11B-1

GROUP 11B

ENGINE OVERHAUL
CONTENTS

GENERAL DESCRIPTION. . . . . . . . . 11B-2 ROCKER ARMS AND CAMSHAFT . . 11B-35

REMOVAL AND INSTALLATION . . . . . . . . 11B-35
SPECIAL TOOLS. . . . . . . . . . . . . . . . 11B-4 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-39

GENERATOR AND IGNITION SYSTEM 11B-8 CYLINDER HEAD AND VALVES. . . . 11B-42
REMOVAL AND INSTALLATION . . . . . . . . 11B-8 REMOVAL AND INSTALLATION . . . . . . . . 11B-42
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-47
SOLENOID AND VACUUM HOSE . . 11B-10
REMOVAL AND INSTALLATION . . . . . . . . 11B-10 OIL PAN AND OIL PUMP. . . . . . . . . . 11B-51
REMOVAL AND INSTALLATION . . . . . . . . 11B-51
TIMING BELT. . . . . . . . . . . . . . . . . . . 11B-11 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-60
REMOVAL AND INSTALLATION . . . . . . . . 11B-11
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 11B-25 PISTON AND CONNECTING ROD . . 11B-61
REMOVAL AND INSTALLATION . . . . . . . . 11B-61
FUEL AND EMISSION PARTS . . . . . 11B-27 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-69
REMOVAL AND INSTALLATION . . . . . . . . 11B-27
CRANKSHAFT AND CYLINDER
INTAKE MANIFOLD . . . . . . . . . . . . . 11B-29 BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 11B-70
REMOVAL AND INSTALLATION . . . . . . . . 11B-29 REMOVAL AND INSTALLATION . . . . . . . . 11B-70
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-74
EXHAUST MANIFOLD. . . . . . . . . . . . 11B-31
REMOVAL AND INSTALLATION . . . . . . . . 11B-31 SPECIFICATIONS . . . . . . . . . . . . . . . 11B-76
FASTENER TIGHTENING
WATER PUMP & WATER HOSE . . . 11B-33 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 11B-76
REMOVAL AND INSTALLATION . . . . . . . . 11B-33 GENERAL SPECIFICATIONS . . . . . . . . . . 11B-79
SERVICE SPECIFICATIONS . . . . . . . . . . . 11B-80
SEALANTS AND ADHESIVES . . . . . . . . . . 11B-82
11B-2 ENGINE OVERHAUL
GENERAL DESCRIPTION

GENERAL DESCRIPTION
M1113000100891
4G63 engine used in LANCER EVOLUTION IX adopts MITSUBISHI INNOVATIVE VALVE TIMING ELEC-
TRONIC CONTROL SYSTEM (MIVEC).
MIVEC mechanism is as follows:
V.V.T. (VARIABLE VALVE TIMING) CONTROL SYSTEM
This V.V.T. system consists of the parts indicated in the illustration.

V.V.T. SPROCKET

CAMSHAFT

OIL FEEDER
CONTROL VALVE

EYE BOLT

OIL FEEDER CONTROL

OIL PIPE JOINT VALVE FILTER AK500009 AC

V.V.T. (VARIABLE VALVE TIMING) SPROCKET

This V.V.T. sprocket is installed to change the valve timing through the vane rotor driven by oil pressure from
the oil feeder control valve.

MAXIMUM RETARD
ANGLE POSITION ADVANCE ANGLE

BASE BLADE

SPROCKET
PLUG CAP

V.V.T. SPROCKET BOLT

VANE ROTOR
WASHER

OIL ROOM O-RING

HOUSING

OIL PASSAGE FOR RETARD

ANGLE OPERATION
AK501795 AC

TSB Revision
 ENGINE OVERHAUL
GENERAL DESCRIPTION
11B-3
CAMSHAFT
The camshaft has the oil passage to transfer the oil
FOR ADVANCE ANGLE pressure from the oil feeder control valve to the
FOR RETARD ANGLE V.V.T. sprocket.

AK501796AC

OIL FEEDER CONTROL VALVE (OCV)

This oil feeder control valve uses an electromagnetic valve which switches oil pressure affecting a vane rotor
on a V.V.T. sprocket ASSY. This is driven by the signal from the engine ECU.

PLUNGER
O-RING TERMINAL
COIL
SPOOL
OIL PRESSURE BOSS COVER
SPRING DRAIN DRAIN
O-RING

SPRING HOLDER SPACER

CORE

SLEEVE
C-STOP RING
ADVANCE RETARDANGLE
ANGLE SIDE SIDE ROD
HOUSING BOBBIN
SLEEVE
CASE

AK201866AD

TSB Revision
11B-4 ENGINE OVERHAUL
SPECIAL TOOLS

SPECIAL TOOLS
M1113000601413

TOOL TOOL NUMBER AND SUPERSESSION APPLICATION

NAME
MD998781 General service tool Supporting flywheel and drive
Flywheel stopper plate

D998781

MD998778 General service tool Removal of crankshaft sprocket

Crankshaft sprocket
puller

MD998785 MD998785 Supporting counterbalance

Sprocket stopper shaft sprocket

MD998767 MD998752-01 Adjustment of timing belt

Tension pulley wrench tension

D998767

MD998738 General service tool • Holding the auto-tensioner

Adjusting screw • Timing belt tension
adjustment

D998738

MD998713 MD998713-01 Installation of camshaft oil seal

Camshaft oil seal
Installer

D998713

MD998442 General service tool Air bleed of lash adjuster

Air bleed wire

MB991654 General service tool Removal and installation of

Cylinder head bolt cylinder head bolt
wrench (12)

B991654

TSB Revision
 ENGINE OVERHAUL
SPECIAL TOOLS
11B-5
TOOL TOOL NUMBER AND SUPERSESSION APPLICATION
NAME
MD998735 MD998735-01 Compression of valve spring
Valve spring compressor

MD998772 MLR-MD998772 or Compression of valve spring

Valve spring compressor General service tool

MD998737 MD998737-01 Installation of valve steam seal

Valve steam seal
installer

MD998727 MD998727-01 Removal of oil pan

Oil pan remover

D998727

MD998162 MD998162-01 Removal and installation of

Plug wrench Use with front case cap plug
MD998783

MD998783 General service tool

Plug wrench retainer

MD998371 MD998371-01 Removal of counterbalance

Silent shaft bearing shaft front bearing
puller

MD998372 MD998372-01 Removal of counterbalance

Silent shaft bearing shaft rear bearing
puller

TSB Revision
11B-6 ENGINE OVERHAUL
SPECIAL TOOLS

TOOL TOOL NUMBER AND SUPERSESSION APPLICATION

NAME
MB991603 General service tool Removal and installation of rear
Bearing installer stopper bearing

MD998705 MD998373-01 Use Installation of counterbalance

Silent shaft bearing with MB990938-01 shaft bearing
installer

MD998285 MD998285-01 Installation of crankshaft front

Crankshaft front oil seal oil seal
guide

D998285

MD998375 MD998375-01
Crankshaft front oil seal
installer

MD998012 − Removal and installation of

Oil pressure switch engine oil pressure switch
wrench

MD998780 MIT216941 Removal and installation of

Piston pin setting tool piston pin

TSB Revision
 ENGINE OVERHAUL
SPECIAL TOOLS
11B-7
TOOL TOOL NUMBER AND SUPERSESSION APPLICATION
NAME
MB992010 − Removal and installation of
Bolt guide piston and connecting rod
assembly

MB990938 MB990938-01 Installation of crankshaft rear oil

Handle seal

MD998776 MD998376-01
Crankshaft rear oil seal
installer

D998776

TSB Revision
11B-8 ENGINE OVERHAUL
GENERATOR AND IGNITION SYSTEM

GENERATOR AND IGNITION SYSTEM

REMOVAL AND INSTALLATION
M1113001000994

CAUTION
Do not remove the ignition coil boot from the ignition coil except the replacement. When removing
the ignition coil boot, always replace it with the new one.

1 3.0 ± 0.5 N·m

10 27 ± 3 in-lb

2 10 ± 2 N·m
89 ± 17 in-lb
12

3 11
13 ± 1 N·m
13
115 ± 8 in-lb
12
13 14 25 ± 5 N·m
20 ± 2 N·m 4 19 ± 3 ft-lb
15 ± 1 ft-lb
24 ± 4 N·m 22 ± 4 N·m
18 ± 2 ft-lb 17 ± 2 ft-lb
8 7

44 ± 10 N·m
33 ± 6 ft-lb 5
8.8 ± 1.0 N·m
6 78 ± 8 in-lb

44 ± 10 N·m
33 ± 6 ft-lb
9

24 ± 4 N·m
18 ± 2 ft-lb 25 ± 4 N·m AK501910AB
19 ± 2 ft-lb

REMOVAL STEPS REMOVAL STEPS (Continued)

1. OIL DIPSTICK 8. GENERATOR
2. O-RING 9. CRANKSHAFT PULLEY
3. OIL DIPSTICK GUIDE 10. CENTER COVER
4. O-RING 11. SPARK PLUG CABLE
5. AUTO-TENSIONER 12. IGNITION COIL
6. WATER PUMP PULLEY >>A<< 13. IGNITION COIL BOOT
7. GENERATOR BRACE 14. SPARK PLUG

TSB Revision
 ENGINE OVERHAUL
GENERATOR AND IGNITION SYSTEM
11B-9
INSTALLATION SERVICE POINTS
.

>>A<< IGNITION COIL BOOT INSTALLATION

CAUTION
• When the ignition coil boot is not installed as indicated,
realize that it would be possibly the causes of the mal-
functions which lead to an inappropriate ignition coil
operation, a damaged ignition coil, a high voltage leak-
age toward the outside and water immersion into the
hole.
• White powders are applied to the fitting area of the
spark plug on the ignition coil boot in order to prevent
the fitting area from baking onto the spark plug. Do not
touch or clean them.
1. Confirm the spring is attached to the new ignition coil boot
AIR-BLEEDING inside.
HOLE
FITTING PART 2. Push and install the new ignition coil boot into the ignition
coil without a clearance, turning the fitting area twice or
three times.
AIR-BLEEDING TOP VIEW 3. After the installation, turn the ignition coil boot so that the air
HOLE bleeding hole can be in position indicated in the illustration.
DO NOT TOUCH THE WHITE
POWDERS APPLIED TO THE
INSIDE AK404096 AE

TSB Revision
11B-10 ENGINE OVERHAUL
SOLENOID AND VACUUM HOSE

SOLENOID AND VACUUM HOSE

REMOVAL AND INSTALLATION
M1113025300126

11 ± 1 N·m
98 ± 8 in-lb
7
11 ± 1 N·m
98 ± 8 in-lb

9.0 ± 1.0 N·m

80 ± 8 in-lb 4
6

9.0 ± 1.0 N·m

80 ± 8 in-lb
5

3
8
9.0 ± 1.0 N·m
80 ± 8 in-lb

AK501891AB

REMOVAL STEPS REMOVAL STEPS (Continued)

1. VACUUM PIPE AND HOSE ASSEMBLY 5. VACUUM HOSE
2. SOLENOID VALVE 6. SOLENOID VALVE
3. SOLENOID VALVE 7. VACUUM PIPE AND HOSE ASSEMBLY
4. VACUUM HOSE 8. VACUUM HOSE ASSEMBLY

TSB Revision
 ENGINE OVERHAUL
TIMING BELT
11B-11
TIMING BELT
REMOVAL AND INSTALLATION
M1113001901149

CAUTION
Never overhaul the V.V.T. sprocket.

11 ± 1 N·m 8 3.5 ± 0.5 N·m

95 ± 9 in-lb 31 ± 4 in-lb

7 12
11 ± 1 N·m
95 ± 9 in-lb 9
1 5
15 6 4
48 ± 5 N·m 16 10 ± 2 N·m
36 ± 3 ft-lb 89 ± 17 in-lb

10
21 ± 4 N·m
2 16 ± 2 ft-lb
17 11
23 ± 3 N·m
17 ± 2 ft-lb
11 ± 1 N·m
11 ± 1 N·m 95 ± 9 in-lb
95 ± 9 in-lb
35
22 36
21
30
167 N·m 49 ± 5 N·m
11 ± 1 N·m 123 ft-lb 36 ± 3 ft-lb
95 ± 9 in-lb
9.0 ± 1.0 N·m
80 ± 8 in-lb

65 ± 5 N·m 45 ± 3 N·m
48 ± 3 ft-lb 14 33 ± 2 ft-lb
32 26 27
34 19 ± 3 N·m
31 14 ± 2 ft-lb
32 ± 2 N·m 3
24 ± 1 ft-lb 24
13
37
33 29
19 49 ± 9 N·m
88 ± 10 N·m 28 36 ± 6 ft-lb
65 ± 7 ft-lb 25 8.8 ± 1.0 N·m
23 78 ± 8 in-lb

18 20
35 ± 6 N·m 54 ± 5 N·m
26 ± 4 ft-lb 40 ± 3 ft-lb AK501892 AB

Removal steps Removal steps (Continued)

1. TIMING BELT FRONT UPPER COVER 7. OIL FILLER CAP
2. TIMING BELT FRONT LOWER COVER 8. CONNENTOR BRACKET
3. POWER STEERING PUMP BRACKET >>O<< 9. ROCKER COVER
4. BREATHER HOSE >>O<< 10. ROCKER COVER GASKET "A"
5. PCV HOSE 11. ROCKER COVER GASKET "B"
6. PCV VALVE >>N<< 12. SEMICIRCULAR PACKING

TSB Revision
11B-12 ENGINE OVERHAUL
TIMING BELT

Removal steps (Continued) Removal steps (Continued)

<<A>> >>M<< 13. PLUG CAP <<G>> >>F<< 26. COUNTERBALANCER SHAFT
<<B>> >>L<< 14. TIMING BELT SPROCKET
>>K<< 15. TENSIONER PULLEY >>E<< 27. SPACER
16. TENSIONER ARM <<H>> >>D<< 28. CRANKSHAFT SPROCKET "B"
>>J<< 17. AUTO-TENSIONER 29. CRANKSHAFT KEY
18. IDLER PULLEY >>C<< 30. ENGINE SUPPORT BRACKET
19. CRANKSHAFT ANGLE SENSOR <<I>> >>B<< 31. V.V.T. SPROCKET BOLT
<<C>> >>I<< 20. OIL PUMP SPROCKET >>B<< 32 V.V.T. SPROCKET
<<D>> >>H<< 21. CRANKSHAFT BOLT <<J>> >>A<< 33 CAMSHAFT SPROCKET BOLT
<<E>> >>H<< 22. CRANKSHAFT SPROCKET 34 CAMSHAFT SPROCKET
>>H<< 23. CRANKSHAFT SENSING BLADE 35 TIMING BELT REAR COVER, RIGHT
24. TENSIONER "B" 36. TIMING BELT REAR UPPER COVER,
<<F>> >>G<< 25. TIMING BELT "B" LEFT
37 TIMING BELT REAR LOWER COVER,
LEFT
Required Special Tools:
• MD998738: Adjusting Screw • MD998781: Flywheel Stopper
• MD998767: Tensioner Pulley Wrench • MD998785: Sprocket Stopper
• MD998778: Crankshaft Sprocket Puller

REMOVAL SERVICE POINTS

.

<<A>> PLUG CAP REMOVAL

Loosen the plug cap, holding the hexagonal portion of the cam-
shaft with a wrench.

AK403832

<<B>> TIMING BELT REMOVAL

1. If the timing belt is to be reused, make an arrow mark with
something like chalk on the back of the belt indicating the
direction of rotation so it may be reinstalled in the same
direction.

AK501768

TSB Revision
 ENGINE OVERHAUL
TIMING BELT
11B-13

TIMING MARKS
CAUTION
Never remove the timing belt with any piston at the top
dead center (TDC). If a piston is at TDC, the exhaust valves
of the cylinder are pushed by the exhaust cams, com-
pressing the valve springs. If the belt is removed under
this condition, the sprocket will be turned in the reverse
direction by the force of the springs, incurring risk of
injury to person.
AK304440AD
2. Set the timing mark of the exhaust camshaft sprocket to a
point about one tooth before the TDC of the No.1 cylinder
piston on compression stroke.
3. Loosen the lock nut of the tensioner pulley, then remove the
timing belt.
.

<<C>> OIL PUMP SPROCKET REMOVAL

1. Remove the plug on the left side of the cylinder block.
2. Insert a Phillips crosspoint screwdriver [shank diameter 8
mm (0.3 inch)] through the plug hole to block the left
counterbalance shaft.
3. Loosen the nut, and then remove the oil pump sprocket.

PLUG
CROSSPOINT
SCREWDRIVER
AK202752 AC

CROSSPOINT
SCREWDRIVER

AK202825 AC

<<D>> CRANKSHAFT BOLT LOOSENING

1. Install special tool MD998781 to hold the flywheel or drive
plate.
2. Loosen and remove the crankshaft bolt and washer.

MD998781

AK202738AF

TSB Revision
11B-14 ENGINE OVERHAUL
TIMING BELT

<<E>> CRANKSHAFT SPROCKET REMOVAL

1. Set special tool MD998778 as shown in the illustration.
MD998778
2. Screw in the center bolt of the special tool to remove the
crankshaft sprocket.

AK304176AD

<<F>> TIMING BELT "B" REMOVAL

CAUTION
Water or oil on the belt shortens its life drastically, so the
removed timing belt, sprocket, and tensioner must be free
from oil and water. These parts should not be washed or
immersed in solvent. Replace parts if contaminated.If there
is oil or water on each part, check the front case oil seals,
camshaft oil seal and water pump for leaks.
1. Mark the belt running direction for reinstallation.
2. Loosen the tensioner "B" bolt, and then remove the timing
belt "B."

AK202758AC

<<G>> COUNTERBALANCE SHAFT SPROCKET REMOVAL

1. Set special tool MD998785 as shown to prevent the
counterbalance shaft sprocket from turning together.
2. Loosen the bolt and remove the sprocket.

MD998785

AK202739AD

TSB Revision
 ENGINE OVERHAUL
TIMING BELT
11B-15
<<H>> CRANKSHAFT SPROCKET "B" REMOVAL
1. Set special tool MD998778 as shown in the illustration.
2. Screw in the center bolt of the special tool to remove
MD998778 crankshaft sprocket "B."

AK202740AD

<<I>> V.V.T. SPROCKET BOLT REMOVAL

Loosen the V.V.T. sprocket bolt, holding the hexagonal portion
of the camshaft with a wrench.

AK403833

<<J>> CAMSHAFT SPROCKET REMOVAL

Remove the camshaft sprocket bolt while preventing the cam-
shaft from rotation using a wrench fitted on the hexagonal por-
tion of the camshaft.

AK202858AC

TSB Revision
11B-16 ENGINE OVERHAUL
TIMING BELT

INSTALLATION SERVICE POINTS

.

>>A<< CAMSHAFT SPROCKET INSTALLATION

Tighten the camshaft sprocket bolt while preventing the cam-
shaft from rotation using a wrench fitted on the hexagonal por-
tion of the camshaft.
Tightening torque: 88 ± 10 N⋅ m (65 ± 7 ft-lb)

AK202858AC

AK202859

>>B<< V.V.T. SPROCKET / V.V.T. SPROCKET BOLT

INSTALLATION
V.V.T. SPROCKET 1. Apply minimum amount of engine oils adequately to the
following portions.
V.V.T.
SPROCKET CAMSHAFT • All directions of camshaft top
BOLT • Inner and outer surfaces of place in which V.V.T. sprocket is
inserted
• Threads and top seat of V.V.T. sprocket bolt
• V.V.T. sprocket bolt seat
2. Install the V.V.T. sprocket.
3. Firmly and deeply insert the V.V.T. sprocket, and then
AK403834AD confirm the V.V.T. sprocket is not rotated, holding the
hexagonal portion of the camshaft with a wrench.
4. Holding the hexagonal portion of the camshaft with a
wrench, tighten the V.V.T. sprocket bolt to the specified
torque of 65 ± 5 N⋅ m.
5. Holding the hexagonal portion of the camshaft with a
wrench, confirm the V.V.T. sprocket is not rotated.
NOTE: This shows the V.V.T. sprocket being locked at the
most retarded angle with the inside pin.

AK403835

TSB Revision
 ENGINE OVERHAUL
TIMING BELT
11B-17
>>C<< ENGINE SUPPORT BRACKET INSTALLATION
Coat the threads of the seal bolt A in the illustration with 3M™
AAD Part number 8672 or equivalent before tightening.
Tightening torque: 49 ± 5 N⋅ m (36 ± 3 ft-lb)

AK202743 AC

>>D<< CRANKSHAFT SPROCKET "B" INSTALLATION

Clean and then degrease the front case of the front case,
SPROCKET "B" crankshaft sprocket "B" and crankshaft surface on which
CRANKSHAFT
sprocket "B" is attached.
NOTE: Degreasing is necessary to prevent decrease in the fric-
tion between contacting surfaces.

DEGREASE
FRONT CASE AK301828AB

>>E<< SPACER INSTALLATION

COUNTER
1. Apply a thin coat of clean engine oil to the lip area of the oil
BALANCE seal.
OIL SEAL SHAFT
2. Install the spacer with the chamfered end facing toward the
SPECER oil seal.

CHAMFERED
AK301298AC

>>F<< COUNTERBALANCE SHAFT SPROCKET

INSTALLATION
1. Install the counterbalance shaft sprocket and screw in the
bolt.
2. Install special tool MD998785 as shown in the illustration to
lock the counterbalance shaft.
MD998785
3. Tighten the bolt, and then remove the special tool.
Tightening torque: 45 ± 3 N⋅ m (33 ± 2 ft-lb)

AK202739AD

TSB Revision
11B-18 ENGINE OVERHAUL
TIMING BELT

>>G<< TIMING BELT "B" INSTALLATION

1. Align timing marks on the crankshaft sprocket "B" and
TIMING counterbalance shaft sprocket with the marks on the front
MARKS
case.
2. Install the timing belt "B" on the crankshaft sprocket "B" and
counterbalance shaft sprocket. There should be no slack on
the tension side.

TIMING MARKS
(ON FRONT CASE)
AK305591AB

3. Make sure that the relationship between the tensioner pulley

center and the bolt center is as shown in the illustration.
TENSIONER "B"

CENTER OF
TENSIONER CENTER OF BOLT
PULLEY AK305592AB

4. Move tensioner "B" in the direction of the arrow while lifting

with your finger to give sufficient tension to the tension side
of timing belt. In this condition, tighten the bolt to secure
tensioner "B." When the bolt is tightened, use care to
prevent the tensioner pulley shaft from turning with the bolt.
If the shaft is turned with the bolt, the belt will be over
tensioned.
Tightening torque: 19 ± 3 N⋅ m (14 ± 2 ft-lb)
TENSIONER "B"
BOLT
AK305593AB

5. Check that timing marks on the sprockets are aligned with

BELT DEFLECTION the timing marks on the front case.
6. With your index finger, press the midway of the span on the
tension side of timing belt "B." The bolt must deflect 5 to 7
mm (0.20 to 0.28 inch).

TIMING
MARKS

TIMING
MARKS AK305594AB

TSB Revision
 ENGINE OVERHAUL
TIMING BELT
11B-19
>>H<< CRANKSHAFT SENSING BLADE/CRANKSHAFT
SPROCKET/CRANKSHAFT BOLT INSTALLATION
CRANKSHAFT SENSING BLADE
1. Clean and then degrease the contacting surfaces of the
crankshaft sprocket, sensing blade and crankshaft.
CRANKSHAFT BOLT
CRANKSHAFT
NOTE: Degreasing is necessary to prevent decrease in the
Clean friction between contacting surfaces.
2. Clean the bolt hole in the crankshaft, the crankshaft
contacting surface of the crankshaft sprocket, and the
washer.
WASHER 3. Install the sensing blade and the crankshaft sprocket to the
DEGREASE
CHAMFER crankshaft.
CRANKSHAFT SPROCKET AK202838 AD
4. Apply small amount of oil to the threads and seating surface
of the crankshaft bolt.
5. Install the washer to the crankshaft bolt with its largely
chamfered side toward the bolt head.
6. Lock the flywheel using the special tool MD998781.
7. Tighten the crankshaft bolt to the specified torque.
Tightening torque: 167 N⋅ m (123 ft-lb)

MD998781

AK202738AF

>>I<< OIL PUMP SPROCKET INSTALLATION

1. Insert a Phillips head screwdriver [shank diameter 8 mm
(0.3 inch)] through the plug hole on the left side of the
cylinder block to block the left counterbalance shaft.
2. Install the oil pump sprocket.
3. Apply a thin coat of engine oil to the seating surface of the
CROSSPOINT nut.
SCREWDRIVER
4. Tighten the nut to the specified torque.
Tightening torque: 54 ± 5 N⋅ m (40 ± 3 ft-lb)
AK202825 AC

>>J<< AUTO-TENSIONER INSTALLATION

1. If the auto-tensioner rod remains in its fully extended
position, reset it to the retracted position as follows:
A
(1) Clamp the auto-tensioner in a vise at right angles to the
B jaws.
(2) Push in the rod little by little with the vise until the set hole
A in the rod is aligned with the set hole B in the cylinder.
(3) Insert a piece of wire [1.4 mm (0.055 inch) diameter] into
the set holes.
(4) Remove the auto-tensioner from the vise.
AK301074AC

TSB Revision
11B-20 ENGINE OVERHAUL
TIMING BELT

2. Install the auto-tensioner in position. Leave the wire installed

until the auto-tensioner is completely installed.

AK300154

>>K<< TENSIONER PULLEY INSTALLATION

Install the tensioner pulley with its holes aligned as shown in
the illustration.

TENSIONER
PULLEY HOLE AK300147 AC

>>L<< TIMING BELT INSTALLATION

1. Bring the timing mark on the exhaust camshaft sprocket to a
TIMING MARKS point one sprocket tooth away from the timing mark on the
rocker cover in the counterclockwise direction.
NOTE: If the timing marks were aligned, the exhaust cam-
shaft would be turned counterclockwise by one sprocket
tooth and stay there by the force of the valve springs.

AK304440AD

2. Align the timing mark on the intake camshaft sprocket with

TIMING MARKS that on the rocker cover.
NOTE: The intake camshaft will be turned slightly clockwise
from where the timing marks are aligned by the force of the
valve springs and stay there.

AK501745 AC

TSB Revision
 ENGINE OVERHAUL
TIMING BELT
11B-21
3. Bring the timing mark on the crankshaft sprocket to a point
one sprocket tooth away from the mating timing mark in the
counterclockwise direction like in the operation with the
exhaust camshaft sprocket.

AK202760AC

4. Align the timing mark on the oil pump sprocket with that on
the cylinder block.
(1) Remove the plug from the cylinder block.
(2) Insert a crosspoint screwdriver with a shank diameter of 8
mm through the plug hole. If it can be inserted 60 mm
(2.36 inches) or more, the sprocket is in the correct
phase. If the insertion depth is up to 20 −25 mm (0.78 −
PLUG 0.98 inch), the screwdriver is blocked by the
CROSSPOINT
SCREWDRIVER counterbalancer shaft. Then turn the oil pump sprocket
AK202752 AC one turn and realign the timing marks. Then check that
the screwdriver can be inserted 60 mm (2.36 inches) or
more. Keep the screwdriver inserted until installation of
timing belt is finished.
(3) Turn the oil pump sprocket counterclockwise by one
sprocket tooth.
TIMING MARKS

AK202761 AC

5. Install the timing belt on the exhaust camshaft sprocket, and

hold it in place with a paper clamp at the point indicated in
the illustration.

AK202771

TSB Revision
11B-22 ENGINE OVERHAUL
TIMING BELT

6. Turn the intake camshaft sprocket counterclockwise to bring

the timing mark on it one sprocket tooth away from the
mating timing mark in the counterclockwise direction. Then
install the timing belt on the sprocket and hold it in place with
a paper clamp.
NOTE: The timing marks will be aligned when the belt is
installed since the intake camshaft is turned slightly clock-
wise by the force of the valve springs.

AK501746

7. Turn the exhaust camshaft sprocket clockwise to align the

TIMING MARKS timing marks, and make sure that the intake camshaft
sprocket timing marks are also aligned.

AK501747 AD

8. Install the timing belt on the idler pulley, oil pump sprocket,
and crankshaft sprocket, in this order.
NOTE: There should be no slack in the installed portion of
the belt.

OIL PUMP
CRANKSHAFT SPROCKET
SPROCKET AK202762AC

9. Install the timing belt on the tensioner pulley.

NOTE: Turning slightly the intake camshaft sprocket coun-
terclockwise will facilitate installation of the belt on the ten-
sioner pulley.
V.V.T.
SPROCKET

TENSIONER
PULLEY
AK501748AC

10.Turn the crankshaft sprocket slightly clockwise to take up

CRANKSHAFT
SPROCKET the slack in the idler pulley portion of the timing belt.
11.Check that each of the timing marks on the crankshaft, oil
pump, and exhaust camshaft sprockets is one sprocket
tooth away from its mating timing mark in the
counterclockwise direction.

AK202763AC

TSB Revision
 ENGINE OVERHAUL
TIMING BELT
11B-23
12.Turn the tensioner pulley counterclockwise using the special
tool MD998767 to give tension to the belt and hold the
tensioner in position by temporarily tightening the tensioner
MD998767
lock bolt.
NOTE: Take up the slack in the belt portion between the
intake and exhaust camshaft sprockets.
13.Turn the crankshaft clockwise to make the timing mark align
with the No.1 cylinder top dead center mark.

AK202764 AC

14.Install the special tool MD998738 and turn down the tool
until the wire (inserted in the auto-tensioner when it was
MD998738 installed) can be moved freely.

AK202774 AC
CAUTION
Prevent the timing belt from slipping as it becomes loose
following rotation of the intake and exhaust camshafts.
15.Loosen the tensioner pulley lock bolt.
16.Turn the torque wrench attached to the special tool
MD998767 counterclockwise until the slack in the timing belt
is taken up.
17.Turn the torque wrench clockwise from the position of step
16 until the torque wrench reading becomes 3.5 N⋅ m (31 in-
lb), then tighten the tensioner pulley lock bolt.
MD998767 AK202775 AC

18.Remove the special tool that was installed in step 14.

19.Turn the crankshaft clockwise two turns, then let it alone for
approx. 15 minutes.
20.Check that the wire (inserted in the auto-tensioner when it
EXTENSION
AMOUNT was installed) can be moved freely. If the wire can be pulled
freely, the belt tensioner is adjusted properly. Remove the
wire. Check that the auto-tensioner rod extends by the
specified amount.
Standard value: 3.8 − 4.5 mm (0.15 − 0.18 inch)
AK202829 AC
CAUTION
Be sure to check the tightening torque of the crankshaft
bolt anytime the crankshaft has been turned counterclock-
wise. If the torque lower than specification, tighten the bolt
to the specified torque.
21.If the wire cannot be pulled out freely, perform the steps 14
through 18 again to make the belt tension proper.
.

TSB Revision
11B-24 ENGINE OVERHAUL
TIMING BELT

>>M<< PLUG CAP INSTALLATION

CAUTION
Do not reuse the washer.
1. Install the washer to the plug cap.
2. Holding the hexagonal portion of the camshaft with a
wrench, tighten the plug cap to the specified torque.
Tightening torque: 32 ± 2 N⋅ m (24 ± 1 ft-lb)

AK403836

>>N<< SEMICIRCULAR PACKING INSTALLATION

1. Remove thoroughly the old sealant remaining on the
semicircular packing, cylinder head, and rocker cover.
2. Apply sealant 3M™ AAD Part number 8672 or equivalent to
the surface indicated in the illustration of the semicircular
packing.
3. Install the semicircular packing on the cylinder head.

AK202860AC

10 mm 4. Apply sealant 3M™ AAD Part number 8660 or equivalent to

(0.4 in) the area indicated in the illustration of the semicircular
packing and cylinder head.

10 mm
(0.4 in)

SEMICIRCULAR
PACKING CYLINDER HEAD AK304411AD

>>O<< ROCKER COVER/ROCKER COVER GASKET A

INSTALLATION
TIMING BELT SIDE 1. Apply beads of sealant MITSUBISHI Genuine Part number
MD970389 or equivalent on the surfaces of the rocker cover
indicated in the illustration.
2. Install the rocker cover gasket A on the rocker cover before
the FIPG hardens.

AK304203AD

TSB Revision
 ENGINE OVERHAUL
TIMING BELT
11B-25
TIMING BELT SIDE 3. Apply beads of sealant MITSUBISHI Genuine Part number
MD970389 or equivalent to the surfaces of the rocker cover
indicated in the illustration.
4. Install the rocker cover on the cylinder head before the FIPG
hardens.

AK304204AD

INSPECTION
M1113002000340
.

TIMING BELT
Check the timing belt closely. Replace the belt with a new one if
any of the following defects are evident:
1. Hardening of rubber backing.
Back side is glossy without resilience and leaves no indent
when pressed with fingernail.

AK100218

2. Surface cracks on the backing rubber.

CRACKS 3. Cracks or peeling of the canvas.
4. Cracks on the tooth bottom.
5. Cracks on the belt sides.
PEELING

CRACKS

CRACKS AK100209AB

6. Abnormal wear on the belt sides.

NOTE: The sides of the belt are normal if they are sharp as
ROUNDED EDGE if cut by a knife.

ABNORMAL WEAR
(EXPOSED CORE WIRE)
AK100219AB

TSB Revision
11B-26 ENGINE OVERHAUL
TIMING BELT

7. Abnormal wear on teeth.

CANVAS WORN Initial stage: Canvas worn (fluffy canvas fibers,
EXPOSING RUBBER
rubbery texture gone, white discoloration, canvas
texture indistinct)
Final stage: Canvas worn, exposing rubber (tooth
MISSING TEETH width reduced)
8. Missing teeth.

AK100220AB

AUTO-TENSIONER
1. Check the auto-tensioner for leaks from the sealed sections.
12 mm Replace it if leaky.
(0.5 in) 2. Check the rod end for wear and other damage.
Replace the auto-tensioner if the rod is badly worn or
damaged.
3. Measure the extension length of the rod.
If it is not within the standard value range, replace the auto-
tensioner.
AKX00477AB Standard value: 12 mm (0.5 inch)

4. Press the rod with a force of 98 to 196 N (22 to 44) and

98 TO 196 N (22 TO 44 lb)
measure the amount of retraction. If the measurement
exceeds the standard value, replace the auto-tensioner.
Standard value: 1.0 mm (0.04 inch) or less
MOVEMENT

AKX00478AB

TSB Revision
 ENGINE OVERHAUL
FUEL AND EMISSION PARTS
11B-27
FUEL AND EMISSION PARTS
REMOVAL AND INSTALLATION
M1113002200333

12 ± 1 N·m
107 ± 8 in-lb 8

15 19 ± 3 N·m
14 ± 2 ft-lb
5 10 1
13
14 2
12 3
11
7
8.8 ± 2.0 N·m 9
79 ± 16 in-lb 6 20 ± 2 N·m
15 ± 1 ft-lb
4

AK203808 AB

REMOVAL STEPS REMOVAL STEPS (Continued)

1. THROTTLE BODY 8. INJECTOR AND FUEL RAIL
>>C<< 2. THROTTLE BODY GASKET 9. INSULATOR
3. EXHAUST GAS RECIRCULATION 10. FUEL RETURN PIPE
VALVE 11. INSULATOR
4. EXHAUST GAS RECIRCULATION >>A<< 12. INJECTOR
VALVE GASKET 13. O-RING
5. FUEL HOSE 14. GROMMET
>>B<< 6. FUEL PRESSURE REGULATOR 15. FUEL RAIL
7. O-RING

TSB Revision
11B-28 ENGINE OVERHAUL
FUEL AND EMISSION PARTS

INSTALLATION SERVICE POINTS

.

>>A<< INJECTOR INSTALLATION

1. Apply a thin coat of engine oil to a new O-ring.
CAUTION
Prevent engine oil from getting into the delivery pipe.
2. Insert the injector into the delivery pipe while turning it in
both directions carefully not to damage the O-ring.
3. Check that the injector turns smoothly. If it does not, the O-
ring may be pinched, so remove the injector and check the
O-ring for damage. If the O-ring is intact, insert the injector
into the delivery pipe and check it for smooth rotation again.
.

>>B<< FUEL PRESSURE REGULATOR INSTALLATION

1. Apply a thin coat of engine oil to a new O-ring.
CAUTION
Prevent engine oil from getting into the delivery pipe.
2. Insert the fuel pressure regulator into the delivery pipe while
turning it in both directions carefully not to damage the O-
ring.
3. Check that the fuel pressure regulator turns smoothly. If it
does not, the O-ring may be jamming, so remove the fuel
pressure regulator and check the O-ring for damage. If the
O-ring is intact, insert it into the delivery pipe and check it for
smooth rotation again.
.

>>C<< THROTTLE BODY GASKET INSTALLATION

Install the throttle body gasket with its tab located as shown in
TAB the illustration.

AK203932AB

TSB Revision
 ENGINE OVERHAUL
INTAKE MANIFOLD
11B-29
INTAKE MANIFOLD
REMOVAL AND INSTALLATION
M1113002700480

5.0 ± 1.0 N·m 19 ± 3 N·m

45 ± 8 in-lb 26 ± 4 ft-lb
36 ± 6 N·m
26 ± 4 ft-lb
3 1

5 2

20 ± 2 N·m
15 ± 1 ft-lb 36 ± 6 N·m
26 ± 4 ft-lb

36 ± 6 N·m
26 ± 4 ft-lb

31 ± 3 N·m
23 ± 2 ft-lb
4

AK501893AB

REMOVAL STEPS REMOVAL STEPS (Continued)

1. ENGINE HANGER >>A<< 4. INTAKE MANIFOLD STAY
>>B<< 2. MANIFOLD ABSOLUTE PRESSURE 5. INTAKE MANIFOLD
SENSOR 6. INTAKE MANIFOLD GASKET
3. O-RING

TSB Revision
11B-30 ENGINE OVERHAUL
INTAKE MANIFOLD

INSTALLATION SERVICE POINTS

.

>>A<< INTAKE MANIFOLD STAY INSTALLATION

Tighten the bolts to the specified torque on both ends after
making sure that the stay is in close contact with the bosses on
the intake manifold and cylinder block.
Tightening torque: 31 ± 3 N⋅ m (23 ± 2 ft-lb)

INTAKE MANIFOLD
STAY

AK202865 AC

>>B<< MANIFOLD ABSOLUTE PRESSURE SENSOR

INSTALLATION
CAUTION
• Install the manifold absolute pressure sensor carefully.
Do not expose the sensor to any physical shock.
• Do not use the sensor that has fallen to floor or any
other surface.

TSB Revision
 ENGINE OVERHAUL
EXHAUST MANIFOLD
11B-31
EXHAUST MANIFOLD
REMOVAL AND INSTALLATION
M1113004901018

23 ± 3 N·m
17 ± 2 ft-lb
12
17 ± 2 N·m
13 ± 1 ft-lb

64 ± 5 N·m
1 20 47 ± 3 ft-lb

19 ± 3 N·m
14 ± 2 ft-lb 19 31 ± 2 N·m
11 ± 1 N·m 23 ± 1 ft-lb
98 ± 8 in-lb

33 ± 6 N·m
24 ± 4 ft-lb 15
16
14 10 ± 1 N·m
55 ± 10 N·m 89 ± 8 in-lb
41 ± 6 ft-lb 42 ± 7 N·m
31 ± 5 ft-lb
13
10 ± 1 N·m 17
89 ± 8 in-lb
3
6
44 ± 5 N·m
33 ± 3 ft-lb
5

23 ± 3 N·m 18
42 ± 7 N·m
17 ± 2 ft-lb 10 31 ± 5 ft-lb

8
59 ± 5 N·m 19 ± 1 N·m
44 ± 3 ft-lb 9
2 14 ± 1 ft-lb
11 9.0 ± 1.0 N·m
4 80 ± 8 in-lb 7
35 ± 6 N·m AK501691AC
26 ± 4 ft-lb 14 ± 1 N·m
124 ± 8 in-lb
REMOVAL STEPS REMOVAL STEPS (Continued)
1. ENGINE HANGER 12. EXHAUST MANIFOLD HEAT
2. TURBOCHARGER HEAT PROTECTOR PROTECTOR
3. OXYGEN SENSOR 13. TURBOCHARGER ASSEMBLY AND
4. EXHAUST FITTING BRACKET PIPE ASSEMBLY
5. EXHAUST FITTING 14. TURBOCHARGER GASKET
6. EXHAUST FITTING GASKET 15. OIL PIPE
7. AIR OUTLET FITTING 16. WATER PIPE B
>>C<< 8. AIR OUTLET FITTING GASKET 17. WATER PIPE A
9. OIL RETURN PIPE 18. TURBOCHARGER ASSEMBLY
10. OIL RETURN PIPE GASKET >>A<< 19. EXHAUST MANIFOLD
>>B<< 11. OIL RETURN PIPE GASKET 20. EXHAUST MANIFOLD GASKET

TSB Revision
11B-32 ENGINE OVERHAUL
EXHAUST MANIFOLD

INSTALLATION SERVICE POINT

.

>>A<< EXHAUST MANIFOLD INSTALLATION

1. Hand tighten all the exhaust manifold mounting nuts.
2. Tighten the M8 nuts to 29 ± 3 N⋅ m (21 ± 2 ft-lb) in the
indicated sequence.
3. Tighten the M10 nuts to 49 ± 5 N⋅ m (36 ± 3 ft-lb) in the
indicated sequence.
4. Tighten the M8 nuts again to 29 ± 3 N⋅ m (21 ± 2 ft-lb) in the
indicated sequence.
5. Finally tighten the M10 nuts and the M8 nuts to the specified
torque, both in the indicated sequence.
Tightening torque:
3 4 5 6 M8: 33 ± 6 N⋅ m (24 ± 4 ft-lb)
M10: 55 ± 10 N⋅ m (41 ± 6 ft-lb)

1 7 9 8 2

AK202866 AC

>>B<< OIL RETURN PIPE GASKET INSTALLATION

Install the oil return pipe gasket with its tab located as shown in
TAB the illustration.
NOTE: The gasket on the turbocharger end of the pipe does
not require special alignment for installation.

AK304540AC

>>C<< AIR OUTLET FITTING GASKET INSTALLATION

Install the air outlet fitting gasket with its tab located as shown
in the illustration.
TAB

A
A AK202868 AC

TSB Revision
 ENGINE OVERHAUL
WATER PUMP & WATER HOSE
11B-33
WATER PUMP & WATER HOSE
REMOVAL AND INSTALLATION
M1113017900509

11 ± 1 N·m
98 ± 8 in-lb
10 ± 1 N·m
4 89 ± 8 in-lb
1
13 ± 2 N·m 13 23 ± 4 N·m
115 ± 17 in-lb 17 ± 2 ft-lb 7
11 ± 1 N·m
29 ± 10 N·m 98 ± 8 in-lb
22 ± 6 ft-lb 8
11 5
10 ± 1 N·m 23 ± 4 N·m
89 ± 8 in-lb 2 17 ± 2 ft-lb

6 11 ± 1 N·m
98 ± 8 in-lb

12 9 3
10

16
23 ± 2 N·m
17 ± 2 ft-lb

15
14
14 ± 1 N·m AK501692AC
124 ± 8 in-lb

REMOVAL STEPS REMOVAL STEPS (Continued)

1. WATER HOSE 8. THERMOSTAT
2. WATER HOSE 9. THERMOSTAT HOUSING
3. WATER HOSE 10. THERMOSTAT HOUSING GASKET
4. WATER HOSE >>A<< 11. WATER INLET PIPE
>>C<< 5. ENGINE COOLANT TEMPERATURE >>A<< 12. O-RING
SENSOR >>A<< 13. O-RING
>>B<< 6. ENGINE COOLANT TEMPERATURE 14. WATER PUMP
GAUGE UNIT 15. WATER PUMP GASKET
7. WATER OUTLET FITTING 16. KNOCK SENSOR

TSB Revision
11B-34 ENGINE OVERHAUL
WATER PUMP & WATER HOSE

INSTALLATION SERVICE POINTS

.

>>A<< WATER INLET PIPE / O-RING INSTALLATION

CAUTION
• Never apply any oil or grease to the O-ring.
• Secure the water inlet pipe after the thermostat housing
has been installed.
Replace the O-rings at both ends of the water inlet pipe with
new ones. Insert the O-rings into the water pump and thermo-
stat housing after wetting their peripheries with water.
.

>>B<< ENGINE COOLANT TEMPERATURE GAUGE UNIT

INSTALLATION
1. When reusing the gauge unit, clean its thread.
2. Apply 3M™ AAD Part number 8672 or equivalent to the
engine coolant temperature gauge unit.

AK100245

>>C< ENGINE COOLANT TEMPERATURE SENSOR

INSTALLATION
1. When reusing the sensor, clean its thread.
2. Apply 3M™ AAD Part number 8731 or equivalent to the
engine coolant temperature sensor.

AK100244

TSB Revision
 ENGINE OVERHAUL
ROCKER ARMS AND CAMSHAFT
11B-35
ROCKER ARMS AND CAMSHAFT
REMOVAL AND INSTALLATION
M1113005401180

11 ± 1 N·m
10 9
98 ± 8 in-lb
12 8
10 ± 2 N·m
11 89 ± 17 in-lb
7
14 ± 1 N·m
124 ± 9 in-lb 10 ± 2 N·m
14 22 ± 4 N·m
3 89 ± 17 in-lb
17 98 ± 8 ft-lb
4
20 6
20 ± 1 N·m 19 15 14 ± 1 N·m
15 ± 1 ft-lb 18 124 ± 9 in-lb
2
11 ± 1 N·m 16 1
98 ± 8 in-lb 22 ± 4 N·m
30 ± 3 N·m 98 ± 8 ft-lb
42 ± 2 N·m 21 5
31 ± 2 ft-lb 22 ± 2 ft-lb 11 ± 1 N·m
11 ± 1 N·m 98 ± 8 in-lb
28 29 27 98 ± 8 in-lb
13 24

22
30 23
31
32 APPLY ENGINE OIL
30 ± 3 N·m TO ALL MOVING
22 ± 2 ft-lb 25 PARTS BEFORE
11 ± 1 N·m 26 INSTALLATION.
98 ± 8 in-lb

AK403842AD

REMOVAL STEPS REMOVAL STEPS (Continued)

>>J<< 1. CAMSHAFT POSITION SENSOR >>E<< 15. BEARING CAP, REAR LEFT
2. O-RING >>E<< 16. BEARING CAP, FRONT
>>I<< 3. COVER >>E<< 17. BEARING CAP NO.5
>>I<< 4. GASKET >>E<< 18. BEARING CAP NO.2
>>H<< 5. CAMSHAFT POSITION SENSING >>E<< 19. BEARING CAP NO.3
CYLINDER >>E<< 20. BEARING CAP NO.4
>>G<< 6. CAMSHAFT POSITION SENSOR >>D<< 21. CAMSHAFT
SUPPORT 22. ROCKER ARM
>>J<< 7. CAMSHAFT POSITION SENSOR <<A>> >>C<< 23. LASH ADJUSTER
8. O-RING 24. OIL DELIVERY BODY
>>I<< 9. COVER 25. OIL FEEDER CONTROL VALVE
>>I<< 10. GASKET 26. O-RING
>>H<< 11. CAMSHAFT POSITION SENSING 27. CHECK VALVE
CYLINDER >>B<< 28. EYE BOLT
>>G<< 12. CAMSHAFT POSITION SENSOR 29. OIL PIPE
SUPPORT
>>A<< 30. OIL FEEDER CONTROL VALVE FILTER
>>F<< 13. CAMSHAFT OIL SEAL
31. OIL PIPE JOINT
>>E<< 14. BEARING CAP, REAR RIGHT
32. GASKET

TSB Revision
11B-36 ENGINE OVERHAUL
ROCKER ARMS AND CAMSHAFT

Required Special Tools:

• MD998442: Air Bleed Wire
• MD998713: Camshaft Oil Seal Installer

REMOVAL SERVICE POINT

.

<<A>> LASH ADJUSTER REMOVAL

CAUTION
When reusing a lash adjuster, it must be washed and
inspected before installation. (Refer to P.11B-39)

INSTALLATION SERVICE POINTS

.

>>A<< OIL FEEFER CONTROL VALVE FILTER INSTALLA-

TION
CAUTION
Install the oil feeder control valve filter on which no foreign
materials, no defects and no deformation are confirmed.
.

>>B<< EYE BOLT INSTALLATION

Holding the oil pipe joint with a spanner, tighten the eye bolt to
the specified torque.
Tightening torque: 42 ± 2 N⋅ m (31 ± 2 ft-lb)
EYE BOLT
NOTE: When the oil pipe joint is rotated together with the eye
bolt at the installation, the oil pump would be possibly dam-
aged.

SPANNER
OIL PIPE JOINT
AK403894AD

>>C<< LASH ADJUSTER INSTALLATION

CAUTION
When reusing a lash adjuster, it must be washed and
inspected before installation. (Refer to P.11B-39)
Install the lash adjuster into the rocker arm, being careful not to
spill the diesel fuel it contains.
.

>>D<< CAMSHAFT INSTALLATION

CAUTION
TIMING BELT SIDE • Do not confuse the intake camshaft with the exhaust
INTAKE CAMSHAFT camshaft.
• As shown in the illustration, the shapes of the intake
camshaft and the exhaust camshaft are different.

EXHAUST CAMSHAFT
AK501789AC

TSB Revision
 ENGINE OVERHAUL
ROCKER ARMS AND CAMSHAFT
11B-37
>>E<< BEARING CAP INSTALLATION
DOWEL PIN
1. Set each camshaft with its dowel pin at the top.

AK203979 AB

2. The bearing caps Nos. 2 −5 are identical in shape for both

intake and exhaust camshafts. Check the identification mark
on each cap before installation.
Identification mark (stamped on front and Nos. 2 − 5
CAP NUMBER bearing caps)
INTAKE/EXHAUST I: intake side
IDENTIFICATION
LETTER E: exhaust side
3. Remove completely any sealant remaining on the bearing
caps and cylinder head.
AK202870 AC

4. Apply sealant (MITSUBISHI Genuine Part number

MD970389 or equivalent) to the surfaces indicated in the
illustration.
5. Install each bearing cap and tighten its bolts in two or three
passes.
6. Finally, tighten the bolts to the specified torque.
Tightening torque: 20 ± 1 N⋅ m (15 ± 1 ft-lb)
7. Check that the rocker arms are correctly installed.
AK103803 NOTE: Wipe off any squeezed out sealant completely.
.

>>F<< CAMSHAFT OIL SEAL INSTALLATION

Use the special tool MD998713 to drive each oil seal into posi-
MD998713 tion in the cylinder head.

AK202872 AC

TSB Revision
11B-38 ENGINE OVERHAUL
ROCKER ARMS AND CAMSHAFT

>>G<< CAMSHAFT POSITION SENSOR SUPPORT

INSTALLATION
1. Remove completely the FIPG remaining on the camshaft
position sensor support and cylinder head.
2. Apply a 3 ± 1 mm diameter bead of FIPG to the indicated
surface of the camshaft position sensor support.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or equivalent

EXHAUST SIDE INTAKE SIDE

AK403895AD

>>H<< CAMSHAFT POSITION SENSING CYLINDER

INSTALLATION
1. Turn the exhaust camshaft to the No.1 cylinder top dead
EXHAUST SIDE INTAKE SIDE centre position.
VANE (SMALL)
PAINT NOTE: The camshaft will slightly turn counterclockwise by
the force of the exhaust valve spring.
2. Install the camshaft position sensing cylinder with the vanes
and paint located as shown in the drawing.

VANE (BIG)
AK501669AC

>>I<< COVER / GASKET INSTALLATION

1. Before the cover and the gasket installations, confirm the
EXHAUST SIDE INTAKE SIDE vanes and paint of the every sensing cylinder are in position
PAINT indicated in the illustration with the camshaft on No.1 top
VANE (SMALL)
dead center of compression stroke.

VANE (BIG)
AK501669AC

2. At the intake side, install the cover notch and the gasket
EXHAUST SIDE INTAKE SIDE projection in position indicated in the illustration, and then
tighten them to the specified torque.
At the exhaust side, the cover and the gasket do not have
PROJECTION the specified direction or angle of the installation.
Tightening torque: 14 ± 1 N⋅ m (124 ± 9 in-lb)
NOTE: The cover and the gasket have no difference
between the front and the reverse sides.
NOTCH
PROJECTION
NOTCH AK403948AD

TSB Revision
 ENGINE OVERHAUL
ROCKER ARMS AND CAMSHAFT
11B-39
>>J<< CAMSHAFT POSITION SENSOR INSTALLATION
Install the camshaft position sensor with paying attention to the
installation direction because an identification paint is not
PAINT applied to the camshaft position sensor at the intake side.

AK501790AC

INSPECTION
M1113005500980
.

CAMSHAFT
Measure the cam height and replace the camshaft if any height
exceeds the specified limit.
Standard value:
Intake: 35.96 mm (1.42 inches)
Exhaust: 35.49 mm (1.40 inches)
Limit:
Intake: 35.46 mm (1.40 inches)
Exhaust: 34.99 mm (1.38 inches)
AK100584

LASH ADJUSTERS
CAUTION
• The lash adjuster is a precision-engineered compo-
nent. Do not allow dust or other foreign matter to enter
it.
• Do not disassemble lash adjusters.
• Use only non-contaminated diesel fuel to clean the lash
adjuster.
1. Prepare three containers and approximately five liters of
diesel fuel. Pour into each container the diesel fuel in an
FOR ROUGH FOR FINISH FOR DIESEL
CLEANING CLEANING FUEL FILLING amount enough for a lash adjuster placed in the container in
its upright position to completely submerge.

A B C
AK300586 AC

TSB Revision
11B-40 ENGINE OVERHAUL
ROCKER ARMS AND CAMSHAFT

2. Place the lash adjuster in container A and wash its outside

surface.
NOTE: Use a nylon brush if there are hard-to-remove
deposits.

DIESEL FUEL
AK300587AD
CAUTION
The steel ball spring of the lash adjuster is extremely
weak. The lash adjuster's functionality may be badly
affected if the special tool is inserted too strongly.
3. While gently pushing the internal steel ball using the special
tool MD998442, move the plunger in and out 5 −10 times to
eliminate stiffness in the plunger and expel contaminated oil.
NOTE: The plunger must be free from jamming and any
DIESEL FUEL other abnormalities. If a defect is found in plunger operation,
MD998442
replace the lash adjuster.
AK202839 AD
CAUTION
The hole in the side of the lash adjuster must be directed
toward the inside of container A. Never direct it toward any
person.
4. Take the lash adjuster out of the container, then move the
plunger by pushing the steel ball gently to discharge the
diesel fuel from the pressure chamber.
MD998442

DIESEL FUEL
AK202840 AE
CAUTION
The steel ball spring of the lash adjuster is extremely
weak. The lash adjuster's functionality may be badly
affected if the special tool is inserted too strongly.
5. Soak the lash adjuster in the diesel fuel in container B. Move
the plunger in and out 5 −10 times by gently pushing the
internal steel ball using the special tool MD998442 until the
plunger moves smoothly to wash the lash adjuster’s
DIESEL FUEL pressure chamber.
MD998442
AK202839 AD
CAUTION
The hole in the side of the lash adjuster must be directed
toward the inside of container B. Never direct it toward any
person.
6. Take the lash adjuster out of the container, then move the
plunger by pushing the steel ball gently to discharge the
diesel fuel from the pressure chamber.
MD998442

DIESEL FUEL
AK202840 AE

TSB Revision
 ENGINE OVERHAUL
ROCKER ARMS AND CAMSHAFT
11B-41

CAUTION
Do not use container C for cleaning. If cleaning is per-
formed in container C, foreign matter could enter the pres-
sure chamber when the chamber is filled with diesel fuel.
7. Soak the lash adjuster in the diesel fuel in container C.
DIESEL FUEL Gently push the internal steel ball using the special tool
MD998442 MD998442.
AK202841 AD

8. Place the lash adjuster upright with the plunger at the top.
Push the plunger firmly until it makes a full stroke, then
return the plunger slowly and release the hold of the steel
ball to allow the pressure chamber to be filled with diesel
fuel.

MD998442 DIESEL FUEL

AK202842 AD

9. Take the lash adjuster out of the container, place it upright

with the plunger at the top, and push the plunger firmly. The
plunger must not move at all.
NOTE: If the lash adjuster contracts, perform the operations
7 through 9 again. Replace the lash adjuster if it still con-
tracts even after the pressure chamber has completely been
filled with diesel fuel (air has been bled).
10.Keep the serviced lash adjusters in their upright positions to
prevent diesel fuel from spilling out. Protect them from dust
AK300588 or other foreign matter. Install the lash adjusters onto the
engine as soon as possible.

TSB Revision
11B-42 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES

CYLINDER HEAD AND VALVES

REMOVAL AND INSTALLATION
78 ± 2 N·m → 0 N·m → 20 ± 2 N·m → +90˚ → +90˚
58 ± 1 ft-lb 0 in-lb 15 ± 1 ft-lb
1
2
8
9
4
5 10
20 14
6
15
12
17
13
16

19
18 11

APPLY ENGINE OIL

TO ALL MOVING
PARTS BEFORE
INSTALLTION.

AK203813 AD

REMOVAL STEPS REMOVAL STEPS (Continued)

<<A>> >>D<< 1. CYLINDER HEAD BOLT <<D>> 11. EXHAUST VALVE
2. CYLINDER HEAD ASSEMBLY <<C>> >>A<< 12. VALVE STEM SEAL
3. CYLINDER HEAD GASKET 13. VALVE SPRING SEAT
<<B>> >>C<< 4. RETAINER LOCK <<C>> >>A<< 14. VALVE STEM SEAL
5. VALVE SPRING RETAINER 15. VALVE SPRING SEAT
>>B<< 6. VALVE SPRING 16. INTAKE VALVE GUIDE
7. INTAKE VALVE 17. EXHAUST VALVE GUIDE
<<B>> >>C<< 8. RETAINER LOCK 18. INTAKE VALVE SEAT
9. VALVE SPRING RETAINER 19. EXHAUST VALVE SEAT
>>B<< 10. VALVE SPRING 20. CYLINDER HEAD

Required Special Tools:

• MB991654: Cylinder Head Bolt Wrench (12) • MD998737: Valve Stem Seal Installer
• MD998735: Valve Spring Compressor • MD998772: Valve Spring Compressor

TSB Revision
 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
11B-43
REMOVAL SERVICE POINTS
.

<<A>> CYLINDER HEAD BOLT REMOVAL

Using the special tool MB991653 to loosen the cylinder head
bolts.

MB991654

AK202723 AC

<<B>> RETAINER LOCK REMOVAL

1. Using special tool MD998735 or MD998772, compress the
MD998735 retainer locks.
2. Remove the retainer locks.
NOTE: Tag removed valves, springs and other components,
noting their cylinder numbers and locations to facilitate reas-
sembly. Store these components safely.

AK202873 AC

MD998772

AK202742 AC

<<C>> VALVE STEM SEAL REMOVAL

Do not reuse removed valve stem seal.

AK304633

TSB Revision
11B-44 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES

<<D>> VALVE HANDLING PRECAUTIONS

WARNING
Sodium reacts violently with water or moisture gener-
ation heat and liberating hydrogen. It must be han-
dled 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.
1. Handling of Sodium-filled Exhaust Valves
(1) Sodium-filled exhaust valves are not dangerous and may
be handled in the same way as ordinary valves unless
they are broken.
(2) Never try to break the valves and expose sodium to the
air.
(3) 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.
(4) Should the exhaust valves be broken, neutralize sodium
using the method described below, and discard the
valves in the same way as ordinary valves.
CAUTION
• Do not let the solution contact the eyes or the skin.
• Should it get in the eyes, immediately flush them with
clean water thoroughly, and receive medical attention.
When it contacts he skin, wash with ample amounts of
clean water.
2. How to Neutralize Sodium
(1) Place a container filled with more than 10 liters (10.6 qt)
of water in a well ventilated large space.
(2) Wear rubber gloves and goggles, and carefully take out
broken valves from the cylinder head.
CAUTION
• Valves must be neutralized one at a time.
• Put a valve in the container only after sodium in the pre-
ceding one has completely reacted with water.
(3) Put a broken valves in the water-filled container and
quickly get away from the container at least 2 or 3 m (6.6
or 9.8 ft)
(4) Keep fire away from the container during the
neutralization. The resulting hydrogen gas is highly
explosive.
NOTE: The reaction occurs when water enters the cavity
in he valve. Hydrogen gas may be trapped inside the
valve, temporarily blocking the water passage. In such a
case, wait until hydrogen gas in released and remaining
sodium reacts with water.

TSB Revision
 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
11B-45
(5) After the neutralization of sodium, water in the container
contains sodium hydroxide and is highly alkaline. The
water solution should be disposed of according to local
regulations.

INSTALLATION SERVICE POINTS

.

>>A<< VALVE STEM SEAL INSTALLATION

CAUTION
• Do not reuse removed valve stem seals.
1. Install the valve spring seat.
RUBBER COLOR: RUBBER COLOR: NOTE: Do not confuse the stem seals for intake valves with
GRAY GRAY GREEN
those for exhaust valves.

AK202875 AC
CAUTION
• The valve stem seal must be installed using the correct
special tool. Incorrect installation could result in oil
leaking past the valve guide.
2. Using special tool MD998737, install a new stem seal to the
valve guide.
MD998737

AK304485 AE

>>B<< VALVE SPRING INSTALLATION

Install the valve spring so that the painted end is on the rocker
arm side.
PAINTED END

AK300717AD

TSB Revision
11B-46 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES

>>C<< RETAINER LOCK INSTALLATION

Using special tool MD998735 or MD998772, compress the
MD998735 valve spring and insert the retainer lock into position.
NOTE: The valve spring, if excessively compressed, causes
the bottom end of retainer to be in contact with the stem seal,
and damage it.

AK202873 AC

MD998772

AK202742 AC

>>D<< CYLINDER HEAD BOLT INSTALLATION

1. When the removed cylinder head bolts are to be reused,
check that the shank length of each bolt meets the limit. If it
exceeds the limit, replace the bolts.
Limit: 99.4 mm (3.91 inches)
2. Apply engine oil to the thread of the bolts and to the
SHANK LENGTH washers.

AK300591AE

TSB Revision
 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
11B-47
3. Using special tool MB991654 tighten the bolts to the
specified torque 78 ± 2 N⋅ m (58 ± 1 ft-lb), using the
tightening sequence shown.
4. Loosen all bolts fully in the reverse order of tightening.
MB991654
5. Retighten the loosened bolts to 20 ± 2 N⋅ m (15 ± 1 ft-lb) in
the tightening sequence shown.

AK202723 AC

TIMING BELT SIDE

8 6 1 3 9

10 4 2 5 7

AK202806 AD
CAUTION
• If the bolt is turned less than 90 degree angle, proper
fastening performance may not be achieved. Be careful
to turn each bolt exactly 90 degree angle.
90˚ • If the bolt is overtightened, loosen the bolt completely
and then retighten it by repeating the tightening proce-
dure from step 1.
6. Make a paint mark across each bolt head and cylinder head.
90˚ 7. Tighten the cylinder head bolts 90 degree angle in the
PAINT MARKS
specified order.
AK202720 AD
8. Tighten the bolts another 90 degree angle in the same order
as in step 7, and check that the paint marks on the cylinder
head bolt are aligned with the paint marks on the cylinder
head.

INSPECTION
M1113007000356
.

CYLINDER HEAD
1. Before cleaning the cylinder head, check it for water leaks,
gas leaks, cracks, and other damage.
2. Remove all oil, water scale, sealant, and carbon. After
cleaning the oil passages, blow air through them to verify
that they are not blocked.
3. Check the cylinder head gasket surface for flatness by using
a straight edge and feeler gauge.
Standard value: 0.05 mm (0.0020 inch)
Limit: 0.2 mm (0.008 inch)
AK202724

TSB Revision
11B-48 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES

4. If flatness exceeds the specified limit, grind the gasket

surface to specification.
Grinding limit: *0.2 mm (0.008 inch)
*Includes/combined with cylinder block grinding
Cylinder head height (Specification when new):
131.9 − 132.1 mm (5.193 − 5.201 inches)
.

VALVE
1. Check the valve face for correct contact. If contact is uneven
or incomplete, reface the valve seat.
2. If the margin is less than specified, replace the valve.
VALVE SEAT Standard value:
CONTACT Intake: 1.0 mm (0.039 inch)
MARGIN
Exhaust: 1.5 mm (0.059 inch)
Limit:
Intake: 0.5 mm (0.020 inch)
Exhaust: 1.0 mm (0.039 inch)
AK100161AB
3. Measure the valve length. If the measurement is less than
specified, replace the valve.
Standard value:
Intake: 109.50 mm (4.311 inches)
Exhaust: 109.70 mm (4.319 inches)
Limit:
Intake: 109.00 mm (4.291 inches)
Exhaust: 109.20 mm (4.299 inches)
.

VALVE SPRING
1. Measure the valve spring free height. If the measurement is
OUT OF SQUARE less than specified, replace the spring.
Standard value: 50.4 mm (1.98 inches)
Limit: 49.4 mm (1.94 inches)
2. Measure the squareness of the spring. If the measurement
FREE HEIGHT is less than specified, replace the spring.
Standard value: 2° or less
Limit: 4°
AK100152 AB

VALVE GUIDE
Measure the clearance between the valve guide and valve
stem. If the clearance exceeds the specified limit, replace the
valve guide or valve, or both.
Standard value:
VALVE
Intake: 0.02 −0.05 mm (0.0008 −0.0020 inch)
GUIDE
Exhaust: 0.05 −0.09 mm (0.0020 −0.0035 inch)
Limit:
STEM O.D.
Intake: 0.10 mm (0.0039 inch)
GUIDE I.D. Exhaust: 0.15 mm (0.0059 inch)
AK100210 AB

TSB Revision
 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
11B-49
VALVE SEAT
Assemble the valve, then measure the valve stem projection
VALVE STEM END
between the end of the valve stem and the spring seating
surface. If the measurement exceeds the specified limit,
VALVE STEM replace the valve seat.
PROJECTION
Standard value:
SPRING SEATING Intake: 49.20 mm (1.9370 inches)
SURFACE Exhaust: 48.40 mm (1.9055 inches)
Limit
Intake: 49.70 mm (1.9567 inches)
AK100206 AB
Exhaust: 48.90 mm (1.9252 inches)
.

VALVE SEAT RECONDITIONING PROCEDURE

1. Before correcting the valve seat, check the clearance
0.9 – 1.3 mm
(0.04 – 0.05 in) between the valve guide and valve. If necessary, replace the
65˚ 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).
43.5˚ – 44˚ 10˚
AK100818 AC

VALVE SEAT REPLACEMENT PROCEDURE

1. Cut the valve seat to be replaced from the inside to reduce
0.5 – 1.0 mm (0.020 – 0.039 in) the wall thickness. Then, remove the valve seat.

CUT AWAY

0.5 – 1.0 mm
(0.020 – 0.039 in)

AK100153AB

2. Rebore the valve seat hole in the cylinder head to match the
selected oversize valve seat diameter.
Intake valve seat hole diameter
0.3 oversize: 35.30 − 35.33 mm (1.3898 − 1.3909
VALVE SEAT
inches)
HEIGHT
0.6 oversize: 35.60 − 35.63 mm (1.4016 − 1.4028
inches)

OVERSIZE VALVE
Exhaust valve seat hole diameter
SEAT HOLE DIAMETER 0.3 oversize: 33.30 − 33.33 mm (1.3110 − 1.3122
AK100154AB
inches)
0.6 oversize: 33.60 − 33.63 mm (1.3228 − 1.3240
inches)
3. Prevent galling of the cylinder head bore by cooling the
valve seat with liquid nitrogen before press-fitting it.

TSB Revision
11B-50 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES

4. Correct the valve seat to achieve the specified width and

angle (refer to VALVE SEAT RECONDITIONING
PROCEDURE).
.

VALVE GUIDE REPLACEMENT PROCEDURE

1. Using a press, push the valve guide out toward the cylinder
block side.
2. Rebore the valve guide hole in the cylinder head to match
the oversize valve guide that is to be fitted.
CAUTION
Do not install a valve guide of the same size again.
Valve guide hole diameters in cylinder head
0.05 oversize: 12.05 − 12.07 mm (0.4744 − 0.4751
inch)
0.25 oversize: 12.25 − 12.27 mm (0.4823 − 0.4831
inch)
0.50 oversize: 12.50 − 12.52 mm (0.4921 − 0.4929
inch)
3. Press-fit the valve guide until it projects by the specified
amount.
Standard value: 19.5 mm (0.768 inch)
CAUTION
• The valve guide must be installed from the upper side
of the cylinder head.
• The valve guides differ in length on the intake and
PROTRUSION exhaust sides.
AK100151AB Valve guide length
Intake: 45.5 mm (1.791 inches)
Exhaust: 50.5 mm (1.988 inches)
4. After press-fitting the valve guide, insert a new valve and
check that it slides smoothly.

TSB Revision
 ENGINE OVERHAUL
OIL PAN AND OIL PUMP
11B-51
OIL PAN AND OIL PUMP
REMOVAL AND INSTALLATION
M1113008101014

19 ± 3 N·m
14 ± 2 ft-lb
29 30
APPLY ENGINE OIL 8
TO ALL MOVING
PARTS BEFORE 27
INSTALLTION.

31
20
23 ± 3 N·m
17 ± 2 ft-lb

54 ± 5 N·m 21
40 ± 5 ft-lb 25 19 28
22 7
15 23
9 10 ± 2 N·m
89 ± 17 in-lb
24 17 ± 1 N·m 6
13 ± 1 ft-lb
14
5 22 ± 4 N·m
17 ± 2 ft-lb

18 4
26 19 ± 3 N·m
13 17 23 ± 3 N·m 14 ± 2 ft-lb
16 36 ± 3 N·m 18 ± 2 ft-lb
12 27 ± 1 ft-lb
19 ± 3 N·m 11 23 ± 3 N·m
14 ± 2 ft-lb 17 ± 2 ft-lb
10 2 9.0 ± 3.0 N·m
80 ± 26 in-lb
44 ± 5 N·m
3 33 ± 3 ft-lb 39 ± 5 N·m 1
14 ± 2 N·m 29 ± 4 ft-lb
124 ± 17 in-lb AK203814AB

REMOVAL STEPS REMOVAL STEPS (Continued)

1. DRAIN PLUG <<C>> >>I<< 18. FLANGE BOLT
>>N<< 2. DRAIN PLUG GASKET >>H<< 19. OIL PUMP CASE
>>M<<3. OIL FILTER 20. OIL PUMP CASE GASKET
<<A>> >>L<< 4. OIL PAN 21. OIL PUMP CASE COVER
5. OIL SCREEN >>G<<22. OIL PUMP DRIVEN GEAR
6. OIL SCREEN GASKET >>G<<23. OIL PUMP DRIVE GEAR
7. BAFFLE PLATER >>F<< 24. CRANKSHAFT OIL SEAL
>>K<< 8. OIL PRESSURE SWITCH >>E<< 25. COUNTERBALANCE SHAFT OIL SEAL
9. OIL COOLER BY-PASS VALVE >>D<< 26. OIL PUMP OIL SEAL
10. RELIEF PLUG 27. COUNTERBALANCE SHAFT, RIGHT
11. GASKET 28. COUNTERBALANCE SHAFT, LEFT
12. RELIEF SPRING <<D>> >>C<< 29. COUNTERBALANCE SHAFT FRONT
13. RELIEF PLUNGER BEARING
14. OIL FILTER BRACKET <<E>> >>B<< 30. COUNTERBALANCE SHAFT REAR
15. OIL FILTER BRACKET GASKET BEARING, RIGHT
<<B>> >>J<< 16. PLUG CAP <<E>> >>A<< 31. COUNTERBALANCE SHAFT REAR
17. O-RING BEARING, LEFT

TSB Revision
11B-52 ENGINE OVERHAUL
OIL PAN AND OIL PUMP

Required Special Tools:

• MB991603: Bearing Installer Stopper • MD998372: Silent Shaft Bearing Puller
• MD998012: Oil Pressure Switch Socket Wrench • MD998375: Crankshaft Front Oil Seal Installer
• MD998054: Oil Pressure Switch Socket Wrench • MD998705: Silent Shaft Bearing Installer
• MD998162: Plug Wrench • MD998727: Oil Pan Remover
• MD998285: Crankshaft Front Oil Seal Guide • MD998783: Plug Wrench Retainer
• MD998371: Silent Shaft Bearing Puller

REMOVAL SERVICE POINTS

.

<<A>> OIL PAN REMOVAL

1. Remove all oil pan bolts.
MD998727 2. Drive in special tool MD998727 between the cylinder block
and oil pan.
NOTE: Never use a screwdriver or chisel to remove the oil
pan. It will deform the oil pan flange and result in oil leakage.
3. Gently hit the special tool on its corner (shoulder), then slide
it along the oil pan to remove it.

AK202574 AE

<<B>> PLUG CAP REMOVAL

1. Fit special tool MD998162 on the plug cap, and then hold it
MD998162 in position with special tool MD998783.
2. Loosen the plug.
3. Remove special tools MD998783 and MD998162, and then
the plug cap.

MD998783
AK202585 AD

<<C>> FLANGE BOLT REMOVAL

1. Remove the plug on the side of the cylinder block.
2. Insert a Phillips screwdriver [shank diameter 8 mm (0.3
inch)] into the plug hole to lock the counterbalance shaft.

PLUG
CROSSPOINT
SCREWDRIVER
AK202752 AC

TSB Revision
 ENGINE OVERHAUL
OIL PAN AND OIL PUMP
11B-53
3. Loosen the flange bolt.

AK304384

<<D>> COUNTERBALANCE SHAFT FRONT BEARING

REMOVAL
Using special tool MD998371, remove the counterbalance
shaft front bearing from the cylinder block.
NOTE: Be sure to remove the front bearing first.
If it has not been removed, special tool MD998372 cannot be
used for rear balance shaft bearing removal.

FRONT
BEARING
MD998371
AK202633 AF

<<E>> COUNTERBALANCE SHAFT REAR BEARING

REMOVAL
1. Install special tools MB991603 and MD998372 in front of the
MB991603 cylinder block when removing the left counterbalance shaft
rear bearing.
2. Using special tool MD998372, remove the right
counterbalance shaft rear bearing from the cylinder block.

MD998372
AK202634 AD

TSB Revision
11B-54 ENGINE OVERHAUL
OIL PAN AND OIL PUMP

INSTALLATION SERVICE POINTS

.

>>A<< COUNTERBALANCE SHAFT REAR BEARING, LEFT

INSTALLATION
1. Install special tool MB991603 to the cylinder block.
MB991603
2. Apply engine oil to the rear bearing outer surface and
bearing hole in the cylinder block.
3. Using special tool MD998705, install the rear bearing.
NOTE: The left rear bearing has no oil holes.

MD998705
AK202548 AE

MB991603 MD998705
(STOPPER)

REAR BEARING
AK300619AE

>>B<< COUNTERBALANCE SHAFT REAR BEARING,

RIGHT INSTALLATION
1. Apply engine oil to the bearing outer surface and bearing
hole in the cylinder block.
2. Using special tool MD998705, install the rear bearing. Make
sure that the oil hole of the bearing is aligned with that of the
MD998705 cylinder block.
(STOPPER)

MD998705
(GUIDE PIN) AK304434AD

MD998705
(STOPPER)

AK300622AE

TSB Revision
 ENGINE OVERHAUL
OIL PAN AND OIL PUMP
11B-55
>>C<< COUNTERBALANCE SHAFT FRONT BEARING
INSTALLATION
1. Apply engine oil to the front bearing outer surface and
bearing hole in the cylinder.
2. Using special tool MD998705, install the front bearing. Make
sure that the oil hole of the bearing is aligned with that of the
MD998705 cylinder block.
(STOPPER)

MD998705
(GUIDE PIN) AK304434AD

MD998705
(STOPPER)

BEARING

CYLINDER
BLOCK
OIL HOLE AK300624AB

>>D<< COUNTERBALANCE SHAFT OIL SEAL

INSTALLATION
Using a suitable socket wrench, install the counterbalance shaft
SOCKET WRENCH oil seal into the front case.

FRONT CASE
OIL SEAL

AK301071AC

>>E<< OIL PUMP OIL SEAL INSTALLATION

Using a suitable socket wrench, install the oil pump oil seal into
SOCKET WRENCH the front case.
OIL SEAL

FRONT CASE

AK301070AC

TSB Revision
11B-56 ENGINE OVERHAUL
OIL PAN AND OIL PUMP

>>F<< CRANKSHAFT FRONT OIL SEAL INSTALLATION

Using special tool MD998375, install the crankshaft front oil
MD998375 seal into the front case.

OIL SEAL
FRONT CASE

AK301072AC

>>G<< OIL PUMP DRIVEN GEAR/OIL PUMP DRIVE GEAR

INSTALLATION
Install the oil pump gears into the front case and line up the
alignment marks.

ALIGNMENT
MARK

AKX00594AB

>>H<< OIL PUMP CASE ASSEMBLY/OIL FILTER BRACKET

INSTALLATION
1. Set special tool MD998285 on the front end of crankshaft
COUNTERBALANCER
SHAFT, LEFT and apply a thin coat of engine oil to the outer surface of
special tool MD998285.
2. Apply engine oil to the lip of the crankshaft front oil seal.

COUNTERBALANCER
SHAFT, RIGHT
MD998285

AK202577 AD

3. Install the oil pump case assembly together with the new
front case gasket.
4. Install the oil filter bracket together with the new gasket.
5. Tighten the all flange bolts to the specified torque.
Tightening torque: 23 ± 3 N⋅ m (17 ± 2 ft-lb)

MD998285

AK202656 AD

TSB Revision
 ENGINE OVERHAUL
OIL PAN AND OIL PUMP
11B-57
>>I<< FLANGE BOLT INSTALLATION
1. Insert a Phillips head screwdriver [shank diameter 8 mm
(0.3 inch)] into the hole in the left side of the cylinder block to
lock the counterbalance shaft.

SCREWDRIVER AKX00573AB

2. Secure the oil pump driven gear onto the left counterbalance
shaft by tightening the flange bolt to the specified torque.
Tightening torque: 36 ± 3 N⋅ m (27 ± 1 ft-lb)
3. Pull out the screwdriver and screw in the plug.

AK304385

>>J<< PLUG CAP INSTALLATION

1. Install a new O-ring to the groove of the front case.
MD998162 2. Install the plug cap to the front case.
3. Fit special tool MD998162 on the plug cap, and then hold it
in position with special tool MD998783.
4. Tighten the plug cap to the specified torque.
Tightening torque: 23 ± 3 N⋅ m (17 ± 2 ft-lb)
5. Remove special tools MD998783 and MD998162.
MD998783
AK202585 AD

>>K<< OIL PRESSURE SWITCH INSTALLATION

CAUTION
Be careful not to block the oil passage with sealant.
1. Apply 3M™ AAD Part number 8672 or equivalent to the
thread of engine oil pressure switch.

AK300715 AD

TSB Revision
11B-58 ENGINE OVERHAUL
OIL PAN AND OIL PUMP

2. Using special tool MD998012, tighten the engine oil

MD998012 pressure switch to the specified torque.
Tightening torque: 19 ± 3 N⋅ m (14 ± 2 ft-lb)

AK204037AC

>>L<< OIL PAN INSTALLATION

1. Clean both gasket surfaces of oil pan and cylinder block.
2. Apply a 4 mm (0.15 inch) diameter bead of sealant
(MITSUBISHI Genuine Part number MD970389 or
equivalent) to the flange of the oil pan.
Apply sealant as indicated by the broken line in the
illustration; the grooves must be traced and the bolt holes
must be surrounded with a bead of sealant.
3. Install the oil pump case assembly to the front side of the
cylinder block.
NOTE: Be sure to install the oil pan quickly while the sealant
is wet (within 15 minutes).
GROOVE

SEALANT
BOLT HOLE

AKX00532AB

4. Fit an 8 mm (0.30 inch) long bolt in each of the two holes

TIMING BELT SIDE identified by the letter "S" in the illustration and a 10 mm
(0.39 inch) long bolt in each of the remaining 17 holes.
Tighten all bolts to the specified torque.
S
Tightening torque: 9.0 ± 3.0 N⋅ m (80 ± 26 in-lb)
NOTE: After installation, keep the sealed area away from
the oil for approximately one hour.

AKX00496AB

TSB Revision
 ENGINE OVERHAUL
OIL PAN AND OIL PUMP
11B-59
>>M<< OIL FILTER INSTALLATION
1. Clean the installation surface of the filter bracket.
2. Apply engine oil to the o-ring of the oil filter.
BRACKET SIDE 3. Install the oil filter to the bracket and tighten it to the
specified torque.
Tightening torque: 14 ± 2 N⋅ m (124 ± 17 in-lb)
4. If no torque wrench is available for tightening, use the
following procedure:
(1) Screw in the oil filter until its o-ring contacts the oil filter
AKX00529AB bracket.
(2) Tighten the oil filter 3/4 turn.
.

>>N<< DRAIN PLUG GASKET INSTALLATION

CAUTION
If the gasket is installed in the wrong direction, oil leaks
will occur.
Install the drain plug gasket in the direction shown.
DRAIN PLUG

OIL PAN
GASKET

OIL PAN
SIDE

AKX00596AB

TSB Revision
11B-60 ENGINE OVERHAUL
OIL PAN AND OIL PUMP

INSPECTION
M1113008200182
.

COUNTERBALANCER SHAFTS
1. Check that the oil holes are not blocked.
Clean if necessary.
2. Check the journals for seizure, damage and defective
contact with bearings.
If any of these faults is found, replace the counterbalancer
shaft, bearings and/or oil pump case assembly.

AK202835AC

OIL PUMP
1. Install the drive and driven gears in the oil pump case.
2. Measure the gear side clearance using a straight edge and
thickness gauge.
Standard values:
Drive gear 0.08 − 0.14 mm (0.0031 − 0.0055 inch)
Driven gear 0.06 − 0.12 mm (0.0023 − 0.0047 inch)

AK202831

TSB Revision
 ENGINE OVERHAUL
PISTON AND CONNECTING ROD
11B-61
PISTON AND CONNECTING ROD
REMOVAL AND INSTALLATION
M1113008401349

6
7
APPLY ENGINE OIL
TO ALL MOVING 8
PARTS BEFORE
INSTALLTION. 10
9 4

12

11

2
20 ± 2 N·m → +90˚ TO 94˚
15 ± 1 ft-lb
1 AK501781AC

REMOVAL STEPS REMOVAL STEPS (Continued)

>>G<<1. NUT >>C<< 7. PISTON RING NO.2
<<A>> >>F<< 2. CONNECTING ROD CAP >>B<< 8. OIL RING
>>E<< 3 CONNECTING ROD BEARING <<C>> >>A<< 9. PISTON PIN
<<B>> >>D<< 4. PISTON AND CONNECTING ROD 10. PISTON
>>E<< 5. CONNECTING ROD BEARING 11. CONNECTING ROD
>>C<< 6. PISTON RING NO.1 12. BOLT

Required special tool:

• MIT216941: Piston Pin Setting Tool
• MB992010: Bolt Guide

TSB Revision
11B-62 ENGINE OVERHAUL
PISTON AND CONNECTING ROD

REMOVAL SERVICE POINTS

.

<<A>> CONNECTING ROD CAP REMOVAL

1. Mark the cylinder number on the side of the connecting rod
big end for correct reassembly.
2. Keep the removed connecting rods, caps, and bearings in
CYLINDER NUMBER
that order according to the cylinder number.

AKX00600AB

<<B>> PISTON AND CONNECTING ROD ASSEMBLY

REMOVAL
1. Not to damage the crank pin, attach a special tool
MB992010 MB992010, to the connecting rod bolt.
2. Remove the piston and connecting rod assembly from the
cylinder block.

CRANK PIN
AK402310 AD

<<C>> PISTON PIN REMOVAL

PISTON PIN SETTING
TOOL MIT216941 ITEM NO. PART NO. DESCRIPTION
1 1. MIT310134 Base
2
2. MIT310136 Piston support
3. MIT310137 Connecting rod guide pin
4. MIT310138 Connecting rod guide pin
3 4 5
5. MIT310139 Connecting rod guide pin
6. MIT310140 Piston support
6 7 8 7. MIT310141 Connecting rod guide pin
8. MIT310142 Piston support
11 9. MIT48143 Press pin
10
10. 216943 Stop screw
9 11. 10396 Nut

1. Remove the stop screw from the base.

AKX00598AB 2. Select the correct piston support for your application (See
above). Fit the piston support onto the base. Place the base
on press support blocks.

TSB Revision
 ENGINE OVERHAUL
PISTON AND CONNECTING ROD
11B-63
3. Insert the press pin through the piston pin hole. Select the
correct connecting rod guide pin (See above). Thread the
guide pin onto the threaded portion of the press pin.
PRESS
PIN CAUTION
To avoid piston damage, the piston support must seat
PISTON PIN squarely against the piston. Verify that the piston pin will
FRONT MARK slide through the hole in the piston support.
FRONT 4. Position the piston assembly on the piston support in the
MARK
press. With the press pin up as shown, insert the guide pin
through the hole in the piston and through the hole in the
piston support.
CONNECTING 5. Press the piston pin out of the assembly.
ROD GUIDE PIN
6. Remove the piston pin from the press pin.
BASE

AKX00516AB

INSTALLATION SERVICE POINTS

.

>>A<< PISTON PIN INSTALLATION

TIMIMG BELT SIDE
1. When replacing the piston, read off the cylinder bore size
CRANKSHAFT
BORE SIZE
mark on the cylinder block as illustrated, and select a piston
MARK according to the flowing table.
CYLINDER BORE PISTON SIZE MARK
No.4 SIZE MARK
No.3 I A
No.2
No.1 II None

AK200852 AC
III C

NOTE: The piston size mark shows on the top of the piston.

TSB Revision
11B-64 ENGINE OVERHAUL
PISTON AND CONNECTING ROD

2. Thread the stop screw and lock nut assembly into the base.
Fit the correct piston support on top of the base. Insert the
press pin, threaded end up, into the hole in the piston
support until the press pin touches the stop screw.
3. Using the markings on the press pin, adjust the stop screw
PRESS
PIN to the depth shown on the instruction for special tool
BASE MIT216941.
PISTON
SUPPORT
LOCKNUT

STOP SCREW

PIN DEPTH SET FLAT PISTON

LOCATION SUPPORT

AKX00599AB

4. Place the base on press support blocks.

5. Slide the piston pin over the threaded end of the press pin,
PRESS PIN and thread the correct guide pin up against it.
6. Coat the piston pin with engine oil. With the connecting rod
PISTON PIN held in position, slide the guide pin through the piston and
FRONT
FRONT connecting rod.
MARK
MARK 7. Press the piston pin through the connecting rod until the
guide pin contacts the stop screw.

CONNECTING
CAUTION
ROD GUIDE PIN Due to production tolerance variations, it is necessary to
visually inspect the piston pin depth after installation to
verify that the piston pin is centered. Adjust if necessary.
BASE
8. Remove the piston assembly from the base. Remove the
guide pin and press pin from the assembly.

STOP JAM NUT

SCREW

AKX00517AB

9. Check that the piston moves smoothly.

AKX00568

TSB Revision
 ENGINE OVERHAUL
PISTON AND CONNECTING ROD
11B-65
.

>>B<< OIL RING INSTALLATION

1. Fit the oil ring coil expander and oil ring into the piston ring
COIL EXPANDER
END GAP groove.
NOTE: The oil ring and coil expander may be installed in
either direction.
NOTE: New coil expander and oil ring are colored for identi-
fication of their sizes.
SIZE IDENTIFICATION COLOR
OIL RING
END GAP Standard None
AK502373 AC
0.50 mm (0.020 in) oversize Red
diameter
1.00 mm (0.040 in) oversize Yellow
diameter

OIL RING END

CAUTION
Do not use a piston ring expander when installing side rail.
2. To install each coil expander, first fit one end of the oil ring
into the piston groove, then press the remaining portion
progressively into position by finger as shown in the
drawing.
3. Make sure that the oil ring move smoothly in both directions.
AK202785 AE

>>C<< PISTON RING NUMBER 2 / PISTON RING NUMBER

1 INSTALLATION
1. To prevent wrong installation, check the identification mark
IDENTIFICATION MARK "1R" of each piston ring. The identification mark is stamped near
IDENTIFICATION SIZE MARK the ring gap:
MARK "2R"
Identification mark:
Number 1 ring: 1R
NO.1 Number 2 ring: 2R
NO.2 NOTE: Size marks on piston rings are as follows.
SIZE SIZE MARK
AKX00527AB Standard No.1 ring (None) White paint to the ring periphery
No.2 ring (None) Black paint to the ring periphery
0.50 mm (0.020 in) 50
oversize diameter
1.00 mm (0.040 in) 100
oversize diameter

TSB Revision
11B-66 ENGINE OVERHAUL
PISTON AND CONNECTING ROD

2. Using the piston ring expander, fit number 2 into the number
2 groove of piston.
NOTE: Install piston rings with identification mark facing up,
to the piston crown side.
3. Install the number 1 piston ring in the same manner as step
2.

AKX00515

>>D<< CONNECTING ROD BEARING INSTALLATION

IDENTIFICATION MARK OF CRANKSHAFT 1. Measure the crankshaft pin diameter and confirm its
PIN DIAMETER classification from the following table. In the case of a
crankshaft supplied as a service part, identification marks of
its pins are stamped at the positions shown in the
illustration.
CRANKSHAFT PIN OUTSIDE CONNECTING
NO.2
DIAMETER ROD BEARING
NO.1 NO.3
IDENTIFICATION SIZE mm (in) IDENTIFICATION
NO.4 MARK MARK
AK102988AB
I 44.995 − 45.000 0
IDENTIFICATION MARK OF CONNECTING (1.7715 − 1.7717)
ROD BEARING SIZE
II 44.985 − 44.995 1
(1.7711 − 1.7715)
III 44.980 − 44.985 2
(1.7709 − 1.7711)

2. If the crankshaft pin outside diameter identification mark is

IDENTIFICATION
MARK "I," for example, select a bearing whose identification mark
AK203964AB
is "0."
If there is no identification mark or no identification color
paint on the crankshaft, measure the pin outside diameter
and select a bearing appropriate for the measured value.
3. Install the selected bearing in the big end and in the cap of
the connecting rod.
.

>>E<< PISTON AND CONNECTING ROD INSTALLATION

1. Apply engine oil on the circumference of the piston, piston
COIL EXPANDER NO.1 rings, and oil ring.
2. Arrange the piston ring and oil ring gaps (oil ring and coil
expander) as shown in the illustration.
TIMING BELT
SIDE PISTON PIN 3. Rotate the crankshaft so that crank pin is on the center of
the cylinder bore.

NO.2 OIL RING

AKX00456AC

TSB Revision
 ENGINE OVERHAUL
PISTON AND CONNECTING ROD
11B-67
4. Not to damage the crank pin, attach a special tool
BOLT
MB992010, to the connecting rod bolt.

MB992010

CONNECTING ROD
AK402300AC

5. Use suitable thread protectors on the connecting rod bolts

before inserting the piston and connecting rod assembly into
the cylinder block.
Care must be taken not to nick the crank pin.
6. Insert the piston and connecting rod assembly into the
cylinder with front mark on the piston crown pointing to the
timing belt side.
CAUTION
Make sure that the piston and connecting rod do not touch
AK202798
the oil jet during installation.
7. Using a suitable piston ring compressor tool, Install the
piston and connecting rod assembly into the cylinder block.
.

>>F<< CONNECTING ROD CAP INSTALLATION

1. Verifying the mark made during disassembly, install the
bearing cap to the connecting rod. If the connecting rod is
new with no index mark, make sure that the bearing locking
notches are on the same side as shown.
CYLINDER NO.

NOTCHES

AKX00535AB

2. Make sure that the connecting rod big end side clearance
meets the specification.
Standard value: 0.10 − 0.25 mm (0.004 − 0.009 inch)
Limit: 0.4 mm (0.015 inch)

AKX00578

TSB Revision
11B-68 ENGINE OVERHAUL
PISTON AND CONNECTING ROD

>>G<< CONNECTING ROD CAP NUT TIGHTENING

1. The connecting rod bolts should be examined before reuse.
If the bolt threads are damaged, the bolt should be replaced.
Hand-thread the nut to the full length of the bolt threads. 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. Loosely tighten each nut to the bolt.
4. Then tighten the nuts alternately to a torque of 20 ± 2 N⋅ m
(15 ± 1 ft-lb) to install the cap properly.
5. Make a paint mark on the head of each nut.
Paint marks
90˚ TO 94˚
CAUTION
Paint marks • If the nut is turned less than 90 degree angle, proper
fastening may not be achieved. Be careful to tighten the
nut exactly at a 90 degree angle.
• If the nut is overtightened (exceeding 94 degree angle),
Bolt
loosen the nut completely and then retighten it by
Nut repeating the tightening procedure from step 3.
6. Make a paint mark on the bolt end at the position 90 degree
AK300612 AD
angle to 94 degree angle from the paint mark made on the
nut in the direction of tightening the nut.
7. Turn the nut further 90 degree angle to 94 degree angle and
make sure that the paint marks on the nut and bolt are
aligned.

TSB Revision
 ENGINE OVERHAUL
PISTON AND CONNECTING ROD
11B-69
INSPECTION
M1113008500343
.

PISTON RING
1. Check for side clearance.
If the limit is exceeded, replace the ring or piston, or both.
Standard value:
No.1: 0.03 − 0.07 mm (0.0012 − 0.0028 inch)
No.2: 0.02 − 0.06 mm (0.0008 − 0.0024 inch)
Limit:
No.1: 0.1 mm (0.0039 inch)
No.2: 0.1 mm (0.0039 inch)
AK202787

2. Install the piston ring into the cylinder bore. Force the ring
FORCE RING DOWN down with a piston, the piston crown being in contact with
WITH PISTON
the ring, to correctly position it at right angles to the cylinder
wall. Then, measure the end gap with a feeler gauge.
If the end gap is excessive, replace the piston ring.
Standard value:
No.1 ring: 0.20 − 0.30 mm (0.0079 −0.0118 inch)
No.2 ring: 0.35 − 0.50 mm (0.0128 −0.0197 inch)
Oil ring: 0.10 − 0.40 mm (0.0039 −0.0157 inch)
PISTON RING END GAP AK202788 AC
Limit:
No.1, No.2 ring: 0.8 mm (0.031 inch)
Oil ring: 1.0 mm (0.039 inch)
.

CRANKSHAFT PIN OIL CLEARANCE

(PLASTIGAGE METHOD)
1. Remove oil from the crankshaft pin and connecting rod
bearing.
2. Cut the plastigage 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 nuts
to the specified torque. (See "Connecting rod cap nut
tightening" procedure.)
4. Carefully remove the connecting rod cap.
PLASTIGAGE 5. Measure the width of the plastigage at its widest part by
AK100208AB
using a scale printed on its package.
Standard value: 0.03 −0.05 mm (0.0012 −0.0020 inch)
Limit: 0.1 mm (0.004 inch)

TSB Revision
11B-70 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK

CRANKSHAFT AND CYLINDER BLOCK

REMOVAL AND INSTALLATION
11 ± 1 N·m
98 ± 8 in-lb
3

1
15 6
132 ± 5 N·m
98 ± 3 ft-lb

4
5 9.0 ± 1.0 N·m
80 ± 8 in-lb
11 ± 1 N·m
12 98 ± 8 in-lb
14 11

13
32 ± 2 N·m
24 ± 1 ft-lb 10

8 APPLY ENGINE OIL

TO ALL MOVING
PARTS BEFORE
25 ± 2 N·m INSTALLTION.
18 ± 1 ft-lb → +90˚
7

AK203816 AB

REMOVAL STEPS REMOVAL STEPS (Continued)

1. FLYWHEEL BOLT >>B<< 9. CRANKSHAFT BEARING, LOWER
2. FLYWHEEL 10. CRANKSHAFT
3. REAR PLATE >>B<< 11. CRANKSHAFT BEARING, UPPER
4. BELL HOUSING COVER >>A<< 12. THRUST BEARING
>>E<< 5. OIL SEAL CASE 13. CHECK VALVE
>>D<< 6. OIL SEAL 14. OIL JET
>>C<< 7. BEARING CAP BOLT 15. CYLINDER BLOCK
>>C<< 8. BEAM BEARING CAP

Required Special Tools:

• MD998776: Crankshaft Rear Oil Seal Installer
• MB990938: Handle

TSB Revision
 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK
11B-71
INSTALLATION SERVICE POINTS
.

>>A<< CRANKSHAFT THRUST BEARING INSTALLATION

1. Install the two thrust bearings in the number 3 bearing bore
in the cylinder block. For easier installation, apply engine oil
to the bearings; this will help hold them in position.
2. The thrust bearings must be installed with their groove side
toward the crankshaft web.

GROOVE
AKX00497AB

>>B<< CRANKSHAFT BEARING INSTALLATION

When bearing replacement is required, select and install the
correct bearing by the following procedure.
IDENTIFICATION MARK OF CRANKSHAFT 1. Measure the crankshaft journal diameter and confirm its
JOURNAL DIAMETER classification from the following table. In the case of a
crankshaft supplied as a service part, identification marks of
its journals are stamped at the positions shown in the
illustration.

NO.2
NO.1 NO.3

NO.4 NO.5 AK102989AB

2. The cylinder block bearing bore diameter identification

IDENTIFICATION MARK OF BEARING marks are stamped at the position shown in the illustration
BORE SIZE
from left to right, beginning at No.1.

NO.1 NO.2 NO.3 NO.4 NO.5

BEARING BORE
IDENTIFICATION
MARK

CYLINDER
INNER
DIAMETER
SIZE MARK

BOTTOM OF REAR FACE OF

CYLINDER BLOCK CYLINDER
BLOCK

AKX00499AC

TSB Revision
11B-72 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK

CRANKSHAFT JOURNAL OUTSIDE CYLINDER BLOCK CRANKSHAFT BEARING

DIAMETER BEARING BORE
IDENTIFICATION SIZE mm (in) IDENTIFICATION MARK IDENTIFICATION MARK
MARK
0 56.994 − 57.000 0 0
(2.2439 − 2.2441)
1 1
2 2
1 56.988 − 56.994 0 1
(2.2436 − 2.2439)
1 2
2 3
2 56.982 − 56.988 0 2
(2.2434 − 2.2436)
1 3
2 4

IDENTIFICATION MARK OF For example, if the crankshaft journal outside diameter identifi-
CRANKSHAFT BEARING SIZE cation mark is "0" and cylinder block bearing bore identification
mark is "1," select a bearing whose identification mark is "1."
If there is no identification mark stamp on the crankshaft, mea-
sure the journal outside diameter and select a bearing appropri-
ate for the measured value.

IDENTIFICATION
MARK
AK203965 AB

3. Install the bearings having an oil groove to the cylinder

block.
GROOVE
4. Install the bearings having no oil groove to the bearing cap.

FOR UPPER

FOR LOWER
AKX00498AB

>>C<< BEARING CAP/BEARING CAP BOLT INSTALLATION

1. Install the bearing caps so that the arrow points to the timing
belt side.
2. Before installing the bearing cap bolts, check that the shank
length of each bolt meets the limit. If it exceeds the limit,
replace the bolt.
Limit (A): 71.1 mm (2.79 inches)
A
3. Apply engine oil to the threaded portion and bearing surface
SHANK LENGTH
of the bolt.
AKX00525AB

TSB Revision
 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK
11B-73
4. Tighten the bolts to 25 ± 2 N⋅ m (18 ± 1 ft-lb) in the tightening
sequence shown.

8 4 1 5 9

7 3 2 6 10

ARROW AK202737 AC

5. Make a paint mark on the head of each bolt.

6. Make a paint mark on the bearing cap at the position 90
PAINT MARK PAINT MARK
degree angle from the paint mark made on the bolt in the
direction of tightening the bolt.
CAUTION
• If the bolt is overtightened, loosen the bolt completely
and then retighten it by repeating the tightening proce-
90˚ dure from step 4.
• If the bolt is turned less than 90 degree angle, proper
AKX00451AB
fastening performance may not be achieved. Be sure to
turn the bolt exactly 90 degree angle.
7. Turn each bolt 90 degree angle in the tightening sequence
specified in step 4, and make sure that the paint marks on
the bolt and cap are aligned.
8. Make sure that the crankshaft turns smoothly and the end
play is correct. If the end play exceeds the limit, replace the
number 3 crankshaft bearings.
Standard value: 0.05 − 0.25 mm (0.002 − 0.009 inch)
Limit: 0.40 mm (0.0015 inch)

AKX00580

>>D<< OIL SEAL INSTALLATION

Using special tools MD998776 and MB990938, press-fit the oil
seal in the case.
MB990938

MD998776

AKX00588AB

TSB Revision
11B-74 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK

>>E<< SEALANT APPLICATION TO OIL SEAL CASE

1. Apply sealant (MITSUBISHI Genuine Part number
MD970389 or equivalent) to the gasket surface of oil seal
case.
NOTE: Be sure to install the case quickly while the sealant is
wet (within 15 minutes).
2. Apply engine oil to the oil seal lip, and then install the oil seal
case onto the cylinder block.
NOTE: After installation, keep the sealed area away from
the oil for approximately one hour.
AKX00581

INSPECTION
M1113008800344
.

CRANKSHAFT JOURNAL OIL CLEARANCE

<PLASTIGAGE METHOD>
1. Remove oil from the crankshaft journal and crankshaft
PLASTIGAGE bearing.
2. Install the crankshaft.
3. Cut the plastigage to the same length as the width of
bearing and place it on journal in parallel with its axis.

AK202826 AC

4. Install the crankshaft bearing cap carefully and tighten the

bolts to the specified torque.
5. Carefully remove the crankshaft bearing cap.
6. Measure the width of the plastigage at its widest part by
using a scale printed on the plastigage package.
Standard value: 0.03 − 0.04 mm (0.0012 −0.0015 inch)
Limit: 0.1 mm (0.003 inch)

PLASTIGAGE
AK202822 AC

CYLINDER BLOCK
1. Visually check for scratches, rust, and corrosion.
Use also a flaw detecting agent for the check. If defects are
evident, correct or replace.
2. 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 (0.0020 inch)
Limit: 0.1 mm (0.003 inch)
3. If the distortion is excessive, correct within the allowable
AK401851
limit or replace.
Grinding limit: 0.2 mm (0.007 inch)
*Includes/combined with cylinder head grinding
Cylinder block height (when new):
290 mm (11.4 inches)

TSB Revision
 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK
11B-75
4. Check cylinder walls for scratches and seizure. If defects
are evident, replace or bore to oversize and replace pistons
and piston rings.
5. Using a cylinder gauge, measure the cylinder bore and
cylindrically. If worn badly, correct the cylinder to an oversize
A and replace the piston and piston rings. Measure at the
B points shown in the illustration.
Standard value:
12 mm
(0.5 in) Cylinder inner diameter 85.0 mm (3.35 inches)
Cylindrically 0.01 mm (0.0003 inch) or less
CENTER
BOTTOM
AKX00457AB

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 (0.020 in) oversize 50
diameter

12.5 mm 1.00 mm (0.040 in) oversize 100

PISTON DIAMETER diameter
AK203804 AB

NOTE: Size mark is stamped on the piston top.

2. Measure the outside diameter (OD) of the piston to be used.
Measure it in thrust direction as shown.
3. Based on the measured piston OD, calculate the boring
finish dimension.
Boring finish dimension = Piston OD +
(clearance between piston OD and cylinder) −
0.02 mm (0.0008 inch) (honing margin)
CAUTION
To prevent distortion that may result from temperature rise
during honing, bore cylinders, working from number 2 to
number 4 to number 1 to number 3.
4. Bore all cylinders to the calculated boring finish dimension.
5. Hone to the final finish dimension (piston OD + clearance
between piston OD and cylinder).
6. Check the clearance between the piston and cylinder.
Clearance between piston and cylinder:
0.02 −0.04 mm (0.0008 −0.0015 inch)
NOTE: When boring cylinders, finish all of four cylinders to
the same oversize. Do not bore only one cylinder to an over-
size.

TSB Revision
11B-76 ENGINE OVERHAUL
SPECIFICATIONS

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1113023401454

ITEM SPECIFICATION
Generator and ignition system
Auto-tensioner assembly bolt M8 24 ± 4 N⋅ m (18 ± 2 ft-lb)
Auto-tensioner assembly bolt M10 44 ± 10 N⋅ m (33 ± 6 ft-lb)
Center cover bolt 3.0 ± 0.5 N⋅ m (27 ± 3 in-lb)
Crankshaft pulley bolt 25 ± 4 N⋅ m (19 ± 2 ft-lb)
Generator brace bolt (flange bolt) 24 ± 4 N⋅ m (18 ± 2 ft-lb)
Generator brace bolt (bolt, washer assembly M8 × 22) 22 ± 4 N⋅ m (17 ± 2 ft-lb)
Generator brace bolt (bolt, washer assembly M8 × 32) 20 ± 2 N⋅ m (15 ± 1 ft-lb)
Generator pivot nut 44 ± 10 N⋅ m (33 ± 6 ft-lb)
Ignition coil bolt 10 ± 2 N⋅ m (89 ± 17 in-lb)
Oil dipstick guide bolt 13 ± 1 N⋅ m (115 ± 8 in-lb)
Spark plugs 25 ± 5 N⋅ m (19 ± 3 ft-lb)
Water pump pulley bolt 8.8 ± 1.0 N⋅ m (78 ± 8 in-lb)
Solenoid and vacuum hose
Solenoid valve assembly bolt 9.0 ± 1.0 N⋅ m (80 ± 8 in-lb)
Vacuum pipe and hose assembly bolt 11 ± 1 N⋅ m (98 ± 8 in-lb)
Timing belt
Auto-tensioner bolt 23 ± 3 N⋅ m (17 ± 2 ft-lb)
Camshaft sprocket bolt 88 ± 10 N⋅ m (65 ± 7 ft-lb)
Connector bracket bolt 11 ± 1 N⋅ m (98 ± 8 in-lb)
Counterbalance shaft sprocket bolt 45 ± 3 N⋅ m (33 ± 2 ft-lb)
Crankshaft angle sensors bolt 8.8 ± 1.0 N⋅ m (78 ± 8 in-lb)
Crankshaft bolt 167 N⋅ m (123 ft-lb)
Engine support bracket bolt 49 ± 5 N⋅ m (36 ± 3 ft-lb)
Idler pulley 35 ± 6 N⋅ m (26 ± 4 ft-lb)
Oil pump sprocket nut 54 ± 5 N⋅ m (40 ± 3 ft-lb)
Plug cap 32 ± 2 N⋅ m (24 ± 1 ft-lb)
Positive crankcase ventilation valve 10 ± 2 N⋅ m (89 ± 17 in-lb)
Power steering pump bracket bolt 49 ± 9 N⋅ m (36 ± 6 ft-lb)
Rocker cover bolt 3.5 ± 0.5 N⋅ m (31 ± 4 in-lb)
Tensioner arm bolt 21 ± 4 N⋅ m (16 ± 2 ft-lb)
Tensioner B bolt 19 ± 3 N⋅ m (14 ± 2 ft-lb)
Tensioner pulley bolt 48 ± 5 N⋅ m (36 ± 3 ft-lb)
Timing belt cover bolt (flange bolt) 11 ± 1 N⋅ m (98 ± 8 in-lb)
Timing belt cover bolt (bolt, washer assembly) 9.0 ± 1.0 N⋅ m (80 ± 8 in-lb)
V.V.T. sprocket bolt 65 ± 5 N⋅ m (48 ± 3 ft-lb)

TSB Revision
 ENGINE OVERHAUL
SPECIFICATIONS
11B-77
ITEM SPECIFICATION
Fuel and emission parts
Exhaust gas recirculation valve bolt 20 ± 2 N⋅ m (15 ± 1 ft-lb)
Fuel pressure regulator bolt 8.8 ± 2.0 N⋅ m (79 ± 16 in-lb)
Injector and fuel rail bolt 12 ± 1 N⋅ m (107 ± 8 in-lb)
Throttle body bolt 19 ± 3 N⋅ m (14 ± 2 ft-lb)
Intake manifold
Engine hanger bolt 19 ± 3 N⋅ m (26 ± 4 ft-lb)
Intake manifold bolt M8 20 ± 2 N⋅ m (15 ± 1 ft-lb)
Intake manifold bolt, nut M10 36 ± 6 N⋅ m (26 ± 4 ft-lb)
Intake manifold stay bolt 31 ± 3 N⋅ m (23 ± 2 ft-lb)
Manifold absolute pressure sensor bolt 5.0 ± 1.0 N⋅ m (45 ± 8 in-lb)
Exhaust manifold
Air outlet fitting bolt 19 ± 1 N⋅ m (14 ± 1 ft-lb)
Engine hanger bolt 19 ± 3 N⋅ m (14 ± 2 ft-lb)
Exhaust fitting bolt 59 ± 5 N⋅ m (44 ± 3 ft-lb)
Exhaust fitting bracket bolt 35 ± 6 N⋅ m (26 ± 4 ft-lb)
Exhaust manifold heat protector bolt 23 ± 3 N⋅ m (17 ± 2 ft-lb)
Exhaust manifold nut M8 33 ± 6 N⋅ m (24 ± 4 ft-lb)
Exhaust manifold nut M10 55 ± 10 N⋅ m (41 ± 6 ft-lb)
Oil pipe bolt (eye bolt M10) 17 ± 2 N⋅ m (13 ± 1 ft-lb)
Oil pipe bolt (eye bolt M12) 31 ± 2 N⋅ m (23 ± 1 ft-lb)
Oil pipe bolt (flange bolt) 11 ± 1 N⋅ m (98 ± 8 in-lb)
Oil return pipe bolt (oil pan side) 14 ± 1 N⋅ m (124 ± 8 in-lb)
Oil return pipe bolt (turbocharger side) 9.0 ± 1.0 N⋅ m (80 ± 8 in-lb)
Oxygen sensor 44 ± 5 N⋅ m (33 ± 3 ft-lb)
Turbocharger assembly and pipe assembly bolt, nut 64 ± 5 N⋅ m (47 ± 3 ft-lb)
Turbocharger heat protector bolt 23 ± 3 N⋅ m (17 ± 2 ft-lb)
Water pipe bolt (eye bolt M12) 42 ± 7 N⋅ m (31 ± 5 ft-lb)
Water pipe bolt (flange bolt) 10 ± 1 N⋅ m (89 ± 8 in-lb)
Water pump & water hose
Engine coolant temperature gauge unit 11 ± 1 N⋅ m (98 ± 8 in-lb)
Engine coolant temperature sensor 29 ± 10 N⋅ m (22 ± 6 ft-lb)
Knock sensor bolt 23 ± 2 N⋅ m (17 ± 2 ft-lb)
Thermostat housing bolt 23 ± 4 N⋅ m (17 ± 2 ft-lb)
Water inlet pipe bolt M6 10 ± 1 N⋅ m (89 ± 8 in-lb)
Water inlet pipe bolt M8 13 ± 2 N⋅ m (115 ± 17 in-lb)
Water outlet fitting bolt 10 ± 1 N⋅ m (89 ± 8 in-lb)
Water pump bolt 14 ± 1 N⋅ m (124 ± 8 in-lb)

TSB Revision
11B-78 ENGINE OVERHAUL
SPECIFICATIONS

ITEM SPECIFICATION
Rocker arms and camshafts
Bearing cap bolt 20 ± 1 N⋅ m (15 ± 1 ft-lb)
Camshaft position sensing cylinder bolt 22 ± 4 N⋅ m (17 ± 2 ft-lb)
Camshaft position sensor bolt 10.8 ± 1.0 N⋅ m (96 ± 8 in-lb)
Camshaft position sensor support bolt 14 ± 1 N⋅ m (124 ± 8 in-lb)
Check valve 30 ± 3 N⋅ m (22 ± 2 ft-lb)
Cover bolt 10 ± 2 N⋅ m (89 ± 17 in-lb)
Eye bolt 42 ± 2 N⋅ m (31 ± 2 ft-lb)
Oil delivery body bolt 11 ± 1 N⋅ m (98 ± 8 in-lb)
Oil feeder control valve bolt 11 ± 1 N⋅ m (98 ± 8 in-lb)
Oil pipe bolt 11 ± 1 N⋅ m (98 ± 8 in-lb)
Oil pipe joint 30 ± 3 N⋅ m (22 ± 2 ft-lb)
Cylinder head and valves
Cylinder head bolt 78 ± 2 N⋅ m (58 ± 1 ft-lb) → 0 N⋅ m (0 in-lb)
→ 20 ± 2 N⋅ m (15 ± 1 ft-lb) → +90° → +90°
Oil pan and oil pump
Baffle plate bolt 22 ± 4 N⋅ m (17 ± 2 ft-lb)
Drain plug 39 ± 5 N⋅ m (29 ± 3 ft-lb)
Flange bolt 36 ± 3 N⋅ m (27 ± 1 ft-lb)
Oil cooler by-pass valve 54 ± 5 N⋅ m (40 ± 3 ft-lb)
Oil filter 14 ± 2 N⋅ m (124 ± 17 in-lb)
Oil filter bracket bolt 19 ± 3 N⋅ m (14 ± 2 ft-lb)
Oil pan bolt 9.0 ± 3.0 N⋅ m (80 ± 26 in-lb)
Engine oil pressure switch 19 ± 3 N⋅ m (14 ± 2 ft-lb)
Oil pump case bolt 23 ± 3 N⋅ m (17 ± 2 ft-lb)
Oil pump cover bolt 17 ± 1 N⋅ m (13 ± 1 ft-lb)
Oil pump cover screw 10 ± 2 N⋅ m (89 ± 17 in-lb)
Oil screen bolt 19 ± 3 N⋅ m (14 ± 2 ft-lb)
Plug cap 23 ± 3 N⋅ m (17 ± 2 ft-lb)
Relief plug 44 ± 5 N⋅ m (33 ± 3 ft-lb)
Pistons and connecting rod
Connecting rod cap nut 20 ± 2 N⋅ m (15 ± 1 ft-lb) → +90° to 94°
Crankshaft and cylinder block
Beam bearing cap bolt 25 ± 2 N⋅ m (18 ± 1 ft-lb) → +90°
Bell housing cover bolt 9.0 ± 1.0 N⋅ m (80 ± 8 in-lb)
Check valve 32 ± 2 N⋅ m (24 ± 1 ft-lb)
Flywheel bolt 132 ± 5 N⋅ m (98 ± 3 ft-lb)
Oil seal case bolt 11 ± 1 N⋅ m (98 ± 8 in-lb)
Rear plate bolt 11 ± 1 N⋅ m (98 ± 8 in-lb)

TSB Revision
 ENGINE OVERHAUL
SPECIFICATIONS
11B-79
GENERAL SPECIFICATIONS
M1113000201169

Descriptions Specifications
Type In-line OHV, DOHC
Number of cylinders 4
Combustion chamber Pentroof type
3
Total displacement dm (cubic inches) 1,997 (122)
Cylinder bore mm (in) 85.0 (3.35)
Piston stroke mm (in) 88.0 (3.46)
Compression ratio 8.8
Number of valve Intake 2
Exhaust 2
Valve timing Intake valve Opens (BTDC) 0° − 30°
Closes (ABDC) 80° − 50°
Exhaust valve Opens (BBDC) 58°
Closes (ATDC) 18°
Lubrication system Pressure feed, full-flow filtration
Oil pump type Trochoid type
Cooling system Water-cooled forced circulation
Water pump type Centrifugal impeller type

TSB Revision
11B-80 ENGINE OVERHAUL
SPECIFICATIONS

SERVICE SPECIFICATIONS
M1113000301218

Items Standard value Limit

Timing belt
Auto tensioner rod length mm (in) 4.8 − 6.0 (0.19 − 0.21) −
Auto tensioner rod production length mm (in) 12 (0.5) −
Auto tensioner rod pushed-in amount 1.0 (0.03) or less −
[when pushed with a force of 98 to 196 N (22 to 44 lb)] mm
(in)
Rocker arms and camshaft
Camshaft cam height mm (in) Intake 35.96 (1.42) 35.46 (1.40)
Exhaust 35.49 (1.40) 34.99 (1.38)
Cylinder head and valve
Cylinder head flatness of gasket surface mm (in) Less than 0.03 (0.0012) 0.2 (0.008)
Cylinder head grinding limit of gasket surface mm (in) − 0.2* (0.008)
*Total resurfacing depth of both cylinder head and cylinder
block
Cylinder head overall height mm (in) 119.9 − 120.1 −
(4.720 − 4.728)
Cylinder head bolt shank length mm (in) − 99.4 (3.913)
Valve stem outside diameter mm (in) 6.0 (0.236) −
Valve stem-to-guide clearance mm (in) Intake 0.02 − 0.05 0.10 (0.0039)
(0.0008 − 0.0020)
Exhaust 0.05 − 0.09 0.15 (0.0059)
(0.0020 − 0.0035)
Valve face angle 45° − 45.5° −
Valve margin mm (in) Intake 1.0 (0.039) 0.5 (0.020)
Exhaust 1.5 (0.059) 1.0 (0.039)
Valve stem projection mm (in) Intake 49.20 (1.9370) 49.70 (1.9567)
Exhaust 48.40 (1.9055) 48.90 (1.9252)
Overall valve length mm (in) Intake 109.50 (4.311) 109.00 (4.291)
Exhaust 109.70 (4.319) 109.20 (4.299)
Valve spring free height mm (in) 50.4 (1.98) 49.4 (1.94)
Valve spring load/installed height N (lb) /mm (in) 279/40 (63/1.57) −
Valve spring squareness Max. 2° 4°
Valve seat contact width mm (in) 0.9 − 1.3 (0.035 − 0.051) −
Valve guide inside diameter mm (in) 6.0 (0.236) −
Valve guide projection mm (in) 19.5 (0.768) −

TSB Revision
 ENGINE OVERHAUL
SPECIFICATIONS
11B-81
Items Standard value Limit
Oversize valve guide hole diameter mm (in) 0.05 oversize 12.05 −12.07 −
diameter (0.4744 −0.4751)
0.25 oversize 12.25 −12.27 −
diameter (0.4921 −0.4929)
0.50 oversize 12.50 −12.52 −
diameter (0.4528 −0.4535)
Oversize intake valve seat hole diameter 0.30 oversize 35.30 −35.33 −
mm (in) diameter (1.3898 −1.3909)
0.60 oversize 35.60 −35.63 −
diameter (1.4016 −1.4028)
Oversize exhaust valve seat hole diameter 0.30 oversize 33.30 −33.33 −
mm (in) diameter (1.3110 −1.3122)
0.60 oversize 33.60 −33.63 −
diameter (1.3228 −1.3240)
Oil pump and oil pan
Oil pump side clearance mm (in) Drive gear 0.08 −0.14 −
(0.0031 −0.0055)
Driven gear 0.06 −0.12 −
(0.0023 −0.0047)
Piston and connecting rod
Piston outside diameter mm (in) 85.0 (3.35) −
Piston ring side clearance mm (in) No.1 0.03 − 0.07 0.1 (0.0039)
(0.0012 −0.0028)
No.2 0.02 − 0.06 0.1 (0.0039)
(0.0008 −0.0024)
Piston ring end gap mm (in) No.1 0.20 − 0.30 0.8 (0.031)
(0.0079 −0.0118)
No.2 0.35 − 0.50 0.8 (0.031)
(0.0128 −0.0197)
Oil ring 0.10 − 0.40 1.0 (0.039)
(0.0039 −0.0157)
Piston pin outside diameter mm (in) 22.0 (0.87) −
Piston pin press-in load [at room temperature] N (lb) 7,350 −17,200 −
(1.653 −3.866)
Crankshaft pin oil clearance mm (in) 0.03 − 0.05 0.1 (0.004)
(0.0012 −0.0020)
Connecting rod big end side clearance mm (in) 0.10 − 0.25 0.4 (0.016)
(0.0039 −0.0098)

TSB Revision
11B-82 ENGINE OVERHAUL
SPECIFICATIONS

Items Standard value Limit

Crankshaft and cylinder block
Crankshaft end play mm (in) 0.05 − 0.25 0.4 (0.016)
(0.0020 −0.0098)
Crankshaft journal outside diameter mm (in) 57 (2.24) −
Crankshaft pin outside diameter mm (in) 45 (1.77) −
Crankshaft journal oil clearance mm (in) 0.02 − 0.04 0.1 (0.004)
(0.0008 − 0.0016)
Cylinder block gasket surface flatness mm (in) 0.05 (0.0020) 0.1 (0.004)
Cylinder block gasket surface grinding limit mm (in) − 0.2 (0.008)
Cylinder block overall height mm (in) 290 (11.4) −
Cylinder bore inside diameter mm (in) 85.0 (3.35) −
Cylinder bore cylindricity mm (in) 0.01 (0.0004) or less −
Piston-to-cylinder clearance mm (in) 0.02 − 0.04 −
(0.0008 − 0.0016)
Bearing cap bolt shank length mm (in) − 71.1 (2.799)

SEALANTS AND ADHESIVES

M1113000500383

Items Specified sealant Quantity

Rocker cover Mitsubishi Genuine Part No.MD970389 or equivalent As required
Semicircular packing 3M™ AAD Part No.8672 or equivalent As required
Engine support bracket 3M™ AAD Part No.8672 or equivalent As required
Engine coolant temperature 3M™ AAD Part No.8731 or equivalent As required
sensor
Engine coolant temperature 3M™ AAD Part No.8672 or equivalent As required
gauge unit
Camshaft position sensor Mitsubishi Genuine Part No.MD970389 or equivalent As required
support
Oil pan Mitsubishi Genuine Part No.MD970389 or equivalent As required
Oil pressure switch 3M™ AAD Part No.8672 or equivalent As required
Oil seal case Mitsubishi Genuine Part No.MD970389 or equivalent As required

TSB Revision