 8EN006t 3 INSTALLATION SERVICE POINTS *A4 CAMSHAFT SPROCKET BOLT TIGHTENING I)B4 TENSIONER SPRING / TENSIONER INSTALLATION (1) Install the tensioner spring and spacer. Do not fully tighten the bolt: from the tightened position, back it off three turns.
PAGE 251
469 ENGINE - Drive Belt and Timing Belt 110-19 +c4 TIMING BELT INSTALLATION (1) Check that the timing belt tensioner and spring have been installed in position. (See #B+) (2) Align the timing mark on the camshaft sprocket with that on the cylinder head. (3) Align the timing mark on the crankshaft sprocket with that on the front case. I Camshaft sprocket / (4) Install the timing belt first on the crankshaft sprocket and then keeping the tension side belt tight, set on the camshaft sprocket.
PAGE 252
11 D-20 469 ENGINE - Fuel and Emission Parts FUEL AND EMISSION PARTS REMOVAL AND INSTALLATION 12 Nm 9 ftlbs. 120 3 19 Nm 14 ft.lbs. Removal steps 1. Throttle body 2. Gasket 3. Fuel rail and injector 4. Insulator 5. Fuel return pipe MIRAGE 6. Fuel hose eB4 7. Fuel pressure regulator 8. O-ring 9. Insulator #A4 10. Injector Il. O-ring 12. Grommet 13. Fuel rail 14. EGR valve 15. tiasket For California 16.
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4G9 ENGINE - Fuel and Emission Parts 1 I’D-21 INSPECTION INJECTORS (1) Using an ohmmeter (circuit tester), test for continuity between terminals of injectors; the circuit should be closed. If failure is detected, replace the injector. Standard value: 13 - 16 IR at 20°C (68°F) 6FU192C EGR VALVE (1) Check the EGR valve for sticking or carbon deposits. If such conditions exist, clean or replace the EGR valve. (2) Connect a hand vacuum pump to the nipple of EGR valve and plug other nipple.
PAGE 254
11 D-22 4G9 ENGINE - Throttle Body THROTTLE BODY DISASSEMBLY AND REASSEMBLY 5 EXPO la Is@ Q @ 1.4 ft.lbs. Removal steps 8); *A4 1. Throttle position sensor 2. Idle air control motor 3. O-ring 4. Throttle body (PO 5. Accelerator cable bracket &a L 96N0275 MIRAGE 2Nm 1.4ft.lbs. -@b 4 cd@ 8 Removal steps QAr) *A4 1. Throttle position sensor 2. Idle air control motor 0 3. O-ring 4.
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11 D-23 4G9 ENGINE - Throttle Body DISASSEMBLY SERVICE POINTS GAr) THROTTLE POSITION SENSOR AND IDLE AIR CONTROL MOTOR REMOVAL (1) Do not disassemble the sensor and motor. (2) Do not clean the sensor and motor using solvent. Clean them with shop towel. 060 THROlTLE BODY REMOVAL (1) Do not remove the throttle valve. (2) Check if the vacuum port or passage is clogged. Use -compressed air to clean the vacuum passage.
PAGE 256
4G9 ENGINE - Throttle Bodv 11 D-24 I)A4 THROTTLE POSITION SENSOR INSTALLATION (1) Install the throttle position sensor to the throttle body as shown in the illustration. 9FUO287 (2) Turn the throttlep.osition sensor 90” clockwise, and tighten the screws. (3) Connect a circuit tester between @ (ground) and @ (output),, or between @ (output) and @ (power). Then, make sure that the resistance changes smoothly when the throttle valve is slowly moved to the fully open position.
PAGE 257
‘1 I D-25 469 ENGINE - Intake Manifold and Water Pump INTAKE MANIFOLD AND WATER PUMP REMOVAL AND INSTALLATION 11 Nm 8- ._..--. ft.lbs. 24 Nm Q 18ft.lbs. 50 Nm 36 ft.lbs. 19 Mm 14 ftlbs. 5 15 I Nrn ,4- 3u 22 ft.lbs. 16 Removal steps 1. Water hose A Water hose B z: Engine coolant temperature gauge unit 4. Engine coolant temperature sensor 5. Water inlet fitting 6. Thermostat 7. Thermostat housing 8. O-ring 9. Intake manifold stay 7. E;tM&manlfold I 31 Nm 22 ft.lbs. 2: Water pipe 3. O-ring 4.
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11 D-26 4G9 ENGINE - Intake Manifold and Water Pump INSTALLATION SERVICE POINTS I)A4 SEALANT APPLICATION TO WATER PUMP Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent 9ENOO89 I)B4 WATER PIPE / O-RING INSTALLATION (1) Wet the O-ring (with water) to facilitate the assembly. Caution 1. Keep the O-ring free of oil or grease. 2. Secure the water pipe after the thermostat housing has been installed. I)c4 ;‘dU;;; APPLICATION TO THERMOSTAT Specified sealant: Mitsubishi Genuine Part No.
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4G9 ENGINE - Intake Manifold and Water Pump 1 m27 I)F4 SEALANT APPLICATION TO ENGINE CFL+JT TEMPERATURE GAUGE UNIT Specified sealant: 3M ATD Part No. 8660 or equivalent Sealant 9EN0092 TSB Revision .
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469 ENGINE - Exhaust Manifold 11 D-28 EXHAUST MANIFOLD REMOVAL AND INSTALLATION 45 Nm 33 ftlbs. 30 Nm 22 ftlbs. I 18 Nm 13 ftlbs. 2 I 22 ftlbs. 18 Nm 13 ftlbs. 7 I 36 Nm 26 klbs. f 36 Nm 36Nm 26 ft.lbs. 4 30 Nm 22 ft.lbs. Removal steps 1992,1993 (Federal) models 1. Oxygen sensor 2. Exhaust manifold cover A 3. Exhaust manifold bracket B 1993 models 4. Exhaust manifold bracket A I 5. Exhaust manifold bracket _ 1992 models 1992, 1993 (Federal) models 6. Exhaust manifold 1993 (California) models 7.
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4GS ENGINE - Rocker Arms and Camshaft ROCKER ARMS AND CAMSHAFT REMOVAL AND INSTALLATION 3.3 Nm 2.4ft.lbs.~ Removal steps 1. Breather hose 2. P.C.V. hose 3. Rocker cover 4. Rocker cover gasket 5. Oil seal +B4 6. Oil seal *A4 7. Rocker arms and rocker arm shaft 8. Rocker arms and rocker arm shaft )A4 9. Rocker shaft spring 10. Rocker arm A 11. Rocker arm B 12. Rocker arm shaft (Intake side) 1 z. &&rstrng screw 15: Rocker arm C 16. Rocker arm shaft (Exhaust side) 17. Adjusting screw 18. Nut 19.
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11 D-30 4GS ENGINE - Rocker Arms and Camshaft INSPECTION CAMSHAFT (1) Measure the cam height Standard value: 37.78 mm Intake 38.09 mm Exhaust Limit: 37.28 mm Intake 37.59 mm Exhaust (1.4874 in.) (1.4996 in.) (1.4677 in.) (1.4799 in.) ROCKER ARM l Check the roller surface. If any dents, damage or seizure is evident, replace the rocker arm. l Check rotation of the roller. If it does not rotate smoothly or if looseness is evident, replace the rocker arm. l Check the inside diameter.
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4GS ENGINE - Rocker Arms and ‘Camshaft llD~?ll (3) Loosen the adjusting screw locknut. (4) Using a feeler gauge, adjust the valve clearance by turning the adjusting screw. Standard value: 0.09 mm LOO4 in.) Intake 0.20 mm LOO8 in.) Exhaust (5) While holding the adjusting screw with a screwdriver, tighten the lock nut. Exhaust 2 Exhaust 4 (6) Rotate clockwise the crankshaft one complete turn. (7) Adjust the valve clearance at the points shown in the illustration.
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11 D-32 469 ENGINE - Cylinder Head and Valves CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION 14 Nm 10 ft.lbs. 12 Nm #:I; e----16Cll - 1 7 62om I L-13 Q & b1148Wl - 1 9 2 -2f T 12 Nm 9 ftlbs. Removal steps 1. Engine hanger 2. Engine hanger eF4 3. Water outlet fitting #E4 4. Oil pressure switch eD4 5. Cylinder head bolt 6. Cylinder head assembly 7. Cylinder head gasket (JAI) +Q 8. Retainer lock 9. Valve spring retainer )B4 10. Valve spring 11. Intake valve (IAI) +C4 12.
PAGE 265
4G9 ENGINE - Cylinder Head and Valves 71~0-33 REMOVAL SERVICE POINTS OAo RETAINER LOCK REMOVAL (1) Store the removed valves, springs and other parts, tagged to indicate their cylinder No. and location to aid reassembly. (IBI) VALVE STEM SEAL REMOVAL (1) Do not reuse removed valve stem seals. INSPECTION CYLINDER HEAD (1) Check the cylinder head gasket surface for flatness by using a straightedge and thickness gauge. Standard value: 0.03 mm (.0012 in.) Limit: 0.2 mm (.008 in.
PAGE 266
469 ENGINE - Cylinder Head and Valves 11 D-34 II-- VALVE SPRING Measure the free height of the spring and, if it is smaller than the limit, replace. Standard value: 50.9 mm (2.004 in.) Limit: 49.9 mm (1.955 in.) Measure the squareness of the spring and, if the limit is exceeded, replace. Standard value: 2” or less Limit: 4” out of square ree eight 1 EN0264 1 EN0279 , VALVE GUIDE (1) Measure the clearance between the valve guide and valve stem.
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4G9 ENGINE - Cylinder Head and Valves I)Dg CYLINDER HEAD BOLT INSTALLATION (1) When installing the cylinder head bolts, check that the shank length of each bolt meets the limit. If the firnit is exceeded, replace the bolt. Limit: Max. 96.4 mm (3.79 in.) (2) Install the washers as illustrated. (3) Apply engine oil to the bolt threads and washers. 9EN0251 (4) According to the tightening sequence, tighten the bolts to 75 Nm (54 ft.lbs.). (5) Loosen the bolts completely. (6) Torque the bolts to 20 Nm (14.
PAGE 268
4G9 ENGINE - Front Case and Oil Pump 11 D-36 FRONT CASE AND OIL PUMP REMOVAL AND INSTALLATION 14 Nm I 1 ft.lbs. I 1 I I Iwo I----8 &--- 7- 45 Nm 33 ft.lbs. I Removal steps )E4 1 Oil filter 2. Drain plug 3. Drain plug gasket 4Ar) I)D4 4. Oil pan 5. Oil screen 6. Oil screen gasket 7. Relief plug 8. Relief spring 9. Relief plunger *C4 10. Oil seal )B4 11. Oil pump case 12. O-ring 13. Oil pump case cover c)Br) *AC 14. Outer rotor cJB~ +A4 15. Inner rotor 40 Nm 29 ft.lbs.
PAGE 269
4G9 ENGINE - Front Case and Oil Pump yrm-37 REMOVAL SERVICE POINTS ~AI) OIL PAN REMOVAL (1) Knock in the special tool deeply between the oil pan and the cylinder block. (2) Hitting the side of the special tool, slide the special tool along the oil pan to remove the oil pan. QBo OUTER ROTOR / INNER ROTOR REMOVAL (1) Make alignment dots on the outer and inner rotors for reference in reassembly. INSPECTION OIL PUMP (1) Check the tip clearance. Standard value: ‘0.03 - 0.08 mm LOO12 - .0031 in.
PAGE 270
4G9 ENGINE - Front Case and Oil Pump 11 D-38 INSTALLATION SERVICE POINTS I)A4 INNER ROTOR / OUTER ROTOR INSTALLATION (1) Apply engine oil to the rotors. Then, install the rotors ensuring that the alignment dots made at disassembly are properly aligned. SEALANT APPLICATION TO OIL PUMP CASE Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent eB4 9EN009t CRANKSHAFT FRONT OIL SEAL INSTALLATION Using the special tool, top the oil seal into the oil pump case.
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4G9 ENGINE - Front Case and Oil Pump I)04 OIL PAN INSTALLATION (1) Remove all the remaining gasket from the mating surfaces using a scraper or a wire brush. (2) Apply a 4 mm (.16 in.) diameter bead of sealant to the oil pan flange. See “Form In-Place Gasket” in introduction. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent (3) The oil pan should be installed within 15 minutes after the application of sealant. /// /-u---L 1 I’ ,’ /L-l\\ 4 mm (.I6 in.
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11 D-40 4G9 ENGINE - Piston and Connecting Rod PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION a-7 8 L2 -1 Removal steps 1. Nut 2. Connecting rod cap 3. Connecting rod bearing 4. Piston and connecting rod 5. Connecting rod bearing 6. Piston ring No. 1 7. Piston ring No. 2 8. Oil ring 9. Piston pin 0. Piston 1. Connecting rod 2.
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III%44 4G9 ENGINE - Piston and Connecting Rod DISASSEMBLY SERVICE POINTS gA0 CONNECTING ROD CAP REMOVAL (1) Mark the cylinder number on the side of the connecting rod big end for correct reassembly. DEN0050 aB0 PISTON PIN REMOVAL Piston pin setting tool MIT21 6941 Item No. Part No.
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11 D-42 469 ENGINE - Piston and Connectina Rod INSPECTION v Piston Ang 5EN006f j ring gap 6EN054E PISTON RING (1) Check the side clearance between the piston ring and ring groove. If the limit is exceeded, replace the ring or piston, or both. Standard value: 0.03 - 0.07 mm (.0012 - .0028 in.) No. 1 No. 2 0.02 - 0.06 mm (.OOOS - .0024 in.) Limit: 0.1 mm (.004 in.) No. 1 0.1 mm (.004 in.) No. 2 Install the piston ring into the cylinder bore.
PAGE 275
469 ENGINE - Piston and Connecting Rod llD43 INSTALLATION SERVICE POINTS I)A4 PISTON PIN INSTALLATION epth set ion I 7EN042t (1) Thread the stop screw and lock nut assembly into the base. Fit the correct piston support on the top of the base. Insert the press pin, threaded end up, into the hole in the piston support until the press pin touches the stop screw. (2) Using the graduations on the press pin, adjust the stop screw to the correct depth of 50 mm (1.97 in.
PAGE 276
11 D-44 469 ENGINE - Piston and Connecting Rod NOTE Do not use any piston ring expander when installing the side rail. Use of a ring expander to expand the side rail end gap can break the side rail, unlike other piston rings. (3) Install the lower side rail in the same procedure as described in step (2). (4) Make sure that the side rails move smoothly in either direction. Side rail gap I 1 EN0269 I)cg PISTON RING No. 2 / PISTON RING No. 1 INSTALLATION (1) Using a piston ring expander, fit No.
PAGE 277
4G9 ENGINE - Piston and Connecting Rod I)E4 CONNECTING ROD BEARING INSTALLATION (1) When the bearings are to be replaced, select correct ones and install them in the correct positions according to the identification marks stamped in the crankshaft.
PAGE 278
11 D-46 4G9 ENGINE - Piston and Connectina Rod I)G4 CONNECTING ROD CAP NUT INSTALLATION (1) Since the connecting rod cap bolts and nuts are torqued using a new procedure, they should be examined BEFORE reuse. If the bolt threads are “necked down”, the bolts should be replaced. Necking can be checked by running a nut with fingers to the full length of the bolt’s thread. If the nut does not run down smoothly, the bolt should be replaced.
PAGE 279
tID;47 469 ENGINE - Crankshaft, Cylinder Block, Flywheel and Drive PI&e CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE PLATE REMOVAL AND INSTALLATION 100 Nm 72 ft.lbs. 2 I 1 7 11 Nm 8 ftlbs. 100 Nm 72 ft.lbs. I ’ I 8 9Nm 7 ft.lbs. 16 Removal steps +E4 1. Flywheel bolt M/T 2. Flywheel #E4 3. Drive plate bolt 4. Adapter plate 5. Drive plate 6. Crankshaft bushing 7. Rear plate 8. Bell housing cover 9. Oil -.. seal case 0. 011 seal 1. Bearing cap bolt 2. Bearing cap 3. Crankshaft bearing, lower 4.
PAGE 280
11 D-48 4G9 ENGINE - Crankshaft, Cvlindes Block. Flvwheel and Drive Plate INSPECTION CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE METHOD) (1) Remove oil from the crankshaft journal and the crankshaft bearing. (2) Install the crankshaft. (3) Cut the plastic gauge to the same length as the width of bearing and place it on the journal in parallel with its axis. (4) Install the crankshaft bearing cap carefully and tighten the bolts to the specified torque. (5) Carefully remove the crankshaft bearing cap.
PAGE 281
469 ENGINE - Crankshaft, Cvlinder Block, Flvwheel and Drive Plate II D-49 BORING CYLINDER (1) Oversize pistons to be used should be determined on the basis of the largest bore cylinder. Piston size identification Size Thrust direction 6EN0554 Identification mark mm (.Ol in.) O.S. 0.50 mm (.02 in.) OS. 0.75 mm (.03 in.) O.S. 1 .OO mm (.04 in.) O.S. 0.25 0.25 0.50 0.75 1.00 NOTE Size mark is stamped on the piston top. (2) Measure outside diameter of piston to be used.
PAGE 282
llD-50 4G9 ENGINE - Crankshaft, Cylinder Block, Flywheel and Drive Plate REASSEMBLY SERVICE POINTS I)A4 CRANKSHAFT BEARING INSTALLATION Check digit Crank pin OD Identification -i+ mark r-J No. 5No. 4- (1) When the bearings are to be replaced, select correct ones and install them in the correct positions according to the identification marks stamped on the crankshaft and the top surface of the cylinder block. Journal OD identlflcation mark k ;= No. l- 9EN013C No. 3 No.
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4G9 ENGINE - Crankshaft, Cylinder Block, Flywheel and Drive Plate llD-51 I)B4 BEARING CAP / BEARING CAP BOLT INSTALLATION (1) Install the bearing caps so that their arrows are positioned on the timing belt side. (2) When installing the bearing cap bolts, check that the shank length of each bolt meet the limit. If the limit is exeeded, replace the bolt. Limit: Max. 71.1 mm (2.79 in.) (3) Toque the bearing cap bolts to 25 Nm (18 ft.lbs.) and, from that position, retighten them further l/4 (90”) turns.
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NOTES
PAGE 285
ENGINE 6672 CONTENTS BRACKET ................................................................ 122 CAMSHAFT, ROCKER ARMS AND BEARING CAPS .................................................... 87 CRANKSHAFT, FLYWHEEL AND DRIVE PLATE ........... . ............................................ 115 CYLINDER HEAD AND VALVES - SOHC ........ 91 CYLINDER HEAD AND VALVES - DOHC ........ 98 EXHAUST MANIFOLD ........................................ 67 2 GENERAL INFORMATION ... .............................
PAGE 286
‘HE-2 6G7 ENGINE - General Information GENERAL INFORMATION SECTIONAL VIEW - SOHC ENGINE for DIAMANTE 7EN0323 TSB Revision
PAGE 287
6G7 ENGINE - General Information llE-3 TEN0324 1% R e v i s i o n \
PAGE 288
IIE-4 6G7 ENGINE - General Information SECTIONAL VIEW - SOHC ENGINE for MONTERO AND TRUCK 7EN0135 TSB Revision I
PAGE 289
667 ENGINE - General Information 7EN0120 TSB Revision I
PAGE 290
WE-6 6G7 ENGINE - General Information SECTIONAL VIEW - DOHC NON-TURBO ENGINE 7EN0325 TSB Revision
PAGE 291
PAGE 292
IIE-8 6G7 ENGINE - General Information SECTIONAL VIEW - DOHC TURBO ENGINE 7EN0335 1 TSB Revision
PAGE 293
667 ENGINE - General Information IIE-9 7EN0334 TSB Revision
PAGE 294
6G7 ENGINE - General Information IIE-10 JJBRICATION SYSTEM - SOHC / Oil pressure switch \ n t Oil pressure gauge unit Oil cooler by-pass valve - MONTERO only Rocke Lash adjuster 7LUOO34 TSB Revision
PAGE 295
667 ENGINE - General Information llE41 is UBRICATION SYSTEM - DOHC Oil pressure switch \ To turbocharger -turbo only Oil pressure gauge unit To oil cooler Turbo only Oil cooler by-pass valve -Turbo only II Relief valve TSB Revision Las
PAGE 296
WE-12 6G7 ENGINE - General Specifications GENERAL SPECIFICATIONS SOHC Description Specifications Type Number of cylinders Combustion chamber Total displacement cm3 (cu.in.1 Cylinder bore x stroke mm (in.
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667 ENGINE - General Specifications DOHC Description Specifications Type Number of cylinders Combustion chamber Total displacement cm3 (cu.in.1 Cylinder bore x stroke mm (in.
PAGE 298
IIE-14 6G7 ENGINE - Service Specifications SERVICE SPECIFICATIONS mm (in.) Cylinder head - SOHC Flatness of gasket surface Grinding limit of gasket surface * Total resurfacing depth of both cylinder head and cylinder block Overall height Oversize rework dimensions of valve guide hole (both intake and exhaust) 0.05 (.002) 0.25 (.OlO) 0.50 (.020) Oversize rework dimension of valve seat hole Intake 0.3 (.012) 0.6 (.024) Exhaust 0.3 (.012) 0.6 (.
PAGE 299
667 ENGINE - Service SDecifications mm (in.) Camshaft - DOHC Cam height Intake Exhaust Standard Limit 35.49(1.3972)*‘,34.91 (1.3744)** 34.99(1.3776)*' 34.41 (1.3547)"' 34.70 (1.3661)"' 34.41 (1.3!%7)"2 35.20(1.3858)*',34.91 (1.3744)*' Journal diameter Oil clearance 26(1.02) 0.05-0.09(.020-.0035) Rocker arm - SOHC I.D. Rocker arm-to-shaft clearance 18.91 -18.93(.7445-.7453) 0.01 -0.04(.0004-.0016) Rocker shaft - SOHC 3.D. Dverall length 18.89-18.90 (.7437-.7441) 333.5(13.
PAGE 300
IIE-16 667 ENGINE - Service SDecifications mm (in.) Valve spring - SOHC Free length Load/Installed height Out-of-squareness N/mm (Ibs./in.) Valve spring - DOHC Free length Load/installed height Out-of-squareness N/mm (Ibs.in.1 Valve seat Seat angle valve contact width Sinkage Service size Piston - SOHC 3.D. ‘iston-to-cylinder clearance Service size ‘iston - DOHC 3.D. ‘iston-to-cylinder clearance Service size Limit 49.8 (1.961) 329/40.4 (725/l .591) Less than 2” 48.8 (1.921) 45.2 (1.780)*‘, 46.
PAGE 301
,llE-17 6G7 ENGINE - Service Specifications mm (in.) Piston ring - SOHC End gap No. 1 ring No. 2 ring Front wheel drive vehicle Rear wheel drive vehicle Oil ring Front wheel drive vehicle Rear wheel drive vehicle Ring to ring groove clearance No.1 ring Front wheel drive vehicle Rear wheel drive vehicle No.2 ring Standard Limit 0.30-0.45(.0118-.0177) 0.8 (.031) 0.45 - 0.60 (.0177 - .0236) 0.25 - 0.45 LOO98 - .0177) 0.8 (.031) 0.8 (.031) 0.20 - 0.60 LOO79 - .0236) 0.20 - 0.70 (.0079 - .0276) ‘I .
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IIE-18 6G7 ENGINE - Service SDecifications mm (in.) Standard Cylinder block Cylinder bore Flatness of gasket surface Grinding limit of top surface * Total resurfacing depth of both cylinder head and cylinder block Limit 91.1 (3.587) 0.05 (.002) “0.2 (.008) Oil pump Tip clearance Side clearance Body clearance 0.03 - 0.08 (0012 - .0031) 0.04-0.10 (.0016- .0039) 0.10 - 0.18 (0040 - .0070) Drive belt - SOHC for DIAMANTE Deflection New belt Used belt Tension gauge N (Ibs.) New belt Used belt 4.0-5.0(.
PAGE 303
667’ ENGINE - Torque Specifications TORQUE SPECIFICATIONS Nm ftlbs. Generator and drive belt Cooling fan bolt Fan pulley bolt 11 11 8 8 Tensioner pulley nut SOHC DIAMANTE, DOHC 50 36 45 33 42 24 42 19 30 17. 30 14 ,’ 45 50 42 24 23 33 36 30 17 17 lrankshaft bolt SOHC DOHC 14 10 13 24 45 155 185 IO 7 9 17 33 122 134.
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IIE-20 6G7 ENGINE - Torque Specifications Nm ft.Ibs.
PAGE 305
6G7 ,ENGlNE - Torque Specifications Nm ft.lbs.
PAGE 306
11 E-22 667 ENGINE - Torque Specifications Nm ft.lbs.
PAGE 307
667 ENGINE - Sealant SEALANT ,. Items Specified sealant Auto tensioner bolt -Turbo Engine coolant temperature sensor Engine coolant temperature gauge unit Rocker cover Bearing cap Oil pressure switch Oil pressure gauge unit Oil pan Oil seal case 3M ATD Part No. 8660 3M NUT Locking Part No.41 71 3M ATD Part No.8660 3M ATD Part No.8660 3M NUT Locking Part No.41 71 3M ATD Part No.8660 3M ATD Part No.8660 MITSUBISHI GENUINE Part No.MD970389 MITSUBISHI GENUINE Part No.
PAGE 308
11 E-24 6G7 ENGINE - SDecial Tools SPECIAL TOOLS SOHC engine only MD99871 9 or Leak-down tester Air bleed wire Camshaft oil seal installer For SOHC engine only ton and timing belt For SOHC engine only TSB Revision
PAGE 309
8G7 ENGINE - Special Tools Tool I Number and tool name Supersession Application MD99871 7 Crankshaft front oil seal installer MD99871 7-01 Installation of crankshaft front oil seal MD99871 8 Crankshaft rear oil seal installer MD998718-01 Use with MB990938, 01 IInstallation of crankshaft rear oil seal MD998719 Pulley holding pins (2) MIT308239 iolding camshaft sprocket when loosening x torquing bolt -or SOHC engine only MD998727 Oil pan remover fqemoval of oil pan M D998729 Valve stem seal in
PAGE 310
11 E-26 6G7 ENGINE - Special Tools seal installer compressor Installation of flywheel TSB Revision
PAGE 311
667 ENGINE - Generator and Drive Belt GENERATOR AND DRIVE BELT REMOVAL AND INSTALLATION - SOHC for DIAMANTE 3 1 2 il 23 Nm 7 155 Nm 112 ft.lbs. 30 ft.lbs. 8 Removal steps +A4 I. Drive belt 2. Tensioner pulley 3. Adjusting bolt 4. Adjusting stud 5. Tensioner bracket 6. Pivot bolt 7. Generator 8. Generator brace QArJ +B4 9. Crankshaft bolt 10. Special washer 11. Crankshaft pulley I 14 Nm 10 ft.lbs.
PAGE 312
IIE-28 6G7 ENGINE - Generator and Drive Belt tEMOVAL AND INSTALLATION - SOHC for MONTERO and TRUCK 13 Nm 9 ftlbs. 13 13 Nm 9 ftlbs. I 12 I IONm 7 ftlbs. Removal steps 1. Drive belt 2. Cooling fan 3. Fan clutch 4. Fan pulley 5. Idler pulley 6. Tensioner pulley 7. Adjusting bolt 8. Adjusting stud 9. Tensioner bracket 0. Cooling fan bracket assembly 1. Tensioner bracket stay 2. Generator brace 3. Generator 4. Crankshaft bolt 5. Special washer 6.
PAGE 313
6G7 ENGINE - Generator and Drive Belt IEMOVAL AND INSTALLATION i DOHC 23 Nm 17 ft.lby 24 Nm 17 ftlbs. 24 Nm 17 ft.lbs. I 4 8 I 45 Nm 33 ft.lbs. 50 Nm 36 klbs. \ 2 50 Nm I 165 Nm 134ft.lbs. Removal steps #A4 1. Drive belt 2. Idler pulley 3. Tensioner pulley 4. Adjusting bolt 5. Adjusting stud 6. Tensioner bracket 7. Generator 8. Generator bracket 9. Bracket (IA(J #64 IO. Crankshaft bolt 11. Special washer 12.
PAGE 314
WE-30 6G7 ENGINE - Generator and Drive Belt REMOVAL SERVICE POINT (JAO CRANKSHAFT BOLT LOOSENING (1) Using the special tool, hold the drive plate or flywheel. (2) Remove the crankshaft bolt. INSTALLATION SERVICE POINT #A4 DRIVE BELT TENSION ADJUSTMENT SOHC for DIAMANTE DRIVE BELT - TENSION CHART Deflection mm (in.) Generator drive belt SOHC for DIAMANTE New USed SOHC for New MONTERO USed and TRUCK NTERO and TRUCK DOHC DOHC New Used I TenEo;bt;uge I 4.5 (.16-.20) 7 l.
PAGE 315
6G7 ENGINE - Generator and Drive Belt (3) If you use a tension gauge, tighten the adjusting bblt to adjust the belt tension to the specification shown .:.in the chart. SOHC for DIAMANTE- w gauge Tension’ w 7EN0399 SOHC for MONTERO and TRUCK 7EL0070 DOHC I)B4 CRANKSHAFT BOLT TIGHTENING (1) Using the special tool, hold the drive plate or flywheel. (2) Install the crankshaft bolt.
PAGE 316
11 E-32 6G7 ENGINE - Intake Manifold Plenum and Throttle Body INTAKE MANIFOLD PLENUM AND THROTTLE BODY REMOVAL AND INSTALLATION - SOHC for DIAMANTE 8 12 Nm 8 ft.lbs. 18 Nm I 22 Nm 16 ftlbs. 5Nm 3.6 ft.lbs. 18Nm 13 ft.lbs. Removal steps For California 1. EGRpipe 2. Ignition coil 3. High tension cable 4. Intake manifold plenum stay, rear 5. Intake manifold plenum stay, front 6. EGR valve 7. EGR valve aasket 1 For California 8. Throttle body 9. Throttle body gasket 10. Ignition power transistor 11.
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6G7 ENGINE - Intake Manifold Plenum and Throttle Body IEMOVAL AND INSTALLATION - SOHC for MONTERO and TRUCK 14 Nm 10 ft.lbs. tr- 18 Nm 13 ft.lbs. 18 Nm 22 Nm 16 ft.lbs. Removal steps 1. EGR pipe For California 2. EGR pipe gasket I 3. Intake inariifold plenum stay, rear 4. Intake manifold plenum stay, front 5. EGR valve 6. EGR valve gasket > For California 7. Throttle body 8. Throttle body gasket 9. Intake manifold plenum 10.
PAGE 318
11 E-34 6G7 ENGINE - Intake Manifold Plenum and Throttle Body {EMOVAL AND INSTALLATION - DOHC NON-TURBO 12 Nm 8 ft.lbs. I 6 8Nm 3 ftlbs. 22 Nm 16 ft.lbs. 18Nm 13 ft.lbs. 3 18Nm 13 ftlbs. Cb,18Nm 13 fklbs. Removal steps 1. EGR pipe For California 2. Intake manifold plenum stay, rear 3. Intake manifold plenum stay, front 5. EGR valve For California 6. EGR valve gasket I 7. Throttle body 8. Intake manifold plenum 9.
PAGE 319
6G7 ENGINE - Intake Manifold Plenum and Throtiib B’ijdy qq-ps5 IEMOVAL AND FUEL SYSTEM - DOHC TURBO m2-?& 18hm 13 ftlbs. 18Nm 13 ft.lbs. 18 Nm 13 ftlbs. Removal steps 1. EGRpipe For California j 2. EGR pipe gasket 3. Intake manifold plenum stay, rear 4. Intake manifold plenum stay, front 5. EGR valve For California I 6. EGR valve aasket 7. Throttle bo?iy 8. Throttle body gasket 9. Intake manifold plenum 10. Intake manifold plenum gasket 1 TSB Revision I.
PAGE 320
11 E-36 6G7 ENGINE - Intake Manifold Plenum and Throttle Body INSPECTION EGR VALVE (1) Check the EGR valve for sticking or carbon deposits. If such conditions exist, clean or replace the EGR valve. (2) Connect a hand vacuum pump to the nipple of the EGR valve and plug other nipple. (3) If there is vacuum leakage, replace the EGR valve. (4) Blow air in from one passage of the EGR to check its condition as follows.
PAGE 321
667 ENGINE - Throttle Body n-E-37 THROTTLE BODY DISASSEMBLY AND REASSEMBLY - SOHC for DIAMANTE, DOHC NON-TURBO 2.5 Nm 1.8 ft.lbs. 2Nin 1.4ft.lbs. Disassembly steps QArJ +A4 1. Throttle position sensor 2. Idle air control motor 3. Throttle body @O 7FU1282 DISASSEMBLY AND REASSEMBLY - For VEHICLES with TRACTION CONTROL 4 I ii+-- 3.5 Nm 2.5 ftlbs. 3.5 Nm 2.5 ft.lbs. !Nm 1.4 ft.lbs.5 Disassembly steps 1. Water hose sensor #B4 6. Throttle body 1.4 ft.lbs.
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6G7 ENGINE - Throttle Body 11 E-38 DISASSEMBLY AND REASSEMBLY - DOHC TURBO Disassembly steps Up to 1992 models 3. Vacuum valve 4. Dash pot- From 1993 models (IAO )A4 5. Throttle position sensor 6. Idle air control motor 0 7. Throttle body DISASSEMBLY AND REASSEMBLY - SOHC for MONTERO and TRUCK 3.5 Nm 2.5 ftlbs. 3 I n Disassembly steps OAO )B4 1. Throttle position sensor (Within closed throttle position switch) 2. Idle air control motor assembly 3. Throttle body 1 /T’ cz!J 2Nm 1.4 ft.lbs.
PAGE 323
6G7 ENGINE - Throttle Body DISASSEMBLY SERVICE POINTS OAo THROlTLE POSITION SENSOR, ACCELERATOR PEDAL POSITION SENSOR AND IDLE AIR CONTROL MOTOR REMOVAL (1) Do not d’rsassemble the sensor and motor. (2) Do not clean the sensor and motor by dipping them into the solvent. Clean them with shop towel. (%r) THROlTLE BODY REMOVAL (1) Do not remove the throttle valve. (2) Check if the vacuum port or passage is clogged. Use compressed air to clean the vacuum passage.
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IIE-40 6G7 ENGINE - Throttle Bodv 6EM069 VACUUM VALVE - DOHC TURBO Up to 1992 models (1) Remove the filter from the vacuum valve. (2) Connect a hand vacuum pump to the black nipple of the vacuum valve. (3) With the other nipple closed by the finger, apply a negative pressure of 500 mmHg (19.7 in.Hg.) to make sure that the negative pressure is maintained. (4) Let go your finger and make sure that the negative pressure leaks out gradually.
PAGE 325
6G7 ENGINE - Throttle Body 7FUO29f 1 gs41 (3) Hold the idle air control motor as shown in the illustration, connect the negative 0 terminal of the power supply to each clip as described in the following steps, and check whether or not a vibrating feeling (a feeling of very slight vibration of the stepper motor) is generated as a result of the activation of the stepper motor. @ Connect the negative 0 terminal of the power supply to the red and black clip.
PAGE 326
11 E-42 6G7 ENGINE - Throttle Bodv Throttle position (3) Connect a circuit tester between 4 (ground) and 2 (output), or between 2 (output) and 1 (power). Then, make sure that the resistance changes smoothly when the throttle valve is slowly moved to the fully open position. (4) Check for continuity across terminals 3 (closed throttle position switch) and 4 (ground) with the throttle valve both fully closed and fully open.
PAGE 327
w43 6G7 ENGINE - Throttle Body )r”““-’ If there is no continuity with throttle valve fully closed, turn the throttle position sensor clockwise, and then check again. (5) If the above specifications are not met, replace TPS. I)c4 ACCELERATOR PEDAL POSITION SENSOR (APS) INSTALLATION (1) Install the accelerator pedal position sensor to the throttle body as shown in the illustration. 7FU1071 (2) Turn the accelerator pedal position sensor 90” clockwise to set it, and tighten the screws.
PAGE 328
6G7 ENGINE - Ignition System 11 E-44 IGNITION SYSTEM SOHC for DIAMANTE 25 Nm 18 ft.lbs. Removal steps 1. Spark plug cables 2. Spark plug 3. Distributor 4.
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6G7 ENGINE - Ignition Svstem ;OHC for MONTERO AND TRUCK 25 Nm 18 ft.lbs. Removal steps 1. Spark plug cables 2. Spark plugs 3. High tension cable *A4 4. Distributor 5. O-ring 6.
PAGE 330
11 E-46 667 ENGINE - Ignition System IOHC for DIAMANTE A N D 3000GT 13 Nm 9 ft.lbs. Removal steps 1. Center cover 2. Spark plug cables 3. Soark oluas 4. Ciamp’ um From 1993 models 5. Ignition coil 6. Engine hanger 7. Ignition power transistor- DIAMANTE 8. ignition power transistor _ 3000GT eB4 9. Crankshaft position sensor- Up to 1992 models 10.
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6G7 ENGINE - Ignition Svstem WE-47 INSTALLATION SERVICE POINTS I)A4 DISTRIBUTOR INSTALLATION - SOljC (1) Turn the crankshaft so that the No. 1 cylinder is at compression top dead center. (2) Align the distributor housing and gear mating marks. (3) With the stud located in the center of the adjusting slot at the distributor, install the distributor. I)B4 ;;RAFKSHAFT POSITION SENSOR INSTALLATION - (1) Turn the crankshaft so that the No. 1 cylinder is at compressi,on top dead center.
PAGE 332
6G7 ENGINE - Timing Belt - SOHC 11 E-48 TIMING BELT - SOHC REMOVAL AND INSTALLATION - DIAMANTE I 26 Nm 19 ft.lbs. 110 Nm 80 ftlbs. 4F 6 Removal steps +D4 1. Engine support bracket 2. Access cover 3. Timing belt front upper cover, right 4. Timing belt cover cap 5. Timing belt front upper cover, left 6. Timing belt front lower cover 7. Flange 4AO &CC 8. Timing belt iB4 9. Tensioner 10. Tensioner spring 11. Crankshaft sprocket QBrJ #A4 12. Camshaft sprocket bolt 13. Camshaft sprocket 14.
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6G7 ENGINE - Timing Belt - SOHC IEMOVAL AND INSTALLATION - MONTERO AND TRUCK 25 Nm 18 ft.lbs. 14 I 11 Nm 8 ftlbs. 19 ft.lbs. Removal steps 1. Access cover 2. Timing belt front upper cover, right 3. Timing belt front upper cover, left 4. Timing belt front lower cover 5. Flange @IO #C4 6. Timing belt eB4 7. Tensioner 8. Tensioner spring 9. Crankshaft sprocket (IBIJ +A4 10. Camshaft sprocket bolt 11. Camshaft sprocket 12. Timing belt rear upper cover, left 13. Generator stay 14.
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WE-50 6G7 ENGINE - Timing Belt - SOHC REMOVAL SERVICE POINTS TIMING BELT REMOVAL (1) Mark the belt running direction for reference in reinstallation. NOTE (1) Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be kept free from oil and water. Do not immerse parts in cleaning solvent. (2) If there is oil or water on any part, check the front case oil seal, camshaft oil seal and water pump for leaks.
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6G7 ENGINE - Timing Belt - SOHC (7) Abnormal wear on teeth (8) Tooth missing and canvas fiber exposed. Rubber exposed Tooth missing and canvas fiber exposed INSTALLATION SERVICE POINTS +A4 CAMSHAFT SPROCKET BOLT INSTALLATION 01w70: I)B4 TIMING BELT TENSIONER INSTALLATION (1) Insert a screwdriver into the hole of the timing belt tensioner arm, move it all the way in the direction of the arrow, and tighten the tensioner lock bolt to temporarily hold this position.
PAGE 336
11 E-52 6G7 ENGINE - Timina Belt - SOHC I)cg TIMING BELT INSTALLATION (1) Align the timing marks of the camshaft sprockets and the crankshaft sprocket. (2) Install the timing belt on the crankshaft sprocket first and while keeping the belt tight on the tension side, install the belt on the left camshaft sprocket. (3) Then, install on the water pump pulley and on the right camshaft sprocket and finally on the timing belt tensioner.
PAGE 337
6G7 ENGINE - Timing Belt - SOHC I)D4 ENGINE SUPPORT BRACKET INSTALLATION - DIAMANTE (I) Tighten the engine support bracket bolts in the order shown in the illustration. NOTE The bolt used at the location shown in the illustration is a reamer bolt (head mark “R”).
PAGE 338
11 E-54 6G7 ENGINE - Timing Belt - DOHC TIMING BELT - DOHC REMOVAL AND INSTALLATION - Up to 1992 models 3Nm 2 ft.lbs. 90 Nm 65 ftlbs. 24 17 RS. / 15 A 6 49 Nm 35 ft.lbs. i 55 Nm 40 ftlbs. Removal steps I)E4 1. Engine support bracket 2. Timing belt front upper cover, right 3. Timing belt front upper cover, left 4. Timing belt front lower cover 4AO $04 5. Timing belt +C4 6. Auto tensioner 7. Tensioner pulley 8. Tensioner arm assembly 9. Idler pulley 10. Idler pulley bracket TSB Revision 30 ft.lbs.
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667 ENGINE - Timing Belt - DOHC tEMOVAL AND INSTALLATION - From 1993 models 3Nm 2 klbs. 3Nm 2 ft.lbs. 25 24 Nm 17 ft.lbs. 10 46Nm 35 ft.lbs. 15 14 r 55 Nm 40 ft.lbs. 421 Nm 30 ft.lbs. r ap 5 2 IlONm 60 ft.lbs. Removal steps eE4 1. Engine support bracket 2. Crankshaft position sensor bracket 3. Timing belt front upper cover, right 4. Timing belt front upper cover, left 5. Timing belt front lower cover OAo eD4 6. Timing belt 7. Crankshaft position sensor 8.
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6G7 ENGINE - Timina Belt - DOHC REMOVAL SERVICE POINTS aA0 TIMING BELT REMOVAL (1) Mark the belt running direction for reference in reinstallation. NOTE (1) Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be kept free from oil and water. Do not immerse parts in cleaning solvent. (2) If there is oil or water on any part, check the front case oil seal, camshaft oil seal and water pump for leaks.
PAGE 341
6G7 ENGINE - Timing Belt - DOHC ljl51 ;_, INSTALLATION SERVICE POINTS I)A4 CAMSHAFT SPROCKET BOLT TIGHTENING (1) Hold the hexagonal portion of the camshaft with a wrench when tightening the camshaft sprocket bolt. Tighten the bolt to the specified torque. +B4 ROCKER COVER INSTALLATION (1) Apply sealant to the areas shown in the illustration. Specified sealant: 3M ATD Part No.8660 or equivalent. Apply sealant 7-G 7EN024 (2) Tighten the rocker cover bolts in the sequence shown in the illustration.
PAGE 342
11 E-58 6G7 ENGINE - Timing Belt - DOHC I)04 TIMING BELT INSTALLATION (1) Using the special tool, line up the crankshaft sprocket timing marks, and then rotate the sprocket one tooth counterclockwise. (2) Line up the timing marks of the camshaft sprockets for left bank. (3) Using two wrenches, line up the timing marks of the camshaft sprockets for right bank. Caution 1. Since valve spring force can turn the camshaft sprocket, be careful not to catch your finger. 2.
PAGE 343
6G7 ENGINE - Timing Belt - DOHC (6) Check that the timing marks of the camshaft sprockets for left bank are in alignment. Then install the timing belt on these sprockets and hold it with a paper clip at the positions shown in the illustration. (7) Install the timing belt on the idler pulley. (8) Install the timing belt on the crankshaft sprocket. (9) Install the timing belt on the tensioner pulley. (1O)Using the special tool, rotate the tensioner pulley clockwise to tighten the center bolt.
PAGE 344
6G7 ENGINE - Timing Belt - DOHC 11 E-60 Timing marks (on right rocker cover) Camshaft sprocket Timing marks (on left rocker cover) Timing mark (on sprocket) Auto tensioner Timing mark (on oil pump case) (on sprocket) Crankshaft sprocket ’ 7EN0235 (13)Loosen the center bolt of the auto-tensioner pulley, and install the special tool and a torque wrench on the pull’ey. While holding the pulley with approximately 10 Nm (7 ftlbs.
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6G7 ENGINE - Timing Belt - DOHC (16)Check that the spacing between the tensioner arm antfaulo tensioner is within the standard limit. Standard value: 3.8 - 4.5 mm (.I50 - .I77 ‘in.) *. r)E4 ENGINE SUPPORT BRACKET INSTALLATION ad I, mark (1) Tighten the engine support bracket bolts in the order shown in the illustration. NOTE The bolt used at the location shown in the illustration is a reamer bolt (head mark “R”).
PAGE 346
6G7 ENGINE - Intake Manifold and Fuel Parts 11 E-62 INTAKE MANIFOLD AND FUEL PARTS REMOVAL AND INSTALLATION - SOHC for DIAMANTE -@-I-10 I/ 9Nm 7 ftlbs. I2 __/J c1 / ,I5 8Nm 8 ftlbs. 19 Nm 14 ftlbs. 16 18 Removal steps 1. injector harness 2. Injector and fuel rail 3. insulator eG4 4. Fuel pressure regulator 5. O-ring 6. Insulator eF4 87. lnj;e;rs 9: Gromet 10. Fuel pipe 11. O-ring 12. Fuel rail *D4 13. Engjne coolant temperature gauge unit +C4 14. Engrne coolant temperature sensor *I34 15.
PAGE 347
6G7 ENGINE - Intake Manifold and Fuel Parts IEMOVAL AND INSTALLATION - SOHC for MONTERO AND TRUCK 12Nm g )f~~bs~ 19Nm 14 ft.lbs. 30 Nm 22 c.lbs. 18 11 Nm 8 ftlbs. 8Nm - 476lklbs. d Removal steps 1. Injector and fuel rail 2. Insulator eG4 3. Fuel pressure regulator 4. O-ring 5. Insulator )F4 6. Injectors 7. O-ring 8. Gromet 9. Fuel rail 10. Water hose A Il. Water hose B 1 TSB Revision 12. Heat pipe 13. Heat pipe gasket 14. Water hose eD4 15. Engine coolant temperature gauge unit eC4 16.
PAGE 348
11 E-64 6G7 ENGINE - Intake Manifold and Fuel Parts {EMOVAL AND INSTALLATION - DOHC IY Nrn ldft Ihe 11 Nm 8 ftlbs. 19 Nm 14 ft.lbs. 19 Nm 14 ft.lbs. -3 18 Nm 13 ft.lbs. --$j Removal steps 1. Injector harness 2. Injector and fuel rail 3. Insulator +G4 4. Fuel pressure regulator 5. O-ring 6. Insulator 7. Injector clip eF4 8. Injectors 9. O-ring 10. Gromet 11. Fuel pipe 12. O-ring 13. Fuel rail *E4 14. Intake manifold TSB 15. Intake manifold gasket I)Dg 16.
PAGE 349
667 ENGINE - Intake Manifold and Fuel Parts INSPECTION INJECTORS (1) Measure the resistance between the terminals of the injectors using a circuit tester. If the resistance is out of?he specification, replace the injector.
PAGE 350
IIE-66 6G7 ENGINE - Intake Manifold and Fuel Parts r)E4 _ Front INTAKE MANIFOLD INSTALLATION - DOHC (1) Tighten the nuts on the right bank to 4 Nm (2.2 ft.lbs.). (2) Tighten the nuts on the left bank to the specified torque. Then tighten the nuts on right bank to the specified torque. (3) Tighten the nuts on the left bank and those on the right bbnk again in that order.
PAGE 351
yfip@7 667 ENGINE - Exhaust Manifold EXHAUST MANIFOLD REMOVAL AND INSTALLATION - SOHC for DIAMANTE 14 Nm IOfLlbs. -I’” /(/ 1 m 6 III 24 Nm l7 ft-‘?m 5--K-a 14 Nm IO ft.lbs. & &- , 6.4 14 D @---1SNm 14 ft.lbs. Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Heat protector 5. Engine hanger, right 6. Exhaust manifold, right )BC 7. Exhaust manifold gasket 8. Heat protector, right 9. Bracket 10. Exhaust manifold, left +B4 11. Exhaust manifold gasket 12. Water hose 13.
PAGE 352
6G7 ENGINE - Exhaust Manifold IEMOVAL AND INSTALLATION - SOHC for MONTERO AND TRUCK 19 Nm 6 I - I/‘,“/ I 18 12Nm 9 ft.lbs. Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Heat protector, right 5. Engine hanger 6. Exhaust manifold, right eB4 7. Exhaust manifold gasket 8. Heat protector, left 9. Bracket 10. Exhaust manifold, left $B4 11. Exhaust manifold gasket 12. Water hose 13. Water hose A 14. Heater pipe 15. Heater pipe gasket 16. Water pipe +A4 17. O-ring *A4 18.
PAGE 353
c 667 ENGINE - Exhaust Manifold IEMOVAL AND INSTALLATION - DOHC NON-TURBO 9 12 14 10 1 ft.lbs. Nm 14 Nm 10 ft.lbs. 9 11m 13 Nm 9 ft.lbs. 14 Nm IO ftlbs. 45 Nm 33 ft.lbs. Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Heat protector, right 5. Engine hanger 6. Exhaust manifold, right 7. Exhaust manifold gasket 8. Heat protector, left 9. Exhaust manifold, left 0. Exhaust manifold gasket 1. O-ring 2. Water inlet pipe 3. O-ring 4. Water pump 15.
PAGE 354
IIE-70 667 ENGINE - Exhaust Manifold REMOVAL AND INSTALLATION - DOHC TURBO 14 Nm 10 ftlbs. - 17 ftlbs. Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring *A4 4. O-ring +A4 5. Water inlet pipe #A4 6. O-ring 7. Water pump 8.
PAGE 355
TIE-71 6G7 ENGINE - Exhaust Manifold 60 Nm 44 ft.lbs. 14Nm __B IO ft.lbs. 31 Nm 22 ft Ibs. “Nm klbs. 14 Nm 10 ftlbs. 60 Nm 43 ftlbs. a 9. Heat protector B 10. Heat protector A 11. Turbocharger stay 12. Exhaust fitting 13. Exhaust fitting gasket 14. Oil pipe 15. Water pipe A, right 16. Water hose 17. Water pipe B, right 18. Water hose 19. Turbocharger, right 20. Turbocharger gasket 21. Ring 22. Oil return pipe, right 23. Oil return pipe gasket 24. Exhaust manifold sta , right +C4 25.
PAGE 356
6G7 ENGINE - Exhaust Manifold 11 E-72 4 %4% 35 IlNm 8 klbs. 25 Nm 18 ft.lbs. -9 ---ml V 31 Nm 22 ftlbs. / 14 Nm IO ftlbs. m 10 Nm 28 14Nm & IO ft.lbs. 27 3im 27. Heat protector D 28. Exhaust fitting, left 29. Exhaust fitting gasket, left 30. Heat protector C 31. Oil return pipe 32. Oil return pipe gasket 33. Oil pipe 34. Water pipe 6, left 35.
PAGE 357
6G7 ENGINE - Exhaust Manifold I O-ring I Water pump I WE-73 INSTALLATION SERVICE POINTS +A4 O-RING AND WATER PIPE INSTALLATION (I) Wet the O-ring (with water) to facilitate assembly. Caution Keep the O-ring free of oil or grease. Water in’let pipe 6EN0594 I I)B4 EXHAUST MANIFOLD GASKET IDENTIFICATION SOHC (1) Install gaskets with cylinder number 0, @ and @ embossed on their top side to the right bank and install those with cylinder number 0, @ and @J to the left bank. Cylinder No.
PAGE 358
6G7 ENGINE - Exhaust Manifold 11 E-74 I)D4 LEFT EXHAUST MANIFOLD INSTALLATION - DOHC TURBO Tighten the nuts in the following order. (1) Tighten four nuts @ to 30 Nm (22 ft.lbs.). (2) -TT;.poranly tighten the turbocharger to the exhaust man- I Groove (3) Tighten nut @ to 30 Nm (22 ft.lbs.). (4) Tighten nuts @ and @ to 50 Nm (36 ftlbs.). (5) Back off nuts @ and @ until a torque value of 10 Nm (7 ft.lbs.) is achieved. (6) Tighten nuts @ and @ to 30 Nm (22 ftlbs.).
PAGE 359
6G7 ENGINE - Turbocharger TURBOCHARGER DISASSEMBLY AND REASSEMBLY Xsassembly steps eD4 *C4 *Bg bAC r 1 1. Snap pin 2. Turbocharger waste gate actuator 3. Coupling 4. Turbine housing 5. Snap ring 6. Turbine wheel assembly 7. 0-rina 8. Combressor cover 71N0098 INSPECTION TURBOCHARGER (1) Manually open and close the waste gate valve to make sure it operates freely. (2) Inspect the oil passage in the cartridge for signs of deposits or blockage.
PAGE 360
11 E-76 6G7 ENGINE - Turbocharger 664 TURBINE WHEEL ASSEMBLY INSTALLATION ) Install the turbine wheel assembly to the compressor cover while aligning the dowel pin and the hole. Caution Use care not to damage the blades of the turbine wheel and compressor wheel. il Chamfered +cg SNAP RING INSTALLATION (1) Fit the snap ring with its chamfered side facing up.
PAGE 361
“14 E~77 667 ENGINE - Rocker Arms and Camshaft - SOHC ROCKER ARMS ANI) CAMSHAFTS - SOHC REMOVAL AND INSTALLATION - DIAMANTE 9Nm 7 ft.lbs.9 @ 7 30 7 Removal steps #E4 ;. Fi;,c:;; cover elII4 3. Circular packing +C4 4. Camshaft oil seal 5. Distributor adaptor 6. O-ring #B4 7.
PAGE 362
IIE-78 6G7 ENGINE - Rocker Arms and Camshaft - SOHC REMOVAL AND INSTALLATION - MONTERO AND TRUCK 9Nm Q- 7 ft.lbs. 9Nm 7 ft.lbs. I - - 0 8 13Nm 9 ft.lbs. ------d t Removal steps 1 Oil filler 2. Oil filler tube eE4 3. Rocker cover 4. Gasket #D4 5. Circular packing I)C4 6. Camshaft oil seal 7. Distributor adaptor 8. O-ring ’ #B4 9.
PAGE 363
6G7 ENGINE - Rocker Arms and Camshaft - SOHC 1 TE39 REMOVAL SERVICE POINT flo ROCKER ARM, SHAFT AND BEARING CAP REMOVAL (1) Install the special tools to the rocker arm to hold the lash adjuster. (2) Loosen the camshaft bearing cap bolt. Do not remove the bolts from the cap. (3) Remove the rocker arm, shaft and bearing cap as an assembly. INSPECTION CAMSHAFT (1) Inspect the camshaft bearing journals for damage and binding. If the journals are binding, also check the cylinder head for damage.
PAGE 364
11 E-80 667 ENGINE - Rocker Arms and Camshaft - SOHC (1) Immerse the lash adjuster in clean diesel fuel. (2) While lightly pushing down the inner steel ball using the small wire, move the plunger up and down four or five times to bleed air. Use of the Retainer facilitates the air bleeding of the rocker arm mounted type lash adjuster. (3) Remove the small wire and press the plunger. If the plunger is hard to be pushed in, the lash adjuster is normal.
PAGE 365
667 ENGINE - Rocker Arms and Camshaft - SOHC +64 ROCKER ARM, SHAFT AND BEARING CAP INSTALLATION (1) Apply a minimum amount of the specified sealant on the four places of the cylinder head. NOTE Be sure the sealing agent does not swell out onto the cam journal surface of the cylinder head. If it swells out, immediately wipe it off before it can dry. Specified sealant: 3M NUT Locking No. 4171 or equivalent Apply sealant Apply sealant * No. 1 and No.
PAGE 366
11 E-82 667 ENGINE - Rocker Arms and Camshaft - SOHC Arrow mark (bearing cap) Rocker arm shaft assembly(B) c7 Arrow mark (cylinder head) Timing belt side Rocker arm shaft ----assembly (A) Arrow mark-(bearing cap) 7EN0176 (3) Tighten the bearing cap bolts to the specified torque. (4) Remove the special tools from all rocker arms. ec4 CAMSHAFT OIL SEAL INSTALLATION (1) Apply a slight amount of engine oil all over the circumference of the camshaft oil seal lip.
PAGE 367
667 ENGINE - Rocker Arms and Camshaft - SOHC #D4 C I R C U L A R P A C K I N G I N S T A L L A T I O N (1) Install a 1.3 to 1.5 mm (.052 to .059 in.) thick spacer to the special tool and drive in the circular packing. NOTE Use of MD724328 spacer for transmission is recommended. MD998714-01 / \\/ 7EN0441 \/ Caution The packing is overdriven if no spacer is fitted to the special tool. 0.5 mm (020 in.
PAGE 368
IIE-84 6G7 ENGINE - Rocker Arms and Rocker Shafts - SOHC DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Bearing cap No.4 0 2. Rocker arm 3. Spring 4. Bearing cap No. 3 5. Bearing cap No. 2 *A4 6. Rocker arm shaft “B” $A4 7. Rocker arm shaft “A” 8. Bearing cap No. 1 DISASSEMBLY SERVICE POINT OAo ROCKER ARM REMOVAL (1) Before disassembly, identify the original location of each rocker arm by a symbol. For example, put symbols as shown below. 1 IN: For No.1 cylinder intake 6EX: For No.
PAGE 369
667 ENGINE - Rocker Arms and Rocker Shafts - SOHC INSPECTION ROCKER ARM (1) Check the roller surface and replace the rocker arm if recesses, damage or heat seizure is observed. (2) Check roller rotation and replace the rocker arm if uneven rotation or roller backlash is observed. (3) Check the inside diameter and replace the rocker arm if damage or seizure is observed. 7EN006r ROCKER ARM SHAFT (1) Check the rocker arm mounting portions of the rocker arm shafts for wear or damage. Replace as necessary.
PAGE 370
11 E-86 6G7 ENGINE - Rocker Arms and Rocker Shafts - SOHC (3) Install the rocker arms, springs and camshaft bearing caps as illustrated. The rocker arms are all equally shaped. Assemble the rocker arms according to the symbols put before disassembly. The bearing caps are also equally shaped. Assemble the caps according to the identification marks as to right and left banks put before disassembly. Front mark Camshaft bearing cap No.4 Camshaft bearing cap No.1 Camshaft bearing cap No.2 Cap No.
PAGE 371
6G7 ENGINE 1 P:E187 - Camshafts, Rocker Arms and Bearing Caps - DOHC CAMSHAFTS, ROCKER ARMS AND BEARING CAPS - DOHC REMOVAL AND INSTALLATION 20 Nm Removal steps 1. Crankshaft position sensoradaptor-Up to 1992 models - F r o m 1993 models #E4 2. Circular packing eD4 3. Camshaft oil seal 4. Bearing cap, front 5. Bearing cap, rear 6. Bearing cap No. 2 7. Bearing cap No. 4 W 8. Bearing cap No. 3 )B( 9. Camshaft 10. Rocker arm #A4 11.
PAGE 372
IIE-88 6G7 ENGINE - Camshafts, Rocker Arms and Bearing Caps - DOHC INSPECTION CAMSHAFT Measure the cam height (longer diameter of the cam). If it exceeds the limit, replace the camshaft. Standard value: Up to 1992 models 35.49 mm (1.3972 in.) Intake side 35.20 mm (1.3858 in.) Exhaust side From 1993 models 34.91 mm (1.3744 in.) Intake side 34.91 mm (1.3744 in.) Exhaust side Limit: Up to 1992 models 34.99 mm (1.3778 in.) Intake side 34.70 mm (1.3661 in.) Exhaust side From 1993 models 34.41 mm (1.3547 in.
PAGE 373
6G7 ENGINE - Camshafts, Rocker Arms and Bearing Caps - DOHC Identification mark 7EN024S Right bank KY 17E439 +64 C A M S H A F T INSTALLATlON (1) Turn the crankshaft to bring No.1 cylinder to the top dead center. (2) Check that the rocker arm is installed correctly on the lash adjuster and valve. (3) Install the camshaft while noting the identification mark (stamped on the hexagon section).
PAGE 374
IIE-90 6G7 ENGINE - c amshafts, I)D4 Rocker Arms and Bearing Caps - DOHC CAMSHAFT OIL SEAL (1) Apply engine oil sparingly all around the lip of the camshaft oil seal. (2) Using the special tool, install the oil seal. +E4 CIRCULAR PACKING (1) Install the circular packing with the special tool.
PAGE 375
l-l E-91 6G7 ENGINE - Cylinder Head and Valve - SOHC CYLINDER HEAD AND VALVE - SOHC REMOVAL AND INSTALLATION 0+5 W6 ce-130 g -0Q 10 -4 7 @E---14 b- 170 Removal steps QAIJ +E4 12. fyks$~; head bolt 3: Cylinder head assembly #D4 4. Cylinder head gasket ~BI) eC4 5. Retainer lock 6. Valve spring retainer #B4 7. Valve spring 8. Inlet valve ~BI) $C4 9. Retainer lock 10. Valve spring retainer IlONm 80 ft.lbs. \ 1. Valve spring 2. Exhaust valve 3. Valve stem seal 4. Valve spring seat 5. Valve stem seal 6.
PAGE 376
11 E-92 6G7 ENGINE - Cylinder Head and Valve - SOHC REMOVAL SERVICE POINTS PRECAUTION FOR REMOVED PARTS (1) Keep removed parts in order according to the cylinder number and intake/exhaust. OAo CYLINDER HEAD BOLT REMOVAL (1) Using the special tool, loosen the cylinder head bolts. Loosen evenly, little by little. ~BI) RETAINER LOCK REMOVAL (1) Using the special tool, compress the spring. (2) Remove the retainer locks. @o VALVE STEM SEAL REMOVAL (I) Do not reuse removed valve stem seals.
PAGE 377
6G7 ENGINE - Cylinder Head and Valve - SOHC INSPECTION CYLINDER HEAD (1) Check the cylinder head gasket surface for flatness by using a straightedge in the directions of A through G shown in the illustration. Standard value: 0.05 mm (.0020 in.) Limit: 0.2 mm (.008 in.) (2) If the service limit is exceeded, correct to meet the specification. Grinding limit: “0.2 mm (.008 in.) * Total resurfacing depth of both cylinder head and cylinder block. Overall height: 84 mm (3.31 in.
PAGE 378
11 E-94 6G7 ENGINE - Cvlinder Head and Valve - SOHC 1 EN0264 VALVE SPRINGS (1 ) Measure the free height of the spring and, if it is smaller than the limit, replace. Standard value: SOHC 49.8 mm (1.961 in.) DOHC up to 1992 models 45.2 mm (1.780 in.) From 1993 models 46.4 mm (1.827 in.) Limit: SOHC 48.8 mm (1.921 in.) DOHC up to 1992 models 44.2 mm (1.740 in.) From 1993 models 45.4 mm (1.878 in.) (2) Measure the squareness of the spring and, if the limit is exceeded, replace.
PAGE 379
6G7 ENGINE - Cylinder Head and Valve - SOHC 1 Installed height I (4) Check the valve seat sinkage. The valve seat sinkage can be determined by measuring the valve spring’s installed height. (If the valve seat sinkage is great, the valve seat’s installed height also is great.) If the valve spring’s installed height exceeds the service limit, replace the insert with an oversize part as described below. Installed height of spring (both intake and exhaust) Standard value: 40.4 mm (1.591 in.) Limit: 41.
PAGE 380
11 E-96 6G7 ENGINE - Cylinder Head and Valve - SOHC NOTE Do not install a valve guide of the same size again. (4) Using the special tool, press-fit the valve guide, working from the cylinder head top surface. (5) After installing valve guides, insert new valves in them to check for sliding condition. (6) When valve guides have been replaced, check for valve contact and correct the valve seats as necessary.
PAGE 381
6G7 ENGINE - Cylinder Head and Valve - SOHC Identification mark +D4 CYLINDER HEAD GASKET IDENTIFlCATl6N’ Caution Do not apply sealant to the cylinder head gasket. Identification mark: DIAMANTE a n d M O N T E R O 7 2 72W TRUCK #E4 CYLINDER HEAD BOLT INSTALLATION MD998051-01 (1) Tighten the cylinder head bolts in the sequence shown. Each bolt should be tightened in two to three steps, torquing progressively. Tighten to the specified torque in the final sequence.
PAGE 382
IIE-98 6G7 ENGINE - Cvlinder Head and Valves - DOHC CYLINDER HEAD AND VALVES - DOHC REMOVAL OF INSTALLATION Non-turbo IlONm 80 ft.lbs. Turbo 125 Nm-+ Back off .+ lg\yE . . 90 ft.lbs. Removal steps I, Cylinder head bolt 2. Washer 3. Cylinder head assembly 4. Cylinder head gasket 5. Retainer lock 6. Valve spring retainer 7. Valve spring 8. Intake valve 9. Retainer lock 1 0. Valve spring retainer eB4 11. Valve spring 12. Exhaust valve QCr$ *A4 13. Valve stem seal 14. Valve spring seat (Gr) +A4 15.
PAGE 383
6G7 ENGINE - Cylinder Head and Valves - DOHC qqp99 REMOVAL SERVICE POINTS gA0 CYLINDER HEAD BOLT REMOVAL (1) Using the special tool, loosen the cylinder head bolts. Loosen evenly, little by little. (‘IBM RETAINER LOCK REMOVAL (1) Using the special tool, compress the spring. (2) Remove the retainer locks. @I) VALVE STEM SEAL REMOVAL (1) Do not reuse removed stem seals. INSPECTION For inspection, only variations from the SOHC engine are described below.
PAGE 384
IIE-100 6G7 ENGINE - Cylinder Head and Valves - DOHC CYLINDER HEAD Cylinder head height (when new): 131.9 - 132.1 mm (5.193 - 5.201 in.) 252 INSTALLATION SERVICE POINTS I)A4 VALVE STEM SEAL INSTALLATION (1) Install the valve spring seat. (2) Using the special tool, install a new stem seal to the valve guide. Caution Do not reuse removed valve stem seal.
PAGE 385
6G7 ENGINE - Cylinder Head and Valves - DOHC 1 TE-‘MN I)D4 CYLINDER HEAD GASKET IDENTIFICATION Identification mark 2DN Non-turbo Turbo 2DT Identifi- 7EN026 I)E4 CYLINDER HEAD BOLT INSTALLATION (1) Tighten the bolts in two to three stages in the illustrated sequence. (2) Back off the bolts once and tighten them to the specified torque in the same procedure as shown in step (1).
PAGE 386
IIE-102 6G7 ENGINE - Oil Pan and Oil Pump OIL PAN AND OIL PUMP REMOVAL AND INSTALLATION - DIAMANTE and 3000GT 23 Nm 17 ft.lbs. 7 11 Nm ** 24 Nm 17 ftlbs. 1 ~~ __ 55 Nm 40 ft.lbs. ) 75 Nm 54 ft.lbs. I 1, 14ft.lbs. 7 ft.lbs. 14 Nm 10 klbs. UJ 33 ft.lbs. 40 Nm 29 ft.lbs. Removal steps I, Transmission stay, right 2. Transmission stay, left eG4 3. Oil pressure switch #F4 4. Oil pressure gauge unit +E4 5. Oil filter 6. Oil cooler by-pass valve*** 7. Oil filter bracket stay 8.
PAGE 387
6G7 ENGINE - Oil Pan and Oil Pump 11!Emw3 {EMOVAL AND INSTALLATION - MONTERO and TRUCK Bolt with head mark “4” 24 Nm 17 ft.lbs. Bolt with head mark “7” 14 Nm 10 ft.lbs. 55 Nm 5 in& Ihc 10 Nm 7 ft.lbs. \ m I< 55 Nm 40 ft.lbs. I 14 Nm 11 ft.lbs. 10 Nm 7 ft.lbs. 19Nm 14 ft.lbs. \ I 45 Nm 33 ft.lbs. 40 Nm 29 ft.lbs. Removal steps #G4 1. Oil pressure switch #F4 2. Oil pressure gauge unit - MONTERO +E4 3. Oil filter 4. Oil cooler by-pass valve - MONTEBO 5. Oil filter bracket 6.
PAGE 388
IIE-104 6G7 ENGINE - Oil Pan and Oil Pumn REMOVAL SERVICE POINT gA0 O I L P A N R E M O V A L (1) Knock the special tool deeply between the oil pan and the cylinder block. (2) Hitting the special tool on the side, slide it along the oil pan to remove it. ~BI) OUTER ROTOR / INNER ROTOR REMOVAL (1) Make alignment dots on the outer and inner rotors for reference in reassembly. INSPECTION OIL PUMP (1) Check the tip clearance. Standard value: 0.03 - 0.08 mm (.0012 - .0031 in.
PAGE 389
6G7 ENGINE - Oil Pan and Oil Pump OIL COOLER BYPASS VALVE (1) Make sure that the valve moves smoothly. (2) Ensure that the dimension L measures the standard value under normal temperature and humidity. Dimension L: 34.5 mm (1.358 in.) (3) The dimension must be the standard value when measured after the valve has been dipped in 100°C (212°F) oil. Dimension L: 40 mm (1.57 in.) or more 6EN0589 INSTALLATION SERVICE POINTS #A$ INNER ROTOR / OUTER ROTOR INSTALLATION (1) Apply engine oil to the rotors.
PAGE 390
IIE-106 6G7 ENGINE - Oil Pan and Oil Pump I)c4 OIL PAN INSTALLATION (1) Remove all the remaining gasket from the mating surfaces using a scraper or a wire brush. (2) Apply a 4 mm (.I6 in.) diameter bead of sealant to the oil pan flange. See “Form In-Place Gasket” in introduction. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent (3) The oil pan should be installed within 15 minutes after the application of sealant. (4) Tighten the flange bolts in the sequence shown in the illustration.
PAGE 391
6G7 ENGINE - Oil Pan and Oil Pump 1 ~@q’@!! +04 DRAIN PLUG GASKET INSTALLATION (1) Install the drain plug gasket as illustrated. I)E4 OIL FILTER INSTALLATION m l v$ket \ (1) Clean the installation surface of the filter bracket. (2) Apply engine oil to the O-ring of the oil filter. (3) Screw the oil filter on until the O-ring contacts the bracket. Then tighten 3/4 turn.
PAGE 392
IIE-108 6G7 ENGINE - Piston and Connecting Rod PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION ! 4 52 Nm 38 ft.lbs. Removal steps 1. Nut GAO #E4 2. Connecting rod cap 3. Connecting rod bearing (lower) eD4 4. Piston, connecting rod assembly 5. Connecting rod bearing (upper) 6. Piston rina No.? 7. Piston rini No.2 8. Oil ring 9. Piston pin 1 0. Piston 1 1. Connecting rod 1 2.
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6G7 ENGINE - Piston and Connecting Rod llEJl69 REMOVAL SERVICE POINTS OAr) CONNECTING ROD CAP REMOVAL (1) Mark the cylinder numberdon the side of the connecting rod big end for correct reassembly. (2) Keep the removed connecting rods, caps, and bearings in order according to the cylinder number.. 7EN044E 1 Q2 e @J 3 Piston pin setting tool MIT21 6941 \ 3 d/ II cl 6O Q 7EN0426 Press pin Piston pin 7ENO426 ITss 060 PISTON PIN REMOVAL Item No. Part No.
PAGE 394
IIE-110 6G7 ENGINE - Piston and Connecting Rod INSPECTION PISTON (1) Replace the piston if scratches or seizure is evident on its surfaces (especially the thrust surface). Replace the piston if it is cracked. PISTON PIN (1) Insert the piston pin into the piston pin hole with a thumb. You should feel a slight resistance. Replace the piston pin if it can be easily inserted or there is an excessive play. (2) The piston and piston pin must be replaced as an assembly.
PAGE 395
6G7 ENGINE - Piston and Connecting Rod CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE METHOD) The crankshaft oil clearance can be measured easily by using a plastic gauge, as follows: (1) Remove oil and grease and any other foreign matters from the crankshaft pin and the bearing inner surface. (2) Install the crankshaft. (3) Cut the plastic gauge to the same length as the width of the bearing and place it on the pin in parallel with its axis.
PAGE 396
6G7 ENGINE - Piston and Connectinn Rod (3) Place the base on the press support blocks. (4) Slide the piston pin over the threaded end of the press pin, and thread the correct guide pin up against it. (5) Coat the piston pin with oil, and with the connecting rod held in position, slide the guide pin through the piston and connecting rod. (6) Press the piston pin through the. connecting rod until the guide pin contacts the stop screw. (7) Remove the piston assembly from the base.
PAGE 397
6G7 ENGINE - Piston and Connecting Rod llE=IA3 bc4 PISTON RING NO.2 / PISTON RING NO.1 INSTALLATION (1) Using a piston ring expander, fit No.2 and then No.1 piston ring into position. NOTE 1. Note the difference in shape between No.1 and No.2 piston rings. 2. Install piston rings No.1 and No.2 with their side having marks facing up (on the piston crown side.) \ 7ENO452 7EN0369 Upper side rail and spacer gap +D4 PISTON AND CONNECTING ROD INSTALLATION No.
PAGE 398
IIE-114 6G7 ENGINE - Piston and Connectinn Rod I)E4 Cylinder No. / CONNECTING ROD CAP INSTALLATION (1) Mate the correct bearing cap with the correct connecting rod by checking with the alignment marks marked during disassembly. If a new connecting rod is used which has no alignment mark, position the notches for locking the bearing on the same side. Notches 7EN045: 3 (2) Check if the thrust clearance in the connecting rod big end is correct. Standard value: 0.10 - 0.25 mm (.0039 - .0098 in.
PAGE 399
1 l’E415 6G7 ENGINE - Crankshaft, Flywheel and Drive Plate CRANKSHAFT, FLYWHEEL AND DRIVE PLATE REMOVAL AND INSTALLATION 23 Nm 17 ftlbs. 1 I 74 7k Nm 54 ft.lbs. 26 75 Nm 54 ft.lbs. 6 14SOHC 79 Nm 57 ft.lbs. DOHC 93 Nm 67 ftlbs. 48Nm 35 ft.lbs. 16 Removal steps 1. Flywheel For MIT 2. Ball bearing > 3. Adaptor plate 4. Drive elate 1 For 4WD A/T 5. Crankshaft adaptor 1 6. Adaptor plate 7. Drive plate For FWD A/T 8. Rear plate 9. Bell housing cover eF4 IO.
PAGE 400
6G7 ENGINE - Crankshaft, Flywheel and Drive Plate INSPECTION CRANKSHAFT If the oil clearance exceeds the limit, replace the bearing, and crankshaft if necessary. (1) Measure the outside diameter of the journals and the inside diameter of the crankshaft bearings. If the difference between them (oil clearance) exceeds the limit, replace the crankshaft bearing and, if necessary, crankshaft. Standard value: 0.02 - 0.05 mm (.0008 - .0020 in.) Limit: 0.1 mm (.004 in.
PAGE 401
6G7 ENGINE - Crankshaft, Flywheel and Drive Plate ll&-1-17 INSPECTION CYLINDER BLOCK (I\ VisuaUy check for scratches, rust, and corrosion. Use also a flaw detecting agent for the check. If defects are evident, correct, or replace. (2) Using a straightedge and feeler gauge, check the block top surface for warpage. Make sure that the surface is free from gasket chips and other foreign matter. Standard value: 0.05 mm (.0020 in.) Limit: 0.1 mm (.0039 in.
PAGE 402
IIE-118 6G7 ENGINE - Crankshaft, Flywheel and Drive Plate (4) Bore all cylinders to the calculated boring finish dimension. Caution To prevent distortion that may result from temperature rise during honing, bore cylinders in the order of No.2, No.4, No.6, No.1, No.3 a n d No.5. (5) Hone to the final finish dimension (piston O.D. + clearance between piston 0-D. and cylinder). (6) Check the clearance between the piston and cylinder. Clearance between piston and cylinder: 0.01 - 0.04 m m (-0004 - .0016 in.
PAGE 403
6G7 ENGINE - Crankshaft, Flywheel and Drive Plate IfE-m I)B4 CRANKSHAFT BEARING (UPPER) / THRUST BEARING A / THRUST BEARING B / CRANKSHAFT BEARING (LOWER) INSTALLATION (1) Classify the crankshaft bearings (upper and lower) by whether there is an oil groove or not. Then, assemble as shown in the illustration. (2) Assemble the thrust bearings (A and B) on the No.3 journal area as shown. Caution Install them with the groove side facing outward.
PAGE 404
IIE-120 6G7 ENGINE - Crankshaft, Flywheel and Drive Plate BEARING CAP / BEARING BOLT INSTALLATION I)c4 (1) Attach the bearing cap on the cylinder block as shown in the illustration. (2) Tighten the bearing cap bolts to the specified torque in the sequence shown in the illustration. (3) Check that the crankshaft rotates smoothly. Cylinder (4) Check the end plate. If it exceeds the limit value, replace the thrust bearing. Standard value : 0.05 - 0.25 mm (.0020 - .0098 in.) Limit: 0.3 mm (.012 in.
PAGE 405
6G7 ENGINE - Crankshaft, Flywheel and Drive Plate IIE-121 I)E4 CRANKSHAFT REAR OIL SEAL INSTALLATION (1) Using the special tool, press-fit a new crankshaft rear oil seal into the oil seal case. 7EN046! i -I M 8990938-01 I I MD99871 8-01 7EN0466 Sealing agent I)F4 OIL SEAL CASE INSTALLATION (1) Apply specified sealant to the area shown in the illustration. Specified sealant: MITSUBISHI GENUINE Part No.
PAGE 406
llE-122 6G7 ENGINE - Bracket BRACKET REMOVAL AND INSTALLATION - DIAMANTE and 3000GT 2 42Nm 30 ft.lbs. I Removal steps 1. Engine support bracket, right 2. Engine support bracket, left 7EN0521 REMOVAL AND INSTALLATION - MONTERO and TRUCK 30 ft.lbs. 25 Nm 18 ft.lbs. Removal steps 1. Roll stopper bracket, front 2.
PAGE 407
ENGINE 4663, 4G64 <1993> CONTENTS BRACKET ................................................................ 115 CRANKSHAFT, FLYWHEEL AND DRIVE PLATE ........................................................ 110 CYLINDER HEAD AND VALVES ........................ 85 EXHAUST MANIFOLD AND WATER PUMP .................................................... 68 FRONT CASE, SILENT SHAFT AND OIL PAN ................................................................ 95 FUEL AND EMISSION CONTROL PARTS ....
PAGE 408
llF-2 4G6 ENGINE <1993> - General Information GENERAL INFORMATION ENGINE SECTIONAL VIEW - SOHC 8 VALVE 6EN0629 TSB Revision
PAGE 409
4G6 ENGINE <1993> - General Information 6EN0630 TS8 Revision
PAGE 410
llF-4 4G6 ENGINE <1993> - General Information ENGINE SECTIONAL VIEW - SOHC 16 VALVE 6EN0616 TSB Revision
PAGE 411
466 ENGINE <1993> - General Information 6EN0614 TSB Revision
PAGE 412
4G6 ENGINE <1993> - General Information - ENGINE SECTIONAL VIEW - DOHC 6EN0619 TSB Revision
PAGE 413
4G6 ENGINE <1993> - General Information I W7 6EN0620 TSB Revision
PAGE 414
4G6 ENGINE <1993> - General Information ENGINE LUBRICATION SYSTEM - SOHC 8 VALVE Rocker shaft %CT.
PAGE 415
4G6 ENGINE <1993> - General Information ENGINE LUBRICATION SYSTEM - DOHC ,Camshaft , , w Oil cooler l I--\ Oil - - I- Oil n Relief valve Oil pumr ‘Crankshaft ‘Silent shaft 6LUOil55 ENGINE LUBRICATION SYSTEM - DOHC-TURBO From thermostat case Oil filter To wate Oil jet / Ixessure switch Crankshaft Oil pump ’ \ ‘ S i l e n t A/ s h a f t 6LUOO56
PAGE 416
IIF-IO 4G6 ENGINE <1993> - General Specifications GENERAL SPECIFICATIONS 4663 SOHC 16 VALVE Items Specifications In-line OHV, SOHC 4 Pentroof type 1,997 (121.9) 85 (3.35) 88 (3.46) 9.5 Type Number of cylinders Combustion chamber Total displacement cm3 (cu. in.) mm (in.) Cylinder bore mm (in.
PAGE 417
466 ENGINE <1993> - General Specifications 4664 SOHC 8 VALVE % I Items Specifications TVP~ In-line of OHV, SOHC 4 Number &nders Combustion chamber cm3 (cu. in.) T&al displacement mm (in.) Cylinder bore mm (in.) Piston stroke Compression ratio Valve timing Intake valve BTDC Opens Closes ABDC Exhaust valve BBDC Opens Closes ATDC Lubrication system Oil pump type Cooling system Water pump type EG R valve njector type and number njector identification No.
PAGE 418
llF-12 466 ENGINE <1993> - General Specifications 4G64 SOHC 16 VALVE Items Specifications Type Number of cylinders Combustion chamber cm3 (cu. in.) Total displacement mm (in.) Cylinder bore mm (in.) Piston stroke Compression ratio Valve timing intake valve BTDC Opens ABDC Closes Exhaust valve BBDC Opens ATDC Closes Lubrication system Oil pump type Cooling system Water pump type EGR valve Injector type and number Injector identification No. Fuel regulated pressure kpa (psi) Throttle bore mm (in.
PAGE 419
1 ‘f-F31 3 466 ENGINE <1993> - General Specifications 4G63 DOHC Items Specifications Type Number of cylinders Combustion chamber cm3 (cu. in.) Total displacement Cylinder bore mm (in.) Piston stroke mm (in.
PAGE 420
llF-14 4G6 ENGINE <1993> - Service Specifications SERVICE SPECIFICATIONS mm (in.) Cylinder head - SOHC 8 VALVE Flatness of gasket surface Grinding limit of gasket surface * Total resurfacing depth of both cylinder head and cylinder block. Overall height Oversize rework dimensions of valve guide hole (both intake and exhaust) 0.05 (002) 0.25 (.OlO) 0.50 (020) Oversize rework dimensions of intake valve seat ring hole 0.30 f.012) 0.60 (.024) Oversize rework dimensions of exhaust valve seat ring hole 0.30 f.
PAGE 421
llF-15 4G6 ENGINE <1993> - Service Specifications mm (in.) Standard Limit 0.05 (.0020) 0.2 (.008) *0.2 (.008) 0.15 (.0059) 131.9-132.1 (5.193-5.201) 0.3 LO1 2) Cylinder head - DOHC Flatness of gasket surface Grinding limit of gasket surface * Total resurfacing depth of both cylinder head and cylinder block Flatness of manifold mounting surface Overall height Oversize rework dimensions of valve guide hole (both intake and exhaust) 0.05 (.002) 0.25 (.OlO) 0.50(.
PAGE 422
llF-16 4G6 ENGINE <1993> - Service Specifications mm (in.) Standard Limit Rocker arm - SOHC 8 VALVE I.D. Rocker arm-to-shaft clearance 18.91 - 18.93 (.7445- .7453) 0.01 - 0.04 (.0004- .0016) 0.1 (.004) Rocker arm - SOHC 16 VALVE I.D. Rocker arm-to-shaft clearance 20.02 - 20.04 i.7882 - .7890) 0.02 - 0.05 (.0008 - .0020) 0.1 i.004) Lash adjuster Leak down test Remarks: Diesel fuel at 15 - 20°C (59 - 68°F) Rocker shaft - SOHC 8 VALVE 3.D. 3verall length Intake Exhaust 4 - 20 seconds/l mm I.04 in.
PAGE 423
466 ENGINE <1993> - Service SDecifications mm (in.) Standard Valve - SOHC 16 VALVE Overall length Intake Exhaust Stem diameter Intake Exhaust Face angle Thickness of valve head (margin) Intake Exhaust Stem-to-guide clearance Intake Exhaust Limit 112.3 (4.421) 114.1 (4.492) 5.97 - 5.98 i.2350 - .2354) 5.95 - 5.97 (.2343 - .2350) 45” - 45”30’ 1 .o (.039) 1.2 (.047) 0.5 (.020) 0.7 (.028) 0.02 - 0.05 i.0008 - .0020) 0.03 - 0.07 LOOI 2 - .0028) 0.10 (.004) 0.15 i.
PAGE 424
llF-18 4G6 ENGINE <1993> - Service SDecifications mm (in.) Limit Standard Valve guide- SOHC 8 VALVE Overall length Intake Exhaust I.D. O.D. Service size Press-in temperature 47 (1.85) 52 (2.05) 8.00 - 8.02 (3150 - .3157) 13.06 - 13.07 (5142 - .5146) 0.05 (.002), 0.25 (.OlO), 0.50 (.020) oversize Room temperature Valve guide - SOHC 16 VALVE Overall length Intake Exhaust I.D. O.D. Service size Press-in temperature 45.5 (1.79) 50.5 (1.99) 6.00 - 6.02 (236 - ,237) 11.06 - 11.07 (4354 - .4358) 0.05 (.
PAGE 425
1 IF49 4G6 ENGINE <1993> - Service SDecifications mm (in.) Standard Limit Piston - DOHC O.D. Non-turbo Turbo Piston to cylinder clearance Non-turbo Turbo Service size 84.97 - 85.00 (3.3453 - 3.3465) 84.96- 84.99 (3.3449 - 3.3461) 0.02 -0.04 (0008 - .0016) 0.03 -0.05 (0012 - .0020) 0.25 LOlO), 0.50 (.020), 0.75 (.030), 1 .OO (.039) over size Piston ring - SOHC End gap No. 1 ring No.
PAGE 426
llF-20 4G6 ENGINE <1993> - Service Specifications mm (in.) Crankshaft End play Journal O.D. Pin O.D. Out-of-roundness and taper of journal and pin Concentricity of journal Oil clearance of journal Oil clearance of pin Standard Limit 0.05 - 0.25 (0020 - .0098) 56.98 - 57.00 (2.2433 - 2.2441) 44.98 - 45.00 (1.7709 - 1.7717) Max. 0.01 (.0004) Max. 0.02 (.0008) 0.02 - 0.05 (0008 - .0020) 0.02 - 0.05 (0008 - .0020) 0.4 (.016) 0.1 (.004) 0.1 (.004) Cylinder block Cylinder I.D. 4G63 4G64 85.00 - 85.03 (3.
PAGE 427
1 IF221 466 ENGINE <1993> - Torque Specifications TORQUE SPECIFICATIONS ^... Nm ft.lbs.
PAGE 428
11 F-22 466 ENGINE <1993> - Torque Specifications Intake manifold Intake manifold bolt and nut Intake manifold bolt (Ml 0) and nut (Ml 0) - DOHC Intake manifold stay bolt - SOHC Intake manifold stay bolt - DOHC Intake manifold plenum bolt and nut Intake manifold plenum stay bolt Water outlet fitting bolt Engine coolant temperature gauge unit Engine coolant temperature sensor Thermostat case nut Nm ft.1b.s.
PAGE 429
q pFip$ 4G6 ENGINE <1993> - Torque Specifications Nm ft.lbs. 6 3 4 2.2 24 20 20 32 11 17 14 14 23 8 20 + 114 turns + l/4 turns 14.
PAGE 430
11 F-24 4G6 ENGINE <1993> - Sealant SEALANT Rocker cover Semi-circular packing Engine support bracket bolt Oil pan gasket Water outlet fitting Engine coolant temperature gauge unit Engine coolant temperature sensor Oil pressure switch Oil pressure gauge unit Rear oil seal case Specified sealant Quantity 3M ATD Part No. 8660 or equivalent 3M ATD Part No. 8660 or equivalent 3M ATD Part No.
PAGE 431
4G6 ENGINE <1993> - Special Tools SPECIAL TOOLS Use with M IT304204 Use with MIT304204 Crankshaft front oil seal installer TSB Revision
PAGE 432
4G6 ENGINE <1993> - Special Tools llF-26 Number and tool name Tool 8 & Supersession Application Air bleeding of lash adjuster For SOHC engine only c”,iFeFter Air bleed of lash adjuster MD998442 Air bleed wire A@ MD998443 Lash adjuster holder (8) MD998443-01 Supporting of the lash adjuster to prevent it from falling when rocker shaft assembly is removed or installed For SOHC engine only MD998705 Silent shaft bearing installer M D998373-0 1 Installation of silent shaft bearing M D9987 13-01 I
PAGE 433
4G6 ENGINE <1993> - Special Tools I'IF-27 tool name compressor Crankshaft rear oil seal installer MD998779 M D998780 Piston pin setting tool MIT21 6941 Removal and installation of piston pin Supporting flywheel and drive plate TSB Revision
PAGE 434
11 F-28 4G6 ENGINE <1993> - Generator and lanition Svstem GENERATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION - SOHC 8 VALVE 25 Nm 18 ftlbs, 1'0 14 Nm 10 ft.lbs. 11 Nm 8 ftlbs. 25 N’m 18 ft.lbs. 11 Nm 8 ft.lbs. Removal steps *DC 1. Drive belt 2. Cooling fan 3. Fan clutch 4. Water pump pulley 5. Power steering pump pulley 6. Generator brace 7. Generator 8. Crankshaft pulley 9. Spark plug cable 10. Spark plug 11. High tension cable 12.
PAGE 435
466 ENGINE <1993> - Generator and Ignition System REMOVAL AND INSTALLATION - SOHC 16 VALVE 25 ‘Nm 18 ft.lbs. r- 14 Nm 10 ft.lbs. 24Nm 17 ftlbs. Removal steps eD4 1. Drive belt 2. Water pump pulley 3. Power steering pump pulley 4. Generator brace 5. Generator 6. Crankshaft pulley 7. Spark plug cable 8. Spark plug )BC 9.
PAGE 436
llF-30 466 ENGINE <1993> - Generator and Ignition System REMOVAL AND INSTALLATION - DOHC 3Nm 2 ft.lbs.- 25 Nm 18 ft.lbs. 8 19 Nm 14 ft.lbs. 23 Nm 17 ft.lbs. ‘Nm ft.lbs. 11 Nm 8 ft.lbs. 24 Nm 17 ft.lbs. d 0 4 10 1 h~?emoval steps #DC 1. Drive belt 2. Water pump pulley 3. Power steering pump pulley 4. Generator brace 5. Generator 6. Crankshaft pulley 24&h 17 klbs. 7. Center cover 8. Spark plug cable 9. Spark plug 10. Ignition power transistor 1 1. Ignition coil #C4 12.
PAGE 437
4G6 ENGINE <1993> - Generator and Ignition System llF-31 INSTALLATION SERVICE POINTS +A4 DISTRIBUTOR INSTALLATION (1) Turn the crankshaft so that the No. 1 cylinder is at top dead center. (2) Align the distributor housing and gear mating marks. (2) Install the distributor to the engine while aligning the fine cut (groove or projection) of the distributor’s installation flange with the center of the distributor installation stud.
PAGE 438
11 F-32 466 ENGINE <1993> - Generator and Ignition System *Dg DRIVE BELT TENSION ADJUSTMENT ADJUSTER TYPE (1) Adjust belt deflection to standard value. Turn adjusting bolt clockwise to increase the belt tension and turn adjusting bolt counterclockwise to decrease the belt tension. Standard value: V-ribbed type belt New belt 7.5 - 9.0 mm (.30 - .35 in.) Used belt 8.0 mm (.32 in.) V-type belt 7.0 - 10.0 mm (.28 - .39 in.) 6EN0595 When using tension gauge for V-ribbed belt only.
PAGE 439
ltF~33 4G6 ENGINE <1993> - Timing Belt TIMING BELT REMOVAL AND INSTALLATION - SOHC 8 VALVE 16 3 I I 46Nm 90 Nm -rJ 1.111 35 ft.lbs. I I I I i7 14 Nm 10 ft.lbs. 49Nm 35 ft.lbs. 55 km 40 ft.lbs. 87 ft.lbs. Removal steps 1. Timing belt front upper cover 2. Timing belt front lower cover (IAI$ #NC 3. Timing belt +K4 4. Tensioner spring *Kg 5. Tensioner pulley ODrJ +Jg 6. Oil pump sprocket ($8 *I4 7. Crankshaft bolt 8. Crankshaft sprocket 9. Flange 10. Tensioner “B” (AG~J*H~ 11.
PAGE 440
11 F-34 466 ENGINE <1993> - Timina Belt REMOVAL AND INSTALLATION - SOHC 16 VALVE 46 Nm 33 ftlbs. 10 ftlbs. -” 19 1 15 I&.,“=. ..- .-mm-... anNm i I 120 Nm 87 ftlbs. ap 2I 24 Nm 17 ft.lbs. Removal steps 1. Timing belt front upper cover 2. Timing be :It front lower cover (IBO )04 3. Timing belt #M4 4. Tensioner pulley 5. Tensioner arm eL4 6. Auto tensioner 7. Idler pulley QOr)eJ4 8. Oil pump sprocket 818 *I4 10. 9. Crankshaft Crankshaft sprocket bolt 11. Flange 12. Tensioner “B” OGr) eH4 13.
PAGE 441
4G6 ENGINE <1993> - Timing Belt 1 TF45 REMOVAL AND INSTALLATION - DOHC 3Nm 2.2 ft.1 16 45\Nm 24 33 ftlbs. ) lb 120 Nm 87 ft.lbs. 55dlm 40 ft.lbs. i9Nm 14 ft.lbs. Removal steps 1. Timing belt front upper cover 2. Timing belt front lower cover 4Cg eP4 3. Timing belt *MC 4. Tensioner pulley 5. Tensioner arm eL4 6. Auto tensioner 7. Idler pulley (100 ~~ 8. Oil pump sprocket $18 +I4 9. Crankshaft bolt 10. Crankshaft sprocket 11. Flange 12. Tensioner “B” (ICI) +Hg 13. Timing belt “B” OHr) eG4 14.
PAGE 442
11 F-36 4G6 ENGINE <1993> - Timing Belt REMOVAL SERVICE POINTS gA0 TIMING BELT REMOVAL (1) Mark the belt running direction for reference in reinstallation. NOTE (1) Water or oil on the belt shorten its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and water. These parts should not be washed. Replace parts if seriously contaminated. (2) If there is oil or water on each part check front case oil seals, camshaft oil seal and water pump for leaks.
PAGE 443
4G6 ENGINE <1993> - Timing Belt 1 w-37 OEr) CRANKSHAFT BOLT LOOSENING GFrj CRANKSHAFT SPROCKET REMOVAL qG0 TIMING BELT “9” REMOVAL (1) Make a mark on the back of the timing belt indicating the direction of rotation so, it may be reassembled in the same direction if it is to be reused. NOTE (1) Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and water. These parts should not be washed.
PAGE 444
11 F-38 466 ENGINE <1993> - Timing Belt (IJO CAMSHAFT SPROCKET BOLT LOOSENiNG OK0 CAMSHAFT SPROCKET BOLT LOOSENING (1) Using a wrench, hold the camshaft at its hexagon (between the No. 2 and No. 3 journals) and remove the camshaft sprocket bolt. Caution Locking the camshaft sprocket with a tool damages the sprocket. (2) Remove the camshaft sprockets. INSPECTION TIMING BELT Replace belt if any of the following conditions exist. u 0 0 008 G (1) Hardening of back rubber. Back side is glossy without.
PAGE 445
466 ENGINE <1993> - Timing Belt llF-39 (6) Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife. Roundededge / Abnormal wear (Fluffy strand) 8EN0067 (7) Abnormal wear on teeth. (8) Missing tooth. Rubber exposed Tooth missing and canvas fiber exposed AUTO TENSIONER (1) Check the auto tensioner for possible leaks and replace as necessary. (2) Check the rod end for wear or damage and replace as necessary. m D 1 - 1 (3) Measure the rod protrusion.
PAGE 446
llF-40 4G6 ENGINE <1993> - Timing Belt INSTALLATION SERVICE POINTS +A4 CAMSHAFT SPROCKET TIGHTENING I)B4 CAMSHAFT SPROCKETS TIGHTENING (1) Using a wrench, hold the camshaft at its hexagon (between the No. 2 and No. 3 journals) and tighten the bolt to the specification. Caution Locking the camshaft sprocket with a tool damages the sprocket. +cg ENGINE SUPPORT BRACKET INSTALLATION (1) Coat the bolts illustrated with sealant before tightening. Specified sealant: 3M ATD Part No.
PAGE 447
4G6 ENGINE <1993> - Timing Belt Apply sealant :::::., . , . . ..:::::::::::::::::i:::::... . . *.-.-.-.a..,. . . . . . . .*.a IbDC . , SEALANT APPLICATION ON SEMI-CIRCULAR PACKING Specified sealant: 3M ATD Part No. 8660 or equivalent : d DEN0053 \I0 mr.,n (19 S-_ in.) ,’ I \ .:“:\Z.::. .:I . .::...:*.:..:,. 2.
PAGE 448
11 F-42 466 ENGINE <1993> - Timing Belt I)Eg SEALANT APPLICATION ON ROCKER COVER Apply sealant to the areas indicated in the illustration. Specified sealant: 3M ATD Part No. 8660 or equivalent IOmm Apply sealant 6EN0396 & , (+lseal I)F4 SPACER INSTALLATION (1) Install the spacer with the chamfered end toward the oil seal.
PAGE 449
4G6 ENGINE <1993> - Timing Belt WF-43 TIMING, BELT “B” INSTALLATION (1) Align timing marks on the crankshaft sprocket “B” and silent shaft sprocket with the marks on the front case respectively. (2) Install the timing belt “B” on the crankshaft sprocket “B” and silent shaft sprocket. There should be no slack on the tension side. I)H4 (3) Make sure that the relationship between the tensioner pulley center and the bolt center is as shown in the illustration.
PAGE 450
11 F-44 4G6 ENGINE <1993> - Timing Belt eJ4 OIL PUMP SPROCKET INSTALLATION (1) Insert a Phillips screwdriver [shank diameter 8 mm (.31 in.) shaft] through the plug hole on the left side of the cylinder block to block the left silent shaft. (2) Install the oil pump sprocket. (3) Apply a proper amount of engine oil to the bearing surfaces of the nuts. (4) Tighten the nuts to the specified torque.
PAGE 451
4G6 ENGINE <1993> - Timing Belt ‘IIF; (6) Install the auto tensioner to front case and tighten to the specified torque. Caution Leave the wire installed in the auto tensioner. TENSIONER PULLEY INSTALLATION (1) Install the tensioner pulley in such direction that its two small holes are arranged vertically. eM4 TIMING BELT INSTALLATION (1) Check that the timing belt tensioner has been installed in position. (See I)K@ (2) Align timing mark on camshaft sprocket with timing mark on cylinder head.
PAGE 452
llF-46 I 4G6 ENGINE <1993> - Timina Belt 6EN0563 1 6EN05641 (8) Turn the crankshaft clockwise by two teeth of camshaft sprocket (or crankshaft sprocket). Timing mark Two teeth (5) Remove the plug on cylinder block and insert a Phillips screwdriver [shank diameter 8 mm (.31 in.)] through the hole (Engine with silent shafts). If it can be inserted as deep as 60 mm (2.4 in.) or more, the timing marks are correctly aligned. If the inserted depth is only 20 - 25 mm (.8 .- 1 .O in.
PAGE 453
4G6 ENGINE <1993> - Timing Belt 11 F-47 (11 )Hold the center of the tension side span of the timing belt (between the camshaft and oil pump sprockets) between your thumb and index finger as shown. Then, make sure that the clearance between the belt back surface and cover is standard value. Standard value: 14 mm (.55 in.) I)04 TIMING BELT INSTALLATION (1) Check that the timing belt tensioner and spring have been installed in position.
PAGE 454
11 F-48 4G6 ENGINE <1993> - Timing Belt (6) Install the timing belt on the crankshaft sprocket, idler pulley, camshaft sprocket, and tensioner pulley in that order. (7) Lift up the tensioner pulley in the direction of arrow and tighten the center bolt. (8) Check to see that all timing marks are lined up. (9) Remove the screwdriver inserted in step (5) and fit the plug. (lO)Give the crankshaft a quarter counter-clockwise turn. Then, turn it clockwise until the timing marks are lined up again.
PAGE 455
4G6 ENGINE <1993> - Timing Belt Camshaft sprocket Intake Dowel “tw49 I)P4 TIMING BELT INSTALLATION (1) Turn the two sprockets so that their dowel pins are located on top. Then, align the timing marks facing each other with the top surface of the cylinder head. When you let go of the exhaust camshaft sprocket, it will rotate one tooth in the counterclockwise direction. This should be taken into account when installing the timing belt on the sprockets.
PAGE 456
llF=50 466 ENGINE <1993> - Timing Belt (5) Thread the timing belt over the intake side camshaft sprocket and fix it at indicated position by a clip. (6) Thread the timing belt over the exhaust side sprocket, aligning the timing marks with the cylinder head top surface using two wrenches. (7) Fix the belt at indicated position by a clip. (8) Thread the timing belt over the idler pulley, the oil pump sprocket, the crankshaft sprocket and the tensioner pulley in the order shown. (9) Remove the two clips.
PAGE 457
4G6 ENGINE <1993> - Timina Belt YlF-51 (14)lnstall the special tools, Socket Wrench and Torque Wrench, on the tensioner pulley, and loosen the tensioner pulley center bolt. NOTE If the special tool is not available, use a commercially available torque wrench that is capable of measuring 0 - 3 Nm (0 - 2.2 ft.lbs.). (15)Torque to 2.6 - 2.8 Nm (1.88 - 2.03 ft.lbs.) with the torque wrench. (16)Holding the tensioner pulley with the special tool and torque wrench, tighten the center bolt to specification.
PAGE 458
11 F-52 4G6 ENGINE <1993> - Fuel and Emission Control Parts FUEL AND EMISSION CONTROL PARTS REMOVAL AND INSTALLATION - SOHC for GALANT/EXPO/EXP LRV 6 .12Nm 9 ftlbs. 22 Nm 16 ft.lbs. Removal steps I. Throttle body 2. Throttle body gasket 3. EGR valve 4. EGR valve gasket 5. EGR temp sensor - For California 6. Injectors and delivery pipe 7. Insulator 8. Fuel pressure regulator “’ 1:: K11Sor *A4 11. Injector clip eB4 12. Injectors 13. O-ring 14. Grommet 15. Fuel rail u-- 5-11Nm 6 ft.lbs.
PAGE 459
4G6 ENGINE <1993> - Fuel and Emission Control Parts Ill=-53 REMOVAL AND INSTALLATION - SOHC for TRUCK 9Nm 6 12 Nm 9 ft.lbs. 22km 16 ft.lbs. Removal steps 1. Throttle body 2. Throttle body gasket 3. EGR valve 4. EGR valve gasket 5. EGR temp sensor- For California 6. Injectors and fuel rail 7. Insulator 8. Fuel pressure regulator 9. O-ring 10. Insulator 11. Injectors 12. O-ring 13. Grommet 14.
PAGE 460
11 F-54 4G6 ENGINE <1993> - Fuel and Emission Control Parts REMOVAL AND INSTALLATION - DOHC 12 Nm 9 ft.lbs. 1 19 Nm 14 ft.lbs. I 3 19 Nm 14 ftlbs. 22 Nm 16ft.lbs. Removal steps 1. Throttle body stay 2. Throttle body 3. Throttle body gasket 4. EGR valve 5. EGR valve gasket 6. EGR temp sensor - For California 7. Injectors and fuel rail 8. Insulator 9. Fuel pressure regulator *C4 10. O-ring 11. Insulator *I34 12. Injectors 13. O-ring 14. Grommet 15.
PAGE 461
466 ENGINE <1993> - Fuel and Emission Control Parts 1 l,F-55 INSPECTION 6EM0381 EGR VALVE (1) Check EGR valve for sticking or carbon deposits. If such conditions exist, clean or replace EGR valve. (2) Connect a hand vacuum pump to the nipple of EGR valve and plug other nipple. (3) Apply a vacuum of 500 mmHg (19.7 in. Hg) to make sure that a vacuum is maintained. If there is a leak, replace the EGR valve. In addition, check the valve for its opening and closing by applying and removing a vacuum.
PAGE 462
11 F-56 4G6 ENGINE <1993> - Fuel and Emission Control Parts (2) Install injector top end into fuel rail. Be careful not to damage the O-ring during installation. DOHC 6EN0521 I)c4 FUEL PRESSURE REGULATOR INSTALLATION (1) Before installing pressure regulator the O-ring must be lubricated with a drop of clean engine O-ring to aid in installation.
PAGE 463
466 ENGINE <1993> - Throttle Body 1 ‘IF-57 THROTTLE BODY DISASSEMBLY AND REASSEMBLY SOHC - TRUCK - Federal 2Nm 1.4ft.lbs.- Disassembly steps (Ar) *A4 1. Throttle position sensor 2. Speed control motor aA 3. Throttle valve set screw eB4 4. Throttle body 6FU1292 SOHC - TRUCK - California SOHC - GALANT 2Nm Disassembly steps $g +A4 I. Throttle position sensor 2. Idle air control motor 3. Throttle valve set screw 4. Throttle body (30 3.
PAGE 464
llF-58 466 ENGINE <1993> - Throttle Body SOHC - EXPO/EXPO LRV 2Nm 1.4ft.lbs. Disassembly steps 1. Accelerator wire bracket -EXPO/EXP LRV $I;! I)A4 2. Throttle position sensor 3. Idle air control motor 4. Throttle valve set screw 5. Throttle body @O 6FU1857 2Nm 1.4ft.lbs. Disassembly steps -l 1. Dash pot 2. Hose GALANT 3. Vacuum valve $18 +A4 4. Throttle posltlon sensor 5. idle air control motor 6. Idle position switch 7. Adjusting nut 8.
PAGE 465
4G6 ENGINE <1993> - Throttle Body tl F-59 DISASSEMBLY SERVICE POINTS gA0 THROTTLE POSITION SENSOR AND IDLE AIR CONTROL MOTOR REMOVAL (1) Do not disassemble the sensor and motor. (2) Do not immerse solvent to clean the sensor and motor. Clean them with shop towel. QBo THROlTLE BODY REMOVAL (1) Do not remove the throttle valve. (2) Check if the vacuum port or passage is clogged. Use compressed air to clean the vacuum passage.
PAGE 466
11 F-60 4G6 ENGINE <1993> - Throttle Bodv 7FU029t Motor position sensor connector Idle speed control servo connector 6FU125 (3) Holding the idle air control motor as shown in the illustration, connect the negative 0 terminal of the power supply to each clip as described in the following steps, and check whether or not a vibrating feeling (a feeling of very slight vibration of the stepper motor) is generated as a result of the activation of the stepper motor.
PAGE 467
4G6 ENGINE <1993> - Throttle Body REASSEMBLY SERVICE POINTS #A4 THROlTLE P O S I T I O N S E N S O R INSTALLAtION SOHC FOR EXPO (1) Install the throttle position sensor to the throttle body as shown in the illustration. (2) Turn the throttle position sensor 90” counterclockwise to set it in position and tighten the screws. u 6FU185E Throttle position sensor output Ground Idle-position switch (3) Connect the circuit tester between @ (ground) and @ (output), or between @ (output) and @ (power).
PAGE 468
11 F-62 466 ENGINE <1993> - Throttle Body (2) Turn the throttle position sensor 90” in the clockwise direction to set it and tighten the screws. Throttle position sensor power Ground (3) Connect the circuit tester between @ (ground) and @ (output), or between @ (output) and @ (power). Then, make sure that the resistance changes smoothly when the throttle valve is slowly moved to the fully open position.
PAGE 469
4G6 ENGINE <1993> - Intake Manifold llF-63 INTAKE MANIFOLD REMOVAL AND INSTALLATION - SOHC - 8 VALVE 5 8 ft.lbs. 13 Removal steps 1. Water hose 2. Water hose +FC 3. Engine coolant temperature gauge unit *E( 4. Engine coolant temperature sensor 5. Water outlet fitting )B4 6. Gasket 7. Thermostat 8. Thermostat housing 9. Gasket 10. Intake manifold plenum stay 11. Intake manifold plenum 12. Intake manifold plenum gasket 13. Intake manifold stay 14. Engine hanger 15. Intake manifold 16.
PAGE 470
11 F-64 466 ENGINE <1993> - Intake Manifold lEMOVAL AND INSTALLATION - SOHC - 16 VALVE 13 Nm 9 ft.lbs. 24 Nm 4Q& IhC I I 5 30Nm _ 22 ftlbs. - 4 11 Nm R*lhe-3~ ‘ub18Nm Removal steps 1. Water hose 2. Water hose +F4 3. Engine coolant temperature sensor eE4 4. Engine coolant temperature gauge unit eD4 5. Water inlet fitting 6. Thermostat 7. Water outlet fitting )C(l 8. Thermostat housing 9. Intake manifold stay 10. Intake manifold 11. Intake manifold gasket TSB Revision 13 ft.lbs. 31 ium 22 ft.lbs.
PAGE 471
llF-65 4G6 ENGINE <1993> - Intake Manifold REMOVAL AND INSTALLATION - DOHC (To turbocharger) T (To oil cooler) @ Removal steps 1. Water hose 2. Water hose 3. Water hose (turbo) 4. Water hose (turbo) *F4 5. Engine coolant temperature gauge unit eE4 6. Engine coolant temperature sensor 7. Water outlet fitting 8. Gasket 9. Thermostat eC4 10. Thermostat case 11. Gasket 12. Intake manifold stay +A4 13. Intake manifold 14. Intake manifold gasket 20 ftlbs.
PAGE 472
466 ENGINE <1993> - Intake Manifold 11 F-66 INSTALLATION SERVICE POINTS *A4 INTAKE MANIFOLD INSTALLATION - DOHC (1) Tighten the intake manifold bolts, noting that the bolts installed at the locations indicated in the illustration are tightened to a different torque. 6lN00453 I)Bg WATER OUTLET FITTING GASKET INSTALLATION (FOR RUBBER COATED METAL GASKET ONLY) (I) install the water outlet fitting gasket with its “UP” mark facing up (toward the water outlet fitting side).
PAGE 473
4G6 ENGINE <1993> - Intake Manifold 11 F-67 I)F4 SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE GAUGE UNIT Specified sealant: 3M ATD Part No.
PAGE 474
11 F-68 4G6 ENGINE <1993> - Exhaust Manifold and Water Pump EXHAUST MANIFOLD AND WATER PUMP REMOVAL AND INSTALLATION - SOHC 8 VALVE 30 Nm 22 ft.lbs. 14 Nm lo ft.lbs. 4 18 Nm 13 ft.lbs. I 3 14 Nm 10 ft.lbs. Removal steps I, Oxgen sensor-Federal 2. Oil level gauge 3. Oil level gauge guide 4. Heat protector 5. Engine hanger 6. Exhaust manifold 7. Exhaust manifold gasket #A4 8. Water inlet pipe #A4 9. O-ring 10. Water pump 11.
PAGE 475
4G6 ENGINE <1993> - Exhaust Manifold and Water Pump 1’1 F-69 ;EMOVAL AND INSTALLATION - SOHC - 16 VALVE 14 Nm 10 ft.uM. 28 Nm 20 ft.lbs. 14 Nm 10 ft.lbs. 2 60 Nm 13 ft.lbs.v Removal steps 1. Oxgen sensor-GALANT/EXPO Federal 2. Oil level gauge 3. Oil level gauge guide 4. O-ring 5. Heat protector 6. Heat protector -GALANT/EXPO.EXP LRV -Federal 7. Engine hanger 8. Exhaust manifold 9: Exhaust manifold gasket #A4 10. Water inlet pipe *A4 11. O-ring 12. Water pump 13.
PAGE 476
llF-70 4G6 ENGINE <1993> - Exhaust Manifold and Water Pump IEMOVAL AND INSTALLATION - DOHC FOR NON-TURBO 14Nm 10 Wbs. 45 Nm l- 33 ft.lbs. 14 Nm 10 ft.lbs. 60 Nm 43 ft.lbs. 14 Nm lo ftlbs. Removal steps 1. Oxygen sensor 2. Oil level gauge 3. Oil level gauge guide 4. O-ring 5. Heat protector “A” 6. Heat protector “B” 7. Engine hanger 8. Exhaust manifold 9. Exhaust manifold gasket *A4 10. Water inlet pipe )A4 11. O-ring 12. Water pump 13.
PAGE 477
4G6 E N G I N E <1993> - Exhaust Manifold and ‘Water Pump 1’?F-71 IEMOVAL AND INSTALLATION - DOHC TURBO 14 Nm IO ft.lbs. 14 Nm 11 Nm ~ - 8ft.lbs. 10 ftlbs. I 60 Nm 6 14 Nm 10 ftlbs. 13 ?!J 27 I 28 I 12 IZI I 24 Nm 11 17 ft.lbs. I\4 Nm 10 ft.lbs. w 9Nm 7 ft.lbs. k9 - 1 2 Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Heat protector “A” 5. Heat protector “B” 6. Exhaust fitting 7. Gasket 8. Air outlet fitting 9. Gasket 10. Water pipe “B” 11. Oil return pipe 12.
PAGE 478
llF-72 4G6 ENGINE <1993> - Exhaust Manifold and Water Pump INSTALLATION SERVICE POINT I)A4 WATER PIPE/O-RING INSTALLATION O-ring (1) Wet the O-ring (with water) to facilitate assembly. Caution Keep the O-ring free of oil or grease.
PAGE 479
466 ENGINE <1993> - Turbocharger l;l’F~73 TURBOCHARGER DISASSEMBLY AND REASSEMBLY 7 Disassembly steps Inspection of turbocharger waste gate V4 actuator operation 1. Snap pin 2. Turbochargerwaste gate actuator *EC 3. Coupling eO4 4. Turbine housing )C4 5. Snap ring #Bg 6. Turbine wheel assembly 7. Compressor cover #A4 8.
PAGE 480
11 F-74 4G6 ENGINE <1993> - Turbocharger INSPECTION es for act 6lN005E Oil passage Water passage whekl 3ENOlJ 73 ; TURBINE HOUSING (1) Check the housing for traces of contact with the turbine wheel, cracks due to overheating, pitching, deformation and other damage. Replace with a new turbine housing if cracked. (2) Operate the turbocharger waste gate valve lever manually to check that the gate can be opened and closed smoothly.
PAGE 481
466 ENGINE <1993> - Turbocharger 11 F-75 +D+ TURBINE HOUSING INSTALLATION (1) Install the turbine housing in relation to the dowel pin. Caution Use care not to damage the blades of turbine wheel. I)E4 COUPLING INSTALLATION (1) Install the coupling and tighten to specified torque. Coupling 1 #F4 TURBOCHARGER WASTE GATE ACTUATOR OPERATION INSPECTION (1) Using a tester, apply a pressure of approx. 72 kPa (10.3 psi) to the actuator and make sure that the rod moves.
PAGE 482
11 F-76 4G6 ENGINE <1993> - Rocker Arms and Camshaft ROCKER ARMS AND CAMSHAFT REMOVAL AND INSTALLATION - SOHC 8 VALVE 6Nm 4 ft.lbs. Tr o-5 20 Nm 14 ft.lbs. 24 Nm 17 ft.lbs.- @--6 Removal steps 1. Breather hose 2. P.C.V. hose Oil filter cap Rocker cover Gasket Semi-circular packin Rocker arms and rotg, er shafts Rear bearing cap Rocker arm D Spring Bearing cap No. 4 Rocker arm C Bearing cap No. 3 Bearing cap No.
PAGE 483
4G6 ENGINE <1993> - Rocker Arms and Camshaft IIF: {EMOVAL AND INSTALLATION - SOHC 16 VALVE Removal steps 1. Breather hose 2. P.C.V. hose 3. Oil filler cap 4. Rocker cover 5. Rocker cover gasket 6. Oil seal eH4 7. Oil seal (rare +G4 8. Rocker arms and rocker arm shaft @Jr) eG4 9. Rocker arms and rocker arm shaft eG4 10. Rocker shaft spring 11. Rocker arm A 12. Rocker arm B 13. Rocker arm shaft (Intake side) +F4 14. Lash adjuster 15. Rocker arm C i 16. Rocker arm shaft (Exhaust side) +F4 17.
PAGE 484
11 F-78 4G6 ENGINE <1993> - Rocker Arms and Camshaft {EMOVAL AND INSTALLATION - DOHC 20 Nm 14 ftlbs: 11 Nm 8 ft.lbs. Removal steps *Eg 1. Bearing cap rear +Eg 2. Bearing cap front eH4 3. Camshaft oil seal eE4 4. Bearing cap No. 5 eE4 5. Bearing cap No. 2 eE4 6. Bearing cap No. 4 #E4 7. Bearing cap No. 3 #A4 8. Camshaft 9. Rocker arm #F4 10. Lash adjuster 11.
PAGE 485
4G6 ENGINE <1993> - Rocker Arms and Camshaft TIF-79 REMOVAL SERVICE POINT OAo ROCKER ARMS AND ROCKER ARM SHAFTS MD998443-01 REMOVAL (1) Before removing rocker arms and shafts assembly, install the special tool as illustrated to prevent adjuster from dropping. 6EN245 INSPECTION CAMSHAFT (1) Measure the cam height. SOHC mm (in.) Limit Standard value Identification mark I Intake D 1.2 Exhaust D 1.2 I 42.40 (1.6693) 37.39 (1.4720) 41.90 (1.6496) 36.89 (1.4524) 42.40 (1.6693) 37.47 (1.4752) 41.
PAGE 486
466 ENGINE <1993> - Rocker Arms and Camshaft Roller Tip I 6EN018E LASH ADJUSTER LEAK DOWN TEST Caution 1. The lash adjuster is a precision part. Keep it free from dust and other foreign matter. 2. Do not disassemble lash adjuster. 3. When cleaning lash adjuster, use clean diesel fuel only. ,SOHC (1) immerse the lash adjuster in clean diesel fuel. (2) While lightly pushing down inner steel ball using the small wire, move the plunger up and down four or five times to bleed air.
PAGE 487
4G6 ENGINE <1993> - Rocker Arms and Camshaft Division = 1 mm t.04 in.) llF-81 (4) After air bleeding, set lash adjuster on the special tool (Leak down tester M D998440). (5) After plunger has gone down somewhat (2 - .5 mm), measure time taken for it to go down 1 mm. Replace if measured time is out of specification. Standard value: 4 - 20 seconds / 1 mm (.04 in.) [Diesel fuel at 15 - 20°C (59 - 68”F)] 7EN043t Scale = 1 mm (.039 in.
PAGE 488
4G6 ENGINE <1993> - Rocker Arms and Camshaft 11 F-82 I)B4 ROCKER SHAFTS INSTALLATION (1) Insert the rocker arm shaft into the front bearing cap so that the notch on the shaft faces up, and insert the installation bolt without tightening it. Front bearing cap sENos7’ i I)c4 WAVE WASHER INSTALLATION (1) Install the wave washer in correct direction as shown. Wave washer side rocker arm 6EN057C CAMSHAFT BEARING CAPS IDENTIFICATION (1) No. 3 bearing cap looks very similar to No. 2 and No.
PAGE 489
4G6 ENGINE <1993> - Rocker Arms and Camshaft I)F4 LASH ADJUSTER INSTALLATION (1) Immerse the lash adjuster in clean diesel fuel. (2) Using a small wire, move the plunger up and down 4 or 5 times while pushing down lightly on the check ball in order to bleed out the air. 6EN042 (3) Insert the lash adjuster to rocker arm, being careful not to spill the diesel fuel. Then use the special tool to prevent adjuster from falling while installing it.
PAGE 490
11 F-84 4G6 ENGINE <1993> - Rocker Arms and Camshaft Apply sealant DENOOX 10mm IOmm (.39 in.) \ $14 SEMI-CIRCULAR PACKING INSTALLATION Specified sealant: 3M ATD Part No.
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CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION - SOHC - 8VALVE Removal steps QArJ eD4 1. Cylinder head bolt 2. Cylinder head assembly eC4 3. Gasket 4. Retainer lock 5. Valve spring retainer eB4 6. Valve spring 7. Intake valve 8. Retainer lock 9. Valve spring retainer #B4 10. Valve spring 11. Exhaust valve c$BrJ +A4 12. Valve stem seal 13. Valve spring seat (IBI) *A4 14. Valve stem seal 15. Valve spring seat 16. Intake valve guide 17. Exhaust valve guide 18. intake valve seat 19. Exhaust valve seat 20.
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4G6 ENGINE <1993> - Cylinder Head and Valves SEMOVAL AND INSTALLATION - SOHC - IGVALVE 1 5-I!?r4 & b1260 - 1 3 &lSm 6-8 S--g 10 2 Removal steps OArJ *II4 1. Cylinder head bolt 2. Cylinder head assembly 3. Cylinder head gasket (IBI) #C4 4. Retainer lock 5. Valve spring retainer eB4 6. Valve spring 7. Intake valve (IBP +C4 8. Retainer lock 9. Valve spring retainer #B4 10. Valve spring 11. Exhaust valve @r) *A4 12. Valve stem seal 13. Valve spring seat (I@ +A4 14. Valve stem seal 15. Valve spring seat 16.
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qqp4)7 4G6 ENGINE <1993> - Cylinder Head and Valves ;EMOVAL AND INSTALLATION - DOHC 16i.U 2- 2 0 Removal steps (rAr$ +E4 1. Cylinder head bolt 2. Cylinder head assembly *D4 3. Gasket (IBI) eC4 4. Retainer lock 5. Valve spring retainer eB4 6. Valve spring 7. Intake valve cJBr$ eC4 8. Retainer lock 9. Valve spring retainer eB4 10. Valve spring 11. Exhaust valve QCrJ )A4 12. Valve stem seal 13. Valve spring seat (10) +A4 14. Valve stem seal 15. Valve spring seat 16. Intake valve guide 17.
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4G6 ENGINE <1993> - Cylinder Head and Valves REMOVAL SERVICE POINTS PRECAUTION FOR REMOVED PARTS (1) Keep removed parts in order according to the cylinder number and intake/exhaust. c)Ao CYLINDER HEAD BOLTS REMOVAL (1) &sing the 12 mm - 12 points socket wrench, loosen the cylinder head bolts. Loosen evenly, little by little. cjBQ RETAINER LOCK REMOVAL (1) Store removed valves, springs and other parts, tagged to indicate their cylinder No. and location for reassembly.
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4G6 ENGINE c1993> - Cylinder Head and Valves ppfl9 @o VALVE STEM SEAL REMOVAL (1) Do not reuse valve stem seal. EOHC - 1 GVALVE 9EN006 INSPECTION CYLINDER HEAD (1) Check the cylinder head gasket surface for flatness by using a straightedge and thickness gauge. Standard value: 0.05 mm (.0020 in.) Limit: 0.2 mm (.008 in.) (2) If the service limit is exceeded, correct to meet specification.
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llF-90 4G6 ENGINE <1993> - Cvlinder Head and Valves Grinding limit: “0.2 mm (.008 in.) * Includes combined with cylinder block grinding. Cylinder head height (Specification when new): SOHC - 8VALVE 89.9 - 90.1 mm (3.539 - 3.547 in.) SOHC - 16VALVE 119.9 - 120.1 mm (4.720 - 4.728 in.) DOHC 131.9 - 132.1 mm (5.193 - 5.201 in.) Valve seat contact Margin \ ree eight 1 EN0261I VALVE (1) Check the valve face for correct contact. If incorrect, reface using valve refacer.
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4G6 ENGINE <1993> - Cylinder Head and Valves llF-91 (2) Measure the squareness of the spring and, if the limit is exceeded, replace. Standard value: SOHC 2” or less DOHC 1.5” or less Limit: Max. 4” Guyde I.D. Guide O.D. VALVE GUIDE (1) Measure the clearance between the valve guide and valve stem. If the limit is exceeded, replace the valve guide or valve, or both. Standard value: SOHC - 8VALVE Intake 0.02 - 0.06 m m (.OOOS - .0024 in.) Exhaust 0.05 - 0.09 mm (.0020 - .0035 in.) SOHC - 16VALVE Intake 0.
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4G6 E N G I N E <1993> - Cylinder Head and Valves 11 F-92 6EN0275 Installation Removal kc VALVE GUIDE REPLACEMENT PROCEDURE Press Press Push rod f-i; Push rod Valve guide Valve guide ii - (2) Rebore the valve seat hole in the cylinder head to a selected oversize valve seat diameter. Seat ring hole diameter: See “Service Specifications” on page llF-14.
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4G6 ENGINE <1993> - Cylinder Head and Valves 11 F/93 I)64 VALVE SPRINGS INSTALLATION (1) Direct the valve spring end with identification color end toward the spring retainer. Identification color 6EN043iI +c4 RETAINER LOCK INSTALLATION (1) The valve spring, if excessively compressed, causes the bottom end of retainer to be in contact with, and damage, the stem seal.
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11 F-94 4G6 ENGINE <1993> - Cylinder Head and Valves I)04 CYLINDER HEAD GASKET IDENTIFICATION Identification mark: 4663 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4664 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caution Do not apply sealant to cylinder head gasket.
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4G6 ENGINE <1993> - Front Case, Silent Shaft and Oil Pan 1 l,F435 FRONT CASE, SILENT SHAFT AND OIL PAN REMOVAL AND INSTALLATION 2 1 17Nm ~34-33 Nm. 24 ft.lbs. 19‘Nm* 7 6 Y KJS. \37Nm 27 ft.lbs. \ 5b Nm gks. 24Nm 40 ft.lbs. 17 ft.lbs. b 12 1; ‘5, - 55 km. 40 ft.lbs. Removal steps 1. Oil filter 7 3il cooler bolt** 3. 3il cooler** 4. Drain plug 5. Drain oluu aasket r- -7 I 7 7. Oil screen 8. Oil screen gasket QBo eL4 9. Plug 10. O-ring (ICI) eK4 11. Flange bolt 12. Oil cooler by-pass valve )F4 13.
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11 F-96 4G6 ENGINE <1993> - Front Case, Silent Shaft and Oil Pan REMOVAL SERVICE POINTS cJAI$ OIL PAN REMOVAL (1) Remove all oil pan bolts. (2) Drive in the service tool between the cylinder block and oil pan. NOTE Never use a screwdriver or chisel, instead of the service tool, as a deformed oil pan flange will result in oil leakage. (IBM PLUG REMOVAL (1) If the plug is too tight, hit the plug head with a hammer two to three times, and the plug will be easily loosened.
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4G6 ENGINE <1993> - Front Case. Silent Shaft and Oil Pan OEo 1 I F-97 LEFT SILENT SHAFT REAR BEARING REMOVAL Using the special tool, remove the left silent shaft rear bearing from the cylinder block. (IFO dEAR BEARING REMOVAL Using the special tool, remove the right silent shaft rear bearing from the cylinder block. INSPECTION FRONT CASE (1) Check oil holes for clogging and clean if necessary. (2) Check left silent shaft front bearing section for wear, damage and seizure.
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11 F-98 4G6 ENGINE <1993> - Front Case, Silent Shaft and Oil Pan OIL PUMP (1) Assemble the oil pump gear to the front case and rotate it to ensure smooth rotation with no looseness. (2) Ensure that there is no ridge wear on the contact surface between the front case and the gear surface of the oil pump cover. (3) Check the side clearance Standard value: 0.06 - 0.14 mm (0031 - .0055 in.) Drive gear 0.06 - 0.12 mm (0024 - .0647 in.
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4G6 ENGINE <1993> - Front Case, Silent Shaft and Oil Pan +D4 11 F-99 OIL PUMP DRIVEN GEAR / OIL PUMP DRIVE GEAR INSTALLATION (1) Apply’ engine oil amply to the gears and line up the alignment marks. +E4 SEALANT APPLICATION TO OIL PRESSURE GAUGE UNIT (1) Coat the threads of switch with sealant and install the switch using the special tool. Specified sealant: 3M ATD Part No. 8660 or equivalent Caution 1. Keep the end of threaded portion clear of sealant. 2. Avoid an overtightening.
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IIF-IOO 4G6 ENGINE <1993> - Front Case. Silent Shaft and Oil Pan +H4 LEFT SILENT SHAFT REAR BEARING INSTALLATION (1) Install the special tool (GUIDE PLATE) tool to the cylinder block. (2) Apply engine oil to the rear bearing outer circumference and bearing hole in cylinder block. (3) Using the special tool, install the rear bearing. NOTE The left rear bearing has no oil holes. 6EN057E 1)14 SILENT SHAFT FRONT BEARING INSTALLATION (1) Using special tools, install front bearing.
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4G6 ENGINE <1993> - Front Case, Silent Shaft and Oil Pan IIF-101 (2) Install the front case assembly through a new front case gasket and temporarily tighten the flange bolts (other than those for tightening the filter bracket). I)K4 FLANGE BOLT INSTALLATION (1) Insert a Phillips screwdriver into a hole in the left side of the cylinder block to lock the silent shaft. 6EN056L (2) Secure the oil pump driven gear onto the left silent shaft by tightening the flange bolt to specified torque.
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llF-102 4G6 ENGINE <1993> - Front Case, Silent Shaft and Oil Pan I)Mg OIL PAN INSTALLATION (1) Clean both mating surfaces of oil pan and cylinder block. (2) Apply a 4 mm (.I6 in.) wide bead of sealant to the entire circumference of the oil pan flange. Specified sealant: MITSUBISHI GENUINE PART No. MD997110 or equivalent (3) The oil pan should be installed in 15 minutes after the application of sealant. 6EN0213 (4) Note the difference in bolt lengths at the location shown.
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4G6 ENGINE <1993> - Piston and Connecting Rod PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION Removal steps (IAI) :!t k kkkecting rod cap +E4 3. Connecting rod bearing #D4 4. Piston and connecting rod assembly )E4 5. Connecting rod bearing +C4 6. Piston ring No. 1 #C4 7. Piston ring No. 2 #B4 8. Oil ring aB0 *A4 9. Piston pin 10. Piston ; 12.
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llF-104 4G6 ENGINE <1993> - Piston and Connectinn Rod REMOVAL SERVICE POINTS OAo CONNECTING ROD CAP REMOVAL number (1) Mark the cylinder number on the side of the connecting rod big end for correct reassembly. (2) Keep the removed connecting rods, caps, and bearings in order according to the cylinder number. 060 PISTON PIN REMOVAL Piston pin setting tool MIT216941 Item No. Part No.
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4G6 ENGINE <1993> - Piston and Connecting Rod 1 .CF;-q@g INSPECTION 5EN006E 6EN054E PISTON (1) Replace the piston if scratches or seizure is evident on its surfaces (especially the thrust surface). Replace the piston if it is cracked. PISTON PIN (1) Insert the piston pin into the piston pin hole with a thumb. You should feel a slight resistance. Replace the piston pin if it can be easily inserted or there is an excessive play. (2) The piston and piston pin must be replaced as an assembly.
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IIF-106 4G6 ENGINE <1993> - Piston and Connectincl Rod CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE METHOD) (1) Remove oil from crankshaft pin and connecting rod bearing. (2) Cut the plastic gauge to the same length as the width of bearing and place it on crankshaft pin in parallel with its axis. (3) Install the connecting rod cap carefully and tighten the bolts to specified torque. (4) Carefully remove the connecting rod cap.
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4G6 ENGINE <1993> - Piston and Connecting Rod ‘,j:::.@::: Press pin -8 Front mark Connecting rod guide pin Stop screw ~ 1 lww7 (3) Place the base on press support blocks. (4) Slide the piston pin over the threaded end of the press pin, and thread the correct guide pin up against it. (5) Coat the piston pin with oil, and with the connecting rod held in position, slide the guide pin through the piston and connecting rod.
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llF-108 4G6 E N G I N E <1993> - Piston and Connecting Rod ec4 PISTON RING NO. 2 / PISTON RING NO. 1 INSTALLATION (1) Using piston ring expander, fit No. 2 and then No. 1 piston ring into position. NOTE (1) Note the difference in shape between No. 1 and No. 2 piston rings. (2) Install piston rings No. 1 and No. 2 with their side having marks facing up (on the piston crown side). 7EN0452 6EN052i DOHC I Non-turbo Turbo 6EN0497 I)D4 PISTON AND CONNECTING ROD INSTALLATION Upper side _ _ .
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I.1 F-RI9 4G6 ENGINE <1993> - Piston and Connecting Rod I)E4 CONNECTING ROD BEARINGS INSTALLATfON (1) When the bearings are to be replaced, select appropriate bearings for assembly according to identification co’tors for the crankshaft. I Connecting rod bearing identification mark Crank pin O.D. identification color Yellow I 1 I None I 2 I White I 3 I +F4 CONNECTING ROD CAP INSTALLATION Cylinder No.
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CRANKSHAFT, FLYWHEEL AND DRIVE PLATE REMOVAL AND INSTALLATION 2 135Nm 98 ft.lbs. -. I35 Nm 98 ft.lbs. 135 Nm 8 - 1 8 TSB Revision 7 98,ft.lbs. Removal steps 1. Flywheel bolt 2. Flywheel 3. Drive plate bolt SOHC-8VALVEAt-f 4. Adapter plate 5. Drive plate - -. 6. urrve plate bolt SOHC - 1 GVALVE AA 7. Adapter plate 8. Drive plate 9. Drive plate bolt 10. Adapter plate [IOHC 11. Drive plate 1 12. Crankshaft bushins I-M 13. Rear plate 14. Bell housing cover eD4 15. Oil seal case +C4 16.
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4G6 ENGINE <1993> - Crankshaft, Flywheel and Drive Plate 1 IF4 11 INSPECTION CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE METHOD) (1) Remove oil from the crankshaft journal and crankshaft bearing. (2) Install the crankshaft. (3) Cut the plastic gauge to the same length as the width of bearing and place it on journal in parallel with its axis. (4) Install the crankshaft bearing cap carefully and tighten the bolts to specified torque. (5) Carefully remove the crankshaft bearing cap.
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‘l’IF-172 4G6 E N G I N E <1993> - Crankshaft, Flywheel and Drive Plate BORING CYLINDER I 1 I _ 1 t - (1) Oversize pistons to be used should be determined on the basis of the largest bore cylinder. Piston size identification 1 w Piston O.D. Thrust direction ~ EN0554 NOTE Size mark is stamped on piston top. (2) Measure outside diameter of piston to be used. Measure it in thrust direction as shown. (3) Based on measured piston O.D. calculate boring finish dimension. Boring finish dimension = Piston O.
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11 F-.1 13 4G6 ENGINE <1993> - Crankshaft, Flvvvheel and Drive Plate REASSEMBLY SERVICE POINTS I)A4 CRANKSHAFT BEARING INSTALLATION (1) When the bearing is to be replaced, select the appropriate bearing for assembly according to the identification color for the crankshaft and the identification mark stamped on the cylinder block.
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1 IF-114 4G6 ENGINE <1993> - Crankshaft, Flvwheel and Drive Plate (4) After installing the bearing caps, make sure that the crankshaft turns smoothly and the end play is correct. If the end play exceeds the limit, replace crankshaft bearings. Standard value: 0.05 - 0.25 mm (.0020 - .0098 in.) Limit: 0.4 mm (.016 in.) I)cg OIL SEAL INSTALLATION I)D4 SEALANT APPLICATION TO OIL SEAL CAqE Specified sealant: Mitsubishi Genuine Part No.
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llF-115 4G6 ENGINE <1993> - Bracket BRACKET Rear wheel drive and four wheel drive 1. Engine support bracket, right 2. Engine support bracket, left 6EN350 Front wheel drive and all wheel drive 65 Nm 47 ft.lbs. 26 ft.lbs. \e\ -‘)\ 0 4 1. Roll stopper bracket, front 2. Engine support bracket, front 3. Exhaust pipe support bracket 4. Roll stopper bracket, rear "9 126 Nm 87 ft.lbs. 6EN0722 1--- HY206012-522 - .
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NOTES