Page 2 - NOTES
11A-0-2 PWEE9615 E Dec. 1996 Mitsubishi Motors Corporation NOTES
Page 3 - General Information; GENERAL INFORMATION; GENERAL SPECIFICATIONS
6G7 ENGINE (E - W) - General Information 11A-0-3 GENERAL INFORMATION GENERAL SPECIFICATIONS Descriptions 6G72-SOHC Type 60 _ OHV, SOHC Number of cylinders 6 Combustion chamber Compact type Total displacement dm 3 2.972 Cylinder bore mm 91.1 Piston stroke mm 76.0 Compression ratio 8.9 Valve timing In...
Page 4 - Specifications; SERVICE SPECIFICATIONS; Timing belt
6G7 ENGINE (E - W) - Specifications 11A-1-1 1. SPECIFICATIONS SERVICE SPECIFICATIONS Items Standard Limit Timing belt Auto-tensioner rod length mm 3.8 - 5.0 - Auto-tensioner rod projection length mm 12 - Auto-tensioner rod pushed-in amount (when pushed with a force of 98 - 196 N) mm 1.0 or less - Ro...
Page 5 - Piston and connecting rod; REWORK DIMENSIONS
6G7 ENGINE (E - W) - Specifications 11A-1-2 Items Limit Standard Oil pump side clearance mm 0.04 - 0.10 - Oil pump body clearance mm 0.10 - 0.18 0.35 Piston and connecting rod Piston outside diameter mm 91.1 - Piston ring to ring groove clearance mm No. 1 0.03 - 0.07 0.1 No. 2 0.02 - 0.06 0.1 Piston...
Page 6 - TORQUE SPECIFICATIONS; Alternator
6G7 ENGINE (E - W) - Specifications 11A-1-3 TORQUE SPECIFICATIONS Items Nm Alternator Drive belt tensioner pulley nut 49 Crankshaft bolt 181 Alternator pivot nut 44 Alternator bolt M8 21 Alternator bolt M10 48 Dipstick tube 13 Air intake plenum Air intake plenum stay bolt M8 17 Air intake plenum sta...
Page 7 - Intake manifold
6G7 ENGINE (E - W) - Specifications 11A-1-4 Items Nm Intake manifold Engine coolant temperature gauge unit 11 Engine coolant temperature sensor 29 Heater pipe bolt 18 Water outlet fitting bolt 18 Water inlet fitting bolt 18 Thermostat housing bolt 18 Water pipe bolt 13 Delivery pipe 11 Intake manifo...
Page 8 - SEALANTS
6G7 ENGINE (E - W) - Specifications 11A-1-5 Items Nm Oil pan, upper bolt 5.9 Baffle plate bolt (oil pan side) 11 Baffle plate bolt (cylinder block side) 9.8 Oil screen bolt 18 Relief plug 44 Oil pump case bolt 13 Oil pump cover bolt 9.8 Piston and connecting rod Connecting rod cap 51 Crankshaft, fly...
Page 9 - Disassembly; forget to remove the old sealant remaining in the bolt holes.
6G7 ENGINE (E - W) - Specifications 11A-1-6 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 ...
Page 10 - Special Tools
6G7 ENGINE (E - W) - Special Tools 11A-2-1 2. SPECIAL TOOLS Tool Number Name Use MB991559 Camshaft oil seal installer adaptor Installation of camshaft oil seal (on left bank) (Used in combination with MD998713) MD998051 Cylinder head bolt wrench Loosening and tightening of cylinder head bolt MD99844...
Page 12 - REMOVAL AND INSTALLATION; Removal steps; Alternator bracket
6G7 ENGINE (E - W) - Alternator 11A-3-1 3. ALTERNATOR REMOVAL AND INSTALLATION 7EN1030 1 2 3 4 5 6 7 8 9 10 13 Nm 21 Nm 48 Nm 44 Nm 49 Nm 181 Nm Removal steps 1. Tensioner pulley A A " " A A 2. Crankshaft bolt 3. Washer 4. Crankshaft pulley 5. Alternator 6. Alternator bracket 7. Dip stick 8....
Page 13 - REMOVAL SERVICE POINTS; (1) With the Special Tool fixed to the drive plate or flywheel; CRANKSHAFT BOLT; (1) With the Special Tool fixed to the drive plate or flywheel
6G7 ENGINE (E - W) - Alternator 11A-3-2 REMOVAL SERVICE POINTS A A " CRANKSHAFT BOLT (1) With the Special Tool fixed to the drive plate or flywheel remove the crankshaft bolt. INSTALLATION SERVICE POINTS " A A CRANKSHAFT BOLT (1) With the Special Tool fixed to the drive plate or flywheel ins...
Page 14 - Air Intake Plenum; Accelerator cable bracket
6G7 ENGINE (E - W) - Air Intake Plenum 11A-4-1 4. AIR INTAKE PLENUM REMOVAL AND INSTALLATION 7EN1031 1 2 3 4 5 6 7 8 9 10 11 12 13 4 Nm 21 Nm 17 Nm 56 Nm 17 Nm 17 Nm 17 Nm 11 Nm 11 Nm 35 Nm Removal steps 1. Air intake plenum stay, front 2. Air intake plenum stay, rear 3. Accelerator cable bracket 4....
Page 15 - THROTTLE BODY GASKET
6G7 ENGINE (E - W) - Air Intake Plenum 11A-4-2 INSTALLATION SERVICE POINTS " A A THROTTLE BODY GASKET (1) Install gasket with protrusion as illustrated. PWEE9615 E Dec. 1996 Mitsubishi Motors Corporation Protrusion 6AE0277
Page 16 - Ignition System
6G7 ENGINE (E - W) - Ignition System 11A-5-1 5. IGNITION SYSTEM REMOVAL AND INSTALLATION 7EN0965 1 2 3 4 1 23 Nm 25 Nm Removal steps 1. Spark plug cable 2. Spark plug 3. Distributor 4. O-ring PWEE9615 E Dec. 1996 Mitsubishi Motors Corporation
Page 17 - Timing Belt
6G7 ENGINE (E - W) - Timing Belt 11A-6-1 6. TIMING BELT REMOVAL AND INSTALLATION 7EN0862 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Nm 88 Nm 23 Nm 44 Nm 48 Nm 13 Nm 11 Nm 9 Nm 11 Nm 44 Nm 13 Nm 44 Nm Removal steps 1. Timing belt front upper cover, rear 2. Timing belt front upper cov...
Page 18 - INSPECTION; TIMING BELT
6G7 ENGINE (E - W) - Timing Belt 11A-6-2 REMOVAL SERVICE POINTS A A " TIMING BELT (1) When the timing belt is to be reused, in order to allow re-installation of the belt so that it travels in the same direction as before it was removed, mark the direction of travel with an arrow before removing ...
Page 19 - Standard value “L”: 12 mm; CAMSHAFT SPROCKET BOLT
6G7 ENGINE (E - W) - Timing Belt 11A-6-3 (7) Badly worn teeth. Initial stage: Canvas is worn (fluffy canvas fibres are visible, rubber is gone and colour has changed to white. Canvas texture is not clear). Last stage: Canvas is worn out and rubber exposed and its width is reduced. (8) Missing tooth....
Page 21 - clockwise a quarter turn, then turn it clockwise and align
6G7 ENGINE (E - W) - Timing Belt 11A-6-5 (8) Using the Special Tool, turn the crankshaft counter- clockwise a quarter turn, then turn it clockwise and align the timing marks. Make sure that all timing marks are in alignment. Timing mark Crankshaft sprocket Right bank Left bank Timing mark Camshaft s...
Page 22 - ENGINE SUPPORT BRACKET
6G7 ENGINE (E - W) - Timing Belt 11A-6-6 (9) Set the Special Tool and a torque wrench on the tensioner pulley. (10)Torque the tensioner pulley to 4.4 Nm. (11) While holding the tensioner pulley, tighten its centre bolt to the specified torque. (12)Turn the crankshaft 2 turns clockwise and let it sta...
Page 23 - Intake Manifold
6G7 ENGINE (E - W) - Intake Manifold 11A-7-1 7. INTAKE MANIFOLD REMOVAL AND INSTALLATION 7EN0874 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 13 Nm 11 Nm 11 Nm 29 Nm 18 Nm 18 Nm 18 Nm 18 Nm 21 Nm 9 Nm 9 Nm 18 Nm 14 Removal steps 1. Engine harness 2. Injector an...
Page 24 - Caution; (1) Install the thermostat in the thermostat case with its jiggle; HEATER INLET AND OUTLET PIPES; (1) Attach the outlet and inlet pipes in this order, one on the; M Nut Locking Part No. 4171 or equivalent
6G7 ENGINE (E - W) - Intake Manifold 11A-7-2 INSTALLATION SERVICE POINTS " A A O-RING / WATER PIPE (1) Wet the O-ring (with water) to facilitate assembly. Caution D Keep the O-ring of oil or grease. " B A THERMOSTAT (1) Install the thermostat in the thermostat case with its jiggle valve loca...
Page 25 - INTAKE MANIFOLD
6G7 ENGINE (E - W) - Intake Manifold 11A-7-3 " F A INTAKE MANIFOLD (1) Tighten the nuts on the right bank to 5 - 8 Nm. (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...
Page 26 - Exhaust Manifold & Water Pump; Engine lift bracket
6G7 ENGINE (E - W) - Exhaust Manifold & Water Pump 11A-8-1 8. EXHAUST MANIFOLD & WATER PUMP REMOVAL AND INSTALLATION 7EN0966 1 2 3 4 5 6 7 8 9 49 Nm 13 Nm 35 Nm 13 Nm 49 Nm 41 Nm 23 Nm Removal steps 1. Heat protector, rear 2. Exhaust manifold, rear " B A 3. Exhaust manifold gasket, rear ...
Page 27 - and
6G7 ENGINE (E - W) - Exhaust Manifold & Water Pump 11A-8-2 INSTALLATION SERVICE POINTS " A A O-RING / WATER PIPE (1) Wet the O-ring (with water) to facilitate assembly. Caution D Keep the O-ring free of oil grease. " B A EXHAUST MANIFOLD GASKET (1) Install gaskets with number 1 , 3 and 5...
Page 28 - Rocker Arms and Camshaft; ROCKER ARMS AND CAMSHAFT; Apply engine oil to all; Rocker shaft spring
6G7 ENGINE (E - W) - Rocker Arms and Camshaft 11A-9-1 9. ROCKER ARMS AND CAMSHAFT REMOVAL AND INSTALLATION Apply engine oil to all moving parts before installation. 7EN0879 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 12 12 9 9 8 8 7 7 12 Nm 31 Nm 3.4 Nm Removal steps 1. Rocker cover 2. Gasket 3. Oil s...
Page 29 - LASH ADJUSTER; CAMSHAFT; LASH ADJUSTER LEAK DOWN TEST
6G7 ENGINE (E - W) - Rocker Arms and Camshaft 11A-9-2 REMOVAL SERVICE POINTS A A " LASH ADJUSTER (1) Before removing the rocker arms and rocker arm shafts, install the Special Tools to prevent the lash adjusters from falling off. INSPECTION CAMSHAFT (1) Measure the cam height. Standard value: IN...
Page 31 - ROCKER SHAFT SPRING; (1) Insert the rocker shaft spring at a slant with respect to; OIL SEAL
6G7 ENGINE (E - W) - Rocker Arms and Camshaft 11A-9-4 " D A ROCKER SHAFT SPRING (1) Insert the rocker shaft spring at a slant with respect to the spark plug guide and install it normal to the guide. " E A OIL SEAL PWEE9615 E Dec. 1996 Mitsubishi Motors Corporation 7EN0723 Rocker shaft spring...
Page 32 - Cylinder Head and Valves; CYLINDER HEAD AND VALVES
6G7 ENGINE (E - W) - Cylinder Head and Valves 11A-10-1 10. CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION Apply engine oil to all moving parts before installation. 7EN0915 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 108 Nm Removal steps A A " 1. Cylinder head bolt 2. Washer 3. Cy...
Page 33 - CYLINDER HEAD BOLT; to the detached valves, springs and other parts and store; VALVE STEM SEAL
6G7 ENGINE (E - W) - Cylinder Head and Valves 11A-10-2 REMOVAL SERVICE POINTS A A " CYLINDER HEAD BOLT A B " RETAINER LOCK (1) Attach a tag with the cylinder No. and mounting location to the detached valves, springs and other parts and store them for reassembly. A C " VALVE STEM SEAL Cau...
Page 34 - CYLINDER HEAD
6G7 ENGINE (E - W) - Cylinder Head and Valves 11A-10-3 INSPECTION CYLINDER HEAD (1) Check the cylinder head for water leaks, gas leaks, damage or cracks before washing it. (2) Completely remove oil, fur, sealer, carbon and the like. After washing the oil passages, blow air through them to make sure ...
Page 37 - VALVE SPRING
6G7 ENGINE (E - W) - Cylinder Head and Valves 11A-10-6 " B A VALVE SPRING (1) Install the valve spring painted red side up. " C A VALVE RETAINER LOCK (1) Using Special Tool install the valve retainer lock. PWEE9615 E Dec. 1996 Mitsubishi Motors Corporation 6EN0544 Stem seal Spring seal Sprin...
Page 38 - Oil Pan and Oil Pump; OIL PAN AND OIL PUMP
6G7 ENGINE (E - W) - Oil Pan and Oil Pump 11A-11-1 11. OIL PAN AND OIL PUMP REMOVAL AND INSTALLATION Apply engine oil to all moving parts before installation. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Nm 23 Nm 9.8 Nm 41 Nm 13 Nm 18 Nm 9.8 Nm 11 Nm 5.9 Nm 11 Nm 39 Nm 44 Nm 9.8 Nm 9....
Page 39 - (1) Apply wood to the oil pan side and remove the oil pan; (1) Draw a setting mark on the oil pump outer and inner rotors; OIL PUMP
6G7 ENGINE (E - W) - Oil Pan and Oil Pump 11A-11-2 REMOVAL SERVICE POINTS A A " OIL PAN (LOWER) (1) Apply wood to the oil pan side and remove the oil pan lower with a plastic hammer. A B " OIL PAN (UPPER) (1) Detach the bolt (1) shown at left. (2) Detach all other bolts. (3) Screw a bolt int...
Page 40 - OIL PUMP INNER AND OUTER ROTORS
6G7 ENGINE (E - W) - Oil Pan and Oil Pump 11A-11-3 (2) Check for side clearance. Standard value: 0.04 - 0.10 mm (3) Check for body clearance. Standard value: 0.10 - 0.18 mmLimit: 0.35 mm INSTALLATION SERVICE POINTS " A A OIL PUMP INNER AND OUTER ROTORS (1) Install the oil pump outer rotor in the...
Page 42 - OIL FILTER
6G7 ENGINE (E - W) - Oil Pan and Oil Pump 11A-11-5 " E A OIL PAN (LOWER) (1) Clean the gasket coating surfaces of the oil pan upper and the oil pan lower. (2) Squeeze out a 4 mm bead of liquid gasket and coat the coating surface with it. Liquid gasket: MITSUBISHI GENUINE Part No. MD970389 orequi...
Page 43 - Piston and Connecting Rod; PISTON AND CONNECTING ROD
6G7 ENGINE (E - W) - Piston and Connecting Rod 11A-12-1 12. PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION 7EN0424 1 2 3 4 5 6 7 8 9 10 11 12 51 Nm Apply engine oil to all moving parts before installation. Removal steps 1. Connecting rod cap nut A A " " E A 2. Connecting rod cap 3. Conne...
Page 44 - CONNECTING ROD CAP
6G7 ENGINE (E - W) - Piston and Connecting Rod 11A-12-2 REMOVAL SERVICE POINTS A A " CONNECTING ROD CAP (1) Enter the cylinder No. on the side of the large end of the connecting rod to facilitate reassembly. A B " PISTON PIN The special piston pin setting tool (MD998780) consists of the part...
Page 45 - PISTON RING
6G7 ENGINE (E - W) - Piston and Connecting Rod 11A-12-3 INSPECTION PISTON RING (1) Check the clearance between the piston ring and the ring groove. If it exceeds the specified limit, change the ring or the piston and piston ring. Standard values: No. 1 0.03 - 0.07 mm No. 2 0.02 - 0.06 mm Limit: 0.1 ...
Page 46 - PISTON PIN
6G7 ENGINE (E - W) - Piston and Connecting Rod 11A-12-4 INSTALLATION SERVICE POINTS " A A PISTON PIN (1) Measure the dimensions of the following parts and portions: A: Piston pin mounting portion B: Distance between piston bosses C: Piston pin D: Connecting rod (2) Calculate by substituting each...
Page 47 - OIL RING; Side rail
6G7 ENGINE (E - W) - Piston and Connecting Rod 11A-12-5 " B A OIL RING (1) Install the oil ring spacer into the piston ring groove. Next install the upper side rail into the piston ring groove, and then install the lower side rail.NOTE D There is no distinction between the upper and lower surfac...
Page 48 - PISTON AND CONNECTING ROD
6G7 ENGINE (E - W) - Piston and Connecting Rod 11A-12-6 " D A PISTON AND CONNECTING ROD (1) Liberally coat the circumference of the piston, piston ring, and oil ring with engine oil. (2) Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in the figure. (3) Rotate the crank...
Page 49 - Crankshaft, Flywheel and Drive Plate
6G7 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate 11A-13-1 13. CRANKSHAFT, FLYWHEEL AND DRIVE PLATE REMOVAL AND INSTALLATION Apply engine oil to all moving parts before installation. 7EN1032 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 74 Nm 11 Nm 74 Nm 11 Nm 93 Nm Removal steps 1. Adaptor p...
Page 50 - CYLINDER BLOCK
6G7 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate 11A-13-2 INSPECTION CRANKSHAFT OIL CLEARANCE (PLASTIGAUGEMETHOD) NOTE If the oil clearance exceeds the limit, replace the bearing, and crankshaft if necessary.This crankshaft oil clearance can be measured easily by using a plastic gauge, as f...
Page 51 - Size
6G7 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate 11A-13-3 BORING CYLINDER (1) Oversize pistons to be used should be determined on the basis of the largest bore cylinder. Piston size identification Size Identification mark 0.50 mm O.S. 0.50 1.00 mm O.S. 1.00 NOTE Size mark is stamped on the ...
Page 52 - CRANKSHAFT BEARING
6G7 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate 11A-13-4 INSTALLATION SERVICE POINTS " A A CRANKSHAFT BEARING When bearing replacement is required, select and install the correct bearing by the following procedure. (1) Measure the crankshaft journal diameter and confirm its classificat...
Page 53 - BEARING CAP / BEARING BOLT
6G7 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate 11A-13-5 (3) Select the correct bearing from the above table on the basis of the identification data confirmed at steps 1 and 2.Example D If the measured value of a crankshaft journal outer diameter is 59.996 mm, the journal is classified as ...
Page 54 - CRANKSHAFT REAR OIL SEAL; oil seal into the seal case.; OIL SEAL CASE; apply it to the coating surface.
6G7 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate 11A-13-6 (4) Check the end play. If it exceeds the limit value, replace the thrust bearing. Standard value: 0.05 - 0.25 mmLimit: 0.3 mm " C A CRANKSHAFT REAR OIL SEAL (1) Using the Special Tool, press-fit a new crankshaft rear oil seal in...
