Mitsubishi 4G6 Series 1992- User Manual

I N T R O D U C T I O N FORM-IN-PLACE GASKET The engine has several areas where the form-in-place gasket 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....

ENGINE General GENERAL ENGINE SECTIONAL VIEW TSB Revision 1

ENGINE General Specifications GENERAL SPECIFICATIONS 1: to 1992 models Number of cylinders Combustion chamber Total displacement Cylinder bore mm (in.) Piston stroke mm (in.) Compression ratio Valve timing Camshaft identification mark Intake valve Opens BTDC Closes ABDC Exhaust valve Opens BBDC Clos...

1 ENGINE Service Specifications SERVICE SPECIFICATIONS mm (in.) Items Standard value Limit Cylinder head Flatness of gasket surface Grinding limit of gasket surface "0.2 Total resurfacing depth of both cylinder head and cylinder block Overall height Oversize rework dimensions of valve guide hole...

ENGINE Service Specifications mm (in.) Items Valve Overall length Intake Exhaust Stem diameter Intake Exhaust Face angle Thickness of valve head (margin) Intake Exhaust Stem-to-guide clearance Intake Exhaust Valve clearance Intake Exhaust Valve spring Free height Intake Exhaust height N/mm Intake Ex...

1 ENGINE Torque Specifications TORQUE SPECIFICATIONS Generator and ignition system Oil level gauge guide mounting bolt W a t e r p u l l e y b o l t pump Generator brace bolt Generator brace mounting bolt Generator pivot nut Crankshaft boltCrankshaft pulley bolt Spark plug Distributor Timing belt En...

ENGINE Torque Specifications Sealant Cylinder head and valves Cylinder head bolt Front case and oil pump O i l d r a i n p l u g pan Oil bolt pan Oil screen bolt Oil relief valve plug Front case bolt Oil pump cover screw Piston and connecting rod Connecting rod cap nut Crankshaft, flywheel and drive...

1 SPECIAL TOOLS ENGINE Special Tools Tool Installation of crankshaft rear oil seal Crankshaft rear oil seal installer Crankshaft front oil seal installer 3 Installation of camshaft oil seal Camshaft oil seal .. Removal of oil pan 0 TSB Revision

ENGINE Special Tools Valve stem seal compressor Flywheel stopper TSB Revision

ENGINE Generator and Ignition System GENERATOR AND IGNITION SYSTEM R E M O V A L A N D I N S T A L L A T I O N 7 23 Nm 14 Nm I 17 12 Nm 9 I 85 Nm 81 Removal steps Oil level gauge 2. Oil level gauge guide3. O-ring 4. Drive belt 5. Water pump pulley 6. Generator brace7. Generator 8. Crankshaft bolt 9....

ENGINE Generator and System 1 1 1 REMOVAL SERVICE POINT CRANKSHAFT BOLT REMOVAL (I) Using the special tool, hold the drive plate or flywheel. (2) Remove the crankshaft bolt. INSTALLATION SERVICE POINTS D I S T R I B U T O R A S S E M B L Y (1) Turn the crankshaft to bring the No. I cylinder piston t...

ENGINE Generator and Ignition System (2) Or using a tension gauge, adjust the tension to the standard value. Standard value: New belt 5 0 0 7 0 0 154 Used belt 400 (88 I b s . ) (3) Tighten the lock bolt to the specified torque.(4) Tighten the nut for pivot bolt to specified torque. TSB Revision I

ENGINE Timing Belt TIMING BELT REMOVAL AND INSTALLATION 8 17 7 Removal steps 1. Timing belt upper cover 2. Timing belt lower cover 3. Timing belt 4. Engine support bracket, left 5. Tensioner spring 6. Tensioner 7. Crankshaft sprocket8. Flange 9. Camshaft sprocket bolt 10. Camshaft sprocket 1 TSB Rev...

ENGINE Timing B e l t R E M O V A L S E R V I C E P O I N T S 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 Water or oil on the belt shortens its life ...

ENGINE Timing Peeling Cracks 1 Roundededge Abnormal wear (Fluffy strand) Rubber exposed Tooth missing and canvas fiber I 01 Water 1 Cracks on rubber backCracks or peeling of canvas Cracks on rib root (5) Cracks on belt sides Abnormal wear of belt sides. The sides are normal if they are sharp as if c...

ENGINE Timina Belt 1 Tensioner slot side bolt head 1 (5) Turn the crankshaft clockwise by 3 crankshaft teeth. (6) Tighten bolt first and then bolt If bolt is tightened first, the tensioner will turn together with the bolt, resulting in an overtensioned belt. (7) Check the belt tension. Hold the tens...

ENGINE Fuel and Emission Parts FUEL AND EMISSION PARTS REMOVAL AND INSTALLATION TSB Revision 19 Nm 14 Removal steps 1. Throttle body 2. Gasket 3. Injectors and fuel rail4. Insulator regulator Insulator 8. Injector clip 9. Injector O-ring 11. Grommet 12. Fuel rail13. EGR valve (For California)14. Gas...

Fuel and Emission Parts 1 INSPECTION INJECTORS (1) Using an ohmmeter (circuit tester), test for, between terminals of injector; the circuit should be closed. If failure is detected, replace the injector. Standard value: 13 16 [at EGR VALVE (1) Check the EGR valve for sticking or carbon deposits. If ...

1 ENGINE Throttle Body THROTTLE BODY DISASSEMBLY AND REASSEMBLY Up to 1992 models 1 1.4 Disassembly steps Throttle position sensor 2. speed control motor 3. Throttle valve set screw 4. Throttle body From 1993 models 1.4 Disassembly steps Throttle position sensor 2. control motor 3. O-ring 4. Throttl...

ENGINE Throttle Bodv Closed throttle position switch* Throttle round Throttle position sensor output Throttle position sensor connector From 1993 models View DISASSEMBLY POINTS THROTTLE POSITION SENSOR AND SPEED CONTROL MOTOR AIR CONTROL REMOVAL D O not disassemble the sensor and motor. not immerse ...

1 E N G I N E Exhaust Manifold and Water EXHAUST MANIFOLD AND WATER PUMP R E M O V A L A N D I N S T A L L A T I O N 7 30 Nm 22 14 10 7 14 Nm Removal steps Exhaust manifold cover “A” 2. Oxygen sensor (FED) 3. Engine hanger4. Exhaust manifold 5. Exhaust manifold cover “B” 6. Exhaust manifold gasket 7...

ENGINE Exhaust Manifold and Water Pump O-ring Water pump Water inlet pipe INSTALLATION SERVICE POINT WATER PIPE O-RING INSTALLATION. Wet the O-ring (with water) to Caution Keep the O-ring free of oil or grease TSB Revision

E N G I N E Rocker Arms and Camshaft ROCKER ARMS AND CAMSHAFT R E M O V A L A N D I N S T A L L A T I O N 1 I 32 Nm 23 Removal steps Breather hose 2. PCV hose 3. Rocker cover 4. Rocker cover gasket 5. Oil seal 6. Rocker arm and rocker arm shaft 7. Rocker arm and rocker arm shaft8. Rocker arm “D”9. W...

1 1 ENGINE Rocker Arms and Camshaft Timing belt side Wave washer Bolt hole center 1 INSPECTION CAMSHAFT (1) Measure the cam height. Standard value: Intake 38.78 (1.5268 ‘in.) Exhaust 3 9 . 1 0 m m , Limit: Intake 38.28 mm (1.5071 in.) Exhaust 38.60 mm (1.5197 in.) ROCKER ARM l Check the roller surfa...

1 ENGINE Rocker Arms and Camshaft Exhaust 1 Exhaust 3 Intake 1 Intake 2 Exhaust 2 Exhaust 4 Intake 3 Intake 4 VALVE CLEARANCE ADJUSTMENT (1) Position the No. cylinder at the top dead center on compression stroke. (2) Adjust the valve clearance at the points shown in the illustration. (3) Loosen the ...

ENGINE Cylinder Head and Valves CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION 73 Nm 53 Removal steps 1. Cylinder head bolt 2. Cylinder head, valve assembly 3. Cylinder head gasket 4. Retainer lock 5. Valve spring retainer 6. Valvespring 7. Intake valve (primary)8. intake valve (secondary) 9. Ret...

ENGINE Cylinder Head and Valves Spring retainer Painted end Stem seal Spring seat Timing belt side Identification mark 1 Timing belt side VALVE SPRING INSTALLATION (1) valve spring with the painted end on the rocker RETAINER LOCK INSTALLATION (1) The valve spring, if excessively compressed, causes t...

ENGINE Front Case and Oil Pump FRONT CASE AND OIL PUMP R E M O V A L A N D I N S T A L L A T I O N 45 Nm 33 I Removal steps 1. Oil filter 2. Drain plug3. Drain plug gasket 4. Oil pan 5. Oil screen 6. Oil screen gasket 7. Relief plug 8. Gasket 9. Relief spring 10. Relief plunger 11. Oil seal 12. Fron...

1 ENGINE Front Case and Oil R E M O V A L S E R V I C E P O I N T S 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. OUTER ROTOR INNER ROTOR REMOVAL Make alig...

ENGINE Front Case and Oil Pump INSTALLATION SERVICE POINTS 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 theentire rotor surface. I CRANKSHAFT FRONT OIL SEAL INSTALLATION (1) Set the sp...

E N G I N E Front Case and Oil 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 surfaces removing all loose material. (2) Apply a 4 mm in.) diameter of sealant to the oil pan flange. Specified sealant: Mitsubishi Genuine Part No. or equiva- lent (3) The oil pan should be instal...

E N G I N E Piston and Connecting Rod . . REMOVAL AND INSTALLATION Removal steps 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 Piston 11. Connecting rod12. Bolt TSB Revision

ENGINE Piston and Connecting Rod No. Piston pin setting tool 6941 Press pin , Piston pin Front mark rod de DISASSEMBLY CONNECTING ROD CAP Mark the cylinder number on the side of the connecting rod big end for correct reassembly. PISTON PIN REMOVAL No. Part No. 1 2 34 5 6 7 89 143 2 16943 11 Descript...

Piston End gap INSPECTION PISTON RING Check for side clearance. If the limit is exceeded, replace the ring or piston, or both. Standard value: No. 1 0 . 0 3 0.07 mm No. 2 0.02 0.08 mm Limit: 0.1 mm in.) (2) insert the piston ring into the cylinder bore. Force the ring down with a piston, the piston ...

ENGINE Piston and Connecting Rod 1 Side rail gap 1 Identification mark stamped No. 1 Barrel Identification mark stamped Taper type No. 2 1 No. No. 2 1 side and OIL RING INSTALLATION Fit the oil ring spacer into the piston ring groove. NOTE The side rails and spacer may be installed in either directi...

ENGINE Piston and Connecting R o d Timing belt side ront mark 1 (3) Rotate crankshaft so that the crank is on the center of the cylinder bore. (4) Use suitable thread protectors on rod bolts before inserting piston and connecting rod assembly into the cylinder block. Care must be taken not to nick t...

ENGINE Crankshaft, Flywheel and Drive Plate CRANKSHAFT, FLYWHEEL AND DRIVE PLATE REMOVAL AND INSTALLATION 19 Nm 11 Nm 8 8 I 3 53 Nm 38 Removal steps Flywheel bolt 2. Flywheel 3. Drive plate bolt4. Adaptor plate 5. Drive plate6. Adaptor plate 7. Crankshaft bushing For 8. Rear plate9. Bell housing cov...

1 ENGINE Crankshaft, Flywheel and Drive Plate INSPECTION CRANKSHAFT JOURNAL OIL CLEARANCE (PLASTICGAUGE 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 ...

ENGINE Crankshaft, Flywheel and Drive Plate Thrustdirection bearing Upper bearing (for No. Upper and lower bearings(for No. 1 BORING CYLINDER (1) Oversize pistons to be used should be determined on basis of the largest bore cylinder. Piston size identification Size Identification 0.25 0.50 mm in.) O...

ENGINE Crankshaft, Flywheel and Drive INSTALLATION OF BEARING (1) Install according to the front mark cap No. Timing belt side Cap No. 1 1 TSB Revision Oil seal Oil seal case 1 (2) After installing the bearing caps, make sure that the crankshaft turns smoothly and the end play is correct. If the end...

ENGINE Bracket REMOVAL AND INSTALLATION Nm 47 2 60 Nm 44 36 Nm 26 1 Nm 67 Removal steps Exhaust pipe support bracket 2. Engine support bracket, front3. Roll stopper bracket, front 4. Roll stopper bracket, rear 1 TSB Revision

ENGINE C O N T E N T S BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT, FLYWHEEL AND DRIVE PLATE . . CYLINDER HEAD AND VALVES EXHAUST MANIFOLD AND WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . ....

ENGINE General Information GENERAL INFORMATION ENGINE SECTIONAL VIEW TSB Revision I

ENGINE Service Specifications mm (in.) Standard Limit Cylinder head Flatness of gasket surface 0.05 0.2 Grinding limit of gasket surface “0.2 Total resurfacing depth of both cylinder head and cylinder block Overall height 88.4 88.6 (3.480 Oversize rework dimensions of valve guide hole (both intake a...

ENGINE Service Specifications mm (in.) Standard Limit Valve Overall length . . Intake 98.2 (3.866) Exhaust 95.5 (3.760) Stem diameter Intake Exhaust 7.93 7.95 Face angle 45” Thickness of valve head (margin) Intake 1.2 0.7 Exhaust 1.5 1 Stem-to-guide clearance Intake 0.03 0.06 0.10 Exhaust 0.05 0.09 ...

ENGINE Service mm (in.) Standard Limit Silent shaft Journal diameter 38.96 38.98 (1.5339 1.5346) (rear) 35.95 35.97 (1.4154 Left (front) 18.47 18.48 (rear) 35.95 35.97 (I Oil clearance 0.02 0.06 (rear) 0.05 0.09 Left 0.02 0.05 0.05 0.09 Piston 80.57 80.60 (3.1720 3.1732) Piston-to-cylinder clearance...

ENGINE Sealant Engine coolant temperature sensor Engine coolant temperature gauge unit Semi-circular packing Oil pan Oil pressure gauge unitOil pressure switch Specified sealant Nut Locking Part No. 4171 or equivalent ATD Part No. 8660 or equivalent ATD Part No. 8660 or equivalent MITSUBISHI GENUINE...

ENGINE Special Tools Removal of crankshaft sprocket TSB Revision

ENGINE Generator and Ignition System GENERATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION 23 Nm 17 14 I 19 7 14 7 12 17 Nm 12 Removal steps Drive belt 2. Water pump 3. Generator brace 4. Generator 5. 6. Damper pulley Adapter 7. Crankshaft pulley 8. Spark plug cable 9. Spark plug Distributor 11. O-...

ENGINE Generator and Ignition System INSTALLATION SERVICE POINTS DISTRIBUTOR INSTALLATION Turn the crankshaft so that the 1 cylinder at dead center. (2) Align the distributor housing and gear mating marks. Crankshaft pulley Crankshaft pulley Water pump pulley (3) Install the distributor to the engin...

ENGINE Timing Belt TIMING BELT R E M O V A L A N D I N S T A L L A T I O N 26 I 13 37 12 27 I I Removal steps 1. Timing belt front upper cover 2. Timing belt front lower cover 3. Timing belt 4. Tensioner 5. Tensioner spring 6. Oil pump sprocket 7. Crankshaft bolt 8. Crankshaft sprocket 9. Flange Ten...

ENGINE Timing Belt I REMOVAL SERVICE POINTS TIMING BELT REMOVAL (1) Mark the belt running direction for reference tion. 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 in.)] to block the left silent shaft. (3...

ENGINE Timing B e l t Cracks 1 SILENT SHAFT SPROCKET REMOVAL CRANKSHAFT SPROCKET REMOVAL CAMSHAFT SPROCKET BOLT LOOSENING INSPECTION TIMING BELT TIMING BELT “B” Replace belt if any of the following exist. (1) Hardening of back rubber the ba ide is glossy without resilience and leaves no indent whe p...

ENGINE Timing Belt Rounded edge Abnormal wear (Fluffy strand) Rubber exposed Tooth missing and canvas Abnormal wear of belt The sides are normal if they are sharp as if cut by a knife. (7) Abnormal wear in teeth(8) Missing tooth INSTALLATION SERVICE POINTS CAMSHAFT SPROCKET BOLT SPACER INSTALLATION ...

11 ENGINE Timing Belt TIMING BELT “B” 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....

E N G I N E Belt Screwdriver OIL PUMP SPROCKET INSTALLATION Insert a Phillips screwdriver [shank diameter 8 mm in.)] through the plug hole on the left side of the cylinder to block the left silent shaft. (2) Install the oil pump sprocket. (3) Tighten the nuts to the specified torque. TENSIONER TENSI...

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 boltis tightened, resulting in an excessive belt tension. (9) Hold the center of the tension side span of the timing belt (between th...

11 ENGINE Fuel and Emission Parts FUEL AND EMISSION PARTS REMOVAL AND INSTALLATION 12 Nm 9 . - 3 19 Nm 22 Nm 16 Removal steps Throttle body assembly 2. Gasket 3. Injector and fuel rail 4. Fuel pressure regulator 5. O-ring6. Fuel rail 7. Insulator 8. Insulator 9. Injector 11. TSB Revision

ENGINE Throttle Body DISASSEMBLY AND Disassembly steps REASSEMBLY 1. Throttle position sensor 2. speed control motor 3. Throttle valve set screw 4. Throttle body DISASSEMBLY SERVICE POINTS P O S I T I O N S E N S O R A N D I D L E S P E E D CONTROL MOTOR REMOVAL- ( 1 ) D o n o t d i s a s s e m b l ...

ENGINE Throttle Bodv Throttle position power supply Ground Throttle View sensor output Throttle position sensor connector 1 B O D Y R E M O V A L Do not remove the throttle (2) Check if the vacuum port or is compressed air to clean the vacuum passage. REASSEMBLY SERVICE POINT POSITION SENSOR INSTALL...

ENGINE Intake Manifold INTAKE MANIFOLD REMOVAL AND INSTALLATION 19 18 13 5 16 Removal steps Water hose “A” 2. Water hose “B”3. Engine coolant temperature gauge unit 4. Engine coolant temperature sensor 5. Water outlet fitting 6. Water outlet fitting gasket7. Thermostat 8. Intake manifold plenum stay...

11 ENGINE Exhaust Manifold and Water Pump EXHAUST MANIFOLD AND WATER PUMP REMOVAL AND INSTALLATION 30 Nm 14 Nm 10 14 Nm Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring4. Exhaust manifold cover “A” 5. Engine hanger 6. Exhaust manifold 7. Exhaust manifold gasket 8. Exhaust manifold...

ENGINE Exhaust Manifold and Water Pump INSTALLATION SERVICE POINT O-ring Water pump WATER INLET PIPE INSTALLATION (1) Wet the 0- . (with water) to facilitate Caution Keep the O-ring free of oil or grease inlet pipe TSB Revision

ENGINE Rocker Arms and REMOVAL SERVICE POINT ROCKER ARM AND SHAFT REMOVAL Mark lash adjusters for installation in the same position. (2) Remove the lash adjuster holders and the lash adjusters. INSPECTION CAMSHAFT Measure the cam height. Standard value: 35.91 mm in.) Limit: 35.41 mm (1.3941 in.) ROC...

ENGINE Rocker Arms and Camshaft Lash Rocker shaft for exhaust Camshaft for intake Front mark Cap No. Rocker cover attachingbolt hole 0 0 No. 2 No. 3 0 0 No. 4 L A S H A D J U S T E R Dip the lash adjuster in clean diesel fuel. (2) While using a small wire to lightly press the check ball downward, mo...

11 ENGINE Rocker Arms and Camshaft Wave washer Wave washer W A V E W A S H E R Install the wave washer in correct ‘direction as shown. I CAMSHAFT OIL SEAL INSTALLATION TSB Revision

ENGINE Cylinder Head and Valves REMOVAL SERVICE POINTS A CYLINDER HEAD BOLT (1) Using the special tool, loosen the cylinder head bolts Loosen evenly, little by little. RETAINER LOCK REMOVAL (1) Store removed valves, springs and other parts, tagged to indicate their cylinder No. and location to aid r...

ENGINE Cylinder Head Free height 1 I.D. Guide Exhaust Intake 1 VALVE Check the valve face for correct contact. If incorrect, reface using a valve 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 valve. , S...

ENGINE Front Case, Oil Pump and Oil Pan FRONT CASE, OIL PUMP AND OIL PAN REMOVAL AND INSTALLATION 17 Nm 2 4 4 33 Removal steps 1 Oil filter 2. Oil pressure switch 3. Oil pressure gauge unit 4. Oil filter bracket 5. Gasket 6. Drain plug Drain plug gasket 9. Oil screen Oil screen gasket 11. Oil pump c...

11 ENGINE Front Case, Oil Pump and Oil Pan General General tool I REMOVAL SERVICE POINTS 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 side of the special tool, slide the special tool along the oil pan to remove it. FLANGE BOL...

ENGINE Front Case, Oil Pump and Oil Pan Guide INSPECTION SILENT SHAFT Check oil holes for clogging. (2) Check journal for seizure, damage, and contact bearing. If there is anything wrong with the journal, replace the silent shaft, bearing or front case assembly. (3) Check the silent shaft oil cleara...

ENGINE Front Case, Oil and Oil Pan wrench (4) Set the special tool on the guide and drive the bearing into the cylinder block. CRANKSHAFT OIL SEAL INSTALLATION (1) Using the special tool, install the crankshaft oil seal into the front case. SILENT SHAFT OIL SEAL INSTALLATION Using a socket wrench, p...

ENGINE Front Case, Oil Pump and Oil Pan case OIL PUMP DRIVEN GEAR OIL PUMP DRIVE GEAR INSTALLATION (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. FLANGE BOLT INSTALLATION (1) a Phillips screwdriver [shank diamet...

ENGINE Front Case, Oil Pump and Oil O I L P A N I N S T A L L A T I O N Clean mating surfaces of both oil pan and cylinder block. (2) Apply a 4 mm in.) diameter of sealant to the oil pan flange. , Specified sealant: MITSUBISHI GENUINE Part “No. or equivalent (3) The oil pan should be installed 15 mi...

ENGINE Front Case, Oil Pump and Oil Pan OIL FILTER INSTALLATION (1) Clean the installation of the filter bracket side. (2) Apply engine oil to the of (3) Screw the oil filter on until the O-ring contacts the base. Then tighten one turn. TSB Revision

11 ENGINE Piston and Connecting Rod PISTON AND CONNECTING ROD R E M O V A L A N D 6 7 Removal steps 1. Nut 2. Connecting rod cap 3. Connecting rod bearing 4. Piston and connecting rod 5. Connecting rod bearing6. Piston ring No. 1 7. Piston ring No. 2 8. Oil ring 9. Piston pin Piston 11. Connecting r...

ENGINE Piston and Connecting Rod inder No. Rear support . Anvil Stop plug 1 Adjustto prop 1 REMOVAL SERVICE POINTS CONNECTING ROD CAP REMOVAL Mark the cylinder number on the side of the connecting rod big end for correct reassembly. PISTON PIN REMOVAL Remove the piston and connecting rod using the s...

ENGINE Piston and Connecting Rod 1 Make certain the piston floats during installation 1 1 REASSEMBLY SERVICE POINTS PISTON PIN INSTALLATION Install the piston and connecting rod as follows, using the special tools (2) Thread the stop plug approximately half way into the bottom of the receiving tube....

ENGINE Piston and Connecting Rod Notches CONNECTING ROD CAP INSTALLATION Verifying the mark made during disassembly the bearing cap to the connecting the is new with no index mark, make sure that the bearing lockingnotches come on the same side as shown. (2) Make sure that connecting rod big end sid...

ENGINE Crankshaft, Flywheel and Drive CRANKSHAFT, FLYWHEEL AND DRIVE PLATE REMOVAL AND INSTALLATION 38 135 88 I 8 7 135 Nm 98 6 Removal steps 1. Flywheel bolt 2. Flywheel For 3. Drive plate bolt4. Adaptor plate5. Drive plate For 6. Crankshaft 7. Rear plate 8. Bell housing cover9. Oil seal case Gaske...

ENGINE Crankshaft, Flywheel and Drive Plate No. Timingbelt side Cap No. Front mark 1 Oil case I 1 BEARING CAP INSTALLATION Install according to the front mark and cap No. (2) After installing the bearing caps, make sure that the crankshaft turns smoothly and the end play is correct. If the end play ...

ENGINE Bracket BRACKET REMOVAL AND INSTALLATION 47 Exhaust pipe support bracket 2. Engine support bracket, right 3. Roll stopper bracket, front 4. Roll stopper bracket, rear 65 47 TSB Revision 120 67

ENGINE 4G61, <1992> CONTENTS I BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 CAMSHAFTS AND ROCKER ARMS DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

ENGINE General Information GENERAL ENGINE SECTIONAL VIEW SOHC TSB Revision . I

ENGINE General Information ENGINE LUBRICATION SYSTEM DOHC-TURBO Oil To Camshaft Silent shaft From thermostat case filter Oil cooler , To turbocharger water inlet pipe Oil pressure Oil pump ‘ S i l e n t s h a f t TSB Revision 1

ENGINE General Specifications GENERAL SPECIFICATIONS SOHC Number of cylinders Combustion chamber Total displacement (cu. in.) Cylinder bore mm (in.) Piston stroke mm (in.) Compression ratio Valve timing camshaft identification mark Intake valve Open BTDC Close ABDC Exhaust valve Open BBDC Close A T ...

E N G I N E Service Specifications mm (in.) Standard Limit Valve SOHC Overall length Intake 106.6 (4.197) Exhaust 108.7 105.2 (4.142) Stem diameter Intake Exhaust 7.93-7.95 Face angle Thickness of valve head (margin) Intake 1.2 0.7 Exhaust 2.0 1.5 Stem-to guideclearance Intake 0.02 0.06 0.10 Exhaust...

ENGINE Service mm (in.) Valve guide DOHC Overall length I.D. Service size Press-in temperature Va seat Seat angle Valve contact width Service size Silent shaft Journal diameter clearance Standard Limit 45.5 (1.791) 50.5 (1.988) 6.60 6.62 12.06 12.07 0.05 0.25 0.50 over size Room temperature 44” 0.9 ...

ENGINE Service Specifications mm (in.) Piston ring SOHCEnd gap Ring-to-ring groove clearance Service size No. 1 ring No. 2 ring Oil ring No. 1 ring No. 2 ring Standard 0.25 0.40 0.20 0.35 0.20 0.40 0.20 0.70 0.03 0.07 2 0.02 0.06 0.25 0.50 0.75 1 over size Limit 0.8 0.8 0.8 0.1 0.1 Piston ring DOHC ...

ENGINE Service Cylinder block Cylinder I.D. Flatness of gasket surface Grinding limit Total resurfacing depth of both cylinder head and cylinder block. Overall height Oil pump Side clearance Drive gear Driven gear belt V-ribbed type belt New belt Used belt type belt V-ribbed type belt New belt Used ...

E N G I N E Torque Specifications TORQUE SPECIFICATIONS Generator and ignition system SOHC Cooling fan bolt Water pump pulley bolt Engine without cooling fanW a t e r p u l l e y b o l t E n g i n e pump with cooling fan Generator brace bolt Generator mounting bolt Generator pivot nut Crankshaft pul...

E N G I N E Toraue Fuel and emission partsEGR valve bolt Throttle body stay nut DOHC Throttle body bolt SOHC Throttle body bolt DOHC Fuel regulator bolt pressure Fuel rail bolt Throttle bodyThrottle position sensor bolt Idle speed control motor bolt Idle air control motor bolt Intake manifold Intake...

E N G I N E Torque Specifications Sealant 1 Bracket Left and right engine support bracket bolt 45 33 Roll stopper bracket bolt, front 65 47 Roll stopper bracket bolt, rear 120 87 Engine support bracket bolt, front 60 43 Exhaust pipe support bracket bolt 36 26 SEALANT N m Rocker coverSemi-circular pa...

E N G I N E Generator and Ignition System SOHC GENERATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION 1 25 Nm 14 Nm 23 Nm 17 I 14 Nm 24 Nm 17 5 4 R W D 9 7 Removal steps 11 8 1. Drive belt 2. Cooling fan***3. Fan clutch*** 4. Water pump 5. Water pump pulley 6. Generator brace 7. Generator8. Cranksha...

ENGINE Generator and Svstem SOHC Water pulley Crankshaft pulley Water pump pulley BRACE BOLT TYPE 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 in.) Used belt 8.0 mm in.) V-type belt 7.0 10.0 mm in.) When using a tensio...

11 ENGINE Generator and Ignition System DOHC GENERATOR AND IGNITION SYSTEM DOHC REMOVAL AND INSTALLATION 18 19 Nm14 11 Nm 8 5 23 Nm I 14 Nm 24 Nm 17 24 Nm 17 Removal steps 1. Drive belt 2. Water pump pulley 3. Water pump pulley (For driving power steering pump) 4. Generator brace 5. Generator 6. Cra...

ENGINE Generator and Ignition DOHC INSTALLATION SERVICE POINTS 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 positio...

ENGINE Timing Belt SOHC TIMING BELT SOHC REMOVAL AND INSTALLATION --- 87 40 18 Removal steps 1. Timing belt front upper cover 2. Timing belt front lower cover 3. Timing belt 4. Tensioner spring 5. Tensioner 6. Oil pump sprocket 7. Crankshaft bolt 8. Crankshaft sprocket9. Flange Tensioner “B” 11. Tim...

ENGINE Belt S O H C REMOVAL SERVICE POINTS TIMING BELT REMOVAL (1) Mark the belt running direction for reference in reinstalla- tion. 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 shou...

ENGINE Timing Belt SOHC Peeling Cracks Cracks 1 SILENT SHAFT SPROCKET REMOVAL CRANKSHAFT SPROCKET “B” REMOVAL 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 leave...

ENGINE Timing Belt SOHC Roundededge Abnormal wear (Fluffy strand) Rubber exposed Tooth missing and canvas fiber Spacer Oil seal Chamfer shaft Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife. Abnormal wear on teeth. Missing tooth. INSTALLATION SERVICE POINTS C...

11 E N G I N E Timing Belt S O H C Center of tensioner 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...

ENGINE Belt SOHC (8) Tighten the tensioner attaching bolt, then tighten the tensioner spacer. CautionIf the tensioner spacer is tightened first, the tensioner turns as the tensioner spacer is tightened, resulting in an excessive belt tension. (9) Hold the center of the tension side span of the timin...

ENGINE Timing Belt DOHC TIMING BELT DOHC REMOVAL AND INSTALLATION 2.2 24 TE NO Engine without silent shafts Engine with silent shafts ' 2 5 Removal steps 1. Timing belt front upper cover 2. Timing belt front lower cover 3. Timing belt 4. Tensioner pulley 5. Tensioner arm 6. Auto tensioner 7. Idler p...

1 ENGINE Timing Belt D O H C SILENT SHAFT SPROCKET REMOVAL CRANKSHAFT SPROCKET “B” REMOVAL CAMSHAFT SPROCKET REMOVAL 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 damage...

E N G I N E Timina Belt D O H C 0 0 0 47 in.) Brass or aluminum aluminum A U T O T E N S I O N E R 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, r...

ENGINE Timing Belt DOHC Apply sealant S E A L A N T A P P L I C A T I O N O N S E M I - C I R C U L A R PACKING Specified sealant: ATD Part No. 8660 or equivalent SEALANT APPLICATION ON ROCKER COVER Apply sealant to the areas indicated in the illustration. Specified sealant: ATD No. 8660 or equivale...

ENGINE Timina Belt D O H C 1 Camshaft sprocket Timing marks Engine with silent shafts Screwdriver T I M I N G B E L T I N S T A L L A T I O N 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. ...

11 E N G I N E Fuel and Emission Control FUEL AND EMISSION CONTROL PARTS R E M O V A L A N D I N S T A L L A T I O N SOHC for 12 Nm 9 7 7 6 12 Nm 19 Nm 14 Removal steps Throttle body 2. Throttle body gasket3. EGR valve 4. EGR valve gasket 5. Injectors and fuel rail6. Insulator 7. Fuel pressure regul...

E N G I N E Fuel and Emission Control Parts AND INSTALLATION SOHC for TRUCK I - - - - 12 9 5 12 9 7 14 Removal steps 1. Throttle body 2. Throttle body gasket 3. EGR valve 4. EGR valve gasket 5. Injectors and fuel rail6. Insulator7. Fuel pressure regulator 8. O-ring9. Insulator injectors 11. O-ring 1...

11 E N G I N E Fuel and Emission Control Parts AND INSTALLATION DOHC 12 9 8 19 14 14 Removal steps 1. Throttle body stay 2. Throttle body 3. Throttle body gasket 4. EGR valve 5. EGR valve gasket 6. Injectors and fuel rail7. Insulator8. Fuel pressure regulator9. O-ring Insulator Injectors 12. O-ring ...

11 ENGINE Throttle Body THROTTLE BODY DISASSEMBLY AND REASSEMBLY SOHC for EXPO Disassembly steps 1. Accelerator wire bracket 2. Throttle position sensor 3. control motor 4. Throttle valve set screw 5. Throttle body 1.4 SOHC for 1.4 Disassembly steps 1. Throttle position sensor 2. Idle speed control ...

ENGINE Throttle Body DOHC 5 Disassembly steps Throttle position sensor 2. air control motor (stepper motor) 3. Closed throttle position switch 4. Adjusting nut5. Throttle body TSB Revision

11 ENGINE Throttle Bodv Red cl Blue DISASSEMBLY SERVICE POINTS 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. THROTTLE BODY REMOVAL (1) Do not rem...

ENGINE Throttle Body Throttle position sensor output Ground Closed position switch Throttle position sensor power REASSEMBLY SERVICE POINTS T H R O T T L E P O S I T I O N S E N S O R SOHC FOR EXPO (1) the throttle position sensor to the throttle body as shown in the illustration. (2) Turn the throt...

ENGINE Throttle Bodv Throttle positionsensor power round Throttle positionsensor output (2) Turn the throttle position sensor 90” clockwise to set it and tighten the screws. (3) Connect a circuit tester between (ground) and (output), or between (output) and (power). Then, make sure that the resistan...

11 ENGINE Intake Manifold INTAKE MANIFOLD REMOVAL AND INSTALLATION SOHC 18 Nm 9 18 Nm 13 18 Nm 13 18 13 8 30 Nm 22 11 16 Removal steps 1. Water hose 2. Water hose 3. Engine coolant temperature gauge unit 4. Engine coolant temperature sensor 5. Water outlet fitting 6. Gasket7. Thermostat 8. Intake ma...

ENGINE Intake Manifold Sealant Sealant INSTALLATION SERVICE POINTS 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. WATER OUTLET FITTING GASKET INSTALLATION (FOR ...

E N G I N E Exhaust Manifold and Water EXHAUST MANIFOLD AND WATER PUMP REMOVAL AND INSTALLATION SOHC 14 18 Nm 13 Removal steps 17 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Heat protector 5. Engine hanger 6. Exhaust manifold7. Exhaust manifold gasket 8. Water inlet pipe 9. O-ring Water...

11 E N G I N E Exhaust Manifold and Water Pump AND INSTALLATION D O H C F O R N O N - T U R B O 28 Nm 20 14 Nm 60 Nm 43 14 Nm 10 24 Nm 17 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 manifold8. Exhaust man...

E N G I N E Exhaust Manifold and Water Pump AND INSTALLATION DOHC TURBO 6043 31 14 Nm 11 Nm 8 14 16 6 7 Removal steps 1. Oil level gauge 2. Oil level gauge guide3. O-ring4. Heat protector “A” 5. Heat protector 6. Exhaust fitting 7. Gasket8. Air outlet fitting9. Gasket I 0. Water pipe 11. Oil return ...

ENGINE Turbocharger DISASSEMBLY AND REASSEMBLY Disassembly steps inspection of turbocharger waste gate actuator operation 1. Snap pin 2. Turbocharger waste gate actuator 3. Coupling 4. Turbine housing 5. Snap ring 6. Turbine wheel assembly 7. Compressor cover 8. O-ring TSB Revision

ENGINE Turbocharger 11 Coupling 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. COUPLING INSTALLATION (1) Install the coupling and tighten it to ...

ENGINE Rocker Arms and Camshaft SOHC ROCKER ARMS AND CAMSHAFT SOHC REMOVAL AND INSTALLATION steps 1. Breather hose 2. hose 3. Packing 4. Oil seal 5. Rocker cover 6. Gasket 7. Semi-circular packing 8. Rocker arms and rocker shafts9. Rear bearing cap Rocker arm 11. Spring EC 12. Rocker arm 13. Bearing...

Arms and Camshaft - - - REMOVAL SERVICE POINT ROCKER ARM AND CAMSHAFT REMOVAL (1) Before removing rocker arms and shafts assembly, install the special tool as illustrated to prevent adjuster from dropping. INSPECTION (1) Measure the cam height Identification mark (Standard value Limit I D: Intake 42...

ENGINE Rocker Arms and Camshaft SOHC Wave washer side rocker arm Timing belt side identification No. 1 No. 2 No. 3 No. 4 No. 1 No. 2 N o . 3 4 Rocker cover mounting bolt hole mark Identification mark No. 4 No. 2 No. 3 Lash WAVE WASHER INSTALLATION Install the wave washer in the correct direction as ...

ENGINE Camshafts and Rocker Arms DOHC CAMSHAFTS AND ROCKER ARMS DOHC REMOVAL AND INSTALLATION 20 Nm 14 6 Nm 8 Removal steps Bearing cap rear 2. Bearing cap front 3. Camshaft oil seal 4. No. 5 Bearing cap 5. Bearing cap No. 2 6. No. 4 Bearing cap 7. Bearing cap No. 38. Camshaft 9. Rocker arm Lash adj...

11 ENGINE Camshafts and Rocker Arms DOHC Roller Tip Scale 1 mm in.) Nut INSPECTION CAMSHAFT (1) Measure the cam height. Identification mark Intake Exhaust Standard value 35.49 (1.3972) 35.20 (1.3858) 35.49 35.20 (1.3972) (1.3858) 35.91 (1.3744) Limit 34.99 (1.3776) 34.70 34.99 34.70 (1.3661) 34.41 (...

E N G I N E Camshafts and Rocker Arms DOHC Camshaft sprocket side Intake side camshaft Dowel pin Cap number Symbol identifyingintake or exhaust Camshaft sprocket side INSTALLATION OF CAMSHAFT Apply engine oil to journals and cams of the camshafts. (2) Install the camshafts on the cylinder head. Use ...

11 ENGINE Cylinder Head and Valves SOHC CYLINDER HEAD AND VALVES SOHC REMOVAL AND INSTALLATION 95 Nm 69 Removal steps head bolt Cylinder head assembly 4. Gasket 5. Retainer lock 6. Valve spring retainer 7. Valve spring 8. Intake valve 9. Retainer lock Valve spring retainer Valve spring 12. Exhaust v...

ENGINE Cvlinder Head and Valves SOHC REMOVAL SERVICE POINTS PRECAUTION FOR REMOVED PARTS (1) Keep removed parts in order according to the cylinder number and intake/exhaust. CYLINDER HEAD BOLT REMOVAL Using the special tool, loosen the cylinder head bolts. Loosen evenly, little by little. RETAINER L...

1 E N G I N E Cvlinder Head and Valves SOHC Free height 1 I.D. Guide O.D. 1 INSPECTION CYLINDER HEAD (1) Check the cylinder head gasket surface for flatness by using a straightedge in the directions of A through shownin the illustration. Standard value: 0.05 mm in.) Limit: 0.2 mm in.) (2) If the ser...

E N G I N E Cylinder Head and Valves SOHC 0.5 1 mm mm in.) 1 1 Removal Installation Press Press a a Push rod -01 Valve guide Valve guide VALVE SEAT RECONDITIONING PROCEDURE Before correcting the valve seat, check for clearance between the valve guide and valve and, if necessary, replace the valve gu...

1 E N G I N E Cylinder Head and Valves SOHC Identification color Stem seal seal 1 61 I INSTALLATION SERVICE POINTS VALVE STEM SEAL INSTALLATION (1) Install the valve spring seat. (2) Using the special tool, install a new stem seal to the valve guide. CautionDo not reuse the valve stem seal. V A L V ...

ENGINE Cylinder Head and Valves SOHC 5 Identification mark Camshaft sprocket side OPTIONAL\ CYLINDER HEAD GASKET IDENTIFICATION Identification mark: . . . . . 63. . . . . 64 Caution Do not apply sealant to cylinder head gasket. CYLINDER HEAD BOLT INSTALLATION Tighten the cylinder head bolts in the s...

E N G I N E Cylinder Head and Valves DOHC CYLINDER HEAD AND VALVES DOHC REMOVAL AND INSTALLATION Removal steps 1. Cylinder head bolt 2. Washer 3. Cylinder head assembly 4. Gasket 5. Retainer lock 6. Valve spring retainer 7. Valve spring8. Intake valve9. Retainer lock Valve spring retainer Valve spri...

E N G I N E Cylinder Head and Valves DOHC 1 REMOVAL SERVICE POINTS CYLINDER HEAD BOLT REMOVAL (1) Using the special tool, loosen the cylinder head bolts. Loosen evenly, little by little. RETAINER LOCK REMOVAL (1) Using the special tool, compress the spring.(2) Remove the retainer locks. Keep removed...

E N G I N E 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 mm in.) Exhaust mm in.) Limit: Intake 0.7 mm in.) Exhaust mm in.) VALVE SPRING Free height: 48.3 mm in.) Limit: 47.4 mm in.) Squareness: 1.5” or less Limit: ...

E N G I N E Cylinder Head and Valves DOHC Valve seat color VALVE SEAT REPLACEMENT PROCEDURE Refer to Page 1 noting that the only difference is in the reboring size. Intake valve seat hole diameter 0.3 mm in.) O.S. . . . . . . . . . . . . . . . . . . . . 35.33 mm (1.3898 I in.) 0.6 mm in.) O.S. . . ....

11 ENGINE Cylinder Head and Valves DOHC Camshaft sprocket side RETAINER LOCK INSTALLATION Using the special tool, compress the valve spring and insert the retainer lock into position. CYLINDER HEAD GASKET IDENTIFICATION Identification mark: 2 0 CYLINDER HEAD BOLT INSTALLATION (1) Tighten the cylinde...

ENGINE Front Case, Silent Shaft and CASE, SILENT SHAFT AND OIL PAN REMOVAL AND INSTALLATION 22 24 40 Removal steps 1. Oil filter 2. Oil cooler bolt*** 3. Oil cooler*** 4. Drain plug 5. Drain plug gasket 6. Oil pan 7. Oil screen 8. Oil screen gasket 9. Flange nut Oil pump sprocket** 1. Plug 12. O-rin...

E N G I N E Front Case, Silent Shaft and Oil Pan 33 Nm24 45 Nm 33 55 Nm 40 55 Nm 40 NOTE DOHC Engine with silent shafts Engine with turbocharger Engine without silent shafts Engine with air-cooling type oil cooler Oil cooler by-pass valve***** 2. Oil pressure switch 3. Oil gauge unit Relief spring 7...

E N G I N E Front Case, Silent Shaft and Oil Pan IEngine without silent shafts Engine without silent shafts OIL PUMP OIL SEAL INSTALLATION CRANKSHAFT FRONT OIL SEAL INSTALLATION Using the special tool, install the crankshaft front oil seal into the front case. OIL PUMP DRIVEN GEAR OIL PUMP DRIVE GEA...

E N G I N E Front Case. Silent Shaft and Oil Pan Engine with silent shafts Engine with silent shafts Cylinder’ block (3) Using the special tool, install the rear bearing. NOTE The left rear bearing has no oil holes. SILENT SHAFT FRONT BEARING INSTALLATION (ENGINE WITH SILENT SHAFTS) Using the specia...

ENGINE Front Case, Silent Shaft and Oil Pan Bolt length with silent shafts 1 (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 in the illustration differs in tightening...

E N G I N E Front Case, Silent Shaft and Oil Pan OIL PAN INSTALLATION Clean both mating surface of the oil pan and the cylinder block. (2) Apply a 4 mm in.) wide bead of sealant to the entire circumference of the oil pan flange. Specified sealant: MITSUBISHI GENUINE PART No. or equivalent (3) The oi...

E N G I N E Piston and Rod n u m b e r pin setting 8 11 Press pin . Piston pin Front mark Connecting rod pin REMOVAL SERVICE POINTS CONNECTING ROD CAP REMOVAL Mark the cylinder number on the side of the connecting rod big end for correct reassembly. (2) Keep the removed connecting rods, caps, and be...

E N G I N E Piston and Rod ring ring 3 INSPECTION PISTON Replace the piston if scratches or seizure is evident on its surfaces (especially the thrust surface). Replace the piston if it is cracked. PISTON PIN Insert the piston pin into the piston pin hole with a thumb. You should feel a slight resist...

ENGINE Piston and Connecting Rod Side gap 1 (8) Check that the piston moves smoothly. 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. (2) Install the upper side rail. To install the side rail, first f...

DOHC E N G I N E Piston and Connecting Rod Non-turbo Turbo No. 1 pulley side No. 2 ring and spacer gap ‘Lower rail Timing belt s i d e , 1 Cylinder No Notches 7 PISTON AND CONNECTING ROD INSTALLATION (1) Liberally coat engine oil on the circumference of the piston, piston ring, and oil ring. (2) Arr...

E N G I N E Crankshaft. 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 p...

E N G I N E Crankshaft, Flywheel and Drive Plate I Lower bearing(for No. Upper bearing (for No. Upper and lower bearings (for No. 3) 1 SOHC Crank- shaftpulley Crank-shaft pulley side INSTALLATION SERVICE POINTS CRANKSHAFT BEARING IDENTIFICATION (1) The upper bearings (on the cylinder block side) for...

E N G I N E Crankshaft, Flywheel and Drive Plate Oil seal Oil separator case 0 0 0 OIL SEAL INSTALLATION OIL SEPARATOR INSTALLATION (1) Force the oil separator into the oil seal case so that the oil hole in the separator is directed downward (arrow in illustration). TSB Revision

BRACKET ENGINE Bracket 1 07 Rear wheel drive and four wheel drive 33 Engine support bracket, right 45 2. Engine support bracket, left 2 33 Front wheel drive and all wheel drive Roll stopper bracket, front 2. Engine support bracket, front 3. Exhaust pipe support bracket 4. Roll stopper bracket, rear ...

ENGINE Service Specifications SERVICE SPECIFICATIONS mm (in.) Standard value Cylinder head Flatness of gasket surface 0.03 2) 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 an...

ENGINE Tools Tool Number and Supersession tool name Application holder sprocket when loosening Use with or bolt Installation of crankshaft rear oil seal 3 Installation of camshaft oil seal Camshaft oil seal installer 6 Crankshaft Turning crankshaft wrench 17 Installation of front oil seal Crankshaft...

ENGINE Special Tools Tool Number I N I Use Use with of crankshaft rear oil seal Crankshaft rear oil seal installer Use with Removal and installation of piston pin Piston pin setting Holding flywheel TSB Revision I

ENGINE Generator and Ignition System Generator a tension gauge, adjust the tension to the standard Standard value: New belt 500 700 (110 154 Used belt 400 (88 (3) Tighten the lock bolt to the specified torque.(4) Tighten the nut for pivot bolt to the specified torque. TSB Revision

ENGINE Thing Belt REMOVAL AND INSTALLATION 90 Nm 65 6 Removal steps 1. Flange 2. Timing belt upper cover 3. Timing belt lower cover 4. Timing belt 5. Tensioner 6. Tensioner spring 7. Crankshaft sprocket 8. Camshaft sprocket bolt 9. Camshaft sprocket TSB Revision

ENGINE Timing Belt Cracks 1 REMOVAL SERVICE POINTS TIMING BELT REMOVAL 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 bracke...

ENGINE Timing Belt Rounded edge (Fluffy strand) Rubber exposed Tooth and canvas 3 (6) Abnormal wear of belt sides. The sides are normal are sharp as if cut by a knife. (7) Abnormal wear on teeth.(8) Missing tooth. INSTALLATION SERVICE POINTS CAMSHAFT SPROCKET BOLT TIGHTENING TENSIONER SPRING TENSION...

ENGINE Drive Belt and Timing Belt I Camshaft sprocket Crankshaft sprocket TIMING BELT INSTALLATION (1) Check that the timing belt tensioner and spring have been installed in position. (See (2) Align the timing mark on the camshaft sprocket with that on the cylinder head. (3) Align the timing mark on...

ENGINE Fuel and Emission Parts 1 Fuel rail Injector INSPECTION INJECTORS (1) Using an ohmmeter (circuit tester), between terminals of injectors; the circuit should be closed. If failure is detected, replace the injector. Standard value: 13 16 at EGR VALVE (1) Check the EGR valve for sticking or carb...

ENGINE Throttle Body THROTTLE BODY DISASSEMBLY AND REASSEMBLY EXPO 5 1.4 Removal steps 1. Throttle position sensor 2. air control motor 3. O-ring 4. Throttle body 5. Accelerator cable bracket MIRAGE 4 Removal steps Throttle position sensor 2. Idle air control motor 3. O-ring 4. Throttle body 1 Revis...

ENGINE Throttle Body DISASSEMBLY SERVICE POINTS 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. Ground Throttle position sensor output Closed throttleposition swit...

11 ENGINE Throttle Bodv Throttle position Closed throttleposition switch Throttle positionsensor output Ground THROTTLE POSITION SENSOR INSTALLATION <MIRAGE> (1) Install the throttle position sensor to the throttle body as shown in the illustration. (2) Turn the sensor clockwise, and tighten t...

ENGINE Intake Manifold and Water Pump INTAKE MANIFOLD AND WATER REMOVAL AND INSTALLATION 15 50 Nm 36 I 11 Nm 8 19 24 Nm 14 5 22 16 Removal steps 1. Water hose A Water hose Engine coolant temperature gauge unit 4. Engine coolant temperature sensor 5. Water inlet fitting 6. Thermostat 7. Thermostat ho...

11 ENGINE Intake Manifold and Water Pump Sealant I INSTALLATION SERVICE POINTS SEALANT APPLICATION TO WATER PUMP Specified sealant: Mitsubishi Genuine Part No. or equiva- lent WATER PIPE O-RING INSTALLATION Wet the O-ring (with water) to facilitate the assembly. Caution 1. Keep the O-ring free of oi...

ENGINE Intake Manifold and Water Pump Sealant SEALANT APPLICATION TO ENGINE TEMPERATURE UNIT Specified sealant: ATD Part No. 8660 or equivalent TSB Revision

ENGINE Exhaust Manifold EXHAUST MANIFOLD REMOVAL AND INSTALLATION 30 Nm 22 I 2 I 18 Nm 7 I 13 36 Nm 18 Nm 13 26 4 45 Nm 33 22 36 Nm 26 30 Nm 22 Removal steps Oxygen sensor (Federal) models 2. Exhaust manifold cover A3. Exhaust manifold bracket 4. Exhaust manifold bracket A 1993 models 5. Exhaust man...

ENGINE Rocker Arms and ‘Camshaft Exhaust 2 Exhaust 4 Intake 3 Intake 4 (3) Loosen the adjusting screw locknut.(4) Using a feeler gauge, adjust the valve clearance by turning the adjusting screw. Standard value: Intake 0.09 mm in.) Exhaust 0.20 mm in.) (5) While holding the adjusting screw with a scr...

11 ENGINE Cylinder Head and Valves out of square ree 1 1 Spring retainer Painted end I 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 in.) Measure the squareness of the spring and, if the limit is ex...

ENGINE Front Case and Oil Pump FRONT CASE AND OIL PUMP REMOVAL AND INSTALLATION 14 I I I 45 33 Removal steps 1 Oil filter 2. Drain plug 3. Drain plug gasket 4. Oil pan 5. Oil screen 6. Oil screen gasket 7. Relief plug8. Relief spring9. Relief plunger Oil seal Oil pump case 12. O-ring13. Oil pump cas...

ENGINE Front Case and Oil Pump REMOVAL SERVICE POINTS 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. OUTER ROTOR INNER ROTOR REMOVAL (1) Make al...

11 ENGINE Front Case and Oil Pump Oil seal TSB Revision INSTALLATION SERVICE POINTS INNER ROTOR OUTER ROTOR INSTALLATION 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 ...

ENGINE Front Case and Oil Pump 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 in.) diameter bead of sealant to the oil pan flange. See “Form In-Place Gasket” in introduction. Specified sealant: Mitsubishi Genuine Pa...

11 ENGINE Piston and Connecting Rod PISTON AND CONNECTING REMOVAL AND INSTALLATION Removal steps 8 1. Nut 2. Connecting rod cap 3. Connecting rod bearing Piston and connecting rod 5. Connecting rod bearing6. Piston ring No. 1 Piston ring No. 2 8. Oil ring9. Piston pin 0. Piston Connecting rod 2. Bol...

ENGINE Piston and Rod Piston ring gap INSPECTION PISTON RING 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: No. 1 0.03 0.07 mm in.) No. 2 0.02 0.06 m m in.) Limit: No. 1 0.1 mm in.) No. 2 0.1 mm in.) In...

ENGINE Piston and Connecting Rod Identification color 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. Crank pin OD identification mark Connecti...

ENGINE Crankshaft, Cylinder Block, Flywheel and Drive CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE PLATE REMOVAL AND INSTALLATION 100 Nm 2 72 16 7 11 Nm 8 7 8 Nm 72 I Removal steps 1. Flywheel bolt 2. Flywheel 3. Drive plate bolt 4. Adapter plate 5. Drive plate6. Crankshaft bushing 1 7. Rear plate...

ENGINE Crankshaft, Cylinder Block, Flywheel and Drive Plate Check digit REASSEMBLY SERVICE POINTS CRANKSHAFT BEARING INSTALLATION (1) When the bearings are to be replaced, select correct ones and install them the correct positions according to the identification marks stamped on the crankshaft and t...

ENGINE C O N T E N T S BRACKET ................................................................ 122 CAMSHAFT, ROCKER ARMS AND BEARING CAPS .................................................... 87 CRANKSHAFT, FLYWHEEL ANDDRIVE PLATE ........ ... . ............................................ 115 CYLIN...

ENGINE General Information GENERAL INFORMATION S E C T I O N A L V I E W SOHC ENGINE for TSB Revision

ENGINE General Information S E C T I O N A L V I E W SOHC ENGINE for MONTERO AND TRUCK TSB Revision I

ENGINE General Information SECTIONAL VIEW DOHC NON-TURBO ENGINE TSB Revision

ENGINE General Information SECTIONAL VIEW DOHC TURBO ENGINE TSB Revision

ENGINE General Information SYSTEM S O H C Oil pressure switch Oil pressure gauge unit Oil cooler by-pass valve MONTERO only Lash adjuster TSB Revision

ENGINE Service mm (in.) Camshaft DOHC Cam height Intake Exhaust Journal diameter Oil clearance Rocker arm I.D. Rocker arm-to-shaft clearance Rocker shaft SOHC length SOHC length Intake Exhaust diameter Intake Exhaust angle guide clearance Intake Exhaust of valve head (Margin) Intake Exhaust DOHC len...

ENGINE Torque Specifications Generator and drive belt Cooling fan bolt N m 11 Fan pulley bolt 11 8 Tensioner pulley nut SOHC DIAMANTE, DOHC 50 36 SOHC MONTERO AND TRUCK 45 33 Tensioner bracket bolt SOHC DIAMANTE 42 30 SOHC MONTERO AND TRUCK 24 42 30 DOHC 19 Idler pulley bolt SOHC MONTERO AND TRUCK 4...

ENGINE Torque Specifications Ignition system Center cover bolt Spark plug Distributor nut Ignition coil bolt SOHC MONTERO AND TRUCK DOHC Ignition power transistor bolt Crankshaft position sensor nut Timing belt SOHCEngine support bracket bolt Tensioner lock bolt sprocket bolt stay bolt bracket bolt ...

Torque Specifications Exhaust manifold Oil level guide bolt gauge Heat protector boltEngine hanger bolt SOHC SOHC MONTERO AND TRUCK DOHC NON-TURBO Exhaust manifold nut SOHC DOHC NON-TURBO DOHC TURBO Heater pipe bolt pipe bolt SOHC MONTERO AND TRUCK bolt pump protector Turbocharger stay bolt fitting ...

11 ENGINE Torque Specifications Nm Oil pan and oil pump Transmission stay bolt 75 54 Oil pressure switch DIAMANTE AND MONTERO AND TRUCK 7 Oil pressure gauge unit DIAMANTE AND 7 MONTERO 55 40 Oil cooler by-pass valve 55 40 Oil filter bracket stay bolt 23 Oil filter bracket bolt DIAMANTE AND 24 MONTER...

ENGINE Special Tools Tool Number and tool name Supersession 7 Crankshaft front oil sealinstaller I 8 Crankshaftrear oil seal installer Pulley holding pins (2) Oil panremover Valve stem seal installer Valve spring compressor Pulley holding pins Camshaft oilseal installer Circular packing installer Us...

11 ENGINE Special Tools seal installer compressor Installation of flywheel TSB Revision

ENGINE Generator and Drive Belt GENERATOR AND DRIVE BELT R E M O V A L A N D I N S T A L L A T I O N SOHC for 3 2 30 155 23 8 14 10 Removal steps Drive belt 2. Tensioner pulley 3. Adjusting bolt4. Adjusting stud 5. Tensioner bracket6. Pivot bolt7. Generator 8. Generator brace 9. Crankshaft bolt Spec...

ENGINE Generator and Drive Belt SOHC for NTERO and TRUCK DOHC REMOVAL SERVICE POINT CRANKSHAFT BOLT LOOSENING (1) Using the special tool, hold the drive plate or flywheel. Remove the crankshaft bolt. INSTALLATION SERVICE POINT DRIVE BELT TENSION ADJUSTMENT DRIVE BELT TENSION CHART Generator drive be...

ENGINE Generator and Drive Belt for for MONTERO and TRUCK DOHC (3) If you use a tension gauge, tighten the adjusting to adjust the belt tension to the specification shown in thechart. CRANKSHAFT BOLT TIGHTENING Using the special tool, hold the drive plate or flywheel. (2) Install the crankshaft bolt...

ENGINE Intake Manifold Plenum and Throttle Body INTAKE MANIFOLD PLENUM AND THROTTLE BODY R E M O V A L A N D I N S T A L L A T I O N SOHC for 8 18 12 8 I 3.6 22 16 13 Removal steps 1. 2. Ignition coil For California 3. High tension cable 4. Intake manifold plenum stay, rear 5. Intake manifold plenum...

ENGINE Intake Manifold Plenum and Throttle Body AND INSTALLATION DOHC NON-TURBO 6 12 Nm 8 3 22 Nm 16 13 3 13 Removal steps EGR pipe For California 2. Intake manifold plenum stay, rear 3. Intake manifold plenum stay, front 5. EGR valve 6. EGR valve gasket For California 7. Throttle body 8. Intake man...

AND FUEL SYSTEM D O H C T U R B O 13 13 Removal steps 1. 2. EGR pipe gasket For California 3. Intake manifold plenum stay, rear 4. Intake manifold plenum stay, front 5. EGR valve 6. EGR valve For California 7. Throttle 8. Throttle body gasket 9. manifold plenum Intake manifold plenum gasket 18 Nm 13...

ENGINE Throttle Body DISASSEMBLY AND REASSEMBLY DOHC TURBO Disassembly steps Up to 1992 models 3. Vacuum valve 4. Dash From 1993 models 5. Throttle position sensor 6. air control motor 7. Throttle body D I S A S S E M B L Y A N D R E A S S E M B L Y SOHC for MONTERO and TRUCK 3 Disassembly steps Thr...

ENGINE Throttle Bodv Red air VACUUM VALVE DOHC TURBO Up to 1992 models 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 (19.7 to make sure that the negativ...

ENGINE Throttle Body I (3) Hold the idle air control motor as shown in the illustration, connect the negative terminal of the power supply toeach 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 genera...

ENGINE Throttle Body Closed throttle Accelerator pedal positionsensor output 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. ACCELERATOR PEDAL POSITION SENSOR INST...

ENGINE Ignition System IGNITION SYSTEM SOHC for 25 Nm 18 Removal steps 1. Spark plug cables 2. Spark plug 3. Distributor 4. O-ring TSB Revision

ENGINE Ignition Svstem INSTALLATION SERVICE POINTS DISTRIBUTOR INSTALLATION (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,...

ENGINE Belt SOHC AND INSTALLATION M O N T E R O A N D T R U C K 11 8 25 14 18 I 19 4 Removal steps 1. Access cover 2. Timing belt front upper cover, right3. Timing belt front upper cover, left 4. Timing belt front lower cover 5. Flange 6. Timing belt Tensioner 8. Tensioner spring9. Crankshaft sprock...

11 ENGINE Timina Belt SOHC TIMING BELT INSTALLATION 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) The...

ENGINE Timing Belt SOHC ad mark ENGINE SUPPORT BRACKET INSTALLATION 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 Revision

ENGINE Timing Belt DOHC TIMING BELT DOHC R E M O V A L A N D I N S T A L L A T I O N Up to 1992 models 2 24 17 90 Nm 65 15 6 49 35 30 55 Nm40 Removal steps 1. Engine support bracket 2. Timing belt front upper cover, right 3. Timing belt front upper cover, left 4. Timing belt front lower cover 5. Tim...

ENGINE Timing Belt DOHC Apply sealant I Spark plug holes INSTALLATION SERVICE POINTS CAMSHAFT SPROCKET BOLT TIGHTENING Hold the hexagonal portion of the camshaft with a wrench when tightening the camshaft sprocket bolt. Tighten the bolt to the specified torque. ROCKER COVER INSTALLATION Apply sealan...

ENGINE Timing Belt DOHC Timing marks (on rightrocker cover) Camshaft sprocket Timing marks (on left rocker cover) Auto tensioner Timing mark (on oil pump case) (on sprocket) Timing mark (on sprocket) Crankshaft sprocket the center bolt of the auto-tensioner pulley, and install the special tool and a...

11 ENGINE Intake Manifold and Fuel INTAKE MANIFOLD AND FUEL PARTS R E M O V A L A N D I N S T A L L A T I O N SOHC for 7 8 19 Nm 14 16 18 Removal steps harness 2. Injector and fuel rail 3. 4. Fuel pressure regulator 5. O-ring 6. Insulator Gromet Fuel pipe 11. O-ring 12. Fuel rail 13. coolant tempera...

ENGINE Intake Manifold and Fuel Parts AND INSTALLATION SOHC for MONTERO AND TRUCK 14 30 Nm 22 11 Nm 8 Removal steps 1. Injector and fuel rail 12. Heat pipe 2. Insulator 13. Heat pipe gasket 3. Fuel pressure regulator 14. Water hose 4. O-ring 15. Engine coolant temperature gauge unit 5. Insulator 16....

ENGINE Intake Manifold and Fuel Parts Alignment mark Jiggle valve II Sealant 1 Sealant Sealant INSPECTION INJECTORS (1) Measure the resistance between the terminals of the injectors using a circuit tester. If the resistance is out specification, replace the injector. Standard value: Non Turbo 13 16 ...

ENGINE Intake Manifold and Fuel Front 71 INTAKE MANIFOLD INSTALLATION DOHC Tighten the nuts on the right bank to 4 Nm (2.2 (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 th...

ENGINE Exhaust Manifold REMOVAL AND INSTALLATION DOHC TURBO 14 Nm Removal steps 1. Oil level gauge Oil level gauge guide 3. O-ring4. O-ring 5. Water inlet pipe 17 6. O-ring7. Water pump 8. Water pump gasket TSB Revision I

ENGINE Exhaust Manifold 14 Nm 60 Nm 60 Nm 44 31 Nm 22 43 a 9. Heat protector Heat protector A 11. Turbocharger stay12. Exhaust fitting 13. Exhaust fitting gasket14. Oil pipe15. Water pipe A, right 16. Water hose17. Water pipe right18. Water hose 19. Turbocharger, right 20. Turbocharger gasket 21. Ri...

ENGINE Exhaust Manifold 8 31 Nm 22 14 Nm 25 Nm 18 Nm 28 27 27. Heat protector 28. Exhaust fitting, left 29. Exhaust fitting gasket, left 30. Heat protector Oil return pipe 32. Oil return pipe gasket 33. Oil pipe34. Water pipe left 35. Water hose TSB Revision

ENGINE Exhaust Manifold I O-ring Water pump Water pipe I For right bank Front Front For left bank Cylinder No. Cylinder No. Groove INSTALLATION SERVICE POINTS O-RING AND WATER PIPE INSTALLATION Wet the O-ring (with water) to facilitate assembly. Caution Keep the O-ring free of oil or grease. EXHAUST...

11 ENGINE Manifold Groove LEFT EXHAUST MANIFOLD INSTALLATION DOHC TURBO Tighten the nuts in the following order. (1) Tighten four nuts to 30 Nm (22 (2) tighten the turbocharger to the exhaust man- (3) Tighten nut to 30 Nm (22 (4) Tighten nuts and to 50 Nm (36 (5) Back off nuts and until a torque val...

ENGINE Turbocharger TURBOCHARGER DISASSEMBLY AND REASSEMBLY steps Snap pin 2. Turbocharger waste gate actuator 3. Coupling 4. Turbine housing 5. Snap ring 6. Turbine wheel assembly 7. 8. cover O-ring INSPECTION TURBOCHARGER Manually open and close the waste gate valve to make sure it operates freely...

ENGINE Turbocharger Chamfered wheel assembly cover 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. SNAP RING INSTALLATION Fit...

ENGINE Rocker Arms and Camshaft SOHC ROCKER ARMS CAMSHAFTS SOHC R E M O V A L A N D I N S T A L L A T I O N 7 7 7 Removal steps cover 3. Circular packing 4. Camshaft oil seal 5. Distributor adaptor6. O-ring7. Rocker shafts and caps Revision

ENGINE Rocker Arms and Camshaft SOHC AND INSTALLATION M O N T E R O A N D T R U C K 9 7 I - - 7 Removal steps 1 Oil filler 2. Oil filler tube 3. Rocker cover 4. Gasket 5. Circular packing 6. Camshaft oil seal 7. Distributor adaptor 8. O-ring 9. Rocker shafts and bearing caps Revision

ENGINE Rocker Arms and Camshaft SOHC REMOVAL SERVICE POINT ROCKER ARM, 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 a...

E N G I N E Rocker Arms and Camshaft SOHC I Division 1 mm 1 Lash 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...

ENGINE Rocker Arms and Camshaft SOHC ROCKER ARM, SHAFT AND BEARING CAPINSTALLATION (1) Apply a minimum amount of the specified sealant on the four places of the cylinder head. NOTEBe sure the sealing agent does not swell out onto the cam journal surface of the cylinder head. If it swells out, immedi...

11 ENGINE Rocker Arms and Camshaft SOHC Rocker arm shaft assembly(B) Arrow mark (bearing cap) Arrow mark (cylinder head) Timing belt side R o c k e r a r m s h a f t - - - - - assembly (A) Arrow cap) (3) Tighten the bearing cap bolts to the specified torque. (4) Remove the special tools from all roc...

ENGINE Rocker Arms and Camshaft SOHC 0.5 mm in.) I - - Spacer / 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 Install a 1.3 to 1.5 mm to in.) thick spacer to the special tool and drive in the circular packing. NOTEUse of spacer for transmission is recom- mended. Caution The packing is overdr...

ENGINE Rocker Arms and Rocker Shafts SOHC DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Bearing cap 2. Rocker arm 3. Spring 4. Bearing cap No. 3 5. Bearing cap No. 2 6. Rocker arm shaft “B” 7. Rocker arm shaft “A” 8. Bearing cap No. 1 DISASSEMBLY SERVICE POINT ROCKER ARM REMOVAL Before disassembly...

ENGINE Rocker Arms and Rocker Shafts SOHC Notch Rocker arm shaft “6” Cap No. armshaft Rocker arm Oil hole shaft (A) - - - - - Rocker arm shaft 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 ...

ENGINE Rocker Arms and Rocker Shafts SOHC 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 equallyshaped. Assemble the caps according ...

ENGINE Camshafts, Rocker Arms and Bearing Caps DOHC CAMSHAFTS, ROCKER ARMS AND BEARING CAPS DOHC REMOVAL AND INSTALLATION 20 Removal steps Crankshaft position sensor 2. Circular packing 3. Camshaft oil seal 4. Bearing cap, front 5. Bearing cap, rear 6. Bearing cap No. 27. Bearing cap No. 48. Bearing...

ENGINE Camshafts, Rocker Arms and Bearing Caps DOHC Identification mark C A M S H A F T Turn the crankshaft to bring 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 (st...

ENGINE amshafts, Rocker Arms and Bearing Caps DOHC C A M S H A F T O I L S E A L Apply engine oil sparingly all around the lip of the camshaft oil seal. Using the special tool, install the oil seal. C I R C U L A R P A C K I N G Install the circular packing with the special tool. TSB Revision

ENGINE Cylinder Head and Valve SOHC CYLINDER HEAD AND VALVE SOHC REMOVAL AND INSTALLATION 7 80 Removal steps head bolt Cylinder head assembly 4. Cylinder head gasket 5. Retainer lock 6. Valve spring retainer 7. Valve spring 8. Inlet valve 9. Retainer lock Valve spring retainer 1. Valve spring 2. Exh...

11 ENGINE Cylinder Head and Valve SOHC REMOVAL SERVICE POINTS PRECAUTION FOR REMOVED PARTS Keep removed parts in order according to the cylinder number and intake/exhaust. CYLINDER HEAD BOLT REMOVAL Using the special tool, loosen the cylinder head bolts. Loosen evenly, little by little. RETAINER LOC...

ENGINE Cylinder Head and Valve SOHC Ridge wear 1 INSPECTION CYLINDER HEAD Check the cylinder head gasket surface for flatness by using a straightedge in the directions of A through shown in the illustration. Standard value: 0.05 mm in.) Limit: 0.2 mm in.) (2) If the service limit is exceeded, correc...

ENGINE Cvlinder Head and Valve SOHC 1 1 VALVE SPRINGS 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.) DOHCup 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 t...

ENGINE Cylinder Head and Valve SOHC height I mm in.) 1 mm in.) 1 1 Removal Installation Press Press Valve guide (4) Check the valve seat The valve seat can be determined by measuring the valve spring’s installed height. (If the valve seat is great, the valve seat’s installed height also is great.) I...

ENGINE Head and Valves DOHC CYLINDER HEAD AND VALVES DOHC REMOVAL OF INSTALLATION Removal steps Non-turbo 80 Turbo Back off 90 . . Cylinder head bolt 2. Washer3. Cylinder head assembly 4. Cylinder head gasket 5. Retainer lock 6. Valve spring retainer7. Valve spring8. Intake valve9. Retainer lock 0. ...

ENGINE Cylinder Head and Valves DOHC CYLINDER HEAD GASKET IDENTIFICATION Identification markNon-turbo Turbo CYLINDER HEAD BOLT INSTALLATION <Turbo engine> (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 tor...

ENGINE Oil Pan and Oil Pump OIL PAN AND OIL PUMP R E M O V A L A N D I N S T A L L A T I O N and 23 Nm 17 24 Nm __ 1 7 17 55 75 Nm 54 I 7 14 Nm 33 40 Nm 29 4 Removal steps Transmission stay, right 2. Transmission stay, left 3. Oil pressure switch 4. Oil pressure gauge unit 5. Oil filter 6. Oil coole...

ENGINE Oil Pan and Oil P u m p AND INSTALLATION M O N T E R O a n d T R U C K Bolt with head mark “4” 24 Nm 17 Bolt with head mark “7” Nm 10 Nm 7 5 55 Nm 55 Nm 40 14 11 45 Nm 33 40 Nm 29 Removal steps Oil pressure switch 2. Oil pressure gauge unit MONTERO 3. Oil filter 4. Oil cooler by-pass valve 5....

E N G I N E Oil Pan and Oil REMOVAL SERVICE POINT O I L P A N R E M O V A L Knock the special tool deeply between the oil pan and the cylinder block. Hitting the special tool on the side, slide it along the oil pan to remove it. O U T E R R O T O R INNER ROTOR REMOVAL Make alignment dots on the oute...

ENGINE Oil Pan and Oil Pump Oil I case OIL COOLER BYPASS VALVE Make sure that the valve moves smoothly. (2) Ensure that the dimension 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 t...

ENGINE Oil Pan and Oil Pump DRAIN PLUG GASKET INSTALLATION (1) Install the drain plug gasket as illustrated. l engine oil 1 I A P P L I C A T I O N T O O I L P R E S S U R E (1) Coat the threads of the switch with sealant and install the switch using the special tool. Specified sealant: ATD Part or ...

E N G I N E Piston and Connecting Rod PISTON AND CONNECTING REMOVAL AND INSTALLATION ROD 4 52 38 Removal steps 1. Nut 2. Connecting rod cap 3. Connecting rod bearing (lower) 4. Piston, connecting rod assembly 5. Connecting rod bearing (upper) 6. Piston rina No.? 1 1 7. Piston 8. Oil ring 9. Piston p...

ENGINE Piston and Connecting Rod Piston pin setting tool 6941 3 Press pin Piston pin REMOVAL SERVICE POINTS CONNECTING ROD CAP REMOVAL (1) Mark the cylinder the side of the connecting rod big end for correct reassembly. (2) Keep the removed connecting rods, caps, and in order according to the cylind...

ENGINE Piston and Connecting Rod Push in by piston Piston ring’ ring gap 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) the piston pin into the piston pin hole with a thu...

ENGINE Piston and Rod Base Press Pin Piston A Pin depth set CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE METHOD) The crankshaft oil clearance can be measured easily by using a plastic gauge, as follows: Remove oil and grease and any other foreign matters from the crankshaft pin and the bearing inner ...

ENGINE Piston and Rod 1 (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 pis...

ENGINE Piston and Connecting Rod Upper side rail and spacer gap MONTERO and TRUCK PISTON RING PISTON RING INSTALLATION (1) Using a piston ring expander, fit and then piston ring into position. NOTE1. Note the difference in shape between and piston rings. 2. Install piston rings and with their side h...

ENGINE Piston and Connectinn Rod Notches Cylinder No. CONNECTING ROD CAP INSTALLATION 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 noalignment mark, position the notches for lock...

ENGINE Crankshaft, Flywheel and Drive Plate INSPECTION CYLINDER BLOCK for scratches, rust, and corrosion. Use flaw detecting agent for the check. If defects are evident,correct, or replace. Using a straightedge and feeler gauge, check the block top surface for Make sure that the surface is free from...

ENGINE Crankshaft, Flywheel and Drive Plate 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 a n d (5) Hone to the final finish dimension (piston O.D. clearance between pist...

ENGINE Crankshaft, Flywheel and Drive Plate CRANKSHAFT BEARING (UPPER) THRUST BEARING A THRUST BEARING CRANKSHAFT BEARING (LOWER) INSTALLATION Classify the crankshaft bearings (upper and by whether there is an oil groove or not. Then, assemble as shown in the illustration. (2) Assemble the thrust be...

ENGINE Crankshaft, Flywheel and Drive Plate BEARING CAP BEARING BOLT INSTALLATION (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 ...

ENGINE Crankshaft, Flywheel and Drive Plate Sealing agent CRANKSHAFT REAR OIL SEAL INSTALLATION Using the special tool, press-fit a new crankshaft rear oil seal into the oil seal case. OIL SEAL CASE INSTALLATION Apply specified sealant to the area shown in the illustration. Specified sealant: M I T ...

BRACKET ENGINE Bracket R E M O V A L A N D I N S T A L L A T I O N and 30 2 Removal steps 1. Engine support bracket, right 2. Engine support bracket, left R E M O V A L A N D I N S T A L L A T I O N MONTERO and TRUCK 30 Removal steps Roll stopper bracket, front 2. Roll stopper bracket, rear TSB Revi...

4G6 ENGINE <1993> - General Information GENERAL INFORMATION ENGINE SECTIONAL VIEW - SOHC 8 VALVE 6EN0629 TSB Revision

4G6 ENGINE <1993> - General Information TS8 Revision 6EN0630

4G6 ENGINE <1993> - General Information ENGINE SECTIONAL VIEW - SOHC 16 VALVE 6EN0616 TSB Revision

ENGINE General Information ENGINE LUBRICATION SYSTEM SOHC 8 VALVE Rocker shaft C r a n k s h a f t shaft Oil pump ENGINE LUBRICATION SYSTEM SOHC 16 VALVE Crankshaft v a l v e Oil pump TSB Revision I

ENGINE General Specifications GENERAL SPECIFICATIONS SOHC 16 VALVE Number of cylinders Combustion chamber Total displacement (cu. in.) Cylinder bore mm (in.) Piston stroke mm (in.) Compression ratio Valve timing ke valve Opens BTDC Closes ABDC Exhaust valve Opens BBDC Closes ATDC Lubrication system ...

ENGINE General Specifications 1 1 SOHC 8 VALVE I Items Number of Combustion chamber displacement (cu. in.) Cylinder bore mm Piston stroke mm (in.) Compression ratio Valve timing Intake valve Opens BTDC Closes ABDC Exhaust valve Opens BBDC Closes ATDC Lubrication system Oil pump type Cooling system W...

E N G I N E Service Specifications mm (in.) Rocker arm SOHC 8 VALVE I.D. Rocker arm-to-shaft clearance Rocker arm SOHC 16 VALVE I.D. Rocker arm-to-shaft clearance Lash adjusterLeak down test Remarks: Diesel fuel at 15 (59 Standard 18.91 18.93 0.01 0.04 20.02 20.04 0.02 0.05 4 20 seconds/l mm in.) Li...

E N G I N E Service Valve guide- SOHC 8 VALVE Overall length Intake Exhaust I.D. O.D. Service size Press-in temperature Valve guide SOHC 16 VALVE Overall length Intake Exhaust I.D. O.D. Service size Press-in temperature Valve guide DOHC Overall length Intake Exhaust I.D. Service size Press-in temper...

E N G I N E Service mm (in.) Piston DOHC O.D. Non-turbo Turbo Piston to cylinder clearance Non-turbo Turbo Service size Standard 84.97 85.00 (3.3453 3.3465) 84.99 (3.3449 0.02 -0.04 0.03 -0.05 0.25 0.50 0.75 1 over size Limit Piston ring SOHC End gap No. 1 ring No. 2 ring 8 VALVE 16 VALVE Oil ring 8...

E N G I N E Torque Specifications TORQUE SPECIFICATIONS Generator and ignition system Cooling fan Fan clutch Water pulley pump Generator mounting bolt Generator brace bolt Generator pivot nut Crankshaft pulley bolt Spark plug Ignition coil bolt Distributor nut Center cover bolt Power transistor bolt...

E N G I N E Torque Specifications Intake manifold Intake manifold bolt and nutIntake manifold bolt (Ml and nut (Ml DOHC Intake manifold stay bolt SOHC Intake manifold stay bolt DOHCIntake manifold plenum bolt and nut Intake manifold plenum stay Water outlet fitting bolt Engine coolant temperature ga...

ENGINE Special Tools SPECIAL TOOLS Use with Use with Crankshaft front oil seal installer TSB Revision

11 ENGINE Generator and Svstem GENERATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION SOHC 8 VALVE 14 Nm 25 Nm 18 11 Nm 8 25 18 Nm 8 Removal steps 1. Drive belt 2. Cooling fan 3. Fan clutch 4. Water pump pulley 5. Power steering pump pulley 6. Generator brace 7. Generator8. Crankshaft pulley9. Spark...

E N G I N E Generator and Ignition System R E M O V A L A N D I N S T A L L A T I O N SOHC 16 VALVE 14 Nm 17 25 18 Removal steps 1. Drive belt 2. Water pump pulley3. Power steering pump pulley 4. Generator brace 5. Generator 6. Crankshaft pulley7. Spark plug cable 8. Spark plug9. Distributor TSB Rev...

ENGINE Generator and Ignition System REMOVAL AND INSTALLATION DOHC steps 1. Drive belt 7. Center cover 2. Water pump pulley 8. Spark plug cable 3. Power steering pump pulley 9. Spark plug 4. Generator brace Ignition power transistor 5. Generator 1 1. Ignition coil 6. Crankshaft pulley 12. Crankshaft...

ENGINE Generator and Ignition System Water pump pulley DRIVE BELT TENSION ADJUSTMENT ADJUSTER TYPE Adjust belt deflection to standard value. Turn adjusting bolt clockwise to increase the belt tension and turn adjustingbolt counterclockwise to decrease the belt tension. Standard value: V-ribbed type ...

ENGINE Timing Belt Apply sealant in.) Apply sealant Cylinder head S E A L A N T A P P L I C A T I O N O N S E M I - C I R C U L A R PACKING Specified sealant: ATD Part No. 8660 or equiva- lent TSB Revision

11 E N G I N E T i m i n g B e l t SEALANT APPLICATION ON ROCKER COVER Apply sealant to the areas indicated in the illustration. Specified sealant: ATD Part No. 8660 or equivalent Apply Chamfer , SPACER INSTALLATION (1) Install the spacer with the chamfered end toward the oil seal. SILENT SHAFT SPRO...

ENGINE Timing Belt 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 te...

ENGINE Timing Belt OIL PUMP SPROCKET INSTALLATION (1) a Phillips screwdriver [shank diameter 8 mm in.) shaft] through the plug hole on the left side of the cylinderblock to block the left silent shaft. (2) Install the oil pump sprocket.(3) Apply a proper amount of engine oil to the bearing surfaces ...

E N G I N E T i m i n g B e l t 11 (11 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 surethat the clearance between the belt back surface and cover is standard value. Standard value: 14 mm...

ENGINE Timina Belt the special tools, Socket Wrench and Torque Wrench, on the tensioner pulley, and loosen the tensioner pulley center bolt. NOTEIf the special tool is not available, use a commercially available torque wrench that is capable of measuring 0 3 N m 2.2 to 2.6 2.8 Nm (1.88 2.03 with the...

E N G I N E Fuel and Emission Control Parts FUEL AND EMISSION CONTROL PARTS REMOVAL AND INSTALLATION SOHC for LRV 6 9 22 16 6 Removal steps Throttle body 2. Throttle body gasket 3. EGR valve 4. EGR valve gasket 5. EGR temp sensor For California 6. Injectors and delivery pipe7. Insulator8. Fuel press...

ENGINE Fuel and Emission Control Parts 1 1 A 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 (19.7 in. Hg) to mak...

11 E N G I N E Fuel and Emission Control Parts (2) Install injector top end into fuel rail. Be careful not to damage the O-ring during installation. FUEL PRESSURE REGULATOR INSTALLATION Before installing pressure regulator the O-ring must be lubricated with a drop of clean engine O-ring to aid inins...

E N G I N E T h r o t t l e B o d y 1 THROTTLE BODY DISASSEMBLY AND REASSEMBLY SOHC TRUCK Federal Disassembly steps 1. Throttle position sensor 2. Speed control motor 3. Throttle valve set screw 4. Throttle body SOHC TRUCK CaliforniaSOHC Disassembly steps Throttle position sensor 2. control motor 3....

ENGINE Throttle Body Throttle position sensor output Ground Idle-position switch Throttle position sensor power REASSEMBLY SERVICE POINTS P O S I T I O N S E N S O R SOHC FOR EXPO (1) the throttle position sensor to the throttle body as shown in the illustration. (2) Turn the throttle position senso...

ENGINE Throttle Body Throttle position sensor power Ground Throttle position sensor output (2) Turn the throttle position sensor 90” in the clockwise direction to set it and tighten the screws. (3) Connect the circuit tester between (ground) and (output), or between (output) and (power). Then, make ...

ENGINE Intake Manifold INTAKE MANIFOLD R E M O V A L A N D I N S T A L L A T I O N SOHC 8 VALVE 5 8 Removal steps 1. Water hose 2. Water hose3. Engine coolant temperature gauge unit 4. Engine coolant temperature sensor 5. Water outlet fitting6. Gasket7. Thermostat8. Thermostat housing9. Gasket Intak...

ENGINE Intake Manifold REMOVAL AND INSTALLATION DOHC turbocharger) (To oil cooler) Removal steps 1. Water hose 2. Water hose3. Water hose (turbo) 4. Water hose (turbo)5. Engine coolant temperature gauge unit 6. Engine coolant temperature sensor 7. Water outlet fitting 8. Gasket9. Thermostat Thermost...

11 ENGINE Intake Manifold SOHC diameterbead sealant SOHC diameter bead sealant Sealant INSTALLATION SERVICE POINTS INTAKE MANIFOLD INSTALLATION DOHC Tighten the intake manifold bolts, noting that the bolts installed at the locations indicated in the illustration are tightened to a different torque. ...

ENGINE Exhaust Manifold and Water Pump EXHAUST MANIFOLD AND WATER PUMP REMOVAL AND INSTALLATION SOHC 8 VALVE Nm 22 I 4 18 Nm 13 3 14 Nm 14 Nm Removal steps Oxgen sensor-Federal 2. Oil level gauge Oil level gauge guide 4. Heat protector 5. Engine hanger 6. Exhaust manifold7. Exhaust manifold gasket 8...

ENGINE Exhaust Manifold and Water Pump AND INSTALLATION SOHC 16 VALVE 14 Nm 10 2 Nm 28 Nm 14 Nm Removal steps Oxgen Federal 2. Oil level gauge 3. Oil level gauge guide4. O-ring 5. Heat protector 6. Heat protector LRV -Federal 7. Engine hanger8. Exhaust manifold 9: Exhaust manifold gasket Water inlet...

ENGINE Exhaust Manifold and Water Pump AND INSTALLATION DOHC FOR NON-TURBO 45 Nm 33 14 Nm 60 Nm 43 14 Nm 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 hanger8. Exhaust manifold 9. Exhaust manifold gasket Wat...

ENGINE Turbocharger TURBOCHARGER DISASSEMBLY AND REASSEMBLY 7 Disassembly steps Inspection of turbocharger waste gate actuator operation 1. Snap pin 2. Turbochargerwaste gate actuator 3. Coupling 4. Turbine housing 5. Snap ring 6. Turbine wheel assembly 7. Compressor cover 8. O-ring TSB Revision

11 ENGINE Turbocharger es foract Oil passage Water passage O-ring 73 0 Chamfered assembly INSPECTION TURBINE HOUSING (1) Check the housing for traces of contact with the turbine wheel, cracks due to overheating, pitching, deformationand other damage. Replace with a new turbine housing if cracked. (2...

ENGINE Turbocharger 11 Coupling 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. COUPLING INSTALLATION (1) Install the coupling and tighten to specified torque. TURBOCHARGER WASTE GATE ACTUATOR OPER...

ENGINE Rocker Arms and Camshaft ROCKER ARMS AND CAMSHAFT REMOVAL AND INSTALLATION SOHC 8 VALVE 20 Nm 14 24 Nm 17 4 Removal steps 1. Breather hose 2. hose Oil filter cap Rocker cover GasketSemi-circular Rocker arms and er shafts Rear bearing capRocker arm Spring Bearing cap No. 4 Rocker arm Bearing c...

ENGINE Rocker Arms and Camshaft 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 7. Oil seal 8. Rocker arms and rocker arm shaft 9. Rocker arms and rocker arm shaft 10. Rocker shaft spring 11. Rocker arm...

ENGINE Rocker Arms and Camshaft Division mm Scale mm in.) Nut l Camshaft sprocket side camshaft Dowel (4) After air bleeding, set lash adjuster on the special tool (Leak down tester (5) After plunger has gone down somewhat mm), measure time taken for it to go down 1 mm. Replace ifmeasured time is ou...

11 E N G I N E Rocker Arms and Camshaft Apply sealant in.) SEMI-CIRCULAR PACKING INSTALLATION Specified sealant: ATD Part No. 8660 or equivalent

ENGINE Cylinder Head and Valves AND INSTALLATION SOHC - 1 3 2 Removal steps 1. Cylinder head bolt 2. Cylinder head assembly 3. Cylinder head gasket 4. Retainer lock 5. Valve spring retainer 6. Valve spring 7. Intake valve 8. Retainer lock 9. Valve spring retainer 10. Valve spring 11. Exhaust valve 1...

E N G I N E 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. CYLINDER HEAD BOLTS REMOVAL (1) the 12 mm 12 points socket wrench, loosen the cylinder head bolts. Loosen evenly, little by li...

E N G I N E Cylinder Head and Valves VALVE STEM SEAL REMOVAL Do not reuse valve stem seal. INSPECTION CYLINDER HEAD (1) Check the cylinder head gasket surface for flatness by using a straightedge and thickness gauge. Standard value: 0.05 mm in.) Limit: 0.2 mm in.) (2) If the service limit is exceede...

E N G I N E Cylinder Head and Valves Identification color VALVE SPRINGS INSTALLATION Direct the valve spring end with identification color end toward the spring retainer. RETAINER LOCK INSTALLATION The valve spring, if excessively compressed, causes the bottom end of retainer to be in contact with, ...

11 E N G I N E Cylinder Head and Valves Identification mark 0 0 CYLINDER HEAD GASKET IDENTIFICATION Identification mark: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 . . . . . . . . . . . . ...

E N G I N E Front Case, Silent Shaft and Oil Pan FRONT CASE, SILENT SHAFT AND OIL PAN REMOVAL AND INSTALLATION 24 2 1 7 6 27 40 17 12 55 km. NOTE DOHC Removal steps 1. Oil filter cooler bolt** cooler** 4. Drain plug 5. Drain aasket 7. Oil screen 8. Oil screen gasket 9. Plug O-ring 11. Flange bolt 12...

E N G I N E Front Case, Silent Shaft and Oil 11 OIL PUMP DRIVEN GEAR OIL PUMP DRIVE GEARINSTALLATION (1) Apply’ engine oil amply to the gears and line up the alignment marks. SEALANT APPLICATION TO OIL PRESSURE GAUGE UNIT Coat the threads of switch with sealant and install the switch using the speci...

ENGINE Front Case. Silent Shaft and Oil Pan Cylinderblock 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, in...

E N G I N E Front Case, Silent Shaft and Oil Pan TSB Revision OIL PAN INSTALLATION Clean both mating surfaces of oil pan and cylinder block. (2) Apply a 4 mm in.) wide bead of sealant to the entire circumference of the oil pan flange. Specified sealant: MITSUBISHI GENUINE PART No. or equivalent (3) ...

ENGINE Piston and Rod number Piston tool 6 7 8 Press mark Front mark rod pin REMOVAL SERVICE POINTS CONNECTING ROD CAP REMOVAL (1) Mark the cylinder number on the side of the connecting rod big end for correct reassembly. (2) Keep the removed connecting rods, caps, and bearings in order according to...

E N G I N E Piston and Connecting Rod Cylinder No. Notches CONNECTING ROD BEARINGS When the bearings are to be replaced, select appropriate bearings for assembly according to identification for the crankshaft. Crank pin O.D. Connecting rod bearing identification color identification mark Yellow I 1 ...

ENGINE Crankshaft, and Drive Plate 11 Crankshaft bore m a Lower bearing Upper bearing(for No. REASSEMBLY SERVICE POINTS CRANKSHAFT BEARING INSTALLATION When the bearing is to be replaced, select the appropriate bearing for assembly according to the identification color for the crankshaft and identif...

1 E N G I N E Crankshaft, and Drive Plate TSB Revision (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 in.) Limit: 0.4 mm in.) OIL SEAL INSTAL...