11B-1

GROUP 11B

ENGINE OVERHAUL
CONTENTS

HOW TO USE THIS MANUAL. . . . . . 11B-2 FUEL AND EMISSION PARTS. . . . . . 11B-29
REMOVAL AND INSTALLATION . . . . . . . . 11B-29
GENERAL INFORMATION . . . . . . . . 11B-4

m
INLET MANIFOLD AND WATER PUMP
GENERAL SPECIFICATIONS . . . . . . 11B-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B-31

o
REMOVAL AND INSTALLATION . . . . . . . . 11B-31
SERVICE SPECIFICATIONS. . . . . . . 11B-4

REWORK DIMENSIONS . . . . . . . . . .
.c11B-6
ROCKER ARMS AND CAMSHAFT . . 11B-35
REMOVAL AND INSTALLATION . . . . . . . . 11B-35
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INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-37
TORQUE SPECIFICATIONS . . . . . . . 11B-7
CYLINDER HEAD AND VALVES. . . . 11B-38
SEALANTS . . . . . . . . . . . . . . . . . . . . 11B-9 REMOVAL AND INSTALLATION . . . . . . . . 11B-38
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INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-41
SPECIAL TOOLS. . . . . . . . . . . . . . . . 11B-10
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OIL PAN AND OIL PUMP. . . . . . . . . . 11B-45

ALTERNATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION . . . . . . . . 11B-45
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B-14
ca

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-52
REMOVAL AND INSTALLATION . . . . . . . . 11B-14
PISTON AND CONNECTING ROD . . 11B-54
EXHAUST MANIFOLD. . . . . . . . . . . . 11B-17 REMOVAL AND INSTALLATION . . . . . . . . 11B-54
REMOVAL AND INSTALLATION . . . . . . . . 11B-17 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-60

TIMING BELT. . . . . . . . . . . . . . . . . . . 11B-19 CRANKSHAFT AND CYLINDER BLOCK

REMOVAL AND INSTALLATION . . . . . . . . 11B-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B-62
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 11B-27 REMOVAL AND INSTALLATION . . . . . . . . 11B-62
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-65
11B-2 ENGINE OVERHAUL
HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL

M1113025100230

HOW TO USE THIS MANUAL

Scope of Service Explanations
This manual describes service procedures performed after removal of the engine from the vehicle.
For removal of the engine from the vehicle, installation of the engine in the vehicle, and on-vehicle inspection and service of
the engine, please use the separate Workshop Manuals prepared for the vehicle.

How to Read Explanations

Service steps
(1) A component part drawing is shown at the beginning of each section to enable the technician to ascertain the installed con-
dition of the component parts.
(2) Service steps are indicated by means of numbers in the component part drawing. Non-reusable parts are indicated as such,
and tightening torques are shown.
·Removal steps
The numbers of the part names match the numbers in the component part drawing and indicate the removal sequence.
·Installation steps

m
Installation steps are omitted wherever installation can be achieved simply by performing the removal steps in reverse.
·Disassembly steps
The numbers of the part names match the numbers in the component part drawing and indicate the disassembly sequence.
·Reassembly steps

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Reassembly steps are omitted wherever reassembly can be achieved simply by performing the disassembly steps in reverse.

.c
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Classification of Service Points
Key service points, service standards, and instructions for <<A>>: Outward-pointing brackets denote removal service points
using special tools are collated as service points and ex- or disassembly service points.
ia

plained in detail. >>A<<: Inward-pointing brackets denote installation service points

or reassembly service points.
rd
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Lubricant and Sealant Symbols

Every location where a lubricant or sealant must be applied . . . . . . . . . . Grease
or added is indicated using a relevant symbol in the compo-
nent part drawing and/or on the page after the component . . . . . . . . . . Sealant or form-in-place gasket (FIPG)
part drawing.
. . . . . . . . . . Brake fluid

. . . . . . . . . . Engine oil or gear oil

Inspection
Only those inspection procedures which use special tools or measuring appliances are described. You must perform general visual inspec-
tion and part cleaning whenever necessary although their procedures are not described in this manual.

AK202851
 ENGINE OVERHAUL
HOW TO USE THIS MANUAL
11B-3

Page number Group title Section title

ENGINE OVERHAUL
11-54 CRANKSHAFT AND CYLINDER BLOCK

CRANKSHAFT AND CYLINDER BLOCK

REMOVAL AND INSTALLATION
11 ± 1 N·m
Denotes non-reusable part.

12 5
11
6
132 ± 5 N·m
20 8
7
9

m
132 ± 5 N·m
10

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11 ± 1 N·m 1
9.0 ± 1.0 N·m

.c 19
18
Tightening torque
gn
2
17

A 3
4
ia

16

Apply engine oil

rd

to all moving
15 parts before
installation.

25 ± 2 N·m → + 90˚
13
ca

25 ± 2 N·m → + 90˚
14 AK303794AB

Removal steps INSTALLATION SERVICE POINTS

1. Flywheel bolt
2. Adapter plate >>A<< THRUST BEARING INSTALLATION
3. Flywheel
4. Crankshaft bushing
5. Drive plate bolt
6. Adapter plate
7. Drive plate
8. Crankshaft bushing
9. Rear plate
10. Bell housing cover
>>E<< 11. Oil seal case
>>D<< 12. Oil seal
Grooves

AK100786AB

The alphabetical character in this category of

heading matches that of the relevant removal Procedures and cautions for removal, instal-
steps, installation steps, disassembly steps, or lation, disassembly, and reassembly are ex-
reassembly steps. plained under this category of heading. AK303970
11B-4 ENGINE OVERHAUL
GENERAL INFORMATION

GENERAL INFORMATION
M1113000100396
VEHICLE AND ENGINE MODELS
Vehicle name Vehicle Engine model Displacement Specification
model mL
Grandis NA4W 4G69-2 2,378 Single overhead camshaft, 16-valve

GENERAL SPECIFICATIONS
M1113000200638

Description Specification
Type In-line OHV, SOHC
Number of cylinders 4
Combustion chamber Pent roof type

m
Total displacement cm3 2,378
Cylinder bore mm 87

o
Piston stroke mm 100
Compression ratio
Valve timing Intake valve
.c
Opens (BTDC)
9.5
0° <Low speed cam A>
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2° <Low speed cam B>
20° <High speed cam>
Closes (ABDC) 46° <Low speed cam A>
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48° <Low speed cam B>

72° <High speed cam>
rd

Exhaust valve Opens (BBDC) 54°

Closes (ATDC) 21°
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Lubrication system Pressure feed, full-flow filtration

Oil pump type Involute gear type

SERVICE SPECIFICATIONS
M1113000300613

Item Standard value Limit

Timing belt
Auto tensioner rod length mm 3.8 − 4.5 −
Auto-tensioner rod projection length mm 12 −
Auto-tensioner rod pushed-in amount [When pushed with a 1.0 or less −
force of 98 − 196 N] mm
Valve clearance mm Intake 0.11 −
Exhaust 0.20 −
Rocker arms and camshaft
 ENGINE OVERHAUL
SERVICE SPECIFICATIONS
11B-5
Item Standard value Limit
Camshaft cam height mm Intake Low speed 34.41 Minimum 33.91
cam A
Low speed 37.47 Minimum 36.97
cam B
High speed 37.21 Minimum 36.71
cam
Exhaust 37.86 Minimum 37.36
Camshaft journal outside diameter mm 45 −
Cylinder head and valves
Cylinder head flatness of gasket surface mm Less than 0.03 0.2
Cylinder head grinding limit of gasket surface mm (Total − 0.2
resurfacing depth of cylinder head and cylinder block)
Cylinder head overall height mm 120 −

m
Cylinder head bolt shank length mm − 99.4
Valve thickness of valve head Intake 1.0 Minimum 0.5
(margin) mm

o
Exhaust 1.2 Minimum 0.7
Valve overall height mm Intake 111.33 Minimum 110.83

Valve stem outside diameter mm

Exhaust .c 113.54
6.0
Minimum 113.04
−
gn
Valve thickness to valve guide Intake 0.02 − 0.04 0.10
clearance mm Exhaust 0.04 − 0.06 0.15
Valve face angle mm 43.5° − 44° −
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Valve spring free length mm Intake 54.8 Minimum 53.8

rd

Exhaust 56.1 Minimum 55.1

Valve spring load/installed height Intake 235/44.2 −
N/mm Exhaust 226/44.2 −
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Valve spring out-of-squareness 2° or less 4°

Valve seat valve contact width mm 0.9 − 1.3 −
Valve guide inside diameter mm 6.0 −
Valve guide projection from cylinder head upper surface 14.0 −
mm
Valve stem projection mm Intake 48.33 48.83
Exhaust 48.34 48.84
Oil pan and oil pump
Oil pump side clearance mm Drive gear 0.08 − 0.14 −
Driven gear 0.06 − 0.12 −
Oil pressure at curb idle speed kPa 78 or more −
[oil temperature is 75 to 90°]
Piston and connecting rod
Piston outside diameter mm 87 −
11B-6 ENGINE OVERHAUL
REWORK DIMENSIONS

Item Standard value Limit

Piston ring side clearance mm No. 1 0.03 − 0.07 0.1
No. 2 0.02 − 0.06 0.1
Piston ring end gap mm No. 1 0.15 − 0.30 0.8
No. 2 0.28 − 0.43 0.8
Oil ring side rail 0.10 − 0.40 1.0
Piston pin outside diameter mm 22.0 −
Piston pin press-in load N (Room temperature) 7,350 − 17,200 −
Crankshaft pin oil clearance mm 0.02 − 0.05 0.1
Connecting rod big end side clearance mm 0.10 − 0.25 0.4
Crankshaft and cylinder block
Crankshaft end play mm 0.05 − 0.25 0.40
Crankshaft journal outside diameter mm 57.0 −

m
Crankshaft pin outside diameter mm 45.0 −
Crankshaft journal oil clearance mm 0.02 − 0.04 0.1

o
Bearing cap bolt shank length mm − 71.1
Piston to cylinder clearance mm 0.02 − 0.04 −
Cylinder block flatness of gasket surface mm
.c
Cylinder block grinding limit of gasket surface mm (Total −
0.05 0.1
0.2
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resurfacing depth of both cylinder head and cylinder block)
Cylinder block overall height mm 284 −
Cylinder block inside diameter mm 87.0 −
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Cylindricity mm 0.01 −
rd

REWORK DIMENSIONS
ca

M1113024300253

Item Standard value

Cylinder head And valves
Diameter of oversize valve seat ring hole in cylinder head Intake 0.3 oversize 35.30 − 35.33
mm 0.6 oversize 35.60 − 35.63
Exhaust 0.3 oversize 33.30 − 33.33
0.6 oversize 33.60 − 33.63
Diameter of oversize valve guide hole in cylinder head mm 0.05 oversize 11.05 − 11.07
0.25 oversize 11.25 − 11.27
0.50 oversize 11.50 − 11.52
 ENGINE OVERHAUL
TORQUE SPECIFICATIONS
11B-7
TORQUE SPECIFICATIONS
M1113023400785

Item Specification
Alternator and ignition system
Auto-tensioner bracket bolt M10 44 ± 10 N⋅m
Auto-tensioner bracket bolt M8 22 ± 4 N⋅m
Camshaft position sensing cylinder bolt 22 ± 4 N⋅m
Camshaft position sensor bolt 10 ± 2 N⋅m
Camshaft position sensor support bolts 14 ± 1 N⋅m
Connector bracket bolts 10 ± 1 N⋅m
Crankshaft pulley bolts 25 ± 4 N⋅m
Alternator bolt 49 ± 9 N⋅m
Alternator pivot nut 44 ± 10 N⋅m
Idler pulley bolt 79 ± 5 N⋅m

m
Ignition coil bolts 10 ± 2 N⋅m
Oil level gauge guide bolts 13 ± 1 N⋅m

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Spark plugs 25 ± 5 N⋅m
Water pump pulley bolts
Exhaust manifold
.c 8.8 ± 1.0 N⋅m
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Oxygen sensors 44 ± 5 N⋅m
Engine hanger bolt 24 ± 3 N⋅m
Exhaust manifold cover bolts 14 ± 1 N⋅m
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Exhaust manifold bracket B bolt 44 ± 5 N⋅m

Exhaust manifold nuts 49 ± 5 N⋅m
rd

Exhaust manifold bracket A bolts 36 ± 5 N⋅m

Timing belt
ca

Auto-tensioner bolts 23 ± 2 N⋅m

Camshaft sprocket bolt 89 ± 9 N⋅m
Counterbalance shaft sprocket bolt 45 ± 3 N⋅m
Crankshaft bolt 167 N⋅m
Crankshaft angle sensor bolts 8.5 ± 0.5 N⋅m
Engine support bracket bolts 49 ± 5 N⋅m
Alternator bracket bolts 49 ± 9 N⋅m
Idler pulley bolt 35 ± 6 N⋅m
Oil pump sprocket nut 54 ± 4 N⋅m
Tensioner "B" bolt 19 ± 3 N⋅m
Tensioner arm bolt 21 ± 4 N⋅m
Tensioner pulley bolt 48 ± 5 N⋅m
Timing belt cover bolts M6 (Bolt, washer assembly) 9.0 ± 1.0 N⋅m
Timing belt cover bolts M6 (Flange bolt and nut) 11 ± 1 N⋅m
Timing belt cover bolts M8 14 ± 1 N⋅m
11B-8 ENGINE OVERHAUL
TORQUE SPECIFICATIONS

Item Specification
Fuel and emission parts
EGR valve bolts 24 ± 3 N⋅m
Fuel pressure regulator bolts 9.0 ± 1.0 N⋅m
Injectors and delivery pipe bolts 11 ± 1 N⋅m
Solenoid valve bracket bolts 11 ± 1 N⋅m
Solenoid valve nut 9.0 ± 1.0 N⋅m
Throttle body bolts 14 ± 3 N⋅m
Vacuum pipe and hose bolts 11 ± 1 N⋅m
Inlet manifold and water pump
Engine coolant temperature sensor 30 ± 9 N⋅m
Engine hanger bolt 24 ± 3 N⋅m
Harness bracket bolts 11 ± 1 N⋅m
Inlet manifold bolts 24 ± 3 N⋅m

m
Inlet manifold nuts 20 ± 2 N⋅m
Inlet manifold stay bolts 31 ± 3 N⋅m

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Detonation sensor 23 ± 2 N⋅m
Oil pressure switch
Thermostat housing bolts
.c 19 ± 3 N⋅m
24 ± 4 N⋅m
gn
Water inlet fitting bolts 13 ± 2 N⋅m
Water inlet pipe bolt 13 ± 2 N⋅m
Water outlet fitting bolts 13 ± 2 N⋅m
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Water pump bolts 14 ± 1 N⋅m

Rocker arms and camshaft
rd

Accumulator body bolt 44 ± 5 N⋅m

Oil control valve bolt 11 ± 1 N⋅m
ca

Nut 9.0 ± 1.0 N⋅m

Rocker arms and rocker arm shaft bolts <exhaust side> 13 ± 1 N⋅m
Rocker arms and rocker arm shaft bolts <intake side> 31 ± 3 N⋅m
Rocker cover bolts 3.5 ± 0.5 N⋅m
Taper plug 47 ± 7 N⋅m
Cylinder head and valves
Cylinder head bolts 78 ± 2 N⋅m → 0 N⋅m → 20 ± 2 N⋅m
→ +90° → +90°
Oil pan and oil pump
Baffle plate bolts 9.0 ± 2.0 N⋅m
Drain plug 39 ± 5 N⋅m
Flange bolt 36 ± 3 N⋅m
Front case bolts 23 ± 3 N⋅m
Oil filter bracket bolts 19 ± 3 N⋅m
Oil filter (except part number MD356000) 17 ± 3 N⋅m
 ENGINE OVERHAUL
SEALANTS
11B-9
Item Specification
Oil filter (part number MD356000) 14 ± 2 N⋅m
Oil level sensor bolts 9.0 ± 1.0 N⋅m
Oil pan bolts 9.0 ± 3.0 N⋅m
Oil pump cover bolts 17 ± 1 N⋅m
Oil pump cover screws 10 ± 2 N⋅m
Oil screen bolts 19 ± 3 N⋅m
Plug 23 ± 3 N⋅m
Relief plug 44 ± 5 N⋅m
Transmission stay bolts 22 ± 4 N⋅m
Piston and connecting rod
Connecting rod cap nuts 20 ± 2 N⋅m → +90° to 94°
Crankshaft and cylinder block
Bearing cap bolts 25 ± 2 N⋅m → +90°

m
Bell housing cover bolts 9.0 ± 1.0 N⋅m
Drive plate bolts (A/T) 132 ± 5 N⋅m

o
Flywheel bolt s(M/T) 132 ± 5 N⋅m
Oil seal case bolts
Rear plate bolts
.c 11 ± 1 N⋅m
11 ± 1 N⋅m
gn
SEALANTS
M1113000500565
ia

Items Specified sealants

Engine support bracket bolts Mitsubishi Genuine Part No.MD970389
rd

or equivalent
Engine coolant temperature sensor LOCTITE 262 or equivalent
Water outlet fitting* Mitsubishi Genuine Part No. MD970389
ca

Thermostat housing* or equivalent

Thermostat housing seal bolt 3M AAD Part No. 8672 or equivalent
Camshaft position sensor support* Mitsubishi Genuine Part No. MD970389
or equivalent
Oil pressure switch Three bond 1141E , 1215 or 1212D or
equivalent
Oil pan* Mitsubishi Genuine Part No. MD970389
Rear oil seal case* or equivalent

NOTE: *: Part to be sealed with a form-in-place gasket (FIPG)

FORM-IN-PLACE GASKET (FIPG)

This engine has several areas where the applying it.
form-in-place gasket (FIPG) is used for sealing. To
ensure that the FIPG fully serves its purpose, it is
necessary to observe some precautions when
11B-10 ENGINE OVERHAUL
SPECIAL TOOLS

Bead size, continuity and location are of paramount CLEANING FIPG APPLICATION
importance. Too thin a bead could cause leaks. Too SURFACE
thick a bead, on the other hand, could be squeezed
Thoroughly remove all substances deposited on the
out of location, causing blocking or narrowing of fluid
FIPG application surface, using a gasket scraper or
passages. To prevent leaks or blocking of passages,
wire brush. Make sure that the FIPG application
therefore, it is absolutely necessary to apply the
surface is flat and smooth. Also make sure that the
FIPG evenly without a break, while observing the
surface is free from oils, greases and foreign
correct bead size.
substances. Do not fail to remove old FIPG that may
FIPG hardens as it reacts with the moisture in the
remain in the fastener fitting holes.
atmospheric air, and it is usually used for sealing
metallic flange areas. APPLICATION OF FIPG
REMOVAL OF FIPG SEALED PARTS Applied FIPG bead should be of the specified size
and free of any break. FIPG can be wiped away
Parts sealed with a FIPG can be easily removed
unless it has completely hardened. Install the mating
without need for the use of a special method. In
parts in position while the FIPG is still wet (in less
some cases, however, the FIPG in joints may have to
than 15 minutes after application). Do not allow FIPG
be broken by tapping parts with a mallet or similar
to spread beyond the sealing areas during
tool. You can also tap a flat, thin gasket scraper into
installation. Avoid operating the engine or letting oils

m
the joint to break the FIPG, taking extreme care not
or water come in contact with the sealed area before
to damage the mating surfaces.The oil pan remover
a time sufficient for FIPG to harden (approximately
(MD998727) is available as a special tool for

o
one hour) has passed. FIPG application method may
removing the oil pan. The tool, however, must not be
vary from location to location. Follow the instruction
.c for each particular case described later in this
manual.
gn
SPECIAL TOOLS
ia

M1113000600658

Tool Number Name Use

rd

MD998781 Flywheel stopper Supporting flywheel and drive

plate
ca

D998781

MB991398 Spark plug wrench Removal and installation of

spark plug

MD998770 Oxygen sensor wrench Removal and installation of

oxygen sensor
 ENGINE OVERHAUL
SPECIAL TOOLS
11B-11
Tool Number Name Use
MD998778 Crankshaft sprocket Removal of crankshaft sprocket
puller

MD998785 Sprocket stopper Supporting counterbalance

shaft sprocket

MB990767 End yoke holder Holding camshaft sprocket

when loosening or torquing bolt

m
B990767

MD998719 Pins

o
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D998719

MD998738 Adjusting screw • Holding the auto-tensioner

• Timing belt tension
adjustment
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D998738
rd

MD998767 Tension pulley wrench Adjustment of timing belt

tension
ca

D998767

MD998054 Oil pressure switch Removal and installation of oil

wrench pressure switch <to cylinder
block>

MD998713 Camshaft oil seal Installation of camshaft oil seal

installer

D998713
11B-12 ENGINE OVERHAUL
SPECIAL TOOLS

Tool Number Name Use

MB991654 Cylinder head bolt Removal and installation of
wrench (12) cylinder head bolt

B991654

MD998735 Valve spring compressor Compression of valve spring

MD998774 Valve steam seal Installation of valve steam seal

installer

m
MD998727 Oil pan remover Removal of oil pan

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D998727
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MD998162 Plug wrench Removal and installation of
front case cap plug
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rd

MD998783 Plug wrench retainer

ca

MD998371 Silent shaft bearing Removal of counterbalance

puller shaft front bearing

MD998372 Silent shaft bearing Removal of counterbalance

puller shaft rear bearing
 ENGINE OVERHAUL
SPECIAL TOOLS
11B-13
Tool Number Name Use
MB991603 Bearing installer stopper Removal and installation of rear
bearing

MD998705 Silent shaft bearing Installation of counterbalance

installer shaft bearing

MD998285 Crankshaft front oil seal Installation of crankshaft front

guide oil seal

m
D998285

MD998375 Crankshaft front oil seal

o
installer
.c
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MD998780 Piston pin setting tool Removal and installation of
piston pin
ia
rd

MB990938 Handle Installation of crankshaft rear oil

seal
ca

MD998776 Crankshaft rear oil seal

installer

D998776
11B-14 ENGINE OVERHAUL
ALTERNATOR AND IGNITION SYSTEM

ALTERNATOR AND IGNITION SYSTEM

REMOVAL AND INSTALLATION
M1113001000574

10 ± 2 N·m 10 ± 2 N·m

25 ± 5 N·m 13 10 ± 1 N·m
1 10
11 14
15
16
13 ± 1 N·m
12
10 ± 1 N·m
14 ± 1 N·m
2
22 ± 4 N·m

m
3
8

o
4

6 44 ± 10 N·m
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gn
8.8 ± 1.0 N·m
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22 ± 4 N·m
rd

25 ± 4 N·m

7
ca

79 ± 5 N·m
5 49 ± 9 N·m
9
AK305760AB

Removal steps REMOVAL SERVICE POINT

1. Oil level gauge <<A>> SPARK PLUG REMOVAL
2. Oil level gauge guide
3. O-ring
4. Auto tensioner
5. Crankshaft pulley
6. Water pump pulley
MB991398
7. Idler pulley
8. Connector bracket
9. Alternator
10. Ignition coil
<<A>> >>C<< 11. Spark plug
12. Connector bracket
13. Camshaft position sensor AK300130 AD

14. O-ring Using special tool Spark plug wrench (MB991398),

>>B<< 15. Camshaft position sensor support removal the spark plug.
<<B>> >>A<< 16. Camshaft position sensing cylinder
 ENGINE OVERHAUL
ALTERNATOR AND IGNITION SYSTEM
11B-15
INSTALLATION SERVICE POINT
<<B>> CAMSHAFT POSITION SENSING >>A<< CAMSHAFT POSITION SENSING
CYLINDER REMOVAL CYLINDER INSTALLATION
<M/T> <M/T>

MD998781 MD998781

AK202738 AD AK202738 AD

<A/T> <A/T>

o m
MD998781 .c
AK300135 AG
MD998781
AK300135 AG
gn
1. Using special tool Fly wheel stopper (MD998781), 1. Using special tool Fly wheel stopper (MD998781),
hold the drive plate. hold the drive plate.
2. Removal the camshaft position sensing cylinder. 2. Tighten the camshaft position sensing cylinder to
ia

the specified torque.

Tightening torque: 22 ± 4 N⋅m
rd

>>B<< CAMSHAFT POSITION SENSOR

SUPPORT INSTALLATION
ca

3 mm

AK300004AE

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.
11B-16 ENGINE OVERHAUL
ALTERNATOR AND IGNITION SYSTEM

Specified sealant: >>C<< SPARK PLUG INSTALLATION

Mitsubishi Genuine Part No.MD970389 or
equivalent

MB991398

AK300130 AD

Using special tool Spark plug wrench (MB991398),

tighten the spark plug to the specified torque.
Tightening torque: 25 ± 5 N⋅m

o m
.c
gn
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rd
ca
 ENGINE OVERHAUL
EXHAUST MANIFOLD
11B-17
EXHAUST MANIFOLD
REMOVAL AND INSTALLATION
M1113004900510

14 ± 1 N·m

14 ± 1 N·m

m
7
49 ± 5 N·m

o
.c 6
gn
1

2
ia

44 ± 4 N·m 3
24 ± 3 N·m 5
rd

44 ± 4 N·m
8
ca

35 ± 6 N·m
44 ± 5 N·m

AK305761AB

Removal steps REMOVAL SERVICE POINT

1. Engine hanger <<A>> OXYGEN SENSOR REMOVE
<<A>> >>B<< 2. Oxygen sensor
<<A>> >>B<< 3. Oxygen sensor
4. Exhaust manifold cover
>>A<< 5. Exhaust manifold bracket B
6. Exhaust manifold
7. Exhaust manifold gasket
8. Exhaust manifold bracket A MD998770

AK300132AD

Using special tool Oxygen sensor wrench

(MD998770), removal the oxygen sensor.
11B-18 ENGINE OVERHAUL
EXHAUST MANIFOLD

INSTALLATION SERVICE POINT

>>A<< EXHAUST MANIFOLD BRACKET >>B<< OXYGEN SENSOR INSTALLATION
"B" INSTALLATION

MD998770

AK300132AD

AK300131 Using special tool Oxygen sensor wrench

(MD998770), installation the oxygen sensor.
Check to ensure that the exhaust manifold bracket
"B" is in close contact with the exhaust manifold and
the cylinder block before tightening the respective

m
mounting bolts to the specified torque.

o
.c
gn
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rd
ca
 ENGINE OVERHAUL
TIMING BELT
11B-19
TIMING BELT
REMOVAL AND INSTALLATION
M1113001900715

48 ± 5 N·m
6
14 ± 1 N·m 5

1
2 23 ± 3 N·m

11 ± 1 N·m
7 21 ± 4 N·m

14 ± 1 N·m

14
12 13
22

m
167 N·m
11 ± 1 N·m 23
3

o
19
9.0 ± 1.0 N·m
4
45 ± 3 N·m
.c 18
gn
26
49 ± 9 N·m
89 ± 9 N·m
25 24
ia

21
10
9
20 49 ± 9 N·m
rd

49 ± 5 N·m
8 8.5 ± 0.5 N·m
16
35 ± 6 N·m
15 17
ca

19 ± 3 N·m
54 ± 4 N·m
11 AB
AK301255 AC

Removal steps Removal steps (Continued)

1. Connector bracket <<D>> >>G<< 14. Crankshaft sprocket
2. Timing belt front upper cover >>G<< 15. Crankshaft sensing blade
3. Timing belt front lower cover 16. Tensioner "B"
<<A>> >>K<< 4. Timing belt <<E>> >>F<< 17. Timing belt "B"
>>J<< 5. Tensioner pulley <<F>> >>E<< 18. Counterbalance shaft sprocket
6. Tensioner arm >>D<< 19. Spacer
>>I<< 7. Auto-tensioner <<G>> >>C<< 20. Crankshaft sprocket "B"
8. Idler pulley 21. Crankshaft key
9. Bracket 22. Alternator bracket
10. Crankshaft angle sensor >>B<< 23. Engine support bracket
<<B>> >>H<< 11. Oil pump sprocket 24. Timing belt rear cover
<<C>> >>G<< 12. Crankshaft bolt <<H>> >>A<< 25. Camshaft sprocket bolt
>>G<< 13. Crankshaft pulley washer 26. Camshaft sprocket
11B-20 ENGINE OVERHAUL
TIMING BELT

REMOVAL SERVICE POINTS <<C>> CRANKSHAFT BOLT LOOSENING

<<A>> TIMING BELT REMOVAL <M/T>

MD998781

AK202738 AD

AK300133
<A/T>
CAUTION
Water or oil on the belt shortens its life
drastically, so the removed timing belt, sprocket,
and tensioner must be washed or immersed in

m
solvent. Replace parts if contaminated. If there is
oil or water on any part, check the front case oil
seals, camshaft oil seal, and water pump for

o
MD998781
leaks.
AK300135 AG
1. Mark the belt running direction for reinstallation.

the timing belt.

.c
2. Loosen the tensioner pulley bolt, and then remove 1. Using special tool Fly wheel stopper (MD998781),
hold the drive plate.
gn
2. Removal the crankshaft bolt and washer.
<<B>> OIL PUMP SPROCKET REMOVAL
1. Remove the plug on the left side of the cylinder <<D>> CRANKSHAFT SPROCKET
ia

block. REMOVAL
rd
ca

AK300134 MD998778 AK300136 AD

2. Insert a Phillips screwdriver (shank diameter 8 1. Set special tool Crankshaft sprocket puller
mm) through the plug hole to block the left (MD998778) as shown in the illustration.
counterbalance shaft.
2. Screw in the center bolt of the special tool to
3. Loosen the nut, and then remove the oil pump remove the crankshaft sprocket.
sprocket.
 ENGINE OVERHAUL
TIMING BELT
11B-21

<<E>> TIMING BELT "B" REMOVAL 2. Loosen the bolt and remove the sprocket.

<<G>> CRANKSHAFT SPROCKET "B"

REMOVAL

AK300137

CAUTION
Water or oil on the belt shortens its life
MD998778
drastically, so the removed timing belt, sprocket, AK300139AD

and tensioner must be free from oil and water.

1. Set special tool Crankshaft sprocket puller
These parts should not be washed or immersed
(MD998778) as shown in the illustration.

m
in solvent. Replace parts if contaminated. If there
is oil or water on each part, check the front case 2. Screw in the center bolt of the special tool to
oil seals, camshaft oil seal and water pump for remove crankshaft sprocket "B."

o
leaks.
1. Mark the belt running direction for reinstallation. <<H>> CAMSHAFT SPROCKET
.c
2. Loosen the tensioner "B" bolt, and then remove
the timing belt "B."
REMOVAL
gn
MB990767

<<F>> COUNTERBALANCE SHAFT

SPROCKET REMOVAL
ia

MD998719
MD998785
rd

AK300140 AD
ca

1. Using special tools to prevent the camshaft

sprocket from rotating.
• End yoke holder (MB990767)
AK300138 AD • Pulley holder pin (MD998719)
1. Set special tool Sprocket stopper (MD998785) as 2. Remove the camshaft sprocket.
shown to prevent the counterbalance shaft
sprocket from turning together.
11B-22 ENGINE OVERHAUL
TIMING BELT

INSTALLATION SERVICE POINTS >>C<< CRANKSHAFT SPROCKET "B"

>>A<< CAMSHAFT SPROCKET INSTALLATION
INSTALLATION
Sprocket "B"
Crankshaft
MB990767

Degrease
Front case AK301828AC
MD998719
AK300141 AD Clean and then degrease the front case of the front
case, crankshaft sprocket "B" and crankshaft surface
1. Using special tools to prevent the camshaft
on which sprocket "B" is attached.
sprocket from rotating.
• End yoke holder (MB990767) NOTE: Degreasing is necessary to prevent decrease
in the friction between contacting surfaces.

m
• Pulley holder pin (MD998719)
2. Tighten the camshaft sprocket bolt to the specified
torque. >>D<< SPACER INSTALLATION

o
Tightening torque: 88 ± 10 N⋅m Counter

>>B<< ENGINE SUPPORT BRACKET

.c Spacer
Oil seal balance
shaft
gn
INSTALLATION
ia

Chamfered
AK301298AD
rd

1. Apply a thin coat of clean engine oil to the lip area

of the oil seal.
2. Install the spacer with the chamfered end facing
ca

toward the oil seal.

AK300142

1. Remove thoroughly the old sealant remaining on >>E<< COUNTERBALANCE SHAFT

the indicated bolt and in its hole.
SPROCKET INSTALLATION
2. Coat the bolt with sealant, then install and tighten
it.
MD998785
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
Tightening torque: 49 ± 5 N⋅m

AK300138 AD

1. Install the counterbalance shaft sprocket and

screw on the bolt.
 ENGINE OVERHAUL
TIMING BELT
11B-23
2. Install special tool Sprocket stopper (MD998785) 4. Move tensioner "B" in the direction of the arrow
as shown in the illustration to lock the while lifting with your finger to give sufficient
counterbalance shaft. tension to the tension side of timing belt. In this
3. Tighten the bolt, and then remove the special tool. condition, tighten the bolt to secure tensioner "B."
Tightening torque: 45 ± 3 N⋅m 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
>>F<< TIMING BELT "B" INSTALLATION be over tensioned.
Tightening torque: 19 ± 3 N⋅m
Timing
mark

Timing
mark

m
AK300143 AD

1. Align timing marks on the crankshaft sprocket "B" AK300146

and counterbalance shaft sprocket with the marks

o
on the front case. 5. Check that timing marks on the sprockets are
aligned with the timing marks on the front 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.
.c 6. With your index finger, press the midway of span
on the tension side of timing belt "B." The bolt
gn
must deflect 5 to 7 mm.

Tensioner "B" >>G<< CRANKSHAFT SENSING

BLADE/CRANKSHAFT
ia

SPROCKET/CRANKSHAFT PULLEY
WASHER/CRANKSHAFT BOLT
rd

INSTALLATION
Center of
bolt
ca

Center of Sensing blade

tensioner pulley Crankshaft
AK300144 AD bolt
Sprocket Crankshaft
3. Make sure that the tensioner pulley center and the Clean
bolt center are positioned as shown in the
illustration.

Washer
Big chamfered side Degrease
AK301075AD

1. Clean and then degrease the contacting surfaces

of the crankshaft sprocket, sensing blade and
crankshaft.
NOTE: Degreasing is necessary to prevent
AK300145 decrease in the friction between contacting
surfaces.
2. Clean the bolt hole in the crankshaft, the
crankshaft contacting surface of the crankshaft
sprocket, and the washer.
11B-24 ENGINE OVERHAUL
TIMING BELT

3. Install the sensing blade and the crankshaft 2. Install the oil pump sprocket.
sprocket to the crankshaft. 3. Apply a thin coat of engine oil to the seating
4. Apply a small amount of engine oil to the threads surface of the nut.
and seating surface of the crankshaft bolt. 4. Tighten the nut to the specified torque.
5. Install the washer to the crankshaft bolt with the Tightening torque: 54 ± 5 N⋅m
larger chamfered side toward the bolt head.
<M/T> >>I<< AUTO-TENSIONER INSTALLATION
If the auto-tensioner rod is fully extended, reset it as
follows:

MD998781

AK202738 AD

m
<A/T>

AK300154

o
1. Clamp the auto-tensioner in a vise with soft jaws.
.c A
gn
MD998781 B
AK300135 AG
ia

6. Using special tool Fly wheel stopper (MD998781),

hold the drive plate.
7. Tighten the crankshaft bolt to the specified torque.
rd

Tightening torque: 167 N⋅m AK301074AD

2. Push in the rod little by little with the vise until the
ca

>>H<< OIL PUMP SPROCKET set hole A in the rod is aligned with hole B in the
INSTALLATION cylinder.
3. Insert a wire (1.4 mm in diameter) into the set
holes. This auto-tensioner setting wire will be
used during timing belt alignment.
4. Unclamp the auto-tensioner from the vise.

AK301073

1. Insert a Phillips head screwdriver (shank diameter

8 mm) through the plug hole on the left side of the
cylinder block to block the left counterbalance
shaft. AK301832
 ENGINE OVERHAUL
TIMING BELT
11B-25
CAUTION
Leave the wire installed in the auto-tensioner. Timing mark
5. Install the auto-tensioner onto the front case and
tighten to the specified torque.
Tightening torque: 23 ± 3 N⋅m

>>J<< TENSIONER PULLEY

INSTALLATION
AK301076AD

3. Align the timing mark on oil pump sprocket with its

mating mark.

60 mm or more

m
Tensioner
pulley hole AK300147AD

o
Set the tensioner pulley so that the holes for
Counter
attaching a wrench may be positioned as shown in balance
the illustration.

>>K<< TIMING BELT INSTALLATION

.c shaft AK301077 AD

4. Remove the plug on the cylinder block and insert

gn
a Phillips head screwdriver (shank diameter 8
mm) through the hole.
Timing mark If it can be inserted as deep as 60 mm or more,
ia

the timing marks are correctly aligned.

If the inserted depth is only 20 to 25 mm, turn the
oil pump sprocket one turn and realign the timing
rd

marks. Then check to ensure that the screwdriver

can be inserted 60 mm or more. Keep the
ca

screwdriver inserted until the timing belt is

AK300148 AD
completely installed.

1. Align the timing mark on the camshaft sprocket

with the timing mark on the rocker cover.
MD998738

AK300151 AD

Timing mark
5. Set the special tool Set screw (MD998738) as
AK300149 AD
shown and screw it in up to the position where the
wire inserted in the auto-tensioner when installing
2. Align the timing mark on the crankshaft sprocket it can be moved lightly.
with the timing mark on the front case. 6. Install the timing belt on the crankshaft sprocket,
oil pump sprocket, idler pulley, camshaft sprocket,
and tensioner pulley in that order.
11B-26 ENGINE OVERHAUL
TIMING BELT

Tightening torque: 48 ± 5 N⋅m

Auto tensioner

AK301295AD

AK301836
7. Lift up the tensioner pulley in the direction of the
arrow and tighten the center bolt. 14. The wire inserted at the auto-tensioner
8. Check that all timing marks are aligned. installation is pulled out and then the special tool
9. Remove the screwdriver inserted in step 5 and Set screw (MD998738) is removed by hand.
install the plug. 15.Give two clockwise turns to the crankshaft. Wait
10.Turn the crankshaft a quarter turn for 15 minutes, then proceed with the following
inspection steps.

m
counterclockwise. Then, turn it clockwise until the
timing marks are aligned again.

o
.c
gn
AK300152
ia

MD998767
AK300150 AD
16.Check to see whether the metal wire (inserted
11.Install special tool Tension pulley socket wrench when the auto-tensioner was installed) can be
rd

(MD998767), socket wrench and torque wrench, removed without any resistance. If the metal wire
onto the tensioner pulley, and loosen the can be removed without any resistance, it means
tensioner pulley center bolt. that the belt has a proper tension. Therefore,
ca

NOTE: Use a torque wrench that can measure 0 remove the metal wire. In this condition, check
to 5.0 N⋅m. that the rod protrusion of the auto-tensioner is
within the standard value.
12.Torque to 3.5 N⋅m with the torque wrench.
Standard value: 3.8 − 4.5 mm
13.Holding the tensioner pulley with special tool
Tension pulley socket wrench (MD998767) and 17.If the metal wire offers resistance when removed,
torque wrench, tighten the center bolt to repeat the previous steps 10 through 15 until the
specification. standard value is obtained as measured by the
rod projection of the auto-tensioner rod.
 ENGINE OVERHAUL
TIMING BELT
11B-27
INSPECTION
M1113002000544
Canvas lost and
TIMING BELT rubber exposed

Missing
Tooth

AK202796 AB

7. Abnormal wear on teeth.

AK202794 Initial stage:
Canvas worn (fluffy canvas fibers, rubbery
Replace the belt if any of the following conditions
texture gone, white discoloration, canvas
exist:
texture indistinct)
1. Hardening of rubber backing. Final stage:
Back side should be glossy without resilience and Canvas worn, exposing rubber (tooth width

m
leave no indent when pressed with fingernail. reduced)
Cracks 8. Missing tooth.

o
Cracks

AUTO-TENSIONER
Peeling of canvas
Cracks in sides
.c
gn
12 mm
ia

Cracks in tooth roots AK202793 AD

2. Cracks on rubber back.

rd

3. Cracks or peeling of canvas.

4. Cracks at bottom of ribs. AK301307AD
ca

5. Cracks on belt sides. 1. Check for oil leaks. If oil leaks are evident, replace
the auto-tensioner.
Rounded edge 2. Check the rod end for wear or damage and
replace the auto-tensioner if necessary.
3. Measure the rod protrusion. If it is out of
specification, replace the auto tensioner.
Standard value: 12 mm

98 TO 196 N
Abnormal wear
(fluffy strand) AK202795 AD
Movement
6. Abnormal wear of belt sides. Normal wear is
indicated if the sides are sharp as if cut by a knife.
Abnormal wear is indicated if the sides are
ragged.

AK301308AD
11B-28 ENGINE OVERHAUL
TIMING BELT

4. Press the rod with a force of 98 to 196 N and 3. Measure the valve clearance marked with arrows
measure the movement of the rod. shown in the figure.
If the measured value is out of the standard value, White arrow mark: When No.1 cylinder is on the
replace the auto-tensioner. top dead center of compression stroke.
Standard value: 1.0 mm or less Black arrow mark: When No.4 cylinder is on the
top dead center of compression stroke.
VALVE CLEARANCE ADJUSTMENT
Perform the adjustment of the valve clearance in the
following procedure.
1. Remove the rocker cover.

Timing mark

AK300153

m
4. Using a thickness gauge, adjust the clearance
between the valve shaft end and the adjusting
screw.

o
AK300148 AE
Standard value (in cold state):
CAUTION
Rotate the crankshaft clockwise at any time.
.c Intake side: 0.11 mm
Exhaust side: 0.20 mm
NOTE: After the engine assembly is installed on
gn
2. Rotate crankshaft clockwise and then align the
the vehicle, check the valve clearance again in
timing mark on the camshaft sprocket with the
the engine warm-up state. Adjust if necessary.
timing mark on the cylinder head. (Place No.1
cylinder on the top dead center of compression 5. Hold the adjusting screw not rotating through a
ia

stroke.) driver and then tighten the rock nut.

6. Rotate the crankshaft one time clockwise and
Intake valve side
then align the timing mark with the timing mark on
rd

the crankshaft sprocket. (Place No.4 cylinder on

the top dead center of compression stroke.)
ca

7. Adjust the valve clearance for the rest of the

valves.
8. Install the rocker cover.

No. 1 No. 2 No. 3 No. 4

Exhaust valve side AK204362AE
 ENGINE OVERHAUL
FUEL AND EMISSION PARTS
11B-29
FUEL AND EMISSION PARTS
REMOVAL AND INSTALLATION
M1113002200559

14 ± 3 N·m
6
9 24 ± 3 N·m

11 ± 1 N·m 10 15
16
11
7
9.0 ± 1.0 N·m
13
14
12
17 2
1
11 ± 1 N·m
8

m
3
9.0 ± 1.0 N·m

o
11 ± 1 N·m
.c
gn
5
4
ia
rd
ca

AK305762AB

Removal steps Removal steps (Continued)

1. Throttle body 10. Fuel pressure regulator
>>C<< 2. Throttle body gasket 11. O-ring
3. Vacuum pipe and hose 12. Insulator
4. Solenoid valve >>B<< 13. Injector
5. Solenoid valve bracket 14. O-ring
6. Vacuum hose 15. Delivery pipe
7. Injector and delivery pipe 16. EGR valve
8. Insulator >>A<< 17. EGR gasket
9. Fuel hose
11B-30 ENGINE OVERHAUL
FUEL AND EMISSION PARTS

INSTALLATION SERVICE POINTS >>B<< INJECTORS INSTALLATION

>>A<< EGR VALVE INSTALLATION
CAUTION

Injector

Projection A
Identification
mark (A, B or C) A

AK305815AB

• The fuel injectors are classified into A, B and

Intake
C by the injection quantity. When replacing manifold
one of fuel injectors, use a same identification

m
mark fuel injector as the other fuel injectors. Delivery pipe
• When replacing the fuel injectors of all
cylinders, use the same identification mark

o
fuel injectors. Injector

.c CAUTION
AK300155AD

Use care not to let engine oil enter the delivery

gn
pipe.
1. Apply clean engine oil to the O-ring.
2. Insert the injector into the delivery pipe.
ia

3. Make sure the injector rotates smoothly.

If not, remove the injector to check the O-ring for
rd

AK305763AB damage, and replace the O-ring if necessary.

Install a new gasket is positioned as shown in the Then, reinstall the injector and check that it
illustration. rotates smoothly.
ca

>>C<< THROTTLE BODY GASKET

INSTALLATION

Projection

AK300579AD

Install a new gasket so that the projection is

positioned as shown in the illustration.
 ENGINE OVERHAUL
INLET MANIFOLD AND WATER PUMP
11B-31
INLET MANIFOLD AND WATER PUMP
REMOVAL AND INSTALLATION
M1113025500067

13 ± 2 N·m
2 11 ± 1 N·m
13 ± 2 N·m
12
24 ± 4 N·m
13

24 ± 3 N·m 9
10
13 ± 2 N·m
15 7 11

m
24 ± 3 N·m 30 ± 9 N·m
1 19 ± 3 N·m 13 ± 2 N·m
18

o
17
5 14

20 ± 2 N·m
.c 6
gn
16
23 ± 2 N·m
19
ia

4
8
rd

31 ± 3 N·m

3
ca

14 ± 1 N·m
AK305764 AB

Removal steps Removal steps (Continued)

1. Water hose 12. Engine cover bracket
2. Water hose 13. Inlet manifold
3. Water pump 14. Inlet manifold gasket
4. Water pump gasket 15. Engine hanger
>>G<< 5. O-ring 16. Detonation sensor
>>G<< 6. Water inlet pipe <<A>> >>C<< 17. Oil pressure switch
>>G<< 7. O-ring >>B<< 18 Engine coolant temperature sensor
>>F<< 8. Inlet manifold stay >>A<< 19. Water outlet fitting
9. Water inlet fitting
>>E<< 10. Thermostat
>>D<< 11. Thermostat housing
11B-32 ENGINE OVERHAUL
INLET MANIFOLD AND WATER PUMP

REMOVAL SERVICE POINT >>B<< SEALANT APPLICATION TO

<<A>> OIL PRESSURE SWITCH ENGINE COOLANT TEMPERATURE
REMOVAL SENSOR

MD998054

AK300156 AD AK202799AB

Using special tool Oil pressure switch wrench CAUTION

(MD998054), removal the oil pressure switch. When using a tool, avoid letting it touch the
connector portion which is made of plastic.
INSTALLATION SERVICE POINTS

m
1. Remove all old sealant remaining on the threads
>>A<< WATER OUTLET FITTING of the coolant temperature sensor and in the
INSTALLATION threaded hole in the thermostat housing.

o
2. Apply sealant to the coolant temperature sensor's
3 mm
.c threads indicated in the drawing.
Specified sealant:
LOCTITE 262 or equivalent
gn
>>C<< SEALANT APPLICATION TO OIL
PRESSURE SWITCH
ia
rd

AK305765AB

1. Apply a 3 mm diameter bead of FIPG to the

indicated surface of the water outlet fitting.
ca

Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
2. Install the housing quickly (within 15 minutes)
AK300715 AB
while the sealant is wet and tighten the bolts to the
specified torque. 1. Apply sealant to the threaded portion.
Tightening torque: 13 ± 2 N⋅m Specified Sealant:
NOTE: After installation, keep the sealed area away Three bond 1215 or equivalent
from the coolant for approximately one hour.
 ENGINE OVERHAUL
INLET MANIFOLD AND WATER PUMP
11B-33
4. Install the housing quickly (within 15 minutes)
MD998054 while the sealant is wet and tighten the bolts to the
specified torque.
Tightening torque: 24 ± 4 N⋅m
NOTE: After installation, keep the sealed area
away from the coolant for approximately one hour.

>>E<< THERMOSTAT INSTALLATION

AK300157 AD

Jiggle valve
2. Using special tool Oil pressure switch wrench
(MD998054), tighten the oil pressure switch to the
specified torque.
Tightening torque: 19 ± 3 N⋅m

>>D<< THERMOSTAT HOUSING Thermostat

m
housing
INSTALLATION AK304588AB

1. Check that the rubber ring is undamaged and

o
seated correctly in the thermostat flange.
2. Install the thermostat as shown in the illustration.
.c The jiggle valve must be at the uppermost
position.
gn
3 mm >>F<< INLET MANIFOLD STAY
INSTALLATION
ia

AK301337AD

1. Remove all old FIPG remaining on the thermostat

rd

housing and cylinder head.

2. Apply a 3 mm diameter bead of FIPG on the Intake
indicated surface of the thermostat housing. manifold
ca

Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent

Cylinder block
AK301361AE

1. Install the inlet manifold stay and tighten the bolts

just finger tight.
2. Check to ensure that the stay is in close contact
with the bosses of the inlet manifold and cylinder
block.
3. First tighten the inlet manifold side bolts to the
AK300158 specified torque, then the cylinder block side bolts
to the specified torque.
3. Coat the bolt with sealant, then install and tighten
Tightening torque: 31 ± 3 N⋅m
it.
Specified sealant:
3M ATD Part No.8672 or equivalent
11B-34 ENGINE OVERHAUL
INLET MANIFOLD AND WATER PUMP

>>G<< WATER INLET PIPE/O-RING 1. Attach a new O-ring to each end of the water inlet
INSTALLATION pipe.
2. Wet the O-ring with water.
CAUTION
Keep the O-ring free of oil or grease. 3. Insert the rear end of the pipe into the thermostat
housing.
O-ring

Water inlet pipe

AK301861AC

o m
.c
gn
ia
rd
ca
 ENGINE OVERHAUL
ROCKER ARMS AND CAMSHAFT
11B-35
ROCKER ARMS AND CAMSHAFT
REMOVAL AND INSTALLATION
M1113005400693

5
Apply engine oil to
all moving parts 1
before installation. 2
3
4 6

13 ± 1 N·m 3.5 ± 0.5 N·m

8
7

13 ± 1 N·m
12 12
12

m
9.0 ± 1.0 N·m 12
12
12
12 11

o
12

13
.c
13
16 17
13
18
28
gn
13 15 12
13 13 16 17
10 14 13 12
11 ± 1 N·m
13 15 12 13
16 17 13
ia

12 20 19 21
15 12 13
16 17 13 22
rd

12 26
15 12 13 23
27
13 24
12 47 ± 7 N·m
ca

13
13 25
44 ± 5 N·m

AK305650 AB

Removal steps Removal steps (Continued)

1. Breather hose <<A>> >>C<< 11. Rocker arms and rocker arm shaft
2. PCV hose (Exhaust side)
3. PCV valve 12.Nut
4. PCV valve gasket >>B<< 13.Adjusting screw
5. Oil filler cap 14.Rocker arm shaft assembly (Intake
6. Rocker cover side)
7. Rocker cover gasket 15.Rocker arm "C"
8. Oil seal 16.Piston arm assembly
>>D<< 9. Oil seal 17.Rocker arm "D"
<<A>> >>C<< 10.Rocker arms and rocker arm shaft 18.Rocker arm shaft (Exhaust side)
(Intake side) >>A<< 19.Oil control valve
11B-36 ENGINE OVERHAUL
ROCKER ARMS AND CAMSHAFT

Removal steps (Continued) >>B<< ADJUSTING SCREW

20.O-ring
INSTALLATION
21.Snap ring
22.Accumulator spring seat
23.Plunger spring
24.Accumulator plunger
25.Accumulator body
26.Taper plug
27.Oil control valve filter
28.Camshaft
3 mm

REMOVAL SERVICE POINT

AK301421 AD
<<A>> ROCKER ARMS AND ROCKER
Install provisionally the screw to rocker arm, insert it
ARM SHAFT REMOVAL so that end of the screw is flush with the edge of the
When the rocker arm is removed from the rocker rocker arm or projects slightly 3 mm.
shaft, keep them with the tags that show the
installation location for the reinstallation of the rocker
>>C<< ROCKER SHAFT

m
arm, the T-lever, the piston arm assembly and so on.
SPRING/ROCKER ARMS AND ROCKER
ARM SHAFT INSTALLATION

o
INSTALLATION SERVICE POINTS 1. In accordance with the tags for the reinstallation,
>>A<< OIL CONTROL VALVE
INSTALLATION
.c install the rocker arm and so on to the rocker arm
shaft.
2. Install the rocker arm shaft with oil hole to the
gn
CAUTION lower (cylinder head) side.
Do not reuse the O-ring. Install the O-ring after
wrap a tape not having adhesion (such as a seal Timing belt side
tape) round the notch on the oil passage of oil
ia

control valve to prevent it from damage. The

damaged O-ring may cause oil leakage.
rd
ca

Tape

AK301422 AD

3. Install the rocker arm, rocker arm shaft assembly

and intake temporarily.
4. Install the rocker arm, rocker arm shaft assembly
AK303651AE and exhaust temporarily.
1. Apply a little amount of engine oil to the O-ring of 5. Confirm the each rocker arm and rocker arm shaft
oil control valve. assembly are in position and then tighten to the
2. Install the oil control valve to the cylinder head. specified torque.
3. Tighten the oil control valve to the specified torque Tightening torque:
of 11 ± 1 N⋅m. M6: 13 ± 1 N⋅m
M8: 31 ± 3 N⋅m
 ENGINE OVERHAUL
ROCKER ARMS AND CAMSHAFT
11B-37

>>D<< CAMSHAFT OIL SEAL Measure the cam height. If it is below the limit,
INSTALLATION replace the camshaft.

A C B A C B A C B A C B

D D D D D D D D

MD998713 AK301488AD
AK300160 AD

1. Apply engine oil to the lip area of the oil seal and Standard Minimum
the front end outside diameter of camshaft. value limit
2. Using special tool Camshaft oil seal installer A: Intake low speed 34.41 mm 33.91 mm
(MD998713), install the camshaft oil seal. cam A

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B: Intake low speed 37.47 mm 36.97 mm
INSPECTION cam B
M1113005500560

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CAMSHAFT C: Intake high speed 37.21 mm 36.71 mm
cam
.c D: Exhaust cam 37.86 mm 37.36 mm
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AK300161
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11B-38 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES

CYLINDER HEAD AND VALVES

REMOVAL AND INSTALLATION
M1113006900635

78 ± 2 N·m → 0 N·m→ → + 90˚ → + 90˚

20 ± 2 N·m
8
1
9
10
20
14
4
5
15
6
17
12
13

m
16 19
11

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18
.c 2
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7
3
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rd

Apply engine oil to

all moving parts
ca

before installation.

AK301262AE

Removal steps Removal steps (Continued)

<<A>> >>D<< 1. Cylinder head bolt >>A<< 12.Valve stem seal
2. Cylinder head assembly 13.Valve spring seat
3. Cylinder head gasket >>A<< 14.Valve stem seal
<<B>> >>C<< 4. Retainer lock 15.Valve spring seat
5. Valve spring retainer 16.Intake valve guide
>>B<< 6. Valve spring 17.Exhaust valve guide
7. Intake valve 18.Intake valve seat
<<B>> >>C<< 8. Retainer lock 19.Exhaust valve seat
9. Valve spring retainer 20.Cylinder head
>>B<< 10.Valve spring
11. Exhaust valve
 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
11B-39
REMOVAL SERVICE POINTS INSTALLATION SERVICE POINTS
<<A>> CYLINDER HEAD BOLTS >>A<< VALVE STEM SEAL
REMOVAL INSTALLATION

MD998774
MB991654

AK300162 AD AK300164 AD

Using special tool Cylinder head bolt wrench CAUTION

(MB991654), loosen the cylinder head bolts. Loosen The special tool must be used to install the valve
each bolt evenly, little by little, by two or three steps. stem seal. Improper installation could result in oil

m
leaking past the valve guide.
<<B>> RETAINER LOCK REMOVAL 1. Install the valve spring seat.
2. Using special tool Valve stem seal installer

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(MD998774), install a new valve stem seal.
MD998735 .c >>B<< VALVE SPRING INSTALLATION
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Painted end
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AK300163 AD
rd

1. Set special tool Valve spring compressor

(MD998735) as illustrated to compress the valve
spring. Remove the retainer lock.
ca

2. Relieve the spring tension and remove the valve, AK300717AB

retainer, spring, etc. Store removed valves, Install the valve spring with its identification color
springs, and other parts, tagged to indicate their painted end (larger pitch side) upward (toward the
cylinder number and location for assembly. valve spring retainer).
Identification:
<Intake> Light blue
<Exhaust> Orange
11B-40 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES

>>C<< RETAINER LOCK INSTALLATION CAUTION

Do not compress the valve spring excessively. It
can damage the stem seal.
MD998735 1. Set special tool Valve spring compressor
(MD998735) as illustrated to compress the valve
spring. Install the retainer locks.
2. Relieve the spring tension. Check that the retainer
locks are seated correctly.

AK300163 AD

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 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
11B-41

>>D<< CYLINDER HEAD BOLT

INSTALLATION
90˚

90˚ Paint mark

Shank length
AK300166 AD

6. Make a paint mark across each bolt head and

AK300591AB cylinder head.
1. When the removed cylinder head bolts are to be 7. Tighten the cylinder head bolts 90 degrees in the
reused, check that the shank length of each bolt specified order.
meets the limit. If it exceeds the limit, replace the CAUTION
bolts. • If the bolt is turned less than 90 degrees,

m
Limit: 99.4 mm proper fastening performance may not be
achieved. Be careful to turn each bolt exactly
2. Apply engine oil to the thread of the bolts and to
90 degrees.

o
the washers.
• If the bolt is overtightened, loosen the bolt
.c completely and then retighten it by repeating
the tightening procedure from step 1.
8. Tighten the bolts another 90 degrees in the same
gn
MB991654
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.
ia

INSPECTION
M1113007000549
rd

AK300165 AD CYLINDER HEAD

Timing belt side
ca

8 6 1 3 9

10 4 2 5 7

AK304589AB AK300167

3. Using special tool Cylinder head bolt wrench 1. Check the cylinder head gasket surface for
(MB991654) tighten the bolts to the specified flatness by using a straight edge and feeler
torque, using the tightening sequence shown. gauge.
Tightening torque: 78 ± 2 N⋅m Standard value: 0.03 mm
Limit: 0.2 mm
4. Loosen all bolts fully in the reverse order of
tightening. 2. If it exceeds the limit, correct to meet
specification.
5. Retighten the loosened bolts to in the tightening
sequence shown. Grinding limit: *0.2 mm
* Includes combined with cylinder block
Tightening torque: 20 ± 2 N⋅m
grinding.
11B-42 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES

Cylinder head height (Specification when VALVE SPRING

new): 120 mm

Out of square
VALVE

Free height
Contact
(Should be at
center of face)
Margin
AK300718AB

1. Measure the free height of the spring. If it is less

than the limit, replace.
AK300593AB
Standard value:
1. Check the valve seat contact. Valve seat contact <Intake> 54.8 mm
should be uniform at the center of the valve face. <Exhaust> 56.1 mm

m
If incorrect, reface using a valve refacer.
Minimum limit:
2. If the margin is below the limit, replace the valve. <Intake> 53.8 mm
Standard value: <Exhaust> 55.1 mm

o
<Intake> 1.0 mm
2. Measure the squareness of the spring. If it
<Exhaust> 1.2 mm
Minimum limit:
<Intake> 0.5 mm
.c exceeds the limit, replace.
Standard value: 2 degrees or less
Limit: 4 degrees
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<Exhaust> 0.7mm

VALVE GUIDE
ia
rd

Valve
ca

guide
Total length

AK304590AB
Stem diameter
3. Measure the valve's total length. If the Guide inside diameter AK300168 AE
measurement is less than the limit, replace the Measure the clearance between the valve guide and
valve. valve stem. If it exceeds the limit, replace the valve
Standard value: guide or valve, or both.
<Intake> 111.33 mm Standard value:
<Exhaust> 113.54 mm <Intake> 0.02 − 0.04 mm
Minimum limit: <Exhaust> 0.04 − 0.06 mm
<Intake> 110.83 mm Limit:
<Exhaust> 113.04 mm <Intake> 0.10 mm
<Exhaust> 0.15 mm
 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
11B-43
VALVE SEAT VALVE SEAT REPLACEMENT
PROCEDURE
Valve stem
end

Valve stem 0.5 - 1 mm

projection

Spring
seating Cut
surface
0.5 - 1 mm
AK300596 AB

Assemble the valve, then measure the valve stem AK300719AB

projection between the end of the valve stem and the
spring seating surface. If the measurement exceeds 1. Cut the valve seat from the inside to thin the wall
the specified limit, replace the valve seat. thickness. Then, remove the valve seat.
Standard value:
<Intake> 48.33 mm

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<Exhaust> 48.34 mm
Limit:

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Valve seat
<Intake> 48.83 mm height
<Exhaust> 48.84 mm

VALVE SEAT RECONDITIONING

.c Oversize hole diameter
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PROCEDURE AK300720AB

Intake side Exhaust side 2. Rebore the valve seat hole in the cylinder head to
0.9 – 1.3 mm 0.9 – 1.3 mm a selected oversize valve seat diameter.
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65˚ 65˚ Intake seat ring hole diameters

0.3 oversize: 35.30 − 35.33 mm
rd

0.6 oversize: 35.60 − 35.63 mm

20˚ 10˚ Exhaust seat ring hole diameters
0.3 oversize: 33.30 − 33.33 mm
ca

43.5˚ – 44˚ 0.6 oversize: 33.60 − 33.63 mm

AK300385AB 3. Before fitting the valve seat, either heat the
cylinder head up to approximately 250°C or cool
1. Before correcting the valve seat, check for
the valve seat in liquid nitrogen, to prevent the
clearance between the valve guide and valve and,
cylinder head bore from galling.
if necessary, replace the valve guide.
4. Using a valve seat cutter, correct the valve seat to
2. Using the seat grinder, correct to obtain the
the specified width and angle.
specified seat width and angle.
3. After correcting the valve seat, lap the valve and See "VALVE SEAT RECONDITIONING
valve seat using lapping compound. Then, check PROCEDURE" on the previous page.
the valve stem projection.
VALVE GUIDE REPLACEMENT
PROCEDURE
1. Using a press, remove the valve guide toward the
cylinder block.
11B-44 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES

CAUTION 3. Press-fit the valve guide until it protrudes 14.0 mm

Do not install a valve guide of the same size from the cylinder head top surface as shown in
again. the illustration.
2. Rebore the valve guide hole of the cylinder head NOTE: When press-fitting the valve guide, work
so that it fits the press-fitted oversize valve guide. from the cylinder head top surface.
Valve guide hole diameters NOTE: Pay attention to the difference in length of
0.05 oversize 11.05 − 11.07 mm the valve guides. (Intake side: 45.5 mm; exhaust
0.25 oversize 11.25 − 11.27 mm side: 50.5 mm)
0.50 oversize 11.50 − 11.52 mm NOTE: After installing the valve guides, insert new
valves in them to check for smooth operation.

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14.0 mm

AK304591AB

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 ENGINE OVERHAUL
OIL PAN AND OIL PUMP
11B-45
OIL PAN AND OIL PUMP
REMOVAL AND INSTALLATION
M1113008100527

29

Apply engine oil to

27
all moving parts 30
before installation.
20

31
19
10 ± 2 N·m
23 ± 3 N·m 28
25 21 9

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17 ± 1 N·m
7
8

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14
22
19 ± 3 N·m
15
24 .c
26
23
19 ± 3 N·m
9.0 ± 2.0 N·m
22 ± 4 N·m
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18
17 2
13 16 36 ± 3 N·m 23 ± 3 N·m 6
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12
23 ± 3 N·m
11 1 9.0 ± 3.0 N·m
10
rd

39 ± 5 N·m
44 ± 5 N·m

9.0 ± 1.0 N·m

3
ca

4
5
9.0 ± 3.0 N·m 22 ± 4 N·m
AK304604AB

Removal steps Removal steps (Continued)

1. Drain plug 17.O-ring
>>M<< 2. Drain plug gasket <<D>> >>I<< 18.Flange bolt
3. Oil level sensor >>H<< 19.Front case
<<A>> >>L<< 4. Oil filter 20.Front case gasket
5. Transmission stay 21.Oil pump cover
<<B>> >>K<< 6. Oil pan >>G<< 22.Oil pump driven gear
7. Baffle plate >>G<< 23.Oil pump drive gear
8. Oil screen >>F<< 24.Crankshaft front oil seal
9. Oil screen gasket >>E<< 25.Oil pump oil seal
10.Relief plug >>D<< 26.Counterbalance shaft oil seal
11. Gasket 27.Counterbalance shaft, left
12.Relief spring 28.Counterbalance shaft, right
13.Relief plunger <<E>> >>C<< 29.Counterbalance shaft, front bearing
14.Oil filter bracket
15.Oil filter bracket gasket
<<C>> >>J<< 16.Plug
11B-46 ENGINE OVERHAUL
OIL PAN AND OIL PUMP

Removal steps (Continued) <<C>> PLUG REMOVAL

<<F>> >>B<< 30.Counterbalance shaft, rear bearing,
right
<<F>> >>A<< 31.Counterbalance shaft, rear bearing, MD998162
left

REMOVAL SERVICE POINTS

<<A>> OIL FILTER REMOVAL

MD998783 AK300171 AD

Fit the teeth of the special tool in notches of the plug

as shown in the drawing and support the tool with the
special tool to loosen the plug.
• Plug wrench (MD998162)
• Plug wrench retainer (MD998783)

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General service tool AK300169 AD
<<D>> FLANGE BOLT REMOVAL

1. Using general service tool, remove the oil filter

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from the oil filter bracket.

<<B>> OIL PAN REMOVAL

.c
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MD998727
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AK300172

1. Remove the plug on the side of the cylinder block.

rd

2. Insert a Phillips screwdriver (shank diameter 8

mm) into the plug hole to lock the counterbalance
shaft.
ca

AK300170 AE

1. Remove the oil pan bolts.

2. Insert the special tool Oil pen remover
(MD998727) into the joint between the cylinder
block and oil pan by tapping the tool with a
hammer.
3. Remove the oil pan by tapping an edge of the
special tool Oil pen remover (MD998727) with a
hammer to move it sideways.
AK300173

3. Loosen the flange bolt.

 ENGINE OVERHAUL
OIL PAN AND OIL PUMP
11B-47

<<E>> COUNTERBALANCE SHAFT • Bearing installer stopper (MB991603)

FRONT BEARING REMOVAL
INSTALLATION SERVICE POINTS
>>A<< LEFT COUNTERBALANCE SHAFT
REAR BEARING INSTALLATION
MB991603

MD998371
AK300174 AD

CAUTION
Be sure to remove the front bearing first. If it has MD998705
(Stopper)
not been removed, special tool Silent shaft AK300177 AD

bearing puller (MD998372) cannot be used for

m
rear balance shaft bearing removal.
MB991603 MD998705
Using special tool Silent shaft bearing puller (Stopper)
(MD998371), remove the counterbalance shaft front

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bearing from the cylinder block.

<<F>> COUNTERBALANCE SHAFT REAR

BEARING REMOVAL
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Rear bearing
AK300619AD

1. Install special tool Silent shaft bearing installer

ia

stopper (MB991603) to the cylinder block.

2. Apply engine oil to the rear bearing outer surface
rd

and bearing hole in the cylinder block.

3. Using special tool Silent shaft bearing installer
(MD998705), install the rear bearing.
ca

MD998372
AK300175AD NOTE: The left rear bearing has no oil holes.

1. Using special tool Silent shaft bearing puller >>B<< RIGHT COUNTERBALANCE
(MD998372), remove the right counterbalance
shaft rear bearing from the cylinder block. SHAFT REAR BEARING INSTALLATION

MB991603

MD998372 MD998705(Guide pin)

AK300176 AD AK300178 AD

2. Using special tools, remove the left 1. Install special tool the guide pin of the Silent shaft
counterbalance shaft rear bearing from the bearing installer (MD998705) in the threaded hole
cylinder block. of the cylinder block as shown.
• Silent shaft bearing puller (MD998372)
11B-48 ENGINE OVERHAUL
OIL PAN AND OIL PUMP

>>C<< COUNTERBALANCE SHAFT

Ratchet ball
FRONT BEARING INSTALLATION
Oil hole
MD998705 (Stopper)

Rear bearing right

AK300621AD
Rear bearing
installing portion
2. Align the ratchet ball of the special tool with the oil
hole in the rear bearing to install the bearing of the AK300623AD

special tool. 1. Remove the rear bearing installing portion from

3. Apply engine oil to the bearing outer surface and the special tool Silent shaft bearing installer
bearing hole in the cylinder block. (MD998705).

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MD998705
(Stopper)

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MD998705(Guide pin) MD998705(Guide pin)
AK300179 AD AK300178 AD

MD998705 2. Install special tool the guide pin of the Silent shaft
ia

(Stopper) bearing installer (MD998705) in the threaded hole

of the cylinder block as shown.
rd

Ratchet ball Oil hole

ca

AK300622AD

4. Using special tool, install the rear bearing. Make

Front bearing right
sure that the oil hole of the bearing is aligned with
the oil hole of the cylinder block. AK304592AB

3. Align the ratchet ball of the special tool with the oil
hole in the rear bearing to install the bearing of the
special tool.
4. Apply engine oil to the front bearing outer surface
and bearing hole in the cylinder.
 ENGINE OVERHAUL
OIL PAN AND OIL PUMP
11B-49
>>E<< OIL PUMP OIL SEAL
MD998705
(Stopper) INSTALLATION
Socket wrench

Oil seal

Front case

MD998705(Guide pin)
AK300179 AD

AK304594AB

Using a suitable socket wrench, install the oil pump

oil seal into the front case.

>>F<< CRANKSHAFT FRONT OIL SEAL

m
INSTALLATION

MD998375

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AK300624

5. Using special tool, install the rear bearing. Make

the oil hole of the cylinder block.

.c
sure that the oil hole of the bearing is aligned with
Oil seal
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Front case
>>D<< COUNTERBALANCE SHAFT OIL
SEAL INSTALLATION
ia

AK304595AB

Socket wrench Using special tool Crankshaft front oil seal installer
(MD998375), install the crankshaft front oil seal into
rd

the front case.

Front case
>>G<< OIL PUMP DRIVEN GEAR/OIL
ca

Oil seal
PUMP DRIVE GEAR INSTALLATION

AK304593AB

Using a suitable socket wrench, install the

counterbalance shaft oil seal into the front case.

Alignment
mark
AK300180 AD

Install the oil pump gears into the front case and
align the alignment marks.
11B-50 ENGINE OVERHAUL
OIL PAN AND OIL PUMP

>>H<< OIL PUMP CASE INSTALLATION >>I<< FLANGE BOLT INSTALLATION

MD998285
AK300181AD AK300172

1. Set special tool Crankshaft front oil seal guide 1. Insert a Phillips head screwdriver (shank diameter
(MD998258) on the front end of crankshaft and 8 mm) into the hole in the left side of the cylinder
apply a thin coat of engine oil to the outer surface block to lock the counterbalance shaft.
of special tool.
2. Apply engine oil to the lip of the crankshaft front
oil seal.

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AK300183

2. Secure the oil pump driven gear onto the left

MD998285
counterbalance shaft by tightening the flange bolt
AK300182 AD
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to the specified torque.

3. Install the front case carefully not to damage the Tightening torque: 36 ± 3 N⋅m
oil seal.
rd

3. Pull out the screwdriver and screw in the plug.

20 mm 40 mm
22 mm >>J<< PLUG INSTALLATION
ca

25 mm
MD998162
32 mm

AK301520AD

MD998783
CAUTION
Carefully install the tightening bolts because of AK300184 AD
the different length respectively.
1. Install a new O-ring to the groove of the front
4. Tighten all flange bolts to the specified torque. case.
Tightening torque: 23 ± 3 N⋅m 2. Install the plug to the front case.
3. Use the special tool to tighten the plug to the
specified torque.
• Plug wrench (MD998162)
• Plug wrench retainer (MD998783)
Tightening torque: 23 ± 3 N⋅m
 ENGINE OVERHAUL
OIL PAN AND OIL PUMP
11B-51
3. Install the shorter bolts in the locations indicated
>>K<< OIL PAN INSTALLATION in the drawing.
CAUTION
Do not apply FIPG over remaining old FIPG.
Doing so could result in oil leakage. >>L<< OIL FILTER INSTALLATION
1. Clean the installation surface of the filter bracket.
1. Thoroughly remove old FIPG from the gasket
surfaces of the cylinder block and oil pan.
Timing belt side

Bolt hole
area

Grooved AK301069AD
area

m
AK202694 AB
2. Apply engine oil to the o-ring of the oil filter.
CAUTION
Too much FIPG will squeeze out, blocking

o
coolant or oil passages, while too thin a bead
could result in leakage.
2. Apply a 4 mm diameter bead of FIPG to the flange
surface all around the oil pan.
.c
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Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent General service tool
ia

AK300186 AD
NOTE: In the grooved areas on the oil pan flange,
apply FIPG bead along the center of the groove. 3. Using general service tool, Install the oil filter to
rd

the bracket and tighten it to the specified torque.

Timing belt side
Tightening torque
Part number MD356000 filter: 14 ± 2 N⋅m
ca

M6 × 8
Other Mitsubishi Genuine filter: 17 ± 3 N⋅m
4. If a torque wrench cannot be used use the
following procedure:
(1) Screw in the oil filter until its o-ring contacts
the oil filter bracket.
(2) Tighten the oil filter as follows:
AK202693 AD
Mitsubishi Genuine filter: 3/4 turn
11B-52 ENGINE OVERHAUL
OIL PAN AND OIL PUMP

>>M<< DRAIN PLUG GASKET 2. Check the oil seal lip for deterioration. Replace
INSTALLATION the oil seal if necessary.

COUNTERBALANCE SHAFT
Drain plug

Oil pan

Gasket Oil pan AK300187

side
1. Check the oil holes for clogging and clean if
necessary.

m
2. Check the journal for seizure, damage and
contact with bearing. If there is anything wrong
with the journal, replace the counterbalance shaft,

o
bearing or front case assembly if required.

.c
AK300601AF OIL PUMP
1. Assemble the oil pump gears to the front case and
gn
CAUTION
rotate it to ensure smooth rotation with no
If the gasket is installed in the wrong direction,
looseness.
oil leaks will occur.
Install the drain plug gasket in the direction shown. 2. Ensure that there is no ridge wear on the contact
ia

surface between the front case and the gear

INSPECTION surface of the oil pump cover.
M1113008200342
rd

FRONT CASE
1. Check the oil passage for clogging. Clean if
necessary.
ca

2. Check the left counterbalance shaft front bearing

for wear, damage and seizure. If the bearing is
damaged, replace the front case.
3. Check the front case for cracks and other
damage.
AK300188
Replace cracked or damaged front case.
3. Check the side clearance.
OIL SEAL Standard value:
1. Check the oil seal lip for wear and damage. Drive gear 0.08 − 0.14 mm
Replace the oil seal if necessary. Driven gear 0.06 − 0.12 mm
 ENGINE OVERHAUL
OIL PAN AND OIL PUMP
11B-53
OIL LEVEL SENSOR Put the oil level sensor in oil, then move the float
up and down with the oil at a temperature either
lower than 40°C or higher than 80°C, and check
for continuity.
40°C
Float position Switch ON/OFF
Condition when down ON (continuity)
Condition when up ON (continuity)
80°C
AK304606AB Float position Switch ON/OFF
Condition when down OFF (no continuity)
Condition when up ON (continuity)

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11B-54 ENGINE OVERHAUL
PISTON AND CONNECTING ROD

PISTON AND CONNECTING ROD

REMOVAL AND INSTALLATION
M1113008400733

6
7
8
10
4

12

Apply engine oil to 11

m
all moving parts
before installation.

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3
2
20 ± 2 N·m → + 90˚ to 94˚
1 AK301260AE

Removal steps REMOVAL SERVICE POINTS

>>G<< 1. Nut
<<A>>CONNECTING ROD CAP
<<A>> >>F<< 2. Connecting rod cap
>>D<< 3. Connecting rod bearing REMOVAL
>>E<< 4. Piston and connecting rod assembly
>>D<< 5. Connecting rod bearing
>>C<< 6. Piston ring No. 1
>>C<< 7. Piston ring No. 2 Cylinder
>>B<< 8. Oil ring number
<<B>> >>A<< 9. Piston pin
10.Piston
11. Connecting rod
12.Bolt

AK202812 AB
 ENGINE OVERHAUL
PISTON AND CONNECTING ROD
11B-55
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 Push rod
bearings in that order according to the cylinder
number.

Front mark
<<B>> PISTON PIN REMOVAL Front
mark
Guide A: 17.9 mm
Push
rod Guide B
Guide C

Base
Guide A: 18.9 mm

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Guide C

Guide A: 20.9 mm

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AK202781 AC
Base

Guide A: 21.9 mm
.c 1. Insert the tool element, Push rod, into the piston
from the front mark side, then attach the element,
Guide C, to the push rod.
gn
2. Place the piston and connecting rod assembly on
the element, Base, with the front mark facing up.
3. Use a press to remove the piston pin.
ia

AK301562 AB
NOTE: Keep the disassembled pistons, piston
pins and connecting rods cylinder by cylinder.
The special tool Piston pin setting tool (MD998780),
rd

consists of the elements shown in the drawing.

INSTALLATION SERVICE POINTS
ca

>>A<< PISTON PIN INSTALLATION

Timing belt side
Crankshaft
bore size mark

No.1 No.4
No.2 No.3

AK301530 AD

1. When replacing a piston, check the cylinder bore

size mark stamped at the indicated location on the
cylinder block and select an appropriate
replacement piston using the following table.
11B-56 ENGINE OVERHAUL
PISTON AND CONNECTING ROD

Cylinder bore size mark Piston size mark 7. Insert the assembly of piston pin, Push rod, and
Guide A (put together in step 4.) into the piston
I A holes from the front mark side.
II No mark
III C 3 mm + L
NOTE: The piston size mark is located on the
piston top surface.

Guide B Guide A
AK301480 AC
D C
8. Screw the tool element, Guide B, into the tool
element, Guide A until the gap between both the
Connecting rod elements is equal to the dimension L (obtained in
step 3.) plus 3 mm.

m
Piston pin
Piston

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Push rod

B A .c Piston pin
gn
Front mark
Front
mark
ia

AK202784 AE

2. Measure the following dimensions: Guide A

rd

A: Piston pin insertion hole length

Base
B: Distance between piston bosses
ca

C: Piston pin length

Guide B
D: Connecting rod small end width
3. Obtain dimension L from the measurements using
the following formula.
L = [(A-C) − (B-D)] ÷ 2 AK202782 AB

4. Insert the tool element, Push rod, into the piston 9. Place the piston and connecting rod assembly
pin and attach the element, Guide A, to the push onto the element, Piston setting base, with the
rod end. front marks facing up.
5. Assemble the connecting rod with the piston with 10.Install the piston pin using a press. If the required
their front marks facing in the same direction. press force is less than the standard value,
6. Apply engine oil to the outside surface of the replace the piston and piston pin assembly or the
piston pin. connecting rod, or both.
Standard value: 7,350 − 17,200 N
 ENGINE OVERHAUL
PISTON AND CONNECTING ROD
11B-57

AK301796

11.Check that the piston moves smoothly.

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11B-58 ENGINE OVERHAUL
PISTON AND CONNECTING ROD

>>B<< OIL RING INSTALLATION >>C<< PISTON RING NUMBER 2/PISTON

1. Fit the oil ring spacer into the piston ring groove. RING NUMBER 1 INSTALLATION
Side rail end Piston ring
expander

AK300190 AD AK300191 AD

Upper
side rail

No.1

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Spacer

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Lower No.2
side rail
AK304597AB
.c AK301452AD

1. Using the piston ring expander, fit number 2 into

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CAUTION
Do not use a piston ring expander when the number 2 groove of piston.
installing side rail. NOTE: Install piston rings with identification mark
2. Install the upper side rail. facing up, to the piston crown side.
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To install the side rail, first fit one end of the rail 2. Install the number 1 piston ring in the same
into the piston groove, then press the remaining manner as step 1.
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portion into position by hand. See illustration. Identification mark:

NOTE: The side rails and spacer may be installed Number 1 ring: 1R
in either direction. Number 2 ring: 2R
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NOTE: New spacers and side rails are colored for NOTE: Confirm the profile for No.1 and No.2
identification of their sizes. piston rings carefully. Install them correctly by
careful attention to the direction of top and
Size Identification color bottom.
Standard None NOTE: The identification mark and the size mark
0.50 mm oversize Red are stamped on the upper plane of the piston ring
diameter (piston top side).
3. Install the lower side rail in the same manner as Size Size mark
described in step 2. Standard None
4. Make sure that the side rails move smoothly in 0.50 mm oversize 50
both directions. diameter
3. To prevent wrong installation, check the
identification mark of each piston ring. The
identification mark is stamped near the ring gap.
 ENGINE OVERHAUL
PISTON AND CONNECTING ROD
11B-59
>>D<< CONNECTING ROD BEARING 3. Install the selected bearing in the big end and in
INSTALLATION the cap of the connecting rod.

Locations of crankshaft pin diameter

marks >>E<< PISTON AND CONNECTING ROD
INSTALLATION
Side rail
No. 1
No. 2
No. 1 No. 3

No. 4 AK304412 AB

Connecting bearing Side rail

No. 2
AK202730 AB

1. Apply engine oil on the circumference of the

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piston, piston rings, and oil ring.
2. Arrange the piston ring and oil ring gaps (side rail
and spacer) as shown in the illustration.

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Identification 3. Rotate the crankshaft so that the crank pin is on
mark position
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AK304598AB

1. Measure the crankshaft pin diameter and confirm

the center of the cylinder bore.
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its classification from the following table. On a
crankshaft supplied as a service part,
identification marks of its pins are stamped at the
positions shown in the illustration.
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Crankshaft pin outside Connecting

diameter rod bearing
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Identification Size mm Identification

mark mark AK300192
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I 44.995 − 45.000 1 4. Use suitable thread protectors on the connecting

II 44.985 − 44.995 2 rod bolts before inserting the piston and
connecting rod assembly into the cylinder block.
III 44.980 − 44.985 3
Care must be taken not to nick the crank pin.
2. If the crankshaft pin outside diameter identification
mark is "I," for example, select a bearing whose 5. Insert the piston and connecting rod assembly
identification mark is "1." into the cylinder with the front mark on the piston
crown pointing to the timing belt side.
If there is no identification color paint on the
6. Using a suitable piston ring compressor tool,
crankshaft, measure the pin outside diameter and
install the piston and connecting rod assembly
select a bearing appropriate for the measured
into the cylinder block.
value.
11B-60 ENGINE OVERHAUL
PISTON AND CONNECTING ROD

>>F<< CONNECTING ROD CAP Tightening torque: 20 ± 2 N⋅m

INSTALLATION
90˚ to 94˚ Paint mark
Paint
Cylinder mark
number

Bolt
Nut
AK301477AD
Notches
AK300193 AD
5. Make a paint mark on the head of each nut.
1. Verifying the mark made during disassembly, 6. Make a paint mark on the bolt end at the position
install the bearing cap to the connecting rod. If the 90 to 94 degrees from the paint mark made on the
connecting rod is new with no index mark, make nut in the direction of tightening the nut.
sure that the bearing locking notches are on the CAUTION

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same side as shown. • If the nut is turned less than 90 degrees,
proper fastening performance may not be
achieved. Be careful to tighten the nut exactly

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90 degrees.
• If the nut is overtightened (exceeding 94
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retighten it by repeating the tightening
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procedure from step 3.
7. Turn the nut 90 to 94 degrees and make sure that
the paint marks on the nut and bolt are aligned.
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AK300194
INSPECTION
2. Make sure that the connecting rod big end side M1113008500547
clearance meets the specification. PISTON
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Standard value: 0.10 − 0.25 mm Replace the piston if scratches or seizure is evident
Limit: 0.4 mm on its surfaces (especially the thrust surface).
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Replace the piston if it is cracked.

>>G<< CONNECTING ROD CAP NUT PISTON PIN
TIGHTENING 1. Insert the piston pin into the piston pin hole with
1. The connecting rod bolts should be examined your thumb. You should feel a slight resistance.
before reuse. If the bolt threads are damaged, the Replace the piston pin if it can be easily inserted
bolt should be replaced. or there is an excessive play.
Hand-thread the nut to the full length of the bolt 2. The piston and piston pin must be replaced as an
threads. If the nut does not run down smoothly, assembly.
the bolt should be replaced.
2. Before installing each nut, apply engine oil to the PISTON RING
threaded portion and bearing surface of the nut. 1. Check the piston ring for damage, excessive
3. Loosely tighten each nut to the bolt. wear, and breakage. Replace if defects are
evident. If the piston has been replaced, the
4. Then tighten the nuts alternately to the specified
piston rings must also be replaced.
torque to install the cap properly.
 ENGINE OVERHAUL
PISTON AND CONNECTING ROD
11B-61
Oil: 1.0 mm

CRANKSHAFT PIN OIL CLEARANCE

<PLASTIC GAUGING MATERIAL
METHOD>
1. Remove oil from the crankshaft pin and the
connecting rod bearing.

AK300195 Plastic gauging

material
2. Check for clearance between the piston ring and
ring groove. If it exceeds the limit, replace the ring
or piston, or both.
Standard value:
Number 1: 0.03 − 0.07 mm
Number 2: 0.02 − 0.06 mm
Limit: 0.1 mm

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AK300196 AD

2. Cut plastic gauging material to the same length as

Push in by

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piston the width of the bearing and place it on the pin,
parallel with its axis.
.c 3. Install the connecting rod cap carefully and tighten
the nuts to the specified torque.
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4. Carefully remove the connecting rod cap.

Piston ring Piston ring gap

AK301481AD
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3. Insert the piston ring into the cylinder bore. Force

the ring down with a piston, the piston crown
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being in contact with the ring, to correctly position

it at right angles to the cylinder wall. Then,
measure the end gap with a feeler gauge.
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Plastic gauging
If the ring gap is excessive, replace the piston material
AK300197 AD
ring.
Standard value: 5. Measure the width of the plastic gauging material
Number 1: 0.15 − 0.30 mm at its widest part by using a scale printed on the
Number 2: 0.28 − 0.43 mm plastic gauging material package.
Oil: 0.10 − 0.40 mm Standard value: 0.02 − 0.05 mm
Limit: 0.1 mm
Limit:
Number 1, Number 2: 0.8 mm
11B-62 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK

CRANKSHAFT AND CYLINDER BLOCK

REMOVAL AND INSTALLATION
M1113008700756

CAUTION
On the flexible flywheel equipped engines, do not remove any of the bolts "A" of the flywheel shown
in the illustration. The balance of the flexible flywheel is adjusted in an assembled condition.
Removing the bolt, therefore, can cause the flexible flywheel to be out of balance giving and resulting
in damage.

11 ± 1 N·m

12 5
11
6
132 ± 5 N·m
20 8

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7
9

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10
132 ± 5 N·m

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9.0 ± 1.0 N·m

19
18
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17
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A 3
4
16

15 Apply engine oil to

all moving parts
before installation.

25 ± 2 N·m → + 90˚
13
25 ± 2 N·m → + 90˚
14 AK304605AB

Removal steps Removal steps (Continued)

1. Flywheel bolt (M/T) 8. Crankshaft bushing (A/T)
2. Adapter plate (M/T) 9. Rear plate
3. Flywheel (M/T) 10.Bell housing cover
4. Crankshaft bushing (M/T) >>E<< 11. Oil seal case
5. Drive plate bolt (A/T) >>D<< 12.Oil seal
6. Adapter plate (A/T) >>C<< 13.Bearing cap bolt (Head 14)
7. Drive plate (A/T) >>C<< 14.Bearing cap bolt (Head 17)
>>C<< 15.Bearing cap
 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK
11B-63
Removal steps (Continued)
Location of crankshaft journal
>>B<< 16.Crankshaft bearing (Lower) diameter marks
17.Crankshaft
>>B<< 18.Crankshaft bearing (Upper)
>>A<< 19.Crankshaft thrust bearing
20.Cylinder block
No. 2
INSTALLATION SERVICE POINTS
No. 1 No. 3
>>A<< CRANKSHAFT THRUST BEARING
INSTALLATION No. 4 No. 5 AK304413 AB
1. Install the two thrust bearings in the number 3
bearing bore in the cylinder block. For easier 1. Measure the crankshaft journal diameter and
installation, apply engine oil to the bearings; this confirm its classification from the following table.
will help hold them in position. 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.

Timing belt side

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No. 1 No. 2 No. 3 No. 4 No. 5

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Cylinder bore
Groove
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AK304599AB
indentification
mark
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2. The thrust bearings must be installed with their AK300198 AD

groove side toward the crankshaft web.

2. The cylinder block bearing bore diameter
identification marks are stamped at the position
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>>B<< CRANKSHAFT BEARING shown in the illustration from left to right,

INSTALLATION beginning at No.1.
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When bearing replacement is required, select and

install the correct bearing by the following procedure.
Crankshaft journal outside diameter Cylinder block Crankshaft bearing Crankshaft bearing
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bearing bore for No.3

Identification mark Size mm Identification mark Identification mark Identification mark
0 56.994 − 57.000 0 1 0
1 2 1
2 3 2
1 56.988 − 56.994 0 2 1
1 3 2
2 4 3
2 56.982 − 56.988 0 3 2
1 4 3
2 5 4
11B-64 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK

Crankshaft bearing 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: 71.1 mm
3. Apply engine oil to the threaded portion and
bearing surface of the bolt.

Identification
mark position
AK304598AC
8 4 1 5 9
For example, if the crankshaft journal outside
diameter identification mark is "0" and cylinder block
bearing bore identification mark is "1," select a
bearing whose identification mark is "2" for number 7 3 2 6 10
1, 2, 4 and 5, and a bearing whose identification
mark is "1" for number 3. Arrow
AK300199 AD
If there is no identification mark on the crankshaft,

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measure the journal outside diameter and select a 4. Tighten the bolts to the specified in the tightening
bearing appropriate for the measured value. sequence shown.
Tightening torque: 25 ± 2 N⋅m

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Groove
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For upper
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For lower 90˚

AK301466AD
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3. Install the bearings having an oil groove to the AK300200 AD

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

4. Install the bearings having no oil groove to the 6. Make a paint mark on the bearing cap 90 degrees
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bearing cap. from the paint mark made on the bolt in the
direction of tightening the bolt.
>>C<< BEARING CAP/BEARING CAP CAUTION
BOLT INSTALLATION • If the bolt is overtightened, loosen the bolt
1. Install the bearing caps so that the arrow points to completely and then retighten it by repeating
the timing belt side. the tightening procedure from step 4.
• If the bolt is turned less than 90 degrees,
proper fastening performance may not be
achieved. Be sure to turn the bolt exactly 90
degrees.
7. Turn each bolt 90 degrees in the tightening
sequence specified in step 4, and make sure that
the paint marks on the bolt and cap are aligned.
Shank length

AK301471AD
 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK
11B-65
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
NOTE: Be sure to install the case quickly while the
sealant is wet (within 15 minutes).
3. Install the oil seal into the cylinder block after
applying an appropriate amount of engine oil to
the entire circumference of its lip portion.
4. Install the rear oil seal case by tightening its bolts
AK300201 to 11 ± 1 N⋅m.
8. Make sure that the crankshaft turns smoothly and NOTE: After installation, keep the sealed area away
the end play is correct. If the end play exceeds the from the oil for approximately one hour.
limit, replace the number 3 crankshaft bearings.
Standard value: 0.05 − 0.25 mm
INSPECTION
Limit: 0.40 mm M1113008800537

CRANKSHAFT JOURNAL OIL

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>>D<< OIL SEAL INSTALLATION CLEARANCE <PLASTIC GAUGING
MATERIAL METHOD>
1. Remove oil from the crankshaft journal and

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MB990938
crankshaft bearing.
MD998776 .c 2. Install the crankshaft.

Plastic gauging material

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AK300202 AD

Use the special tools to press-fit the rear oil seal in

the rear oil seal case.
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• Handle (MB990938)
• Crankshaft rear oil seal installer (MD998776) AK300203 AD
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>>E<< SEALANT APPLICATION TO OIL 3. Cut the plastic gauging material to the same
length as the width of bearing and place it on
SEAL CASE journal in parallel with its axis.
1. Remove completely old FIPG remaining on the 4. Install the crankshaft bearing cap carefully and
rear oil seal case and cylinder block. tighten the bolts to the specified torque.
5. Carefully remove the crankshaft bearing cap.

Plastic gauging material

AK300576AD

2. Apply a bead of FIPG to the surface of the rear oil AK300204 AD

seal case as shown in the drawing.

11B-66 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK

6. Measure the width of the plastic gauging material 5. Using a cylinder gauge, measure the cylinder
at its widest part by using a scale printed on the bore and cylindrically. If worn badly, correct the
plastic gauging material package. cylinder to an oversize and replace the piston and
Standard value: 0.02 − 0.04 mm piston rings. Measure at the points shown in the
Limit: 0.1 mm illustration.
Standard value:
Cylinder inner diameter 87.0 mm
CYLINDER BLOCK
Cylindrically 0.01 mm or less
C D E
A F
B G
BORING CYLINDER

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AK300205

1. Visually check for scratches, rust, and corrosion. Piston outside Thrust
diameter direction
Use also a flaw detecting agent for the check. If

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AK300577AC
AD
defects are evident, correct or replace.
2. Using a straightedge and feeler gauge, check the.c
block top surface for warpage. Make sure that the
surface is free from gasket chips and other foreign
1. Oversize pistons to be used should be determined
on the basis of the largest bore cylinder.
Piston size identification
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matter. Size Identification mark
Standard value: 0.05 mm 0.50 mm oversize 50
Limit: 0.1 mm diameter
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3. If the distortion is excessive, correct within the

NOTE: Size mark is stamped on the piston top.
allowable limit or replace.
2. Measure the outside diameter (OD) of the piston
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Grinding limit: 0.2 mm

to be used. Measure it in thrust direction as
*Includes/combined with cylinder head
shown.
grinding
3. Based on the measured piston OD, calculate the
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Cylinder block height (when new):

284 mm boring finish dimension.
Boring finish dimension = [Piston OD] +
4. Check cylinder walls for scratches and seizure. If
[0.02 - 0.04 mm(clearance between piston OD
defects are evident, replace or bore to oversize
and cylinder)] −[0.02 mm (honing margin)]
and replace pistons and piston rings.
CAUTION
To prevent distortion that may result from
A temperature rise during honing, bore cylinders,
B working from number 2 to number 4 to number 1
to number 3.
4. Bore all cylinders to the calculated boring finish
12mm
dimension.
Center 5. Hone to the final finish dimension (piston OD +
Bottom clearance between piston OD and cylinder).
AK300206 AD 6. Check the clearance between the piston and
cylinder.
Clearance between piston and cylinder:
0.02 − 0.04 mm
 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK
11B-67
NOTE: When boring cylinders, finish all of four
cylinders to the same oversize. Do not bore only
one cylinder to an oversize.

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