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Mitsubishi 6A1 SERIES Automobile Parts User Manual

1. Items Standard value Limit Timing belt Auto tensioner rod projection mm 12 0 Auto tensioner rod pushed in amount when pushed with a force 1 0 or less of 98 196 N mm Rocker arm and camshaft lt SOHC gt Camshaft cam height mm Intake 35 20 34 70 Exhaust 34 70 34 20 Camshaft journal diameter mm 45 Rocker cover and camshaft lt MIVEC gt Camshaft cam height mm Intake Low speed cam 34 34 33 84 High speed cam 36 46 35 96 Exhaust Low speed cam 34 40 33 90 High speed cam 35 86 35 36 Camshaft journal diameter mm 26 Valve clearance mm Intake 0 10 Exhaust 0 13 Cylinder head and valve Flatness of cylinder head gasket surface mm Cylinder head gasket surface grinding limit including grinding of Less than 0 03 cylinder block gasket surface mm Cylinder head overall height SOHC 119 9 120 1 MIVEC 119 6 119 8 Cylinder head bolt nominal length mm 96 4 Valve margin mm Intake 1 0 0 5 Exhaust 1 3 0 8 Valve stem diameter mm 6 0 Valve stem to guide clearance Intake 0 02 0 05 0 10 Exhaust 0 04 0 07 0 15 Valve face angle 45 45 5 Valve stem projection mm SOHC 48 45 48 95 MIVEC 48 40 48 90 Mitsubishi Motors Corporation Feb 1997 PWEE9622 11A 1 2 6A1 ENGINE E W Specifications
2. Items Standard value Limit Overall valve length mm Intake SOHC 113 02 112 52 MIVEC 112 37 111 87 Exhaust SOHC 115 32 114 82 MIVEC 110 74 110 74 Valve spring free height mm SOHC 49 9 48 9 MIVEC 51 5 50 5 Valve spring load installed SOHC 265 43 4 height N mm MIVEC 255 44 5 Valve spring squareness 2 4 Valve seat contact width mm 0 9 1 3 Valve guide internal diameter mm 6 6 Valve guide projection mm SOHC 14 0 MIVEC 19 0 Oil pump case and oil pan Oil pump tip clearance mm 0 06 0 18 Oil pump side clearance mm 0 04 0 10 Oil pump body clearance mm 0 10 0 18 0 35 Piston and connecting rod Piston outside diameter mm 6A12 78 4 6A13 81 0 Piston ring side clearance mm No 1 ring 0 02 0 06 No 2 ring 0 02 0 06 Piston ring end gap mm No 1 ring 0 20 0 35 0 8 No 2 ring 0 35 0 50 0 8 Oil ring 0 20 0 50 1 0 Piston pin outside diameter mm 19 0 Piston pin press in load at room temperature N 4 900 14 700 Crankshaft pin oil clearance mm 0 02 0 05 0 1 Connecting rod big end side clearance mm 0 10 0 25 0 4 Crankshaft cylinder block flywheel and drive plate Crankshaft end play mm 0 05 0 25 0 4 Mitsubishi Motors Corporation Feb 1997 PWEE9622 Items 6A1 ENGINE E W Specifications Standard value 11A 1 3 Crankshaft journal diameter mm 6A12 53 0 6A13 96 0 Crankshaft pin diameter mm 6A12
3. Intake side 34 91 mm Exhaust side Limit 34 70 mm Intake side 34 41 mm Exhaust side Mitsubishi Motors Corporation Feb 1997 PWEE9622 11A 9 4 6 1 ENGINE E W Rocker Arm and Camshaft lt SOHC gt LASH ADJUSTER LEAK DOWN TEST Caution e The lash adjuster is a precision part Keep it free from dust and other foreign matters e Do not disassemble lash adjuster e When cleaning lash adjuster use clean diesel fuel only 1 Immerse the lash adjuster in clean diesel fuel 2 While lightly pushing down inner steel ball using the special tool Air bleed wire MD998442 move the plunger up and down four or five times to bleed air Use of the special tool Retainer MD998441 helps facilitate the air bleeding of the rocker arm mounted type lash adjuster 3 Remove the special tool Air bleed wire MD998442 and press the plunger If the plunger is hard to be pushed in the lash adjuster is normal If the plunger can be pushed in all the way readily bleed the lash adjuster again and test again If the plunger is still loose replace the lash adjuster Caution e Upon completion of air bleeding hold lash adjuster upright to prevent inside diesel fuel from spilling MD998442 7 7 S Diesel fuel VANG 4 After air bleeding set lash adjuster on the special tool Leak down teste
4. Ee asp aa s Y D agi pre GJE Mitsubishi Motors Corporation Feb 1997 PWEE9622 6A1 ENGINE E W Cylinder Head and Valves 11A 12 1 12 CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION lt SOHC gt Removal steps Cylinder head bolt 11 Cylinder head cp PAM 12 Cylinder head gasket 13 04 pB Gp 4 3 2 3 4B e 6 7 PB 10 Retainer lock C PAM 14 Valve spring retainer 1 Valve spring Intake valve Retainer lock Valve spring retainer Valve spring Mitsubishi Motors Corporation Feb 1997 PWEE9622 16 17 18 19 20 Apply engine oil to all moving parts before installation SAEOI65 Exhaust valve Valve stem seal Valve spring seat Valve stem seal 5 Valve spring seat Intake valve guide Exhaust valve guide Intake valve seat Exhaust valve seat Cylinder head 11A 12 2 6A1 ENGINE E W Cylinder Head and Valves REMOVAL AND INSTALLATION lt MIVEC gt e 8 4 5 gt e 12 1 9 8 9 amp 13 Apply engine oil to all moving parts before installation 6AE0314 Removal steps A PPDa 1 Cylinder head bolt D 11 Exhaust valve 2 Oylinder head C PAM 12 Valve stem seal 3 Cylinder head gasket 13 Valve spring seat BD pCd 4 Retainer lock C 14 Valve stem seal 5 Valve spring retainer 15 Valve spring seat p
5. ae Specified sealant Mitsubishi Genuine Part No MD970389 or equivalent D lt THERMOSTAT INSTALLATION 1 Install the thermostat so that the jiggle valve will be located in the thermostat housing as shown pE SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE SENSOR Specified sealant 3M Nut locking Part No 4171 or equivalent O Mitsubishi Motors Corporation Feb 1997 PWEE9622 11A 7 4 6A1 ENGINE E W Water Pump and Water Pipe pF SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE GAUGE UNIT Specified sealant 3M ATD Part No 8660 or equivalent 6 0071 Mitsubishi Motors Corporation Feb 1997 PWEE9622 6A1 ENGINE E W Intake Manifold and Exhaust Manifold 11A 8 1 8 INTAKE MANIFOLD AND EXHAUST MANIFOLD REMOVAL AND INSTALLATION lt SOHC gt 13 Nm 49 Nm 6AE0362 Removal steps Intake manifold Gasket Heat protector right Exhaust manifold stay Exhaust manifold right Gasket Heat protector left Exhaust manifold left Gasket gt G N Mitsubishi Motors Corporation Feb 1997 PWEE9622 11A 8 2 6A1 ENGINE E W Intake Manifold and Exhaust Manifold REMOVAL AND INSTALLATION lt MIVEC gt 49 Nm 6AE0391 Removal steps Intake manifold Gasket Heat protector right Exhaust manifold stay Exhaust manifold right Gasket Heat protector left Exhaust manifold left Gasket gt G N Mitsubishi Motor
6. 4 Throttle body 17 Insulator pC 5 Gasket p B 18 Injector 6 Connector bracket 19 Grommet 7 Connector bracket 20 O ring 8 Accelerator cable bracket 21 Fuel pipe 9 Ignition failure sensor 22 O ring 10 Air temperature sensor 23 Fuel pressure regulator 11 Gasket 24 O ring 12 Air intake plenum 25 Delivery pipe 13 Gasket 26 Alternator bracket Mitsubishi Motors Corporation Feb 1997 PWEE9622 6A1 ENGINE E W Fuel and Emission Control Parts 11A 5 3 Projection Mitsubishi Motors Corporation Feb 1997 6AE0061 INSTALLATION SERVICE POINTS DAM FUEL PRESSURE REGULATOR INSTALLATION 1 Apply spindle oil or gasoline to the new O ring installed on the fuel pressure regulator 2 Insert the fuel pressure regulator in the delivery pipe 3 Make sure that the fuel pressure regulator turns smoothly then align the threaded holes and tighten the regulator bolts to specification Caution e Ifthe regulator does not turn smoothly the O ring probably gets caught somewhere in the delivery pipe In such a case remove the fuel pressure regulator and reinsert it into the delivery pipe Check it again for smooth rotation before securing DBM INJECTOR INSTALLATION 1 Install new grommet and O ring on the injector 2 Apply spindle oil or gasoline to the O ring of the injector 3 While turning the injector in both directions install it in the delivery pipe 4 Make sure that t
7. E W Piston and Connecting Rod 11A 14 3 INSTALLATION SERVICE POINTS p A PISTON PIN INSTALLATION 1 Measure the following dimensions of the piston piston pin and connecting rod A Piston pin insertion hole length B Distance between piston bosses C Piston pin length D Connecting rod small end width 2 Calculate the following formula by substituting the measured values w A C B D l 2 3 Insert the Push Rod special tool into the piston pin and attach the guide A to the push rod end 4 Assemble the connecting rod in the piston with their front marks facing the same direction 5 Apply engine oil to the entire periphery of the piston pin 6 Insert the piston pin push rod and guide A assembly having assembled step 3 from the guide side into mE 2 Connecting rod the piston pin hole on the front marked side Piston pin 7 0432 7 Screw the guide into the guide until the between both guides amounts to the value L obtained in step 2 plus 3 mm Guide B Guide A 8 Place the piston and connecting rod assembly onto the piston setting base with the front marks directed upward 9 Press fit the piston pin using a press If the press fitting force required is less than the standard value replace the piston and piston pin set or and the connecting rod Standard value 5 000 15 000 N Push rod Piston pin A ZAN GE
8. I Ro EN s SN SUE YQ SUQ NET hasa UU 2 PESE S Guide B Mitsubishi Motors Corporation Feb 1997 PWEE9622 11A 14 4 6A1 ENGINE E W Piston and Connecting Rod 2 Side rail gap egge XIII Wa Ca Z E Identification mark Identification mark No 2 ring gap and spacer gap Mitsubishi Motors Corporation mi Size mark side rail Feb 1997 6EN0549 p B 4OIL RING INSTALLATION 1 Fit the oil ring spacer into the piston ring groove NOTE The side rails and spacer may be installed in either direction Install the upper side rail To install the side rail first fit one end of the rail into the piston groove then press the remaining portion into position by finger See illustration NOTE Do not use piston ring expander when installing side rail Use of ring expander to expand the side rail end gap can break the side rail unlike other piston rings Install the lower side rail in the same procedure as described in step 2 Make sure that the side rails move smoothly in either direction p C PISTON RING NO 2 PISTON RING NO 1 1 INSTALLATION Using piston ring expander install the piston rings with their side having identification marks facing up Identification mark No 1 ring T No 2 ring 2T NOTE The piston ring is stamped with the following size mark Size Size mark Standard size None 0 50 mm O S 50 1 00 mm O S 1
9. Low speed cam L VALVE CLEARANCE ADJUSTMENT NOTE Adjust the valve clearance for each cylinder and for both intake and exhaust valves with the piston at the compression stroke top dead center 1 Bring the No 1 cylinder piston into the compression stroke top dead center 2 Use the special tool to loosen the adjusting screw SES EE 3 Insert a thickness gauge of the thickness specified below 3 N jja between the low speed cam narrow cam roller VE Tale EE 0 10 mm ExhHausU Ge 0 13 mm 4 Screw in one of the two adjusting screws until it comes into contact with the valve when the turning torque changes Mitsubishi Motors Corporation Feb 1997 PWEE9622 11A 10 6 6A1 ENGINE E W Rocker Cover and Camshaft lt MIVEC gt Mitsubishi Motors Corporation Feb 1997 S 6 Screw in the other adjusting screw until it comes into contact with the valve when the turning torque changes and then tighten the lock nut Loosen the adjusting screw that was screwed in first slightly until the turning torque becomes almost zero Screw in the adjusting screw until it comes into contact with the valve again when the turning torque changes and tighten the lock nut Remove the thickness gauge Screw the special tool into the top of piston of the rocker arm H and pull up the tool to make sure that the piston can be lifted smoothly by hand Perform valve clearance adjustment
10. Tighten the bolts to specified torque INSPECTION CRANKSHAFT OIL CLEARANCE PLASTIC GAUGE METHOD 1 Remove oil from crankshaft journal and crankshaft bearing 2 Install the crankshaft 3 Cut the plastic gauge to the same length as the width of bearing and place it on journal in parallel with its axis i AC i J 4 a ef N IN N De de NS T uc 6AE0101 4 Install the crankshaft bearing cap carefully and tighten the bolts to specified torque 5 Carefully remove the crankshaft bearing cap 6 Measure the width of the plastic gauge at its widest part by using a scale printed on the plastic gauge package Standard value 0 02 0 04 mm Limit 0 1 mm Mitsubishi Motors Corporation Feb 1997 PWEE9622 Crankshaft Cylinder Block Flywheel and 6A1 ENGINE E W Drive Plate 9 11A 15 5 CYLINDER BLOCK 1 Using a straightedge and feeler gauge check the block top surface for warpage Make sure that the surface is free from gasket chips and other foreign matter Standard value 0 05 mm or less Limit 0 1 mm 2 If the distortion is excessive correct within the allowable limit or replace Grinding limit 0 2 mm The total thickness of the stock allowed to be removed from cylinder block and mating cylinder head is 0 2 mm at maximum Cylinder block height when new 6A12 190 mm 6A13 209 mm 3 Check cylinder walls for scratches and seizure If defects are evident cor
11. camshaft holder 5 Tighten the bolts in the order indicated in the illustration 6 Check the torque of the x marked bolts See section B lt for the checking order 7 Verify that the pad of each adjusting screw is in place Mitsubishi Motors Corporation Feb 1997 PWEE9622 11A 10 4 6A1 ENGINE E W Rocker Cover and Camshaft lt MIVEC gt Right bank lt pE CAMSHAFT OIL SEAL INSTALLATION TR 1 When installing the left bank camshaft oil seal use the gt MD998713 special tool to prevent interference with the knock pin MD998713 pF CIRCULAR PACKING INSTALLATION 6AE0241 G lt q ROCKER COVER INSTALLATION 1 Apply the specified sealant to the area shown Specified sealant 3M ATD Part No 8660 or equivalent INSPECTION OIL CONTROL VALVE 1 Connect a 12VDC power supply between terminals 1 and 2 of the oil control valve and check if the valve operates smoothly Mitsubishi Motors Corporation Feb 1997 PWEE9622 6A1 ENGINE E W Rocker Cover and Camshaft lt MIVEC gt 11A 10 5 CAMSHAFT 1 Measure the cam heights If the specified limit is exceeded replace the camshaft E nd has an identification mark on its rear end surface Identification mark Standard value Limit IN 3 L 34 34 mm 33 84 mm H 36 46 mm 35 96 mm EX L 34 40 mm 33 90 mm H 35 86 mm 35 36 mm mark location
12. less than 120 they may not hold the cylinder head with sufficient strength e f a bolt is overtightened completely remove all the bolts and carry out the installation procedure again from step 1 PWEE9622 6A1 ENGINE E W Cylinder Head and Valves 11A 12 7 INSPECTION CYLINDER HEAD 1 Check the cylinder head gasket surface for flatness by using a straightedge and thickness gauge Standard value 0 03 mm Limit 0 2 mm 2 If the service limit is exceeded correct to meet the specification Grinding limit 0 2 mm Includes combined with cylinder block grinding Cylinder head height Specification when new 119 9 120 1 mm lt SOHC gt 119 6 119 8 mm lt MIVEC gt VALVE 1 Check the valve face for correct contact If incorrect reface using a valve refacer Valve should make a uniform contact with the seat at the centre of valve face 2 If the margin is smaller than the service limit replace Valve seat the valve contact Margin Standard value mm Limit mm Intake 1 0 0 5 Exhaust 1 3 0 8 3 Measure the overall height of the valve If the specified limit is exceeded replace the valve Standard value Limit mm mm Intake 113 02 112 52 112 37 111 87 Exhaust 115 32 114 82 110 74 110 74 Mitsubishi Motors Corporation Feb 1997 PWEE9622 11A 12 8 6A1 ENGINE E W Cylinder Head and Valves Out of square Valve stem end Valve stem projecti
13. or equivalent As required Drive plate bolt 3M Nut Locking Part No 4171 or equivalent As required Flywheel bolt 3M Nut Locking Part No 4171 or equivalent parts sealed by foam in place gasket Mitsubishi Motors Corporation Feb 1997 PWEE9622 As required 11A 1 8 6A1 ENGINE E W Specifications FORM IN PLACE GASKET FIPG The engine has several areas where the form in place gasket FIPG is in use To ensure that the gasket fully serves its purpose it is necessary to observe some precautions when applying the gasket Bead size continuity and location are of paramount importance Too thin a bead could cause leaks Too thick a bead on the other hand could be squeezed out of location causing blocking or narrowing of the fluid feed line To eliminate the possibility of leaks from a joint therefore it is absolutely necessary to apply the gasket evenly without a break while observing the correct bead size The FIPG used in the engine is a room temperature vulcanisation RTV type and is supplied in a 100 gram tube Part No MD970389 or MD997110 Since the RTV hardens as it reacts with the moisture in the atmospheric air it is normally used in the metallic flange areas The FIPG Part No MD970389 can be used for sealing both engine oil and coolant while Part No MD997110 can only be used for engine oil sealing Disassembly The parts assembled with the FIPG can be easily disassembled
14. paint mark on the area around the bolt bearing surface at location 90 to 100 in the direction of tightening the bolt Give a 90 to 100 turn to the bolts in the tightening sequence Make sure that the paint mark on the bolt and that on the area around the bolt bearing surface are in alignment Caution e If the bolts are tightened by an angle of less than 90 they may not hold the cap with sufficient strength e bolt is tightened by an angle exceeding 100 completely remove all the bolts and carry out the installation procedure again from step 1 After installing the bearing caps make sure that the crankshaft turns smoothly and the end play is correct If the end play exceeds the limit replace crankshaft bearings Standard value 0 05 0 25 mm Limit 0 4 mm PWEE9622 Crankshaft Cylinder Block Flywheel and 11A 15 4 6A1 ENGINE E W Drive Plate p C OIL SEAL INSTALLATION 1 Apply engine oil to oil seal lip MB990938 MD998776 APPLICATION OF OIL SEAL CASE Specified sealant Mitsubishi Genuine Part No MD970389 or equivalent pE DRIVE PLATE BOLT FLYWHEEL BOLT INSTALLATION 1 Remove all the remaining sealant from bolts and thread holes of crankshaft 2 Apply engine oil to the flange of bolt 3 Apply engine oil into the thread holes of crankshaft 4 Apply specified sealant to the thread of bolts Specified sealant 3M Nut Locking Part No 4171 or equivalent 5
15. piston and cylinder 0 02 0 04 mm NOTE When boring cylinders finish all of four cylinders to same oversize Do not bore only one cylinder to an oversize Mitsubishi Motors Corporation Feb 1997 PWEE9622 NOTES Service Bulletins Click on the applicable bookmark to select the Service Bulletin SERVICE BULLETIN QUALITY INFORMATION ANALYSIS MITSUBISHI OVERSEAS SERVICE DEPT MITSUBISHI MOTORS CORPORATION MOTORS SERVICE BULLETIN no msB 01E11 001 lt Model gt lt M Y gt ADDITION OF 6A1 ENGINE WATER PUMP EC GALANT EAO 01 10 INSTALLATION PROCEDURES Group ENGINE Draft No OOEN620614 INTERNATIONAL INFORMATION Le CAR ADMINISTRATION T MASAKI MANAGER TECHNICAL SERVICE PLANNING OFFICE Subject 1 Description It has been found that when the 6A1 engine is installed the water pump impeller interferes with the cylinder block Therefore the procedures for positioning the water pump that are to be followed when the water pump is installed have been introduced 2 Applicable Manuals Manual 1 Pub No Language ENGINE 6A1 W E PWEE9202 English 11A 7 2 Workshop Manual PWES9203 Spanish PWEF9204 French PWEG9205 German PWED9206 Dutch ENGINE 6A1 E W 11A 7 3 Workshop Manual PWES9623 Spanish PWEG9625 German ENGINE 6A1 E W Workshop Manual 6A1 ENGINE E W Water Pump and Water P
16. without use of a special method In some cases however the sealant between the joined surfaces may have to be broken by lightly striking with a mallet or similar tool A flat and thin gasket scraper may be lightly hammered in between the joined surfaces In this case however care must be taken to prevent damage to the joined surfaces For removal of the oil pan the special tool Oil Pan Remover MD998727 is available Be sure to use the special tool to remove the oil pan Surface Preparation Thoroughly remove all substances deposited on the gasket application surfaces using a gasket scraper or wire brush Check to ensure that the surfaces to which the FIPG is to be applied is flat Make sure that there are no oils greases and foreign substances deposited on the application surfaces Do not forget to remove the old sealant remained in the bolt holes Form in Place Gasket Application When assembling parts with the FIPG you must observe some precautions but the procedures is very simple as in the case of a conventional precut gasket Applied FIPG bead should be of the specified size and without breaks Also be sure to encircle the bolt hole circumference with a completely continuous bead The FIPG can be wiped away unless it is hardened While the FIPG is still moist in less than 15 minutes mount the parts in position When the parts are mounted make sure that the gasket is applied to the required area only In addition do not appl
17. 00 D lt PISTON AND CONNECTING ROD INSTALLATION 1 2 3 Liberally coat engine oil on the circumference of the piston piston ring and oil ring Arrange the piston ring and oil ring gaps side rail and spacer as shown in the figure Rotate crankshaft so that the crank pin is on center of the cylinder bore PWEE9622 Mitsubishi Motors Corporation 6A1 ENGINE E W Piston and Connecting Rod Crankshaft pin identification mark No 6 Check digit 6AE0341 Identification mark 6AEO115 Cylinder No Notches Feb 1997 11A 14 5 4 Use suitable thread protectors on connecting rod bolts before inserting piston and connecting rod assembly into cylinder block Care must be taken not to nick crank pin 5 Using a suitable piston ring compressor tool install piston and connecting rod assembly into the cylinder block Caution e Insert the front mark arrow on the top of the piston so it faces the engine front timing belt side pE CONNECTING ROD BEARINGS INSTALLATION 1 When the bearings are to be replaced select correct ones and install them in the correct positions according to the identification marks stamped on the crankshaft lt 6A12 gt Crankshaft pin Connecting rod bearing Identification mark Outer diameter mm Identification mark I 42 995 43 000 42 985 42 995 lt 6A13 gt Crankshaft pin 42 980 42 985 Conn
18. 11 Bearing cap M8 24 Mitsubishi Motors Corporation Feb 1997 PWEE9622 11A 1 6 Items 6A1 ENGINE E W Specifications Arm spring holder Rocker arm and rocker shaft cap lt MIVEC gt Hocker shaft cap Cylinder head and valves Cylinder head bolt 20 120 120 Oil pan and oil pump Oil pressure switch 10 Oil filter cover 21 Water hose 30 Bolt 68 Drain plug 39 Oil level sensor 9 Oil pan 7 Oil screen 19 Baffle plate 9 Relief plug 44 Oil pump case 14 Oil pump case cover 12 Piston and connecting rod Connecting rod 18 90 100 Crankshaft cylinder block flywheel and drive plate Detonation sensor 23 Idler pulley bracket 35 Flywheel bolt 98 Drive plate bolt 98 Rear plate 11 Bell housing cover 9 Oil seal case 11 Bearing cap bolt Mitsubishi Motors Corporation Feb 1997 PWEE9622 25 90 100 6A1 ENGINE E W Specifications 11A 1 7 NEW TIGHTENING METHOD BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA A new type of bolts to be tightened in plastic area is currently used in some parts of the engine The tightening method for the bolts is different from the conventional one Be sure to observe the method described in the text when tightening the bolts Service limits are provided for the bolts Make sure that the service limits described in the text are strictly
19. 11A 0 1 ENGINE 6A1 SERIES CONTENTS GENERAL INFORMATION 11A 0 3 Le SPECIFICATIONS enee 11A 1 1 SERVICE SPECIFICATIONS 11A 1 1 REWORK DIMENSIONS 11A 1 3 TORQUE SPECIFICATION 11A 1 4 NEW TIGHTENING METHOD BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA 11A 1 7 SEALANTS EE 11A 1 7 FORM IN PLACE GASKET FIPG 11A 1 8 2 Or CIA VO Lei ansia e es LU tU ee ee 11A 2 1 JJDRIVE D W 11A 3 1 4 TIMING BELT W 11A 4 1 5 FUEL AND EMISSION CONTROL 11A 5 1 GS IGNITION SYSTEM 11 6 1 7 WATER PUMP AND WATER PIPE 11A 7 1 8 INTAKE MANIFOLD AND EXHAUST MANIFOLD 11A 8 1 9 ROCKER ARM AND CAMSHAFT SOHC 11A 9 1 10 ROCKER COVER AND CAMSHAFT lt MIVEC gt 11A 10 1 11 ROCKER ARM AND ROCKER SHAFT CAP lt MIVEG gt 11A 11 1 12 CYLINDER HEAD AND VALVES 11A 12 1 13 OIL PUMP CASE AND PAN 11A 13 1 14 PISTON AND CONNECTING ROD 11A 14 1 15 CRANKSHAFT CYLINDER BLOCK FLYWHEEL AND DRIVE PLATE 11A 15 1 Mitsubishi Motors Corporation F
20. 2 10 6A1 ENGINE E W Cylinder Head and Valves 3 Press fit the valve guide until it protrude specified value SOHC 14 mm DOHC 19 mm as shown in the illustration Caution e Press the valve guide from the cylinder head top surface e Valve guide for intake valve and that for exhaust valve are different in length 45 5 mm for intake valve 50 5 mm for exhaust valve 4 After the valve guide has been installed insert a new valve to check for smooth sliding motion Mitsubishi Motors Corporation Feb 1997 PWEE9622 6A1 ENGINE E W Oil Pump Case and Oil Pan 11A 13 1 13 OIL PUMP CASE AND OIL PAN REMOVAL AND INSTALLATION lt SOHC gt Apply engine oil to all moving parts before installation 6AE0393 Removal steps 14 1 Oil pressure switch pD 14 Oil pan upper Hq 2 Oil filter 15 Buffle plate 3 Oil filter cover 16 Oil screen 4 Water hose for Europe and GCC 17 Gasket 5 Water pipe for Europe and GCC 18 Relief plug 6 Water pipe for Europe and GCC 19 Relief spring 7 Bolt for Europe and GCC 20 Relief plunger G lt 4A 8 Oil cooler for Europe and GCC BC 21 Oil seal 9 Drain plug p B 22 Oil pump case KE 10 Gasket 23 O ring 11 Oil level sensor For Europe 24 Oil pump case cover 12 Cover kA 25 Outer rotor p D4 13 Oil pan lower kA 26 Inner rotor Mitsubishi Motors Corporation Feb 1997 11A 13 2 6A1 ENGINE E W Oil Pump Case and Oil Pan REMOVAL AND INST
21. 43 0 6A13 51 0 Crankshaft journal oil clearance mm 0 02 0 04 Cylinder block gasket surface flatness mm 0 05 Cylinder block gasket surface grinding limit including grinding of cylinder head gasket surface mm Cylinder block overall height mm 6A12 190 0 6A13 209 0 Cylinder block cylindricity mm 0 01 or less Cylinder block internal diame ter mm 6A12 78 4 6A13 81 0 Bearing cap bolt nominal length mm Piston to cylinder clearance mm REWORK DIMENSIONS Item 0 02 0 04 Standard Cylinder head and valves Cylinder head oversize valve guide hole diameter mm 11 05 11 07 11 25 11 27 11 50 11 52 Oversize intake valve seat ring hole diameter mm 29 80 29 82 30 10 30 12 32 30 32 32 32 60 32 62 Oversize exhaust valve seat ring diameter mm 27 80 27 82 28 10 28 12 Mitsubishi Motors Corporation Feb 1997 29 80 29 82 PWEE9622 30 10 30 12 11A 1 4 6A1 ENGINE E W Specifications TORQUE SPECIFICATION Items Nm Alternator and drive belt Alternator pivot nut 44 Alternator bolt 21 Oil level gauge guide 23 Tensioner pulley 15 Engine hanger 23 Tensioner pulley bracket A 45 Crankshaft bolt 182 Engine cover 3 Timing belt Timing belt front cover 11 Engine sup
22. 7 Removal steps pF 4 1 Engine coolant temperature gauge ki 8 Thermostat unit p C4 9 Water outlet fitting p E 4 2 Engine coolant temperature sensor 10 Thermostat housing 3 Water hose 11 Gasket 4 Water hose p B 12 O ring 5 Heater pipe p B 13 Water pipe 6 O ring Bq 14 O ring 7 Water inlet fitting p Ag 15 Water pump Mitsubishi Motors Corporation Feb 1997 PWEE9622 11A 7 2 6A1 ENGINE E W Water Pump and Water Pipe REMOVAL AND INSTALLATION lt MIVEC gt 23 Nm Removal steps Engine hanger Engine coolant temperature gauge unit Engine coolant temperature sensor 1 pF 2 3 4 Water hose 5 6 f pE Water hose Water inlet fitting Thermostat pDE Mitsubishi Motors Corporation Feb 1997 PWEE9622 18 Nm 6 6AE0280 Cq 8 Water outlet fitting 9 Thermostat housing 10 Gasket p B4 11 O ring p B 12 Water pipe pB 13 O ring pA 14 Water pump 6A1 ENGINE E W Water Pump and Water Pipe 11A 7 3 TN INSTALLATION SERVICE POINTS diameter pA SEALANT APPLICATION TO WATER PUMP bead sealant Specified sealant Mitsubishi Genuine Part No MD970389 or equivalent p B WATER PIPE O RING INSTALLATION 1 Wet the O ring with water to facilitate assembly Caution e Keep the O ring free of oil or grease e Securethe water pipe after the thermostat housing has been installed C lt q SEALANT APPLICATION TO WATER OUTLET SN FITTING diameter
23. ALLATION lt MIVEC gt ima 10 SS 13 0 e 10 Nm Apply engine oil to all moving parts before Installation 6AE0312 Removal steps pl 1 Oil pressure switch 10 Relief plug pH 2 Oil filter 11 Relief spring 3 Oil filter cover 12 Relief plunger 4 Drain plug p C4 13 Oil seal KE 5 Gasket B lt q 14 Oil pump case A PEW 6 Oil pan 15 O ring 7 Oil screen 16 Oil pump case cover 8 Gasket 17 Outer rotor 9 Buffle plate 18 Inner rotor Mitsubishi Motors Corporation Feb 1997 PWEE9622 6A1 ENGINE E W Oil Pump Case and Oil Pan 11A 13 3 7 m UIT AX al 6AE0087 3 mm diameter bead sealant Mitsubishi Motors Corporation Feb 1997 REMOVAL SERVICE POINT Ap OIL PAN REMOVAL 1 Knock the special tool deeply between the oil pan and the cylinder block 2 Hitting the side of the special tool slide the special tool along the oil pan to remove it INSTALLATION SERVICE POINTS DAM INNER ROTOR OUTER ROTOR INSTALLATION 1 Apply engine oil to the rotors Then install the rotors ensuring that the alignment dots made at disassembly are properly aligned pB SEALANT APPLICATION TO OIL PUMP CASE Specified sealant Mitsubishi Genuine Part No MD970389 or equivalent p C lt OIL SEAL INSTALLATION 1 Apply engine oil to the oil seal lip Using the special tool knock the oil seal into the oil pump case PWEE9622 11A 13 4 6A1 ENGINE E W Oil Pum
24. After tightening the bolts to the specified torque tighten them another 90 to 100 or 240 twice 120 The tightening method varies on different areas Observe the tightening method described observed e Areas where the bolts are in use 1 Cylinder head bolts 2 Main bearing cap bolts 8 Connecting rod cap bolts e Tightening Method in the text SEALANTS Item Specified sealant Quantity Water pump Mitsubishi Genuine Part No MD970389 or equivalent As required Water outlet fitting Mitsubishi Genuine Part No MD970389 or equivalent As required Engine coolant temperature sensor 3M Nut Locking Part No 4171 or equivalent As required Engine coolant temperature gauge unit 3M ATD Part No 8660 or equivalent As required Camshaft bearing 3M ATD Part No 8660 or equivalent As required Cam cap 3M ATD Part No 8660 or equivalent As required Oil control valve 3M ATD Part No 8660 or equivalent As required Camshaft holder Mitsubishi Genuine Part No MD970389 or equivalent As required Rocker cover 3M ATD Part No 8660 or equivalent As required Oil pump case Mitsubishi Genuine Part No MD970389 or equivalent As required Oil pan Mitsubishi Genuine Part No MD970389 or equivalent As required Oil pressure switch 3M ATD Part No 8660 or equivalent As required Oil seal case Mitsubishi Genuine Part No MD970389
25. B 6 Valve spring 16 Intake valve guide 7 Intake valve 17 Exhaust valve guide B 4 8 Retainer lock 18 Intake valve seat 9 Valve spring retainer 19 Exhaust valve seat p B 10 Valve spring 20 Cylinder head O Mitsubishi Motors Corporation Feb 1997 PWEE9622 6A1 ENGINE E W Cylinder Head and Valves 11A 12 3 MB991653 lt MIVEC gt MB991653 NN SS m E N QS sy ar di 1 1177 iiij lt MIVEC gt gt UNS lt gt Z MA AS EG MD998772 SIK MD998735 Mitsubishi Motors Corporation Feb 1997 REMOVAL SERVICE POINTS PRECAUTION FOR REMOVED PARTS Keep removed parts in order according to the cylinder number and intake exhaust side Ap CYLINDER HEAD BOLT REMOVAL 1 Using the special tool loosen the cylinder head bolts Loosen evenly little by little RETAINER LOCK REMOVAL 1 Store removed valves springs and other parts tagged to indicate their cylinder Nos and location for reassembly PWEE9622 11A 12 4 Mitsubishi Motors Corporation 6A1 ENGINE E W Cylinder Head and Valves Feb 1997 VALVE STEM SEAL REMOVAL 1 Do not reuse removed valve stem seals D VALVE HANDLING PRECAUTIONS 1 Sodium reacts violently with water or moisture generation heat and liberating hydrogen It must be handled with utmost care because otherwise the following dangerous conditions may result Loss of eyesight if s
26. I AIO Crankshaft Bearing identi fication mark Outer diameter mm Identifi cation mark Inner diameter mm Identifica tion mark 55 994 56 000 O 60 000 60 006 60 006 60 012 60 012 60 018 55 988 55 994 60 000 60 006 60 006 60 012 60 012 60 018 55 982 55 988 60 000 60 006 60 006 60 012 MDI OINI O N 60 012 60 018 2 Install the bearings having an oil groove to block OI AIO 05 N OI N the cylinder 8 Install the bearings having no oil groove to the bearing caps 4 Install the thrust bearings at the No 3 upper bearing with the grooved side toward the crank web PWEE9622 Crankshatt Cylinder Block Flywheel and 6A1 ENGINE E W Drive Plate 11A 15 3 mm Shank length Paint marks Mitsubishi Motors Corporation Feb 1997 pB BEARING CAP BEARING CAP BOLT 1 2 INSTALLATION Install the bearing caps so that their arrows are positioned on the timing belt side When installing the bearing cap bolts check that the shank length of each bolt meets the limit If the limit is exceeded replace the bolt Limit max 71 1 mm Apply engine oil to the threaded portion and bearing surface of the bolt Tighten the bearing cap bolts to 25 Nm torque in the tightening sequence Make a paint mark on the head of each nut Make a
27. Oil ring E 3 Connecting rod bearing MB pA 9 Piston pin D 4 Piston and connecting rod 10 Piston E 5 Connecting rod bearing 11 Connecting rod 6 Piston ring No 1 12 Bolt Mitsubishi Motors Corporation Feb 1997 PWEE9622 11A 14 2 6A1 ENGINE E W Piston and Connecting Rod REMOVAL SERVICE POINTS Ap CONNECTING ROD CAP REMOVAL 1 Mark the large end of the connecting rod with the cylinder Cylinder No number for use during reassembly PISTON PIN REMOVAL Piston pin setting tool MD998780 consists of the parts shown in the illustration at left 179mm To remove the piston pin Guide D MB991659 is also used in combination with the Piston pin setting tool Piston pin setting tool MD998780 Push rod C 9 Guide A 21 9 mm 1 Insert the Push Rod special tool into the piston from the side on which the front mark is stamped in the piston Push rod head and attach the guide D to the push rod end 2 Place the piston and connecting rod assembly on the Piston Pin Setting Base special tool with the front mark facing upward 3 Using a press remove the piston pin NOTE Keep the disassembled pistons piston pins and connecting rods in order according to the cylinder number KE A 5 en Ek EG R FLL Ke Pat s E SS Se ee lat tat Ze Ge SE NNN ee ENN Mitsubishi Motors Corporation Feb 1997 PWEE9622 6A1 ENGINE
28. P INSTALLATION 1 Apply sealant to the illustrated points of the camshaft holders Specified sealant part No 8660 or equivalent 2 Install the bearing caps and cam caps correctly according to the I intake and E exhaust marks as well as the stamped cap numbers and front marks 3 Tighten the bolts in the sequence of the numbers shown in the illustration Intake Front mark cU HC Ni Exhaust Cap No 6AE0308 Mitsubishi Motors Corporation Feb 1997 PWEE9622 6A1 ENGINE E W Rocker Cover and Camshaft lt MIVEC gt 11A 10 3 COIL CONTROL VALVE INSTALLATION 1 Apply the specified sealant to the area shown Specified sealant 3M ATD Part No 8660 or equivalent D SEMI CIRCULAR PACKING CAMSHAFT HOLDER INSTALLATION 1 Make sure that the retainer of each adjusting screw is fitted correctly Caution e If the protrusion on the retainer is not correctly fitted in the groove of the screw the pad could slip off the retainer 2 Apply 3 mm thick bead of foam in place gasket FIPG to the gasket surface of the camshaft holder Caution e Since the FIPG could cause blocking of engine oil passages be careful not to apply FIPG to other locations than specified Specified sealant Mitsubishi Genuine Part No MD970389 or equivalent 3 Install the semi circular packings 4 Raise the rocker arms until the rollers come into contact with the cams and install the
29. TION SERVICE POINTS p A CRANKSHAFT PULLEY BOLT INSTALLATION 1 Hold the flywheel or drive plate in position with the special tool before installing the crankshaft pulley bolts J IN W ef IN DEZ es AS A ia 9 EZ e ef p Li z Li E d MD998781 3 PWEE9622 Feb 1997 O Mitsubishi Motors Corporation 6A1 ENGINE E W Timing Belt 11A 4 1 4 TIMING BELT REMOVAL AND INSTALLATION lt SOHC gt 88 Nm 24 Nm 49 N 6AE0357 Removal steps 1 Timing belt front cover upper right B lt q 10 Auto tensioner 2 Timing belt front cover upper left 11 Crankshaft sprocket 3 Timing belt front cover lower 12 Sensing plate 4 Engine support bracket 13 Crankshaft spacer 5 Angle sensor DB 14 Camshaft sprocket bolt MA pCd 6 Timing belt 15 Camshaft sprocket 7 Tensioner pulley 16 Idler pulley 8 Tensioner arm 17 Timing belt rear cover center 9 Tensioner spacer 18 Connector bracket Mitsubishi Motors Corporation Feb 1997 PWEE9622 11A 4 2 6A1 ENGINE E W Timing Belt REMOVAL AND INSTALLATION lt MIVEC gt Removal steps 6AE0388 1 Timing belt front cover upper right 13 Crankshaft sprocket 2 Timing belt front cover upper left 14 Sensing plate 3 Timing belt front cover lower 15 Washer 4 Engine support bracket MB pAd 16 Camshaft sprocket bolt 5 Angle sensor 17 Camshaft sprocket 6 Angle sensor 18 Camshaft sprocket with sensin
30. and a torque wrench of 0 5 Nm to the tensioner pulley 10 Torque the tensioner pulley to 3 Nm with the torque wrench 11 While holding the tensioner pulley tighten the center bolt to specification 12 Turn the crankshaft clockwise 2 turns and let it stand for about 5 minutes 13 Make sure that the wire which has been inserted when installing the auto tensioner can be removed easily Belt tension should be acceptable if the wire can be easily removed Remove the wrench The belt tension can also be verified by checking the protrusion amount of the auto tensioner rod which should conform to the following Standard value 3 8 4 5 mm 14 If the wire cannot be removed easily or the rod protrusion is not up to specification repeat steps 9 through 12 to obtain the correct tension INSPECTION TIMING BELT Replace belt if any of the following conditions exist 1 Hardening of back rubber Back side is glossy without resilience and leaves no indent when pressed with fingernail PWEE9622 6A1 ENGINE E W Timing Belt Rounded edge Abnormal wear Fluffy strand Rubber exposed Tooth missing and canvas fiber exposed Mitsubishi Motors Corporation Feb 1997 2 9 4 5 6 7 8 Cracks on rubber back Cracks or peeling of canvas Cracks on tooth bottom Cracks or belt sides Abnormal wear of belt sides The sides are normal if they are sharp as if cut by a knife Abnormal wear
31. at all timing marks are aligned correctly Turn the crankshaft counterclockwise a quarter turn Turn back the crankshaft clockwise until the timing marks align again 9 Install the special tool and a torque wrench of 0 5 Nm to the tensioner pulley 10 Torque the tensioner pulley to Nm with the torque wrench 11 While holding the tensioner pulley tighten the center bolt to specification 12 Turn the crankshaft clockwise 2 turns and let it stand for about 5 minutes PWEE9622 11A 4 6 6A1 ENGINE E W Timing Belt gt D TIMING BELT INSTALLATION 1 Turn the crankshaft sprocket so that its timing mark will be away from the mating timing mark by approx three teeth Caution e f the timing marks are aligned the piston is brought to the TDC When the camshaft is turned under this condition the valves may interfere with the piston 2 Bring the timing marks of the camshaft sprockets as shown in the illustration Caution e If one of the camshaft sprockets on the right bank is turned with the timing mark on the other sprocket aligned there may be danger for the intake and exhaust valves to interfere with each other 3 Align the timing mark on the crankshaft sprocket with the mating timing mark and then turn the crankshaft counterclockwise by one tooth 4 Place the timing belt over the sprockets in the following method Caution e The camshaft sprockets on the right bank can turn very easily bec
32. ause of the valve spring tension Use care not to allow your fingers to get caught between the sprockets 1 Align the timing mark of the right bank exhaust camshaft sprocket with the mating timing mark and hold the timing belt on the sprocket with a paper clip 2 Align the timing mark of the intake camshaft sprocket and place the timing belt around that sprocket Then clip the belt at the location shown Caution e The camshaft sprockets can turn easily and do not give excessive tension to the timing belt 3 Place the timing belt around the idler pulley Mitsubishi Motors Corporation Feb 1997 PWEE9622 A Po ANY E AS MESS OS So O Mitsubishi Motors Corporation 6A1 ENGINE E W Timing Belt 11A 4 7 Feb 1997 4 On the left bank make sure that the timing marks of the camshaft sprockets are aligned and then hold the timing belt on these sprockets with paper clips Place the timing belt around the water pump pulley Place the timing belt around the crankshaft sprocket Place the timing belt around the tensioner pulley 5 Move the pulley the direction the arrow and hold it in raised position by tightening the tensioner pulley bolt 6 Check that all timing marks are aligned correctly Turn the crankshaft counterclockwise a quarter turn 8 Turn back the crankshaft clockwise until the timing marks align again 9 Install the special tool
33. eb 1997 PWEE9622 11A 0 2 NOTES Mitsubishi Motors Corporation Feb 1997 PWEE9622 6A1 ENGINE E W General Information GENERAL INFORMATION GENERAL SPECIFICATIONS Descriptions 6A12 6A13 Type 60 V OHV DOHC for each bank 60 V OHV SOHC for each bank Number of cylinders 6 6 Combustion chamber Pentroof type Pentroof type Total displacement dm 1 998 2 498 Cylinder bore mm 78 4 81 0 Piston stroke mm 69 0 80 8 Compression ratio 10 0 9 5 1 or 9 0 2 Intake valve Valve timing Opens BTDC 15 Low speed cam 37 5 High speed cam 15 Closes ABDC 41 Low speed cam 82 5 High speed cam 53 Exhaust valve Opens BBDC 41 75 Low speed cam High speed cam 53 Closes ATDC 15 30 Low speed cam High speed cam 15 Lubrication system Pressure feed full flow filtration Pressure feed full flow filtration Oil pump type Trochoid type Trochoid type Cooling system Water cooled forced circulation Water cooled forced circulation Water pump type NOTE 1 Europe and Hong Kong 2 GCC and Export Mitsubishi Motors Corporation Feb 1997 Centrifugal impeller type PWEE9622 Centrifugal impeller type 11A 0 3 6A1 ENGINE E W Specifications 11A 1 1 1 SPECIFICATIONS SERVICE SPECIFICATIONS
34. ecting rod bearing Identification mark Outer diameter mm Identification mark I 90 995 51 000 II 50 985 50 995 III 50 980 50 985 pF CONNECTING ROD CAP INSTALLATION 1 Mate the correct bearing cap with the correct connecting rod by checking with the alignment marks marked during disassembly If a new connecting rod is used which has no alignment mark position the notches for locking the bearing on the same side PWEE9622 11A 14 6 6A1 ENGINE E W Piston and Connecting Rod 2 Check if the thrust clearance in the connecting rod big end is correct Standard value 0 10 0 25 mm Limit 0 4 mm G lt q CONNECTING ROD CAP NUT INSTALLATION 1 Since the connecting rod bolts and nuts are torqued using a new procedure they should be examined BEFORE reuse If the bolt threads are necked down the bolts should be replaced Necking can be checked by running a nut with fingers to the full length of the bolt s thread If the nut does not run down smoothly the bolt should be replaced 2 Before installation of each nut apply engine oil to the threaded portion and bearing surface of the nut 3 Install each nut to the bolt and tighten it finger tight Then tighten the nuts alternately to install the cap properly 4 Tighten the nuts to a torque of 18 Nm 5 Make a paint mark on the head of each nut 6 Make a paint mark on the bolt at the position 90 to 100 fro
35. f the flywheel shown in the illustration The balance of the flexible flywheel is adjusted in an assembled condition Removing the bolt therefore can cause the flexible flywheel to be out of balance giving damage to the flywheel PWEE9622 11A 15 2 Crankshaft journal identification mark 6AE0343 Cylinder bore size gt mark reference No 4 No 2 Cylinder block bearing bore identification mark Timing belt side en 6 0344 Oil groove Sa Identification mark Groove Sa Identification mark 6AE0116 Mitsubishi Motors Corporation Feb 1997 Crankshaft Cylinder Block Flywheel and 6A1 ENGINE E W Drive Plate INSTALLATION SERVICE POINTS DAM CRANKSHAFT BEARING INSTALLATION 1 When replacing bearing select a one of proper size according to the identification marks stamped on both crankshaft and cylinder block lt 6A12 gt Crankshaft Journal Cylinder Block Bearing Bore Crankshaft Bearing Identi fication mark Outer diameter mm Identifi cation mark Inner diameter mm Identifica tion mark 52 994 53 000 O 57 000 57 006 57 006 57 012 57 012 57 018 52 988 52 994 57 000 57 006 57 006 57 012 57 012 57 018 lt 6A13 gt 52 982 52 988 Crankshaft Journal 57 000 57 006 57 006 57 012 MDI OINI O 57 012 57 018 Cylinder Block Bearing Bore O
36. g 7 Spacer plate A p D4 8 Timing belt 19 Idler pulley 9 Tensioner pulley 20 Timing belt rear cover left 10 Tensioner arm 11 Tensioner spacer p B 4 12 Auto tensioner Mitsubishi Motors Corporation Feb 1997 PWEE9622 Timing belt rear cover right Timing belt rear cover center Connector bracket 6A1 ENGINE E W Timing Belt 11A 4 3 REMOVAL SERVICE POINTS Ap TIMING BELT REMOVAL 1 Mark the belt running direction for reference in reinstallation 2 Loosen the bolt that secures the tensioner pulley to remove the timing belt 9 lt B gt CAMSHAFT SPROCKET BOLT REMOVAL 27 VEU e INSTALLATION SERVICE POINTS DAM CAMSHAFT SPROCKET BOLT INSTALLATION s SCH x Mitsubishi Motors Corporation Feb 1997 PWEE9622 MB990767 11A 4 4 6A1 ENGINE E W Timing Belt MD998754 Ge E SC I PB lt AUTO TENSIONER SETTING 1 Set the auto tensioner in a vice while making sure it Is not tilted 2 Slowly close the vice to force the rod in until the set hole A of the rod is lined up with the set hole B of the cylinder 3 Insert a 1 4 mm wire in the set hole 4 Remove the auto tensioner from the vice gt C TIMING BELT INSTALLATION 1 Turn the crankshaft sprocket so that its timing mark will be away from the mating timing mark by approx three teeth Caution e If the timing marks are aligned the piston is brought to the TDC When t
37. h and angle 3 After correcting the valve seat lap the valve and valve seat using lapping compound Then check the valve stem projection refer to VALVE SEAT in INSPECTION VALVE SEAT REPLACEMENT PROCEDURE 1 Cut the valve seat to be replaced from the inside to thin the wall thickness Then remove the valve seat 2 Rebore the valve seat hole in the cylinder head to a selected oversize valve seat diameter Intake valve seat hole diameter 0 3 O S lt SOHC gt 29 80 29 82 mm lt MIVEC gt 32 30 32 32 mm 0 6 O S lt SOHC gt 30 10 30 12 mm lt MIVEC gt 32 60 32 62 mm Exhaust valve seat hole diameter 0 3 O S lt SOHC gt 27 80 27 82 mm lt MIVEC gt 29 80 29 82 mm 0 6 O S lt SOHC gt 28 10 28 12 mm lt MIVEC gt 30 10 30 12 mm 3 Before fitting the valve seat either heat the cylinder head up to approximately 250 C or cool the valve seat in liquid nitrogen to prevent the cylinder head bore from galling 4 Correct the valve seat to the specified width and angle VALVE GUIDE REPLACEMENT 1 Force the valve guide out toward the cylinder block using a press 2 Machine the valve guide hole in the cylinder head to the size of the oversize valve guide to be installed Caution e Do not use the valve guide of the same size as the removed one Valve guide hole diameters in cylinder head 0 05 O S 11 05 11 07 mm 0 25 O S 11 25 11 27 mm 0 50 O S 11 50 11 52 mm PWEE9622 11A 1
38. he camshaft is turned under this condition the valves may interfere with the piston 6AE0329 2 Bring the timing marks of the camshaft sprockets as shown in the illustration Mitsubishi Motors Corporation Feb 1997 PWEE9622 A Gd 5 NE _MB990685 CW 2 DE S Gs Sas OG N ee Mitsubishi Motors Corporation 6A1 ENGINE E W Timing Belt 11A 4 5 Feb 1997 6AE0331 3 Align the timing mark on the crankshaft sprocket with that on the cylinder block side Fit the timing belt on the sprockets in the following order 1 Sel Fit the timing belt on the crankshaft sprocket and then while giving tension to the belt fit it on the water pump sprocket Fit the belt on the left bank camshaft sprocket Fit the belt on the idler pulley while keeping it tight Align the timing mark on the right bank camshaft sprocket with the mark on the cylinder block and then fit the belt on the camshaft sprocket Caution The camshaft sprockets are prone to rotate Avoid giving excessive tension to the timing belt when it is fitted Make sure that the left bank portion of the belt is not slack when the belt is fitted on the tensioner pulley If it is slack remove the belt and fit it again beginning with the first step Move the tensioner pulley in the direction of the arrow and hold it in raised position by tightening the tensioner pulley bolt Check th
39. he injector turns smoothly Caution e If the injector does not turn smoothly the O ring probably gets caught somewhere in the delivery pipe In such a case remove the injector and reinsert it into the delivery pipe Check it again for smooth rotation 5 On the right bank align the marks on the injector and delivery pipe GASKET INSTALLATION 1 Locate the projection on the gasket as shown PWEE9622 6A1 ENGINE E W Ignition System 11A 6 1 6 IGNITION SYSTEM REMOVAL AND INSTALLATION lt SOHC gt 25 Nm 6AE0374 Removal steps 1 Spark plug cable 2 Spark plug 3 Water cover kA 4 Distributor O Mitsubishi Motors Corporation Feb 1997 PWEE9622 11A 6 2 6A1 ENGINE E W Ignition System REMOVAL AND INSTALLATION lt MIVEC gt Removal steps 1 Spark plug cable 2 Ignition coil 3 Spark plug Alignment mark SOM NAL uer gt LU Mitsubishi Motors Corporation Feb 1997 6AE0406 INSTALLATION SERVICE POINT lt DISTRIBUTOR INSTALLATION 1 Turn the crankshaft clockwise to bring the No 1 cylinder piston to the compression stroke top dead center 2 Align the mark on the distributor housing with the mark on the coupling 3 Install the distributor while aligning the coupling key with the keyway in the camshaft end PWEE9622 6A1 ENGINE E W Water Pump and Water Pipe 11 7 1 7 WATER PUMP AND WATER PIPE REMOVAL AND INSTALLATION lt SOHC gt 6AE040
40. ing lash adjuster in rocker arm holder attime ofremoval and installation of rocker arm and rocker shaft assembly MD998713 Camshaft oil seal Installation of camshaft oil seal installer MD998716 Crankshaft wrench Rotation of crankshaft when installing piston and timing belt MD998717 Crankshaft front oil Installation of crankshaft front oil seal seal installer MD998719 Pulley holder pin Use with MB990767 2 MD998727 Oil pan remover Removal of oil pan Mitsubishi Motors Corporation Feb 1997 PWEE9622 6A1 ENGINE E W Special Tools 11A 2 3 Tool Number Name Use MD998735 Valve spring Compression of valve spring compressor MD998754 Pin Use with MB990767 MD998767 Tensioner pulley Adjustment of timing belt tension socket wrench MD998772 Valve spring Removal and installation of valve and related compressor parts MD998774 Valve stem seal Installation of valve stem seal installer MD998775 Valve stem seal Installation of valve stem seal installer MD998776 Crankshaft rear oil Installation of crankshaft rear oil seal seal installer Use with MB990938 MD998777 Camshaft oil seal Installation of camshaft oil seal installer adapter Mitsubishi Motors Corporation Feb 1997 PWEE9622 11A 2 4 6A1 ENGINE E W Special Tools Number Name Use MD998780 SETTING TOOL Piston pin Removal and installation of piston pin MD998781 Flywheel stopper Holding flywheel and dr
41. ipe INSTALLATION SERVICE POINTS diameter pA SEALANT APPLICATION TO WATER PUMP Specified sealant Mitsubishi Genuine Part No MD970389 or equivalent 4 page added here 6AE0067 gt B WATER PIPE O RING INSTALLATION 1 Wet the O ring with water to facilitate assembly Caution e Keep the O ring free of oil or grease e Secure the water pipe after the thermostat housing has been installed gt C SEALANT APPLICATION TO WATER OUTLET FITTING 3 mm diameter Specified sealant Mitsubishi Genuine Part No MD970389 or equivalent 6AE0068 gt D THERMOSTAT INSTALLATION 1 Install the thermostat so that the jiggle valve will be located in the thermostat housing as shown 6AE0069 gt E SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE SENSOR Specified sealant 3M Nut locking Part No 4171 or equivalent 6AE0070 lt Added gt Install the water pump and tighten the bolts 1 and 2 in that order Turn the pulley by hand and ensure that the impeller does not interfere with the cylinder block Tighten the bolts other than bolts 1 and 2 6AE0415
42. ive plate Mitsubishi Motors Corporation MD998784 Feb 1997 Valve spring compressor adapter PWEE9622 Compression of valve spring MIVEC Use with MD998772 6A1 ENGINE E W Drive Belt 11A 3 1 3 DRIVE BELT REMOVAL AND INSTALLATION lt SOHC gt 6AE0356 Removal steps 1 Drive belt 9 Tensioner pulley bracket B 2 Alternator 10 Adjusting stud 3 Oil level gauge dipstick 11 Adjusting bolt 4 Oil level gauge guide A 4 12 Crankshaft bolt 5 O ring 13 Special washer 6 Tensioner pulley 14 Crankshaft pulley 7 Engine hanger 15 Flange 8 Tensioner pulley bracket A 16 Engine cover Mitsubishi Motors Corporation Feb 1997 PWEE9622 11A 3 2 6A1 ENGINE E W Drive Belt REMOVAL AND INSTALLATION lt MIVEC gt 182 Nm 6AE0387 Removal steps 1 Drive belt 9 Tensioner pulley bracket B 2 Alternator 10 Adjusting stud 3 Oil level gauge dipstick 11 Adjusting bolt 4 Oil level gauge guide A 4 12 Crankshaft bolt 5 O ring 13 Special washer 6 Tensioner pulley 14 Crankshaft pulley 7 Engine hanger 15 Flange 8 Tensioner pulley bracket A 16 Engine cover Mitsubishi Motors Corporation Feb 1997 PWEE9622 11A 3 3 6A1 ENGINE E W Drive Belt REMOVAL SERVICE POINTS Ap CRANKSHAFT PULLEY BOLT REMOVAL 1 Hold the flywheel or drive plate in position with the special tool before removing the crankshaft pulley bolts Ns NANG e INSTALLA
43. m crankshaft pin and connecting rod bearing Cut the plastic gauge to the same length as the width of bearing and place it on crankshaft pin in parallel with axis Install the connecting rod cap carefully and tighten the bolts to specified torque Carefully remove the connecting rod cap Measure the width of the plastic gauge at its widest part by using a scale printed on the plastic gauge package Standard value 0 02 0 05 mm Limit 0 1 mm PWEE9622 Crankshaft Cylinder Block Flywheel and 6A1 ENGINE E W Drive Plate 11A 15 1 15 CRANKSHAFT CYLINDER BLOCK FLYWHEEL AND DRIVE PLATE REMOVAL AND INSTALLATION Removal steps Detonation sensor Idler pulley bracket lt M T gt Flywheel bolt lt M T gt Plate lt M T gt Adapter plate lt M T gt Flexible flywheel lt M T gt Adapter plate lt M T gt Drive plate bolt lt A T gt Adapter plate lt A T gt 10 Drive plate lt A T gt 11 Rear plate 12 Bell housing cover lt MIVEC gt p D4 13 Oil seal case BC 14 Oil seal 15 Bearing cap bolt pE Mitsubishi Motors Corporation Feb 1997 e Apply engine oil to all i moving parts before installation 6AE0394 B lt q 16 Bearing cap 17 Crankshaft bearing lower 18 Crankshaft 19 Thrust bearing p Ag 20 Crankshaft bearing upper 21 Cylinder block Caution On the flexible wheel equipped engines do not remove any of the bolts A o
44. m the paint mark made on the nut in the direction of tightening the nut 7 Give a 90 to 100 turn to the nut and make sure that the paint mark on the nut and that on the bolt are in alignment Caution e If the nuts are tightened by an angle of less than 90 they may not hold the caps with sufficient strength Ifa nut is tightened by an angle exceeding 100 completely remove all the nuts and carry out the installation procedure again from step 1 Mitsubishi Motors Corporation Feb 1997 PWEE9622 6A1 ENGINE E W Piston and Connecting Rod 11A 14 7 Z Push in by the piston yy aa Piston ring Mitsubishi Motors Corporation O Piston FING 7EN0476 Feb 1997 INSPECTION PISTON RING 1 Check the side clearance between the piston ring and ring groove If the limit is exceeded replace the ring or piston or both Standard value No 1 0 03 0 07 mm No 2 0 02 0 06 mm Limit No 1 0 1 mm No 2 0 1 mm Install the piston ring into the cylinder bore Force it down with a piston its crown being in contact with the ring to correctly position it at right angles to the cylinder wall Then measure the end gap with a feeler gauge lf the ring gap is excessive replace piston ring Standard value No 1 0 25 0 40 mm No 2 0 40 0 55 mm Oil 0 10 0 35 mm Limit No 1 No 2 0 8 mm Oil 1 0 mm CRANKSHAFT PIN OIL CLEARANCE PLASTIC GAUGE METHOD 1 Remove oil fro
45. o not reuse the valve stem seal e Always use the special tool to install the valve M stem seal If the seal is improperly fitted engine TX 2 oil may work its way down along the valve stem W BM Z NO 22 KEE 6AE0169 NN N RS UN N p B VALVE SPRING INSTALLATION retainer 1 Install the valve spring with the painted end on the rocker arm side Stem seal Spring seat RETAINER LOCK INSTALLATION 1 The valve spring if excessively compressed causes the bottom end of retainer to be in contact with and damage the stem seal e SS hs Se I Mitsubishi Motors Corporation Feb 1997 PWEE9622 11A 12 6 6A1 ENGINE E W Cylinder Head and Valves W wm 0 MIVEC gt gt gt AN MD998735 9EN0251 MB991614 Mitsubishi Motors Corporation Feb 1997 p D lt CYLINDER HEAD BOLT INSTALLATION 1 When installing the cylinder head bolts check that the shank length of each bolt meets the limit If the limit is exceeded replace the bolts Limit max 96 4 mm Install the washers as illustrated Apply engine oil to the bolt threads and washers Retighten the loosened bolts to a torque of 20 Nm in the specified tightening sequence 5 Make paint marks on the cylinder head bolts and cylinder head 6 Give a 120 turn to the bolts in the specified tightening sequence Caution e If the bolts are tightened by an angle of
46. odium gets in eyes Burns if sodium contact skin Fire hazard Handling of Sodium filled Exhaust Valves Sodium filled exhaust valves are not dangerous and may be handled in the same way as ordinary valves unless they are broken Never try to break the valves and expose sodium to the air When worn exhaust valves are to be discarded have them disposed of by a salvage company equipped with special disposal system notifying them that the valves contain sodium Should the exhaust valves be broken neutralize sodium using the method described below and discard the valves in the same way as ordinary valves How to Neutralize Sodium Place a container filled with more than 10 liters of water in a well ventilated large space Wear rubber gloves and goggles and carefully take out broken valves from the cylinder head Put a broken valve in the water filled container and quickly get away from the container at least 2 or 3 m PWEE9622 6A1 ENGINE E W Cylinder Head and Valves 11A 12 5 INSTALLATION SERVICE POINTS Stem seals p A VALVE STEM SEAL INSTALLATION for exhaust re s valves Black 1 Install the valve spring seat 2 Use the special tool to fit a new stem seal on the valve guide NOTE Valve stem seals for intake valves are different from those for exhaust valves They are identified by colors of their spring sections as follows Stem seals for intake valves Silver Stem seals for exhaust valves Black Caution e D
47. on Spring seating surface Mitsubishi Motors Corporation Feb 1997 VALVE SPRING 1 Measure the valve spring s free height If the measurement is less than specified replace the spring Standard value Limit mm mm 49 9 48 9 91 5 90 5 2 Measure the squareness of the spring If the measurement exceeds the specified limit replace the spring Standard value 2 or less Limit 4 VALVE SEAT 1 Assemble the valve then measure the valve stem projection between the end of the valve stem and the spring seating surface If the measurement exceeds the specified limit replace the valve seat Standard value Limit mm mm 48 45 48 95 48 40 48 90 VALVE GUIDE 1 Measure the clearance between the valve guide and valve stem If the limit is exceeded replace the valve guide or valve or both Standard value Intake 0 02 0 05 mm Exhaust 0 04 0 07 mm Limit Intake 0 10 mm Exhaust 0 15 mm PWEE9622 0 9 1 3 mm Valve seat height Oversize valve seat hole diameter Mitsubishi Motors Corporation 6A1 ENGINE E W Cylinder Head and Valves 11A 12 9 Feb 1997 VALVE SEAT RECONDITIONING PROCEDURE 1 Before correcting the valve seat check the clearance between the valve guide and valve If necessary replace the valve and or valve guide 2 Using the appropriate special tool or seat grinder correct the valve seat to achieve the specified seat widt
48. on teeth Missing tooth AUTO TENSIONER 1 Check for oil leaks If oil leaks are evident replace the auto tensioner Check the rod end for wear or damage and replace the auto tensioner if necessary Measure the rod projection length L If the reading is outside the standard value replace the auto tensioner Standard value L 12 mm Press the rod by a force of 98 to 196 N and measure the rod stroke If the measured value exceeds the standard value replace the tensioner Standard value 1mm or less PWEE9622 6A1 ENGINE E W Fuel and Emission Control Parts 5 FUEL AND EMISSION CONTROL PARTS REMOVAL AND INSTALLATION lt SOHC gt Removal steps Air intake plenum stay front Air intake plenum stay rear EGR valve Gasket Vacuum pipe Throttle body Gasket Air intake plenum Gasket Control harness Delivery pipe and injector ka O cO O O gt gt G N ech Mitsubishi Motors Corporation Feb 1997 PWEE9622 Insulator Insulator Injector Grommet O ring Fuel pipe 8 O ring Fuel pressure regulator O ring Delivery pipe Alternator bracket 11A 5 2 6A1 ENGINE E W Fuel and Emission Control Parts REMOVAL AND INSTALLATION lt MIVEC gt 12 Nm 3 6AE0390 Removal steps 1 Air intake plenum stay front 14 Control harness 2 Air intake plenum stay rear 15 Delivery pipe and injector 3 Vacuum pipe 16 Insulator
49. p Case and Oil Pan D lt q OIL PAN INSTALLATION lt SOHC gt 1 Clean the cylinder block and oil pan gasket application surfaces 2 Install the oil pan within 15 minutes after FIPG has been applied to the entire flange surfaces of the oil pan Specified sealant Mitsubishi Genuine Part No MD970389 or equivalent 6AE0366 4 mm diameter p E 4OIL PAN INSTALLATION lt MIVEC gt mQ bead sealant 1 Clean the cylinder block and oil pan gasket application surfaces 2 Install the oil pan within 15 minutes after FIPG has been applied to the entire flange surfaces of the oil pan Specified sealant Mitsubishi Genuine Part No MD970389 or equivalent F lt DRAIN PLUG GASKET INSTALLATION 1 Install the drain plug gasket in the shown direction Drain plug gasket Mitsubishi Motors Corporation Feb 1997 PWEE9622 6A1 ENGINE E W Oil Pump Case and Oil Pan 11A 13 5 G OIL COOLER INSTALLATION 1 Install the oil cooler with the oil cooler s positioning projection positioned against the rib on cylinder block H lt OIL FILTER INSTALLATION 1 Clean the surfaces of the cylinder block on which the oil filter is to be mounted 2 Apply engine oil to the O ring of the oil filter 3 Turn down the oil filter until the O ring contacts the cylinder block surface and then give the oil filter one more turn or tighten with a 16 Nm torque NOTE For MD135737 oil filter the tightening torque
50. port bracket 49 Angle sensor 9 Angle sensor connector bracket 11 Tensioner pulley 48 Tensioner arm 24 Auto tensioner 21 Camshaft sprocket bolt 88 Idler pulley 35 Timing belt rear cover 11 Angle sensor connector bracket 11 Fuel and emission control parts Air intake plenum stay 18 Connector bracket 11 EGR valve 22 Throttle body 12 Air intake plenum 18 Delivery pipe 12 Fuel pipe 9 Fuel pressure regulator 9 Alternator bracket 23 Mitsubishi Motors Corporation Feb 1997 PWEE9622 6A1 ENGINE E W Specifications 11A 1 5 Items Nm Ignition system Spark plug 25 Water cover SOHC 11 Distributor SOHC 13 Ignition failure sensor MIVEC 10 Condenser bracket assembly MIVEC 5 Ignition coil MIVEC 10 Water pump and water pipe Engine hanger MIVEC 11 Engine coolant temperature gauge unit 11 Engine coolant temperature sensor 29 Heater pipe SOHC 23 Water inlet fitting 18 Water outlet fitting 18 Thermostat housing 23 Water pipe 13 Water pump 23 Intake manifold and exhaust manifold Intake manifold 17 Heat protector 13 Exhaust manifold stay 44 Exhaust manifold 49 Rocker arm and camshaft lt SOHC gt Rocker cover 4 Rocker arm and rocker shaft 31 Thrust case 24 Rocker arm and camshaft lt MIVEC gt Rocker cover 4 Oil control valve holder 9 Cam cap 54 Bearing cap M6
51. r MD998440 5 After plunger has gone down somewhat 0 2 0 5 mm measure time taken for it to go down 1 mm Replace if measured time is out of specification Graduations 1mm MD998440 Standard value 4 20 seconds 1 mm Diesel fuel at 15 20 C Mitsubishi Motors Corporation Feb 1997 PWEE9622 6A1 ENGINE E W Rocker Cover and Camshaft lt MIVEC gt 11 10 1 10 ROCKER COVER AND CAMSHAFT lt MIVEG gt REMOVAL AND INSTALLATION Apply engine oil to all moving parts before installation 6AE0315 Removal steps pG 1 Rocker cover 8 Oil control valve 2 Rocker cover gasket kB 9 cap 3 Oil seal 10 Oil control valve holder 4 Circuit packing B lt q 11 Camshaft bearing cap 5 Oil seal 12 Arm spring holder 6 Camshaft holder 13 Arm spring 7 Semi circular packing pA 14 Camshaft Mitsubishi Motors Corporation Feb 1997 PWEE9622 11A 10 2 6A1 ENGINE E W Rocker Cover and Camshaft lt MIVEC gt INSTALLATION SERVICE POINT pA CAMSHAFT INSTALLATION 1 Intake valve camshaft and exhaust valve camshaft can be identified by their diameters at the portions indicated in the illustration Right bank Intake valve camshaft 25 mm camshaft Exhaust valve camshaft 30 mm Left bank camshaft 2 Before installing each camshaft apply engine oil to its journals and cams 3 The camshaft dowel pins must be positioned as shown in the illustration DBM CAMSHAFT BEARING CAP CAM CA
52. rect bored to oversize or replace 4 Using cylinder gauge measure the cylinder bore and cylindricity If worn badly correct cylinder to an oversize and replace piston and piston rings Measure at the points shown in illustration Standard value Cylinder LD 6A12 78 40 78 43 mm 6A13 81 00 81 03 mm Out of roundness and taper of cylinder bore 0 01 mm or less BORING CYLINDER 1 Oversize pistons to be used should be determined on the basis of the largest bore cylinder Piston size identification Size Identification mark 0 50 mm O S 0 50 1 00 mm O S 1 00 NOTE Size mark is stamped on piston top 2 Measure outside diameter of piston to be used Measure it in thrust direction as shown 3 Based on measured piston O D calculate boring finish dimension Boring finish dimension Piston O D Clearance between piston O D and cylinder 0 02 mm honing margin Mitsubishi Motors Corporation Feb 1997 PWEE9622 Crankshaft Cylinder Block Flywheel and 11A 15 6 GA1 ENGINE E W Drive Plate 4 Bore all cylinders to calculated boring finish dimension Caution e To prevent distortion that may result from temperature rise during honing bore cylinders working from No 1 No 2 No 3 No 4 No 5 and No 6 5 Hone to final finish dimension piston O D clearance between piston O D and cylinder 6 Check clearance between piston and cylinder Clearance between
53. s Corporation Feb 1997 PWEE9622 6A1 ENGINE E W Rocker Arm and Camshaft lt SOHC gt 11A 9 1 9 ROCKER ARM AND CAMSHAFT lt SOHC gt REMOVAL AND INSTALLATION 4 Nm 401 Removal steps Rocker cover Rocker cover gasket Oil seal Oil seal Rocker arm and rocker shaft Rocker arm and rocker shaft Rocker shaft spring Rocker arm A Rocker arm B Mitsubishi Motors Corporation Feb 1997 10 BBq 11 12 13 PB 14 15 16 A 17 PWEE9622 Apply engine oil to all moving parts before installation 6AE0336 Rocker arm shaft Lash adjuster Rocker arm C Rocker arm shaft Lash adjuster Thrust case O ring Camshaft 11A 9 2 6A1 ENGINE E W Rocker Arm and Camshaft lt SOHC gt he y Ke MD998443 A For right bank For left bank MD998442 MD998443 Lash adjuster amp NA Mitsubishi Motors Corporation Feb 1997 REMOVAL SERVICE POINT ROCKER ARMS AND ROCKER ARM SHAFTS REMOVAL 1 Before removing rocker arms and shafts assembly install the special tool as illustrated to prevent adjuster from dropping INSTALLATION SERVICE POINTS CAMSHAFT INSTALLATION 1 Apply engine oil to journals and cams of the camshaft before installation Be sure to install the correct camshafts on the correct bank Do not confuse the intake camshaft with the exhaust one pB LASH ADJUSTER INSTALLATION 1 Immerse the lash adju
54. s for other cylinders by turning every time the crankshaft through 120 60 In camshaft sprocket angle and following the above steps 2 through 8 Perform the adjustments in the following order of cylinder number No 2 No gt No 4 gt No 5 gt No 6 PWEE9622 6A1 ENGINE E W Rocker and Rocker Shaft Cap lt MIVEC gt 11 11 1 11 ROCKER ARM AND ROCKER SHAFT CAP lt MIVEC gt REMOVAL AND INSTALLATION Apply engine oil to all moving parts before installation 6AE0300 Removal steps pB 4 1 Rocker shaft cap 12 Wave washer 2 Seal cap A 13 Exhaust rocker arm assembly A 3 Seal cap C 14 Nut 4 Intake rocker arm assembly A 15 Adjusting screw 5 Nut 16 Exhaust rocker arm H 6 Adjusting screw 17 Piston H 7 Intake rocker arm H 18 Piston spring H 8 Piston H 19 Exhaust T lever L 9 Piston spring H p Ag 20 Spring guide 10 Intake T lever 21 Wave washer kA 11 Spring guide 22 Camshaft holder Mitsubishi Motors Corporation Feb 1997 PWEE9622 11A 11 2 6A1 ENGINE E W Rocker Arm and Rocker Shaft Cap lt MIVEC gt Y Sale INSTALLATION SERVICE POINTS vin e WO er p A lt 4 SPRING GUIDE INSTALLATION 1 Install the spring guide with the concave side toward the rocker arm The waved washer may be installed with either side out B ROCKER SHAFT CAP INSTALLATION ee d 1 Tighten the bolts in the sequence shown l aa Z ma 2 Make sure that each rocker arm moves smoothly
55. should be 14 Nm kl SEALANT APPLICATION TO SEALANT TO OIL PRESSURE SWITCH 1 Apply sealant to the threads of the switch Specified sealant 3M ATD Part No 8660 or equivalent Caution e Use care not to allow the sealant to plug the oil passage Oil passage INSPECTION OIL PUMP 1 Check the tip clearance Standard value 0 06 0 18 mm 2 Check the side clearance Standard value 0 04 0 10 mm Mitsubishi Motors Corporation Feb 1997 PWEE9622 11A 13 6 6A1 ENGINE E W Oil Pump Case and Oil Pan 3 Check the body clearance Standard value 0 10 0 18 mm Limit 0 35 mm f 7 E 6AE0090 OIL LEVEL SENSOR FOR EUROPE 1 Put the oil level sensor in the oil then move the float up and down with the oil at a temperature either lower than 40 C or higher than 80 C and check for continuity 40 C Float position Switch ON OFF Condition when down ON continuity Condition when up ON continuity 80 C Float position Switch ON OFF Condition when down OFF no continuity Condition when up ON continuity Mitsubishi Motors Corporation Feb 1997 PWEE9622 6A1 ENGINE E W Piston and Connecting Rod 11A 14 1 14 PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION 2 1 Apply engine oil to all moving parts before installation 6 095 Removal steps Gq 1 Nut p C4 7 Piston ring No 2 A KE 2 Connecting rod cap pB 8
56. ster in clean diesel fuel 2 Using the special tool air bleed wire move the plunger up and down 4 or 5 times while pushing down lightly on the check ball in order to bleed out the air 3 Insert the lash adjuster to rocker arm being careful not to spill the diesel fuel Then use the special tool to prevent adjuster from falling while installing it C lt ROCKER SHAFT SPRING ROCKER ARMS AND ROCKER ARM SHAFT INSTALLATION 1 Temporarily tighten the rocker shaft with the bolt so that all rocker arms on the inlet valve side do not push the valves 2 Fit the rocker shaft spring from the above and position it so that it is right angles to the plug guide NOTE Install the rocker shaft spring before installing the exhaust side rocker arms and rocker arm shaft PWEE9622 6A1 ENGINE E W Rocker Arm and Camshaft lt SOHC gt 11A 9 3 NOTE Install the rocker shaft spring before installing the exhaust side rocker arms and rocker arm shaft 3 Remove the special tool for securing the lash adjuster 4 Make sure that the notch in the rocker arm shaft is in the direction as illustrated D lt CAMSHAFT OIL SEAL INSTALLATION 1 When installing the left bank camshaft oil seal use the special tool to prevent interference with the knock pin INSPECTION CAMSHAFT 1 Measure the cam height lobe diameter and if the limit is exceeded replace the camshaft Standard value 35 20 mm
57. y any oil or water to the sealing locations or start the engine until a sufficient amount of time about one hour has passed after installation is completed The FIPG application procedure may vary on different areas Observe the procedure described in the text when applying the FIPG Mitsubishi Motors Corporation Feb 1997 PWEE9622 6A1 ENGINE E W Special Tools 2 SPECIAL TOOLS 11A 2 1 Tool Number Name Use MB990685 Torque wrench Adjustment of timing belt tension MB990938 Handle Use with MD998776 MB990767 Crankshaft pulley Holding camshaft sprocket when loosening holder and tightening of bolt Use with MD998719 MB991477 Valve adjusting Adjustment of valve clearance MIVEC wrench MB991478 Valve adjusting Adjustment of valve clearance MIVEC wrench feeler gauge set MB991479 Rocker arm Adjustment of valve clearance MIVEC piston checker MB991614 Angle gauge Tightening cylinder head bolt MB991653 Cylinder head bolt Tightening and loosening of cylinder head bolt wrench MB991659 Guide D Removal of piston pin Use with MD998780 Mitsubishi Motors Corporation Feb 1997 PWEE9622 6A1 ENGINE E W Special Tools Tool Number Name Use MD998440 Leak down tester Leak down test of lash adjuster MD998441 Lash adjuster Air bleeding of lash adjuster retainer MD998442 Air bleed wire Air bleeding of lash adjuster MD998443 Lash adjuster Retainer for hold

Mitsubishi 6A1 SERIES Automobile Parts User Manual

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