Mitsubishi 6A1 Users Manual ENGINE Workshop 6A1(E W)
6A1 SERIES 6A1_Engine_Manual
6A1 to the manual 9018e481-fbb8-4b81-94b2-5b1400825c30
2015-01-24
: Mitsubishi Mitsubishi-6A1-Users-Manual-231350 mitsubishi-6a1-users-manual-231350 mitsubishi pdf
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11A-0-1 ENGINE 6A1 SERIES CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-0-3 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1 REWORK DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-3 TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-4 NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-7 SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-7 FORM-IN-PLACE GASKET (FIPG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-8 2. SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-2-1 3. DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-3-1 4. TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-4-1 5. FUEL AND EMISSION CONTROL PARTS . . . . . . . . . . . . . . . . . . . . . . 11A-5-1 6. IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-6-1 7. WATER PUMP AND WATER PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-7-1 8. INTAKE MANIFOLD AND EXHAUST MANIFOLD . . . . . . . . . . . . . . 11A-8-1 9. ROCKER ARM AND CAMSHAFT. . . . . . . . . . . . . . . . . . . . 11A-9-1 10. ROCKER COVER AND CAMSHAFT . . . . . . . . . . . . . . . . . 11A-10-1 11. ROCKER ARM AND ROCKER SHAFT CAP . . . . . . . . 11A-11-1 12. CYLINDER HEAD AND VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-12-1 13. OIL PUMP CASE AND OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-13-1 14. PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-14-1 15. CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-15-1 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-0-2 NOTES E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 6A1 ENGINE (E - W) - General Information 11A-0-3 GENERAL INFORMATION GENERAL SPECIFICATIONS Descriptions 6A12 6A13 Type 60° V, OHV, DOHC (for each bank) 60° V, OHV, SOHC (for each bank) Number of cylinders 6 6 Combustion chamber Pentroof type Pentroof type Total displacement dm3 1,998 2,498 Cylinder bore mm 78.4 81.0 Piston stroke mm 69.0 80.8 Compression ratio 10.0 9.5*1 or 9.0*2 Opens (BTDC) 15° (Low-speed cam) 37.5° (High-speed cam) 15° Closes (ABDC) 41° (Low-speed cam) 82.5° (High-speed cam) 53° Opens (BBDC) 41° (Low-speed cam) 75° (High-speed cam) 53° Closes (ATDC) 15° (Low-speed cam) 30° (High-speed cam) 15° Lubrication system Pressure feed, full-flow filtration Pressure feed, full-flow filtration Oil pump type Trochoid type Trochoid type Cooling system Water-cooled forced circulation Water-cooled forced circulation Water pump type Centrifugal impeller type Centrifugal impeller type Valve timing Intake valve Exhaust valve NOTE *1: Europe and Hong Kong *2: GCC and Export E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-1-1 6A1 ENGINE (E - W) - Specifications 1. SPECIFICATIONS SERVICE SPECIFICATIONS Items Standard value Limit Auto tensioner rod projection mm 12.0 - Auto tensioner rod pushed-in amount (when pushed with a force of 98 - 196 N) mm 1.0 or less - Intake 35.20 34.70 Exhaust 34.70 34.20 45 - (Low-speed cam) 34.34 33.84 (High-speed cam) 36.46 35.96 (Low-speed cam) 34.40 33.90 (High-speed cam) 35.86 35.36 26 - Intake 0.10 - Exhaust 0.13 - Flatness of cylinder head gasket surface mm - - Cylinder head gasket surface grinding limit (including grinding of cylinder block gasket surface) mm Less than 0.03 - Cylinder head overall height mm SOHC 119.9 - 120.1 - MIVEC 119.6 - 119.8 - Cylinder head bolt nominal length mm - 96.4 Valve margin mm Intake 1.0 0.5 Exhaust 1.3 0.8 6.0 - Intake 0.02 - 0.05 0.10 Exhaust 0.04 - 0.07 0.15 45° - 45.5° - SOHC 48.45 48.95 MIVEC 48.40 48.90 Timing belt Rocker arm and camshaft Camshaft cam height mm Camshaft journal diameter mm Rocker cover and camshaft Camshaft cam height mm Intake Exhaust Camshaft journal diameter mm Valve clearance mm Cylinder head and valve Valve stem diameter mm Valve stem-to-guide clearance mm Valve face angle Valve stem projection mm E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-1-2 6A1 ENGINE (E - W) - Specifications Items Standard value Limit SOHC 113.02 112.52 MIVEC 112.37 111.87 SOHC 115.32 114.82 MIVEC 110.74 110.74 SOHC 49.9 48.9 MIVEC 51.5 50.5 SOHC 265/43.4 - MIVEC 255/44.5 - Valve spring squareness 2° 4° Valve seat contact width mm 0.9 - 1.3 - Valve guide internal diameter mm 6.6 - Valve guide projection mm SOHC 14.0 - MIVEC 19.0 - Oil pump tip clearance mm 0.06 - 0.18 - Oil pump side clearance mm 0.04 - 0.10 - Oil pump body clearance mm 0.10 - 0.18 0.35 6A12 78.4 - 6A13 81.0 - No.1 ring 0.02 - 0.06 - No.2 ring 0.02 - 0.06 - No.1 ring 0.20 - 0.35 0.8 No.2 ring 0.35 - 0.50 0.8 Oil ring 0.20 - 0.50 1.0 Piston pin outside diameter mm 19.0 - Piston pin press-in load (at room temperature) N 4,900 - 14,700 - Crankshaft pin oil clearance mm 0.02 - 0.05 0.1 Connecting rod big end side clearance mm 0.10 - 0.25 0.4 0.05 - 0.25 0.4 Overall valve length mm Intake Exhaust Valve spring free height mm Valve spring height N/mm load/installed Oil pump case and oil pan Piston and connecting rod Piston outside diameter mm Piston ring side clearance mm Piston ring end gap mm Crankshaft, cylinder block, flywheel and drive plate Crankshaft end play mm E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-1-3 6A1 ENGINE (E - W) - Specifications Items Standard value Limit Crankshaft journal diameter mm 6A12 53.0 - 6A13 56.0 - Crankshaft pin diameter mm 6A12 43.0 - 6A13 51.0 - Crankshaft journal oil clearance mm 0.02 - 0.04 0.1 Cylinder block gasket surface flatness mm 0.05 - Cylinder block gasket surface grinding limit (including grinding of cylinder head gasket surface) mm - 0.2 Cylinder block overall height mm 6A12 190.0 - 6A13 209.0 - 0.01 or less - 6A12 78.4 - 6A13 81.0 - Bearing cap bolt nominal length mm - 71.1 Piston-to-cylinder clearance mm 0.02 - 0.04 - Cylinder block cylindricity mm Cylinder block internal diameter mm REWORK DIMENSIONS Item Standard Cylinder head and valves Cylinder head oversize valve guide hole diameter mm Oversize intake valve seat ring hole diameter mm SOHC MIVEC Oversize exhaust valve seat ring diameter mm SOHC MIVEC E Mitsubishi Motors Corporation Feb. 1997 0.05 O.S. 11.05 - 11.07 0.25 O.S. 11.25 - 11.27 0.50 O.S. 11.50 - 11.52 0.3 O.S. 29.80 - 29.82 0.6 O.S. 30.10 - 30.12 0.3 O.S. 32.30 - 32.32 0.6 O.S. 32.60 - 32.62 0.3 O.S. 27.80 - 27.82 0.6 O.S. 28.10 - 28.12 0.3 O.S. 29.80 - 29.82 0.6 O.S. 30.10 - 30.12 PWEE9622 11A-1-4 6A1 ENGINE (E - W) - Specifications TORQUE SPECIFICATION Items Nm Alternator and drive belt Alternator pivot nut 44 Alternator bolt 21 Oil level gauge guide 23 Tensioner pulley 15 Engine hanger 23 Tensioner pulley bracket A 45 Crankshaft bolt 182 Engine cover 3 Timing belt Timing belt front cover 11 Engine support bracket 49 Angle sensor 9 Angle sensor connector bracket 11 Tensioner pulley 48 Tensioner arm 24 Auto tensioner 21 Camshaft sprocket bolt 88 Idler pulley 35 Timing belt rear cover 11 Angle sensor connector bracket 11 Fuel and emission control parts Air intake plenum stay 18 Connector bracket 11 EGR valve 22 Throttle body 12 Air intake plenum 18 Delivery pipe 12 Fuel pipe 9 Fuel pressure regulator 9 Alternator bracket 23 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 6A1 ENGINE (E - W) - Specifications Items Nm Ignition system Spark plug 25 Water cover (SOHC) 11 Distributor (SOHC) 13 Ignition failure sensor (MIVEC) 10 Condenser bracket assembly (MIVEC) 5 Ignition coil (MIVEC) 10 Water pump and water pipe Engine hanger (MIVEC) 11 Engine coolant temperature gauge unit 11 Engine coolant temperature sensor 29 Heater pipe (SOHC) 23 Water inlet fitting 18 Water outlet fitting 18 Thermostat housing 23 Water pipe 13 Water pump 23 Intake manifold and exhaust manifold Intake manifold 17 Heat protector 13 Exhaust manifold stay 44 Exhaust manifold 49 Rocker arm and camshaft Rocker cover 4 Rocker arm and rocker shaft 31 Thrust case 24 Rocker arm and camshaft Rocker cover 4 Oil control valve holder 9 Cam cap 24 Bearing cap M6 11 Bearing cap M8 24 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-1-5 11A-1-6 6A1 ENGINE (E - W) - Specifications Items Nm Arm spring holder 11 Rocker arm and rocker shaft cap Rocker shaft cap 11 Cylinder head and valves Cylinder head bolt 20 + 120° + 120° Oil pan and oil pump Oil pressure switch 10 Oil filter cover 21 Water hose 30 Bolt 68 Drain plug 39 Oil level sensor 9 Oil pan 7 Oil screen 19 Baffle plate 9 Relief plug 44 Oil pump case 14 Oil pump case cover 12 Piston and connecting rod Connecting rod 18 + 90° - 100° Crankshaft, cylinder block, flywheel and drive plate Detonation sensor 23 Idler pulley bracket 35 Flywheel bolt 98 Drive plate bolt 98 Rear plate 11 Bell housing cover 9 Oil seal case 11 Bearing cap bolt 25 + 90° - 100° E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 6A1 ENGINE (E - W) - Specifications 11A-1-7 NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA A new type of bolts, to be tightened in plastic area, is currently used in some parts of the engine. The tightening method for the bolts is different from the conventional one. Be sure to observe the method described in the text when tightening the bolts. Service limits are provided for the bolts. Make sure that the service limits described in the text are strictly observed. D D Areas where the bolts are in use: (1) Cylinder head bolts (2) Main bearing cap bolts (3) Connecting rod cap bolts Tightening Method After tightening the bolts to the specified torque, tighten them another 90° to 100°, or 240° (twice 120°). The tightening method varies on different areas. Observe the tightening method described in the text. SEALANTS Item Specified sealant Quantity Water pump* Mitsubishi Genuine Part No. MD970389 or equivalent As required Water outlet fitting* Mitsubishi Genuine Part No. MD970389 or equivalent As required Engine coolant temperature sensor 3M Nut Locking Part No. 4171 or equivalent As required Engine coolant temperature gauge unit 3M ATD Part No. 8660 or equivalent As required Camshaft bearing 3M ATD Part No. 8660 or equivalent As required Cam cap 3M ATD Part No. 8660 or equivalent As required Oil control valve 3M ATD Part No. 8660 or equivalent As required Camshaft holder* Mitsubishi Genuine Part No. MD970389 or equivalent As required Rocker cover 3M ATD Part No. 8660 or equivalent As required Oil pump case* Mitsubishi Genuine Part No. MD970389 or equivalent As required Oil pan* Mitsubishi Genuine Part No. MD970389 or equivalent As required Oil pressure switch 3M ATD Part No. 8660 or equivalent As required Oil seal case* Mitsubishi Genuine Part No. MD970389 or equivalent As required Drive plate bolt 3M Nut Locking Part No. 4171 or equivalent As required Flywheel bolt 3M Nut Locking Part No. 4171 or equivalent As required *: parts sealed by foam-in-place gasket (FIPG) E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-1-8 6A1 ENGINE (E - W) - Specifications FORM-IN-PLACE GASKET (FIPG) The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to apply the gasket evenly without a break, while observing the correct bead size. The FIPG used in the engine is a room temperature vulcanisation (RTV) type and is supplied in a 100-gram tube (Part No. MD970389 or MD997110). Since the RTV hardens as it reacts with the moisture in the atmospheric air, it is normally used in the metallic flange areas. The FIPG, Part No. MD970389, can be used for sealing both engine oil and coolant, while Part No. MD997110 can only be used for engine oil sealing. Disassembly The parts assembled with the FIPG can be easily disassembled without use of a special method. In some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces. For removal of the oil pan, the special tool “Oil Pan Remover” (MD998727) is available. Be sure to use the special tool to remove the oil pan. Surface Preparation Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure that there are no oils, greases and foreign substances deposited on the application surfaces. Do not forget to remove the old sealant remained in the bolt holes. Form-in-Place Gasket Application When assembling parts with the FIPG, you must observe some precautions, but the procedures is very simple as in the case of a conventional precut gasket. Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time (about one hour) has passed after installation is completed. The FIPG application procedure may vary on different areas. Observe the procedure described in the text when applying the FIPG. E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 6A1 ENGINE (E - W) - Special Tools 11A-2-1 2. SPECIAL TOOLS Tool E Mitsubishi Motors Corporation Number Name Use MB990685 Torque wrench Adjustment of timing belt tension MB990938 Handle Use with MD998776 MB990767 Crankshaft pulley holder Holding camshaft sprocket when loosening and tightening of bolt. Use with MD998719 MB991477 Valve adjusting wrench Adjustment of valve clearance (MIVEC) MB991478 Valve adjusting wrench feeler gauge set Adjustment of valve clearance (MIVEC) MB991479 Rocker arm piston checker Adjustment of valve clearance (MIVEC) MB991614 Angle gauge Tightening cylinder head bolt MB991653 Cylinder head bolt wrench Tightening and loosening of cylinder head bolt MB991659 Guide D Removal of piston pin (Use with MD998780) Feb. 1997 PWEE9622 11A-2-2 Tool E Mitsubishi Motors Corporation 6A1 ENGINE (E - W) - Special Tools Number Name Use MD998440 Leak-down tester Leak-down test of lash adjuster MD998441 Lash adjuster retainer Air bleeding of lash adjuster MD998442 Air bleed wire Air bleeding of lash adjuster MD998443 Lash adjuster holder Retainer for holding lash adjuster in rocker arm at time of removal and installation of rocker arm and rocker shaft assembly MD998713 Camshaft oil seal installer Installation of camshaft oil seal MD998716 Crankshaft wrench Rotation of crankshaft when installing piston and timing belt. MD998717 Crankshaft front oil seal installer Installation of crankshaft front oil seal MD998719 Pulley holder pin (2) Use with MB990767 MD998727 Oil pan remover Removal of oil pan Feb. 1997 PWEE9622 6A1 ENGINE (E - W) - Special Tools Tool E Mitsubishi Motors Corporation 11A-2-3 Number Name Use MD998735 Valve spring compressor Compression of valve spring MD998754 Pin Use with MB990767 MD998767 Tensioner pulley socket wrench Adjustment of timing belt tension MD998772 Valve spring compressor Removal and installation of valve and related parts MD998774 Valve stem seal installer Installation of valve stem seal MD998775 Valve stem seal installer Installation of valve stem seal MD998776 Crankshaft rear oil seal installer Installation of crankshaft rear oil seal Use with MB990938 MD998777 Camshaft oil seal installer adapter Installation of camshaft oil seal Feb. 1997 PWEE9622 11A-2-4 Tool E Mitsubishi Motors Corporation 6A1 ENGINE (E - W) - Special Tools Number Name Use MD998780 SETTING TOOL Piston pin Removal and installation of piston pin MD998781 Flywheel stopper Holding flywheel and drive plate MD998784 Valve spring compressor adapter Compression of valve spring (MIVEC) (Use with MD998772) Feb. 1997 PWEE9622 6A1 ENGINE (E - W) - Drive Belt 11A-3-1 3. DRIVE BELT REMOVAL AND INSTALLATION 3 Nm 16 44 Nm 21 Nm 2 44 Nm 11 9 1 23 Nm 3 23 Nm 15 7 6 12 8 10 44 Nm 13 14 182 Nm 4 15 Nm 5 Removal steps 1. Drive belt 2. Alternator 3. Oil level gauge (dipstick) 4. Oil level gauge guide 5. O-ring 6. Tensioner pulley 7. Engine hanger 8. Tensioner pulley bracket A E Mitsubishi Motors Corporation Feb. 1997 9. 10. 11. AA" "AA 12. 13. 14. 15. 16. PWEE9622 Tensioner pulley bracket B Adjusting stud Adjusting bolt Crankshaft bolt Special washer Crankshaft pulley Flange Engine cover 11A-3-2 6A1 ENGINE (E - W) - Drive Belt REMOVAL AND INSTALLATION 3 Nm 16 21 Nm 44 Nm 2 1 11 44 Nm 9 3 13 23 Nm 23 Nm 7 6 10 14 44 Nm 8 4 15 Nm 15 12 182 Nm 5 Removal steps 1. Drive belt 2. Alternator 3. Oil level gauge (dipstick) 4. Oil level gauge guide 5. O-ring 6. Tensioner pulley 7. Engine hanger 8. Tensioner pulley bracket A E Mitsubishi Motors Corporation Feb. 1997 9. 10. 11. AA" "AA 12. 13. 14. 15. 16. PWEE9622 Tensioner pulley bracket B Adjusting stud Adjusting bolt Crankshaft bolt Special washer Crankshaft pulley Flange Engine cover 6A1 ENGINE (E - W) - Drive Belt 11A-3-3 REMOVAL SERVICE POINTS AA" CRANKSHAFT PULLEY BOLT REMOVAL (1) Hold the flywheel or drive plate in position with the special tool before removing the crankshaft pulley bolts. INSTALLATION SERVICE POINTS MD998781 E Mitsubishi Motors Corporation 6AE0039 Feb. 1997 "AA CRANKSHAFT PULLEY BOLT INSTALLATION (1) Hold the flywheel or drive plate in position with the special tool before installing the crankshaft pulley bolts. PWEE9622 11A-4-1 6A1 ENGINE (E - W) - Timing Belt 4. TIMING BELT REMOVAL AND INSTALLATION 11 Nm 6 88 Nm 35 Nm 17 16 15 14 48 Nm 24 Nm 8 12 13 18 11 9 11 Nm 7 5 1 11 Nm 21 Nm 3 10 2 4 9 Nm 49 Nm 11 Nm 11 Nm Removal steps 1. Timing belt front cover, upper right 2. Timing belt front cover, upper left 3. Timing belt front cover, lower 4. Engine support bracket 5. Angle sensor AA" "CA 6. Timing belt 7. Tensioner pulley 8. Tensioner arm 9. Tensioner spacer E Mitsubishi Motors Corporation Feb. 1997 "BA 10. 11. 12. 13. AB" "AA 14. 15. 16. 17. 18. PWEE9622 Auto tensioner Crankshaft sprocket Sensing plate Crankshaft spacer Camshaft sprocket bolt Camshaft sprocket Idler pulley Timing belt rear cover, center Connector bracket 11A-4-2 6A1 ENGINE (E - W) - Timing Belt REMOVAL AND INSTALLATION 12 Nm 23 21 11 Nm 88 Nm 11 Nm 17 16 22 48 Nm 9 10 18 19 11 5 35 Nm 8 6 17 44 Nm 11 Nm 15 14 12 20 1 13 22 Nm 2 11 Nm 7 9 Nm 9 Nm 49 Nm 9 Nm 4 3 11 Nm Removal steps 1. Timing belt front cover, upper right 2. Timing belt front cover, upper left 3. Timing belt front cover, lower 4. Engine support bracket 5. Angle sensor 6. Angle sensor 7. Spacer AA" "DA 8. Timing belt 9. Tensioner pulley 10. Tensioner arm 11. Tensioner spacer "BA 12. Auto tensioner E Mitsubishi Motors Corporation Feb. 1997 13. 14. 15. AB" "AA 16. 17. 18. PWEE9622 19. 20. 21. 22. 23. Crankshaft sprocket Sensing plate Washer Camshaft sprocket bolt Camshaft sprocket Camshaft sprocket with sensing plate Idler pulley Timing belt rear cover, left Timing belt rear cover, right Timing belt rear cover, center Connector bracket 6A1 ENGINE (E - W) - Timing Belt 11A-4-3 REMOVAL SERVICE POINTS AA" TIMING BELT REMOVAL (1) Mark the belt running direction for reference in reinstallation. (2) Loosen the bolt that secures the tensioner pulley to remove the timing belt. 6AE0135 6AE0044 AB" CAMSHAFT SPROCKET BOLT REMOVAL MB990767 MD998719 6AE0137 MB990767 MD998754 6AE0045 INSTALLATION SERVICE POINTS MD998719 "AA CAMSHAFT SPROCKET BOLT INSTALLATION MB990767 6AE0138 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-4-4 6A1 ENGINE (E - W) - Timing Belt MD998754 MB990767 6AE0048 (B) "BA AUTO TENSIONER SETTING (1) Set the auto tensioner in a vice, while making sure it is not tilted. (2) Slowly close the vice to force the rod in until the set hole (A) of the rod is lined up with the set hole (B) of the cylinder. (A) 6AE0049 (3) Insert a 1.4 mm wire in the set hole. (4) Remove the auto tensioner from the vice. 6AE0050 "CA TIMING BELT INSTALLATION (1) Turn the crankshaft sprocket so that its timing mark will be away from the mating timing mark by approx. three teeth. Caution D If the timing marks are aligned, the piston is brought to the TDC. When the camshaft is turned under this condition, the valves may interfere with the piston. 6AE0329 (2) Bring the timing marks of the camshaft sprockets as shown in the illustration. Timing mark 6AE0358 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 6A1 ENGINE (E - W) - Timing Belt 6AE0331 11A-4-5 (3) Align the timing mark on the crankshaft sprocket with that on the cylinder block side. (4) Fit the timing belt on the sprockets in the following order: 1) Fit the timing belt on the crankshaft sprocket and then, while giving tension to the belt, fit it on the water pump sprocket. 2) Fit the belt on the left bank camshaft sprocket. 3) Fit the belt on the idler pulley while keeping it tight. 4) Align the timing mark on the right bank camshaft sprocket with the mark on the cylinder block, and then fit the belt on the camshaft sprocket. Caution D The camshaft sprockets are prone to rotate. Avoid giving excessive tension to the timing belt when it is fitted. 5) Make sure that the left bank portion of the belt is not slack when the belt is fitted on the tensioner pulley. If it is slack, remove the belt and fit it again beginning with the first step. 6AE0143 (5) Move the tensioner pulley in the direction of the arrow and hold it in raised position by tightening the tensioner pulley bolt. (6) Check that all timing marks are aligned correctly. (7) Turn the crankshaft counterclockwise a quarter turn. (8) Turn back the crankshaft clockwise until the timing marks align again. 6AE0057 (9) Install the special tool and a torque wrench of 0 - 5 Nm to the tensioner pulley. (10)Torque the tensioner pulley to 3 Nm with the torque wrench. (11)While holding the tensioner pulley, tighten the center bolt to specification. (12)Turn the crankshaft clockwise 2 turns and let it stand for about 5 minutes. MD998767 MB990685 6AE0058 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-4-6 6A1 ENGINE (E - W) - Timing Belt "DA TIMING BELT INSTALLATION (1) Turn the crankshaft sprocket so that its timing mark will be away from the mating timing mark by approx. three teeth. MD998716 Caution D If the timing marks are aligned, the piston is brought to the TDC. When the camshaft is turned under this condition, the valves may interfere with the piston. 6AE0051 (2) Bring the timing marks of the camshaft sprockets as shown in the illustration. Caution D If one of the camshaft sprockets on the right bank is turned with the timing mark on the other sprocket aligned, there may be danger for the intake and exhaust valves to interfere with each other. 6AE0311 (3) Align the timing mark on the crankshaft sprocket with the mating timing mark, and then turn the crankshaft counterclockwise by one tooth. 6AE0053 (4) Place the timing belt over the sprockets in the following method. Caution D The camshaft sprockets on the right bank can turn very easily because of the valve spring tension. Use care not to allow your fingers to get caught between the sprockets. Paper clip 6AE0054 1) Align the timing mark of the right bank exhaust camshaft sprocket with the mating timing mark and hold the timing belt on the sprocket with a paper clip. 2) Align the timing mark of the intake camshaft sprocket and place the timing belt around that sprocket. Then, clip the belt at the location shown. Caution D The camshaft sprockets can turn easily and do not give excessive tension to the timing belt. 3) Place the timing belt around the idler pulley. 6AE0055 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 6A1 ENGINE (E - W) - Timing Belt 11A-4-7 4) On the left bank, make sure that the timing marks of the camshaft sprockets are aligned and then hold the timing belt on these sprockets with paper clips. 5) Place the timing belt around the water pump pulley. 6) Place the timing belt around the crankshaft sprocket. 7) Place the timing belt around the tensioner pulley. 6AE0056 (5) Move the tensioner pulley in the direction of the arrow and hold it in raised position by tightening the tensioner pulley bolt. (6) Check that all timing marks are aligned correctly. (7) Turn the crankshaft counterclockwise a quarter turn. (8) Turn back the crankshaft clockwise until the timing marks align again. 6AE0057 (9) Install the special tool and a torque wrench of 0 - 5 Nm to the tensioner pulley. (10)Torque the tensioner pulley to 3 Nm with the torque wrench. (11)While holding the tensioner pulley, tighten the center bolt to specification. (12)Turn the crankshaft clockwise 2 turns and let it stand for about 5 minutes. MD998767 MB990685 6AE0058 (13)Make sure that the wire, which has been inserted when installing the auto tensioner, can be removed easily. Belt tension should be acceptable if the wire can be easily removed. Remove the wrench. The belt tension can also be verified by checking the protrusion amount of the auto tensioner rod which should conform to the following. Standard value: 3.8 - 4.5 mm 6AE0059 (14)If the wire cannot be removed easily or the rod protrusion is not up to specification, repeat steps (9) through (12) to obtain the correct tension. INSPECTION TIMING BELT Replace belt if any of the following conditions exist. (1) Hardening of back rubber. Back side is glossy without resilience and leaves no indent when pressed with fingernail. 8EN0066 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-4-8 6A1 ENGINE (E - W) - Timing Belt Cracks Peeling (2) (3) (4) (5) Cracks Cracks Cracks Cracks on rubber back. or peeling of canvas. on tooth bottom. or belt sides. Cracks Cracks 1EN0249 (6) Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife. Rounded edge Abnormal wear (Fluffy strand) 8EN0067 (7) Abnormal wear on teeth. (8) Missing tooth. Rubber exposed Tooth missing and canvas fiber exposed 8EN0068 AUTO-TENSIONER (1) Check for oil leaks. If oil leaks are evident, replace the auto-tensioner. (2) Check the rod end for wear or damage and replace the auto-tensioner if necessary. (3) Measure the rod projection length “L”. If the reading is outside the standard value, replace the auto tensioner. “L” Standard value “L”: 12 mm 6AE0046 (4) Press the rod by a force of 98 to 196 N and measure the rod stroke. If the measured value exceeds the standard value, replace the tensioner. 98 - 196 N Stroke Standard value: 1 mm or less 6EN1033 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-5-1 6A1 ENGINE (E - W) - Fuel and Emission Control Parts 5. FUEL AND EMISSION CONTROL PARTS REMOVAL AND INSTALLATION 12 Nm 6 18 Nm 22 Nm 7 18 Nm 18 Nm 2 3 5 4 8 18 Nm 9 18 Nm 1 9 Nm 12 Nm 20 10 11 19 16 15 21 17 23 Nm 22 14 13 18 9 Nm 12 Removal steps 1. Air intake plenum stay, front 2. Air intake plenum stay, rear 3. EGR valve 4. Gasket 5. Vacuum pipe 6. Throttle body "CA 7. Gasket 8. Air intake plenum 9. Gasket 10. Control harness 11. Delivery pipe and injector E Mitsubishi Motors Corporation Feb. 1997 12. 13. "BA 14. 15. 16. 17. 18. "AA 19. 20. 21. 22. PWEE9622 Insulator Insulator Injector Grommet O-ring Fuel pipe O-ring Fuel pressure regulator O-ring Delivery pipe Alternator bracket 11A-5-2 6A1 ENGINE (E - W) - Fuel and Emission Control Parts REMOVAL AND INSTALLATION 11 Nm 11 Nm 18 Nm 6 18 Nm 12 Nm 7 18 Nm 3 9 8.8 Nm 8 18 Nm 4 5 12 1 2 13 11 14 10 9 Nm 12 Nm 24 14 Nm 25 23 22 19 20 21 18 17 16 15 9 Nm 23 Nm 26 Removal steps 1. Air intake plenum stay, front 2. Air intake plenum stay, rear 3. Vacuum pipe 4. Throttle body "CA 5. Gasket 6. Connector bracket 7. Connector bracket 8. Accelerator cable bracket 9. Ignition failure sensor 10. Air temperature sensor 11. Gasket 12. Air intake plenum 13. Gasket E Mitsubishi Motors Corporation Feb. 1997 14. 15. 16. 17. "BA 18. 19. 20. 21. 22. "AA 23. 24. 25. 26. PWEE9622 Control harness Delivery pipe and injector Insulator Insulator Injector Grommet O-ring Fuel pipe O-ring Fuel pressure regulator O-ring Delivery pipe Alternator bracket 6A1 ENGINE (E - W) - Fuel and Emission Control Parts 11A-5-3 INSTALLATION SERVICE POINTS "AA FUEL PRESSURE REGULATOR INSTALLATION (1) Apply spindle oil or gasoline to the new O-ring installed on the fuel pressure regulator. (2) Insert the fuel pressure regulator in the delivery pipe. (3) Make sure that the fuel pressure regulator turns smoothly; then align the threaded holes and tighten the regulator bolts to specification. 6AE0061 Caution D If the regulator does not turn smoothly, the O-ring probably gets caught somewhere in the delivery pipe. In such a case, remove the fuel pressure regulator and reinsert it into the delivery pipe. Check it again for smooth rotation before securing. "BA INJECTOR INSTALLATION (1) Install new grommet and O-ring on the injector. (2) Apply spindle oil or gasoline to the O-ring of the injector. (3) While turning the injector in both directions, install it in the delivery pipe. (4) Make sure that the injector turns smoothly. 6AE0062 Caution D If the injector does not turn smoothly, the O-ring probably gets caught somewhere in the delivery pipe. In such a case, remove the injector and reinsert it into the delivery pipe. Check it again for smooth rotation. (5) On the right bank, align the marks on the injector and delivery pipe. "CA GASKET INSTALLATION (1) Locate the projection on the gasket as shown. Projection 6AE0277 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-6-1 6A1 ENGINE (E - W) - Ignition System 6. IGNITION SYSTEM REMOVAL AND INSTALLATION 1 4 13 Nm 25 Nm 2 11 Nm 3 Removal steps 1. Spark plug cable 2. Spark plug 3. Water cover "AA 4. Distributor E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-6-2 6A1 ENGINE (E - W) - Ignition System REMOVAL AND INSTALLATION 1.0 Nm 25 Nm 1 3 2 Removal steps 1. Spark plug cable 2. Ignition coil 3. Spark plug INSTALLATION SERVICE POINT "AA DISTRIBUTOR INSTALLATION (1) Turn the crankshaft clockwise to bring the No. 1 cylinder piston to the compression stroke top dead center. (2) Align the mark on the distributor housing with the mark on the coupling. (3) Install the distributor while aligning the coupling key with the keyway in the camshaft end. Alignment mark 6AE0151 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-7-1 6A1 ENGINE (E - W) - Water Pump and Water Pipe 7. WATER PUMP AND WATER PIPE REMOVAL AND INSTALLATION 18 Nm 4 9 23 Nm 18 Nm 29 Nm 3 5 2 10 6 8 13 Nm 1 14 11 Nm 12 11 23 Nm 13 23 Nm 15 Removal steps "FA 1. Engine coolant temperature gauge unit "EA 2. Engine coolant temperature sensor 3. Water hose 4. Water hose 5. Heater pipe 6. O-ring 7. Water inlet fitting E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 "DA 8. Thermostat "CA 9. Water outlet fitting 10. Thermostat housing 11. Gasket "BA 12. O-ring "BA 13. Water pipe "BA 14. O-ring "AA 15. Water pump 7 11A-7-2 6A1 ENGINE (E - W) - Water Pump and Water Pipe REMOVAL AND INSTALLATION 8 29 Nm 18 Nm 23 Nm 3 2 13 Nm 13 10 9 11 12 1 18 Nm 23 Nm 14 Removal steps 1. Engine hanger "FA 2. Engine coolant temperature gauge unit "EA 3. Engine coolant temperature sensor 4. Water hose 5. Water hose 6. Water inlet fitting "DA 7. Thermostat E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 18 Nm 7 4 5 6 "CA 8. 9. 10. "BA 11. "BA 12. "BA 13. "AA 14. Water outlet fitting Thermostat housing Gasket O-ring Water pipe O-ring Water pump 11 Nm 11A-7-3 6A1 ENGINE (E - W) - Water Pump and Water Pipe 3 mm diameter bead sealant INSTALLATION SERVICE POINTS "AA SEALANT APPLICATION TO WATER PUMP Specified sealant: Mitsubishi Genuine equivalent Part No. MD970389 or 6AE0067 "BA WATER PIPE / O-RING INSTALLATION (1) Wet the O-ring (with water) to facilitate assembly. Caution D Keep the O-ring free of oil or grease. D Secure the water pipe after the thermostat housing has been installed. "CA SEALANT APPLICATION TO WATER OUTLET FITTING 3 mm diameter bead sealant Specified sealant: Mitsubishi Genuine equivalent Part No. MD970389 or 6AE0068 "DA THERMOSTAT INSTALLATION (1) Install the thermostat so that the jiggle valve will be located in the thermostat housing as shown. Jiggle valve 6AE0069 "EA SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE SENSOR Specified sealant: 3M Nut locking Part No. 4171 or equivalent 6AE0070 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-7-4 6A1 ENGINE (E - W) - Water Pump and Water Pipe "FA SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE GAUGE UNIT Specified sealant: 3M ATD Part No. 8660 or equivalent 6AE0071 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-8-1 6A1 ENGINE (E - W) - Intake Manifold and Exhaust Manifold 8. INTAKE MANIFOLD AND EXHAUST MANIFOLD REMOVAL AND INSTALLATION 17 Nm 3 13 Nm 1 2 5 6 7 9 44 Nm 49 Nm 13 Nm 4 8 49 Nm Removal steps 1. Intake manifold 2. Gasket 3. Heat protector, right 4. Exhaust manifold stay 5. Exhaust manifold, right 6. Gasket 7. Heat protector, left 8. Exhaust manifold, left 9. Gasket E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-8-2 6A1 ENGINE (E - W) - Intake Manifold and Exhaust Manifold REMOVAL AND INSTALLATION 1 17 Nm 2 3 13 Nm 5 6 7 9 44 Nm 49 Nm 4 13 Nm 8 49 Nm Removal steps 1. Intake manifold 2. Gasket 3. Heat protector, right 4. Exhaust manifold stay 5. Exhaust manifold, right 6. Gasket 7. Heat protector, left 8. Exhaust manifold, left 9. Gasket E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-9-1 6A1 ENGINE (E - W) - Rocker Arm and Camshaft 9. ROCKER ARM AND CAMSHAFT REMOVAL AND INSTALLATION 4 Nm 31 Nm 1 2 6 3 10 9 5 8 9 8 9 7 13 7 7 8 12 24 Nm 12 11 12 14 16 15 17 Apply engine oil to all moving parts before installation. 4 "DA AA" "CA AA" "CA "CA Removal steps 1. Rocker cover 2. Rocker cover gasket 3. Oil seal 4. Oil seal 5. Rocker arm and rocker shaft 6. Rocker arm and rocker shaft 7. Rocker shaft spring 8. Rocker arm A 9. Rocker arm B E Mitsubishi Motors Corporation Feb. 1997 10. "BA 11. 12. 13. "BA 14. 15. 16. "AA 17. PWEE9622 Rocker arm shaft Lash adjuster Rocker arm C Rocker arm shaft Lash adjuster Thrust case O-ring Camshaft 11A-9-2 6A1 ENGINE (E - W) - Rocker Arm and Camshaft REMOVAL SERVICE POINT AA" ROCKER ARMS AND ROCKER ARM SHAFTS REMOVAL (1) Before removing rocker arms and shafts assembly, install the special tool as illustrated to prevent adjuster from dropping. MD998443 6AE0160 INSTALLATION SERVICE POINTS "AA CAMSHAFT INSTALLATION (1) Apply engine oil to journals and cams of the camshaft before installation. Be sure to install the correct camshafts on the correct bank. Do not confuse the intake camshaft with the exhaust one. For right bank For left bank 6AE0180 "BA LASH ADJUSTER INSTALLATION (1) Immerse the lash adjuster in clean diesel fuel. (2) Using the special tool (air bleed wire), move the plunger up and down 4 or 5 times while pushing down lightly on the check ball in order to bleed out the air. MD998442 Diesel fuel 6EN0421 (3) Insert the lash adjuster to rocker arm, being careful not to spill the diesel fuel. Then use the special tool to prevent adjuster from falling while installing it. MD998443 Lash adjuster 6AE0161 "CA ROCKER SHAFT SPRING / ROCKER ARMS AND ROCKER ARM SHAFT INSTALLATION (1) Temporarily tighten the rocker shaft with the bolt so that all rocker arms on the inlet valve side do not push the valves. (2) Fit the rocker shaft spring from the above and position it so that it is right angles to the plug guide. 6AE0162 E Mitsubishi Motors Corporation Feb. 1997 NOTE Install the rocker shaft spring before installing the exhaust side rocker arms and rocker arm shaft. PWEE9622 11A-9-3 6A1 ENGINE (E - W) - Rocker Arm and Camshaft NOTE Install the rocker shaft spring before installing the exhaust side rocker arms and rocker arm shaft. (3) Remove the special tool for securing the lash adjuster. (4) Make sure that the notch in the rocker arm shaft is in the direction as illustrated. 6AE0163 "DA CAMSHAFT OIL SEAL INSTALLATION (1) When installing the left bank camshaft oil seal, use the special tool to prevent interference with the knock pin. Right bank MD998713 6AE0164 Left bank MD998713 MD998777 6AE0181 INSPECTION CAMSHAFT (1) Measure the cam height (lobe diameter) and, if the limit is exceeded, replace the camshaft. Standard value: 35.20 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake side 34.91 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust side 9EN0058 E Mitsubishi Motors Corporation Feb. 1997 Limit: 34.70 mm 34.41 mm PWEE9622 Intake side Exhaust side ........................................... ....................................... 11A-9-4 6A1 ENGINE (E - W) - Rocker Arm and Camshaft LASH ADJUSTER LEAK DOWN TEST Caution D The lash adjuster is a precision part. Keep it free from dust and other foreign matters. D Do not disassemble lash adjuster. D When cleaning lash adjuster, use clean diesel fuel only. MD998442 Diesel fuel MD998441 6EN0186 (1) Immerse the lash adjuster in clean diesel fuel. (2) While lightly pushing down inner steel ball using the special tool (Air bleed wire MD998442), move the plunger up and down four or five times to bleed air. Use of the special tool (Retainer MD998441) helps facilitate the air bleeding of the rocker arm mounted type lash adjuster. (3) Remove the special tool (Air bleed wire MD998442) and press the plunger. If the plunger is hard to be pushed in, the lash adjuster is normal. If the plunger can be pushed in all the way readily, bleed the lash adjuster again and test again. If the plunger is still loose, replace the lash adjuster. Caution D Upon completion of air bleeding, hold lash adjuster upright to prevent inside diesel fuel from spilling. MD998440 (4) After air bleeding, set lash adjuster on the special tool (Leak down tester MD998440). (5) After plunger has gone down somewhat [0.2 - 0.5 mm], measure time taken for it to go down 1 mm. Replace if measured time is out of specification. Graduations = 1 mm Lash adjuster Standard value: 4 - 20 seconds/1 mm (Diesel fuel at 15 - 20°C) 6EN0187 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 6A1 ENGINE (E - W) - Rocker Cover and Camshaft 11A-10-1 10. ROCKER COVER AND CAMSHAFT REMOVAL AND INSTALLATION 4 Nm 1 11 Nm 24 Nm 2 9 Nm 24 Nm 8 3 10 9 11 Nm 24 Nm 11 24 Nm 4 11 Nm Apply engine oil to all moving parts before installation. 9 12 13 6 14 5 7 Removal steps "GA 1. Rocker cover 2. Rocker cover gasket 3. Oil seal "FA 4. Circuit packing "EA 5. Oil seal "DA 6. Camshaft holder "DA 7. Semi-circular packing E Mitsubishi Motors Corporation Feb. 1997 "CA 8. Oil control valve "BA 9. Cam cap 10. Oil control valve holder "BA 11. Camshaft bearing cap 12. Arm spring holder 13. Arm spring "AA 14. Camshaft PWEE9622 11A-10-2 6A1 ENGINE (E - W) - Rocker Cover and Camshaft INSTALLATION SERVICE POINT Left bank camshaft Right bank camshaft "AA CAMSHAFT INSTALLATION (1) Intake valve camshaft and exhaust valve camshaft can be identified by their diameters at the portions indicated in the illustration. Intake valve camshaft: 25 mm Exhaust valve camshaft: 30 mm 6AE0229 IN EX IN Dowel pin Right bank EX Dowel pin (2) Before installing each camshaft, apply engine oil to its journals and cams. (3) The camshaft dowel pins must be positioned as shown in the illustration. Left bank 6AE0230 "BA CAMSHAFT BEARING CAP / CAM CAP INSTALLATION (1) Apply sealant to the illustrated points of the camshaft holders. Specified sealant: 3M ATD part No. 8660 or equivalent 6AE0233 (2) Install the bearing caps and cam caps correctly according to the “I” (intake) and “E” (exhaust) marks as well as the stamped cap numbers and front marks. (3) Tighten the bolts in the sequence of the numbers shown in the illustration. Cap No. Intake Front mark Exhaust Cap No. 6AE0308 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 6A1 ENGINE (E - W) - Rocker Cover and Camshaft 11A-10-3 "CA OIL CONTROL VALVE INSTALLATION (1) Apply the specified sealant to the area shown. Specified sealant: 3M ATD Part No. 8660 or equivalent 6AE0236 "DA SEMI-CIRCULAR PACKING / CAMSHAFT HOLDER INSTALLATION (1) Make sure that the retainer of each adjusting screw is fitted correctly. Screw Protrusion Caution D If the protrusion on the retainer is not correctly fitted in the groove of the screw, the pad could slip off the retainer. Groove Retainer Pad 6AE0237 (2) Apply 3 mm thick bead of foam-in-place gasket (FIPG) to the gasket surface of the camshaft holder. Caution D Since the FIPG could cause blocking of engine oil passages, be careful not to apply FIPG to other locations than specified. Specified sealant: Mitsubishi Genuine equivalent 6AE0238 8 4 2 6 10 7 3 1 5 9 Feb. 1997 No. MD970389 or (3) Install the semi-circular packings. (4) Raise the rocker arms until the rollers come into contact with the cams, and install the camshaft holder. (5) Tighten the bolts in the order indicated in the illustration. (6) Check the torque of the K-marked bolts. See section "BA for the checking order. (7) Verify that the pad of each adjusting screw is in place. 6AE0239 E Mitsubishi Motors Corporation Part PWEE9622 11A-10-4 6A1 ENGINE (E - W) - Rocker Cover and Camshaft "EA CAMSHAFT OIL SEAL INSTALLATION (1) When installing the left bank camshaft oil seal, use the special tool to prevent interference with the knock pin. Right bank MD998713 6AE0306 Left bank MD998777 MD998713 6AE0307 "FA CIRCULAR PACKING INSTALLATION MD998713 6AE0241 "GA ROCKER COVER INSTALLATION (1) Apply the specified sealant to the area shown. Specified sealant: 3M ATD Part No. 8660 or equivalent Sealant application areas 10 mm 10 mm 10 mm 6AE0242 INSPECTION 1 OIL CONTROL VALVE (1) Connect a 12VDC power supply between terminals (1) and (2) of the oil control valve and check if the valve operates smoothly. 2 + - 6AE0206 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 6A1 ENGINE (E - W) - Rocker Cover and Camshaft 11A-10-5 Valve 6AE0227 CAMSHAFT (1) Measure the cam heights. If the specified limit is exceeded, replace the camshaft. NOTE Each camshaft has an identification mark on its rear end surface. ( ): Identification mark IN (3) 9N0058 EX (C) High-speed cam (H) Identification mark location 16 mm 21 mm Standard value Limit L 34.34 mm 33.84 mm H 36.46 mm 35.96 mm L 34.40 mm 33.90 mm H 35.86 mm 35.36 mm Low-speed cam (L) 6AE0228 VALVE CLEARANCE ADJUSTMENT NOTE Adjust the valve clearance for each cylinder and for both intake and exhaust valves with the piston at the compression stroke top dead center. (1) Bring the No. 1 cylinder piston into the compression stroke top dead center. (2) Use the special tool to loosen the adjusting screw. (3) Insert a thickness gauge of the thickness specified below between the low-speed cam (narrow cam) and roller. Thickness gauge Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13 mm (4) Screw in one of the two adjusting screws until it comes into contact with the valve (when the turning torque changes). MB991477 6AE0285 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-10-6 6A1 ENGINE (E - W) - Rocker Cover and Camshaft (5) Screw in the other adjusting screw until it comes into contact with the valve (when the turning torque changes), and then tighten the lock nut. (6) Loosen the adjusting screw that was screwed in first slightly (until the turning torque becomes almost zero). Screw in the adjusting screw until it comes into contact with the valve again (when the turning torque changes) and tighten the lock nut. (7) Remove the thickness gauge. (8) Screw the special tool into the top of piston of the rocker arm “H”, and pull up the tool to make sure that the piston can be lifted smoothly by hand. (9) Perform valve clearance adjustments for other cylinders by turning every time the crankshaft through 120° (60° in camshaft sprocket angle) and following the above steps (2) through (8). Perform the adjustments in the following order of cylinder number: No. 2 ® No. 3 ® No. 4 ® No. 5 ® No. 6 MB991479 Piston 6AE0286 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 6A1 ENGINE (E - W) - 11A-11-1 Rocker Arm and Rocker Shaft Cap 11. ROCKER ARM AND ROCKER SHAFT CAP REMOVAL AND INSTALLATION 22 20 21 13 20 13 21 13 14 19 20 21 11 12 15 4 18 16 11 12 17 3 4 5 10 11 12 7 1 2 6 11 Nm 9 8 Apply engine oil to all moving parts before installation. 4 Removal steps "BA 1. Rocker shaft cap 2. Seal cap A 3. Seal cap C 4. Intake rocker arm assembly A 5. Nut 6. Adjusting screw 7. Intake rocker arm H 8. Piston H 9. Piston spring H 10. Intake T-lever "AA 11. Spring guide E Mitsubishi Motors Corporation Feb. 1997 12. 13. 14. 15. 16. 17. 18. 19. "AA 20. 21. 22. PWEE9622 Wave washer Exhaust rocker arm assembly A Nut Adjusting screw Exhaust rocker arm H Piston H Piston spring H Exhaust T-lever L Spring guide Wave washer Camshaft holder 11A-11-2 6A1 ENGINE (E - W) T-lever Spring guide Waved washer Rocker Arm and Rocker Shaft Cap INSTALLATION SERVICE POINTS "AA SPRING GUIDE INSTALLATION (1) Install the spring guide with the concave side toward the rocker arm. The waved washer may be installed with either side out. Concave side Either side may be out 6 5 2 1 4 3 6AE0247 "BA ROCKER SHAFT CAP INSTALLATION (1) Tighten the bolts in the sequence shown. (2) Make sure that each rocker arm moves smoothly. 10 8 7 9 6AE0249 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 6A1 ENGINE (E - W) - Cylinder Head and Valves 11A-12-1 12. CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION 1 4 5 6 12 20 13 16 17 19 14 8 9 15 10 11 18 7 3 Apply engine oil to all moving parts before installation. Removal steps AA" "DA 1. Cylinder head bolt 2. Cylinder head 3. Cylinder head gasket AB" "CA 4. Retainer lock 5. Valve spring retainer "BA 6. Valve spring 7. Intake valve AB" "CA 8. Retainer lock 9. Valve spring retainer "BA 10. Valve spring E Mitsubishi Motors Corporation Feb. 1997 11. AC" "AA 12. 13. AC" "AA 14. 15. 16. 17. 18. 19. 20. PWEE9622 Exhaust valve Valve stem seal Valve spring seat Valve stem seal Valve spring seat Intake valve guide Exhaust valve guide Intake valve seat Exhaust valve seat Cylinder head 2 11A-12-2 6A1 ENGINE (E - W) - Cylinder Head and Valves REMOVAL AND INSTALLATION 1 4 5 12 8 9 6 13 14 10 15 16 17 2 20 19 18 11 7 3 Apply engine oil to all moving parts before installation. Removal steps AA" "DA 1. Cylinder head bolt 2. Cylinder head 3. Cylinder head gasket AB" "CA 4. Retainer lock 5. Valve spring retainer "BA 6. Valve spring 7. Intake valve AB" "CA 8. Retainer lock 9. Valve spring retainer "BA 10. Valve spring E Mitsubishi Motors Corporation Feb. 1997 AD" 11. Exhaust valve AC" "AA 12. Valve stem seal 13. Valve spring seat AC" "AA 14. Valve stem seal 15. Valve spring seat 16. Intake valve guide 17. Exhaust valve guide 18. Intake valve seat 19. Exhaust valve seat 20. Cylinder head PWEE9622 6A1 ENGINE (E - W) - Cylinder Head and Valves 11A-12-3 REMOVAL SERVICE POINTS PRECAUTION FOR REMOVED PARTS Keep removed parts in order according to the cylinder number and intake/exhaust side. MB991653 AA" CYLINDER HEAD BOLT REMOVAL (1) Using the special tool, loosen the cylinder head bolts. Loosen evenly, little by little. 6AE0166 MB991653 6AE0408 AB" RETAINER LOCK REMOVAL (1) Store removed valves, springs and other parts, tagged to indicate their cylinder Nos. and location for reassembly. MD998772 6AE0167 MD998784 MD998772 6AE0253 MD998735 6EN1068 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-12-4 6A1 ENGINE (E - W) - Cylinder Head and Valves AC" VALVE STEM SEAL REMOVAL (1) Do not reuse removed valve stem seals. 6AE0082 AD" VALVE HANDLING PRECAUTIONS (1) Sodium reacts violently with water or moisture generation heat and liberating hydrogen. It must be handled with utmost care because otherwise the following dangerous conditions may result: Loss of eyesight if sodium gets in eyes. Burns if sodium contact skin. Fire hazard. (2) Handling of Sodium-filled Exhaust Valves Sodium-filled exhaust valves are not dangerous and may be handled in the same way as ordinary valves unless they are broken. Never try to break the valves and expose sodium to the air. When worn exhaust valves are to be discarded, have them disposed of by a salvage company equipped with special disposal system, notifying them that the valves contain sodium. Should the exhaust valves be broken, neutralize sodium using the method described below, and discard the valves in the same way as ordinary valves. (3) How to Neutralize Sodium Place a container filled with more than 10 liters of water in a well ventilated large space. Wear rubber gloves and goggles, and carefully take out broken valves from the cylinder head. Put a broken valve in the water-filled container and quickly get away from the container at least 2 or 3 m. E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 6A1 ENGINE (E - W) - Cylinder Head and Valves 11A-12-5 INSTALLATION SERVICE POINTS Stem seals for intake valves: Silver Stem seals for exhaust valves: Black 7EN0763 "AA VALVE STEM SEAL INSTALLATION (1) Install the valve spring seat. (2) Use the special tool to fit a new stem seal on the valve guide. NOTE Valve stem seals for intake valves are different from those for exhaust valves. They are identified by colors of their spring sections as follows: Stem seals for intake valves: Silver Stem seals for exhaust valves: Black Caution D Do not reuse the valve stem seal. D Always use the special tool to install the valve stem seal. If the seal is improperly fitted, engine oil may work its way down along the valve stem. MD998774 6AE0169 MD998775 6AE0409 Spring retainer Painted end "BA VALVE SPRING INSTALLATION (1) Install the valve spring with the painted end on the rocker arm side. Stem seal Spring seat 6EN0437 "CA RETAINER LOCK INSTALLATION (1) The valve spring, if excessively compressed, causes the bottom end of retainer to be in contact with, and damage, the stem seal. MD998772 6AE0167 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-12-6 6A1 ENGINE (E - W) - Cylinder Head and Valves MD998784 MD998772 6AE0253 MD998735 6EN1068 "DA CYLINDER HEAD BOLT INSTALLATION (1) When installing the cylinder head bolts, check that the shank length of each bolt meets the limit. If the limit is exceeded, replace the bolts. Limit: max. 96.4 mm (2) Install the washers as illustrated. (3) Apply engine oil to the bolt threads and washers. Length of shank 9EN0251 (4) Retighten the loosened bolts to a torque of 20 Nm in the specified tightening sequence. 6AE0392 MB991614 120° 6AE0339 E Mitsubishi Motors Corporation Feb. 1997 (5) Make paint marks on the cylinder head bolts and cylinder head. (6) Give a 120° turn to the bolts in the specified tightening sequence. Caution D If the bolts are tightened by an angle of less than 120°, they may not hold the cylinder head with sufficient strength. D If a bolt is overtightened, completely remove all the bolts and carry out the installation procedure again from step (1). PWEE9622 11A-12-7 6A1 ENGINE (E - W) - Cylinder Head and Valves INSPECTION CYLINDER HEAD (1) Check the cylinder head gasket surface for flatness by using a straightedge and thickness gauge. Standard value: 0.03 mm Limit: 0.2 mm (2) If the service limit is exceeded, correct to meet the specification. 6AE0083 Grinding limit: *0.2 mm *Includes/combined with cylinder block grinding Cylinder head height (Specification when new): 119.9 - 120.1 mm 119.6 - 119.8 mm Valve seat contact Margin 6EN0542 VALVE (1) Check the valve face for correct contact. If incorrect, reface using a valve refacer. Valve should make a uniform contact with the seat at the centre of valve face. (2) If the margin is smaller than the service limit, replace the valve. Standard value mm Limit mm Intake 1.0 0.5 Exhaust 1.3 0.8 (3) Measure the overall height of the valve. If the specified limit is exceeded, replace the valve. Intake Exhaust E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 Standard value mm Limit mm SOHC 113.02 112.52 MIVEC 112.37 111.87 SOHC 115.32 114.82 MIVEC 110.74 110.74 11A-12-8 6A1 ENGINE (E - W) - Cylinder Head and Valves Out of square VALVE SPRING (1) Measure the valve spring’s free height. If the measurement is less than specified, replace the spring. Standard mm Free height 1EN0264 value Limit mm SOHC 49.9 48.9 MIVEC 51.5 50.5 (2) Measure the squareness of the spring. If the measurement exceeds the specified limit, replace the spring. Standard value: 2_ or less Limit: 4_ Valve stem end Valve stem projection VALVE SEAT (1) Assemble the valve, then measure the valve stem projection between the end of the valve stem and the spring seating surface. If the measurement exceeds the specified limit, replace the valve seat. Standard mm Spring seating surface DEN0212 value Limit mm SOHC 48.45 48.95 MIVEC 48.40 48.90 VALVE GUIDE (1) Measure the clearance between the valve guide and valve stem. If the limit is exceeded, replace the valve guide or valve, or both. Valve guide Standard value: Intake: 0.02 - 0.05 mm Exhaust: 0.04 - 0.07 mm 1EN0279 E Mitsubishi Motors Corporation Feb. 1997 Limit: Intake: 0.10 mm Exhaust: 0.15 mm PWEE9622 6A1 ENGINE (E - W) - Cylinder Head and Valves 0.9 - 1.3 mm 0.9 - 1.3 mm 65_ 65_ 15_ 44_ 44_ 15_ 1EN0105 11A-12-9 VALVE SEAT RECONDITIONING PROCEDURE (1) Before correcting the valve seat, check the clearance between the valve guide and valve. If necessary, replace the valve and/or valve guide. (2) Using the appropriate special tool or seat grinder, correct the valve seat to achieve the specified seat width and angle. (3) After correcting the valve seat, lap the valve and valve seat using lapping compound. Then, check the valve stem projection (refer to VALVE SEAT in INSPECTION). VALVE SEAT REPLACEMENT PROCEDURE (1) Cut the valve seat to be replaced from the inside to thin the wall thickness. Then, remove the valve seat. (2) Rebore the valve seat hole in the cylinder head to a selected oversize valve seat diameter. 0.5 - 1.0 mm Cut away 0.5 - 1.0 mm 1EN0274 Intake valve seat hole diameter 0.3 O.S. : 29.80 - 29.82 mm : 32.30 - 32.32 mm 0.6 O.S. : 30.10 - 30.12 mm : 32.60 - 32.62 mm Exhaust valve seat hole diameter 0.3 O.S. : 27.80 - 27.82 mm : 29.80 - 29.82 mm 0.6 O.S. : 28.10 - 28.12 mm : 30.10 - 30.12 mm Valve seat height Oversize valve seat hole diameter 1EN0275 (3) Before fitting the valve seat, either heat the cylinder head up to approximately 250_C or cool the valve seat in liquid nitrogen, to prevent the cylinder head bore from galling. (4) Correct the valve seat to the specified width and angle. VALVE GUIDE REPLACEMENT (1) Force the valve guide out toward the cylinder block using a press. (2) Machine the valve guide hole in the cylinder head to the size of the oversize valve guide to be installed. Caution D Do not use the valve guide of the same size as the removed one. Valve guide hole diameters 0.05 O.S.: 11.05 - 11.07 0.25 O.S.: 11.25 - 11.27 0.50 O.S.: 11.50 - 11.52 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 in cylinder head mm mm mm 11A-12-10 6A1 ENGINE (E - W) - Cylinder Head and Valves (3) Press-fit the valve guide until it protrude specified value (SOHC: 14 mm, DOHC: 19 mm) as shown in the illustration. Caution D Press the valve guide from the cylinder head top surface. D Valve guide for intake valve and that for exhaust valve are different in length. (45.5 mm for intake valve; 50.5 mm for exhaust valve) 14 mm 1EN0106 (4) After the valve guide has been installed, insert a new valve to check for smooth sliding motion. 19 mm 19 mm 6AE0254 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-13-1 6A1 ENGINE (E - W) - Oil Pump Case and Oil Pan 13. OIL PUMP CASE AND OIL PAN REMOVAL AND INSTALLATION 6 Apply engine oil to all moving parts before installation. 12 Nm 26 24 25 2 22 14 Nm 8 23 1 7 19 Nm 20 19 21 17 16 4 21 Nm 5 68 Nm 15 30 Nm 9 Nm 18 10 Nm 44 Nm 3 7 Nm 14 12 10 39 Nm 7 Nm 9 13 9 Nm 11 Removal steps "IA 1. Oil pressure switch "HA 2. Oil filter 3. Oil filter cover 4. Water hose (for Europe and GCC) 5. Water pipe (for Europe and GCC) 6. Water pipe (for Europe and GCC) 7. Bolt (for Europe and GCC) "GA 8. Oil cooler (for Europe and GCC) 9. Drain plug "FA 10. Gasket 11. Oil level sensor (For Europe) 12. Cover "DA 13. Oil pan lower E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 7 Nm "DA 14. 15. 16. 17. 18. 19. 20. "CA 21. "BA 22. 23. 24. "AA 25. "AA 26. Oil pan upper Buffle plate Oil screen Gasket Relief plug Relief spring Relief plunger Oil seal Oil pump case O-ring Oil pump case cover Outer rotor Inner rotor 11A-13-2 6A1 ENGINE (E - W) - Oil Pump Case and Oil Pan REMOVAL AND INSTALLATION 2 17 18 21 Nm 14 14 Nm 9 12 Nm 3 16 15 13 12 11 44 Nm 10 1 7 Nm 8 7 19 Nm 10 Nm 7 Nm 6 39 Nm 4 5 Apply engine oil to all moving parts before installation. Removal steps "IA 1. Oil pressure switch "HA 2. Oil filter 3. Oil filter cover 4. Drain plug "FA 5. Gasket AA" "EA 6. Oil pan 7. Oil screen 8. Gasket 9. Buffle plate E Mitsubishi Motors Corporation Feb. 1997 "CA "BA "AA "AA PWEE9622 10. 11. 12. 13. 14. 15. 16. 17. 18. Relief plug Relief spring Relief plunger Oil seal Oil pump case O-ring Oil pump case cover Outer rotor Inner rotor 11A-13-3 6A1 ENGINE (E - W) - Oil Pump Case and Oil Pan REMOVAL SERVICE POINT MD998727 AA" 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. 6AE0087 INSTALLATION SERVICE POINTS "AA INNER ROTOR / OUTER ROTOR INSTALLATION (1) Apply engine oil to the rotors. Then, install the rotors ensuring that the alignment dots made at disassembly are properly aligned. 6AE0091 "BA SEALANT APPLICATION TO OIL PUMP CASE 3 mm diameter bead sealant Specified sealant: Mitsubishi Genuine equivalent Part No. MD970389 or 6AE0092 "CA OIL SEAL INSTALLATION (1) Apply engine oil to the oil seal lip. Using the special tool, knock the oil seal into the oil pump case. MD998717 E Mitsubishi Motors Corporation 6AE0093 Feb. 1997 PWEE9622 11A-13-4 6A1 ENGINE (E - W) - Oil Pump Case and Oil Pan "DA OIL PAN INSTALLATION (1) Clean the cylinder block and oil pan gasket application surfaces. (2) Install the oil pan within 15 minutes after FIPG has been applied to the entire flange surfaces of the oil pan. Specified sealant: Mitsubishi Genuine equivalent Part No. MD970389 or f4 Groove Bolt hole "EA OIL PAN INSTALLATION (1) Clean the cylinder block and oil pan gasket application surfaces. (2) Install the oil pan within 15 minutes after FIPG has been applied to the entire flange surfaces of the oil pan. 4 mm diameter bead sealant Specified sealant: Mitsubishi Genuine equivalent Part No. MD970389 6AE0094 Oil pan side "FA DRAIN PLUG GASKET INSTALLATION (1) Install the drain plug gasket in the shown direction. Drain plug gasket 7EN0307 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 or 6A1 ENGINE (E - W) - Oil Pump Case and Oil Pan 11A-13-5 "GA OIL COOLER INSTALLATION (1) Install the oil cooler, with the oil cooler’s positioning projection positioned against the rib on cylinder block. 6AE0172 "HA OIL FILTER INSTALLATION (1) Clean the surfaces of the cylinder block on which the oil filter is to be mounted. (2) Apply engine oil to the O-ring of the oil filter. (3) Turn down the oil filter until the O-ring contacts the cylinder block surface, and then give the oil filter one more turn (or tighten with a 16 Nm torque). NOTE For MD135737 oil filter, the tightening torque should be 14 Nm. "IA SEALANT APPLICATION TO SEALANT TO OIL PRESSURE SWITCH (1) Apply sealant to the threads of the switch. Specified sealant: 3M ATD Part No. 8660 or equivalent Caution D Use care not to allow the sealant to plug the oil passage. Oil passage 9EN0094 INSPECTION OIL PUMP (1) Check the tip clearance. Standard value: 0.06 - 0.18 mm 6AE0088 (2) Check the side clearance. Standard value: 0.04 - 0.10 mm 6AE0089 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-13-6 6A1 ENGINE (E - W) - Oil Pump Case and Oil Pan (3) Check the body clearance. Standard value: 0.10 - 0.18 mm Limit: 0.35 mm 6AE0090 OIL LEVEL SENSOR (FOR EUROPE) (1) Put the oil level sensor in the oil, then move the float up and down with the oil at a temperature either lower than 40°C or higher than 80°C, and check for continuity. 40°C 6AE0192 Float position Switch ON/OFF Condition when down ON (continuity) Condition when up ON (continuity) 80°C Float position Condition when down Condition when up E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 Switch ON/OFF OFF (no continuity) ON (continuity) 6A1 ENGINE (E - W) - Piston and Connecting Rod 11A-14-1 14. PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION Apply engine oil to all moving parts before installation. 6AE0095 "GA AA" "FA "EA "DA "EA "CA Removal steps 1. Nut 2. Connecting rod cap 3. Connecting rod bearing 4. Piston and connecting rod 5. Connecting rod bearing 6. Piston ring No.1 E Mitsubishi Motors Corporation Feb. 1997 "CA 7. Piston ring No.2 "BA 8. Oil ring AB" "AA 9. Piston pin 10. Piston 11. Connecting rod 12. Bolt PWEE9622 11A-14-2 6A1 ENGINE (E - W) - Piston and Connecting Rod REMOVAL SERVICE POINTS Cylinder No. AA" CONNECTING ROD CAP REMOVAL (1) Mark the large end of the connecting rod with the cylinder number for use during reassembly. DEN0050 Piston pin setting tool MD998780 Push rod Guide A: 17.9 mm AB" PISTON PIN REMOVAL Piston pin setting tool (MD998780) consists of the parts shown in the illustration at left. To remove the piston pin, Guide D (MB991659) is also used in combination with the Piston pin setting tool. Guide B Guide A: 18.9 mm Guide C Guide A: 20.9 mm Guide D MB991659 Guide A: 21.9 mm Base 9EN0780 Push rod Front mark Front mark (1) Insert the Push Rod (special tool) into the piston from the side on which the front mark is stamped in the piston head, and attach the guide D to the push rod end. (2) Place the piston and connecting rod assembly on the Piston Pin Setting Base (special tool) with the front mark facing upward. (3) Using a press, remove the piston pin. NOTE Keep the disassembled pistons, piston pins and connecting rods in order according to the cylinder number. Guide D Base 7EN0390 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 6A1 ENGINE (E - W) - Piston and Connecting Rod INSTALLATION SERVICE POINTS Piston B A C D Connecting rod Piston pin 11A-14-3 "AA PISTON PIN INSTALLATION (1) Measure the following dimensions of the piston, piston pin and connecting rod. A: Piston pin insertion hole length B: Distance between piston bosses C: Piston pin length D: Connecting rod small end width (2) Calculate the following formula by substituting the measured values. (A - C) - (B - D) L= 2 (3) Insert the Push Rod (special tool) into the piston pin and attach the guide A to the push rod end. (4) Assemble the connecting rod in the piston with their front marks facing the same direction. (5) Apply engine oil to the entire periphery of the piston pin. (6) Insert the piston pin, push rod and guide A assembly having assembled in step (3) from the guide A side into the piston pin hole on the front marked side. 7EN0432 (7) Screw the guide B into the guide A until the gap between both guides amounts to the value L obtained in step (2) plus 3 mm. 3 mm + L Guide B Guide A 7EN0433 (8) Place the piston and connecting rod assembly onto the piston setting base with the front marks directed upward. (9) Press-fit the piston pin using a press. If the press-fitting force required is less than the standard value, replace the piston and piston pin set or/and the connecting rod. Push rod Piston pin Front mark Front mark Standard value: 5,000 - 15,000 N Guide A Base Guide B 7EN0391 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-14-4 6A1 ENGINE (E - W) - Piston and Connecting Rod "BA 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 fit one end of the rail into the piston groove, then press the remaining portion into position by finger. See illustration. 6AE0194 NOTE Do not use piston ring expander when installing side rail. Use of ring expander to expand the side rail end gap can break the side rail, unlike other piston rings. Side rail gap (3) Install the lower side rail in the same procedure as described in step (2). (4) Make sure that the side rails move smoothly in either direction. 1EN0269 "CA PISTON RING NO. 2 / PISTON RING NO. 1 INSTALLATION (1) Using piston ring expander, install the piston rings with their side having identification marks facing up. Piston ring expander Identification mark: No. 1 ring: T No. 2 ring: 2T 7EN0452 Identification mark Identification mark Size mark NOTE The piston ring is stamped with the following size mark. Size Size mark Standard size None No.1 0.50 mm O.S. 50 No.2 1.00 mm O.S. 100 9EN0524 Upper side rail No. 1 Piston pin No. 2 ring gap and spacer gap E Mitsubishi Motors Corporation "DA PISTON AND CONNECTING ROD INSTALLATION (1) Liberally coat engine oil on the circumference of the piston, piston ring, and oil ring. (2) Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in the figure. (3) Rotate crankshaft so that the crank pin is on center of the cylinder bore. Lower side rail 6EN0549 Feb. 1997 PWEE9622 6A1 ENGINE (E - W) - Piston and Connecting Rod 11A-14-5 (4) Use suitable thread protectors on connecting rod bolts before inserting piston and connecting rod assembly into cylinder block. Care must be taken not to nick crank pin. (5) Using a suitable piston ring compressor tool, install piston and connecting rod assembly into the cylinder block. Caution D Insert the front mark (arrow) on the top of the piston so it faces the engine front (timing belt side). 6AE0097 Crankshaft pin identification mark No.2 No.4 No.1 No.3 No.5 "EA CONNECTING ROD BEARINGS 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 on the crankshaft. <6A12> Connecting rod bearing Crankshaft pin No.6 Check digit Identification mark Outer diameter mm I 42.995 - 43.000 1 II 42.985 - 42.995 2 III 42.980 - 42.985 3 6AE0341 Identification mark <6A13> Connecting rod bearing Crankshaft pin Identification mark Identification mark Outer diameter mm Identification mark I 50.995 - 51.000 1 II 50.985 - 50.995 2 III 50.980 - 50.985 3 "FA CONNECTING ROD CAP INSTALLATION (1) Mate the correct bearing cap with the correct connecting rod by checking with the alignment marks marked during disassembly. If a new connecting rod is used which has no alignment mark, position the notches for locking the bearing on the same side. E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-14-6 6A1 ENGINE (E - W) - Piston and Connecting Rod (2) Check if the thrust clearance in the connecting rod big end is correct. Standard value: 0.10 - 0.25 mm Limit: 0.4 mm 9EN0073 "GA CONNECTING ROD CAP NUT INSTALLATION (1) Since the connecting rod bolts and nuts are torqued using a new procedure they should be examined BEFORE reuse. If the bolt threads are “necked down” the bolts should be replaced. Necking can be checked by running a nut with fingers to the full length of the bolt’s thread. If the nut does not run down smoothly, the bolt should be replaced. 90° - 100° Bolt Nut Paint marks Paint marks 6EN0954 (2) Before installation of each nut, apply engine oil to the threaded portion and bearing surface of the nut. (3) Install each nut to the bolt and tighten it finger tight. Then tighten the nuts alternately to install the cap properly. (4) Tighten the nuts to a torque of 18 Nm. (5) Make a paint mark on the head of each nut. (6) Make a paint mark on the bolt at the position 90° to 100° from the paint mark made on the nut in the direction of tightening the nut. (7) Give a 90° to 100° turn to the nut and make sure that the paint mark on the nut and that on the bolt are in alignment. Caution D If the nuts are tightened by an angle of less than 90°, they may not hold the caps with sufficient strength. D If a nut is tightened by an angle exceeding 100°, completely remove all the nuts and carry out the installation procedure again from step (1). E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 6A1 ENGINE (E - W) - Piston and Connecting Rod 11A-14-7 INSPECTION PISTON RING (1) Check the side clearance between the piston ring and ring groove. If the limit is exceeded, replace the ring or piston, or both. Standard value: No. 1 0.03 - 0.07 mm No. 2 0.02 - 0.06 mm 7EN0475 Push in by the piston 0.1 mm 0.1 mm Install the piston ring into the cylinder bore. Force it down with a piston, its crown being in contact with the ring, to correctly position it at right angles to the cylinder wall. Then, measure the end gap with a feeler gauge. If the ring gap is excessive, replace piston ring. Piston ring gap Piston ring Limit: No. 1 No. 2 Plastic gauge 7EN0476 1EN0246 Standard value: No. 1 No. 2 Oil 0.25 - 0.40 mm 0.40 - 0.55 mm 0.10 - 0.35 mm Limit: No. 1, No. 2 Oil 0.8 mm 1.0 mm CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE METHOD) (1) Remove oil from crankshaft pin and connecting rod bearing. (2) Cut the plastic gauge to the same length as the width of bearing and place it on crankshaft pin in parallel with its axis. (3) Install the connecting rod cap carefully and tighten the bolts to specified torque. (4) Carefully remove the connecting rod cap. (5) Measure the width of the plastic gauge at its widest part by using a scale printed on the plastic gauge package. Standard value: 0.02 - 0.05 mm Limit: 0.1 mm E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 6A1 ENGINE (E - W) - Crankshaft, Cylinder Block, Flywheel and Drive Plate 11A-15-1 15. CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE PLATE REMOVAL AND INSTALLATION 5 4 6 11 Nm 35 Nm 2 23 Nm A 11 3 1 14 98 Nm 13 7 21 8 12 98 Nm 9 11 Nm 10 9 Nm 19 18 20 Apply engine oil to all moving parts before installation. 17 16 15 "EA "EA "DA "CA "BA Removal steps 1. Detonation sensor 2. Idler pulley bracket 3. Flywheel bolt 4. Plate 5. Adapter plate 6. Flexible flywheel 7. Adapter plate 8. Drive plate bolt 9. Adapter plate 10. Drive plate 11. Rear plate 12. Bell housing cover 13. Oil seal case 14. Oil seal 15. Bearing cap bolt E Mitsubishi Motors Corporation Feb. 1997 "BA 16. Bearing cap "AA 17. Crankshaft bearing, lower 18. Crankshaft "AA 19. Thrust bearing "AA 20. Crankshaft bearing, upper 21. Cylinder block Caution On the flexible wheel equipped engines, do not remove any of the bolts “A” of the flywheel shown in the illustration. The balance of the flexible flywheel is adjusted in an assembled condition. Removing the bolt, therefore, can cause the flexible flywheel to be out of balance, giving damage to the flywheel. PWEE9622 11A-15-2 6A1 ENGINE (E - W) - INSTALLATION SERVICE POINTS Crankshaft journal identification mark No.1 Crankshaft, Cylinder Block, Flywheel and Drive Plate "AA CRANKSHAFT BEARING INSTALLATION (1) When replacing bearing, select a one of proper size according to the identification marks stamped on both crankshaft and cylinder block. No.2 No.4 <6A12> No.3 Check digit 6AE0343 No.4 No.3 Cylinder bore size mark (reference) No.2 Crankshaft Journal Cylinder Block Bearing Bore Crankshaft Bearing Identification mark Identification mark Identification mark 1 Outer diameter mm 52.994 - 53.000 No.1 Cylinder block bearing bore identification mark 2 Timing belt side 6AE0344 3 52.988 - 52.994 52.982 - 52.988 Inner diameter mm 0 57.000 - 57.006 1 1 57.006 - 57.012 2 2 57.012 - 57.018 3 0 57.000 - 57.006 2 1 57.006 - 57.012 3 2 57.012 - 57.018 4 0 57.000 - 57.006 3 1 57.006 - 57.012 4 2 57.012 - 57.018 5 <6A13> Crankshaft Journal Cylinder Block Bearing Bore Crankshaft Bearing Identification mark Identification mark Identification mark 1 2 3 Oil groove Identification mark E Mitsubishi Motors Corporation Feb. 1997 55.994 - 56.000 55.988 - 55.994 55.982 - 55.988 Inner diameter mm 0 60.000 - 60.006 1 1 60.006 - 60.012 2 2 60.012 - 60.018 3 0 60.000 - 60.006 2 1 60.006 - 60.012 3 2 60.012 - 60.018 4 0 60.000 - 60.006 3 1 60.006 - 60.012 4 2 60.012 - 60.018 5 (2) Install the bearings having an oil groove to the cylinder block. (3) Install the bearings having no oil groove to the bearing caps. (4) Install the thrust bearings at the No. 3 upper bearing with the grooved side toward the crank web. Groove Identification mark Outer diameter mm 6AE0116 PWEE9622 6A1 ENGINE (E - W) - Crankshaft, Cylinder Block, Flywheel and Drive Plate 11A-15-3 "BA BEARING CAP / BEARING CAP BOLT INSTALLATION (1) Install the bearing caps so that their arrows are positioned on the timing belt side. (2) When installing the bearing cap bolts, check that the shank length of each bolt meets the limit. If the limit is exceeded, replace the bolt. Shank length Limit: max. 71.1 mm 9EN0477 (3) Apply engine oil to the threaded portion and bearing surface of the bolt. (4) Tighten the bearing cap bolts to 25 Nm torque in the tightening sequence. Arrow 6AE0108 (5) Make a paint mark on the head of each nut. (6) Make a paint mark on the area around the bolt bearing surface at location 90° to 100° in the direction of tightening the bolt. (7) Give a 90° to 100° turn to the bolts in the tightening sequence. Make sure that the paint mark on the bolt and that on the area around the bolt bearing surface are in alignment. Paint marks 90° - 100° Paint marks 6EN0955 Caution D If the bolts are tightened by an angle of less than 90°, they may not hold the cap with sufficient strength. D If a bolt is tightened by an angle exceeding 100°, completely remove all the bolts and carry out the installation procedure again from step (1). (8) 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 Limit: 0.4 mm 6AE0109 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-15-4 6A1 ENGINE (E - W) - Crankshaft, Cylinder Block, Flywheel and Drive Plate "CA OIL SEAL INSTALLATION (1) Apply engine oil to oil seal lip. MB990938 MD998776 9EN0077 "DA APPLICATION OF OIL SEAL CASE Specified sealant: Mitsubishi Genuine equivalent Part No. MD970389 or 6AE0110 "EA DRIVE PLATE BOLT / FLYWHEEL BOLT INSTALLATION (1) Remove all the remaining sealant from bolts and thread holes of crankshaft. (2) Apply engine oil to the flange of bolt. (3) Apply engine oil into the thread holes of crankshaft. (4) Apply specified sealant to the thread of bolts. Specified sealant: 3M Nut Locking Part No. 4171 or equivalent 9EN0102 (5) Tighten the bolts to specified torque. INSPECTION CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE METHOD) (1) Remove oil from crankshaft journal and crankshaft bearing. (2) Install the crankshaft. (3) Cut the plastic gauge to the same length as the width of bearing and place it on journal in parallel with its axis. 6AE0101 (4) Install the crankshaft bearing cap carefully and tighten the bolts to specified torque. (5) Carefully remove the crankshaft bearing cap. (6) Measure the width of the plastic gauge at its widest part by using a scale printed on the plastic gauge package. Standard value: 0.02 - 0.04 mm Limit: 0.1 mm 6AE0102 E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 6A1 ENGINE (E - W) A C D B E Crankshaft, Cylinder Block, Flywheel and Drive Plate 11A-15-5 CYLINDER BLOCK (1) Using a straightedge and feeler gauge, check the block top surface for warpage. Make sure that the surface is free from gasket chips and other foreign matter. F G Standard value: 0.05 mm or less Limit: 0.1 mm (2) If the distortion is excessive, correct within the allowable limit or replace. 6AE0103 Grinding limit: 0.2 mm The total thickness of the stock allowed to be removed from cylinder block and mating cylinder head is 0.2 mm at maximum. Cylinder block height (when new): 6A12 190 mm 6A13 209 mm (3) Check cylinder walls for scratches and seizure. If defects are evident, correct (bored to oversize) or replace. (4) Using cylinder gauge, measure the cylinder bore and cylindricity. If worn badly, correct cylinder to an oversize and replace piston and piston rings. Measure at the points shown in illustration. 12 mm 6AE0104 Standard value: Cylinder I.D.: 6A12 78.40 - 78.43 mm 6A13 81.00 - 81.03 mm Out-of-roundness and taper of cylinder bore: 0.01 mm or less BORING CYLINDER (1) Oversize pistons to be used should be determined on the basis of the largest bore cylinder. Piston size identification 6AE0105 Size Identification mark 0.50 mm O.S. 0.50 1.00 mm O.S. 1.00 NOTE Size mark is stamped on piston top. (2) Measure outside diameter of piston to be used. Measure it in thrust direction as shown. (3) Based on measured piston O.D. calculate boring finish dimension. Boring finish dimension = Piston O.D. + (Clearance between piston O.D. and cylinder) - 0.02 mm (honing margin) E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 11A-15-6 6A1 ENGINE (E - W) - Crankshaft, Cylinder Block, Flywheel and Drive Plate (4) Bore all cylinders to calculated boring finish dimension. Caution D To prevent distortion that may result from temperature rise during honing, bore cylinders, working from No. 1, No. 2, No. 3, No. 4, No. 5 and No. 6 (5) Hone to final finish dimension (piston O.D. + clearance between piston O.D. and cylinder.) (6) Check clearance between piston and cylinder. Clearance between piston and cylinder: 0.02 - 0.04 mm NOTE When boring cylinders, finish all of four cylinders to same oversize. Do not bore only one cylinder to an oversize. E Mitsubishi Motors Corporation Feb. 1997 PWEE9622 NOTES Service Bulletins Click on the applicable bookmark to select the Service Bulletin. SERVICE BULLETIN QUALITY INFORMATION ANALYSIS OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION SERVICE BULLETIN Subject: Group: No.: MSB-01E11-001 Date: 2001-07-25 ADDITION OF 6A1 ENGINE WATER PUMP INSTALLATION PROCEDURES ENGINE Draft No.: 00EN620614 INFORMATION INTERNATIONAL CAR ADMINISTRATION OFFICE (EC)GALANT(EA0) 01-10 T.MASAKI-MANAGER TECHNICAL SERVICE PLANNING 1. Description: It has been found that when the 6A1 engine is installed, the water pump impeller interferes with the cylinder block. Therefore, the procedures for positioning the water pump that are to be followed when the water pump is installed, have been introduced. 2. Applicable Manuals: Manual ENGINE 6A1 (W-E) Workshop Manual ENGINE 6A1 (E-W) Workshop Manual Pub. No. PWEE9202 PWES9203 PWEF9204 PWEG9205 PWED9206 PWEW9207 PWEE9622 PWES9623 PWEF9624 PWEG9625 PWED9626 PWEW9627 Language Page(s) (English) 11A-7-2 (Spanish) (French) (German) (Dutch) (Swedish) (English) 11A-7-3 (Spanish) (French) (German) (Dutch) (Swedish) ENGINE 6A1 (E-W) Workshop Manual 6A1 ENGINE (E-W) – Water Pump and Water Pipe 11A-7-3 INSTALLATION SERVICE POINTS 3 mm diameter bead sealant ►A◄ SEALANT APPLICATION TO WATER PUMP Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent 4th page added here. 6AE0067 ►B◄ WATER PIPE / O-RING INSTALLATION (1) Wet the O-ring (with water) to facilitate assembly. Caution • Keep the O-ring free of oil or grease. • Secure the water pipe after the thermostat housing has been installed. ►C◄ SEALANT APPLICATION TO WATER OUTLET FITTING 3 mm diameter bead sealant Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent 6AE0068 ►D◄THERMOSTAT INSTALLATION (1) Install the thermostat so that the jiggle valve will be located in the thermostat housing as shown. Jiggle valve 6AE0069 ►E◄SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE SENSOR Specified sealant: 3M Nut locking Part No. 4171 or equivalent 6AE0070 3 (1) Install the water pump and tighten the bolts 1 and 2 in that order. (2) Turn the pulley by hand and ensure that the impeller does not interfere with the cylinder block. (3) Tighten the bolts other than bolts 1 and 2. Water pump 6AE0415 4
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