11A-0-1ꢀ
ENGINEꢀ
6A1 SERIESꢀ
CONTENTSꢀ
GENERAL INFORMATIONꢀ. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ꢀ 11A-0-3ꢀ
1. SPECIFICATIONSꢀ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ꢀ 11A-1-1ꢀ
SERVICE SPECIFICATIONSꢀ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ꢀ 11A-1-1ꢀ
REWORK DIMENSIONSꢀ. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ꢀ 11A-1-3ꢀ
TORQUE SPECIFICATIONꢀ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ꢀ 11A-1-4ꢀ
NEW TIGHTENING METHODꢀ- BY USE OF BOLTS TO BEꢀ
TIGHTENED IN PLASTIC AREAꢀ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ꢀ 11A-1-7ꢀ
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ꢀ 11A-1-7ꢀ
FORM-IN-PLACE GASKET (FIPG)ꢀ. . . . . . . . . . . . . . . . . . . . . . . . . . . . ꢀ 11A-1-8ꢀ
2. SPECIAL TOOLSꢀ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ꢀ 11A-2-1ꢀ
3. DRIVE BELTꢀ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ꢀ 11A-3-1ꢀ
4. TIMING BELTꢀ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ꢀ 11A-4-1ꢀ
5. FUEL AND EMISSION CONTROL PARTSꢀ. . . . . . . . . . . . . . . . . . . . . . ꢀ 11A-5-1ꢀ
6. IGNITION SYSTEMꢀ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ꢀ 11A-6-1ꢀ
7. WATER PUMP AND WATER PIPEꢀ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ꢀ 11A-7-1ꢀ
8. INTAKE MANIFOLD AND EXHAUST MANIFOLDꢀ. . . . . . . . . . . . . . ꢀ 11A-8-1ꢀ
9. ROCKER ARM AND CAMSHAFT <SOHC>ꢀ . . . . . . . . . . . . . . . . . . . . ꢀ 11A-9-1ꢀ
10. ROCKER COVER AND CAMSHAFT <MIVEC> . . . . . . . . . . . . . . . . . ꢀ11A-10-1ꢀ
11. ROCKER ARM AND ROCKER SHAFT CAP <MIVEC>ꢀ . . . . . . . . ꢀ11A-11-1ꢀ
12. CYLINDER HEAD AND VALVESꢀ. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ꢀ11A-12-1ꢀ
13. OIL PUMP CASE AND OIL PANꢀ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-13-1ꢀ
14. PISTON AND CONNECTING RODꢀ. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ꢀ11A-14-1ꢀ
15. CRANKSHAFT, CYLINDER BLOCK, FLYWHEELꢀ
AND DRIVE PLATEꢀ. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-15-1ꢀ
Mitsubishi Motors Corporationꢀ
Feb. 1997ꢀ
PWEE9622ꢀ
K
11A-0-3ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Generalꢀ Informationꢀ
GENERALꢀ INFORMATIONꢀ
GENERALꢀ SPECIFICATIONSꢀ
Descriptions
6A12
6A13
Type
60è V, OHV, DOHC (for each bank)
60è V, OHV, SOHC (for each bank)
Number of cylinders
Combustion chamber
Total displacement dm3
Cylinder bore mm
Piston stroke mm
Compression ratio
6
6
Pentroof type
1,998
Pentroof type
2,498
78.4
81.0
69.0
80.8
10.0
9.5*1 or 9.0*2
15è
Valve timing
Intake
valve
Opens
(BTDC)
15è (Low-speed cam)
37.5è (High-speed cam)
Closes
41è (Low-speed cam)
82.5è (High-speed cam)
53è
53è
15è
(ABDC)
Exhaust Opens
41è (Low-speed cam)
75è (High-speed cam)
valve
(BBDC)
Closes
(ATDC)
15è (Low-speed cam)
30è (High-speed cam)
Lubrication system
Oil pump type
Pressure feed, full-flow filtration
Trochoid type
Pressure feed, full-flow filtration
Trochoid type
Cooling system
Water pump type
Water-cooled forced circulation
Centrifugal impeller type
Water-cooled forced circulation
Centrifugal impeller type
NOTE
*1: Europe and Hong Kong
*2: GCC and Export
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
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11A-1-1ꢀ
6A1ꢀ ENGINEꢀ (Eꢀ-W)ꢀ - Specificationsꢀ
1.ꢀ SPECIFICATIONSꢀ
SERVICEꢀ SPECIFICATIONSꢀ
Items
Standard value
12.0
Limit
Timingꢀbeltꢀ
Auto tensioner rod projection mm
-
-
Auto tensioner rod pushed-in amount (when pushed with a force 1.0 or less
of 98 - 196 N) mm
Rockerꢀarmꢀandꢀcamshaftꢀ<SOHC>ꢀ
Camshaft cam height mm
Intake
35.20
34.70
45
34.70
34.20
-
Exhaust
Camshaft journal diameter mm
Rockerꢀcoverꢀandꢀcamshaftꢀ<MIVEC>ꢀ
Camshaft cam height mm
Intake
(Low-speed cam)
34.34
33.84
(High-speed cam) 36.46
(Low-speed cam) 34.40
35.96
Exhaust
33.90
(High-speed cam) 35.86
35.36
Camshaft journal diameter mm
Valve clearance mm
26
-
-
-
Intake
0.10
0.13
Exhaust
Cylinderꢀheadꢀandꢀvalveꢀ
Flatness of cylinder head gasket surface mm
-
-
-
Cylinder head gasket surface grinding limit (including grinding of Less than 0.03
cylinder block gasket surface) mm
Cylinder head overall height SOHC
119.9 - 120.1
119.6 - 119.8
-
-
mm
MIVEC
-
Cylinder head bolt nominal length mm
96.4
0.5
0.8
-
Valve margin mm
Intake
1.0
Exhaust
1.3
Valve stem diameter mm
6.0
Valve stem-to-guide clearance Intake
0.02 - 0.05
0.04 - 0.07
45è - 45.5è
48.45
0.10
0.15
-
mm
Exhaust
Valve face angle
Valve stem projection mm
SOHC
MIVEC
48.95
48.90
48.40
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
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11A-1-2ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Specificationsꢀ
Items
Standard value
Limit
Overall valve length mm
Intake
SOHC
MIVEC
SOHC
MIVEC
113.02
112.37
115.32
110.74
49.9
112.52
111.87
Exhaust
114.82
110.74
Valve spring free height mm
SOHC
MIVEC
48.9
51.5
50.5
Valve spring load/installed SOHC
265/43.4
255/44.5
2è
-
-
height N/mm
MIVEC
Valve spring squareness
4è
-
Valve seat contact width mm
Valve guide internal diameter mm
0.9 - 1.3
6.6
-
Valve guide projection mm
SOHC
MIVEC
14.0
-
19.0
-
Oilꢀpumpꢀcaseꢀandꢀoilꢀpanꢀ
Oil pump tip clearance mm
Oil pump side clearance mm
Oil pump body clearance mm
Pistonꢀandꢀconnectingꢀrodꢀ
Piston outside diameter mm
0.06 - 0.18
0.04 - 0.10
0.10 - 0.18
-
-
0.35
6A12
6A13
78.4
-
81.0
-
Piston ring side clearance mm No.1 ring
No.2 ring
0.02 - 0.06
0.02 - 0.06
0.20 - 0.35
0.35 - 0.50
0.20 - 0.50
19.0
-
-
Piston ring end gap mm
No.1 ring
No.2 ring
Oil ring
0.8
0.8
1.0
-
Piston pin outside diameter mm
Piston pin press-in load (at room temperature) N
Crankshaft pin oil clearance mm
4,900 - 14,700
0.02 - 0.05
0.10 - 0.25
-
0.1
0.4
Connecting rod big end side clearance mm
Crankshaft,ꢀcylinderꢀblock,ꢀflywheelꢀandꢀdriveꢀplateꢀ
Crankshaft end play mm
0.05 - 0.25
0.4
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-1-3ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Specificationsꢀ
Items
Standard value
Limit
Crankshaft journal diameter 6A12
53.0
-
mm
6A13
56.0
-
Crankshaft pin diameter mm
6A12
6A13
43.0
-
51.0
-
Crankshaft journal oil clearance mm
0.02 - 0.04
0.05
0.1
-
Cylinder block gasket surface flatness mm
Cylinder block gasket surface grinding limit (including grinding of
cylinder head gasket surface) mm
-
0.2
Cylinder block overall height 6A12
190.0
-
mm
6A13
209.0
-
Cylinder block cylindricity mm
0.01 or less
78.4
-
Cylinder block internal diame- 6A12
ter mm
-
6A13
81.0
-
Bearing cap bolt nominal length mm
Piston-to-cylinder clearance mm
-
71.1
-
0.02 - 0.04
REWORKꢀ DIMENSIONSꢀ
Item
Standard
Cylinderꢀheadꢀandꢀvalvesꢀ
Cylinder head oversize valve guide hole diameter mm
0.05 O.S.
0.25 O.S.
11.05 - 11.07
11.25 - 11.27
11.50 - 11.52
29.80 - 29.82
30.10 - 30.12
32.30 - 32.32
32.60 - 32.62
27.80 - 27.82
28.10 - 28.12
29.80 - 29.82
30.10 - 30.12
0.50 O.S.
0.3 O.S.
0.6 O.S.
0.3 O.S.
0.6 O.S.
0.3 O.S.
0.6 O.S.
0.3 O.S.
0.6 O.S.
Oversize intake valve seat SOHC
ring hole diameter mm
MIVEC
Oversize exhaust valve SOHC
seat ring diameter mm
MIVEC
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
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11A-1-4ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Specificationsꢀ
TORQUEꢀ SPECIFICATIONꢀ
Items
Nm
Alternatorꢀandꢀdriveꢀbeltꢀ
Alternator pivot nut
Alternator bolt
44
21
23
15
23
45
182
3
Oil level gauge guide
Tensioner pulley
Engine hanger
Tensioner pulley bracket A
Crankshaft bolt
Engine cover
Timingꢀbeltꢀ
Timing belt front cover
Engine support bracket
Angle sensor
11
49
9
Angle sensor connector bracket
Tensioner pulley
11
48
24
21
88
35
11
11
Tensioner arm
Auto tensioner
Camshaft sprocket bolt
Idler pulley
Timing belt rear cover
Angle sensor connector bracket
Fuelꢀandꢀemissionꢀcontrolꢀpartsꢀ
Air intake plenum stay
Connector bracket
EGR valve
18
11
22
12
18
12
9
Throttle body
Air intake plenum
Delivery pipe
Fuel pipe
Fuel pressure regulator
Alternator bracket
9
23
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622
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11A-1-5ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Specificationsꢀ
Items
Nm
Ignitionꢀsystemꢀ
Spark plug
25
11
13
10
Water cover (SOHC)
Distributor (SOHC)
Ignition failure sensor (MIVEC)
Condenser bracket assembly (MIVEC)
Ignition coil (MIVEC)
Waterꢀpumpꢀandꢀwaterꢀpipeꢀ
Engine hanger (MIVEC)
Engine coolant temperature gauge unit
Engine coolant temperature sensor
Heater pipe (SOHC)
Water inlet fitting
5
10
11
11
29
23
18
18
23
13
23
Water outlet fitting
Thermostat housing
Water pipe
Water pump
Intakeꢀmanifoldꢀandꢀexhaustꢀmanifoldꢀ
Intake manifold
17
13
44
49
Heat protector
Exhaust manifold stay
Exhaust manifold
Rockerꢀarmꢀandꢀcamshaftꢀ<SOHC>ꢀ
Rocker cover
4
Rocker arm and rocker shaft
Thrust case
31
24
Rockerꢀarmꢀandꢀcamshaftꢀ<MIVEC>ꢀ
Rocker cover
4
Oil control valve holder
Cam cap
9
24
11
24
Bearing cap M6
Bearing cap M8
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622
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11A-1-6ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Specificationsꢀ
Items
Nm
11
Arm spring holder
Rockerꢀarmꢀandꢀrockerꢀshaftꢀcapꢀ<MIVEC>ꢀ
Rocker shaft cap
Cylinderꢀheadꢀandꢀvalvesꢀ
Cylinder head bolt
Oilꢀpanꢀandꢀoilꢀpumpꢀ
Oil pressure switch
Oil filter cover
11
20 + 120è + 120è
10
21
30
68
39
9
Water hose
Bolt
Drain plug
Oil level sensor
Oil pan
7
Oil screen
19
9
Baffle plate
Relief plug
44
14
12
Oil pump case
Oil pump case cover
Pistonꢀandꢀconnectingꢀrodꢀ
Connecting rod
18 + 90è - 100è
Crankshaft,ꢀcylinderꢀblock,ꢀflywheelꢀandꢀdriveꢀplateꢀ
Detonation sensor
Idler pulley bracket
Flywheel bolt
23
35
98
Drive plate bolt
98
Rear plate
11
Bell housing cover
Oil seal case
9
11
Bearing cap bolt
25 + 90è - 100è
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
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11A-1-7ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Specificationsꢀ
NEWꢀ TIGHTENINGꢀ METHODꢀ - BYꢀ USEꢀ OFꢀ BOLTSꢀ TOꢀ BEꢀ TIGHTENEDꢀ INꢀ
PLASTICꢀ AREAꢀ
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.
J
Areas where the bolts are in use:
(1) Cylinder head bolts
(2) Main bearing cap bolts
(3) Connecting rod cap bolts
J
Tightening Method
After tightening the bolts to the specified torque, tighten them another 90è to 100è, or 240è (twice
120è). The tightening method varies on different areas. Observe the tightening method described
in the text.
SEALANTSꢀ
Item
Specified sealant
Quantity
Water pump*
Mitsubishi Genuine Part No. MD970389 or equivalent
Mitsubishi Genuine Part No. MD970389 or equivalent
3M Nut Locking Part No. 4171 or equivalent
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
Water outlet fitting*
Engine coolant temperature sensor
Engine coolant temperature gauge unit 3M ATD Part No. 8660 or equivalent
Camshaft bearing
Cam cap
3M ATD Part No. 8660 or equivalent
3M ATD Part No. 8660 or equivalent
Oil control valve
Camshaft holder*
Rocker cover
Oil pump case*
Oil pan*
3M ATD Part No. 8660 or equivalent
Mitsubishi Genuine Part No. MD970389 or equivalent
3M ATD Part No. 8660 or equivalent
Mitsubishi Genuine Part No. MD970389 or equivalent
Mitsubishi Genuine Part No. MD970389 or equivalent
3M ATD Part No. 8660 or equivalent
Oil pressure switch
Oil seal case*
Drive plate bolt
Flywheel bolt
Mitsubishi Genuine Part No. MD970389 or equivalent
3M Nut Locking Part No. 4171 or equivalent
3M Nut Locking Part No. 4171 or equivalent
*: parts sealed by foam-in-place gasket (FIPG)
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
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11A-1-8ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Specificationsꢀ
FORM-IN-PLACEꢀ GASKETꢀ (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.
Disassemblyꢀ
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.
Surfaceꢀ Preparationꢀ
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-Placeꢀ Gasketꢀ Applicationꢀ
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.
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
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11A-2-1ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Specialꢀ Toolsꢀ
2.ꢀ SPECIALꢀ TOOLSꢀ
Tool
Number
Name
Use
MB990685
MB990938
MB990767
MB991477
MB991478
MB991479
MB991614
MB991653
MB991659
Torque wrench
Adjustment of timing belt tension
Handle
Use with MD998776
Crankshaft pulley Holding camshaft sprocket when loosening
holder
and tightening of bolt.
Use with MD998719
Valve adjusting
wrench
Adjustment of valve clearance (MIVEC)
Adjustment of valve clearance (MIVEC)
Adjustment of valve clearance (MIVEC)
Tightening cylinder head bolt
Valve adjusting
wrench feeler
gauge set
Rocker arm
piston checker
Angle gauge
Cylinder head bolt Tightening and loosening of cylinder head bolt
wrench
Guide D
Removal of piston pin (Use with MD998780)
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
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11A-2-2ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Specialꢀ Toolsꢀ
Tool
Number
Name
Use
MD998440
Leak-down tester
Leak-down test of lash adjuster
MD998441
MD998442
MD998443
MD998713
MD998716
MD998717
MD998719
MD998727
Lash adjuster
retainer
Air bleeding of lash adjuster
Air bleeding of lash adjuster
Air bleed wire
Lash adjuster
holder
Retainer for holding lash adjuster in rocker arm
at time of removal and installation of rocker arm
and rocker shaft assembly
Camshaft oil seal Installation of camshaft oil seal
installer
Crankshaft wrench Rotation of crankshaft when installing piston
and timing belt.
Crankshaft front oil Installation of crankshaft front oil seal
seal installer
Pulley holder pin Use with MB990767
(2)
Oil pan remover
Removal of oil pan
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-2-3ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Specialꢀ Toolsꢀ
Tool
Number
Name
Use
MD998735
Valve spring
compressor
Compression of valve spring
MD998754
MD998767
MD998772
MD998774
MD998775
MD998776
MD998777
Pin
Use with MB990767
Tensioner pulley
socket wrench
Adjustment of timing belt tension
Valve spring
compressor
Removal and installation of valve and related
parts
Valve stem seal Installation of valve stem seal
installer
Valve stem seal Installation of valve stem seal
installer
Crankshaft rear oil Installation of crankshaft rear oil seal
seal installer
Use with MB990938
Camshaft oil seal Installation of camshaft oil seal
installer adapter
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
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11A-2-4ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Specialꢀ Toolsꢀ
Tool
Number
Name
Use
MD998780
SETTING TOOL
Piston pin
Removal and installation of piston pin
MD998781
MD998784
Flywheel stopper
Holding flywheel and drive plate
Valve spring
compressor
adapter
Compression of valve spring (MIVEC)
(Use with MD998772)
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
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11A-3-1ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Driveꢀ Beltꢀ
3.ꢀ DRIVEꢀ BELTꢀ
REMOVALꢀ ANDꢀ INSTALLATIONꢀ <SOHC>ꢀ
3 Nm ꢀ
16ꢀ
44ꢀNmꢀ
21ꢀNmꢀ
2ꢀ
44ꢀNmꢀ
11ꢀ
9ꢀ
1ꢀ
23ꢀNmꢀ
3ꢀ
23ꢀNmꢀ
15ꢀ
7ꢀ
6ꢀ
12ꢀ
14ꢀ
13ꢀ
10ꢀ
44ꢀNmꢀ
8ꢀ
182ꢀNmꢀ
4ꢀ
15ꢀNmꢀ
5ꢀ
Removalꢀ stepsꢀ
1. Drive belt
2. Alternator
9. Tensioner pulley bracket B
10. Adjusting stud
3. Oil level gauge (dipstick)
4. Oil level gauge guide
5. O-ring
11. Adjusting bolt
GA+ +AG 12. Crankshaft bolt
13. Special washer
14. Crankshaft pulley
15. Flange
6. Tensioner pulley
7. Engine hanger
8. Tensioner pulley bracket A
16. Engine cover
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-3-2ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Driveꢀ Beltꢀ
REMOVALꢀ ANDꢀ INSTALLATIONꢀ <MIVEC>ꢀ
3 Nm ꢀ
16ꢀ
21ꢀNmꢀ
44ꢀNmꢀ
2ꢀ
1ꢀ
11ꢀ
44ꢀNmꢀ
9ꢀ
3ꢀ
23ꢀNmꢀ
13ꢀ
23ꢀNmꢀ
7ꢀ
15ꢀ
6ꢀ
12ꢀ
10ꢀ
14ꢀ
44ꢀNmꢀ
8ꢀ
182ꢀNmꢀ
4ꢀ
5ꢀ
15ꢀNmꢀ
Removalꢀ stepsꢀ
1. Drive belt
2. Alternator
9. Tensioner pulley bracket B
10. Adjusting stud
11. Adjusting bolt
3. Oil level gauge (dipstick)
4. Oil level gauge guide
5. O-ring
GA+ +AG 12. Crankshaft bolt
13. Special washer
14. Crankshaft pulley
15. Flange
6. Tensioner pulley
7. Engine hanger
8. Tensioner pulley bracket A
16. Engine cover
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-3-3ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Driveꢀ Beltꢀ
REMOVALꢀ SERVICEꢀ POINTSꢀ
GA+ CRANKSHAFTꢀ PULLEYꢀ BOLTꢀ REMOVALꢀ
(1) Hold the flywheel or drive plate in position with the special
tool before removing the crankshaft pulley bolts.
INSTALLATIONꢀ SERVICEꢀ POINTSꢀ
+AG CRANKSHAFTꢀ PULLEYꢀ BOLTꢀ INSTALLATIONꢀ
(1) Hold the flywheel or drive plate in position with the special
tool before installing the crankshaft pulley bolts.
MD998781
6AE0039
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-4-1ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Timingꢀ Beltꢀ
4.ꢀ TIMINGꢀ BELTꢀ
REMOVALꢀ ANDꢀ INSTALLATIONꢀ <SOHC>ꢀ
24ꢀ
ꢀ
11ꢀNmꢀ
Removalꢀ stepsꢀ
1. Timing belt front cover, upper right
2. Timing belt front cover, upper left
3. Timing belt front cover, lower
4. Engine support bracket
+BG 10. Auto tensioner
11. Crankshaft sprocket
12. Sensing plate
13. Crankshaft spacer
5. Angle sensor
GB+ +AG 14. Camshaft sprocket bolt
15. Camshaft sprocket
GA+ +CG 6. Timing belt
7. Tensioner pulley
16. Idler pulley
8. Tensioner arm
17. Timing belt rear cover, center
18. Connector bracket
9. Tensioner spacer
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-4-2ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Timingꢀ Beltꢀ
REMOVALꢀ ANDꢀ INSTALLATIONꢀ <MIVEC>ꢀ
12ꢀNmꢀ
23ꢀ
21ꢀ
11ꢀNmꢀ
11ꢀNmꢀ
88ꢀNmꢀ
17ꢀ
16ꢀ
22ꢀ
18ꢀ
48ꢀNmꢀ
9ꢀ
10ꢀ
19ꢀ
35ꢀNmꢀ
8ꢀ
5ꢀ
6ꢀ
11ꢀ
17ꢀ
20ꢀ
44ꢀNmꢀ
11ꢀNmꢀ
15ꢀ
14ꢀ
1ꢀ
13ꢀ
12ꢀ
22ꢀNmꢀ
2ꢀ
7ꢀ
11ꢀNmꢀ
9 Nm ꢀ
9 Nm ꢀ
49ꢀNmꢀ
9 Nm ꢀ
4ꢀ
3ꢀ
11ꢀNmꢀ
Removalꢀ stepsꢀ
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
13. Crankshaft sprocket
14. Sensing plate
15. Washer
GB+ +AG 16. Camshaft sprocket bolt
17. Camshaft sprocket
6. Angle sensor
18. Camshaft sprocket with sensing
plate
7. Spacer
GA+ +DG 8. Timing belt
19. Idler pulley
9. Tensioner pulley
20. Timing belt rear cover, left
21. Timing belt rear cover, right
22. Timing belt rear cover, center
23. Connector bracket
10. Tensioner arm
11. Tensioner spacer
+BG 12. Auto tensioner
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-4-3ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Timingꢀ Beltꢀ
REMOVALꢀ SERVICEꢀ POINTSꢀ
GA+ TIMINGꢀ BELTꢀ REMOVALꢀ
(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
6AE0137
6AE0045
6AE0138
GB+ CAMSHAFTꢀ SPROCKETꢀ BOLTꢀ REMOVALꢀ
MB990767
MD998719
MB990767
MD998754
INSTALLATIONꢀ SERVICEꢀ POINTSꢀ
+AG CAMSHAFTꢀ SPROCKETꢀ BOLTꢀ INSTALLATIONꢀ
MD998719
MB990767
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-4-4ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Timingꢀ Beltꢀ
MD998754
MB990767
6AE0048
+BG AUTOꢀ TENSIONERꢀ SETTINGꢀ
(1) Set the auto tensioner in a vice, while making sure it
is not tilted.
(B)
(A)
(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.
6AE0049
6AE0050
6AE0329
6AE0358
(3) Insert a 1.4 mm wire in the set hole.
(4) Remove the auto tensioner from the vice.
+CG TIMINGꢀ BELTꢀ INSTALLATIONꢀ
(1) Turn the crankshaft sprocket so that its timing mark will
be away from the mating timing mark by approx. three
teeth.
Cautionꢀ
J
Ifꢀ theꢀ timingꢀ marksꢀ areꢀ aligned,ꢀ theꢀ pistonꢀ isꢀ
broughtꢀtoꢀtheꢀTDC.ꢀWhenꢀtheꢀcamshaftꢀisꢀturnedꢀ
underꢀthisꢀcondition,ꢀtheꢀvalvesꢀmayꢀinterfereꢀwithꢀ
theꢀ piston.ꢀ
(2) Bring the timing marks of the camshaft sprockets as shown
in the illustration.
Timing mark
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
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11A-4-5ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Timingꢀ Beltꢀ
(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.
6AE0331
Cautionꢀ
J
Theꢀcamshaftꢀsprocketsꢀareꢀproneꢀtoꢀrotate.ꢀAvoidꢀ
givingꢀexcessiveꢀtensionꢀtoꢀtheꢀtimingꢀbeltꢀwhenꢀ
itꢀ isꢀ 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
6AE0057
6AE0058
(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.
MD998767
(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.
MB990685
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-4-6ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Timingꢀ Beltꢀ
+DG TIMINGꢀ BELTꢀ INSTALLATIONꢀ
(1) Turn the crankshaft sprocket so that its timing mark will
be away from the mating timing mark by approx. three
teeth.
Cautionꢀ
J
Ifꢀ theꢀ timingꢀ marksꢀ areꢀ aligned,ꢀ theꢀ pistonꢀ isꢀ
broughtꢀtoꢀtheꢀTDC.ꢀWhenꢀtheꢀcamshaftꢀisꢀturnedꢀ
underꢀthisꢀcondition,ꢀtheꢀvalvesꢀmayꢀinterfereꢀwithꢀ
theꢀ piston.ꢀ
MD998716
6AE0051
(2) Bring the timing marks of the camshaft sprockets as shown
in the illustration.
Cautionꢀ
J
Ifꢀoneꢀofꢀtheꢀcamshaftꢀsprocketsꢀonꢀtheꢀrightꢀbankꢀ
isꢀ turnedꢀ withꢀ theꢀ timingꢀ markꢀ onꢀ theꢀ otherꢀ
sprocketꢀ aligned,ꢀ thereꢀ mayꢀ beꢀ dangerꢀ forꢀ theꢀ
intakeꢀandꢀexhaustꢀvalvesꢀtoꢀinterfereꢀwithꢀeachꢀ
other.ꢀ
6AE0311
6AE0053
6AE0054
6AE0055
(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.
Cautionꢀ
J
Theꢀ camshaftꢀ sprocketsꢀ onꢀ theꢀ rightꢀ bankꢀ canꢀ
turnꢀ veryꢀ easilyꢀ becauseꢀ ofꢀ theꢀ valveꢀ springꢀ
tension.ꢀUseꢀcareꢀnotꢀtoꢀallowꢀyourꢀfingersꢀtoꢀgetꢀ
caughtꢀ betweenꢀ theꢀ sprockets.ꢀ
Paper clip
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.
Cautionꢀ
J
Theꢀ camshaftꢀ sprocketsꢀ canꢀturnꢀeasilyꢀandꢀ
doꢀ notꢀ giveꢀ excessiveꢀ tensionꢀ toꢀ theꢀ timingꢀ
belt.ꢀ
3) Place the timing belt around the idler pulley.
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-4-7ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Timingꢀ Beltꢀ
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
6AE0057
6AE0058
6AE0059
8EN0066
(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.
MD998767
(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.
MB990685
(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.
Standardꢀ value:ꢀ 3.8ꢀ - 4.5ꢀ mmꢀ
(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.
INSPECTIONꢀ
TIMINGꢀ BELTꢀ
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.
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-4-8ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Timingꢀ Beltꢀ
(2) Cracks on rubber back.
Cracks
(3) Cracks or peeling of canvas.
(4) Cracks on tooth bottom.
(5) Cracks or belt sides.
Peeling
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
8EN0068
6AE0046
(7) Abnormal wear on teeth.
(8) Missing tooth.
Rubber exposed
Tooth missing
and canvas
fiber exposed
AUTO-TENSIONERꢀ
“L”
(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.
Standardꢀ valueꢀ “L”:ꢀ 12ꢀ mmꢀ
(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
Standardꢀ value:ꢀ 1ꢀ mmꢀ orꢀ lessꢀ
6EN1033
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-5-1ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Fuelꢀ andꢀ Emissionꢀ Controlꢀ Partsꢀ
5.ꢀ FUELꢀ ANDꢀ EMISSIONꢀ CONTROLꢀ PARTSꢀ
REMOVALꢀ ANDꢀ INSTALLATIONꢀ <SOHC>ꢀ
12ꢀNmꢀ
6ꢀ
18ꢀNmꢀ
18ꢀNmꢀ
7
22ꢀNmꢀ
18ꢀNmꢀ
2
5ꢀ
3ꢀ
4ꢀ
8ꢀ
18ꢀNmꢀ
9ꢀ
18ꢀNmꢀ
1ꢀ
9 Nm ꢀ
12ꢀNmꢀ
20ꢀ
10ꢀ
19
11ꢀ
16ꢀ
15ꢀ
14ꢀ
13ꢀ
21ꢀ
17ꢀ
18ꢀ
23ꢀNmꢀ
9 Nm ꢀ
22ꢀ
12ꢀ
Removalꢀ stepsꢀ
1. Air intake plenum stay, front
2. Air intake plenum stay, rear
3. EGR valve
12. Insulator
13. Insulator
+BG 14. Injector
15. Grommet
16. O-ring
4. Gasket
5. Vacuum pipe
6. Throttle body
17. Fuel pipe
18. O-ring
+CG 7. Gasket
8. Air intake plenum
9. Gasket
+AG 19. Fuel pressure regulator
20. O-ring
10. Control harness
11. Delivery pipe and injector
21. Delivery pipe
22. Alternator bracket
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-5-2ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Fuelꢀ andꢀ Emissionꢀ Controlꢀ Partsꢀ
REMOVALꢀ ANDꢀ INSTALLATIONꢀ <MIVEC>ꢀ
11ꢀNmꢀ
12ꢀNmꢀ
11ꢀNmꢀ
18ꢀNmꢀ
7ꢀ
6ꢀ
18ꢀNmꢀ
3ꢀ
9ꢀ
18ꢀNmꢀ
8.8ꢀNmꢀ
8ꢀ
18ꢀNmꢀ
4ꢀ
5ꢀ
12ꢀ
1ꢀ
2ꢀ
13ꢀ
9 Nm ꢀ
11ꢀ
12ꢀNmꢀ
14ꢀ
10ꢀ
24ꢀ
14ꢀNmꢀ
25ꢀ
23ꢀ
22ꢀ
19ꢀ
18ꢀ
20ꢀ
21ꢀ
16
17ꢀ
15
9 Nm ꢀ
23ꢀNmꢀ
26ꢀ
Removalꢀ stepsꢀ
1. Air intake plenum stay, front
2. Air intake plenum stay, rear
3. Vacuum pipe
14. Control harness
15. Delivery pipe and injector
16. Insulator
4. Throttle body
17. Insulator
+CG 5. Gasket
+BG 18. Injector
6. Connector bracket
7. Connector bracket
8. Accelerator cable bracket
9. Ignition failure sensor
10. Air temperature sensor
11. Gasket
19. Grommet
20. O-ring
21. Fuel pipe
22. O-ring
+AG 23. Fuel pressure regulator
24. O-ring
12. Air intake plenum
13. Gasket
25. Delivery pipe
26. Alternator bracket
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-5-3ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Fuelꢀ andꢀ Emissionꢀ Controlꢀ Partsꢀ
INSTALLATIONꢀ SERVICEꢀ POINTSꢀ
+AG FUELꢀ PRESSUREꢀ REGULATORꢀ INSTALLATIONꢀ
(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.
Cautionꢀ
6AE0061
6AE0062
6AE0277
J
Ifꢀtheꢀregulatorꢀdoesꢀnotꢀturnꢀsmoothly,ꢀtheꢀO-ringꢀ
probablyꢀgetsꢀcaughtꢀsomewhereꢀinꢀtheꢀdeliveryꢀ
pipe.ꢀ Inꢀ suchꢀ aꢀ case,ꢀ removeꢀ theꢀ fuelꢀ pressureꢀ
regulatorꢀ andꢀ reinsertꢀ itꢀ intoꢀ theꢀ deliveryꢀ pipe.ꢀ
Checkꢀitꢀagainꢀforꢀsmoothꢀrotationꢀbeforeꢀsecuring.ꢀ
+BG INJECTORꢀ INSTALLATIONꢀ
(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.
Cautionꢀ
J
Ifꢀtheꢀinjectorꢀdoesꢀnotꢀturnꢀsmoothly,ꢀtheꢀO-ringꢀ
probablyꢀgetsꢀcaughtꢀsomewhereꢀinꢀtheꢀdeliveryꢀ
pipe.ꢀ Inꢀ suchꢀ aꢀ case,ꢀ removeꢀ theꢀ injectorꢀ andꢀ
reinsertꢀ itꢀ intoꢀ theꢀ deliveryꢀ pipe.ꢀ Checkꢀ itꢀ againꢀ
forꢀ smoothꢀ rotation.ꢀ
(5) On the right bank, align the marks on the injector and
delivery pipe.
+CG GASKETꢀ INSTALLATIONꢀ
Projection
(1) Locate the projection on the gasket as shown.
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-6-1ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Ignitionꢀ Systemꢀ
6.ꢀ IGNITIONꢀ SYSTEMꢀ
REMOVALꢀ ANDꢀ INSTALLATIONꢀ <SOHC>ꢀ
1ꢀ
13ꢀNmꢀ
4ꢀ
25ꢀNmꢀ
2ꢀ
11ꢀNmꢀ
3ꢀ
Removalꢀ stepsꢀ
1. Spark plug cable
2. Spark plug
3. Water cover
+AG 4. Distributor
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-6-2ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Ignitionꢀ Systemꢀ
REMOVALꢀ ANDꢀ INSTALLATIONꢀ <MIVEC>ꢀ
1.0ꢀNmꢀ
25ꢀNmꢀ
1ꢀ
3
2ꢀ
Removalꢀ stepsꢀ
1. Spark plug cable
2. Ignition coil
3. Spark plug
INSTALLATIONꢀ SERVICEꢀ POINTꢀ
+AG DISTRIBUTORꢀ INSTALLATIONꢀ
(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
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-7-1ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Waterꢀ Pumpꢀ andꢀ Waterꢀ Pipeꢀ
7.ꢀ WATERꢀ PUMPꢀ ANDꢀ WATERꢀ PIPEꢀ
REMOVALꢀ ANDꢀ INSTALLATIONꢀ <SOHC>ꢀ
18ꢀNmꢀ
4ꢀ
9ꢀ
23ꢀNmꢀ
18ꢀNmꢀ
29ꢀNmꢀ
3ꢀ
5ꢀ
2ꢀ
10ꢀ
6ꢀ
7
8ꢀ
13ꢀNmꢀ
1ꢀ
14ꢀ
11ꢀNmꢀ
23ꢀNmꢀ
12ꢀ
11
13ꢀ
23ꢀNmꢀ
15ꢀ
Removalꢀ stepsꢀ
+FG 1. Engine coolant temperature gauge
+DG 8. Thermostat
unit
+CG 9. Water outlet fitting
10. Thermostat housing
11. Gasket
+EG 2. Engine coolant temperature sensor
3. Water hose
4. Water hose
+BG 12. O-ring
5. Heater pipe
+BG 13. Water pipe
+BG 14. O-ring
6. O-ring
7. Water inlet fitting
+AG 15. Water pump
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-7-2ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Waterꢀ Pumpꢀ andꢀ Waterꢀ Pipeꢀ
REMOVALꢀ ANDꢀ INSTALLATIONꢀ <MIVEC>ꢀ
8ꢀ
18ꢀNmꢀ
29ꢀNmꢀ
6ꢀ
18ꢀNmꢀ
7ꢀ
3ꢀ
23ꢀNmꢀ
4
5ꢀ
2ꢀ
11ꢀNmꢀ
13ꢀNmꢀ
13ꢀ
10ꢀ
9
11ꢀ
12ꢀ
1ꢀ
18ꢀNmꢀ
23ꢀNmꢀ
14ꢀ
Removalꢀ stepsꢀ
1. Engine hanger
+FG 2. Engine coolant temperature gauge
unit
+CG 8. Water outlet fitting
9. Thermostat housing
10. Gasket
+EG 3. Engine coolant temperature sensor
4. Water hose
+BG 11. O-ring
+BG 12. Water pipe
+BG 13. O-ring
5. Water hose
6. Water inlet fitting
+AG 14. Water pump
+DG 7. Thermostat
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-7-3ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Waterꢀ Pumpꢀ andꢀ Waterꢀ Pipeꢀ
INSTALLATIONꢀ SERVICEꢀ POINTSꢀ
+AG SEALANTꢀ APPLICATIONꢀ TOꢀ WATERꢀ PUMPꢀ
3 mm
diameter
bead sealant
Specifiedꢀ sealant:ꢀ
Mitsubishiꢀ Genuineꢀ Partꢀ No.ꢀ MD970389ꢀ orꢀ
equivalentꢀ
6AE0067
+BG WATERꢀ PIPEꢀ /ꢀ O-RINGꢀ INSTALLATIONꢀ
(1) Wet the O-ring (with water) to facilitate assembly.
Cautionꢀ
J
J
Keepꢀ theꢀ O-ringꢀ freeꢀ ofꢀ oilꢀ orꢀ grease.ꢀ
Secureꢀtheꢀwaterꢀpipeꢀafterꢀtheꢀthermostatꢀhousingꢀ
hasꢀ beenꢀ installed.ꢀ
+CG SEALANTꢀ APPLICATIONꢀ TOꢀ WATERꢀ OUTLETꢀ
3 mm
diameter
bead sealant
FITTINGꢀ
Specifiedꢀ sealant:ꢀ
Mitsubishiꢀ Genuineꢀ Partꢀ No.ꢀ MD970389ꢀ orꢀ
equivalentꢀ
6AE0068
6AE0069
6AE0070
+DG THERMOSTATꢀ INSTALLATIONꢀ
(1) Install the thermostat so that the jiggle valve will be located
in the thermostat housing as shown.
Jiggle valve
+EG SEALANTꢀ APPLICATIONꢀ TOꢀ ENGINEꢀ COOLANTꢀ
TEMPERATUREꢀ SENSORꢀ
Specifiedꢀ sealant:ꢀ
3Mꢀ Nutꢀ lockingꢀ Partꢀ No.ꢀ 4171ꢀ orꢀ equivalentꢀ
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
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11A-7-4ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Waterꢀ Pumpꢀ andꢀ Waterꢀ Pipeꢀ
+FG SEALANTꢀ APPLICATIONꢀ TOꢀ ENGINEꢀ COOLANTꢀ
TEMPERATUREꢀ GAUGEꢀ UNITꢀ
Specifiedꢀ sealant:ꢀ
3Mꢀ ATDꢀ Partꢀ No.ꢀ 8660ꢀ orꢀ equivalentꢀ
6AE0071
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-8-1ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Intakeꢀ Manifoldꢀ andꢀ Exhaustꢀ Manifoldꢀ
8.ꢀ INTAKEꢀ MANIFOLDꢀ ANDꢀ EXHAUSTꢀ MANIFOLDꢀ
REMOVALꢀ ANDꢀ INSTALLATIONꢀ <SOHC>ꢀ
1ꢀ
17ꢀNmꢀ
3ꢀ
2
13ꢀNmꢀ
6ꢀ
5ꢀ
7ꢀ
9ꢀ
44ꢀNmꢀ
49ꢀNmꢀ
13ꢀNmꢀ
4ꢀ
8ꢀ
49ꢀNmꢀ
Removalꢀ stepsꢀ
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
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
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11A-8-2ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Intakeꢀ Manifoldꢀ andꢀ Exhaustꢀ Manifoldꢀ
REMOVALꢀ ANDꢀ INSTALLATIONꢀ <MIVEC>ꢀ
1ꢀ
2ꢀ
17ꢀNmꢀ
3ꢀ
13ꢀNmꢀ
6ꢀ
5ꢀ
7ꢀ
9ꢀ
44ꢀNmꢀ
49ꢀNmꢀ
4ꢀ
13ꢀNmꢀ
8ꢀ
49ꢀNmꢀ
Removalꢀ stepsꢀ
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
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-9-1ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Rockerꢀ Armꢀ andꢀ Camshaftꢀ <SOHC>ꢀ
9.ꢀ ROCKERꢀ ARMꢀ ANDꢀ CAMSHAFTꢀ <SOHC>ꢀ
REMOVALꢀ ANDꢀ INSTALLATIONꢀ
4 Nm ꢀ
31ꢀNmꢀ
1ꢀ
2ꢀ
6ꢀ
3ꢀ
10ꢀ
9ꢀ
7ꢀ
9ꢀ
5ꢀ
8ꢀ
13ꢀ
7ꢀ
8ꢀ
9ꢀ
7ꢀ
8ꢀ
12ꢀ
24ꢀNmꢀ
12ꢀ
11ꢀ
12ꢀ
15ꢀ
14ꢀ
16ꢀ
17ꢀ
Apply engine oil to all
moving parts before
installation.
4ꢀ
Removalꢀ stepsꢀ
1. Rocker cover
10. Rocker arm shaft
2. Rocker cover gasket
3. Oil seal
+BG 11. Lash adjuster
12. Rocker arm C
13. Rocker arm shaft
+BG 14. Lash adjuster
15. Thrust case
+DG 4. Oil seal
GA+ +CG 5. Rocker arm and rocker shaft
GA+ +CG 6. Rocker arm and rocker shaft
+CG 7. Rocker shaft spring
8. Rocker arm A
16. O-ring
+AG 17. Camshaft
9. Rocker arm B
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-9-2ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Rockerꢀ Armꢀ andꢀ Camshaftꢀ <SOHC>ꢀ
REMOVALꢀ SERVICEꢀ POINTꢀ
GA+ ROCKERꢀ ARMSꢀ ANDꢀ ROCKERꢀ ARMꢀ SHAFTSꢀ
MD998443
REMOVALꢀ
(1) Before removing rocker arms and shafts assembly, install
the special tool as illustrated to prevent adjuster from
dropping.
6AE0160
6AE0180
6EN0421
6AE0161
6AE0162
INSTALLATIONꢀ SERVICEꢀ POINTSꢀ
+AG CAMSHAFTꢀ INSTALLATIONꢀ
(1) Apply engine oil to journals and cams of the camshaft
before installation.
Be sure to install the correct camshafts on the correct
bank.
For right bank
Do not confuse the intake camshaft with the exhaust
one.
For left bank
+BG LASHꢀ ADJUSTERꢀ INSTALLATIONꢀ
(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
(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
+CG ROCKERꢀ SHAFTꢀ SPRINGꢀ /ꢀ ROCKERꢀ ARMSꢀ ANDꢀ
ROCKERꢀ ARMꢀ SHAFTꢀ INSTALLATIONꢀ
(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.
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
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11A-9-3ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Rockerꢀ Armꢀ andꢀ Camshaftꢀ <SOHC>ꢀ
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
+DG CAMSHAFTꢀ OILꢀ SEALꢀ INSTALLATIONꢀ
Rightꢀ bankꢀ
(1) When installing the left bank camshaft oil seal, use the
special tool to prevent interference with the knock pin.
MD998713
6AE0164
Leftꢀ bankꢀ
MD998713
MD998777
6AE0181
INSPECTIONꢀ
CAMSHAFTꢀ
(1) Measure the cam height (lobe diameter) and, if the limit
is exceeded, replace the camshaft.
Standardꢀ value:ꢀ
35.20ꢀ mmꢀ
34.91ꢀ mmꢀ
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ꢀ
Intakeꢀ sideꢀ
Exhaustꢀ sideꢀ
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ꢀ
Limit:ꢀ
34.70ꢀ mmꢀ
34.41ꢀ mmꢀ
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ꢀ
Intakeꢀ sideꢀ
Exhaustꢀ sideꢀ
9EN0058
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ꢀ
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-9-4ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Rockerꢀ Armꢀ andꢀ Camshaftꢀ <SOHC>ꢀ
LASHꢀ ADJUSTERꢀ LEAKꢀ DOWNꢀ TESTꢀ
Cautionꢀ
J
Theꢀlashꢀadjusterꢀisꢀaꢀprecisionꢀpart.ꢀKeepꢀitꢀfreeꢀ
fromꢀ dustꢀ andꢀ otherꢀ foreignꢀ matters.ꢀ
Doꢀ notꢀ disassembleꢀ lashꢀ adjuster.ꢀ
Whenꢀcleaningꢀlashꢀadjuster,ꢀuseꢀcleanꢀdieselꢀfuelꢀ
only.ꢀ
J
J
(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.
MD998442
Use of the special tool (Retainer MD998441) helps
facilitate the air bleeding of the rocker arm mounted type
lash adjuster.
Diesel fuel
(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.
MD998441
6EN0186
If the plunger is still loose, replace the lash adjuster.
Cautionꢀ
J
Uponꢀ completionꢀ ofꢀ airꢀ bleeding,ꢀ holdꢀ lashꢀ
adjusterꢀuprightꢀtoꢀpreventꢀinsideꢀdieselꢀfuelꢀfromꢀ
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.
Graduations = 1 mm
MD998440
Standardꢀ value:ꢀ 4ꢀ - 20ꢀ seconds/1ꢀ mmꢀ
(Dieselꢀ fuelꢀ atꢀ 15ꢀ - 20èC)ꢀ
Lash adjuster
6EN0187
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-10-1ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Rockerꢀ Coverꢀ andꢀ Camshaftꢀ <MIVEC>ꢀ
10.ꢀ ROCKERꢀ COVERꢀ ANDꢀ CAMSHAFTꢀ <MIVEC>ꢀ
REMOVALꢀ ANDꢀ INSTALLATIONꢀ
4 Nm ꢀ
1ꢀ
11ꢀNmꢀ
24ꢀNmꢀ
2ꢀ
9 Nm ꢀ
24ꢀNmꢀ
8
3ꢀ
10ꢀ
9
11ꢀNmꢀ
24ꢀNmꢀ
11ꢀ
24ꢀNmꢀ
4ꢀ
11ꢀNmꢀ
9
Apply engine oil to all
moving parts before
installation.
12ꢀ
13ꢀ
6
14ꢀ
5ꢀ
7ꢀ
Removalꢀ stepsꢀ
+GG 1. Rocker cover
+CG 8. Oil control valve
2. Rocker cover gasket
3. Oil seal
+BG 9. Cam cap
10. Oil control valve holder
+BG 11. Camshaft bearing cap
12. Arm spring holder
13. Arm spring
+AG 14. Camshaft
+FG 4. Circuit packing
+EG 5. Oil seal
+DG 6. Camshaft holder
+DG 7. Semi-circular packing
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-10-2ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Rockerꢀ Coverꢀ andꢀ Camshaftꢀ <MIVEC>ꢀ
INSTALLATIONꢀ SERVICEꢀ POINTꢀ
+AG CAMSHAFTꢀ INSTALLATIONꢀ
Left bank
camshaft
(1) Intake valve camshaft and exhaust valve camshaft can
be identified by their diameters at the portions indicated
in the illustration.
Intakeꢀ valveꢀ camshaft:ꢀ 25ꢀ mmꢀ
Exhaustꢀ valveꢀ camshaft:ꢀ 30ꢀ mmꢀ
Right bank
camshaft
6AE0229
(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.
IN
EX
Right
bank
Dowel pin
IN
EX
Left
bank
Dowel pin
6AE0230
+BG CAMSHAFTꢀ BEARINGꢀ CAPꢀ /ꢀ CAMꢀ CAPꢀ
INSTALLATIONꢀ
(1) Apply sealant to the illustrated points of the camshaft
holders.
Specifiedꢀ sealant:ꢀ
3Mꢀ ATDꢀ partꢀ No.ꢀ 8660ꢀ orꢀ equivalentꢀ
(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.
6AE0233
Cap No.
Intake
Front mark
Exhaust
Cap No.
6AE0308
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
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11A-10-3ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Rockerꢀ Coverꢀ andꢀ Camshaftꢀ <MIVEC>ꢀ
+CG OILꢀ CONTROLꢀ VALVEꢀ INSTALLATIONꢀ
(1) Apply the specified sealant to the area shown.
Specifiedꢀ sealant:ꢀ
3Mꢀ ATDꢀ Partꢀ No.ꢀ 8660ꢀ orꢀ equivalentꢀ
6AE0236
6AE0237
6AE0238
+DG SEMI-CIRCULARꢀ PACKINGꢀ /ꢀ CAMSHAFTꢀ
HOLDERꢀ INSTALLATIONꢀ
(1) Make sure that the retainer of each adjusting screw is
fitted correctly.
Screw
Protrusion
Cautionꢀ
Groove
J
Ifꢀ theꢀ protrusionꢀ onꢀ theꢀ retainerꢀisꢀ notꢀcorrectlyꢀ
fittedꢀinꢀ theꢀ grooveꢀ ofꢀtheꢀ screw,ꢀ theꢀ padꢀ couldꢀ
slipꢀ offꢀ theꢀ retainer.ꢀ
Retainer
Pad
(2) Apply 3 mm thick bead of foam-in-place gasket (FIPG)
to the gasket surface of the camshaft holder.
Cautionꢀ
J
Sinceꢀ theꢀ FIPGꢀ couldꢀ causeꢀ blockingꢀ ofꢀ engineꢀ
oilꢀpassages,ꢀbeꢀcarefulꢀnotꢀtoꢀapplyꢀFIPGꢀtoꢀotherꢀ
locationsꢀ thanꢀ specified.ꢀ
Specifiedꢀ sealant:ꢀ
Mitsubishiꢀ Genuineꢀ Partꢀ No.ꢀ MD970389ꢀ orꢀ
equivalentꢀ
(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 Q-marked bolts. See section +BG
for the checking order.
8
7
4
2
6
10
(7) Verify that the pad of each adjusting screw is in place.
3
1
5
9
6AE0239
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
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11A-10-4ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Rockerꢀ Coverꢀ andꢀ Camshaftꢀ <MIVEC>ꢀ
+EG CAMSHAFTꢀ OILꢀ SEALꢀ INSTALLATIONꢀ
Rightꢀbankꢀ
(1) When installing the left bank camshaft oil seal, use the
special tool to prevent interference with the knock pin.
MD998713
6AE0306
Leftꢀbankꢀ
MD998777
MD998713
6AE0307
+FG CIRCULARꢀ PACKINGꢀ INSTALLATIONꢀ
MD998713
6AE0241
+GGROCKERꢀ COVERꢀ INSTALLATIONꢀ
(1) Apply the specified sealant to the area shown.
Specifiedꢀ sealant:ꢀ
3Mꢀ ATDꢀ Partꢀ No.ꢀ 8660ꢀ orꢀ equivalentꢀ
Sealant application
areas
10 mm
10 mm
10 mm
6AE0242
INSPECTIONꢀ
OILꢀ CONTROLꢀ VALVEꢀ
1
2
ꢀ
(1) Connect a 12VDC power supply between terminals (1)
and (2) of the oil control valve and check if the valve
operates smoothly.
+ꢀ
-
6AE0206
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-10-5ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Rockerꢀ Coverꢀ andꢀ Camshaftꢀ <MIVEC>ꢀ
Valve
6AE0227
CAMSHAFTꢀ
(1) Measure the cam heights. If the specified limit isexceeded,
replace the camshaft.
NOTE
Each camshaft has an identification mark on its rear end
surface.
( ): Identification mark
Standard value
34.34 mm
Limit
IN (3)
L
33.84 mm
35.96 mm
33.90 mm
35.36 mm
9N0058
H
L
36.46 mm
EX (C)
34.40 mm
High-speed cam (H)
H
35.86 mm
16 mm
Identification
mark location
Low-speed
cam (L)
21 mm
6AE0228
VALVEꢀ CLEARANCEꢀ ADJUSTMENTꢀ
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
Intakeꢀ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ꢀ 0.10ꢀ mmꢀ
Exhaustꢀ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ꢀ 0.13ꢀ mmꢀ
(4) Screw in one of the two adjusting screws until it comes
into contact with the valve (when the turning torque
changes).
MB991477
6AE0285
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
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11A-10-6ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Rockerꢀ Coverꢀ andꢀ Camshaftꢀ <MIVEC>ꢀ
(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 120è (60è
in camshaft sprocket angle) and following the above steps
(2) through (8). Perform the adjustments in the following
order of cylinder number:
MB991479
No. 2 ç No. 3 ç No. 4 ç No. 5 ç No. 6
Piston
6AE0286
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-11-1ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Rockerꢀ Armꢀ andꢀ Rockerꢀ Shaftꢀ Capꢀ <MIVEC>ꢀ
11.ꢀ ROCKERꢀ ARMꢀ ANDꢀ ROCKERꢀ SHAFTꢀ CAPꢀ <MIVEC>ꢀ
REMOVALꢀ ANDꢀ INSTALLATIONꢀ
22ꢀ
20ꢀ
21ꢀ
13ꢀ
20ꢀ
13ꢀ
21ꢀ
13ꢀ
14ꢀ
19ꢀ
20ꢀ
21ꢀ
11ꢀ
12ꢀ
15ꢀ
4ꢀ
3ꢀ
18ꢀ
17ꢀ
11ꢀ
12ꢀ
16ꢀ
4ꢀ
5ꢀ
11ꢀ
10ꢀ
1
2ꢀ
12ꢀ
7ꢀ
6ꢀ
11ꢀNmꢀ
9ꢀ
8ꢀ
Apply engine oil to all
moving parts before
installation.
4ꢀ
Removalꢀ stepsꢀ
+BG 1. Rocker shaft cap
2. Seal cap A
12. Wave washer
13. Exhaust rocker arm assembly A
14. Nut
3. Seal cap C
4. Intake rocker arm assembly A
5. Nut
15. Adjusting screw
16. Exhaust rocker arm H
17. Piston H
6. Adjusting screw
7. Intake rocker arm H
8. Piston H
18. Piston spring H
19. Exhaust T-lever L
9. Piston spring H
10. Intake T-lever
+AG 20. Spring guide
21. Wave washer
+AG 11. Spring guide
22. Camshaft holder
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-11-2ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Rockerꢀ Armꢀ andꢀ Rockerꢀ Shaftꢀ Capꢀ <MIVEC>ꢀ
INSTALLATIONꢀ SERVICEꢀ POINTSꢀ
+AG SPRINGꢀ GUIDEꢀ INSTALLATIONꢀ
Spring guide
Waved washer
T-lever
(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
6AE0247
+BG ROCKERꢀ SHAFTꢀ CAPꢀ INSTALLATIONꢀ
(1) Tighten the bolts in the sequence shown.
(2) Make sure that each rocker arm moves smoothly.
10
2
1
4
3
8
7
9
6
5
6AE0249
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-12-1ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Cylinderꢀ Headꢀ andꢀ Valvesꢀ
12.ꢀ CYLINDERꢀ HEADꢀ ANDꢀ VALVESꢀ
REMOVALꢀANDꢀINSTALLATIONꢀ<SOHC>ꢀ
1ꢀ
4ꢀ
6ꢀ
5ꢀ
12ꢀ
20ꢀ
13ꢀ
16ꢀ
8ꢀ
9ꢀ
14ꢀ
17ꢀ
19ꢀ
11ꢀ
2ꢀ
10
15ꢀ
18ꢀ
7ꢀ
3ꢀ
Apply engine oil to all
moving parts before
installation.
Removalꢀ stepsꢀ
GA+ +DG 1. Cylinder head bolt
2. Cylinder head
11. Exhaust valve
GC+ +AG 12. Valve stem seal
13. Valve spring seat
3. Cylinder head gasket
GB+ +CG 4. Retainer lock
5. Valve spring retainer
+BG 6. Valve spring
7. Intake valve
GC+ +AG 14. Valve stem seal
15. Valve spring seat
16. Intake valve guide
17. Exhaust valve guide
18. Intake valve seat
GB+ +CG 8. Retainer lock
9. Valve spring retainer
+BG 10. Valve spring
19. Exhaust valve seat
20. Cylinder head
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-12-2ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Cylinderꢀ Headꢀ andꢀ Valvesꢀ
REMOVALꢀANDꢀINSTALLATIONꢀ<MIVEC>ꢀ
1ꢀ
4ꢀ
5ꢀ
8ꢀ
12ꢀ
6ꢀ
13
9ꢀ
14ꢀ
10ꢀ
15ꢀ
16ꢀ
17ꢀ
2ꢀ
20ꢀ
19ꢀ
18ꢀ
7ꢀ
11
3ꢀ
Apply engine oil to all
moving parts before
installation.
Removalꢀ stepsꢀ
GA+ +DG 1. Cylinder head bolt
2. Cylinder head
GD+
11. Exhaust valve
GC+ +AG 12. Valve stem seal
13. Valve spring seat
3. Cylinder head gasket
GB+ +CG 4. Retainer lock
5. Valve spring retainer
+BG 6. Valve spring
7. Intake valve
GC+ +AG 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
GB+ +CG 8. Retainer lock
9. Valve spring retainer
+BG 10. Valve spring
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-12-3ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Cylinderꢀ Headꢀ andꢀ Valvesꢀ
REMOVALꢀ SERVICEꢀ POINTSꢀ
<SOHC>ꢀ
PRECAUTIONꢀ FORꢀ REMOVEDꢀ PARTSꢀ
Keep removed parts in order according to the cylinder number
and intake/exhaust side.
MB991653
GA+ CYLINDERꢀ HEADꢀ BOLTꢀ REMOVALꢀ
(1) Using the special tool, loosen the cylinder head bolts.
Loosen evenly, little by little.
6AE0166
<MIVEC>ꢀ
MB991653
6AE0408
GB+ RETAINERꢀ LOCKꢀ REMOVALꢀ
<SOHC>ꢀ
(1) Store removed valves, springs and other parts, tagged
to indicate their cylinder Nos. and location for reassembly.
MD998772
6AE0167
<MIVEC>ꢀ
MD998784
MD998772
MD998735
6AE0253
6EN1068
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-12-4ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Cylinderꢀ Headꢀ andꢀ Valvesꢀ
GC+ VALVEꢀ STEMꢀ SEALꢀ REMOVALꢀ
(1) Do not reuse removed valve stem seals.
6AE0082
GD+ VALVEꢀ HANDLINGꢀ PRECAUTIONSꢀ
(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.
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-12-5ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Cylinderꢀ Headꢀ andꢀ Valvesꢀ
INSTALLATIONꢀ SERVICEꢀ POINTSꢀ
Stem seals
+AG VALVEꢀ STEMꢀ SEALꢀ INSTALLATIONꢀ
for exhaust
Stem seals for intake
valves: Silver
valves: Black
(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:
7EN0763
Stem seals for intake valves: Silver
Stem seals for exhaust valves: Black
<SOHC>ꢀ
Cautionꢀ
MD998774
J
J
Doꢀ notꢀ reuseꢀ theꢀ valveꢀ stemꢀ seal.ꢀ
Alwaysꢀ useꢀ theꢀ specialꢀ toolꢀ toꢀ installꢀ theꢀ valveꢀ
stemꢀseal.ꢀIfꢀtheꢀsealꢀisꢀimproperlyꢀfitted,ꢀengineꢀ
oilꢀmayꢀworkꢀitsꢀwayꢀdownꢀalongꢀtheꢀvalveꢀstem.ꢀ
6AE0169
<MIVEC>ꢀ
MD998775
6AE0409
+BG VALVEꢀ SPRINGꢀ INSTALLATIONꢀ
Spring
retainer
(1) Install the valve spring with the painted end on the rocker
arm side.
Painted
end
Stem seal
Spring
seat
6EN0437
+CG RETAINERꢀ LOCKꢀ INSTALLATIONꢀ
<SOHC>ꢀ
(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
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-12-6ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Cylinderꢀ Headꢀ andꢀ Valvesꢀ
<MIVEC>ꢀ
MD998784
MD998772
MD998735
6AE0253
6EN1068
9EN0251
6AE0392
+DG CYLINDERꢀ HEADꢀ BOLTꢀ INSTALLATIONꢀ
(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.ꢀ 96.4ꢀ mmꢀ
(2) Install the washers as illustrated.
(3) Apply engine oil to the bolt threads and washers.
Length of shank
(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
MB991614
head.
(6) Give a 120è turn to the bolts in the specified tightening
sequence.
Cautionꢀ
120è
J
J
Ifꢀtheꢀboltsꢀareꢀtightenedꢀbyꢀanꢀangleꢀofꢀlessꢀthanꢀ
120è,ꢀ theyꢀ mayꢀ notꢀ holdꢀ theꢀ cylinderꢀ headꢀ withꢀ
sufficientꢀ strength.ꢀ
Ifꢀaꢀboltꢀisꢀovertightened,ꢀcompletelyꢀremoveꢀallꢀ
theꢀboltsꢀandꢀcarryꢀoutꢀtheꢀinstallationꢀprocedureꢀ
againꢀ fromꢀ stepꢀ (1).ꢀ
6AE0339
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-12-7ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Cylinderꢀ Headꢀ andꢀ Valvesꢀ
INSPECTIONꢀ
CYLINDERꢀ HEADꢀ
(1) Check the cylinder head gasket surface for flatness by
using a straightedge and thickness gauge.
Standardꢀ value:ꢀ 0.03ꢀ mmꢀ
Limit:ꢀ 0.2ꢀ mmꢀ
(2) If the service limit is exceeded, correct to meet the
specification.
6AE0083
Grindingꢀ limit:ꢀ *0.2ꢀ mmꢀ
*Includes/combined with cylinder block grinding
Cylinderꢀ headꢀ heightꢀ (Specificationꢀ whenꢀ new):ꢀ
119.9ꢀ - 120.1ꢀ mmꢀ <SOHC>ꢀ
119.6ꢀ - 119.8ꢀ mmꢀ <MIVEC>ꢀ
VALVEꢀ
(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.
Valve seat
contact
Margin
Standard value mm
Limit mm
Intake
1.0
1.3
0.5
0.8
Exhaust
6EN0542
(3) Measure the overall height of the valve. If the specified
limit is exceeded, replace the valve.
Standard value Limit mm
mm
Intake
SOHC
MIVEC
SOHC
MIVEC
113.02
112.37
115.32
110.74
112.52
111.87
114.82
110.74
Exhaust
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-12-8ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Cylinderꢀ Headꢀ andꢀ Valvesꢀ
VALVEꢀ SPRINGꢀ
Out of square
(1) Measure the valve spring’s free height. If the measurement
is less than specified, replace the spring.
Standard
mm
value Limit mm
Free
height
SOHC
MIVEC
49.9
51.5
48.9
50.5
(2) Measure the squareness of the spring. If the measurement
exceeds the specified limit, replace the spring.
1EN0264
Standardꢀ value:ꢀ 2b orꢀ lessꢀ
Limit:ꢀ 4b
VALVEꢀ SEATꢀ
Valve stem end
(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.
Valve stem
projection
Spring seating
surface
Standard
mm
value Limit mm
SOHC
MIVEC
48.45
48.40
48.95
48.90
DEN0212
VALVEꢀ GUIDEꢀ
(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
Standardꢀ value:ꢀ
Intake:ꢀ 0.02ꢀ - 0.05ꢀ mmꢀ
Exhaust:ꢀ 0.04ꢀ - 0.07ꢀ mmꢀ
Limit:ꢀ
Intake:ꢀ 0.10ꢀ mmꢀ
Exhaust:ꢀ 0.15ꢀ mmꢀ
1EN0279
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-12-9ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Cylinderꢀ Headꢀ andꢀ Valvesꢀ
VALVEꢀ SEATꢀ RECONDITIONINGꢀ PROCEDUREꢀ
0.9 - 1.3 mm
0.9 - 1.3 mm
65b
(1) Before correcting the valve seat, check the clearance
between the valve guide and valve. If necessary, replace
the valve and/or valve guide.
65b
(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).
15b
15b
44b
44b
1EN0105
VALVEꢀ SEATꢀ REPLACEMENTꢀ PROCEDUREꢀ
0.5 - 1.0 mm
(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.
Cut away
Intakeꢀ valveꢀ seatꢀ holeꢀ diameterꢀ
0.3ꢀ O.S.ꢀ <SOHC>:ꢀ 29.80ꢀ - 29.82ꢀ mmꢀ
<MIVEC>:ꢀ 32.30ꢀ - 32.32ꢀ mmꢀ
0.5 - 1.0 mm
0.6ꢀ O.S.ꢀ <SOHC>:ꢀ 30.10ꢀ - 30.12ꢀ mmꢀ
<MIVEC>:ꢀ 32.60ꢀ - 32.62ꢀ mmꢀ
1EN0274
Exhaustꢀ valveꢀ seatꢀ holeꢀ diameterꢀ
0.3ꢀ O.S.ꢀ <SOHC>:ꢀ 27.80ꢀ - 27.82ꢀ mmꢀ
<MIVEC>:ꢀ 29.80ꢀ - 29.82ꢀ mmꢀ
0.6ꢀ O.S.ꢀ <SOHC>:ꢀ 28.10ꢀ - 28.12ꢀ mmꢀ
<MIVEC>:ꢀ 30.10ꢀ - 30.12ꢀ mmꢀ
Valve seat
height
Oversize valve seat
hole diameter
1EN0275
(3) Before fitting the valve seat, either heat the cylinder head
up to approximately 250bC 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.
VALVEꢀ GUIDEꢀ REPLACEMENTꢀ
(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.
Cautionꢀ
J
Doꢀnotꢀuseꢀ theꢀvalveꢀ guideꢀofꢀtheꢀsameꢀ sizeꢀasꢀ
theꢀ removedꢀ one.ꢀ
Valveꢀ guideꢀ holeꢀ diametersꢀ inꢀ cylinderꢀ headꢀ
0.05ꢀ O.S.:ꢀ 11.05ꢀ - 11.07ꢀ mmꢀ
0.25ꢀ O.S.:ꢀ 11.25ꢀ - 11.27ꢀ mmꢀ
0.50ꢀ O.S.:ꢀ 11.50ꢀ - 11.52ꢀ mmꢀ
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-12-10ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Cylinderꢀ Headꢀ andꢀ Valvesꢀ
(3) Press-fit the valve guide until it protrude specified value
<SOHC>ꢀ
(SOHC: 14 mm, DOHC: 19 mm) as shown in the
illustration.
Cautionꢀ
J
Pressꢀtheꢀvalveꢀguideꢀfromꢀtheꢀcylinderꢀheadꢀtopꢀ
surface.ꢀ
Valveꢀguideꢀforꢀintakeꢀvalveꢀandꢀthatꢀforꢀexhaustꢀ
valveꢀareꢀdifferentꢀinꢀlength.ꢀ(45.5ꢀmmꢀforꢀintakeꢀ
valve;ꢀ 50.5ꢀ mmꢀ forꢀ exhaustꢀ valve)ꢀ
J
14 mm
(4) After the valve guide has been installed, insert a new
valve to check for smooth sliding motion.
1EN0106
<DOHC>ꢀ
19 mm
19 mm
6AE0254
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-13-1ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Oilꢀ Pumpꢀ Caseꢀ andꢀ Oilꢀ Panꢀ
13.ꢀ OILꢀ PUMPꢀ CASEꢀ ANDꢀ OILꢀ PANꢀ
REMOVALꢀANDꢀINSTALLATIONꢀ<SOHC>ꢀ
6ꢀ
Apply engine oil to all
moving parts before
installation.
12ꢀNmꢀ
24
25ꢀ
2ꢀ
26ꢀ
22ꢀ
14ꢀNmꢀ
8ꢀ
17ꢀ
16ꢀ
7ꢀ
23ꢀ
19ꢀNmꢀ
20ꢀ
21ꢀ
4ꢀ
21ꢀNmꢀ
5ꢀ
19ꢀ
68ꢀNmꢀ
15ꢀ
30ꢀNmꢀ
1ꢀ
9 Nm ꢀ
18ꢀ
10ꢀNmꢀ
44ꢀNmꢀ
3ꢀ
7 Nm ꢀ
14ꢀ
12ꢀ
10ꢀ
39ꢀNmꢀ
7 Nm ꢀ
9ꢀ
13ꢀ
9 Nm ꢀ
7 Nm ꢀ
11ꢀ
Removalꢀ stepsꢀ
+IG 1. Oil pressure switch
+HG 2. Oil filter
+DG 14. Oil pan upper
15. Buffle plate
16. Oil screen
3. Oil filter cover
4. Water hose (for Europe and GCC)
17. Gasket
5. Water pipe (for Europe and GCC)
6. Water pipe (for Europe and GCC)
7. Bolt (for Europe and GCC)
+GG 8. Oil cooler (for Europe and GCC)
9. Drain plug
18. Relief plug
19. Relief spring
20. Relief plunger
+CG 21. Oil seal
+BG 22. Oil pump case
23. O-ring
+FG 10. Gasket
11. Oil level sensor (For Europe)
12. Cover
24. Oil pump case cover
+AG 25. Outer rotor
+AG 26. Inner rotor
+DG 13. Oil pan lower
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-13-2ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Oilꢀ Pumpꢀ Caseꢀ andꢀ Oilꢀ Panꢀ
REMOVALꢀANDꢀINSTALLATIONꢀ<MIVEC>ꢀ
2ꢀ
17ꢀ
18ꢀ
21ꢀNmꢀ
14
14ꢀNmꢀ
9ꢀ
3ꢀ
12ꢀNmꢀ
16ꢀ
15ꢀ
7 Nm ꢀ
12ꢀ
11ꢀ
8ꢀ
44ꢀNmꢀ
10ꢀ
1
13ꢀ
7ꢀ
19ꢀNmꢀ
10ꢀNmꢀ
7 Nm ꢀ
6ꢀ
39ꢀNmꢀ
4ꢀ
5ꢀ
Apply engine oil to all
moving parts before
installation.
Removalꢀ stepsꢀ
+IG 1. Oil pressure switch
+HG 2. Oil filter
3. Oil filter cover
10. Relief plug
11. Relief spring
12. Relief plunger
4. Drain plug
+CG 13. Oil seal
+BG 14. Oil pump case
15. O-ring
+FG 5. Gasket
GA+ +EG 6. Oil pan
7. Oil screen
8. Gasket
16. Oil pump case cover
+AG 17. Outer rotor
9. Buffle plate
+AG 18. Inner rotor
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-13-3ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Oilꢀ Pumpꢀ Caseꢀ andꢀ Oilꢀ Panꢀ
REMOVALꢀ SERVICEꢀ POINTꢀ
GA+ OILꢀ PANꢀ REMOVALꢀ
MD998727
(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
6AE0091
6AE0092
6AE0093
INSTALLATIONꢀ SERVICEꢀ POINTSꢀ
+AG INNERꢀ ROTORꢀ /ꢀ OUTERꢀ ROTORꢀ INSTALLATIONꢀ
(1) Apply engine oil to the rotors. Then, install the rotors
ensuring that the alignment dots made at disassembly
are properly aligned.
+BG SEALANTꢀ APPLICATIONꢀ TOꢀ OILꢀ PUMPꢀ CASEꢀ
3 mm diameter
bead sealant
Specifiedꢀ sealant:ꢀ
Mitsubishiꢀ Genuineꢀ Partꢀ No.ꢀ MD970389ꢀ orꢀ
equivalentꢀ
+CG OILꢀ SEALꢀ INSTALLATIONꢀ
(1) Apply engine oil to the oil seal lip.
Using the special tool, knock the oil seal into the oil pump
case.
MD998717
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-13-4ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Oilꢀ Pumpꢀ Caseꢀ andꢀ Oilꢀ Panꢀ
+DG OILꢀ PANꢀ INSTALLATIONꢀ <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.
Specifiedꢀ sealant:ꢀ
Mitsubishiꢀ Genuineꢀ Partꢀ No.ꢀ MD970389ꢀ orꢀ
equivalentꢀ
f 4
Groove
Bolt
hole
+EG OILꢀ PANꢀ INSTALLATIONꢀ <MIVEC>ꢀ
4 mm diameter
bead sealant
(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.
Specifiedꢀ sealant:ꢀ
Mitsubishiꢀ Genuineꢀ Partꢀ No.ꢀ MD970389ꢀ orꢀ
equivalentꢀ
6AE0094
+FG DRAINꢀ PLUGꢀ GASKETꢀ INSTALLATIONꢀ
(1) Install the drain plug gasket in the shown direction.
Oil pan
side
Drain plug
gasket
7EN0307
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-13-5ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Oilꢀ Pumpꢀ Caseꢀ andꢀ Oilꢀ Panꢀ
+GGOILꢀ COOLERꢀ INSTALLATIONꢀ
(1) Install the oil cooler, with the oil cooler’s positioning
projection positioned against the rib on cylinder block.
6AE0172
+HG OILꢀ FILTERꢀ INSTALLATIONꢀ
(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.
+IG SEALANTꢀ APPLICATIONꢀ TOꢀ SEALANTꢀ TOꢀ OILꢀ
PRESSUREꢀ SWITCHꢀ
(1) Apply sealant to the threads of the switch.
Specifiedꢀ sealant:ꢀ
3Mꢀ ATDꢀ Partꢀ No.ꢀ 8660ꢀ orꢀ equivalentꢀ
Cautionꢀ
J
Useꢀcareꢀnotꢀtoꢀallowꢀ theꢀsealantꢀtoꢀplugꢀtheꢀoilꢀ
passage.ꢀ
Oil passage
9EN0094
6AE0088
6AE0089
INSPECTIONꢀ
OILꢀ PUMPꢀ
(1) Check the tip clearance.
Standardꢀ value:ꢀ 0.06ꢀ - 0.18ꢀ mmꢀ
(2) Check the side clearance.
Standardꢀ value:ꢀ 0.04ꢀ - 0.10ꢀ mmꢀ
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-13-6ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Oilꢀ Pumpꢀ Caseꢀ andꢀ Oilꢀ Panꢀ
(3) Check the body clearance.
Standardꢀ value:ꢀ 0.10ꢀ - 0.18ꢀ mmꢀ
Limit:ꢀ 0.35ꢀ mmꢀ
6AE0090
OILꢀ LEVELꢀ SENSORꢀ (FORꢀ 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 40èC or higher than 80èC, and check for continuity.
40èC
Float position
Switch ON/OFF
ON (continuity)
ON (continuity)
Condition when down
Condition when up
6AE0192
80èC
Float position
Switch ON/OFF
OFF (no continuity)
ON (continuity)
Condition when down
Condition when up
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-14-1ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Pistonꢀ andꢀ Connectingꢀ Rodꢀ
14.ꢀ PISTONꢀ ANDꢀ CONNECTINGꢀ RODꢀ
REMOVALꢀ ANDꢀ INSTALLATIONꢀ
Apply engine oil to all
moving parts before
installation.
6AE0095
Removalꢀ stepsꢀ
+GG 1. Nut
+CG 7. Piston ring No.2
+BG 8. Oil ring
GB+ +AG 9. Piston pin
10. Piston
GA+ +FG 2. Connecting rod cap
+EG 3. Connecting rod bearing
+DG 4. Piston and connecting rod
+EG 5. Connecting rod bearing
+CG 6. Piston ring No.1
11. Connecting rod
12. Bolt
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-14-2ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Pistonꢀ andꢀ Connectingꢀ Rodꢀ
REMOVALꢀ SERVICEꢀ POINTSꢀ
GA+ CONNECTINGꢀ RODꢀ CAPꢀ REMOVALꢀ
(1) Mark the large end of the connecting rod with the cylinder
number for use during reassembly.
Cylinder No.
DEN0050
GB+ PISTONꢀ PINꢀ REMOVALꢀ
Piston pin setting tool MD998780
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.
e A:
mm
e A:
mm
e A:
mm
e A:
mm
Base
9EN0780
(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.
Push rod
(3) Using a press, remove the piston pin.
Front mark
NOTE
Front
mark
Keep the disassembled pistons, piston pins and
connecting rods in order according to the cylinder number.
Guide D
Base
7EN0390
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-14-3ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Pistonꢀ andꢀ Connectingꢀ Rodꢀ
INSTALLATIONꢀ SERVICEꢀ POINTSꢀ
+AG PISTONꢀ PINꢀ INSTALLATIONꢀ
Piston
(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
B
A
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.
D
C
Connecting rod
Piston pin
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.
Push rod
Piston pin
If the press-fitting force required is less than the standard
value, replace the piston and piston pin set or/and the
connecting rod.
Standardꢀ value:ꢀ 5,000ꢀ - 15,000ꢀ Nꢀ
Front mark
Front
mark
Guide A
Base
Guide B
7EN0391
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-14-4ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Pistonꢀ andꢀ Connectingꢀ Rodꢀ
+BG OILꢀ RINGꢀ INSTALLATIONꢀ
(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
Side rail gap
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.
1EN0269
+CG PISTONꢀ RINGꢀ NO.ꢀ 2ꢀ /ꢀ PISTONꢀ RINGꢀ NO.ꢀ 1ꢀ
INSTALLATIONꢀ
(1) Using piston ring expander, install the piston rings with
their side having identification marks facing up.
Identificationꢀ mark:ꢀ
No.ꢀ 1ꢀ ring:ꢀ Tꢀ
Piston ring expander
No.ꢀ 2ꢀ ring:ꢀ 2Tꢀ
7EN0452
NOTE
Identification mark
Identification mark
The piston ring is stamped with the following size mark.
Size mark
Size
Size mark
None
50
Standard size
0.50 mm O.S.
1.00 mm O.S.
No.1
No.2
100
9EN0524
+DG PISTONꢀ ANDꢀ CONNECTINGꢀ RODꢀ INSTALLATIONꢀ
Upper
side rail
No. 1
(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.
Piston pin
(3) Rotate crankshaft so that the crank pin is on center of
the cylinder bore.
Lower
No. 2 ring gap
and spacer gap
side rail
6EN0549
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-14-5ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Pistonꢀ andꢀ Connectingꢀ Rodꢀ
(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.
Cautionꢀ
J
Insertꢀ theꢀ frontꢀ markꢀ (arrow)ꢀ onꢀ theꢀ topꢀ ofꢀ theꢀ
pistonꢀ soꢀ itꢀ facesꢀ theꢀ engineꢀ frontꢀ (timingꢀ beltꢀ
side).ꢀ
6AE0097
+EG CONNECTINGꢀ RODꢀ BEARINGSꢀ INSTALLATIONꢀ
Crankshaft pin
identification mark
(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.
No.2
No.4
No.1
No.3
No.5
<6A12>
Crankshaft pin
Connecting rod
bearing
No.6
Check
digit
Identification mark
Outer diameter mm Identification mark
I
42.995 - 43.000
42.985 - 42.995
42.980 - 42.985
1
2
3
6AE0341
II
III
<6A13>
Crankshaft pin
Connecting rod
bearing
Identification mark
Outer diameter mm Identification mark
I
50.995 - 51.000
50.985 - 50.995
50.980 - 50.985
1
2
3
Identification mark
II
III
+FG CONNECTINGꢀ RODꢀ CAPꢀ INSTALLATIONꢀ
(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.
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-14-6ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Pistonꢀ andꢀ Connectingꢀ Rodꢀ
(2) Check if the thrust clearance in the connecting rod big
end is correct.
Standardꢀ value:ꢀ 0.10ꢀ - 0.25ꢀ mmꢀ
Limit:ꢀ 0.4ꢀ mmꢀ
9EN0073
+GGCONNECTINGꢀ RODꢀ CAPꢀ NUTꢀ INSTALLATIONꢀ
(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 90è to
100è from the paint mark made on the nut in the direction
of tightening the nut.
marks
Paint
marks
(7) Give a 90è to 100è turn to the nut and make sure that
the paint mark on the nut and that on the bolt are in
alignment.
6EN0954
Cautionꢀ
J
Ifꢀtheꢀnutsꢀareꢀtightenedꢀbyꢀanꢀangleꢀofꢀlessꢀthanꢀ
90è,ꢀ theyꢀ mayꢀ notꢀ holdꢀ theꢀ capsꢀ withꢀ sufficientꢀ
strength.ꢀ
J
Ifꢀaꢀnutꢀisꢀtightenedꢀbyꢀanꢀangleꢀexceedingꢀ100è,ꢀ
completelyꢀremoveꢀallꢀtheꢀnutsꢀandꢀcarryꢀoutꢀtheꢀ
installationꢀ procedureꢀ againꢀ fromꢀ stepꢀ (1).ꢀ
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
11A-14-7ꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Pistonꢀ andꢀ Connectingꢀ Rodꢀ
INSPECTIONꢀ
PISTONꢀ RINGꢀ
(1) Check the side clearance between the piston ring and
ring groove. If the limit is exceeded, replace the ring or
piston, or both.
Standardꢀ value:ꢀ
No.ꢀ 1ꢀ
No.ꢀ 2ꢀ
0.03ꢀ - 0.07ꢀ mmꢀ
0.02ꢀ - 0.06ꢀ mmꢀ
Limit:ꢀ
7EN0475
No.ꢀ 1ꢀ
No.ꢀ 2ꢀ
0.1ꢀ mmꢀ
0.1ꢀ mmꢀ
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.
Standardꢀ value:ꢀ
No.ꢀ 1ꢀ
No.ꢀ 2ꢀ
Oilꢀ
0.25ꢀ - 0.40ꢀ mmꢀ
0.40ꢀ - 0.55ꢀ mmꢀ
0.10ꢀ - 0.35ꢀ mmꢀ
ring gap
Piston ring
7EN0476
Limit:ꢀ
No.ꢀ 1,ꢀ No.ꢀ 2ꢀ 0.8ꢀ mmꢀ
Oilꢀ 1.0ꢀ mmꢀ
CRANKSHAFTꢀ PINꢀ OILꢀ CLEARANCEꢀ (PLASTICꢀ
GAUGEꢀ 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.
Plastic gauge
1EN0246
Standardꢀ value:ꢀ 0.02ꢀ - 0.05ꢀ mmꢀ
Limit:ꢀ 0.1ꢀ mmꢀ
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
Crankshaft,ꢀCylinderꢀBlock,ꢀFlywheelꢀandꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Driveꢀ Plateꢀ
11A-15-1ꢀ
15.ꢀCRANKSHAFT,ꢀ CYLINDERꢀ BLOCK,ꢀ FLYWHEELꢀ ANDꢀ DRIVEꢀ
PLATEꢀ
REMOVALꢀ ANDꢀ INSTALLATIONꢀ
5ꢀ
4ꢀ
6ꢀ
11ꢀNmꢀ
Aꢀ
35ꢀNmꢀ
23ꢀNmꢀ
2ꢀ
11ꢀ
3ꢀ
1ꢀ
14ꢀ
98ꢀNmꢀ
13ꢀ
7ꢀ
21ꢀ
8ꢀ
12ꢀ
98ꢀNmꢀ
9ꢀ
11ꢀNmꢀ
10ꢀ
9 Nm ꢀ
19ꢀ
18ꢀ
16ꢀ
20ꢀ
Apply engine oil to all
moving parts before
installation.
17ꢀ
15ꢀ
Removalꢀ stepsꢀ
1. Detonation sensor
+BG 16. Bearing cap
2. Idler pulley bracket <M/T>
+AG 17. Crankshaft bearing, lower
18. Crankshaft
+EG 3. Flywheel bolt <M/T>
4. Plate <M/T>
+AG 19. Thrust bearing
+AG 20. Crankshaft bearing, upper
21. Cylinder block
5. Adapter plate <M/T>
6. Flexible flywheel <M/T>
7. Adapter plate <M/T>
+EG 8. Drive plate bolt <A/T>
9. Adapter plate <A/T>
10. Drive plate <A/T>
11. Rear plate
Cautionꢀ
Onꢀ theꢀ flexibleꢀ wheelꢀ equippedꢀ engines,ꢀ doꢀ notꢀ
removeꢀanyꢀofꢀtheꢀboltsꢀ“A”ꢀofꢀtheꢀflywheelꢀshownꢀ
inꢀ theꢀ illustration.ꢀ
12. Bell housing cover <MIVEC>
Theꢀ balanceꢀofꢀ theꢀ flexibleꢀ flywheelꢀ isꢀ adjustedꢀ inꢀ
anꢀ assembledꢀ condition.ꢀ Removingꢀ theꢀ bolt,ꢀ
therefore,ꢀcanꢀcauseꢀtheꢀflexibleꢀflywheelꢀtoꢀbeꢀoutꢀ
ofꢀ balance,ꢀ givingꢀ damageꢀ toꢀ theꢀ flywheel.ꢀ
+DG 13. Oil seal case
+CG 14. Oil seal
+BG 15. Bearing cap bolt
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
Crankshaft,ꢀCylinderꢀBlock,ꢀFlywheelꢀandꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Driveꢀ Plateꢀ
11A-15-2ꢀ
INSTALLATIONꢀ SERVICEꢀ POINTSꢀ
+AG CRANKSHAFTꢀ BEARINGꢀ INSTALLATIONꢀ
Crankshaft journal
identification mark
(1) When replacing bearing, select a one of proper size
according to the identification marks stamped on both
crankshaft and cylinder block.
No.1
No.2
No.4
<6A12>
No.3
Cylinder Block Bearing
Bore
Crankshaft
Bearing
Crankshaft Journal
Check
digit
Identi-
Identifi-
Inner diameter
cation
6AE0343
Outer diameter
Identifica-
tion mark
fication
mark
mm
mm
mark
Cylinder bore size
mark (reference)
0
1
2
0
1
2
0
1
2
57.000 - 57.006
57.006 - 57.012
57.012 - 57.018
57.000 - 57.006
57.006 - 57.012
57.012 - 57.018
57.000 - 57.006
57.006 - 57.012
57.012 - 57.018
1
2
3
2
3
4
3
4
5
No.4 No.2
1
2
52.994 - 53.000
No.3
No.1
Cylinder block
bearing bore
identification
mark
52.988 - 52.994
52.982 - 52.988
3
Timing belt side
6AE0344
<6A13>
Cylinder Block Bearing
Bore
Crankshaft
Bearing
Crankshaft Journal
Identi-
fication
mark
Identifi-
Inner diameter
cation
Outer diameter
mm
Identifica-
tion mark
mm
mark
0
1
2
0
1
2
0
1
2
60.000 - 60.006
60.006 - 60.012
60.012 - 60.018
60.000 - 60.006
60.006 - 60.012
60.012 - 60.018
60.000 - 60.006
60.006 - 60.012
60.012 - 60.018
1
2
3
2
3
4
3
4
5
1
2
3
55.994 - 56.000
55.988 - 55.994
55.982 - 55.988
(2) Install the bearings having an oil groove to the cylinder
block.
Oil groove
Groove
(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.
Identification
mark
Identification
mark
6AE0116
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
Crankshaft,ꢀCylinderꢀBlock,ꢀFlywheelꢀandꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Driveꢀ Plateꢀ
11A-15-3ꢀ
+BG BEARINGꢀ CAPꢀ /ꢀ BEARINGꢀ CAPꢀ BOLTꢀ
INSTALLATIONꢀ
(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.ꢀ 71.1ꢀ mmꢀ
9EN0477
6AE0108
6EN0955
(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
(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 90è to 100è in the direction of tightening
the bolt.
(7) Give a 90è to 100è 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
90è - 100è
Cautionꢀ
J
Ifꢀtheꢀboltsꢀareꢀtightenedꢀbyꢀanꢀangleꢀofꢀlessꢀthanꢀ
90è,ꢀ theyꢀ mayꢀ notꢀ holdꢀ theꢀ capꢀ withꢀ sufficientꢀ
strength.ꢀ
Paint marks
J
Ifꢀaꢀboltꢀisꢀtightenedꢀbyꢀanꢀangleꢀexceedingꢀ100è,ꢀ
completelyꢀremoveꢀallꢀtheꢀboltsꢀandꢀcarryꢀoutꢀtheꢀ
installationꢀ procedureꢀ againꢀ fromꢀ stepꢀ (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.
Standardꢀ value:ꢀ 0.05ꢀ - 0.25ꢀ mmꢀ
Limit:ꢀ 0.4ꢀ mmꢀ
6AE0109
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
Crankshaft,ꢀCylinderꢀBlock,ꢀFlywheelꢀandꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Driveꢀ Plateꢀ
11A-15-4ꢀ
+CG OILꢀ SEALꢀ INSTALLATIONꢀ
(1) Apply engine oil to oil seal lip.
MB990938
MD998776
9EN0077
+DG APPLICATIONꢀ OFꢀ OILꢀ SEALꢀ CASEꢀ
Specifiedꢀ sealant:ꢀ
Mitsubishiꢀ Genuineꢀ Partꢀ No.ꢀ MD970389ꢀ orꢀ
equivalentꢀ
6AE0110
9EN0102
6AE0101
6AE0102
+EG DRIVEꢀ PLATEꢀ BOLTꢀ /ꢀ FLYWHEELꢀ BOLTꢀ
INSTALLATIONꢀ
(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.
Specifiedꢀ sealant:ꢀ
3Mꢀ Nutꢀ Lockingꢀ Partꢀ No.ꢀ 4171ꢀ orꢀ equivalentꢀ
(5) Tighten the bolts to specified torque.
INSPECTIONꢀ
CRANKSHAFTꢀ OILꢀ CLEARANCEꢀ (PLASTICꢀ GAUGEꢀ
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.
Standardꢀ value:ꢀ 0.02ꢀ - 0.04ꢀ mmꢀ
Limit:ꢀ 0.1ꢀ mmꢀ
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
Crankshaft,ꢀCylinderꢀBlock,ꢀFlywheelꢀandꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Driveꢀ Plateꢀ
11A-15-5ꢀ
CYLINDERꢀ BLOCKꢀ
C
D
E
F
A
B
(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.
G
Standardꢀ value:ꢀ 0.05ꢀ mmꢀ orꢀ lessꢀ
Limit:ꢀ 0.1ꢀ mmꢀ
(2) If the distortion is excessive, correct within the allowable
limit or replace.
Grindingꢀ limit:ꢀ 0.2ꢀ mmꢀ
6AE0103
Theꢀ totalꢀ thicknessꢀ ofꢀ theꢀ stockꢀ allowedꢀ toꢀ beꢀ
removedꢀfromꢀcylinderꢀblockꢀandꢀmatingꢀcylinderꢀ
headꢀ isꢀ 0.2ꢀ mmꢀ atꢀ maximum.ꢀ
Cylinderꢀ blockꢀ heightꢀ (whenꢀ new):ꢀ
6A12ꢀ
6A13ꢀ
190ꢀ mmꢀ
209ꢀ mmꢀ
(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.
Standardꢀ value:ꢀ
Cylinderꢀ I.D.:ꢀ
12 mm
6A12ꢀ
6A13ꢀ
78.40ꢀ - 78.43ꢀ mmꢀ
81.00ꢀ - 81.03ꢀ mmꢀ
Out-of-roundnessꢀ andꢀ taperꢀ ofꢀ cylinderꢀ bore:ꢀ
0.01ꢀ mmꢀ orꢀ lessꢀ
6AE0104
BORINGꢀ CYLINDERꢀ
(1) Oversize pistons to be used should be determined on
the basis of the largest bore cylinder.
Pistonꢀ sizeꢀ identificationꢀ
Size
Identification mark
0.50 mm O.S.
1.00 mm O.S.
0.50
1.00
6AE0105
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.
Boringꢀ finishꢀ dimensionꢀ =ꢀ Pistonꢀ O.D.ꢀ +ꢀ(Clearanceꢀ
betweenꢀpistonꢀO.D.ꢀandꢀcylinder)ꢀ- 0.02ꢀmmꢀ(honingꢀ
margin)ꢀ
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
Crankshaft,ꢀCylinderꢀBlock,ꢀFlywheelꢀandꢀ
6A1ꢀ ENGINEꢀ (E-W)ꢀ - Driveꢀ Plateꢀ
11A-15-6ꢀ
(4) Bore all cylinders to calculated boring finish dimension.
Cautionꢀ
J
Toꢀ preventꢀ distortionꢀ thatꢀ mayꢀ resultꢀ fromꢀ
temperatureꢀ riseꢀ duringꢀ honing,ꢀ boreꢀ cylinders,ꢀ
workingꢀ fromꢀ No.ꢀ 1,ꢀ No.ꢀ 2,ꢀ No.ꢀ 3,ꢀ No.ꢀ 4,ꢀ No.ꢀ 5ꢀ
andꢀ No.ꢀ 6ꢀ
(5) Hone to final finish dimension (piston O.D. + clearance
between piston O.D. and cylinder.)
(6) Check clearance between piston and cylinder.
Clearanceꢀ betweenꢀ pistonꢀ andꢀ cylinder:ꢀ
0.02ꢀ - 0.04ꢀ mmꢀ
NOTE
When boring cylinders, finish all of four cylinders to same
oversize. Do not bore only one cylinder to an oversize.
MitsubishiꢀMotorsꢀCorporationꢀ
Feb.ꢀ1997ꢀ
PWEE9622ꢀ
K
NOTESꢀ
Service Bulletins
Click on the applicable bookmark to select the Service Bulletin.
SERVICE BULLETIN
QUALITY INFORMATION ANALYSIS
OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION
No.: MSB-01E11-001
SERVICE BULLETIN
Date: 2001-07-25
<Model>
<M/Y>
ADDITION OF 6A1 ENGINE WATER PUMP
INSTALLATION PROCEDURES
(EC)GALANT(EA0)
01-10
Subject:
Group:
ENGINE
Draft No.: 00EN620614
INTERNATIONAL
CAR
INFORMATION
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
ENGINE 6A1 (W-E)
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
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
THERMOSTAT INSTALLATION
D
► ◄
Jiggle valve
(1) Install the thermostat so that the jiggle valve will be located in
the thermostat housing as shown.
6AE0069
E SEALANT APPLICATION TO ENGINE COOLANT
► ◄
TEMPERATURE SENSOR
Specified sealant:
3M Nut locking Part No. 4171 or equivalent
6AE0070
3
<Added>
(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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