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

Open the PDF directly: View PDF .
Page Count: 83

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 <SOHC> 11A-9-1

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

10.ROCKER COVER AND CAMSHAFT <MIVEC> 11A-10-1

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

11. ROCKER ARM AND ROCKER SHAFT CAP <MIVEC> 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

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

11A-0-1

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

ENGINE

6A1 SERIES

CONTENTS

11A-0-2

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

NOTES

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 dm31,998 2,498

Cylinder bore mm 78.4 81.0

Piston stroke mm 69.0 80.8

Compression ratio 10.0 9.5*1or 9.0*2

Valve timing Intake

valve

Opens

(BTDC)

15°(Low-speed cam)

37.5°(High-speed cam)

15°

Closes

(ABDC)

41°(Low-speed cam)

82.5°(High-speed cam)

53°

Exhaust

valve

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

NOTE

*1: Europe and Hong Kong

*2: GCC and Export

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Specifications 11A-1-1

1. SPECIFICATIONS

SERVICE SPECIFICATIONS

Items Standard value Limit

Timing belt

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 -

Rocker arm and camshaft <SOHC>

Camshaft cam height mm Intake 35.20 34.70

Exhaust 34.70 34.20

Camshaft journal diameter mm 45 -

Rocker cover and camshaft <MIVEC>

Camshaft cam height mm Intake (Low-speed cam) 34.34 33.84

(High-speed cam) 36.46 35.96

Exhaust (Low-speed cam) 34.40 33.90

(High-speed cam) 35.86 35.36

Camshaft journal diameter mm 26 -

Valve clearance mm Intake 0.10 -

Exhaust 0.13 -

Cylinder head and valve

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 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

Valve stem diameter mm 6.0 -

Valve stem-to-guide clearance Intake 0.02 - 0.05 0.10

Exhaust 0.04 - 0.07 0.15

Valve face angle 45°- 45.5°-

Valve stem projection mm SOHC 48.45 48.95

MIVEC 48.40 48.90

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Specifications

11A-1-2

Items LimitStandard value

Overall valve length mm Intake SOHC 113.02 112.52

MIVEC 112.37 111.87

Exhaust SOHC 115.32 114.82

MIVEC 110.74 110.74

Valve spring free height mm SOHC 49.9 48.9

MIVEC 51.5 50.5

Valve spring load/installed SOHC 265/43.4 -

height N/mm

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 case and oil pan

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

Piston and connecting rod

Piston outside diameter mm 6A12 78.4 -

6A13 81.0 -

Piston ring side clearance mm No.1 ring 0.02 - 0.06 -

No.2 ring 0.02 - 0.06 -

Piston ring end gap mm 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

Crankshaft, cylinder block, flywheel and drive plate

Crankshaft end play mm 0.05 - 0.25 0.4

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Specifications 11A-1-3

Items LimitStandard value

Crankshaft journal diameter 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 6A12 190.0 -

6A13 209.0 -

Cylinder block cylindricity mm 0.01 or less -

Cylinder block internal diame- 6A12 78.4 -

ter mm

6A13 81.0 -

Bearing cap bolt nominal length mm - 71.1

Piston-to-cylinder clearance mm 0.02 - 0.04 -

REWORK DIMENSIONS

Item Standard

Cylinder head and valves

Cylinder head oversize valve guide hole diameter mm 0.05 O.S. 11.05 - 11.07

0.25 O.S. 11.25 - 11.27

0.50 O.S. 11.50 - 11.52

Oversize intake valve seat SOHC 0.3 O.S. 29.80 - 29.82

ring hole diameter mm

0.6 O.S. 30.10 - 30.12

MIVEC 0.3 O.S. 32.30 - 32.32

0.6 O.S. 32.60 - 32.62

Oversize exhaust valve SOHC 0.3 O.S. 27.80 - 27.82

seat ring diameter mm

0.6 O.S. 28.10 - 28.12

MIVEC 0.3 O.S. 29.80 - 29.82

0.6 O.S. 30.10 - 30.12

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Specifications

11A-1-4

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

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Specifications 11A-1-5

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 <SOHC>

Rocker cover 4

Rocker arm and rocker shaft 31

Thrust case 24

Rocker arm and camshaft <MIVEC>

Rocker cover 4

Oil control valve holder 9

Cam cap 24

Bearing cap M6 11

Bearing cap M8 24

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Specifications

11A-1-6

Items Nm

Arm spring holder 11

Rocker arm and rocker shaft cap <MIVEC>

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°

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

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.

DAreas where the bolts are in use:

(1) Cylinder head bolts

(2) Main bearing cap bolts

(3) Connecting rod cap bolts

DTightening 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)

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Specifications

11A-1-8

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.

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Special Tools 11A-2-1

2. SPECIAL TOOLS

Tool 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)

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Special Tools

11A-2-2

Tool UseNameNumber

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

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Special Tools 11A-2-3

Tool UseNameNumber

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

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Special Tools

11A-2-4

Tool UseNameNumber

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)

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Drive Belt 11A-3-1

3. DRIVE BELT

REMOVAL AND INSTALLATION <SOHC>

12 13 14

21 Nm

15 Nm

23 Nm

3Nm

23 Nm

44 Nm

182 Nm

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

9. Tensioner pulley bracket B

10. Adjusting stud

11. Adjusting bolt

AA""

AA12. Crankshaft bolt

13. Special washer

14. Crankshaft pulley

15. Flange

16. Engine cover

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Drive Belt

11A-3-2

REMOVAL AND INSTALLATION <MIVEC>

14 15

21 Nm

15 Nm

23 Nm

44 Nm

23 Nm

44 Nm

3Nm

44 Nm

182 Nm

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

9. Tensioner pulley bracket B

10. Adjusting stud

11. Adjusting bolt

AA""

AA12. Crankshaft bolt

13. Special washer

14. Crankshaft pulley

15. Flange

16. Engine cover

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

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

"AACRANKSHAFT PULLEY BOLT INSTALLATION

(1) Hold the flywheel or drive plate in position with the special

tool before installing the crankshaft pulley bolts.

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0039

MD998781

6A1 ENGINE (E-W) - Timing Belt 11A-4-1

4. TIMING BELT

REMOVAL AND INSTALLATION <SOHC>

11 12 13

15 16

11 Nm

21 Nm

9Nm

48 Nm

24 Nm

49 Nm

35 Nm

88 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""

CA6. Timing belt

7. Tensioner pulley

8. Tensioner arm

9. Tensioner spacer

"BA10. Auto tensioner

11. Crankshaft sprocket

12. Sensing plate

13. Crankshaft spacer

AB""

AA14. Camshaft sprocket bolt

15. Camshaft sprocket

16. Idler pulley

17. Timing belt rear cover, center

18. Connector bracket

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Timing Belt

11A-4-2

REMOVAL AND INSTALLATION <MIVEC>

910

12 13 1415

11 Nm

12 Nm

9Nm

48 Nm

44 Nm

49 Nm

35 Nm

88 Nm 17

11 Nm

22 Nm

9Nm

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""

DA8. Timing belt

9. Tensioner pulley

10. Tensioner arm

11. Tensioner spacer

"BA12. Auto tensioner

13. Crankshaft sprocket

14. Sensing plate

15. Washer

AB""

AA16. Camshaft sprocket bolt

17. Camshaft sprocket

18. Camshaft sprocket with sensing

plate

19. Idler pulley

20. Timing belt rear cover, left

21. Timing belt rear cover, right

22. Timing belt rear cover, center

23. Connector bracket

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

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.

AB"CAMSHAFT SPROCKET BOLT REMOVAL

INSTALLATION SERVICE POINTS

"AACAMSHAFT SPROCKET BOLT INSTALLATION

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0135

6AE0044

6AE0137

MB990767

MD998719

6AE0045

MB990767

MD998754

6AE0138

MB990767

MD998719

6A1 ENGINE (E-W) - Timing Belt

11A-4-4

"BAAUTO 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.

(3) Insert a 1.4 mm wire in the set hole.

(4) Remove the auto tensioner from the vice.

"CATIMING 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

DIf 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.

(2) Bring the timing marks of the camshaft sprockets as shown

in the illustration.

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0048

MB990767

MD998754

6AE0049

(A)

(B)

6AE0050

6AE0329

6AE0358

Timing mark

6A1 ENGINE (E-W) - Timing Belt 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

DThe 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.

(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.

(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.

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0331

6AE0143

6AE0057

6AE0058

MD998767

MB990685

6A1 ENGINE (E-W) - Timing Belt

11A-4-6

"DATIMING 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

DIf 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.

(2) Bring the timing marks of the camshaft sprockets as shown

in the illustration.

Caution

DIf 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.

(3) Align the timing mark on the crankshaft sprocket with

the mating timing mark, and then turn the crankshaft

counterclockwise by one tooth.

(4) Place the timing belt over the sprockets in the following

method.

Caution

DThe 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.

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

DThe camshaft sprockets can turn easily and

do not give excessive tension to the timing

belt.

3) Place the timing belt around the idler pulley.

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0051

MD998716

6AE0311

6AE0053

6AE0054

Paper clip

6AE0055

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.

(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.

(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.

(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

(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.

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0056

6AE0057

6AE0058

MD998767

MB990685

6AE0059

8EN0066

6A1 ENGINE (E-W) - Timing Belt

11A-4-8

(2) Cracks on rubber back.

(3) Cracks or peeling of canvas.

(4) Cracks on tooth bottom.

(5) Cracks or belt sides.

(6) Abnormal wear of belt sides. The sides are normal if

they are sharp as if cut by a knife.

(7) Abnormal wear on teeth.

(8) Missing tooth.

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.

Standard value “L”: 12 mm

(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.

Standard value: 1 mm or less

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

1EN0249

Cracks

Peeling

8EN0067

Rounded edge

Abnormal wear

(Fluffy strand)

8EN0068

Rubber exposed

Tooth missing

and canvas

fiber exposed

6AE0046

“L”

6EN1033

98 - 196 N

Stroke

6A1 ENGINE (E-W) - Fuel and Emission Control Parts 11A-5-1

5. FUEL AND EMISSION CONTROL PARTS

REMOVAL AND INSTALLATION <SOHC>

345

17 18

18 Nm

9Nm

22 Nm

23 Nm

12 Nm

18 Nm

9Nm

12 Nm

18 Nm

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

"CA7. Gasket

8. Air intake plenum

9. Gasket

10. Control harness

11. Delivery pipe and injector

12. Insulator

13. Insulator

"BA14. Injector

15. Grommet

16. O-ring

17. Fuel pipe

18. O-ring

"AA19. Fuel pressure regulator

20. O-ring

21. Delivery pipe

22. Alternator bracket

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Fuel and Emission Control Parts

11A-5-2

REMOVAL AND INSTALLATION <MIVEC>

18 Nm

23 Nm

12 Nm

14 Nm

9Nm

18 Nm

11 12 Nm

11 Nm

18 Nm

8.8 Nm

18 Nm

Removal steps

1. Air intake plenum stay, front

2. Air intake plenum stay, rear

3. Vacuum pipe

4. Throttle body

"CA5. 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

14. Control harness

15. Delivery pipe and injector

16. Insulator

17. Insulator

"BA18. Injector

19. Grommet

20. O-ring

21. Fuel pipe

22. O-ring

"AA23. Fuel pressure regulator

24. O-ring

25. Delivery pipe

26. Alternator bracket

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Fuel and Emission Control Parts 11A-5-3

INSTALLATION SERVICE POINTS

"AAFUEL 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.

Caution

DIf 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.

"BAINJECTOR 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.

Caution

DIf 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.

"CAGASKET INSTALLATION

(1) Locate the projection on the gasket as shown.

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0061

6AE0062

6AE0277

Projection

6A1 ENGINE (E-W) - Ignition System 11A-6-1

6. IGNITION SYSTEM

REMOVAL AND INSTALLATION <SOHC>

25 Nm

11 Nm

13 Nm

Removal steps

1. Spark plug cable

2. Spark plug

3. Water cover

"AA4. Distributor

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Ignition System

11A-6-2

REMOVAL AND INSTALLATION <MIVEC>

25 Nm

1.0 Nm

Removal steps

1. Spark plug cable

2. Ignition coil

3. Spark plug

INSTALLATION SERVICE POINT

"AADISTRIBUTOR 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.

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0151

Alignment mark

6A1 ENGINE (E-W) - Water Pump and Water Pipe 11A-7-1

7. WATER PUMP AND WATER PIPE

REMOVAL AND INSTALLATION <SOHC>

1112

13 Nm

18 Nm

23 Nm

29 Nm

11 Nm

23 Nm

18 Nm

Removal steps

"FA1. Engine coolant temperature gauge

unit

"EA2. Engine coolant temperature sensor

3. Water hose

4. Water hose

5. Heater pipe

6. O-ring

7. Water inlet fitting

"DA8. Thermostat

"CA9. Water outlet fitting

10. Thermostat housing

11. Gasket

"BA12. O-ring

"BA13. Water pipe

"BA14. O-ring

"AA15. Water pump

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Water Pump and Water Pipe

11A-7-2

REMOVAL AND INSTALLATION <MIVEC>

13 Nm

18 Nm

23 Nm

29 Nm

18 Nm

11 Nm

23 Nm

Removal steps

1. Engine hanger

"FA2. Engine coolant temperature gauge

unit

"EA3. Engine coolant temperature sensor

4. Water hose

5. Water hose

6. Water inlet fitting

"DA7. Thermostat

"CA8. Water outlet fitting

9. Thermostat housing

10. Gasket

"BA11. O-ring

"BA12. Water pipe

"BA13. O-ring

"AA14. Water pump

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Water Pump and Water Pipe 11A-7-3

INSTALLATION SERVICE POINTS

"AASEALANT APPLICATION TO WATER PUMP

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or

equivalent

"BAWATER PIPE / O-RING INSTALLATION

(1) Wet the O-ring (with water) to facilitate assembly.

Caution

DKeep the O-ring free of oil or grease.

DSecure the water pipe after the thermostat housing

has been installed.

"CASEALANT APPLICATION TO WATER OUTLET

FITTING

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or

equivalent

"DATHERMOSTAT INSTALLATION

(1) Install the thermostat so that the jiggle valve will be located

in the thermostat housing as shown.

"EASEALANT APPLICATION TO ENGINE COOLANT

TEMPERATURE SENSOR

Specified sealant:

3M Nut locking Part No. 4171 or equivalent

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0067

3mm

diameter

bead sealant

6AE0068

3mm

diameter

bead sealant

6AE0069

Jiggle valve

6AE0070

6A1 ENGINE (E-W) - Water Pump and Water Pipe

11A-7-4

"FASEALANT APPLICATION TO ENGINE COOLANT

TEMPERATURE GAUGE UNIT

Specified sealant:

3M ATD Part No. 8660 or equivalent

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0071

6A1 ENGINE (E-W) - Intake Manifold and Exhaust Manifold 11A-8-1

8. INTAKE MANIFOLD AND EXHAUST MANIFOLD

REMOVAL AND INSTALLATION <SOHC>

13 Nm

17 Nm

44 Nm

49 Nm

13 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

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Intake Manifold and Exhaust Manifold

11A-8-2

REMOVAL AND INSTALLATION <MIVEC>

13 Nm

17 Nm

44 Nm

49 Nm

13 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

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Rocker Arm and Camshaft <SOHC> 11A-9-1

9. ROCKER ARM AND CAMSHAFT <SOHC>

REMOVAL AND INSTALLATION

Apply engine oil to all

moving parts before

installation.

14 15

4Nm

24 Nm

31 Nm

Removal steps

1. Rocker cover

2. Rocker cover gasket

3. Oil seal

"DA4. Oil seal

AA""

CA5. Rocker arm and rocker shaft

AA""

CA6. Rocker arm and rocker shaft

"CA7. Rocker shaft spring

8. Rocker arm A

9. Rocker arm B

10. Rocker arm shaft

"BA11. Lash adjuster

12. Rocker arm C

13. Rocker arm shaft

"BA14. Lash adjuster

15. Thrust case

16. O-ring

"AA17. Camshaft

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Rocker Arm and Camshaft <SOHC>

11A-9-2

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.

INSTALLATION SERVICE POINTS

"AACAMSHAFT 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.

"BALASH 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.

(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.

"CAROCKER 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.

NOTE

Install the rocker shaft spring before installing the exhaust

side rocker arms and rocker arm shaft.

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0160

MD998443

6AE0180

For right bank

For left bank

6EN0421

Diesel

fuel

MD998442

6AE0161

Lash adjuster

MD998443

6AE0162

6A1 ENGINE (E-W) - Rocker Arm and Camshaft <SOHC> 11A-9-3

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.

"DACAMSHAFT OIL SEAL INSTALLATION

(1) When installing the left bank camshaft oil seal, use the

special tool to prevent interference with the knock pin.

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

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

Limit:

34.70 mm Intake side

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

34.41 mm Exhaust side

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

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0163

6AE0164

Right bank

MD998713

6AE0181

MD998713

Left bank

MD998777

9EN0058

6A1 ENGINE (E-W) - Rocker Arm and Camshaft <SOHC>

11A-9-4

LASH ADJUSTER LEAK DOWN TEST

Caution

DThe lash adjuster is a precision part. Keep it free

from dust and other foreign matters.

DDo not disassemble lash adjuster.

DWhen cleaning lash adjuster, use clean diesel fuel

only.

(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

DUpon completion of air bleeding, hold lash

adjuster upright to prevent inside diesel fuel from

spilling.

(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.

Standard value: 4 - 20 seconds/1 mm

(Diesel fuel at 15 - 20°C)

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6EN0186

MD998442

Diesel fuel

MD998441

6EN0187

Graduations = 1 mm

MD998440

Lash adjuster

6A1 ENGINE (E-W) - Rocker Cover and Camshaft <MIVEC> 11A-10-1

10. ROCKER COVER AND CAMSHAFT <MIVEC>

REMOVAL AND INSTALLATION

Apply engine oil to all

moving parts before

installation.

4Nm

24 Nm

11 Nm

24 Nm

24 Nm 9Nm

Removal steps

"GA1. Rocker cover

2. Rocker cover gasket

3. Oil seal

"FA4. Circuit packing

"EA5. Oil seal

"DA6. Camshaft holder

"DA7. Semi-circular packing

"CA8. Oil control valve

"BA9. Cam cap

10. Oil control valve holder

"BA11. Camshaft bearing cap

12. Arm spring holder

13. Arm spring

"AA14. Camshaft

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Rocker Cover and Camshaft <MIVEC>

11A-10-2

INSTALLATION SERVICE POINT

"AACAMSHAFT 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

(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.

"BACAMSHAFT 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

(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.

6AE0308

Intake

Exhaust

Cap No.

Front mark

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0229

Left bank

camshaft

Right bank

camshaft

6AE0230

Right

bank

Dowel pin

Left

bank

Dowel pin

EXIN

6AE0233

6A1 ENGINE (E-W) - Rocker Cover and Camshaft <MIVEC> 11A-10-3

"CAOIL CONTROL VALVE INSTALLATION

(1) Apply the specified sealant to the area shown.

Specified sealant:

3M ATD Part No. 8660 or equivalent

"DASEMI-CIRCULAR PACKING / CAMSHAFT

HOLDER INSTALLATION

(1) Make sure that the retainer of each adjusting screw is

fitted correctly.

Caution

DIf the protrusion on the retainer is not correctly

fitted in the groove of the screw, the pad could

slip off the retainer.

(2) Apply 3 mm thick bead of foam-in-place gasket (FIPG)

to the gasket surface of the camshaft holder.

Caution

DSince the FIPG could cause blocking of engine

oil passages, be careful not to apply FIPG to other

locations than specified.

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or

equivalent

(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.

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0236

6AE0237

Protrusion

Groove

Screw

Retainer

Pad

6AE0238

6AE0239

106248

7 3 1 5 9

6A1 ENGINE (E-W) - Rocker Cover and Camshaft <MIVEC>

11A-10-4

"EACAMSHAFT OIL SEAL INSTALLATION

(1) When installing the left bank camshaft oil seal, use the

special tool to prevent interference with the knock pin.

"FACIRCULAR PACKING INSTALLATION

"GAROCKER COVER INSTALLATION

(1) Apply the specified sealant to the area shown.

Specified sealant:

3M ATD Part No. 8660 or equivalent

INSPECTION

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.

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0306

Right bank

MD998713

6AE0307

Left bank

MD998713

MD998777

6AE0241

MD998713

6AE0242

Sealant application

areas

10 mm

6AE0206

6A1 ENGINE (E-W) - Rocker Cover and Camshaft <MIVEC> 11A-10-5

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 Standard value Limit

IN (3) L 34.34 mm 33.84 mm

H36.46 mm 35.96 mm

EX (C) L 34.40 mm 33.90 mm

H35.86 mm 35.36 mm

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.

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).

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0227

Valve

9N0058

21 mm

16 mm

6AE0228

High-speed cam (H)

Identification

mark location Low-speed

cam (L)

6AE0285

Thickness gauge

MB991477

6A1 ENGINE (E-W) - Rocker Cover and Camshaft <MIVEC>

11A-10-6

(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

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0286

Piston

MB991479

6A1 ENGINE (E-W) - Rocker Arm and Rocker Shaft Cap <MIVEC> 11A-11-1

11. ROCKER ARM AND ROCKER SHAFT CAP <MIVEC>

REMOVAL AND INSTALLATION

Apply engine oil to all

moving parts before

installation.

10 11

16 17

11 Nm

22 20

Removal steps

"BA1. 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

"AA11. Spring guide

12. Wave washer

13. Exhaust rocker arm assembly A

14. Nut

15. Adjusting screw

16. Exhaust rocker arm H

17. Piston H

18. Piston spring H

19. Exhaust T-lever L

"AA20. Spring guide

21. Wave washer

22. Camshaft holder

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Rocker Arm and Rocker Shaft Cap <MIVEC>

11A-11-2

INSTALLATION SERVICE POINTS

"AASPRING 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.

"BAROCKER SHAFT CAP INSTALLATION

(1) Tighten the bolts in the sequence shown.

(2) Make sure that each rocker arm moves smoothly.

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0247

Spring guide

Waved washer

T-lever

Either side may be out

Concave

side

6AE0249

6A1 ENGINE (E-W) - Cylinder Head and Valves 11A-12-1

12. CYLINDER HEAD AND VALVES

REMOVAL AND INSTALLATION <SOHC>

Apply engine oil to all

moving parts before

installation.

12 13

Removal steps

AA""

DA1. Cylinder head bolt

2. Cylinder head

3. Cylinder head gasket

AB""

CA4. Retainer lock

5. Valve spring retainer

"BA6. Valve spring

7. Intake valve

AB""

CA8. Retainer lock

9. Valve spring retainer

"BA10. Valve spring

11. Exhaust valve

AC""

AA12. Valve stem seal

13. Valve spring seat

AC""

AA14. 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

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Cylinder Head and Valves

11A-12-2

REMOVAL AND INSTALLATION <MIVEC>

Apply engine oil to all

moving parts before

installation.

15 16

Removal steps

AA""

DA1. Cylinder head bolt

2. Cylinder head

3. Cylinder head gasket

AB""

CA4. Retainer lock

5. Valve spring retainer

"BA6. Valve spring

7. Intake valve

AB""

CA8. Retainer lock

9. Valve spring retainer

"BA10. Valve spring

AD"11. Exhaust valve

AC""

AA12. Valve stem seal

13. Valve spring seat

AC""

AA14. 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

EFeb. 1997Mitsubishi Motors Corporation

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.

AA"CYLINDER HEAD BOLT REMOVAL

(1) Using the special tool, loosen the cylinder head bolts.

Loosen evenly, little by little.

AB"RETAINER LOCK REMOVAL

(1) Store removed valves, springs and other parts, tagged

to indicate their cylinder Nos. and location for reassembly.

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0166

<SOHC>

MB991653

6AE0408

<MIVEC>

MB991653

6AE0167

<SOHC>

MD998772

6AE0253

<MIVEC>

MD998784

MD998772

6EN1068

MD998735

6A1 ENGINE (E-W) - Cylinder Head and Valves

11A-12-4

AC"VALVE STEM SEAL REMOVAL

(1) Do not reuse removed valve stem seals.

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.

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0082

6A1 ENGINE (E-W) - Cylinder Head and Valves 11A-12-5

INSTALLATION SERVICE POINTS

"AAVALVE 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

DDo not reuse the valve stem seal.

DAlways 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.

"BAVALVE SPRING INSTALLATION

(1) Install the valve spring with the painted end on the rocker

arm side.

"CARETAINER 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.

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

7EN0763

Stem seals for intake

valves: Silver

Stem seals

for exhaust

valves: Black

6AE0169

<SOHC>

MD998774

6AE0409

<MIVEC> MD998775

6EN0437

Painted

end

Spring

retainer

Stem seal

Spring

seat

6AE0167

<SOHC>

MD998772

6A1 ENGINE (E-W) - Cylinder Head and Valves

11A-12-6

"DACYLINDER 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.

(4) Retighten the loosened bolts to a torque of 20 Nm in

the specified tightening sequence.

(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

DIf the bolts are tightened by an angle of less than

120°, they may not hold the cylinder head with

sufficient strength.

DIf a bolt is overtightened, completely remove all

the bolts and carry out the installation procedure

again from step (1).

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0253

MD998784

<MIVEC>

MD998772

6EN1068

MD998735

9EN0251

Length of shank

6AE0392

6AE0339

120°

MB991614

6A1 ENGINE (E-W) - Cylinder Head and Valves 11A-12-7

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.

Grinding limit: *0.2 mm

*Includes/combined with cylinder block grinding

Cylinder head height (Specification when new):

119.9 - 120.1 mm <SOHC>

119.6 - 119.8 mm <MIVEC>

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.

Standard value

Limit mm

Intake SOHC 113.02 112.52

MIVEC 112.37 111.87

Exhaust SOHC 115.32 114.82

MIVEC 110.74 110.74

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0083

6EN0542

Valve seat

contact Margin

6A1 ENGINE (E-W) - Cylinder Head and Valves

11A-12-8

VALVE SPRING

(1) Measure the valve spring’s free height. If the measurement

is less than specified, replace the spring.

Standard 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 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 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.

Standard value:

Intake: 0.02 - 0.05 mm

Exhaust: 0.04 - 0.07 mm

Limit:

Intake: 0.10 mm

Exhaust: 0.15 mm

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

1EN0264

Out of square

Free

height

DEN0212

Valve stem end

Valve stem

projection

Spring seating

surface

1EN0279

Valve

guide

6A1 ENGINE (E-W) - Cylinder Head and Valves 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.

Intake valve seat hole diameter

0.3 O.S. <SOHC>: 29.80 - 29.82 mm

<MIVEC>: 32.30 - 32.32 mm

0.6 O.S. <SOHC>: 30.10 - 30.12 mm

<MIVEC>: 32.60 - 32.62 mm

Exhaust valve seat hole diameter

0.3 O.S. <SOHC>: 27.80 - 27.82 mm

<MIVEC>: 29.80 - 29.82 mm

0.6 O.S. <SOHC>: 28.10 - 28.12 mm

<MIVEC>: 30.10 - 30.12 mm

(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

DDo not use the valve guide of the same size as

the removed one.

Valve guide hole diameters in cylinder head

0.05 O.S.: 11.05 - 11.07 mm

0.25 O.S.: 11.25 - 11.27 mm

0.50 O.S.: 11.50 - 11.52 mm

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

1EN0105

0.9 - 1.3 mm

65_

44_44_

15_

1EN0274

0.5 - 1.0 mm

Cut away

0.5 - 1.0 mm

1EN0275

Valve seat

height

Oversize valve seat

hole diameter

6A1 ENGINE (E-W) - Cylinder Head and Valves

11A-12-10

(3) Press-fit the valve guide until it protrude specified value

(SOHC: 14 mm, DOHC: 19 mm) as shown in the

illustration.

Caution

DPress the valve guide from the cylinder head top

surface.

DValve 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)

(4) After the valve guide has been installed, insert a new

valve to check for smooth sliding motion.

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

1EN0106

14 mm

<SOHC>

6AE0254

<DOHC>

19 mm 19 mm

6A1 ENGINE (E-W) - Oil Pump Case and Oil Pan 11A-13-1

13. OIL PUMP CASE AND OIL PAN

REMOVAL AND INSTALLATION <SOHC>

Apply engine oil to all

moving parts before

installation.

19 Nm

44 Nm

10 Nm

9Nm

7Nm

9Nm

39 Nm

21 Nm

68 Nm

14 Nm

12 Nm

30 Nm

Removal steps

"IA1. Oil pressure switch

"HA2. 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)

"GA8. Oil cooler (for Europe and GCC)

9. Drain plug

"FA10. Gasket

11. Oil level sensor (For Europe)

12. Cover

"DA13. Oil pan lower

"DA14. Oil pan upper

15. Buffle plate

16. Oil screen

17. Gasket

18. Relief plug

19. Relief spring

20. Relief plunger

"CA21. Oil seal

"BA22. Oil pump case

23. O-ring

24. Oil pump case cover

"AA25. Outer rotor

"AA26. Inner rotor

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Oil Pump Case and Oil Pan

11A-13-2

REMOVAL AND INSTALLATION <MIVEC>

Apply engine oil to all

moving parts before

installation.

15 16

19 Nm

39 Nm

21 Nm

44 Nm

7Nm

10 Nm

14 Nm

12 Nm

Removal steps

"IA1. Oil pressure switch

"HA2. Oil filter

3. Oil filter cover

4. Drain plug

"FA5. Gasket

AA""

EA6. Oil pan

7. Oil screen

8. Gasket

9. Buffle plate

10. Relief plug

11. Relief spring

12. Relief plunger

"CA13. Oil seal

"BA14. Oil pump case

15. O-ring

16. Oil pump case cover

"AA17. Outer rotor

"AA18. Inner rotor

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Oil Pump Case and Oil Pan 11A-13-3

REMOVAL SERVICE POINT

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.

INSTALLATION SERVICE POINTS

"AAINNER 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.

"BASEALANT APPLICATION TO OIL PUMP CASE

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or

equivalent

"CAOIL SEAL INSTALLATION

(1) Apply engine oil to the oil seal lip.

Using the special tool, knock the oil seal into the oil pump

case.

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0087

MD998727

6AE0091

6AE0092

3 mm diameter

bead sealant

6AE0093

MD998717

6A1 ENGINE (E-W) - Oil Pump Case and Oil Pan

11A-13-4

"DAOIL PAN INSTALLATION <SOHC>

(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 Part No. MD970389 or

equivalent

Bolt

hole

Groove

"EAOIL PAN INSTALLATION <MIVEC>

(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 Part No. MD970389 or

equivalent

"FADRAIN PLUG GASKET INSTALLATION

(1) Install the drain plug gasket in the shown direction.

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0094

4 mm diameter

bead sealant

7EN0307

Oil pan

side

Drain plug

gasket

6A1 ENGINE (E-W) - Oil Pump Case and Oil Pan 11A-13-5

"GAOIL COOLER INSTALLATION

(1) Install the oil cooler, with the oil cooler’s positioning

projection positioned against the rib on cylinder block.

"HAOIL 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.

"IASEALANT 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

DUse care not to allow the sealant to plug the oil

passage.

INSPECTION

OIL PUMP

(1) Check the tip clearance.

Standard value: 0.06 - 0.18 mm

(2) Check the side clearance.

Standard value: 0.04 - 0.10 mm

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0172

9EN0094

Oil passage

6AE0088

6AE0089

6A1 ENGINE (E-W) - Oil Pump Case and Oil Pan

11A-13-6

(3) Check the body clearance.

Standard value: 0.10 - 0.18 mm

Limit: 0.35 mm

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

Float position Switch ON/OFF

Condition when down ON (continuity)

Condition when up ON (continuity)

80°C

Float position Switch ON/OFF

Condition when down OFF (no continuity)

Condition when up ON (continuity)

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0090

6AE0192

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

Removal steps

"GA1. Nut

AA""

FA2. Connecting rod cap

"EA3. Connecting rod bearing

"DA4. Piston and connecting rod

"EA5. Connecting rod bearing

"CA6. Piston ring No.1

"CA7. Piston ring No.2

"BA8. Oil ring

AB""

AA9. Piston pin

10. Piston

11. Connecting rod

12. Bolt

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Piston and Connecting Rod

11A-14-2

REMOVAL SERVICE POINTS

AA"CONNECTING ROD CAP REMOVAL

(1) Mark the large end of the connecting rod with the cylinder

number for use during reassembly.

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.

(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.

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

DEN0050

Cylinder No.

9EN0780

Piston pin setting tool MD998780

Push rod

Guide B

Guide C

Base

Guide A:

17.9 mm

Guide A:

18.9 mm

Guide A:

20.9 mm

Guide A:

21.9 mm

Guide D

MB991659

7EN0390

Push rod

Front mark

Front

mark

Guide D

Base

6A1 ENGINE (E-W) - Piston and Connecting Rod 11A-14-3

INSTALLATION SERVICE POINTS

"AAPISTON 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)

(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.

(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.

(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.

Standard value: 5,000 - 15,000 N

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

7EN0432

Piston

Piston pin

Connecting rod

7EN0433

3mm+L

Guide B

Guide A

7EN0391

Push rod

Piston pin

Front mark

Front

mark

Guide A

Base

Guide B

6A1 ENGINE (E-W) - Piston and Connecting Rod

11A-14-4

"BAOIL 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.

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.

(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.

"CAPISTON 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.

Identification mark:

No. 1 ring: T

No. 2 ring: 2T

NOTE

The piston ring is stamped with the following size mark.

Size Size mark

Standard size None

0.50 mm O.S. 50

1.00 mm O.S. 100

"DAPISTON 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.

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0194

1EN0269

Side rail gap

7EN0452

Piston ring expander

9EN0524

Size mark

Identification mark

No.1

No.2

6EN0549

Upper

side rail No. 1

No. 2 ring gap

and spacer gap

Lower

side rail

Piston pin

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

DInsert the front mark (arrow) on the top of the

piston so it faces the engine front (timing belt

side).

"EACONNECTING 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>

Crankshaft pin Connecting rod

bearing

Identification mark Outer diameter mm Identification mark

I42.995 - 43.000 1

II 42.985 - 42.995 2

III 42.980 - 42.985 3

<6A13>

Crankshaft pin Connecting rod

bearing

Identification mark Outer diameter mm Identification mark

I50.995 - 51.000 1

II 50.985 - 50.995 2

III 50.980 - 50.985 3

"FACONNECTING 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.

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0097

6AE0341

Crankshaft pin

identification mark

Check

digit

No.1

No.3

No.5

No.2

No.4

No.6

Identification mark

6A1 ENGINE (E-W) - Piston and Connecting Rod

11A-14-6

(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

"GACONNECTING 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.

(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

DIf the nuts are tightened by an angle of less than

90°, they may not hold the caps with sufficient

strength.

DIf a nut is tightened by an angle exceeding 100°,

completely remove all the nuts and carry out the

installation procedure again from step (1).

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

9EN0073

6EN0954

90°- 100°

Paint

marks

Nut

Bolt

Paint

marks

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

Limit:

No. 1 0.1 mm

No. 2 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.

Standard value:

No. 1 0.25 - 0.40 mm

No. 2 0.40 - 0.55 mm

Oil 0.10 - 0.35 mm

Limit:

No. 1, No. 2 0.8 mm

Oil 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

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

7EN0475

7EN0476

Push in

by the piston

Piston ring

Piston

ring gap

1EN0246

Plastic gauge

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

23 Nm

35 Nm

19 18

9Nm

11 Nm

98 Nm

11 Nm

Apply engine oil to all

moving parts before

installation.

Removal steps

1. Detonation sensor

2. Idler pulley bracket <M/T>

"EA3. Flywheel bolt <M/T>

4. Plate <M/T>

5. Adapter plate <M/T>

6. Flexible flywheel <M/T>

7. Adapter plate <M/T>

"EA8. Drive plate bolt <A/T>

9. Adapter plate <A/T>

10. Drive plate <A/T>

11. Rear plate

12. Bell housing cover <MIVEC>

"DA13. Oil seal case

"CA14. Oil seal

"BA15. Bearing cap bolt

"BA16. Bearing cap

"AA17. Crankshaft bearing, lower

18. Crankshaft

"AA19. Thrust bearing

"AA20. 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

EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Crankshaft, Cylinder Block, Flywheel and

Drive Plate

11A-15-2

INSTALLATION SERVICE POINTS

"AACRANKSHAFT BEARING INSTALLATION

(1) When replacing bearing, select a one of proper size

according to the identification marks stamped on both

crankshaft and cylinder block.

<6A12>

Crankshaft Journal Cylinder Block Bearing

Bore

Crankshaft

Bearing

Identi-

fication

mark

Outer diameter

Identifi-

cation

mark

Inner diameter

Identifica-

tion mark

057.000 - 57.006 1

152.994 - 53.000 157.006 - 57.012 2

257.012 - 57.018 3

057.000 - 57.006 2

252.988 - 52.994 157.006 - 57.012 3

257.012 - 57.018 4

057.000 - 57.006 3

352.982 - 52.988 157.006 - 57.012 4

257.012 - 57.018 5

<6A13>

Crankshaft Journal Cylinder Block Bearing

Bore

Crankshaft

Bearing

Identi-

fication

mark

Outer diameter

Identifi-

cation

mark

Inner diameter

Identifica-

tion mark

060.000 - 60.006 1

155.994 - 56.000 160.006 - 60.012 2

260.012 - 60.018 3

060.000 - 60.006 2

255.988 - 55.994 160.006 - 60.012 3

260.012 - 60.018 4

060.000 - 60.006 3

355.982 - 55.988 160.006 - 60.012 4

260.012 - 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.

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0343

Crankshaft journal

identification mark

Check

digit

No.1

No.3

No.2

No.4

6AE0344

Cylinder block

bearing bore

identification

mark

Cylinder bore size

mark (reference)

Timing belt side

No.1No.3

No.2No.4

6AE0116

Oil groove

Identification

mark

Identification

mark

Groove

6A1 ENGINE (E-W) - Crankshaft, Cylinder Block, Flywheel and

Drive Plate 11A-15-3

"BABEARING 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.

Limit: max. 71.1 mm

(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.

(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.

Caution

DIf the bolts are tightened by an angle of less than

90°, they may not hold the cap with sufficient

strength.

DIf 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

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

9EN0477

Shank length

6AE0108

Arrow

6EN0955

Paint marks

90°- 100°

6AE0109

6A1 ENGINE (E-W) - Crankshaft, Cylinder Block, Flywheel and

Drive Plate

11A-15-4

"CAOIL SEAL INSTALLATION

(1) Apply engine oil to oil seal lip.

"DAAPPLICATION OF OIL SEAL CASE

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or

equivalent

"EADRIVE 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

(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.

(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

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

9EN0077

MB990938

MD998776

6AE0110

9EN0102

6AE0101

6AE0102

6A1 ENGINE (E-W) - 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.

Standard value: 0.05 mm or less

Limit: 0.1 mm

(2) If the distortion is excessive, correct within the allowable

limit or replace.

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.

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

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)

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

6AE0103

CDE

6AE0104

12 mm

6AE0105

6A1 ENGINE (E-W) - Crankshaft, Cylinder Block, Flywheel and

Drive Plate

11A-15-6

(4) Bore all cylinders to calculated boring finish dimension.

Caution

DTo 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.

PWEE9622

EFeb. 1997Mitsubishi Motors Corporation

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 No.: MSB-01E11-001

Date: 2001-07-25 <Model> <M/Y>

Subject: ADDITION OF 6A1 ENGINE WATER PUMP

INSTALLATION PROCEDURES

(EC)GALANT(EA0) 01-10

Group: ENGINE Draft No.: 00EN620614

INFORMATION INTERNATIONAL

CAR

ADMINISTRATION

OFFICE 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 Pub. No. Language Page(s)

ENGINE 6A1 (W-E) PWEE9202 (English) 11A-7-2

Workshop Manual PWES9203 (Spanish)

PWEF9204 (French)

PWEG9205 (German)

PWED9206 (Dutch)

PWEW9207 (Swedish)

ENGINE 6A1 (E-W) PWEE9622 (English) 11A-7-3

Workshop Manual PWES9623 (Spanish)

PWEF9624 (French)

PWEG9625 (German)

PWED9626 (Dutch)

PWEW9627 (Swedish)

INSTALLATION SERVICE POINTS

SEALANT APPLICATION TO WATER PUMP

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or equivalent

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.

SEALANT APPLICATION TO WATER OUTLET FITTING

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or equivalent

THERMOSTAT INSTALLATION

(1) Install the thermostat so that the jiggle valve will be located in

the thermostat housing as shown.

SEALANT APPLICATION TO ENGINE COOLANT

TEMPERATURE SENSOR

Specified sealant:

3M Nut locking Part No. 4171 or equivalent

ENGINE 6A1 (E-W) Workshop Manual

6A1 ENGINE (E-W) – Water Pump and Water Pipe 11A-7-3

6AE0067

3 mm diameter

bead sealant

4th page added here.

3 mm diameter

bead sealant

6AE0068

6AE0069

Jiggle valve

6AE0070

A◄

►

B◄

►

C◄

►

D◄

►

E◄

►

(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.

<Added>

6AE0415

Water pump

Mitsubishi 6A1 Users Manual ENGINE Workshop 6A1(E W)

6A1 SERIES 6A1_Engine_Manual

6A1 to the manual 9018e481-fbb8-4b81-94b2-5b1400825c30

Navigation menu

Versions of this User Manual:

Views

Navigation