11-1 ENGINE CONTENTS ema SPECIFICATIONS . 2 Alternator Drive Belt Tension Inspection General Specifications ....... 2 and A|USIMEN ......ceeeseeeceseeecsees 88 Power Steering Oil Pump Drive Bett Service Specifications . Tension Inspection and Adjustment Sealants o ........ 34 SPECIAL TOOLS ... 5 Power Steering Oil Pump and Air Conditioner Compressor Drive Belt ENGINE <4G1>............ 7 Tension Inspection and Adjustment - .... 36 ‘SERVICE ADJUSTMENT PROCEDURES .... 7 Valve Clearance Inspection and Adjustment 35 Attemator Drive Belt Tension Inspection Ignition Timing Inspection and Adjustment . 36 ae NEE eee nel ele 7 Idle Speed Inspection .......... vs 38 ower Steering Oil Pump Drive Bel : Tension Inspection and Adjustment........ 7 ine ne. ey Pete eens ‘Air Conditioner Compressor Drive Belt a ota ieee te erence cede Tension inspection and Adjustment . - 8 Manifold Vacuum Inspection 38-1 Valve Clearance Inspection and Adjustment 9 Timing Belt Tension Adjustment 39 Ignition Timing Inspection end Adjustment . 10 Lash Adjusters Check <4G93> 40 Idle Speed Inspection 2 Basic le Speed eae Idle Mixture Inspection : a3 justment .............. Refer to GROUP 13 Compression Pressure Inspection .......... 18 CRANKSHAFT PULLEY .... 42 Manifold Vacuum inspection 16 : Timing Belt Tension Adjustment........... 18 CAMSHAFT AND CAMSHAFT OIL SEAL .. sisteteeeseetsesss 48 Basic Idle Speed Adjustment Refer toGROUP 13 CAMSHAFT AND CAMSHAFT OIL SEAL CADIS oe ecece eee teeeee 45 (CRANKSHAFT PULLEY . ”7 CAMSHAFT AND CAMSHAFT OIL SEAL...., 18 CLPAN «++ cae OIL PAN... eeeeeseeeeeeeeeeeeeeeerneees 20 CRANKSHAFT OIL SEAL ............00006. 22 CYLINDER HEAD GASKET ................ 24 ‘TIMING BELT ENGINE ASSEMBLY .. ENGINE <4G9>....... (© Mitabishi Motors Corporation Deo, 1958 Pwmestt7.0 CRANKSHAFT OIL SEAL ..........00005055 50 CYLINDER HEAD GASKET <4G92>......... 54 CYLINDER HEAD GASKET <4G93>......... 59 TIMING BELT <4G92>..........2.000000055 64 TIMING BELT <4G93> .. ENGINE ASSEMBLY <4G92> . ENGINE ASSEMBLY <4G93> .11-1-1 ENGINE <4D68> .. ‘SERVICE ADJUSTMENT PROCEDURES .... Drive Belt Tension Inspection and Adjustment Valve Clearance Inspection and Adjustment .... i Injection Timing Adjustment Engine Idle Speed Inspection and Adjustment . : Compression Pressure inspection Timing Bett Adjustment CAMSHAFT AND CAMSHAFT OIL SEAL... OIL PAN .. ; CRANKSHAFT FRONT OIL SEAL........... CRANKSHAFT REAR OIL SEAL ............ CYLINDER HEAD GASKET ............26.5 TIMING BELT AND TIMING BELT B ENGINE ASSEMBLY (© mitsubishi Motors Corporation Jun. 1082 79 81 82 Pwmtest17-811-1-2 NOTES © tmtsubis Motors Corporation Jun. 1952 PWMESTT?-A ‘ADDED11-2 ENGINE — Specifications SPECIFICATIONS GENERAL SPECIFICATIONS eno Items 4613 4G92 G93 4068 Number and avengornert of inde 4, intne 4, ining 4. intng 4, intne Total displacement me (cu.in.) | 1,299 (79.3) 1,897 (97.5) 1,834 (111.9) 1,998 (121.9) Bore x Stoke mmmin) | 710x820 | siox7s |sioxsso | 827 x 330 (2.80 x 3.23) (3.19 x 3.08) (3.19 x 3.50) (3.26 x 3.66) Compression rato 85 100 108 na Firing order 1-3-4-2 1-3-4-2 1-3-4-2 = Iniection order - = = |te-a2 Combustion chamber Pentroof type Pentroof type Pentroof type ‘Swirl type. Camshaft arrangement Single overhead | Single overhead | Double overhead | Single overhead camshaft camshaft camshaft camshaft Valve timing Intake, Open | BTDC 15° BIDC 14° BTOC 20° BTDC 20° BIG te Close | ABDC 53° ABDC 58° ABDC 60° ABDC 48° ABDC 42°" ‘Exhaust Open | BBDC 57° BBOC 52° BBDC 60° BBDC 54° B8De st Closed | ATDC 15° ATOC 16° ATOC 16° ATDC 22° ATDC 6°" Rocker arm Roller follower Roller follower Roller follower Roller follower ‘pe pe pe ype Lash adjuster Not equipped Not equipped Equipped Not equipped NOTE +: indicates specifications for MWV engines. (© Mitsubishi Motors Corporation Dee. 1898, PwMest17.0 eviseDENGINE — Specifications 11-3 SERVICE SPECIFICATIONS items 4613 4692 4693 4068 Standard value Drive beit deflection mn (in) ‘Altemator V-ribbed type ‘When checked 70-90 85-120 85-120 7.0-10.0 (028-035 =| (0.33-0.47) | 0.33-0.47) | (0.28-0.39) When @ new belt is installed | 5.5-7.0 70-88 70-85 60-70 (0.21-0.28 | (0.28-0.93) | (0.28-0.33) | (0.24-0.28) When a used belt is installed | 8.0 (0.31) 95 (0.37) 95 (0.37) 80-90 (0.31-0.35) Power steering oil pump When checked 55-75 95-115 95-115 55-80 (0.22-0.30) | (0.374-0.483)"' | (0.374-0.453)"" | (0.22-0.39) When @ new belt is installed | 40-55 75-90 75-90 45-55 (0.16-0.22) (0.295-0.364)*" | (0.295-0.354)*" | (0.18-0.22) When @ Used belt is installed | 6.5-7.5 95-115 95-115 60-70 (0.22-0.30) | (0.374-0.45a)"" | (0.374-0.453)"" | (0.24-0.28) Air conditioner compressor When checked 6.0-7.0 - - 7.0-8.0 (0.24-0.28) (0.28-0.31) When a new belt is installed | 5.0-6.0 - - 50-60 (0.20-0.24) (0.20-0.24) When a used belt is installed | 6.0-7.0 - - 7.0-80 (0.24-0.28) (6.28-0.31) Power steering oil pump and air conditioner compressor ‘When checked - 68-76 68-76 - (0.268-0.299) | (0.268-0.299) When a new belt is installed - 55-60 55-60 - 40.217-0.236) | (0.217-0,236) When a used belt is installed - 68-76 68-76 - (0.268-0.289) | (0.268-0.209) Basic ignition timing S°BTDC + 2° | S°BTDC + 2° | S*BTDC + 2° — Injection timing = = - ATC Idle speed min. | 750 * 100 800 + 100 800 + 100 750 & 100 700 £ 100? CO concentration and HC concentration at idle CO concentration % | 0.5 or less 0.5 oF loss, 0 or less - HC concentration ppm | 100 or less, 100 or tess 100 or less - Compression pressure kPa (kgler®, psi) (250-400 r/min.) | 1400 (14.0, 199) | 1480 (14.5, 206) | 1600 (15.0, 213) | 3500 (36.0, 49.8) Intake manifold vacuum kPa (kafor’ Approx. 71 ‘Approx. 67 Approx. 67 = (630, 21) (600, 20) (600, 20) Valve clearance (at hot) mm find Intake 0.200.008 | 0.20 (0.008) - 0.25 (0.010) Exhaust 0.25 (0.010) | 0.300.012) = 0.25 (0.010) Timing belt tension man fin) = 3311.30) = 4-5 (0.16-0.20) (© Mansubishi Motors Comorstion Dee. 1995 Revise11-4 ENGINE. Specifications tems 4g13 4G92 4G93 4D68 Limit ‘Compression pressure KPa (kg/om?, psi} (250-400 r/min.) | min. 1000 min, 1100 min. 1150 min, 2560 (10.0, 142) (11.0, 156) (11.5, 164) (25.6, 364) Compression pressure difference of all cylinder kPa ikg/cm?, psi) | max. 100 (1.0, 14}] max. 100 (1.0, 14)] max, 100 (1.0, 14}] max. 300 (8.0, 43) NOTE ‘*: indicates specifications for vehicles without air conditioner. +) indicates specifications for MVV engines SEALANTS Engine _| items Specified sealant Remarks ' MITSUBISHI GENUINE PART | Somi-drying sealant fe Oil pan and cylinder block MD997170 or equivalent 269 Semi-circuler packing and rocker | 3M ATD Part No. 8680 or equiv- cover seal, end cylinder head | alent seal Oil pan and eylinder block MITSUBISHI GENUINE PART | Semi-rying sealant MD970389 or equivalent Flywheel assembly or _ | 3M Stud locking 4170 or equiva~ drive plate mounting bolt | lent threads. Thermostat case assembly and} MITSUBISHI GENUINE PART | Semi oo : & sub assembly Reading of engine rer ROM pack (for rmultiuse tester) eS For the number, refer to GROUP 00 Precautions Belore Service MBe91502.— MUTA sub “ olo a Pax essembly Reading of engine rom ROM pack ‘eso? {© tab Aetore Corporation Dee. 188 Poe neveENGINE - Special Tools 11-6-1 Application Tool Number Name Use: AG1 | 4G9 | 406 GENERAL SER- Cylinder head bolt | Loosening and tightening of oO a MICE TOOL Wwrenen cylinder heed bot GENERAL Wectenichang- | Sipporing engine assemawy | © | © | © SERVICE er, engine when removing and instal TOOL, ling transmission MZ203827 MD938389 Pre-stroke Adjusting injection timing °o Imeosunng eater mib938364 Camshaft oil seal __| Installation of camshaft oil ° installer seal MD998383 ‘Crankshaft front oil | Installation of crankshaft oO ‘seal guide front oil seal ‘MD998382 ‘Crankshaft front oil ‘seal installer ‘MD998781 Flywheel stopper | Securing the flywheel O}0|/o ohio erate Sommosnincaranin ne rns 9 reusen11-6-2 NOTES © Mitsubishi Motore Conporation sun. 1992 wnatENGINE <4G1> - Service Adjustment Procedures 11-7 700 N (10 kg, 22 i Crankshaft pulley Alternator pulley eves ‘Aduusting bat (© MitsubishiMotors Corporation Dee. 1991 ENGINE<4G1> SERVICE ADJUSTMENT PROCEDURES ALTERNATOR DRIVE BELT TENSION INSPECTION AND ADJUSTMENT enFOEM ALTERNATOR DRIVE BELT TENSION INSPECTION Check the tension by pulling or pushing at the centre of the belt, between pulleys with a force of 100 N (10 ka, 22 Ibs.) as shown, in the figure, Measure drive belt deflection amount. Standard value: 7.0-9.0 mm (0.28-0.35 in.) ALTERNATOR DRIVE BELT TENSION ADJUSTMENT (1) Loosen the nut of the alternator pivot bolt. (2) Loosen the lock boit. 3) Turn the adjusting bolt to adjust the amount of belt deflec- tion to the standard value. ‘Standard value: Hf used belt (with correct tension) is used; 8.0 mm (0.31 in) Ianew beltisused; _ 5.5-7.0 mm (0.22-0.28 in.) (4) Tighten the lock bolt Tightening torque: 12-15 Nm (1.2-1.5 kgm, 9-11 ft.lbs.) (6) Tighten the nut of the alternator pivot bolt, Tightening torque: 20-25 Nm (2.0-2.5 kgm, 14-18 ft-lbs.) POWER STEERING OIL PUMP DRIVE BELT TEN- SION INSPECTION AND ADJUSTMENT POWER STEERING OIL PUMP DRIVE BELT TENSION IN- ‘SPECTION Check the tension by pulling or pushing at the centre of the belt between pulleys with a force of 100 N (10 kg, 22 Ibs.). Measure drive belt defiection amount Standard value: 5.5-7.5 mm (0.22-0.30 in.)11-8 ENGINE <4G1> - Service Adjustment Procedures Water pump pulley Power steering oil pump pulley © mtsubishimotors Corporation Dee. 1951 POWER STEERING OIL PUMP DRIVE BELT TENSION AD- JUSTMENT (1) Loosen power steering oil pump fixing bolt (2) Move power steering oil pump, tension belt moderately and adjust tension. Standard value: If used belt (with correct tension) is used; 5,5-7.5 mm (0.22-0.30 in.) Ifa new belt is used; 4.0-5.5 mm (0.16-0.22 (3) Tighten fixing bolt, Tightening torque: 40 Nm (4.0 kgm, 29 ft.lbs.) (4) Check belt tension and adjust if necessary. AIR CONDITIONER COMPRESSOR DRIVE BELT TENSION INSPECTION AND ADJUSTMENT AIR CONDITIONER COMPRESSOR DRIVE BELT TENSION INSPECTION Check the tension by pulling or pushing at the centre of the belt between pulleys with a force of 100 N (10 kg, 22 Ibs). Measure drive belt deflection amount. Standard value: 6.0-7.0 mm (0.24-0.28 in.) AIR CONDITIONER COMPRESSOR DRIVE BELT TENSION ADJUSTMENT (1) Loosen tension pulley fixing nut A. (2) Agjust belt tension with adjusting bolt B ‘Standard value: if used belt (with correct tension} is used; 6.0-7.0 mm (0.24-0.28 in.) Ifa new belt is used; 5.0-6.0 mm (0,20-0.24 in.) (3) Tighten fixing nut A. (4) Check the belt tension after driving, Standard value: 6.0-7.0 mm (0.24-0.28 pwmestt7ENGINE <4G1> - Service Adjustment Procedures 11-9 VALVE CLEARANCE INSPECTION AND ADJUSTMENT row (1) Start the engine and allow it to warm up untilthe engine coo!- ant temperature reaches 80 to 96°C (176 to 203°F). (2) Remove all spark plugs from the cylinder head for easy in- spection. (3) Remove the rocker cover. (4) Turn the crankshaft clockwise until the notch on the pulley is lined up with the “T" mark on the timing indicator. T Timing indicator (5) Move the rocker arms on the No. 1 and No. 4 cylinders up ‘and down by hand to determine which cylinder has its piston at the top dead centre on the compression stroke. if both intake and exhaust valve rocker arms have a valve lash, the piston in the cylinder corresponding to these rocker arms is at the top dead centre on the compression stroke. (6) Valve clearance inspection and adjustment can be per- formed on rocker arms indicated by white arrow {when the No. 1 cylinder piston is at the top dead centré’on the ‘compression stroke, and on rocker arms indicated by solid arrows § when the No. 4 cylinder piston is at the top dead centre on the compression stroke. No.1 No.2 No.3 No.4 (7) Measure the valve clearance. If the valve clearance is not as specified, loosen the rocker arm lock nut and adjust the clearance using a feeler gauge while turning the adjusting screw. ‘Standard value (hot engine): Intake valve 0.20 mm (0.008 in.) Exhaust valve 0.25 mm (0.010 in.) cc) While holding the adjusting sorew with a screwdriver to pre- vent it from turning, tighten the lock nut securely. {© Mitsubishi Motors Corporation Jon. 1092 PUMESHT7-A sevisen11-10 ENGINE <4G1> - Service Adjustment Procedures Paper clip CoMieubiehi Motors Corporation Dee 1988 (9) Tum the crankshaft through 360° to line up the notch on the crankshaft pulley with the “T” mark on the timing indicator. (10) Repeat steps (7) and (8) on other valves for clearance adjust- ment. (11) Install the rocker cover. (12) Install the spark plugs and tighten to the specified torque. Tightening torque: 25 Nm (2.5 kgm, 18 ft.lbs.) IGNITION TIMING INSPECTION AND ADJUSTMENT enups (1) Before inspection and adjustment set vehicle in the follow- ing condition. © Engine coolant temperature: 80-95°C (176-203°F) © Lamps, electric cooling fan and all accessories: OFF © Transmission: Neutral Insert a paper clip into the 1 pin connector (blue) as shown in the illustration at left. (2) (3) Connect a primary-voltage-detection type of tachometer to ‘the paper clip. NOTE Do not use the multi-use tester (MUT) or MUTI. If tested with the MUT or MUT-II connected to the diagnosis. connector, the ignition timing will not be the basic timing but be ordinary timing. (4) Set up a timing light. (6) Start the engine and run at ial. (6) Check that engine idle speed is within the standard value. Standard value: 750: 100 r/min, unest17.0 eviseDENGINE <4G1> - Service Adjustment Procedures 11-11 (7) Turn the ignition switch to OFF. (8) Remove the waterproof connector from the ignition timing \ontion TAR adjustment connector (brown). adjustment (9) Connect the jumper wire with the cfip to the ignition timing connector adjustment terminal, and earth this to the body as illus- Bown ated. CEI Lee] NOTE ee Grounding this terminal sets the engine to the basic ignition ‘J timing. (10) Start the engine and run it at idle. (11) Check that basic ignition timing is within the standard value. ‘Standard value: 5° BTDC +2° (12) f not within the standard value, loosen distributor fixing nut and adjust by rotating distributor body, (13) Tighten mounting nut after adjusting, Tightening torque: 12 Nm (1.2 kg, 9 ft-lbs.) JENo124 (14) Stop the engine, remove the jumper wire from the ignition timing adjustment connector (brown), and return the con- Rector to its original condition (15) Start the engine and check that ignition timing at the stan- dard value. Standard value: Approx. 10° BTDC NOTE 1. Ignition timing is variable within about +7°, even under normal operating, 2. Anditis automatically further advanced by about 5°from 10° BTDC at higher altitudes. (16) Sealing tape is to be attached to the fixing nut only for ve- hicles for Switzerland NOTE Sealing tape is attached to all vehicles when new. © Mitsubishi Motors Corporation Dec. 1984 Pwmeon711-12 ENGINE <4G1> - Service Adjustment Procedures IDLE SPEED INSPECTION aro (1) Before inspection and adjustment set vehicles in the follow- ing condition. ‘© Engine coolant temperature: 80-95°C (176-203°F) Lamps, electric cooling fan and all accessories: OFF © Transmission: Neutral (2) Check the basic ignition timing. Adjust if necessary. Standard value: 5° BTDC + 2° () After turing the ignition switch to OFF, connect the multi- use tester (MUT) or MUT-II to the diagnosis connector. (4) Start the engine and run it at idle. (6) Run the engine at idle for 2 minutes. (6) Check the idle speed, Curb idle speed: 7504100 r/min. NOTE The idle speed is adjusted automatically by the idle speed control (ISC) system. 7) If there isa deviation from the standard value, refer to GROUP 13-Check Chart Classified by Problem Symptoms, and check the MPI components. IDLE MIXTURE INSPECTION (1) Before inspection, set vehicles in the following condition: Engine coolant temperature: 80-95°C (176-203°F) © Lamps, electric cooling fan and all accessories: OFF ® Transmission: Neutral (2) Check that the basic ignition timing is within the standard value ‘Standard value: 5° BTDC + 2° (3) After turning the ignition switch to OFF, connect the multi- use tester (MUT) or MUTI to the diagnosis connector. (4) Start the engine end run it at 2,500 r/min. for 2 minutes. (8) Set the CO, HC tester. (6) Check the CO concentration and the HC concentration at idle. ‘Standard value CO concentration: 0.5% or less HC concentration: 100 ppm or less © MieubishiMotors Corporation Dee. 1888 Pwiteot7.0 REVISEDENGINE <4G1> - Service Adjustment Procedures 11-13 (7) If there is @ deviation from the standard value, check the following items: © Diagnosis output © Closed-loop control (When the closed-loop control is carried out normally, the output signal of the oxygen sensor changes between 0-400mV and 600-1,000mV atidle) Combustion pressure Injector Ignition coil, spark plug cable, spark plug Evaporative emission control system © Compression pressure NOTE Replace the three way catalyst when the CO and HC concentrations do not remain inside the standard value, even though the result of the inspection is normal on all items. COMPRESSION PRESSURE INSPECTION ENtFoAO, (7) Before inspection, check that the engine oil, starter and bat- tery ate normal. Also, set the vehicle to the following condi- tion: © Engine coolant temperature: 80-95°C (176-203°F) © Lamps, electric cooling fan and all accessories: OFF © Transmission: Neutral {2) Disconnect the spark plug cables. (3) Remove all of the spark plugs. (4) Disconnect the distributor 6 pin connector, NOTE Doing this will prevent the engine control unit from carrying out ignition and fuel injection. (G) Cover the spark plug hole with a rag etc., andafterthe engine has been cranked, check that no foreign material is adhering to the rag. Caution 1. Keep away from the spark plug hole when cranking. 2. compression is measured with water, oil, fuel, etc., that has come from oracks inside the cylinder, these materials will become heated and will gush out from the spark plug hole, which is dangerous. {6} Set compression gauge to one of the spark plug holes. (7) Crank the engine with the throttle vaive fully open and mea- sure the compression pressure. Standard value (at engine speed of 250-400 r/mi 1400 kPa (14.0 kg/cm?, 199 psi) Limit (at engine speed of 250-400 r/min.): min. 1000 kPa (10.0 kg/em?, 142 psi) ‘© Mksubishi Motors Corporation Dec. 1655 pwneest37.0 revise11-14 ENGINE <4G1> - Service Adjustment Procedures (8) Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are be- low the limit. Limit: max. 100 kPa (1.0 kg/cm?, 14 psi) (9) If there is a cylinder with compression or a compression dif- ference that is outside the limit, pour a small amount of en- gine oil through the spark plug hole, and repeat the opera- tions in steps (7) and (). © Ifthe compression increases after oil is added, the cause ‘of the malfunetion is a worn or damaged piston ring and/ ‘or cylinder inner surface. ® If the compression does not rise after oil is added, the ‘cause is a burnt or defective valve seat, or pressure is leaking from the gasket. (10}Connect the distributor connector. (11)install the spark plugs and spark plug cables. (12)Use the multi-use tester (MUT) or MUFAII to erase the setf- diagnosis codes, NOTE This will erase the problem code resulting from the distribu- tor connector being disconnected. © Mitaubiahi Motors Corporation Dee 1050 Pwntest17.0 ReviseENGINE <4G1> - Service Adjustment Procedures 11-15 MANIFOLD VACUUM INSPECTION enewep, (1) The vehicle should be repaired as follows before the inspec- tion, Engine coolant temperature: 80-95°C (176-203°F) © Lamps, electric cooling fan, and accessories: OFF © Transmission: Neutral (2) Connect the multi-use tester (MUT) or MUT-. (3) Disconnect the vacuum hose from the nipple for taking off fuel pressure regulator vacuum from the air intake plenum. (4) Connect a three-way joint between the removed vacuum, hose and the nipple and connect a vacuum gauge to the joint. (©) Start the engine and check that idle speed is within the stan- dard value range. (6) Check the manifold vacuum. Standard value: Approx. 71 kPa (530 mmHg, 21 in.Hg) TIMING BELT TENSION ADJUSTMENT. enrrar The timing belt has an automatic tension adjusting mechanism. Adjustment can be made by the following procedure. (1) Remove the water pump pulley. (2) Remove the air conditioner pulley bracket. (3) Remove the timing belt upper cover. (4) Remove the timing belt lower cover. (5) Remove the spark plugs. (6) Tum the crankshaft clockwise to check that the timing belt is okay over its entire length. Caution Always turn the crankshaft clockwise. a ‘Turn the crankshaft clockwise to bring the No. 1 cylinder pis- ton to the top dead centre on the compression stroke. Caution For aligning the timing marks, never turn the crankshaft counterclockwise as it could cause inadequate belt ten- ° sioning. Timning mark Timing mark ten0004| ‘© Miuubichi Motors Corporation Das. 1983 Pwrmest77-D eviseD11-16 Two sprocket teeth| 1210020] ‘orvorsa 11/4 of bolt heed width 010153 (© mitsubishi Motors Corporation Dec. 1801 ENGINE <4G1> - Service Adjustment Procedures (8) Loosen both pivot side and slot side tensioner bolts and ten- sion the belt, making use of the tensioner spring force. (9) Turn the crankshaft clockwise by.two sprocket teeth (18°) (10) Push the timing belt tensioner in the direction of the arrow to check that each sprocket is Kept in firm and complete en- gagement with the belt cogs. ‘After this check, release hand pressure so that only the ten- sioner spring acts on belt and tighten the slot side bolt and then the pivot side bolt to fix the tensioner in position. (11) Check the timing belt tension. Hold the timing belt tensioner and timing belt together by hand and give the belt slight thumb pressure ata pointlevel with tensioner centre. Make sure that the belt cog crest de- flects approximately 1/4 of the tensioner attaching bolt head width. (12) Install the spark plugs. (13) Install the timing belt lower cover. (14) install the timing belt upper cover. (15) install the air conditioner pulley bracket. (1)install the water pump pulley and-adjust the drive belt deflection. Pwncor7ENGINE <4G1> - Crankshaft Pulley CRANKSHAFT PULLEY REMOVAL AND INSTALLATION Pre-removal and Installation Operation Je" Removal and Installation of Under Cov- Removal steps © Drive belt tension adjustment (Reter to P11-7) 1. Drive belt (Air conditioner 2: Drive belt (Power steering) 3° Drive belt (Alternator) 984-4. Crankshaft compressor pulley ‘Air conditioner) 494. 5. Crankshaft pulley. 11-17 70-1901 Brats. ‘© Mineubishi Motors Corporation SERVICE POINTS OF REMOVAL AND INSTALLA- TION 4, REMOVAL AND INSTALLATION OF CRANKSHAFT COM- PRESSOR PULLEY / 5. CRANKSHAFT PULLEY Caution 1. This drive belt will get damaged. Do Not use the en- gine’s drive belt. 2. Never use a damaged drive belt. Pwncon?1 CAMSHAFT AND CAMSHAFT OIL SEAL ewe REMOVAL AND INSTALLATION 8 ENGINE <4G1> - Camshaft and Pre:zemoval and Post installation Op- eratio o Remove gre Intalation of Tring Blt (Refer to 11-2 Renova and instalation of Distributor (Fifer to GROUP 16~ Distibuion Lip section . ‘ornoo42 Engine oil o orso1s Removatsteps 1. Rocker cover 2. Camshaft sprocket e994 3 Cilseal * Vale clearance jnapgction and aust ment (Refer to P:11-9. 4, Roceramm assembly 4 5 Camshatt SERVICE POINTS OF REMOVAL enen0 2. REMOVAL OF CAMSHAFT SPROCKET (© Mikaubis Motors Corporation Dee. 2007 wnees117ENGINE <4G1> - Camshaft and Camshaft Oil Seal 11-19 SERVICE POINTS OF INSTALLATION exioae 5. INSTALLATION OF CAMSHAFT (1) Position the dowel pin of the camshaft as shown in the ilustration, MD 998306 Ciseat 3. INSTALLATION OF OIL SEAL 0998307 (1) Install the special tool, Guide on the camshaft. (2) Apply oil to the oil seal and insert the oil seal along the Guide until it contacts the cylinder head. (3) Using the special tool, Installer, press-fit the cil seal into ‘the cylinder head. Comshatt venase| (© Miteubichi eters Corporation Dee. 1891 ‘pente911711-20 ENGINE <4G1> - Oil Pan OIL PAN e1tKa REMOVAL AND INSTALLATION Pre-removel and Post-installation Op- ration Draining and Supaiving of Engine Oil ‘© Removal and Installation of Oil Level ge ‘¢ Removal and Installation of Front Ex- haust Pipe (Refer to GROUP 15 ~ Ex: haust Pipe and Muffler) Specified sealant: MITSUBISHI ~ GENUINE PART No, MD897110 or equivalent H | o1s00st Removal steps 08 kom 1. Bell housing cover oe 2. Drain plug be 3 Gasket 496 4 Oilpan paar ‘ower ) SERVICE POINTS OF REMOVAL sane | 4, REMOVAL OF OIL PAN = sz After removing the oil pan mounting bolts, remove the oil pan with the special tool and a brass bar. Caution Perform this slowly to avoid deformation of the oil pan 4 flange. (© Mitsubishi Motors Corporation Dee. 1891 pwnee9117ENGINE <4G1> - Oil Pan 11-21 SERVICE POINTS OF INSTALLATION exo 4. INSTALLATION OF OIL PAN Caution After cleaning the oil pan mounting bolt holes in the oil seal case, the oil pan should be installed. 2. INSTALLATION OF GASKET Replace the gasket with a new gasket, and install it in the Dain plug) direction shown in the illustration. gasket il pan side enoa07 (© tMtaubishi Motors Corporation Dee. 1991 pwntesii711-22 ENGINE <4G1> — Crankshaft CRANKSHAFT OIL SEAL enue. REMOVAL AND INSTALLATION Pre removal and Post installation Op- eration }@ Romoval and instalation of Oil Pan (eter to 11-20) J*_ Romoval and insiallaton of Tansmis- Lip section sion Assembly (Refer to GROUP 22 or » Lip section 23~ Transmission Assombiy) commooea| moo '¢ Removal and installation of Clutch Cov- or and Disc Engine oit Engine oil 130-140 Nm 3-1.4 kam felbs. 400 orsor0 Removal steps of crankshaft front oil seal “1. Crankshaft sprocket 4 2. Crankshaft front oil seal Removal steps of crankshaft rear oil seal 4% 3. Flywheel assembly or drive plate 4 4. Crankshaft rear oil seal ‘Deubichi Motors Corporation Dee 1991 annestt7ENGINE <4G1> — Crankshaft Oil Seal ol Cylinder Seal ~$> block side ® > Oil seal Oil seat © MitsubishiNtotors Corporation Jan. 1908 11-23 SERVICE POINTS OF REMOVAL enusar 3. REMOVAL OF FLYWHEEL ASSEMBLY OR DRIVE PLATE (1) Fix the crank shaft pulley by using the V-ribbed belt and the special tool Caution (1) Because the V-ribbed belt installed in the vehicle may be damaged, use a disused V-ribbed belt. (2) Do not use a damaged V-ribbed belt. (2) Remove the flywheel assembly or the drive plate SERVICE POINTS OF INSTALLATION enUCAL 4, INSTALLATION OF CRANKSHAFT REAR OIL SEAL (1) Apply a small amount of engine oil to the entire circum- ference of the oil seal ip. (2) Tap the oil seal as shown in the illustration unti itis flush with the oil seal case. 2. INSTALLATION OF CRANKSHAFT FRONT OIL SEAL (1) Apply @ small amount of engine oil to the entire circum- ference of the oil seal lip. (2) Tap the oil seal until itis flush with the oil seal case. pwnne9117.8 Revise11-24 ENGINE <4G1> — Cylinder Head Gasket CYLINDER HEAD GASKET REMOVAL AND INSTALLATION [Pre-removal Operation Je" Reduce the Inner Pressure of Fuel Line| and Hose (Refer to GROUP 13 ~ Ser- ioe Adjustment Procedures.) Pos 'st-installation Operation Installation of Air Intake Hoso (Refer to GROUP 15 - Air Cleaner) Refiling the Engine Oil Je. Draining the Engine Coolant '® Refiling the Engine Coolent Je Draining the Engine Oi '® Agjusting the Accolorator Cable (Refer Je Removal of Air Intake Hose (Refer to to GROUP 13 ~ Service Adjustment GROUP 15 ~ Air Cleaner) Procedures.) shim 8.5 kgm 3.6 felbs, Removal steps Earth cable connection Accelerator cable connection PCV hose connection Breather hose connection Vacuurn hose connection Water hose connection {Throttle body —+ thermostat housing) Water hose connection {Throttie body —+ water inlet piped Water hose connection (Hester unit - thermostat housing) High-pressure hose connection 9 ‘Oning Return hose connection Brake booster vacuum hose connection 10 Engine mounting stay 14, Vacuum hose 418. Radiator upper hose Delivery pipe BSAS0 @ N ompuns Engine oit {© MiteobiehitMotors Corporation Doe. 1997 PumestT?ENGINE <4G1> - Cylinder Head Gasket 11-25 oe eitibs. 16. Oxygen sensor connector ee 17. Ignition coil connector 18. Crank angle sensor and top dead center ‘Sensor connector 19, Engine coolant temperature sensor con- Cogne s£old engines 20. Wt temperature gauge unt connec- em te skp 21. Throttle position sensor connector 22, Idle switch connector 28. Idle speed contro! connector 24. Injector connector 25. Control harness 26. Rocker cover 4% 27. Timing belt upper cover 4% 28. Camshaft sprocket 29. Selt-locking nuts 8 84 30. Cylinder head assembly 31. Gasket 432. Cylinder head gasket 65-75 Nm 65-75 47-54 tt) 24Nm 2a kgm 17 ftlbs. {© mitsubishi Motors Comporation Dee. 1881 pwmests711-26 ENGINE <4G1> - Cylinder Head Gasket orsoio: Exhaust side ois: (© mitsubishi Motors Corporation ee. 1997 SERVICE POINTS OF REMOVAL ex1s800 27. REMOVAL OF TIMING BELT UPPER COVER ‘After removing the timing belt upper cover, rotate the crank- shaft clockwise and align the timing marks. Caution The crankshaft must always be rotated clockwise. 28. REMOVAL OF CAMSHAFT SPROCKET (1) Use the special tool to remove the camshaft sprocket with the timing belt attached. (2) Tie the camshaft sprocket and timing belt with a wire so that the position of the camshaft sprocket will not move with respect to the timing belt. 30. REMOVAL OF CYLINDER HEAD ASSEMBLY Using the special tool, loosen the bolts in the order shown in the illustration {in 2 6r3 cycles), remove them and then re- move the cylinder head assembly. Punmeon7<€ Camshaft sprocket side ‘dentiication mark TES” serra Exhaust side 1015s. (© MitsobiahiMotors Corporation Dec. 1981 11-27 SERVICE POINTS OF INSTALLATION enuoey 32. INSTALLATION OF CYLINDER HEAD GASKET (1) Use @ scraper to remove the cylinder head gasket from the cylinder block. Caution Take care that no foreign material gets into the cylin- der, or into the engine coolant or oil passages. (2) Place the cylinder head gasket on the cylinder block with the marks facing upward. 30, INSTALLATION OF CYLINDER HEAD ASSEMBLY (1) Use a scraper to remove the cylinder head gasket from the cylinder head assembly. Caution Take care that no foreign material gets into the en- gine coolant or oil passages. 2) Using the special tool, tighten the bolts in the order shown repeating the sequence once or twice. Pente911711-28 TIMING BELT REMOVAL AND INSTALLATION Pre-removal and post-installation Op- Je "Removal and Installation of Under Cow /* Removal and Installation of Crenkshatt Pais. Mount (Refer to GROUP 32 ~ Mount.) ine 2 kgm 72-827 felbs. w ENGINE <4G1> - Timing Belt 0180058 Removal steps eee 1 Ti ee 2 Ti ee ee 3. Timing belt belt upper cover belt lower cover Sifting mark’ 180109] © iteabishittetore Corporation Dec. 1097 SERVICE POINTS OF REMOVAL 1, REMOVAL OF TIMING BELT UPPER COVER ‘After removing the timing belt upper cover, rotate the crank- shaft clockwise and align the timing marks. Caution The crankshaft should always be turned only clockwise. Pwnneot17ENGINE <4G1> - Timing Belt 11-29 Timing bat tensioner, Timing merk one Tiening mark Crankshaft sprocket 1eN0029 18 ls x 18 14 X 0.71) 0.24 x 571) 38 4 x 1.60) ‘Thread diameter x Length mm (in) oworse (© MisubishiMoters Corporation Dee. 1851 3. REMOVAL OF TIMING BELT (1) Loosen the timing belt tensioner bolts. (2) Move the timing belt tensioner to the water pump side and temporarily tighten the bolt so that the tensioner doesn't return. (3) Remove the timing belt. Caution if the timing belt is to be re-used, use chalk to mark (on its flat side) an arrow indicating the clockwi direction. SERVICE POINTS OF INSTALLATION 3. INSTALLATION OF TIMING BELT (1) Align the timing marks on the camshaft sprocket and crankshaft sprocket. (Now the piston in No. 1 cylinder is at the top dead centre on the compression stroke.) (2) Set the timing belt first on crankshaft sprocket and then keeping the tension side of belt tight, set on the cam- shaft sprocket Caution If the timing belt is re-used, install so that the arrow marked on it at time of removal is pointing in the clockwise direction. (3) Apply counterclockwise force (in the direction B) to the camshaft sprocket to give tension to the belt on tension side and make sure that all timing marks are lined up. (4) Install the crankshaft pulley temporarily. This is to pre- vent the belt from coming off when crankshaft is turned. cvreoe 2. INSTALLATION OF TIMING BELT LOWER COVERY 1. TIMING BELT UPPER COVER Note that the timing belt lower and upper cover attaching bolts differ in size from one place to another. pwmeot711-30 ENGINE <4G1> — Engine Assembly ENGINE ASSEMBLY REMOVAL AND INSTALLATION Pre-removal Operation #" Releasing of Fuel Line Presse Rafer 10 GROUP 13 - Service Adjustment Procedures. Removal of the Hood * Draning ofthe Coolant Refer to GROUP 14 ~ Service Adjustment Pro cedures.) J» Removal of the Transmission Assem- bly (Refer to GROUP 22, 23 Trane mmission Assembly) '* Removal of the Radiator (Refer to GROUP 14 - Radiator) Removal steps Earth cable connection Breather hose connection Vacuum hose connection Heater hose connection Osing Return hose connection Seenomaen= Vacuum hose connection ‘Accalerator cable connection High-pressure hose connection Brake booster vacuum hose connection Post-installation Operation ‘#" Installation of the Radiator (Refer to GROUP 14 Radiator) Installation of the Transmission Assern- bly (Reter to GROUP 22, 23 ~ Trans- mission Assembl ) Supeling ofthe Coolant Refer to GAGUP Ue Senige Austen Pro- cedures) Irstaloten of te Hood Recsleretgr Cole Agantment Refer to GHOUE 15 Serie asnent Froceswos orsooee © titsubienimoters Corporation Dee. 1991ENGINE <4G1> - Engine Assembly 11-31 Oxygen sensor connector Igrtion cal connector rank angle sensor and top dead center sensor connector 14. Engine coolant temperature sensor con- rector 15, Water temperature gauge unit connec- 1 1 1 tor 16, Throttle position sensor connector 17. Idle switch connector 18. Idle speed control connector 49. Injector connector 20. Control harness: 40m 21. Alternator connector 40% 22) Power steering oil pressure switch con- 2a nector © Adjustment of Vrribbed belts (Refer to 211-7.) 23. Vatibbed belt for air conditioner 4% 24. Airconditioner compressor 2. Veribbed belt for power steering 24 ee 26. Power stearing oii pump Nm rig oni 2B 50m 5.0 kam 36 elbs, 25Nm 27. Seltlocking nuts and bolts aS 25 kgm 28. Gasket Teribs. orsonos 28. Engine mount bracket (Refer to GROUP 32— Engine Mounting) 4 © 4.30. Engine assembly (© MiaeubehiMotors Corporation Dee 7991 Pest?11-32 ENGINE <4G1> - Engis SERVICE POINTS OF REMOVAL ertreaa 24. REMOVAL OF AIR CONDITIONER COMPRESSOR, Disconnect the air conditioner compressor connector and re- move the compressor from the compressor bracket with the hose still attached. NOTE Place the removed air conditioner compressor in a placé where it will not be a hindrance when removing and installing the engine assembly, and tie it with cord, 26. REMOVAL OF POWER STEERING OIL PUMP Remove the power steering oil pump from the bracket with the hose attached NOTE Place the removed power steering oil pump in a place where it will not be @ hindrance when removing and installing the engine assembly, and tie it with a cord. e Assembly 30. REMOVAL OF ENGINE ASSEMBLY After checking that all cables, hoses and harness connec- tors, etc., are disconnected from the engine, lift the chain block slowly to remove the engine assembly upward from the engine compartment. SERVICE POINTS OF INSTALLATION errtons 30. INSTALLATION OF ENGINE ASSEMBLY Install the engine essembly while checking to be sure that, the cables, hoses, and harness connectors are not clamped. ‘© Misubisn Motors Corporation Dec. 1881 Pwracort7ENGINE <4G9> - Service Adjustment Procedures 11-33 ENGINE <4G9> SERVICE ADJUSTMENT PROCEDURES ALTERNATOR DRIVE BELT TENSION INSPECTION AND ADJUSTMENT entosts ALTERNATOR DRIVE BELT TENSION INSPECTION Check the tension by pulling or pushing at the centre of the belt between pulleys with a force of 100 N (10 kg, 22 Ibs.) as shown in the figure. Measure drive belt deflection amount. Standard value: 8.5-12 mm (0.34-0.47 in.) 100 N (10 kg, 22 be. Alternator pulley Bolle 9=N0001 ALTERNATOR DRIVE BELT TENSION ADJUSTMENT (1), Loosen the nut of the alternator pivot bolt. (2) Loosen the lock bolt. (3) Turn the adjusting bolt to adjust the amount of belt deflec- tion to the standard value. ‘Standard value: If used belt (with correct tension) is used 9.5 mm (0.37 in.) Wanewbeltisused _7.0-8.5 mm (0.28-0.34 in.) (4) Tighten the lock bolt Tightening torque: 20-25 Nm (2.0-2.5 kgm, 14-18 ft.lbs.) (5) Tighten the nut of the alternator pivot bolt, Tightening torque: 45 Nm (4.5 kgm, 33 ft lbs.) © mitsubishiMetors Corporation Deo. 1991 Pwwmest1711-34 ENGINE <4G9> - Service Adjustment Procedures POWER STEERING OIL PUMP DRIVE BELT TEN- Olt pump puley SION INSPECTION AND ADJUSTMENT 1. Press in the V-ribbed belt at the illustrated position with about 100 N (10 kg, 22 lbs.) and measure deflection. Use a belt tension gauge to check that the belt tension is at the standard value. ‘Standard value: Crankshaft Salley Deflection mm (in.) | Tension N (ka, tbs.) ‘When belt tension | 9.5=11.6 400-600 is readjusted (0.374-0.453) (40-60, 88-132) When new belts | 7.5-9.0 | 650-850 installed (0.295-0.354) (65-85, 143-187) 2. Ifthe deflection is out of the standard velues, adjust the belt tension using the following procedures. (1) Loosen bolts A and B (for holding the oil pump) (2) Place a bar or similar object against the body of the oil pump, and, while manually providing the suitable amount of tension, adjust the amount of fiexion of the belt. {3} Tighten bolts A and B in that order, (4) Check the amount of flexion of the belt; readjustif neces- sary. Caution ‘The check should be made after turning the engine one time or more in the regular direction of rotation s3c0048 {to the right), (© Miteubishi Motors Corporation Dee. 001 Pwmeons7ENGINE <4G9> - Service Adjustment Procedures 11-35 POWER STEERING OIL PUMP AND AIR CONDI- TIONER COMPRESSOR DRIVE BELT TENSION IN- SPECTION AND ADJUSTMENT ‘Adjusting So pulley bolt 1. Press in the Vribbed belt at the illustrated position with about 100 N (10 kg, 22 Ibs.) and measure defiection. Use a belt tension gauge to check that the belt tension is at Ss the standard value, lcompressor Tension pulley cu Standard valu loutey Deflection mm {in.) | Tension N (kg, Ibs.) When belt tension | 6.8-7.6 500-630 is readjusted (0.268-0,299) | (60-63, 110-139) ‘When new beltis | 5.5-6.0 760-800 installed (0.217-0.236) (75-80, 165-176) 4692 (© Mteubihi Motors Corporation Dee 1901 2. Ifthe deflection is out of the standard values, loosen the ten- sion pulley nut and adjust the belt tension with adjusting bolt. VALVE CLEARANCE INSPECTION AND ADJUST- MENT <4G92> erro Refer to P.11-9. ‘Standard value (hot engin Intake vaive 0.20 mm (0.008 in.) Exhaust valve 0.30 mm (0.012 in.) IGNITION TIMING INSPECTION AND ADJUST- MENT enFunK (1) Before inspection and adjustment set vehicle in the follow- ing condition. ‘© Engine coolant temperature: 80-95*C (176-203°F) ® Lamps, electric cooling fan and all accessories: OFF © Transmission: Neutral (P range on vehicles with A/T) (2) Insert a paper clip into the 1 pin connector (blue) as shown in the illustration at left pwntests7ENGINE <4G9> — Service Adjustment Procedures the paper clip. NOTE ignition timing but be ordinary timing, (4) Set up a timing light. (5) Start the engine and run at idle. Standard value: NOTE <4693> speed, gine speed. (7) Tur the ignition switch to OFF. adjustment connector (brown). o trated. NOTE timing. (10) Start the engine and run it at idle. (3) Connect a primary-voltage-detection type of tachometer to Do not use the multi-use tester (MUT) or MUT-IL If tested with the MUT or MUT-II connected to the diag- nosis connecter, the ignition timing will not be the basic (6) Check that engine idle speed is within the standard value 4G92 (Except MVV), 493800 + 100 r/min 4G92-MVV 700 & 100 r/min The tachometer indication is a half of actual engine Therefore, multiply the reading by 2 to know actual en- (8) Remove the waterproof connector from the ignition timing Conneot the jumper wire with the clip to the ignition timing adjustment terminal, and earth this to the body as illus- Grounding this terminal sets the engine to the basic ignition (11) Check that basic ignition timing is within the standard value. Standard value: 5° BTDC+2° (© Mitsubishi Motors Corporation Dec, 1058 utesty7.>ENGINE <4G9> - Service Adjustment Procedures 11-37 (12)If not within the standard value, loosen distributor <4G92> or crank angle sensor <4G93> fixing nut and adjust by rotat- ing distributor <4G92> or crank angie sensor <4G93> body. (13) Tighten mounting nut after adjusting, Tightening torque: 12 Nm (1.2 kg, 9 ft-lbs.) (14) Stop the engine, remove the jumper wire from the ignition timing adjust ment connector, (brown), and return the con- Rector to its original condition. (15) Start the engine and check that ignition timing at the stan- dard value. Standard value: 4G92 (Except MV), 4G93_ Approx. 8° BTDC 4G92-MVV Approx. 12° BTDC NOTE 1. Ignition timing is variable within about +7°, even under normal operating. 2. And it is automatically further advanced by about 5° from 8 BTDC (12° BTDC for 4G92-MW) at higher al- titudes. (16) Sealing tape is to attached to the fixing nut only for vehicles for Switzerland. NOTE Sealing tape is attached to all vehicles when. new. (© Mitsubishi Motors Corporation Dec. 1883 Pnaest17-0 ReviseENGINE <4G9> — Service Adjustment Procedures IDLE SPEED INSPECTION ‘enexoe (a) (2 i) (a) 6) © ” Before inspection and adjustment set vehicles in the fol lowing condition © Engine coolant temperature: 80-95°C (176-203°F) © Lamps, electric cooling fan and all accessories: OFF ‘® Transmission: Neutral (P range on vehicles with A/T) Check the basic ignition timing. Adjust if necessary. Standard value: 5° BTDC 42° After turing the ignition switch to OFF, connect the multi-use tester (MUT) or MUTT to the diagnosis connector. For the procedures for connecting the MUT and MUT-I1, refer to GROUP 13-Troubleshooting Start the engine and run it at idle. Run the engine at idle for 2 minutes. Check the idle speed, Curb idle speed: 4G92 (Except MVV), 4G93_ 800 + 100 r/min 4G92-MVV 700 + 100 r/min NOTE The idle speed is adjusted automatically by the idle speed control {ISC) systern. If there is a deviation from the standard value, refer to GROUP 13 - Check Chart Classified by Problem Symptoms, and check the MPI components. IDLE MIXTURE INSPECTION a (2) (© Miaubishi Motors Crporstion Dee. 1908, Before inspection, set vehicles in the following condition: ‘© Engine coolant temperature: 80-85°C (176-203°F) ‘© Lamps, electric cooling fan and all accessories: OFF ‘© Transmission: Neutral (P range on vehicles with AT) ace that the basic ignition timing is within the standard value. ‘Standard value: 5° BTDC +2° PwnMEst17.0 ReviseENGINE <4G9> — Service Adjustment Procedures 11-38-1 © itaubisht Motors Corporation ee, 1992 (3) After turing the ignition switch to OFF connect the multi-use tester (MUT) or MUTI to the diagnosis connector. For the procedures for connecting the MUT and MUTI, tefer to GROUP 13 ~ Troubleshooting. (4) Start the engine and run it at 2,500 r/min for 2 minutes. (6) Set the CO, HC tester (6) Check the CO concentration and the HC concentration at idle. Standard value : 100 ppm or (7) If there is a deviation from the standard value, check the following items: © Diagnosis output '* Closed-loop control (When the closed-loop control is carried out normally, the output signal of the oxygen sensor changes between 0-400mV and 600- 1,000mV at idle.) Combustion pressure Injector Ignition coil, spark plug cable, spark plug Leak in the EGR system and in the EGR valve Evaporative emission control system ‘© Compression pressure NOTE Replace the three way catalyst when the CO and HC concentrations do not remain inside the standard value, ‘even though the result of the inspection is normal on all items. COMPRESSION PRESSURE INSPECTION swear Refer to P.11-13. ‘Standard value (at engine speed of 250-400 r/t weer aGa2 1,450 kPa (14.5 kg/cm?, 206 psi) 4G93 1,500 kPa (15.0 kg/cm’, 213 psi) Limit (at engine speed of 250-400 r/min.): 4G92 min. 1100 kPa (11.0 kg/cm’, 156 psi) 4G93 min, 1150 kPa (11.5 kg/em*, 164 psi) MANIFOLD VACUUM INSPECTION enrwee Refer to P.11-15. Standard value: Approx. 67 kPa (500 mmHg, 20 in.Hg) Punesr17.0 ‘AooeD11-38-2 NOTE © tsubishi Motors Comoration Dec, 1098 pwnaegt17-D ‘ADDEDENGINE <4G9> ~ Service Adjustment Procedures 11-39 \ Se Timing belt tensioner ‘mounting bolt 9eNO034 © Mitsubishi Motors Corporation Dee. 1801, TIMING BELT TENSION ADJUSTMENT enrroL (1) Remove the timing belt upper cover. <4G92> (2) Turn the crankshaft clockwise for one tum or more to set the No. 1 oylinder to top dead compression center. (3) Remove the access cover. (4) Loosen the timing belt tensioner fixing bolt to apply tension to the belt by means of the force of the tensioner spring. Caution ‘The bolt can be loosened 80°20", Ifthe bolt is loosened more than necessary, the bolt may fall inside the cover. {5) Tighten the timing belt tensioner fixing bol (6) Check that the clearance between the timing belt and’ the under cover is at the standard value as shown in the illustra- tion, Standard value: Approx. 33 mm (1.30 in.) (7) Install the access cover. (@) Install the timing belt upper cover. pwetes11711-40 ENGINE <4G9> - Service Adjustment Procedures t MAX. MIN. High-pressure chember ZENO393, {© Misubishi Motors Corporation Des. 1991 LASH ADJUSTERS CHECK <4G93> NOTE Soon after the engine is started or while itis running, abnormal noise (clattering) which may be attributed to the adjuster sounds but does not stop. In this case, check the following. (1) Check the engine oil, and refill or replace oil if necessary. NOTE 1. If the oil amount is small, air will be sucked from the oil strainer and mixed in the oil passage. 2. Ifthe oil amountis excessive, the oil will be stirred by the crank and mixed with a large amount of air. 3. Airand oil can not be separated easily in the deteriorated oil, and the amount of air mixed in the oil increases. eran, If such mixed-in air enters the high pressure chamber in the lash adjuster, the air in the high-pressure chamber will be compressed while the valve is opened, the lash adjuster will be excessively compressed and abnormal noise will be pro- duced when the valve is closed. This is the same phenomenon which ogcurs when the valve clearance is improperly adjusted to be excessively large. However, it will return to be normalif the air entrappedin the adjuster is released in this case. Start the engine, and slowly race* it several times (10 times or less), If the abnormal noise is eliminated by racing the engine, it means that the air is released from the high-pressure cham- ber of the lash adjuster and the function of the lash adjuster is retumed to normal. * Gradually increase the engine speed from the idle speed 103,000 r/min. (for 30 seconds), and then gradually slow down the engine to the idling speed (for 30 seconds). NOTE 1. Ifthe vehicle is parked on a slope for a long time, the oil will be sometimes reduced in the lash adjuster, and air will enter the high-pressure chamber when the engine is started. 2. After the vehicle is parked for a long time, the oil will go out of the oil passage. Since it takes a little time tosupply oil to the lash adjuster, air sometimes enters the high- pressure chamber. Q) waneo317ENGINE <4G9> - Servi (© Mitaubiahi Motors Corporation sn, 1992 Adjustment Procedures 11-41 (3) if any abnormal noise is not eliminated by racing, check the lash adjuster. ‘Stop the engine. Set the engine so that cylinder No. 1 is positioned at the top dead centre of the compression, Press the rocker armat the area indicated by the arrow mark to check whether the rocker arm is lowered or not. Slowly turn the crankshaft 360 degrees clockwise. In the same procedure as Step @, check the rocker arm at the area indicated by the arrow mark. ee @ ee 6 If the rocker arm can be lowered easily when the part of the rocker arm which is directly above the top of the lash adjuster is pressed, the lash adjuster is defective and should be replaced with a new part. Furthermore, when replacing the lash adjuster, bleed all of the air from the lash adjuster and then install, After this, check to be sure that there is no abnormality by car- rying out the inspection in steps (1) to (5). NOTE 1. Aleak-down test can be carried out to accurately de- termine whether the lash adjusteris defective or not. 2. For the procedures for the leek-down test and air bleeding of the lash adjuster, refer to the Engine Workshop Manual. 3. Furthermore, if the rocker arm feels extremely stiff and cannot be lowered when it is pressed, the lash adjuster is normal, so investigate for some other cause of the abnormality. Pemtesst7-8 eviseD11-42 ENGINE <4G9> ~ Crankshaft Pulley CRANKSHAFT PULLEY onus | REMOVAL AND INSTALLATION 6 { 2 ovsoora Removal steps * Drive bet tension adjustment 1. Drive belt (Air conditioner) 2. Drive beit (Alternator) > %4 3. Crankshaft pulley bolt 35.2 Glancshott pulley wesner 6. Crankshaft pulley 6. Dust cover SERVICE POINTS OF REMOVAL evusen 3. REMOVAL OF CRANKSHAFT PULLEY BOLT « SERVICE POINTS OF INSTALLATION er08E 4. INSTALLATION OF CRANKSHAFT PULLEY WASHER/3. (CRANKSHAFT PULLEY BOLT ‘When installing the crankshaft pulley bolt, install so that the burred side of the crankshaft pulley washer is at the bolt side. © Mieubishi Motors Corporation Doc. 1087 Pwmeont7ENGINE <4G9> ~ Camshaft and Camshaft Oil Seal <4G92> CAMSHAFT AND CAMSHAFT OIL SEAL <4G92> REMOVAL AND INSTALLATION Pre-removal Operation jn Post-installation Operation #° Removal of Pistrioutr Refer to * Instation of Timing Bet Cover eter Engine Adjustment (Refer to P11-33) Cam section and « | journal section Removal steps ‘Accelerator cable connection Breather hose connection PCV hose connection Rocker cover Valve clearance adjustment (Refer to P:11-35.) ‘Timing belt (Refer to P.11-64.) Camshaft sprocket Camshaft oil seal Flocker arms and rocker arm shaft assembly (Intake side) Rocker arms and rocker atm shaft assembly (Exhaust side) shaft 11-43 (© Miteabihi Meters Corporation Dee. 1997 west?11-44 ENGINE <4G9> - Camshaft and Camshaft Oil Seal <4G92> SERVICE POINTS OF REMOVAL eral 6. REMOVAL OF CAMSHAFT SPROCKET B996719. 8. REMOVAL OF ROCKER ARMS AND ROCKER ARM. SHAFT ASSEMBLY (INTAKE SIDE)/9. ROCKER ARMS AND ROCKER ARM SHAFT ASSEMBLY (EXHAUST SIDE) Caution Do not disassemble the rocker arms and rocker arm shaft assembly. SERVICE POINTS OF INSTALLATION cerimcant 7. INSTALLATION OF CAMSHAFT OIL SEAL © MiteubiehiMotoreCorporstion Doe. 1991 Pwmest17ENGINE <4G9> - Camshaft and Camshaft Oil Seal <4G93> CAMSHAFT AND CAMSHAFT OIL SEAL <4G93> REMOVAL AND INSTALLATION [Pre-removal Operation 'e' Removal of Erenk Angle Senso: (Refer to GROUP 16 ~ Crank Angle Sensor) © Removal of Timing Belt Cover (Refer to P1168), Post-installation Op for 10 GROUP 16 ~ Crank Angle Sen- toP 11-69) ron in Sealant: 3M ATD Part No, 8660 oF equivalent omooaa, Engine oil Removal steps 1. Accelerator cable connection 2. Breather hose connection 3. PCV valve hose connection 44. Rocker cover 5. Semicircular packing 4 8. Camshaft oll seal © Valve clearance adjustment (Refer to 4 9. Bearing cap P.11-35,) 10. Camshaft 8, Ting bet Refer to P1169) 411. Comshatt or Camshaft sprocket Je" Installation of Crank Angle Sensor (Re- sor) J* instalation of Timing Belt Cover (Refer Je Engine Adjustment (Refer to °.11.33) 11-45 orsors7 (© bsubichi Motors Corporation Dee. 1991 PME11-46 ENGINE <4G9> - Camshaft and Camshaft Oil Seal <4G93> Se camshaft sprocket sido Notch La Intake side camshaft senozea Cap No, Identification mark for imtake side and ‘exhaust side senorat SERVICE POINTS OF REMOVAL entH8A0, 7. REMOVAL OF CAMSHAFT SPROCKET SERVICE POINTS OF INSTALLATION ‘ermcaa 11, INSTALLATION OF CAMSHAFT (1) Apply engine oil to journals and cams of the camshafts. (2) Install the camshafts on the cylinder head. Use care not to confuse the intake camshaft with the ex- haust one. The intake camshaft has a notch on its rear end for driving the crank angle sensor. 9. INSTALLATION OF BEARING CAP * (1) Set the camshaft dowel pins in the positions shown in the illustration. NOTE Place the notch for tightening the cam shaft head bolt in the correct position. (2) Because bearing caps No. 2-5 have the same shape, check the identification mark when installing so.as not to mistake the cap number and the intake or exhaust side. Identification marks (embossed on the front and bearing caps nos. 2-5.) L......Intake side R.....Exhaust side (3) Tighten the bearing caps in the order shown two to three times by torquing progressively. Tighten to specification in the final sequence. (4) Check to ensure that the rocker arm is heldin position on the lash adjuster and valve stem end Punests7ENGINE <4G9> - Camshaft and Camshaft Oil Seal <4G93> 11-47 8, INSTALLATION OF CAMSHAFT OIL SEAL eno1 74} ‘© Misublshi motors Comporation Dee. 1061 Pwesr1711-48 ENGINE <4G9> —- Oil Pan OIL PAN REMOVAL AND INSTALLATION orsonse 60 Nil 4 pcs eerste GSR SGGRIan ECT Soham | Berner and Pstnwataton bs. | 2 Brenig and Suppvingof Engine Ol Retort GROUP 2” Serves Acustent ocedutes Removal and instalation of Oi Lovet Gauge Removal steps 1) Font exaust pipe a asket eae 4% 3. Transfer assembly 0.160.087 4: Beli housing cover 5. Drive shaft center bearing mounting bolt 8° Drain plug crm én) 4 7 Bean Bug casket ” il pan Specified sealant: 1G, Bgereen assembly ITSUBISHI GENUINE PART MD970389 or equivalent (© Witeubish Motors Corporation Dee. 1951 PIMs?ENGINE <4G9> - Oil Pan 11-49 iBg91193 27 Ollpan sce (© takeudieh Motors Corporation ee 1901 SERVICE POINTS OF REMOVAL enneom 3. REMOVAL OF TRANSFER ASSEMBLY (1) With the propelier shaft still installed, remove the trans- fer mounting bott. 2) Insert a flet-tipped screwdriver between the transfer and transmission to remove the transfer from the center shaft. (3) Remove the transfer from the propeller shaft Caution Do not lower the rear end of the transfer, as this wi cause the transfer oil to flow out. (4) After removing the transfer assembly, insert the special tool to prevent transfer oil from flowing out. (6) Suspend the propeller shaft from the vehicle body with wire, etc. 8. REMOVAL OF OIL PAN After removing the oil pan mounting bolts and nuts, remove the cil pan with the special tool and a brass bar. Caution Perform this slowly to avoid deformation of the oil pan flange. SERVICE POINTS OF INSTALLATION 7. INSTALLATION OF DRAIN PLUG GASKET Install the drain plug gasket in the direction so that it faces ‘ag shown in the illustration. Pweoty711-50 ENGINE <4G9> - Crankshaft Oil Seal CRANKSHAFT OIL SEAL REMOVAL AND INSTALLATION Pre-removal and Post-inetallation eration. - }* Removal and Installation of Timing Belt (Refer to P.11-64, 69.) - @ o1sone Crankshaft front oil seal removal steps 1. Crankshaft sprocket 2. Key @ 3. Crankshaft front oil seal Crankshaft rear oil seal removal steps 4. Adapter plate 40 4 5. Flywheel assembly or drive plate 4 6. Crankshaft rear oll seal (© Mitsubishi Motors Corporation ee. 1991 PwMESTT?ENGINE <4G9> - Crankshaft Oil Seal 11-51 SEALANT AND LUBRICATION POINTS. 7 © Lip section _ornooaz| Lin section Engine oif orson9 ‘Engine of, bolt washer surface) Specified sealant: 3M Stud locking 4170 or equivalent (© Mksubishi Motors Corporation Dee. 1861 PwMESTT?11-52 ENGINE <4G9> - Crankshaft Oil Seal o1no09e MB8990938 Mp398776 $ noon? (© Mitsubishi Motors Corporation Dec. 1881 SERVICE POINTS OF REMOVAL enusag 5. REMOVAL OF FLYWHEEL ASSEMBLY OR DRIVE PLATE Stop the crankshaft pulley from turning, and remove the fly- wheel assembly or drive plate . Caution (1) Use only the specified special tools, otherwise the damper section of the crankshaft pulley could be damaged. (2) In order not to damage the timing belt lower cover and front flange, hold the special tool securely so that it doesn’t move. SERVICE POINTS OF INSTALLATION enveam 6. INSTALLATION OF CRANKSHAFT REAR OIL SEAL (1) Apply a small mount of engine oil to the entire circumfer- ence of the oil seal lip. (2) Install the oil seal by tapping it as far as the chamfered position of the oil seal case as shown in the illustration. INSTALLATION OF FLYWHEEL ASSEMBLY OR DRIVE PLATE (1) Clean the sealant, oil and other particles that are adhering to the mounting bolts, the thread sections of the crank shaft, and the flywheel assembly or drive plate . (2) Apply oil to the washer surfaces of the flywheel assem- bly bolts or the drive plate bolts. (3) Apply specified sealant to the thread sections of the Mounting bolts. Specified sealant: 3M Stud locking 4170 or equivalent (4) Tighten the mounting bolts to the specified torque. (6) After installation, clean off any sealant adhering to the ends of the flywheel assembly mounting bolts or the drive plate mounting bolts of the crankshaft, Pwmestt7ENGINE <4G9> - Crankshaft Oil Seal : 11-53 7 oe Crankshaft > 0998717 Oil seal ren (© MitsubichiMotors Corporation Dee. 1001 3. INSTALLATION OF CRANKSHAFT FRONT OIL SEAL {1) Apply @ small amount of engine oil to the entire ciroum- ference of the oil seal lip {2) Tap the oil seal until itis flush with the oil seal case. PwMEon711-54 ENGINE <4G9> — Cylinder Head Gasket <4G92> CYLINDER HEAD GASKET <4G92> REMOVAL AND INSTALLATION » Pre-removal Operation Je" Releasing of Fuel Line Pressure (Refer 1 GROUP 13 ~ Service Adjustment Procedures.) Bainng ofthe Coolant (Refer to GROUP 14 ~ Service Adjustment Pro- cedures.) Draining of the Engine Oi Removal of the Air Intake Hose (Refer to GROUP 18~ Air Cleaner} Removal steps Breather hose connection PCV hose Vacuum hose connection ‘Water hose connection (Thermo- stat case ~ throttle body) Water hose connection (Throttle body — water init fitting) . Fuol high pressure hose connec- tion Oxing Fue! return hose connection Accelerator cable connection Brake booster vacuum hose con- nection 11, Engine coolant temperature switch connector 12. Oxygen sensor connector 13, Oll pressure switch connector 14. Water temperature gauge unit connector 18. Engine coolant temperature sen- 0° connector 16. Engine coolant temperature ‘switch connector < 17. Distributor connector 18. Condenser connector 19. Idle speed control connector 20. TPS connector 21° Injector connector 22. Detonation sensor connector 23. Control harness assembly 24, Spark plug cable Bom @ om pene Delivery pipe - z side @@> & Ja 7 Engine off Post-installation Operation ©" Instolation of the Ai Intake Hose (Re- fer to GROUP 15 - Air Cleaner) © Supplying of the Coolant (Refer to GROUP 14~ Service Adjustment Pro- godures.} '* Supplying of the Engine Oi ‘© Accelerator Cable Agjustment (Refer to GROUP 13 - Service Adjustment Procedures.) (© Mitsubishi Motors Corperation Doe. 1007 ‘PWREDIT7ENGINE <4G9> - Cylinder Head Gasket <4G92> - Cold Engine 75m 0Nm—20Nm ~ +90" —> 480° 7.5 kgm +O kgm —» 2.0 kgm —> +90"; +90° 54 felbs, — Oftlbs. > 14ftlbs. + 490° — +90° 2320.5 om tin} (60.12+0.02) wow Removal steps 25. Connection for radiator upper hose 4 26. Water inlet iting, thermostat and thermostat case assembly ing 28. Rocker cover 29. Timing belt upper cover 30. Camshaft sprocket 31. Solf-locking nuts 32. Gasket 4 33. Cylinder head bolt 4 34. Washer 4 35. Cylinder head assembly 4 36. Cylinder head gasket Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent orsor6 (© Mitsubishi Motors Corporation Dee, 1991 PEST?11-56 Timing mark Cornshatt sprocket me900767 Intake side Exhaust side Loosening order © Mitsubishi Motors Corporation Dee. 1881 ENGINE <4G9> — Cylinder Head Gasket <4G92> SERVICE POINTS OF REMOVAL, ernaaaz 30, REMOVAL OF CAMSHAFT SPROCKET (1) Rotate the crankshatt in the forward (right) direction and align the timing mark, Caution The crankshaft must always be rotated in the for- ward direction only. (2) Tie the camshaft sprocket and timing belt with a cord so that the position of the camshaft sprocket will not move with respect to the timing belt. (3) Use the special tool to remove the camshaft sprocket with the timing belt attached. Caution After removing the camshaft sprocket, be surenotto rotate the crankshaft. 35, REMOVAL OF CYLINDER HEAD ASSEMBLY Loosen the bolts in 2 or 3 steps in order of the numbers. shown in the illustration, and remove the cylinder head as- sembly. Pwmest17ENGINE <4G9> - Cylinder Head Gasket <4G92> 11-57 Intake side 'entification mark => “cas” Front of Exhaust side Install 30 that the sagging side mace by poi cut 3 19 washer is facing Washer Upword Cylinder head orcon © Mitsubishi Motors Corporation Den 1891 SERVICE POINTS OF INSTALLATION enwoev 36. INSTALLATION OF CYLINDER HEAD GASKET (1) Use a scraper or gasket remover to remove the gasket adhering to the cylinder block. Caution When doing this, be careful not to let any foreign substances such as gasket scraps enter the cylinder or the coolant and oil passages. (2) Place the cylinder head gasket on top of the cylinder block so thet the identification mark is facing upwards as in the illustration. Caution The cylinder head gasket is easy to mis-install, so be sure to check it. If it is mis-installed, malfunctions such as no oil rising to the cylinder head will occur. 35. INSTALLATION OF CYLINDER HEAD ASSEMBLY/34. WASHER/33. CYLINDER HEAD BOLT (1) Use a scraper or gasket remover to remove the gasket adhering to the cylinder head assembly. Caution When doing this, be careful not to let any foreign substances such as gasket scraps enter the cylinder or the coolant and oil passages. (2) When installing the cylinder head bolts, the length below the head of the boits should be within the standard value. If itis outside the standard value, replace the bolts. Limit: Within 96.4 mm (3.795 in.) (3) Apply a small anount of engine oil to the thread section and the washer of the cylinder head bolt. (4) Install so thet the sagging side made by tapping out the washer is facing upward.11-58 ENGINE <4G9> - Cylinder Head Gasket <4G92> Intake side Front of engine => (6) Tighten using the angular tightening method. a of - Cylinder Head Gasket <4G93> 11-59 “ CYLINDER HEAD GASKET <4G93> fi REMOVAL AND INSTALLATION oe receerel eee “eialatan One taro eset ne Presse fe por > Fr dobo oar nate tae He «BER con ate feats othe Aca tp Gent econ ie, o SRO Arcane a Sareot te nee ae Deal ess ore 2 Pere se ater eee edgy Bechara Se ot a OL eae See cs maene eg seer chi iron fo pres penis Removal steps Tacecee oe Fee Cun nose conection ms 3. Radiator hose connection (upper, lower) e | & Setgrhoee commorton oped " Fee Ne as oameton 7. Fuel return hose connection oom Gyelegne ose commas 3 & Warne cee, Seti, | 02000 ae 10, Vapour hose connection ‘411. Water inlet fitting, thermostat and ecified sealant: thermostat case assembly TSUBISHI GENUINE PART MD970389 or equive aN ee fe Sata cobs | 23% J [ BE aa s 8 @@b Fo nase 6 rt Engine oil ‘© MMRsubici Motors Corporation Dee. 1001 ‘PwMEStT711-60 ENGINE <4G9> - Cylinder Head Gasket <4G93> 21 22. 12. Engine coolant temperature ‘switch connector (for AVC) 13. Oilpressure switch connector 14. Oxygen sensor connector 15. Engine coolant temperature ‘switch connector ossoo00, 16. Water temperature gauge unit connector 17. Injector connector 18. Crank angle sensor connector 19. Throttle position sensor connector 20. lal speed control connector 21. Power transistor connector 22: Ignition coil connector 23. Contfol hanes © MisubishMoters Corporation Dee. 1991, pwnteans7ENGINE <4G9> — Cylinder Head Gasket <4G93> 11-61 tomm| (0:39in) equivalent omooes Sealant: 3M ATD Part No. 8660 or 25. Spark plus 28. Rocker cov 24, Center cover cable connection er 27. Semi-circular packing 7.5 kgm 0 kgm — 2.0 kgm ~+ 490" ~+ 490° ‘lbs, —+ Oftlbs. +14 Rubs, —> +90" > +90° o Exhaust side Loosening order © Witsbishi Motors Corporation ‘Dee 1991 28 Sees Ue #4 30. Cylinder head 230 ae 31. Gasket 0180006 Intake side Front of engine => SERVICE POINTS OF REMOVAL event 30. REMOVAL OF CYLINDER HEAD ASSEMBLY Loosen the bolts in 2 or 3 steps in order of the numbers shown in the illustration, and remove the cylinder head as~ sembly. west?ENGINE <4G9> — Cylinder Head Gasket <4G93> int Identification take side ent mak = Front of engine orcons Exhaust side la Install so that the, geggng sie mado bby tapping out the Washer {washer is facing upward, Cylinder head (© Miaeabiani Motors Comoration SERVICE POINTS OF INSTALLATION ervey 32. INSTALLATION OF CYLINDER HEAD GASKET (1) Use a scraper or gasket remover to remove the gasket adhering to the cylinder block. Caution When doing this, be careful not to let any foreign substances such as gasket scraps enter the cylinder or the coolant and oil passages. (2) Place the cylinder head gasket on top of the cylinder biock so that the identification markis facing upwards as in the illustration, Caution i The cylinder head gasket is easy to mis-instail, so be sure to check it. if it is mis-installed, malfunctions such as no oil rising to the cylinder head will occur. V 30. INSTALLATION OF CYLINDER HEAD ASSEMBLY/29. CYLINDER HEAD BOLT (1) Use a soraper or gasket remover to remove the gasket adharing to the cylinder head assembly. Caution When doing this, be careful not to let any foreign substances such as gasket scraps enter the cylinder or the coolant and oil passages. When installing the cylinder head bolts, the length below the head of the bolts should be within the standard value. If itis outside the standard value, replace the bolts, Limit: Within 96.4 mm (3.795 in.) (3) Apply a small amount of engine oil to the thread section and the washer of the cylinder head bot. Q (4) install so thet the sagging side made by tapping out the washer is facing upward.ENGINE <4G9> - Cylinder Head Gasket <4G93> Intake side 11-63 (8) Tighten using the anguler tightening method. fA [a eo oe e@ e a g a8 a oO oe @ Operation contents Remarks ‘Tighten to 75. Nm (75 karn, 64 fills) Carty out in the order shown in the ilystration, Fully loosen. Carty out in the reverse (der to that shown in| the lustration. Exhaust side Tighten to 20 Nn (kgm, 14 ftlbs.) Carry out in the order shown in the ilustration, Tgten by 74 turn Carry out in the ord show in the ilustration, Front of engine => “Hy & Procedure © + ® 4 i 2 Tahtenng order + ® ® [ten by 174 turn Carty out in the order mm fin) 3208 (00.12.0.02) (© ntteubis Motore Corporation oc. 1091 shown in the ilustration, 11. INSTALLATION OF WATER INLET FITTING, THERMO- ‘STAT AND THERMOSTAT CASE ASSEMBLY (1) Loosen the water inlet pipe bolt shown in the illustration. (2) Apply specified sealant to the thermostat case assembly as shown in the illustration. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent (3) Apply @ small amount of water to the O-ring of the water inlet pipe, and press the thermostat case assembly onto ‘the water inlet pipe. (4) install the thermostat case assembly mounting bolt. (©) Tighten the water inlet pipe bolt. Pwncons711-64 ENGINE <4G9> ~ Timing Belt <4G92> TIMING BELT <4G92> REMOVAL AND INSTALLATION ca Pre-removal Operation Je""Removal of the Under Cover Post-installation Operation ‘¢/Adustmont of Drive Belt Tension (Re- ferto P1133) ‘instalation ofthe Under Cover Be 10Nm kam 7 ftlbs. 2 4 € 7 186.Nm 185 k watt 1690017 Removal steps 4 7. Timing belt lower cover 1. Clamp section of Air conditioner ee 8 Flange 2, Drive belt (Power steering, Air conditioner) 4 & Adjustment of timing belt tension i. 3. Drive belt (Alternaton 40 84 9. Timing belt 49 4 4 Crankshaft bolt 10. Timing belt tensioner 49 84 5. Crankshaft pulley 11. Tensioner spacer 4. 6. Timing belt upper cover 12) Tensioner spring ‘D taksublch Motors Corporation Dee. 1991 Peinteon7ENGINE <4G9> - Timing Belt <4G92> 11-65 SERVICE POINTS OF REMOVAL erceHa 4, REMOVAL OF CRANKSHAFT BOLT/5. CRANKSHAFT PULLEY Use the special tool to stop the crankshaft pulley from turn- ing, and remove the crankshaft bolt. Caution Hold the special tool securely so that it doesn’t move. 9. REMOVAL OF TIMING BELT (1) Tum the crankshaft clockwise (right turn) to align each timing mark and to set the No. 1 cylinder at compression ‘top dead centre. Caution The crankshaft should always be turned only clock- wise. (2) Loosen the timing belt tensioner bot. (3) Seta screwdriver to the timing belt tensioner and press it fully back in the direction of the arrow. (4) Provisionally tighten the timing belt tensioner bolt. (8) Remove the timing belt. Caution if the timing belt is to be re-used, use chalk to mark the flat side of the belt with an arrow indicating the direction of rotation (right turn). ‘© rmeubihittotors Corporation Dee. 1991 Pwnestt711-66 ENGINE <4G9> - Timing Belt <4G92> Timing belt tensioner 2 OA SERVICE POINTS OF INSTALLATION 9. INSTALLATION OF TIMING BELT pulley Crankshaft sprocket Bat tensi Camshaft fae nor ‘sprocket a © MitsubishiMotors Corporation Dee. 1801 (1) With the timing belt tensioner bolt loosened, use a screwdriver to fully turn the timing belt tensioner as close to the engine mount as possible, and then provi- sionally tighten the tensioner bolt, (2) Align each of the camshaft sprocket and the crankshaft sprocket timing marks. {3) Install the timing belt in the following order, while making ‘sure that the tension side of the belt is not slackened. ® Crankshaft sprocket ® Water pump sprocket © Camshaft sprocket ® Tensioner pulley Caution After installing the timing belt, apply force to turn the camshaft sprocket in the reverse direction, and recheck to be sure that the beltiis fully tensioned and that each timing mark is in the proper position. © ADJUSTMENT OF TIMING BELT TENSION (1} Initially loosen the fixing bolt of the tensioner pulley fixed to the engine mount side by 1/2-1/4 turn, and use the force of the tensioner spring to apply tension to the belt, ‘Tum the crankshaft in the proper rotation direction (right ‘tum) for two rotations, and recheck to be sure that the timing marks on each sprocket are aligned Caution As the purpose of this procedure is to apply the prop- er amount of tension to the tension side of the timing belt by using the cam driving torque, turn the crank- shaft only by the amount given above. Be sure not to turn the crankshaft in the opposite direction (left turn). Q Pwmesin?ENGINE <4G9> - Timing Belt <4G92> 11-67 Camshaft sprocket Under cover Water pump sprocket orcons, Crankshatt sprocket 4 Front of engine / Rear of engine mp Crankshaft Flange [© rmteubishimotere Corporation Dee. 1881 (G) After checking to be sure that no belt teeth in the section marked with % are lifted up and that the teeth in each sprocket are engaged, secure the tensioner pulley. Lastly, lightly clamp the centre of the span between the camshaft sprocket and the water pump sprocket on the belt ‘tension side with your thumb and forefinger as shown in the illustration, and check to be sure thet the clearance A be- ‘tween the reverse surface of the belt and the inside of the under cover seal line is at the standard value. Standard value: Approx. 30 mm (1.18 in.) 4) 8. INSTALLATION OF FLANGE Install the flange as shown in the illustration. 7. INSTALLATION OF TIMING BELT LOWER COVER/6. TIM- ING BELT UPPER COVER Install the bolts, being careful not to mistake the bolt sizes. Abolt: 6 x 18 (0.24 x 0.72) B bolt: 6 x 30 (0.24 x 1.18) [diameter x tength mm (in.)}11-68 ENGINE <4G9> - Timing Belt <4G92> 5. INSTALLATION OF CRANKSHAFT PULLEY/4. CRANK- SHAFT BOLT (1) Apply engine cil to the bearing surface and to the thread section of the crankshaft bolt. (2) Use the special tool to stop the crankshaft pulley from turning, and install the crankshaft bolt. Caution Hold the special tool securely so that it doesn’t move. (© miteubichiMotors Corporation Doe 1961 Pwmesty7ENGINE <4G9> ~ Timing Belt <4G93> 11-69 TIMING BELT <4G93> enna REMOVAL AND INSTALLATION installation Operation jon of Under Cover ion of Crankshaft Pulley mn (Refer to P.11-42,) Removal steps 1. Rubber plug 4 2. Timing belt upper cover 4 3. Timing belt lower cover '@ Adjustment of timing belt tension 4994 4 Timing bolt 4 5. Auto tensioner 6. Tension pulley and arm assembly (© titeubshittctore Corporation Dox. 1001 PunestT?11-70 ENGINE <4G9> - Ti 1g Belt <4G93> ‘Timing mark Timing mark contact pidce pI ‘Contact piece i ‘o0s0047 (© Misubiti Motors Corporation Jun. 1092 SERVICE POINTS OF REMOVAL ‘ecoeo 4, REMOVAL OF TIMING BELT (1) Turn the crankshaft clockwise to align each timing mark Caution The crankshaft must always be turned clockwise. (2) Loosen the tensioner pulley center bolt and remove the timing bek. Caution If the timing belt is to be re-used, use chalk to mark (on its flat side) an arrow indicating the clockwise direction. SERVICE POINTS OF INSTALLATION np0e 5. INSTALLATION OF AUTO TENSIONER (1) Using a press or vise, compress the push rod of the auto tensioner as slowly as possible and align pin hole A of the push rod and pin hole B of the tensioner cylinder. Caution (1) The auto tensioner must be placed at a right angle to the pressing surface of the press or vise. {2) If the compression speed is too fast, the push rod may become bent, so carry out this operation slowly. (2) Insert a 2.0 mm (0.06 in.) Allen wrench into the aligned pin holes. NOTE If the auto tensioner has been replaced, the pins are set in the auto tensioner. {3) install the tensioner to engine.ENGINE <4G9> ‘Camshaft sprocket Timing meri Timing mark ing Belt <4G93> 4, INSTALLATION OF TIMING BELT (1) Align the timing marks of each camshaft sprocket and ‘the crankshaft sprocket. (2) Loosen the tensioner pulley center bolt. (3) Move the crankshaft sprocket half a tooth width in the anti-clockwise direction. (4) Place the timing belt on the intake-side camshaft sprock- et, and holditin the position shown in the illustration with a double clip, (6) Place the timing belt on the exhaust side sprocket while using two wrenches to align the timing marks (6) Hold the belt in the position shown in the illustration with another double clip. Ponmestrra REVISED11-71-1 ENGINE <4G9> - Timing Belt <4G93> (© mitsubishi Motors Corporation Jun, 1992 (7) Place the belt onto the idler pulley, water pump sprocket, ‘crankshaft sprocket and tensioner pulley in that order. {8) Remove the two double clips. (Q) Lift the tensioner pulley in the direction of the arrow and tighten the tensioner pulley bott. {10)Check to be sure that all timing marks are aligned. (11)Agjust the timing belt tension. PwMESNT7-A ‘ADDED11-71-2 NOTES (© Meaubis Motors Corporation Jun 1952 PUMERTT-A ‘ADDED11-72 ENGINE <4G9> - Timing Belt <4G93> Fixing bot Allen wrench Bolt clameter X length ‘me fin) 3. ADJUSTMENT OF TIMING BELT TENSION (1) After turning the crankshaft a 1/4 turn anti-clockwise, ‘umn it clockwise to the position where the timing marks are aligned, (2) Loosen the fixing bolt of the tensioner pulley and using ‘the special tool anda torque wrench, apply tension tothe timing belt; then tighten the fixing bolt at the specified torque. Standard value: 0.26 kgm (timing belt tension torque) Caution ‘When tightening the fixing bolt, ensure that the ten- sioner pulley shaft doesn’t rotate with the bolt. (3) Take out the 2mm (0.06 in} Allen wrench from the auto tensioner. At this time, check to be sure that the 2mm {0.06 in) Allen wrench can be pulled out easily. Turn the crankshaft clockwise 2 turns, and after leaving it in this position for 5 minutes or more, check again to be sure that the auto tensioner 2mm (0.06 in) Allen wrench can be pulled out or inserted easily. NOTE Even if the 2mm (0.06 in} Allen wrench cannot be easily inserted, then it is satisfactory if the amount of protru- sion of the auto tensioner rod is within the standard val- ue, Standard value: 3.8-4.5 mm (0.15 -0.17 in) If itis outside the standard value, repeat the operations in steps (1) to (4). (4) Check to be sure that the timing marks on all sprockets are aligned INSTALLATION OF TIMING BELT LOWER COVER/2. TIMING BELT UPPER COVER ‘The dimensions of the installation bolts for the timing belt covers differ according to the installation location, so be sure ot to install thé bolts in the incorrect locations. weno. ReviseENGINE <4G9> - Engine Assembly <4G92> 11-73 ' ENGINE ASSEMBLY <4G92> REMOVAL AND INSTALLATION Pre-removal Operation o" Rolgasing of Foal Line Pressure Refer to GROU Procedures, Removal of the Hood Draining of tng Coolant Refer to GROUP 14 Serie Acustment Pro ures) Remove of the Tangmission Assem- ‘bly (Refer to GROUP 22, 23 ~ Trans- mission Assembly.) Flamoval of the Radiator (Refer to GROUP 14 - Radiator) 13 Serve Adustment Delivery pine 1 q 6 , i 20 ee, Onin ese Engine oil Removal steps 1. Vacuum hose connection ¥ 9. Engine coolant temperature switch con- E Wecterhose connection Thermostat hous- raver ing — heater unit} * 40. Oxygen sensor connector 3. Heater hose connection (Heater unit + 11. Oil pressure switch connector Water inlet pipe) 12. Water temperature gauge unit connector 4. Fuel high pressure hose connection 13: Engine coolant temperature sensor con- 6. O-ring nector 6: Fuel return hose connection > 14. Engine coolant temperature switch con- 5; aceolralr table Sonnscton nowy or condonser fen 8. Brake booster vacuum hose connection 15. Distributor connector 18. Condenser connector 17. Idle speed control connector 1g Fes eornecir 18 Ijecroreomector «28, BESte sensor connector 21. Control harness assembly 32: shometor harness connection Cumanaltniontoerrion Dota 711-74 ENGINE <4G9> - Engine Assembly <4G92> FovingaiaionDneaion | rere cia | eRe cine > Sook a son Ase ase Sra SoS Bees = Serres Coen ate FTE oe eet. oe fellate od Ce ee non ete Seabee Peat a = StS cma Rereeal osea saat Becher eae eA) we res008 Removal steps 23. Power steering oil pressure switch connector 24. Air conditioner compressor connector 28. \Veibbed belt 4% 26: Power steering oil pump connection @% 27. Airconditioner compressor connection 28\- Front exhaust pipe connection 29. Gasket 30. Starter and alternator harness clamp 494 31. Engine mount bracket So4 32: Engine assembly ‘© Mitsublahi Motors Corporation Dec. 1097 ‘PwRESIT7ENGINE <4G9> - Engine Assembly <4G92> 11-75 SERVICE POINTS OF REMOVAL enrTaAN 26. REMOVAL OF POWER STEERING OIL PUMP Remove the power steering oil pump from the bracket with the hose attached. NOTE Place the removed power steering oll pumpina place where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord. 27. REMOVAL OF AIR CONDITIONER COMPRESSOR Disconnect the air conditioner compressor connector and re- move the compressor from the compressor bracket with the hose still attached. NOTE Place the removed air conditioner compressor in a place where it will not be 2 hindrance when removing andinstalling the engine assembly, and tie it with a cord. 31. REMOVAL OF ENGINE MOUNT BRACKET (1) Support the engine with a garage jeck. (2) Hold the engine assembly with a chain block, etc. (3) Place the garage jack against the engine oil pan with a piece of wood in between, and after raising the engine Until there is no weight on the engine mount brackets, re- move the engine mount brackets. 32. REMOVAL OF ENGINE ASSEMBLY ' After checking that all cables, hoses and harness connec- 101s, etc., are disconnected from the engine; lift the chain block slowly to remove the engine assembly upward from: ‘the engine compartment. (© Mitsubishi Motors Corporation Dee. 1801 Pontes11-76 ENGINE <4G9> - Engine Assembly <4G92> SERVICE POINTS OF INSTALLATION entosa 32. INSTALLATION OF ENGINE ASSEMBLY Install the engine assembly while checking to be sure that the cables, hoses, and hamess connectors are not clamped. 31, INSTALLATION OF ENGINE MOUNT BRACKET (1) Place garage jack against the engine oil pan with apiece of wood in between, and install the engine mount brack- ‘et while adjusting the position of the engine. (2) Support the engine with a garage jack. (3) Remove the chain block and support the engine assem- bly with the special tool. © Mitsubishi Motors Corporation Dee. 1001 west? 4ENGINE <4G9> — En: e Assembly <4G93> 11-77 ENGINE ASSEMBLY <4G93> REMOVAL AND INSTALLATION Pre-removal Operation je" Releasing of Fuol Line Pressure (Refer to GROUP 13 ~ Service Adustment Procedures.) Removal of the Hood Draining of the Coolant (Refer to GROUP 14 ~ Service Adjustment Pro- Codures.) Removal of the Transmission Asser bly Geter to GROUP 22, 28 Trans- mission Assembiy) Removal of the Radiator (Refer to GROUP 14 - Radiator) Removal steps "Accelerator cable connection Brake Dooster vacuum hose connection Breather hose connection Positive crankcase ventilation hose connection High-pressure hose connection O-ring Return hose connection Heater hose connection Vapour Rose connection SONomReN= Post-installation Operation enmaz instalation of the Radiator Refer 10 GROUP 14 ~ Radiator) Installation of the Transmission Asserr-| by (Refer to GROUP 22, 23 ~ Tens- mission Assembiy.) Supaiying of the Coolant Reto: GROUP 14 Service Adjustment Pro- cedures.) Installation of the Hood ‘Acealeratar Cable Adustment (Refer fo GROUP 13 - Service Adjustment Procedures.) \Vaiboed Beit Tension Adjustment of Power Steering Oil Pump and Air Con ditioner Compressor (Refer to P1135.) Delivery pipe 6 osncora Engine olf © Mitsubishi Meters Corporation Dec. 1981 Puen?11-78 ENGINE <4G9> - Engine Assembly <4G93> 101216 11 4 10. Engine coolant temperature Switch connector tor A/C) 1}. Qll pressure switch connector 12. Oxygen sensor connector 18, Engine coolant temperature switch connector 14, Water temperature gauge unit connector 18. Injector connector 16. Crank angle sensor connector 17. Throttle position sensor connec- tor 18. Idle speed control connector 18. Power transistor connector 20. Ignition coli connector 21. Controt hamess 22. Alternator connector 28. Detonation sensor connector conan 24, Power steering oil pressure switch connector ‘© Adjustment of drive belts Refer to P.118) 28. Power steering oil pump and air conditioner compressor drive belt 26. Power steering oll pump (Refer to P.11-75.) 25 27. Ait conditioner compressor (Refer to P:11-75) o1s0201 28. Self-locking nuts and bolts 29. Gasket 30. Engine mount bracket {Refer to P.11-75, 76) 31. Engine assembly {Refer to P.11-79, 76) © itsubishi Motors Corporation Doe. 1997 PwnnesrT7ENGINE <4D68> — Service Adjustment Procedures 11-79 ENGINE <4D68> SERVICE ADJUSTMENT PROCEDURES DRIVE BELT TENSION INSPECTION AND A conaitoner ADJUSTMENT nro paloy DRIVE BELT TENSION INSPECTION ‘Check the tension by pulling or pushing at the centre of the belt between pulleys with a force cf 9B N {10 kg, 22 Ibs.) as shown in the figure. Measure drive belt deflection amount. Ac conditioner tension Power steering iiley’ ‘il pump, pulley Water pump Alternator pulley Crankshaft pulley acco ‘Standard value: mm (in.) Items During inspection When retightening —_| When fitting naw belt used belt Alternator drive belt 7.0-10.0 80-90 60-70 (028-039) (031 -0.35) (0.24-0.28) Power steering oil pump drive belt, 55-80 60-70 45-65 (022-031) (024-028) (0.18 0.22) Air conditioner compressor drive belt 70-80 70-80 50-60 (028-031) (028-031) (0.20 0.24) (© Mitsubishi Motors Corporation Jun, 1982 PwMEsTTTA ‘ADDED11-80 ENGINE <4D68> - Service Adjustment Procedures DRIVE BELT TENSION ADJUSMENT ALTERNATOR DRIVE BELT (1) Loosen the flange bolt and nut that are securing the alterna- tor, (2) Apply a bar to the stator section of the alternator and lever it to adjust the belt deflection amount so that itis at the stan- dard value. (3) Tighten the flange bolt and nut that were previously loos- ened to the specified torque. Tightening torque Flange bolt: 12-15Nm 12-15 kgm 10-11 ftlbs. Nut: 20-25 Nm 2.0-2.5 kgm 14-18 ftilbs. (4) Turn the crankshaft one full rotation or more in the forward direction (rotation to the right) to turn over the engine, and then recheck the belt deflection amount and readjust if nec- essaty, NOTE ‘The crankshatt should always be turned in the forward direc- tion of rotation. POWER STEERING OIL PUMP DRIVE BELT (1) Loosen power steering oil pump fixing bolt. (2) Move power steering oil pump, tension belt moderately and adjust tension. (3) Tighten the fixing bolts in the order A, B and C. Tightening torque: 39 Nm (4.0 kgm, 29 ft.lbs.) (4) Check belt tension after driving. AIR CONDITIONER COMPRESSOR DRIVE BELT TENSION ADJUSTMENT (1) Loosen tension pulley fixing bolt A. (2) Adjust belt tension with adjusting bolt B. (3) Tighten fixing bolt A. (4) Check the belt tension after driving. 1008s ‘Gi ntnaiahi Motors Gorwortion dan. 1952 PUMESHTT-A ‘ADDEDENGINE <4D68> - Service Adjustment Procedures 11-81 VALVE CLEARANCE INSPECTION AND ADJUSTMENT enrpax (1) Startthe engine and allow it to warm up untilthe engine coo ant temperature reaches 80 to 95°C (176 to 203°F). (2) Remove all glow plugs from the cylinder heads for easy in- speation. (Refer to GROUP 16 - Glow System.) {8) Remove the rocker cover. (4) Turn the crankshaft clockwise until the notch on the pulley is lined up with the “T” mark on the timing indicator. 1DENG674 (5) Move the rocker arms on the No. 1 and No. 4 cylinders up and down by hand to determine which cylinder has its piston at the top dead centre on the compression stroke. If both in- take and exhaust vaive rocker arms have a valve lash, the pis- ton in the cylinder corresponding to these rocker arms is at the top dead centre on the compression stroke. (6) Valve clearance inspection and adjustment can be per- formed on rocker arms indicated by white arrows o when the No. 1 cylinder pistonis at the top dead centre on the com- pression stroke, and on rocker arms indicated by solid ar- rows * when the No. 4 cylinder piston is at the top dead centre on the compression stroke. (7) Measure the valve clearance. NOTE When inserting the thickness gauge, push the pad from the Adjusting ‘opposite side from the thickness gauge insertion side with a flat-tipped screwdriver or similar tool to make a gap, end Ped then insert the thickness gauge. Tide Tir (© nateubishiNtotors Corporation dun. 1052 PWMREST ITA ‘ADDED11-82 ENGINE <4D68> — Service Adjustment Procedures When you try to insert the thickness gauge, if the pad is not pushed with a flattipped screwdriver or similar tool and no gap ismade, the pad will tilt as shown in the illustration and the thick- ness gauge will not be able to be inserted. (8) If the valve clearance is not as specified, loosen the rocker arm lock nut and adjust the clearance ‘using a thickness ‘gauge while turning the adjusting screw. ‘Standard value (hot engine): Intake valve 0.25 mm (0.010 in.) Exhaust valve 0.25 mm (0.010 in.) (9) While holding the adjusting screw with a screwdriver to pre- vent it from turning, tighten the lock nut securely. (10)Turn the crankshaft through 360° to line up the notch on the crankshaft pulley with the “T” mark on the timing indicator. (11)Repeat steps (6) and (7) on other valves for clearance adjust- ment. (12)Apply a coating of the specified sealant to the semi-circular Apoly packing and cylinder head to surfaces. Specified sealant: 3M ATD Part No. 8660 or equivalent (13)Instal! the rocker cover. (14)Install the glow plugs and tighten to the specified torque. 18 Nm (1.8 kgm, 13 ft.lbs.) [Aooly sealant 10 mm (oin) INJECTION TIMING ADJUSTMENT enevan (1) After warming up the engine, check to be sure that the fast, idle lever is separated from the accelerator lever. (2) To make the crankshaft turn more easily, remove the four glow plugs. © mitsubishi Motors Corporation Jun, 1992 POMESHT?-A ‘ADDEDENGINE <4D68>:- Service Adjustment Procedures 11-83 4 sng aed (3) Turn the crankshaft clockwise (right turn) to align each timing a Tianna raat mark and to set the NO. 1 cylinder at compression top dead centre. ‘omnoss7 (4) Remove the timing check plug installed at the rear of the ine jection pump. aes <7] =... (5). Install the: special tool to the rear of the injection pump. (6). Install.a dial gauge to the special tool MD998389 ‘Turn this knob to install in the plug hole. a (7) Turn the crankshaft clockwise to move the No. 1 cylinder approximately 30° before compression top dead centre... {8) Set the needle of the dial gauge to 0. (8) Check to be sure that the needle doesn’t move even if the crankshaft is tured slightly (2-3° both clockwise and anti- ‘counter clockwise. (10)IF the needle moves, the injection pump pluger is lifted, so reset it by turning the crankshaft to @ position where the needle doesn’t move. Set at z2r0 feprsics Gin loess ooatinn. (11)Turn the crankshaft pulley clockwise to align the crankshaft pulley notch to 9° ATDC. ‘Set10 9 ATDC (12}Take a reading of the value displayed on the dial gauge. Standard value: 0.97-1.03 mm (0.038-0.041 in.) ‘© MisubiohI Motors Comeration duly 1098 Pemest17-0 : ‘REVISED11-84 ENGINE <4D68> - Service Adjustment Procedures Injection pump pee SA. when higher tnan| \ standard yelue U when lower than standard value cxuoose ‘© Misubiehi Motore Corporation Jun, 1982 (13)If the value'is outside the standard value, adjust the injection timing by the following procedure. © Loosen the four injection pipe Union nuts on the injection pump side. (Do not remove the'union nuts.) When loos- ening the nuts, hold the delivery valve holders with 2 spanner so that they don’t turn a the same time. © Loosen the two injection pump mounting nuts and the ‘two injection pump mounting bolts. (Do not remove the nuts and bolts.) © Tiltthe injection pump to the left and right and adjust so that the value displayed on the dial gauge is at the stan- dard value. ® Temporarily tighten the two mounting nuts and bolts of ‘the injection pump. © Repeat steps (7) - (12) to check if the adjustment has been made correctly. © Securely tighten the injection pump mounting nuts and bolts. ® Securely tighten the injection pipe union nuts. When tightening the nuts, hold the delivery valve holders with ‘a spanner so that they don’t turn at the same time. (14)Remove the special tool. (15}After replacing the gasket with a new gasket, securely tighten the timing check plug. PwMesnT7A ‘ADDEDENGINE <4D68> - Service Adjustment Procedures 11-85 ENGINE IDLE SPEED INSPECTION AND ADJUSTMENT NOTE Carry out inspection and adjustment of the idle speed after checking that the injection timing is normal (1) Before inspection and adjustment set vehicle in the follow- ing condition. @ Engine coolant temperature: 80-95°C (176-203°F) @ Lamps, electric cooling fan and all accessories: OFF. © Transmission: Neutral {2} Connect a tachometer to the injection nozzle or the injection pipe. Caution When the tachometer is connected to the injection pipe, the pipe mounting clamps should all be removed. (3) Check the idle speed. ‘Standard value: 750 + 100 r/min. : Zs = iction nozzle (4) If the idle speed is outside the standard value, loosen the lock nut on the idle adjusting screw and adjust by turning the idle adjusting screw. After adjustment, securely tighten the lock nut. (© miteubichi Motors Corporation Jun, 1062 PwMESt17-A ‘anpen11-86 ENGINE <4D68> — Service Adjustment Procedures ‘© Mittens Motors Corworation un, 1952 COMPRESSION PRESSURE INSPECTION ener (1) Check to be sure that the engine oil, starting motor and bat- tery are in the normal condition. (2) Start the engine and allow it to warm up until the tempera- {ure of the engine coolant reaches 80 to 95°C (176 to 203°F). {3} Remove the injection pipes. (4) Remove the fuel return hose. {6) Hold the hexagonal section of the fuel return pipe with a wrench, and remove the nut that fastens the pipe to each in- jection nozzle, (6) Remove the fuel retum pipe and gasket. (7) Using @ deep socket wrench, remove all the injection nozzles. NOTE Attach a tag indicating the cylinder number to each nozzle that has been removed. (8) Remove the holder gasket and nozzle gasket from the injec- tion nozzle hole in the cylinder head. {9} Disconnect the fuel cut solenoid valve connector. NOTE This will stop fuel injection from being carried out. (10)Cover the injection nozzle mounting hole with a ag, and after the engine has been cranked, check that no foreign material is adhering to the rag. Caution 1. Keep away from the injection nozzle mounting hole when erankii 2. If compression is measure while water, oil, fuel, ete., that has come from cracks’is inside the cylinder, ‘these materials will become heated and will gush ‘out from the injection nozzle mounting hole, which is dangerous. (111)Attach the adapter to the injection nozzle hole and connect a compression gauge to the adapter. (12)Crank the engine and measure the compression pressure. Standard value (at engine speed of 250 r/min.): 3,500 kPa (35.0 kg/cm, 498 psi) Limit (at engine speed of 250 r/mi min. 2,560 kPa (25.6 kg/cm, 364 psi) PWMESITT-A ‘ADDEDENGINE <4D68> ~ Service Adjustment Procedures 11-87 Holder gasket Nozzle gasket rusts Timing marks (© Mitubiah Motors Compartion von 1982 (13)Measure the compression of all the cylinders, and check that the pressure differences between each cylinder are below the limit. Limit: max. 300 kPa (3.0 kg/cm, 43 psi) (14)If there is a cylinder with compression or a compression dif- ference that is outside the limit, pour a small amount of e! gine oil through the injection nozzle mounting hole, and re- peat the operations in steps (11) to (13). © Ifthe compression increases after oils added, the cause of the maifunction is a worn or damaged piston ring and/ or oylinder inner surface. @ If the compression does not rise after oil is added, the cause is a burnt or defective valve seat, or pressure is leaking from the gasket. (15)Connect the fuel cut solenoid valve connector. For information regarding the servicing procedures for these causes of malfunction, refer to the ENGINE AND TRANS- MISSION MANUAL. (16)Clean nozzle holder installation area of the cylinder head. (17}Fit a new nozzle gasket and holder gasket into the nozzle holder hole in the cylinder head. (18)Install the injection nozzles in their correct position referring to the cylinder numbers indicated on the tags that were at- tached to each nozzle at the time of removal. Tighten the nozzles to specified torque. Tightening torque: 55 Nm (5.5 kgm, 40 ft.lbs.) (19)Install the gaskets and fuel return pipe. (20)Install the injection pipes. TIMING BELT ADJUSTMENT ro: (1) Tum crankshaft clockwise to bring No. 1 cylinder piston to top dead centre on compression stroke. Caution For aligning the timing marks, never turn the crankshaft anticlockwise as it could cause inadequate belt tension. Pwnnest37 A ‘ADDEDENGINE <4D68> - Service Adjustment Procedures ining na 2B tooth - Crankshaft Pulley 11-89 CRANKSHAFT PULLEY ra REMOVAL AND INSTALLATION [Pra-removal and installation Operation '#* Removal and Installation of Under Cov- er Removal steps © Drive belt tension adjustment (Refer to P.11-79) 1. Drive belt (Power steering) 2. Drive belt (Air conditioner orxoone 3. Drive belt (Aiternaton 4 Crankshaft pulley ‘© MisubishiMotorsCompertion Jun 1982 Penesnt7 8 ‘ApDeD11-90 ENGINE <4D68> - Camshaft and Camshaft Oil Se: CAMSHAFT AND CAMSHAFT OIL SEAL REMOVAL AND INSTALLATION en Pre-removal and Post-installation Op- sin eration os Removal and Intaltion of Tring Belt 3 lbs, roferto P1108), eae 6Nm $f ta 2 Lip section 2 ! 3 ce ornooaa, ‘Cam section and journal section S 2022Kim 28-32 ke 20-28 ft 8 6 vais 19:21.1Nm er; 121 kam Engine oil TeaB fe 192.1 kgm TAS ttibs. Removal steps 20m Breather hose connection eo Reorder oni, Semi-citcular packing Camshaft sprocket Camshaft ol seal Rocker arm and shaft assembly Camshaft beering cap Camshaft on « ” PNORRON- orsorss (© MitubishiMotoreComporation Jun. 1082 ‘PwOMEDTT7-A "ADDEDENGINE <4D68> - Camshaft and Camshaft Oil Seal <4D68> 11-91 yy fee ch idee at) Boxing Zep onxenr Ofeeat camshatt ‘MD998364 ¢ T5.5 mm 2zn 1 é 10996719 or, pagers (© Miteabihi Motors Corporation on. 1982 SERVICE POINTS OF REMOVAL erHBAO 4, REMOVAL OF CAMSHAFT SPROCKET SERVICE POINTS OF INSTALLATION EnTHeAD, 7, INSTALLATION OF CAMSHAFT BEARING CAP ‘The cap numbers are embossed on the top surface of the bearing caps, so install in the order of the numbers. However, no numbers are embossed on bearing caps 1 and 5. 6. INSTALLATION OF ROCKER ARM AND. SHAFT ASSEMBLY (1) Install the rocker arm and shaft assembly to the bearing caps. (2) Set the rocker arm springs into the bearing cap indents. (3) Check the valve clearance and adjust if necessary. (Refer 10 P.11-81) 5. INSTALLATION OF CAMSHAFT OIL SEAL (1) Apply 2 small amount of engine oil to the entire cireum- ference of the oil seal lip and camshaft. (2) Use the special tool to tap in the oil seal. NOTE The oil seal should be tapped in until the distance from the end of the camshaft to the end of the oil seal is as shown in the illustration. 4, INSTALLATION OF CAMSHAFT SPROCKET Punests7-a ‘novo11-92 eae ENGINE <4D68> — Oil Pan OIL PAN REMOVAL AND INSTALLATION smoval and Post-installation Op- 3 “Draning and Supping of Engine Ot 5 Removal and instalation of Covel '¢ Rlonoval ang Installation of Front Ex- Foust Sipe (Refer to GROUP TEx aust Pipe ena Mutter) : MITSUBISHI GENUINE PART No. MD970389 or equivalent Removal steps Boll housing cover Oil retumn hose Oil pan Drain plug 94° 6. Gasket ” RORS Drive shaft center bearing mounting bolt ert. orsores p9ee727- _ Pee =a aes ing98727 | (© Mitsubishi Motors Corporation Jun. 192 SERVICE POINTS OF REMOVAL 4. REMOVAL OF OIL PAN PWMESNT?-A ‘ADDEDENGINE <4D68> - Oil Pan z 11-93 SERVICE POINTS OF INSTALLATION ‘erkoen ran gt 6. INSTALLATION OF GASKET ain plug gosket cane Replace the gasket with a new gasket, and install it in the CP Su8 direction shown in the illustration. (© mteubichi Motors Corporation Jun 1062 PwnRESTT7 A ‘apoeD11-94 ENGINE <4D68> - Crankshaft Front Oil Seal CRANKSHAFT FRONT OIL SEAL enue REMOVAL AND INSTALLATION (Refer to P1 ‘ m6 iy aa ‘ ie) Engine oil 9 Removal steps $f i Ganichatt bot 1 46 982 Crankshaft sprocket 7 3. Flange . ‘D> babadtld + Grate sprocket 8 {Engine oi #1. Crankshatt bolt SERVICE POINTS OF REMOVAL enum 1. REMOVAL OF CRANKSHAFT BOLT/2. CRANKSHAFT ‘SPROCKET Oleca SERVICE POINTS OF INSTALLATION enero oaall x Front INSTALLATION OF CRANKSHAFT FRONT OIL SEAL cae — case Apply engine ollto the entire circumference of the oil seal ip, and then tap in the oil seal until itis flush with the front lower > case. Mpsie083 Mosse3e2 vcs (© Mma Motors Carsaration aun. 182 Pwo. ‘ADDED2. INSTALLATION OF CRANKSHAFT BOLT B990767 CRANKSHAFT REAR OIL SEAL REMOVAL AND INSTALLATION Crankshaft sproct Pre-removal and Post-installation Operations ¢" Removal and Installation of Transmission Assom- bly Refer to GROUPS 22 and 23 ~ Transmission sembly) ‘© Removal and Installation of Clutch Cover and Disk ‘© Removal and Installation of Oil Pan (Refer to P1192), oe Removal steps Elywhee! bot Eyanee Pt) <> Drive pate bolt Adapter plate Drive plate Crankshaft bushing Crankshaft rear oll Seal on we nogpens } ” | / Crankshaft Rear Oi 11-95 CRANKSHAFT SPROCKET/1. Crankshaft ood Engine oil 130-140 Nm 13-14 kgm 94-101 felbs, (© Mitsubishi Motors Corporation Jun. 1982 PwMESTTT-A11-96 ENGINE <4D68> - Crankshaft Front Oil Seal and Crankshaft Rear Oil Seal SERVICE POINTS OF REMOVAL enusas 1, REMOVAL OF FLYWHEEL BOLT /3. DRIVE PLATE BOLT Use the special tool to secure the flywheel or drive plate, and remove the bolt. SERVICE POINTS OF INSTALLATION enucar 7. INSTALLATION OF CRANKSHAFT REAR OIL SEAL (1) Apply a small amount of engine oil to the entire circum- ference of the oil seal lip. (2} Tap in the oil seal as shown in the illustration. owsores 3. INSTALLATION OF DRIVE PLATE BOLT /1. FLYWHEEL BOLT Use the special tool to secure the fiywheel or drive plate, and install the bolt. (© MitsublhI Motors Corporation Jun. 192 PwMESNTT A ‘ADDEDENGINE <4D68> - Cylinder Head Gasket 11-97 CYLINDER HEAD GASKET ent REMOVAL AND INSTALLATION Pre-removal and Post-installation Operations ‘© Draining and Supplying of the Costant (Refer fo GROUP 14 ~Service Adjustment roce- ures.) ‘© Draining and Supplying of the Engine Oil ‘¢ Removal and Installation of the Air Intake Hose and Air Cleaner Assembly. Sealant: 3M ATD Part No. 8660 or Cylinder equivalent block “ PED Bead diemeter ‘> 2es0mm (0.03-0.12 inj} ‘xing ‘Specified sealant: Esum ol ‘cen MITSUBISHI GENUINE PART ook 1MD370388 ot eq 43 fabs. Removal steps 1. Engine coolant temperature sensor and ‘engine coolant temperature gauge unit 2. Engine coolant temperature switch con- rector (A/C) 3. Glow plug connector 4. Engine hanger 5. Raciator upper hose connection 6 Heater hose connection 7. Weter hose connection 8. Timing belt upper cover 8. Rocker cover 10. Semécircular packit 11. Glow plug plate 12. Glow plug 4413. Thermostat case assembly 14. Oillevel gauge 18Nm 18 kam Bhlbs, < 10-13. Nm 10-13 kam 7 Stele 10-12Nm a 0-2 kgm + ohibe (© MisubichiMotors Corporation Jan 1982 PWMESTTI-A roy11-98 ENGINE <4D68> ~ Cylinder Head Gasket 27-31. Nm 19-21Nm 3232 kom 19-2.1 kgm 1-415 ttibs. 20-23 ftlbs. 19-21.1Nm 1.9-2.1 kgm TH18 tebe. orno042| Cam section and journal section 24m sid 2akgm xn eee Engine oil Gold Engine 38 Nm Om 30m 90" 200" .0 kgm > 0 kam — 4.0 kgm — +30" 85 felbs. ~ Oe lbs. = 29 fb, > $90" — $90" Removal steps 44 $4 15. Fuel injection pipe 4 6425. Cylinder head bott #4 86 16. Comshaft sprocket 26. Gylinder head assembly 44-17. Gil seal 6 27. Cylinder head gasket 44 18, Rocker arm and shaft assembly 44 19. Camshaft bearing cap 20. Camshaft 21. Rocker shaft support 22) Selfocking nut 23. Gasket 24. Fuel retum hose ‘© Mitsbiohi Motor Comportion Jun. 1862 PUIMEDTTA ‘ADDEDENGINE <4D68> — Cylinder Head Gasket 11-99 SERVICE POINTS OF REMOVAL ens 15, DISCONNECTION OF INJECTION PIPE When loosening nuts at both ends of injection pipe, hold the other side (pump side-delivery holder, nozzle side-nozzle holder) with wrench and loosen nut. Caution After disconnecting the injection pipe, plug the opening so that no foreign particles get inside the pump or into the injection nozzle. 16. REMOVAL OF CAMSHAFT SPROCKET (1) Rotate the crankshaft clockwise and check that the cam- shaff sprocket's timing mark and the injection sprocket's timing mark are aligned, Caution The crankshaft should always be turned in a clock- wise direction. (2) Use the special tool to loosen the camshaft sprocket bolt (3) Remove the camshaft sprocket with the timing belt still attached, and place it on the timing belt lower cover. NOTE At this time, tie the timing belt and camshaft sprocket and also the timing belt and injection pump sprocket to- gether with cord or similar so thet they do not become unmeshed. Caution The crankshaft should not be turned after the cam- shaft sprocket has been removed. 25. REMOVAL OF CYLINDER HEAD BOLT Loosen each of the bolts in 2 or 3 steps (in the order shown, in the illustration), and then remove the cylinder head assem- biy. ornoaet (© tsubleht Motors Corporation Jun. 1992 Pwene9t17.4, ‘ADDED11-100 ENGINE <4D68> - Cylinder. Head Gasket Identification mark Identification holes SERVICE POINTS OF INSTALLATION enupev 27. INSTALLATION OF CYLINDER HEAD GASKET 0) Wipe off any oil or grease from the gasket mounting sur- face. (2) Check the number of identification holes on the cylinder head gasket that was removed, and select a cylinder head gasket with the same number of identification holes. (3) Place the cylinder head gasket on top of the cylinder bblock so that the identification mark is facing upwards es in the illustration, 25, INSTALLATION OF CYLINDER HEAD BOLT (1) When installing the cylinder head bolts, the length below the head of the bolts should be within the standard value. If itis outside the standard value, replace the bolts. pid oil 7 Limit: Within 119.7 mm (4.713 in.) Washer end (2) Apply a small amount of engine oil to the thread section Gon ot bop. and the washer of the cylinder head bolt. pot odo mp (3) Tighten the bolts in order by the following procedure. Procedure | Operation contents | Remarks © | Tghtentos0Nm Carry outin the order {90 kgm, 65 feos) shown inthe istration ¥ cay ut inthe rverse or © | Fully loosen do to that shown nthe f= : tuswation Tighten to 40. Nm Carry outin tho order ornoae1 © | oom 29 fis Shown in the tstation 7 shown ithe ilstration %@ —_| Tighten by 1/4 turn | Cary out in the order t Shown i the istration (© Mitubehi Motors Comoration un. 192 Pumest 178 ‘0069ENGINE <4D68> -— Cylinder Head Gasket 11-101 Cap No. J) _ wail 7 dv indent: er) Bonin Son ee ‘Camshaft, L snes cove ‘eaxoor| © tasubientotore Corporation “Jon. 82 19. INSTALLATION OF CAMSHAFT BEARING CAP ‘The cap numbers are embossed on the top surface of the bearing caps, so install in the order of the numbers. However, no numbers are embossed on bearing caps 1 and 5. 18.INSTALLATION OF ROCKER ARM AND SHAFT ASSEMBLY (1) Install the rocker arm and sheft assembly to the bearing caps. (2) Set the rocker arm springs into the bearing cap indents. (8) Check the valve clearance and adjust if necessary. (Refer to P.11-%«,) 17. INSTALLATION OF CAMSHAFT OIL SEAL (1) Apply a small amount of engine oil to the entire circum- ference of the oil seal lip and camshaft. (2) Use the special tool to tap in the oil seal NOTE The oil seal should be tapped in until the distance from ‘the end of the camshaft to the end of the oil seal is as shown in the illustration, 16. INSTALLATION OF CAMSHAFT SPROCKET 15, INSTALLATION OF FUEL INJECTION PIPE ‘When tightening the nuts at both ends of the fuel injection pipe, hold the other side (pump-side delivery holder, nozzie- side nozzle holder) with a wrench, and tighten the nuts to the specified torque. Pnesrt7 A ‘ADDED11-102 ENGINE <4D68> — Cylinder Head Gasket ‘Thermostat case assembly O-ring A-ha Water inlet pipe essemibly 26v0001 “Thermostat case assembly {(10108-0.12 in.)_ovcoors ‘© MitubishiMotore Corporation Jun. 1982 13. INSTALLATION OF THERMOSTAT CASE ASSEMBLY (1) Insert the O-+ing into the groove of the water inlet pipe assembly and rinse the outside of the O-ring with water, (2) Apply specified seslant to the sections of the thermostat case assembly shown in the illustration. ‘Semi-dry sealant: Three bond 1207F (3) After rinsing the inside of the thermostat case assembly with water, install the thermostat case assembly hole and the water iniet pipe. (4) Tighten the thermostat case assembly mounting bolts. Pwnacont7 AENGINE <4D68> - Timing Bolt and Timing Bolt B 11-103 TIMING BELT AND TIMING BELT B eno REMOVAL AND INSTALLATION 58m SBkqm az telbs. 110-130'Nm 191m 100-120 Nm 11-13 kgm km 8 19 kgm 72-87 Rubs. eee et wD ¥ < << engreon 8 Pa 7 25Nm 72-87 ft.lbs. ao ‘Timing belt removal steps 1. Engine mount bracket 10. Timing belt lower cover © Agjustment of drive belt tensions 94 ¢ Adjustment of timing belt tension (Refer to P.11-79.) 49 94-11. Timing belt 2. Power steering drive belt 3. Air Leiner keg belt ‘Timing belt B removal steps 4, Altemator drive bet 4b 94-11. Timing belt Crank pulley | $8 88 12. Creniohatt bor 7 Rrcortitonerteorerpuley assem: YS 1G: Canker serockr a 15. Timing belt B tensioner 8. Timing belt upper cover “we Adjustment of tming belt B tension 8. Airconditoner compressor connection eth 16 cotene © Mitsubishi Motors Corporation dun. 1902 UMEDA "ADDED11-104 ENGINE <4D68> — Timing Belt and Timing Belt B SERVICE POINTS OF REMOVAL. enoe0., 11, REMOVAL OF TIMING BELT (1) Align the timing marks. Timing marks (2) Using along extension, loosen the installation bolt of the timing belt tensioner (from the engine rear) 3) Move the timing belt tensioner downward and loosely tighten the bolt so that the tensioner doesn’t return; then remove the timing belt Caution If the timing belt is to be re-used, use chalk to mark (on its flat side) an arrow indicating the clockwise direction. Lowest oart of oval hole 12./13. REMOVAL OF CRANKSHAFT SPROCKET AND CRANKSHAFT BOLT 16. REMOVAL OF TIMING BELT “B” Caution If the timing belt “B” is to be re-used, use chalk to mark {on its flat side) an arrow indicating the clockwise direc- tion. (© Miaubia Motors Commeration Jun, 1992 PwMestt7 8 ‘ADDEDENGINE <4D68> — Timing Belt and Timing Belt B 11-105 SERVICE POINTS OF INSTALLATION enone 16. INSTALLATION OF TIMING BELT “B” {1) Ensure that crankshaft sprocket’B" timing mark and the counterbalance shaft sprocket timing mark are aligned. (2) Fit timing belt “B” over crankshaft sprocket “B" and the counterbalance shaft sprocket. Ensure that there is, no slack in the belt. © ADJUSTMENT OF TIMING BELT “B” TENSION (1) Temporarily fix the timing belt “B” tensioner such that the centre of the tensioner pulley is to the left and above the centre of the installation bolt, and temporari- ly attach the tensioner pulley so that the flange is toward the front of the engine. (2) Holding the timing belt "B” tensioner up with your finger in the direction of the arrow, place pressure on the timing belt so that the tension side of the belt is taut. Now tighten the bolt to fix the tensioner. Caution When tightening the bolt, ensure that the tensioner pulley shaft does not rotate with the bolt. Allowing it to rotate with the bolt can cause excessive tension of the belt, (3) Check to ensure that when centre of span on tension side is depressed with index finger in direction of arrow, tension of belt is up to specification Standard value: 5-7 mm (0.20-0.28 in.) + Contié of installation bolt™“pmiowe 14./13./12, INSTALLATION OF FLANGE, CRANKSHAFT Crankshaft ‘SPROCKET AND CRANKSHAFT BOLT (1) When installing, be sure the direction is correct. Crankshaft Crankshaft sprocket sprocket Flange on0795 ‘© Mikexbioni Motors Corporation Jun. 1982 PwneEst 7A ‘ADDEDB990767 Crankshaft sprocket cams srocket Wyecton Tring meek Sprodket ine =k ing mae Oil pump Crantshat {@) fy sprocket spesket WS moser Lowest part of oval ole AoE in toon ota Timing mark 7 mark ENGINE <4D68> - Timing Belt and Timing Belt B (2) Install the crankshaft sprocket by using the special too! 11. INSTALLATION OF TIMING BELT (1) Ensure that the timing marks of the camshaft sprock- et, the injection pump sprocket, the crankshaft sprock- et, and the oil pump sprocket are all aligned (2) Move the timing bett tensioner downward and loosely tighten the bolt so that the tensioner doesn't return. (3) Install the timing belt onto the crankshaft sprocket, the timing belt idler, the camshaft sprocket, the injection pump sprocket, and the oil pump sprocket in that order. Caution If the timing belt is reused, install so that the arrow marked on it at the time of removal is pointing in the clockwise direction. © ADJUSTMENT OF TIMING BELT TENSION (1) Turn the crankshaft anticlockwise by a distance equiv. alent to 1/2 tooth of the camshaft sprocket in order to correct looseness at the timing belt idler side. (2) Loosen (by 1/6 to 1/2 turn) the tensioner installation bolt previously secured provisionally, taking advantage of the force of the tensioner spring to provide tension to the belt. PwMestT7-A ‘ADDEDENGINE <4D68> - Timing Belt and Timing Belt B 11-107 Camshaft Sprocket Injection pump Sprocket ‘ene (© Mitsubishi Motors Corporation von. 1992 (3) In addition, turn the crankshaft anticlockwise by a distance equivalent to 2-1/2 teeth. {4} Tighten the timing belt tensioner at the specified torque. (6) Tum the crankshaft clockwise and align the timing mark. (6) Using the index finger, press between the camshaft sprocket and the injection pump and sprocket, and check whether or not the amount of flexion is within, the standard value range or not, Standard value range: 4-5 mm (0.16-0.20 in.) PwMesTY7-8 ‘ADDED11-108 ENGINE ASSEMBLY REMOVAL AND INSTALLATION ENGINE <4D68> — En; Assembly Preremoval Operations. ()” Removal of Hood (Refer to GROUP 42 - Hood) 12) Prevention of Fue! Flow (Refer to GROUP 13 ~ Sorvice Adjustment Procedures) (2) Braining of Engine Coolant {@) Removal of Tangmission Assembly (Refer to GROUPS 22 and 23 ~ Transmission Ass (8) Romoval of Radiator Ascombly (ater to GROUP Post.inatallation Operations {0 ingtalton of Recstor Assembly (Refer to Group ‘a= achat) ° (2) Instalton of Tansmission Assombly Refer to GROUES Sand 38 tanaisson hase) 19) Supplying of Engine Coolant (8 Abeta of Acoso: cable eter to GROUP 13 Service sajustment Procedures) 14~ Radiator (8) Air Bleeding of Fuel Line (Refer to GROUP 13 ~ ‘Service Adjustment Procedures) (6)_Installation of Hood (Refer to GROUP 42 — Hood) Removal steps ‘Accelerator cable connection Fuel hose (return) connection !. Fuel hose (main) connection Heater hose connection Brake booster vacuum hose connection EGR vacuum hose connection Vacuum hose connection for air condi- tioner idle-up solenoid valve Mogae ovsowe 8 8. Control harness connection 9. Fuel injection pump harness connection }0. Lever (throttle) position sensor connec- tor © Adjustment of drive belts (P.11-78.) 11. Power steering drive belt orsows 46 12. Power steering oll pum 3 4 18. Air conditioner drive bel 46 14. Air conditioner compressor (© mansubis Motors Corporation Jun. 1092 PwMEnTT-A "ADDEDENGINE <4D68> - Engine Assembly 45kam 7 15. Engine oil feed hose connection 16. Engine oil return hose connection 7. Self-ocking nut and bolt 8. Gasket 9. Alternator connector 0. Cil pressure switch connector 48 94-21. Engine mount bracket 44 © 22. Engine assembly 11-109 orsor2 © Mitsubishi Moters Corporation Jun, 2H PUMESTTTA "ADDED11-110 ENGINE <4D68> - Engine Assembly SERVICE POINTS OF REMOVAL enTeaN 12, REMOVAL OF POWER STEERING OIL PUMP Remove the power steering oil pump from the bracket with the hose attached. NOTE Place the removed power steering oil pump ina place where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord. 14,.REMOVAL OF AIR CONDITIONER COMPRESSOR Disconnect the air conditioner compressor connector and re- Move the compressor from the compressor bracket with the hose still attached. NOTE Place the removed air conditioner compressor in a place ‘where it will not be a hindrance when removing and installing the engine assembly, and tie it with @ cord. 21. REMOVAL OF ENGINE MOUNT BRACKET (1) Support the engine with a garage jack. (2) Hold the engine assembly with a chain block, etc. (G) Place the garage jack against the engine oil pan with a piece of wood in between, and after raising the engine until there is no weight on the engine mount brackets, re- move the engine mount brackets. REMOVAL OF ENGINE ASSEMBLY After checking that all cables, hoses and hamess connec- tors, etc., are disconnected from the engine, lift the chain block slowly to remove the engine assembly upward from the engine compartment, SERVICE POINTS OF INSTALLATION errtoaa, 21. INSTALLATION OF ENGINE MOUNT BRACKET (1) Place a garage jack against the engine oil pan with apiece of wood in between, and install the engine mount brack- ‘et while adjusting the position of the engine. (2) Support the engine with a garage jack. (8) Remove the chain block and support the engine assem- bly with the special tool. nees117-4, ‘ADDED