Ev6 Xe11

11-1
ENGINE
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . 2 EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . 31
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 3 WATER PUMP AND WATER HOSE . . . . . 34

Service Specifications . . . . . . . . . . . . . . . . . . . . . . 3
cardiagn.com
ROCKER ARMS AND CAMSHAFT . . . . . . 37
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . 5
New Tightening Method by Use of Bolts CYLINDER HEAD AND VALVES . . . . . . . . 43
to Be Tightened in Plastic Area . . . . . . . . . . . . 9
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FRONT CASE, COUNTERBALANCE
SHAFT AND OIL PAN . . . . . . . . . . . . . . . . . 51
Form-In-Place Gasket . . . . . . . . . . . . . . . . . . . . 10
PISTON AND CONNECTING ROD . . . . . . 59
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 11
CRANKSHAFT AND FLYWHEEL . . . . . . . . 67
ALTERNATOR AND IGNITION SYSTEM . 14
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . 73
TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . 15
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . 75
FUEL AND EMISSION CONTROL PARTS 27
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . 79
SECONDARY AIR SYSTEM AND INTAKE
MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . 83
11-2 ENGINE – General Information
GENERAL INFORMATION
Descriptions Specifications
Type In-line OHV, SOHC
Number of cylinders 4
Combustion chamber Pentroof + curved top piston type
Total displacement dm3 1,997
Cylinder bore mm 85.0
Piston stroke mm 88.0
Compression ratio 8.8
Valve timing Intake valve Opens (BTDC) 21°
Closes (ABDC) 59°
Exhaust valve Opens (BBDC) 58°
cardiagn.com
Closes (ATDC) 18°
Lubrication system Pressure feed, full-flow filtration
Oil pump type Involute gear type

ENGINE – Specifications 11-3
SPECIFICATIONS
SERVICE SPECIFICATIONS
Items Standard value Limit
Timing belt
Auto-tensioner rod projection length mm 12 –

Auto-tensioner rod pushed-in amount [when pushed with a force of 98 1.0 or less –
– 196 N] mm
Rocker arms and camshaft
Camshaft cam height mm Intake 35.79 35.29
Exhaust 35.49 34.99
Camshaft journal outer diameter mm 26 –
Cylinder head and valves
Cylinder head flatness of gasket surface mm Less than 0.05 0.2
cardiagn.com
Cylinder head grinding limit of gasket surface mm – 0.2
Total resurfacing depth of both cylinder head and cylinder block
Cylinder head overall height mm 131.9 – 132.1 –
Cylinder head bolt shank length mm – Maximum 99.4
Valve thickness of valve head (margin) mm Intake 1.0 0.5
Exhaust 1.5 1.0
Overall valve length mm Intake 109.5 109.0
Exhaust 109.7 109.2
Valve thickness to valve guide clearance Intake 0.02 – 0.05 0.10

mm
Exhaust 0.05 – 0.09 0.15
Valve face angle 45° – 45.5° –
Valve spring free length mm 48.3 47.3

Valve spring load/installed height N/mm 294/40.0 –
Valve spring out-of-squareness 1.5° or less Maximum 4°
Valve seat contact width mm 0.9 – 1.3 –
Valve guide inner diameter mm 6.6 –
Valve guide projection from cylinder head upper surface mm 20.5 –
Valve stem projection mm Intake 49.20 49.70
Exhaust 48.40 48.90
Oversize rework dimensions of valve guide 0.05 O.S. 12.05 – 12.07 –

hole mm
0.25 O.S. 12.25 – 11.27 –
0.50 O.S. 12.50 – 12.52 –
11-4 ENGINE – Specifications
Intake oversize rework dimensions of valve 0.3 O.S. 35.30 – 35.33 –

guide hole mm
0.6 O.S. 35.60 – 35.63 –
Exhaust oversize rework dimensions of 0.3 O.S. 33.30 – 33.33 –

valve guide hole mm
0.6 O.S. 33.60 – 33.63 –
Front case and oil pan
Oil pump side clearance mm Drive gear 0.08 – 0.14 –
Driven gear 0.06 – 0.12 –
Oil pressure at curb idle speed kPa [Oil temperature is 75 to 90°C] 78 or more –
Piston and connecting rod
Piston outer diameter mm 85.0 –
Piston ring side clearance mm No. 1 ring 0.04 – 0.075 –
cardiagn.com
No. 2 ring 0.02 – 0.06 –
Piston ring end gap mm No. 1 ring 0.25 – 0.35 0.8

No. 2 ring 0.40 – 0.55 0.8
Oil ring 0.10 – 0.40 1.0
Piston pin outer diameter mm 21.0 –
Piston pin press-in load N (Room temperature) 7,350 – 17,200 –
Crankshaft pin oil clearance mm 0.02 – 0.05 0.1
Connecting rod big end side clearance mm 0.10 – 0.25 0.4
Crankshaft and flywheel
Crankshaft end play mm 0.05 – 0.25 0.40
Crankshaft journal outer diameter mm 57.0 –

Crankshaft pin outer diameter mm 44.0 –
Crankshaft journal oil clearance mm 0.02 – 0.04 0.1
Bearing cap bolt shank length mm – Maximum 71.1
Piston to cylinder clearance mm 0.02 – 0.04 –
Cylinder block grinding limit of gasket surface mm – 0.2

Total resurfacing depth of both cylinder head and cylinder block
Cylinder block overall height mm 284 –
Cylinder block inner diameter mm 85.0 –
Cylinder block cylinder mm 0.01 –
Turbocharger
Waste gate actuator operation check kPa 100 113.3
Alternator
Rotor coil resistance Ω Approx. 3 – 5 –
Protrusion length of brush mm – 2
Starter motor
Commutator runout mm 0.05 0.1
Commutator outer diameter mm 32.0 31.4
Commutator undercut mm 0.5 –
TORQUE SPECIFICATIONS
Items Nm
Alternator and ignition system
Oil level gauge guide 13
cardiagn.com
Water pump pulley 9
Alternator brace (Alternator side) 21
Alternator brace (Tightened with water pump) 23
Alternator pivot bolt 44
Crankshaft pulley 25
Center cover 3
Spark plug 25
Ignition coil 10
Timing belt
Timing belt cover (Flange bolt) 11
Timing belt cover (Washer bolt) 9
Power steering pump bracket 49
Tensioner pulley 49
Tensioner arm 24
Auto tensioner 24
Idler pulley 48
Crank angle sensor 9
Oil pump sprocket 54
Camshaft bolt 118
Tensioner “B” 19
Counterbalance shaft sprocket 45

Items Nm
Rocker cover 3.5
Engine support bracket 49
Camshaft sprocket bolt 88
Timing belt rear right cover 11
Timing belt rear left upper cover 11
Fuel and emission control parts
Throttle body 18
Fuel pressure regulator 9
Delivery pipe 11
Vacuum tank bracket 9
Solenoid valve bracket 9
cardiagn.com
Solenoid valve 9
Vacuum hose and vacuum pipe 11
Secondary air intake manifold
Heat protector 13
Vacuum hose and vacuum pipe 11
Air pipe (Heat protector side) 13
Air pipe (Cam position sensor side) 11
Air pipe (Eye bolt) 49
Air pipe (Control valve side) 24
Air control valve 21
Air control valve bracket 24
Intake manifold stay 30
Intake manifold (M8) 19
Intake manifold (M10) 35
Exhaust manifold
Engine hanger 12
Heat protector (Turbocharger side) 14
Oxygen sensor 54
Exhaust fitting bolt 59
Exhaust fitting nut 59
Air outlet fitting 19

Items Nm
OIl return pipe (Turbocharger side) 9
Oil return pipe (Oil pan side – Head mark 7) 9
Oil return pipe (Oil pan side – Head mark 10) 13
Oil pipe 11
Oil pipe eye bolt (Cylinder head side) 16
Oil pipe eye bolt (Turbocharger side) 30
Water pipe 11
Water pipe eye bolt 41
Exhaust manifold (M8) 29
Exhaust manifold (M10) 49
Exhaust manifold (Turbocharger side) 59
cardiagn.com
Water pump and water hose
Water temperature sensor 29
Water temperature gauge unit 11
Water inlet fitting 24
Water outlet fitting (M6) 10
Water outlet fitting (M8) 13
Thermostat housing 24
Thermostat housing (Clamp) 11
Water inlet pipe (Cylinder block) 13
Water inlet pipe (Outlet fitting) 10
Water pump 14
Knock sensor 22
Rocker arms and camshaft
Camshaft position sensor 9
Camshaft position sensor cover 10
Camshaft position sensing cylinder 21
Camshaft position sensing support 13
Camshaft bearing cap 20
Oil delivery body 11
Cylinder head and valves
Cylinder head bolt [Tighten to 78 Nm and then completely before tightening to final torque 20 ! 90° + 90°
specification]
Items Nm
Front case and oil pan
Drain plug 39
Oil pan 7
Oil screen 19
Buffle plate 22
Oil pressure switch 10
Oil cooler by-pass valve 54
Relief plug 44
Plug 24
Front case 24
Oil pump cover (Screw) 10
cardiagn.com
Oil pump cover (Bolt) 16
Piston and connecting rods
Connecting rod nut 20 + 90° to 94°
Crankshaft and flywheel
Flywheel bolt 132
Rear plate 11
Bell housing cover 9
Oil seal case 11
Beam bearing cap bolt 25 + 90°
Check valve 32
Throttle body
Throttle position sensor 3.5
Idle speed control body assembly 3.5
Turbocharger
Waste gate actuator 11

NEW TIGHTENING METHOD – BY USE OF BOLTS TO BE TIGHTENED IN
PLASTIC AREA
A new type of bolts, to be tightened in plastic area, is currently used some parts of the engine. The
tightening method for the bolts is different from the conventional one. Be sure to observe the method
described in the text when tightening the bolts.
Service limits are provided for the bolts. Make sure that the service limits described in the text are strictly
observed.
D Areas where the bolts are in use:
(1) Cylinder head bolts
(2) Main bearing cap bolts
(3) Connecting rod cap bolts
D Tightening method
After tightening the bolts to the specified torque, tighten them another 90° or 180° (twice 90°). The
tightening method varies on different areas. Observe the tightening method described in the text.
SEALANTS
Item Specified sealant Quantity
Engine support bracket bolt 3MTM AAD Part No. 8672 or equivalent As required
cardiagn.com
Semi-circular packing 3MTM AAD Part No. 8672 or equivalent As required
Rocker cover 3MTM AAD Part No. 8672 or equivalent As required
Oil return pipe gasket 3MTM AAD Part No. 8731 or equivalent As required
Thermostat housing Mitsubishi Genuine Part No. MD970389 or As required

equivalent
Water outlet fitting Mitsubishi Genuine Part No. MD970389 or As required

equivalent
Engine coolant temperature gauge unit 3MTM AAD Part No. 8672 or equivalent As required
Engine coolant temperature sensor 3MTM AAD Part No. 8731 or equivalent As required
Cam position sensor support Mitsubishi Genuine Part No. MD970389 or As required
equivalent
Oil pressure switch 3MTM AAD Part No. 8672 or equivalent As required
Oil pan Mitsubishi Genuine Part No. MD970389 or As required

equivalent
Oil seal case Mitsubishi Genuine Part No. MD970389 or As required

equivalent
FORM-IN-PLACE GASKET
The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket
fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead
size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick
a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the
fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to
apply the gasket evenly without a break, while observing the correct bead size.
The FIPG used in the engine is a room temperature vulcanisation (RTV) type and is supplied in a 100-gram
tube (Part No. MD970389). Since the RTV hardens as it reacts with the moisture in the atmospheric
air, it is normally used in the metallic flange areas. The FIPG, Part No. MD970389, can be used for
sealing both engine oil and coolant, while Part No. MD997110 can only be used for engine oil sealing.
Disassembly
The parts assembled with the FIPG can be easily disassembled without use of a special method. In
some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking
with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the
joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.
For removal of the oil pan, the special tool “Oil Pan Remover” (MD998727) is available. Be sure to use
the special tool to remove the oil pan.
cardiagn.com
Surface Preparation
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure
that there are no oils, greases and foreign substances deposited on the application surfaces. Do not
forget to remove the old sealant remained in the bolt holes.
Form-in-Place Gasket Application

When assembling parts with the FIPG, you must observe some precautions, but the procedures is very
simple as in the case of a conventional precut gasket.
Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the
bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is
hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When
the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do
not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time
(about one hour) has passed after installation is completed.
The FIPG application procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.
ENGINE – Special Tools 11-11
SPECIAL TOOLS
Tool Number Name Use
MD998781 Flywheel stopper Holding of flywheel and drive plate
MD998778 Crankshaft Removal of crankshaft sprocket

sprocket puller
MD998719 Pulley holder pin Holding camshaft sprocket
cardiagn.com
MB990767 Crankshaft pulley
holder
MD998785 Sprocket stopper Holding silent shaft sprocket
MD998767 Tensioner puller Adjustment of timing belt tension

socket wrench
MD998738 Set screw
MD998713 Camshaft oil seal Installation of camshaft oil seal

installer
MD998442 Lash adjuster wire Air bleeding of lash adjuster

11-12 ENGINE – Special Tools

MB991654 Cylinder head bolt Removal and installation of cylinder head bolt
wrench (12)
MD998772 Valve spring Removal and installation of valve and related

compressor parts
MD998735 Valve spring

compressor
MD998737 Valve stem seal Installation of valve stem seal
cardiagn.com
installer
MD998727 Oil pan remover Removal of oil pan
MD998162 Plug wrench Removal and installation of front case cap plug
Use with MD998783.
MD998783 Plug wrench Removal and installation of front case cap plug
retainer
MD998371 Silent shaft bearing Removal of counterbalance shaft front bearing

puller
MD998372 Silent shaft bearing Removal of counterbalance shaft rear bearing

puller
ENGINE – Special Tools 11-13

MB991603 Silent shaft bearing Guide stopper for removal and installation of
puller stopper counterbalance shaft rear bearing
Use with MD998372.
MD998705 Silent shaft bearing Installation of counterbalance shaft front and

installer rear bearing
MD998375 Crankshaft front Installation of crankshaft front oil seal

seal installer
MD998285 Crankshaft front oil Guide for installation of crankshaft front oil seal
cardiagn.com
seal guide Use with MD998375.
MD998780 Piston setting tool Removal and installation of piston pin
MB990938 Handle Installation of crankshaft rear oil seal
MD998776 Crankshaft rear oil

seal installer
11-14 ENGINE – Alternator and Ignition System
ALTERNATOR AND IGNITION SYSTEM

REMOVAL AND INSTALLATION
9
3 Nm
10 Nm
1
10
2 11
25 Nm
15 12
16
cardiagn.com
14
13 Nm
44 Nm
4
3 7
13
6
21 Nm
23 Nm
9 Nm
25 Nm
8
Removal steps
1. Oil level gauge 9. Center cover
2. O-ring 10. Spark plug cable
3. Oil level gauge guide 11. Ignition coil
4. O-ring 12. Spark plug
5. Water pump pulley 13. Breather hose
6. Alternator brace 14. PCV hose
7. Alternator 15. PCV valve
8. Crankshaft pulley 16. PCV valve gasket
ENGINE – Timing Belt 11-15
TIMING BELT
7 23
11 Nm 1 8 26
49 Nm 22
24
2 3.5 Nm
24 Nm
24 Nm 25
9
30
11 Nm
11 Nm
14 27
13
cardiagn.com
118 Nm 31
9 Nm 49 Nm 3
4 30 Nm
6 45 Nm 18 19
29
19 Nm 5
32 11
28
21
88 Nm
20 49 Nm
15 16 9 Nm
17
48 Nm 12
54 Nm
10
Removal steps
1. Timing belt front upper cover AE" "GA 17. Timing belt B
2. Timing belt front center cover AF" "FA 18. Counterbalance shaft sprocket
3. Rubber plug "EA 19. Crankshaft spacer
4. Timing belt front lower cover AG" 20. Crankshaft sprocket B
5. Power steering pump bracket 21. Crankshaft key
AA" "LA 6. Timing belt 22. Oil filler cap
"KA 7. Tensioner pulley "DA 23. Rocker cover
8. Tensioner arm 24. Rocker cover gasket A
"JA 9. Auto tensioner 25. Rocker cover gasket B
10. Idler pulley "CA 26. Semi-circular packing
11. Crank angle sensor "BA 27. Engine support bracket
AB" "IA 12. Oil pump sprocket AH" "AA 28. Camshaft sprocket bolt
AC" "HA 13. Crankshaft sprocket bolt 29. Camshaft sprocket
AD" 14. Crankshaft sprocket 30. Timing belt rear right cover
15. Crankshaft sensing blade 31. Timing belt rear left upper cover
16. Tensioner B 32. Timing belt rear left lower cover
11-16 ENGINE – Timing Belt
REMOVAL SERVICE POINTS

AA" TIMING BELT REMOVAL
(1) If the timing belt is to be reused, chalk an arrow mark
on the back surface of the belt so that the belt can be
reinstalled in the same direction.
(2) Place the exhaust camshaft sprocket in a position where
the timing mark for No. 1 cylinder is positioned about
one tooth before the top dead center of the compression
stroke.
Timing mark Caution

The camshaft sprocket on the exhaust side can turn
very easily because of the valve spring tension. Use
care not to allow your fingers to get caught by the
sprocket.
(3) Loosen the lock nut of the tensioner pulley, then remove
the timing belt.
cardiagn.com
AB" OIL PUMP SPROCKET REMOVAL
(1) Remove the plug on the left side of cylinder block.
(2) Insert a screwdriver (shank diameter 8 mm) to block the
counterbalance shaft.
(3) Remove the nut.
(4) Remove the oil pump sprocket.
AC" CRANKSHAFT BOLT LOOSENING

(1) Hold the drive plate with the special tool as shown.
(2) Remove the crankshaft bolt.
AD" CRANKSHAFT SPROCKET REMOVAL

If it is difficult to remove the sprocket, use the special tool.
AE" TIMING BELT “B” REMOVAL
Make a mark on the back of the timing belt indicating the
direction of rotation so it may be reassembled in the same
direction if it is to be reused.
NOTE
(1) Water or oil on the belt shortens its life drastically, so
the removed timing belt, sprocket, and tensioner must
be free from oil and water. These parts should not be
washed. Replace parts if seriously contaminated.
6EN1322
(2) If there is oil or water on each part check front case
oil seals, camshaft oil seal and water pump for leaks.
AF" COUNTERBALANCE SHAFT SPROCKET
REMOVAL
(1) Set the special tool as shown to prevent the
MD998785 counterbalance shaft sprocket from turning together.
(2) Loosen the bolt and remove the sprocket.
cardiagn.com
AG" CRANKSHAFT SPROCKET “B” REMOVAL
If it is difficult to remove the sprocket, use the special tool.
AH" CAMSHAFT SPROCKET BOLT LOOSENING

Use a wrench to hold the hexagonal part of the camshaft,
and then remove the camshaft sprocket mounting bolt.
INSTALLATION SERVICE POINTS

"AA CAMSHAFT SPROCKET BOLT TIGHTENING
Using a wrench, hold the camshaft at its hexagon and tighten
the bolt to the specification.
"BA ENGINE SUPPORT BRACKET INSTALLATION

Coat the bolts illustrated with sealant before tightening.
Specified sealant: 3MTM AAD Part No. 8672 or equivalent
"CA SEALANT APPLICATION TO SEMI-CIRCULAR

PACKING
cardiagn.com
10 mm
Semi- 10 mm
circular
packing
Cylinder head
"DA SEALANT APPLICATION TO ROCKER COVER
Apply sealant to the areas indicated in the illustration.
Apply sealant
10 mm
10 mm
10 mm
Apply sealant
cardiagn.com
10 mm
Apply sealant
Apply sealant
"EA SPACER INSTALLATION

Install the spacer with the chamfered end toward the oil seal.
Counter-
Sharp balance
edge shaft
"FA COUNTERBALANCE SHAFT SPROCKET

INSTALLATION
(1) Install the counterbalance shaft sprocket and screw the
MD998785 bolt.
(2) Install special tool MD998785 as shown in the illustration
to lock the counterbalance shaft.
(3) Tighten the bolt, and then remove the special tool.
"GA TIMING BELT “B” INSTALLATION

(1) Align timing marks on the crankshaft sprocket “B” and
Timing
marks counterbalance shaft sprocket with the marks on the front
(on front Timing case respectively.
case) marks (2) Install the timing belt “B” on the crankshaft sprocket “B”
and counterbalance shaft sprocket. There should be no
slack on the tension side.
(3) Make sure that the relationship between the tensioner

pulley center and the bolt center is as shown in the
illustration.
cardiagn.com
(4) Move the tensioner “B” in the direction of arrow while
lifting with a finger to give a sufficient tension to the tension
side of timing belt. In this condition, tighten bolt to secure
tensioner “B”. When the bolt is tightened, use care to
prevent shaft from turning together. If shaft is turned
together, belt will be overtensioned.
(5) Check to ensure that timing marks on sprockets and front

case are in alignment.
(6) Press with index finger the center of span on the tension
side of timing belt “B”. The bolt must deflect 5 – 7 mm.
"HA CRANKSHAFT BOLT TIGHTENING

(1) Using the special tool, hold the flywheel or drive plate.
(2) Install the crankshaft pulley in position.
"IA OIL PUMP SPROCKET INSTALLATION
(1) Insert a Phillips screwdriver (shank diameter 8 mm shaft)
through the plug hole on the left side of the cylinder
block to block the left counterbalance shaft.
(2) Install the oil pump sprocket.
(3) Apply a proper amount of engine oil to the bearing surfaces
of the nuts.
(4) Tighten the nuts to the specified torque.
6EN0564
"JA AUTO TENSIONER INSTALLATION

(1) If the auto tensioner rod is in its fully extended position,
A reset it as follows.
(2) Clamp the auto-tensioner in the vise with soft jaws.
B
(3) Push in the rod little by little with the vise until the set
hole A in the rod is aligned with the hole B in the cylinder.
cardiagn.com
(4) Insert a wire (1.4 mm in diameter) into the set holes.
(5) Unclamp the auto tensioner from the vise.
(6) Install the auto tensioner to front case and tighten to

the specified torque.
Caution
Leave the wire installed in the auto tensioner.
"KA TENSIONER PULLEY INSTALLATION

Install the tensioner pulley in such direction that its two small
holes are arranged vertically.
Small holes
6EN1323
"LA TIMING BELT INSTALLATION

Timing mark
(1) Place the exhaust side camshaft sprocket in a position
where its timing mark is one tooth offset from the timing
mark on the rocker cover in the counterclockwise direction.
NOTE
Even if the timing marks on the sprocket and the rocker
cover are brought into alignment, the exhaust camshaft
is forced back by the valve spring tension. It is stabilized
at a position one tooth before the timing mark.
(2) Align the timing mark on the intake side camshaft sprocket
with that on the rocker cover.
Timing mark
NOTE
Even if the timing marks on the sprocket and the cover
are brought into alignment, the intake camshaft is forced
to turn one tooth in the clockwise direction by the valve
spring tension and stabilized there.
cardiagn.com
(3) Place the timing mark on the crankshaft sprocket one
tooth this side from the mated timing mark as in the case
of the camshaft sprocket.
(4) Align the timing mark on oil pump sprocket with its mating
Oil pump mark.
sprocket
timing marks
6EN1327
(5) Remove the plug on cylinder block and insert a Phillips

screwdriver (shank diameter 8 mm) through the hole
(Engine with counterbalance shafts).
If it can be inserted as deep as 60 mm or more, the
timing marks are correctly aligned. If the inserted depth
is only 20 – 25 mm, turn the oil pump sprocket one turn
and realign timing marks. Then check to ensure that the
Plug
screwdriver can be inserted 60 mm or more. Keep the
Screwdriver screwdriver inserted until installation of timing belt is
finished.
6EN1026
(6) Remove the Phillips screwdriver. Place the oil pump
sprocket in a position where its timing mark is one tooth
offset from the mated timing mark in the counterclockwise
Timing mark
direction.
6EN1327
(7) Fit the timing belt over the exhaust side camshaft sprocket,
and secure it at the illustrated position using a paper
clip.
cardiagn.com
(8) Turn the intake side camshaft sprocket as shown to a
position where its timing mark is one tooth offset from
the mated timing mark in the counterclockwise direction.
Then, fit the timing belt over the sprocket and secure
it with a paper clip.
NOTE
The intake camshaft will be turned a little clockwise by
the valve spring tension and stabilized in position even
if the belt is clipped at one tooth offset position.
(9) Check to ensure that the timing marks on the intake

Timing mark
camshaft sprocket side are in alignment when the exhaust
camshaft sprocket is turned clockwise to align the timing
marks.
NOTE
The timing belt span between the intake and exhaust
sprockets will have 17 cogs.
(10)Fit the timing belt over the idler pulley, oil pump sprocket
and crankshaft sprocket in this order.
NOTE
Be careful that the belt does not become slack.
Oil pump
sprocket
Crankshaft
sprocket
(11)Fit the timing belt over the tensioner pulley.

NOTE
When fitting the timing belt over the tensioner pulley,
turn the intake side camshaft sprocket a little
counterclockwise, as this will facilitate the work.
Crankshaft
(12)Turn the crankshaft pulley a little in the illustrated direction
sprocket to pull up the timing belt at the idler pulley side.
(13)Check to ensure that the timing marks on the crankshaft
sprocket, oil pump sprocket and exhaust camshaft
sprocket are all offset one tooth from the corresponding
timing marks in the counterclockwise direction.
cardiagn.com
(14)Using the special tool, turn the tensioner pulley in the
illustrated direction to strain the timing belt. Then, secure
the tensioner temporarily by tightening the retaining bolt
MD998767
lightly.
NOTE
There must be no slack in the timing belt between the
intake and exhaust camshafts.
(15)Turn the crankshaft to align the timing mark with the mark
for No. 1 cylinder top dead center in the compression
stroke.
(16)Set the special tool as shown and screw it in up to the

position where the wire inserted in the auto-tensioner
MD998738 when installing it can be moved lightly.
(17)Loosen the retaining bolt of the tensioner pulley.
Caution
Loosening the retaining bolt can cause the intake
and exhaust camshafts to turn, resulting in slackened
timing belt. Use care that the timing belt does not
come off the sprockets at this time.
(18)Pull up the slack of the timing belt by turning the tensioner
in illustrated direction using the special tool and a torque
MD998767
wrench (0 – 5 Nm).
(19)From this position, turn back the tensioner until the torque
wrench reading becomes 3.5 Nm, then secure it by
tightening the retaining bolt.
(20)Remove the special tool attached in step (16).
(21)Rotate the crankshaft clockwise 2 turns. Then, leave it
intact 15 minutes.
(22)Check to see that the wire inserted when installing the
auto-tensioner can be pulled out lightly. If it can be pulled
out lightly, the timing belt is being tensioned properly.
If so, remove the wire. In addition, check that the rod
protrusion from the auto-tensioner meets the standard
cardiagn.com
value, which is also an indication of properly tensioned
timing belt.
Standard value: 3.8 – 4.5 mm
(23)If the wire cannot be removed with a light force, repeat
steps (16) through (21) until the proper belt tensioner
is obtained.
INSPECTION
TIMING BELT
Replace belt if any of the following conditions exist.
(1) Hardening of back rubber.
Back side is glossy without resilience and leaves no indent
when pressed with fingernail.
(2) Cracks on rubber back.

(3) Cracks or peeling of canvas.
(4) Cracks on rib root.
(5) Cracks on belt sides.
(6) Abnormal wear of belt sides. The sides are normal if

they are sharp as if cut by a knife.
(7) Abnormal wear on teeth.

(8) Missing tooth.
cardiagn.com
AUTO TENSIONER
(1) Check the auto tensioner for possible leaks and replace
as necessary.
12 mm (2) Check the rod end for wear or damage and replace as
necessary.
(3) Measure the rod protrusion. If it is out of specification,
replace the auto tensioner.
Standard value: 12 mm
(4) Press the rod with a force of 98 to 196 N and measure

98 to 196 N its protrusion.
(5) If the measured value is 1 mm or more shorter than the
value obtained in step (3), replace the auto tensioner.
Movement
ENGINE – Fuel and Emission Control Parts 11-27
FUEL AND EMISSION CONTROL PARTS
11 Nm
11
11 Nm
3 1 18 Nm
12
9
9 Nm 10
8
5 6
4
cardiagn.com
14 7
2
15
16
9 Nm
13
Removal steps
1. Throttle body 9. O-ring
"CA 2. Throttle body gasket 10. Grommet
3. Fuel return pipe 11. Delivery pipe
"BA 4. Fuel pressure regulator 12. Vacuum hose and vacuum pipe
5. O-ring 13. Vacuum tank
6. Insulator 14. Vacuum tank bracket
7. Insulator 15. Solenoid valve
"AA 8. Injector 16. Solenoid valve bracket
11-28 ENGINE – Fuel and Emission Control Parts

"AA INJECTORS INSTALLATION
(1) Before installing an injector, the rubber O-ring must be
lubricated with a drop of clean engine oil to aid in
installation.
(2) Install injector top end. Be careful not to damage O-ring
during installation.
Grommet
O-ring
cardiagn.com
1EN0388
"BA FUEL PRESSURE REGULATOR INSTALLATION

(1) Apply a small amount of new engine oil to the O-ring.
Insert the fuel pressure regulator into the delivery pipe
being careful not to damage the O-ring.
Caution
Be sure not to let engine oil get into the delivery
pipe.
(2) Check that the fuel pressure regulator turns smoothly.
If it does not turn smoothly, the O-ring may be trapped.
Remove the fuel pressure regulator and check the O-ring
for damage, and then re-insert it into the delivery pipe
and check once again.
"CA GASKET INSTALLATION

Projection Position the projection as shown in the illustration.
ENGINE – Secondary Air System and Intake Manifold 11-29
SECONDARY AIR SYSTEM AND INTAKE MANIFOLD
5
21 Nm
24 Nm
21 Nm
4
6
11 Nm
35 Nm
3
24 Nm
2 7
49 Nm
10 11 Nm 13 Nm
35 Nm
cardiagn.com
35 Nm
19 Nm
9
11
8
30 Nm
Removal steps
1. Exhaust manifold heat protector "AA 7. Air control valve bracket
2. Vacuum hose and vacuum pipe 8. Intake manifold stay
"BA 3. Air pipe assembly 9. Alternator brace stay
4. Air control valve gasket 10. Intake manifold
5. Air control valve assembly 11. Intake manifold gasket
6. Engine hanger
11-30 ENGINE – Secondary Air System and Intake Manifold

"AA AIR CONTROL VALVE BRACKET INSTALLATION
(1) Attach the air control valve bracket and the engine hanger
to the intake manifold using bolts and nuts with which
the intake manifold is also installed to the engine.
(2) Tighten the bolts and nuts to the specified torque in the
(1) sequence given in the illustration.
(3)
(2)
"BA AIR PIPE ASSEMBLY INSTALLATION

(3)
(4) (1) Install the air pipe assembly to the exhaust manifold and
to the air control valve and secure it provisionally by
tightening the fasteners handtight.
(2) Tighten the fasteners to the specified torque in the
sequence given in the illustration.
cardiagn.com
(2) (1)
ENGINE – Exhaust Manifold 11-31
EXHAUST MANIFOLD
16 Nm
19 59 Nm
1
18
12 Nm
11 Nm
29 Nm
30 Nm
14
15
cardiagn.com
49 Nm 10 Nm
13
41 Nm
4 12
10 Nm 16
5
59 Nm
17
14 Nm 11 41 Nm
59 Nm
8 7
3
2 19 Nm
10
54 Nm 9 Nm
9 6
Head mark 7: 9 Nm
Head mark 10: 13 Nm
Removal steps
1. Engine hanger 11. Oil return pipe gasket
2. Turbocharger heat protector (Turbocharger side)
3. Oxygen sensor 12. Turbocharger assembly
4. Exhaust fitting 13. Turbocharger gasket
5. Exhaust fitting gasket 14. Oil pipe
6. Air outlet fitting 15. Water pipe
"CA 7. Air outlet fitting gasket 16. Water pipe
8. Oil return pipe 17. Turbocharger
"BA 9. Gasket "AA 18. Exhaust manifold
"BA 10. Oil return pipe gasket 19. Exhaust manifold gasket
(Oil pan side)
11-32 ENGINE – Exhaust Manifold

"AA EXHAUST MANIFOLD INSTALLATION
3 4 5 6 Tighten the exhaust manifold mounting nuts to the specified
torque in the sequence given in the illustration.
1 7 9 8 2
Timing belt side "BA GASKET / OIL RETURN GASKET INSTALLATION

Oil pan EVOLUTION IV AND V
Install the gasket with the silicon-printed side toward the oil
pan and with the tabbed end directed as shown.
cardiagn.com
Oil return
Silicon print pipe gasket
Timing belt side EVOLUTION VI

(1) Install the gasket with the tabbed end directed as shown.
Oil pan
Oil return
pipe gasket
(2) Apply sealant to both sides of the oil return pipe gasket
Oil pan and leave it for 20 minutes to dry before installing. Tighten
Oil return
pipe the mounting bolts to the specified torque.
Specified sealant:
3MTM AAD Part No. 8731 or equivalent
NOTE
If mounting bolts with head mark 7 have been used,
Gasket be sure to replace them with bolts having head mark
10.
ENGINE – Exhaust Manifold 11-33
"CA GASKET INSTALLATION
Position the projection as shown in the illustration.
Projection
cardiagn.com
11-34 ENGINE – Water Pump and Water Hose
WATER PUMP AND WATER HOSE

REMOVAL AND INSTALLATION <EVOLUTION VI>
11
1
10 Nm
2
4 8
13 Nm
7
9.8 Nm
24 Nm 11 Nm
12
24 Nm
13 5
29 Nm
cardiagn.com
11 Nm
6
9 3
16 10
22 Nm
15
14
14 Nm
Removal steps
1. Water hose 9. Thermostat housing
2. Water hose 10. Thermostat housing gasket
3. Water hose "AA 11. O-ring
4. Water hose "AA 12. Water inlet pipe
"EA 5. Water temperature sensor "AA 13. O-ring
"DA 6. Water temperature gauge unit 14. Water pump
7. Thermostat 15. Water pump gasket
8. Water outlet fitting 16. Knock sensor
ENGINE – Water Pump and Water Hose 11-35
REMOVAL AND INSTALLATION <EVOLUTION IV or V>
24 Nm
13 Nm 13 Nm
11
8
1
24 Nm
9
4
6 7
2
10 11 Nm
12
13 5
3
29 Nm
cardiagn.com
16
22 Nm
15
14
14 Nm
Removal steps
1. Water hose "CA 9. Water outlet fitting
2. Water hose "BA 10. Thermostat housing
3. Water hose "AA 11. O-ring
4. Water hose "AA 12. Water inlet pipe
"EA 5. Water temperature sensor "AA 13. O-ring
"DA 6. Water temperature gauge unit 14. Water pump
7. Water inlet fitting 15. Water pump gasket
8. Thermostat 16. Knock sensor
11-36 ENGINE – Water Pump and Water Hose
Water pipe INSTALLATION SERVICE POINTS

"AA WATER PIPE / O-RING INSTALLATION
Wet the O-ring (with water) to facilitate assembly.
Caution
Keep the O-ring free of oil or grease.
O-ring 6EN0594
"BA THERMOSTAT HOUSING INSTALLATION

Apply 3 mm diameter of form-in-place gasket (FIPG) to the
location shown in the illustration.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or equivalent
cardiagn.com
"CA WATER OUTLET FITTING INSTALLATION
Specified sealant:
"DA SEALANT APPLICATION TO ENGINE COOLANT

TEMPERATURE GAUGE UNIT
(1) When reusing the gauge unit, clean its thread.
(2) Apply the specified sealant to the thread.
Specified sealant:
9EN0092
"EA SEALANT APPLICATION TO ENGINE COOLANT

TEMPERATURE SENSOR
(1) When reusing the sensor, clean its thread.
(2) Apply the specified sealant to the thread.
Specified sealant:
9EN0091
ENGINE – Rocker Arms and Camshaft 11-37
ROCKER ARMS AND CAMSHAFT
8
20 Nm
11 21 Nm 3 10 Nm
14 4
9 6
13
12 13 Nm
2
10 1
5
15
9 Nm
cardiagn.com
11 Nm
7
18
16
17
Apply engine oil to all

moving parts before
installation.
Removal steps
1. Cam position sensor "CA 10. Camshaft bearing cap front
2. O-ring "CA 11. Camshaft bearing cap No. 5
3. Cam position sensor support cover "CA 12. Camshaft bearing cap No. 2
4. Cam position sensor support "CA 13. Camshaft bearing cap No. 3
gasket "CA 14. Camshaft bearing cap No. 4
"FA 5. Cam position sensing cylinder "BA 15. Camshaft
"EA 6. Cam position sensor support 16. Rocker arm
"DA 7. Camshaft oil seal "AA 17. Lash adjuster
"CA 8. Camshaft bearing cap rear right 18. Oil delivery body
"CA 9. Camshaft bearing cap rear left
11-38 ENGINE – Rocker Arms and Camshaft

"AA LASH ADJUSTER INSTALLATION
Caution
If the lash adjuster is re-used, clean the lash adjuster.
Fit the lash adjuster onto rocker arm without allowing diesel
fuel to spill out.
"BA CAMSHAFT INSTALLATION

Camshaft sprocket side
(1) Apply engine oil to the journals and cams of the camshafts.
Install the camshafts on the cylinder head.
Slit Use care not to confuse the intake camshaft with the
exhaust one. The intake camshaft has a slit on its rear
end for driving the crankshaft position sensor.
cardiagn.com
Intake side
camshaft
Dowel pin (2) Install the crankshaft sprocket B or spacer and flange
to one end of the crankshaft, and turn the crankshaft
until the timing marks are lined up, setting No. 1 cylinder
to the TDC.
(3) Set the camshafts so that their dowel pins are positioned
at top.
"CA BEARING CAP INSTALLATION

(1) According to the identification mark stamped on the top
of each bearing cap, install the caps to the cylinder head.
Only “L” or “R” is stamped on front bearing cap. Cap
Cam number No. is stamped on No. 2 to No. 5 bearing caps. Rear
Symbol identifying bearing cap has no stamping.
intake or exhaust I: For intake camshaft side
E: For exhaust camshaft side
Timing belt side (2) Tighten the bearing caps in the order shown two to three
times by torquing progressively.
Tighten to the specification in the final sequence.
(3) Check to ensure that the rocker arm is positioned correctly
on the lash adjuster and valve stem end.
"DA CAMSHAFT OIL SEAL INSTALLATION
MD998713
(1) Apply engine oil to lib area of the oil seal and the front
end outside diameter of the camshaft.
(2) Using special tool install the camshaft oil seals.
"EA CAMSHAFT POSITION SENSOR SUPPORT

INSTALLATION
Specified sealant:
cardiagn.com
"FA CAMSHAFT POSITION SENSING CYLINDER
Paint mark INSTALLATION
(1) Set the No. 1 cylinder to the compression top dead center
position (so that dowel pin of the exhaust camshaft is
at the top).
(2) Install the camshaft position sensing cylinder so that the
white paint mark is facing in the direction shown in the
Camshaft illustration.
position
sensor
INSPECTION
CAMSHAFT
Measure the cam height.
Item Standard value mm Limit mm
Intake 35.79 35.29
Exhaust 35.49 34.99
ROCKER ARM
Roller
(1) Check the roller surface. If any dents, damage or seizure
is evident, replace the rocker arm.
(2) Check rotation of the roller. If it does not rotate smoothly
Tip
or if looseness is evident, replace the rocker arm.
(3) Check the inside diameter. If damage or seizure is evident,
replace the rocker arm.
LASH ADJUSTER
Caution
(1) The lash adjusters are precision-engineered
mechanisms. Do not allow them to become
contaminated by dirt or other foreign substances.
(2) Do not attempt to disassemble the lash adjusters.
(3) Use only fresh diesel fuel to clean the lash adjusters.
(1) Prepare three containers and approximately five liters

Outside Inside Filling with of diesel fuel. Into each container, pour enough diesel
cleaning cleaning diesel fuel fuel to completely cover a lash adjuster when it is standing
upright. Then, perform the following steps with each lash
adjuster.
cardiagn.com
A B C
(2) Place the lash adjuster in container A and clean its outside
surface.
NOTE
Use a nylon brush if deposits are hard to remove.
Diesel
fuel
(3) While gently pushing down the internal steel ball using
wire (0.5 mm in diameter) or special tool MD998442,
move the plunger through 5 to 10 strokes until it slides
smoothly. In addition to eliminating stiffness in the plunger,
this operation will remove dirty oil.
Caution
The steel ball spring is extremely weak, so the lash
adjuster’s functionality may be lost if the air bleed
Diesel fuel wire is pushed in hard.
MD998442
NOTE
If the plunger remains stiff or the mechanism appears
otherwise abnormal, replace the lash adjuster.
(4) Removal the lash adjuster from the container. Then, push
down the steel ball gently and push the plunger to eliminate
diesel fuel from the pressure chamber.
Caution
Make sure the oil hole in the side of the body is pointing
toward container A. Do not point the oil hole at yourself
MD998442 or other people.
Diesel fuel
(5) Place the lash adjuster in container B. Then, gently push

down the internal steel ball using wire (0.5 mm in diameter)
or special tool MD998442 and move the plunger through
5 to 10 strokes until it slides smoothly. This operation
will clean the lash adjuster’s pressure chamber.
Caution
The steel ball spring is extremely weak, so the lash
adjuster’s functionality may be lost if the air bleed
Diesel fuel wire is pushed in hard.
cardiagn.com
MD998442
(6) Remove the lash adjuster from the container. Then, push
down the steel ball gently and push the plunger to eliminate
diesel fuel from the pressure chamber.
Caution
Make sure the oil hole in the side of the body is pointing
toward container A. Do not point the oil hole at yourself
MD998442 or other people.
Diesel fuel
(7) Place the lash adjuster in container C. Then, gently push

down the internal steel ball using wire (0.5 mm in diameter)
or special tool MD998442.
Caution
Do not use container C for cleaning. If cleaning is
performed in container C, foreign matter could enter
the pressure chamber when chamber is filled with
diesel fuel.
MD998442 Diesel fuel
(8) Stand the lash adjuster with its plunger at the top, then
push the plunger downward firmly until it moves through
its greatest possible stroke. Return the plunger slowly,
then release the steel ball and allow the pressure chamber
to fill with diesel fuel.
Diesel fuel
MD998442
(9) Remove the lash adjuster from the container, then stand
the lash adjuster with its plunger at the top. Push the
plunger firmly and check that it does not move. Also,
check that the lash adjuster’s height matches that of a
new lash adjuster.
NOTE
If lash adjuster contracts, perform the operations (7)
through (9) again to fill it with diesel fuel completely.
Replace the lash adjuster if it still contracts after performing
these steps.
(10)Stand the lash adjuster upright to prevent diesel fuel from
spilling out. Do not allow the lash adjuster to become
contaminated by dirt or other foreign matter. Fit the lash
adjuster onto the engine as soon as possible.
cardiagn.com
ENGINE – Cylinder Head and Valves 11-43
CYLINDER HEAD AND VALVES

moving parts before 78 Nm → Loosen completely → 20 Nm + 90_ + 90_
installation.
1
8
20 9
14
4
5 10
12 15
6 17
13
16
cardiagn.com
19
11
18
7 2
Removal steps
AA" "DA 1. Cylinder head bolt AC" 11. Exhaust valve
2. Cylinder head assembly "AA 12. Valve stem seal
3. Cylinder head gasket 13. Valve spring seat
AB" "CA 4. Retainer lock "AA 14. Valve stem seal
5. Valve spring retainer 15. Valve spring seat
"BA 6. Valve spring 16. Intake valve guide
7. Intake valve 17. Exhaust valve guide
AB" "CA 8. Retainer lock 18. Intake valve seat
9. Valve spring retainer 19. Exhaust valve seat
"BA 10. Valve spring 20. Cylinder head
11-44 ENGINE – Cylinder Head and Valves

PRECAUTION FOR REMOVED PARTS
Keep removed parts in order according to the cylinder number
MB991654 and intake/exhaust.
AA" CYLINDER HEAD BOLTS REMOVAL
Using the special tool, loosen the cylinder head bolts. Loosen
evenly, little by little.
AB" RETAINER LOCK REMOVAL

Store removed valves, springs and other parts, tagged to
indicate their cylinder No. and location for reassembly.
cardiagn.com
MD998772
MD998735
AC" VALVE HANDLING PRECAUTIONS

(1) Sodium reacts violently with water or moisture generation
heat and liberating hydrogen. It must be handled with
utmost care because otherwise the following dangerous
conditions may result:
Loss of eyesight if sodium gets in eyes.
Burns if soduim contact skin.
Fire hazard.
(2) Handling of Soduim-filled Exhaust Valves
Soduim-filled exhaust valves are not dangerous and may
be handled in the same way as ordinary valves unless
they are broken.
Never try to break the valves and expose soduim to the
air. When worn exhaust valves are to be discarded, have
them disposed of by a salvage company equipped with
special disposal system, notifying them that the valves
contain soduim.
Should the exhaust valves be broken, neutralize soduim
using the method described below, and discard the valves
in the same way as ordinary valves.
(3) How to Neutralize Sodium
Place a container filled with more than 10 liters of water
in a well ventilated large space.
Wear rubber gloves and goggles, and carefully take out
broken valves from the cylinder head.
Put a broken valve in the water-filled container and quickly
get away from the container at least 2 or 3 m.
Caution
1. Valves must be neutralized one at a time.
2. Put a valve in the container only after soduim
in the preceding one has completely reacted with
water.
Keep fire away from the container during the
neutralization. The resulting hydrogen gas is highly
explosive.
When the reaction has finished (there is no more
generation of hydrogen gas), take the valves out of the
container with large tweezers or the like.
NOTE
The reaction occurs when water enters the cavity in the
cardiagn.com
valve. Hydrogen gas may be trapped inside the valve,
temporarily blocking the water passage. In such a case,
wait until hydrogen gas in released and remaining soduim
reacts with water.
After the neutralization of soduim, water in the container
contains soduim hydroxide and is highly alkaline. The
water solution should be disposed of according to local
regulations.
Caution
1. Do not let the solution contact the eyes or the
skin.
2. Should it get in the eyes, immediately flush them
with clean water thoroughly, and receive medical
attention. When it contacts the skin, wash with
ample amounts of clean water.

"AA VALVE STEM SEAL INSTALLATION
(1) Install the valve spring seat.
(2) The special tool must be used to install the valve stem
seal. Improper installation could result in oil leaks past
MD998737 the valve guide.
Caution
Do not reuse removed valve stem seals.
"BA VALVE SPRING INSTALLATION

Direct the valve spring end with identification color toward
the spring retainer.
"CA RETAINER LOCK INSTALLATION

The valve spring, if excessively compressed, causes the
bottom end of the retainer to be in contact with, and damage,
the stem seal.
cardiagn.com
MD998772
MD998735
"DA CYLINDER HEAD BOLT INSTALLATION

(1) When installing the cylinder head bolts, check that the
shank length of each bolt meets the limit. If the limit is
exceeded, replace the bolt.
Limit: Max. 99.4 mm
(2) Apply engine oil to the bolt threads and to the washers.
Shank length
6EN0782
(3) Using the special tool (MB991654) and according to the

Timing belt side tightening sequence, tighten the bolts to the specified
torque.
Tightening torque: 78 Nm
(4) Loosen all bolts fully.
(5) Retighten the loosened bolts to a torque of 20 Nm in
the specified tightening sequence.
(6) Make paint marks on the cylinder head bolt heads and
cylinder head.
(7) Give a 90° turn to the cylinder head bolts in the specified
90° tightening sequence.
(8) Give another 90° turn to the cylinder head bolts and make
sure that the paint mark on the head of each cylinder
head bolt and that on the cylinder head are on the same
straight line.
90°
Paint mark
Caution
1. If the bolt is turned less than 90°, proper fastening
6AE0297
performance may not be expected. When
tightening the bolt, therefore, be careful to give
a sufficient turn to it.
2. If the bolt is overtightened, loosen the bolt
completely and then retighten it by repeating the
tightening procedure from step (1).
cardiagn.com
INSPECTION
CYLINDER HEAD
(1) Check the cylinder head gasket surface for flatness by
using a straightedge and thickness gauge.
Standard value: 0.05 mm
Limit: 0.2 mm
(2) If the service limit is exceeded, correct to meet
specification.
9EN0064 Grinding limit: *0.2 mm
* Includes combined with cylinder block grinding.
Cylinder head height (Specification when new):
131.9 – 132.1 mm
VALVE
(1) Check the valve face for correct contact. If incorrect, reface
using a valve refacer. Valve seat contact should be
maintained uniform at the center of valve face.
(2) If the margin exceeds the service limit, replace the valve.
Intake 1.0 0.5
Exhaust 1.5 1.0
(3) Measure valve’s total length. If measurement is less than

specified, replace the valve.
Intake 109.5 109.0
Exhaust 109.7 109.2
cardiagn.com
VALVE SPRING
Out of (1) Measure the free height of spring and, if it is smaller
square
than the limit, replace.
Standard value mm Limit mm
Free 48.3 47.3
height
(2) Measure the squareness of the spring and, if the limit
is exceeded, replace.
1EN0264 Standard value Limit
1.5° 4°
VALVE GUIDE
Measure the clearance between the valve guide and valve
stem. If the limit is exceeded, replace the valve guide or
valve, or both.
Valve
guide Item Standard value mm Limit mm
Intake 0.02 – 0.05 0.10
Exhaust 0.05 – 0.09 0.15
VALVE SEAT
Valve stem end
Assemble the valve, then measure the valve stem projection
between the end of the valve stem and the spring seating
Valve stem
projection surface. If the measurement exceeds the specified limit,
replace the valve seat.
Spring seating Item Standard value mm Limit mm
surface
Intake 49.20 49.70
Exhaust 48.40 48.90
DEN0212
VALVE SEAT RECONDITIONING PROCEDURE

(1) Before correcting the valve seat, check for clearance
0.9 – 1.3 mm
between the valve guide and valve and, if necessary,
replace the valve guide.
(2) Using the seat grinder, correct to obtain the specified
seat width and angle.
(3) After correcting the valve seat, lap the valve and valve
seat using lapping compound. Then, check the valve
cardiagn.com
stem projection (refer to VALVE SEAT in INSPECTION).
43.5° – 44°
6EN0491
0.5 – 1 mm VALVE SEAT REPLACEMENT PROCEDURE

(1) Cut the valve seat to be replaced from the inside to thin
the wall thickness. Then, remove the valve seat.
0.5 – 1 mm
(2) Rebore the valve seat hole in the cylinder head to a

selected oversize valve seat diameter.
Valve seat ring hole diameter
Height of Item Standard value mm
seat ring
Intake 0.30 O.S. 35.30 – 35.33
0.60 O.S. 35.60 – 35.63
Exhaust 0.30 O.S. 33.30 – 33.33
Oversize I.D.
1EN0275
0.60 O.S. 33.60 – 33.63
(3) Before fitting the valve seat, either heat the cylinder head
up to approximately 250°C or cool the valve seat in liquid
nitrogen, to prevent the cylinder head bore from galling.
(4) Using a valve seat cutter, correct the valve seat to the
specified width and angle.
See “VALVE SEAT RECONDITIONING PROCEDURE”.
VALVE GUIDE REPLACEMENT PROCEDURE

(1) Force the valve guide out toward the cylinder block using
a press.
(2) Machine the valve guide hole in the cylinder head to
the size of the oversize valve guide to be installed.
Caution
Do not use the valve guide of the same size as the
removed one.
Valve gauge hole diameters in cylinder head
Item Standard value mm
0.05 O.S. 12.05 – 12.07
0.25 O.S. 12.25 – 12.27
0.50 O.S. 12.50 – 12.52
cardiagn.com
(3) Press-fit the valve guide until it protrude specified value
19.5 mm as shown in the illustration.
Caution
1. Press the valve guide from the cylinder head top
surface.
2. Valve guide for intake valve and that for exhaust
valve are different in length. (45.5 mm for intake
valve; 50.5 mm for exhaust valve)
Protrusion (4) After the valve guide has been installed, insert a new
1EN0106 valve to check for smooth sliding motion.
ENGINE – Front Case, Counterbalance Shaft and Oil Pan 11-51
FRONT CASE, COUNTERBALANCE SHAFT AND OIL PAN
10 Nm 29 31
Apply engine oil to all 8
moving parts before
installation.
20 28
30
24 Nm 10 Nm
25 7 27
54 Nm 21
15
cardiagn.com
9 22 Nm
19 16 Nm
14
24 6
22 5
18 26 23 19 Nm
17 36 Nm
13 16 19 Nm 4
12
24 Nm 24 Nm
11
18 Nm
10
2
44 Nm 39 Nm
1 7 Nm
3
Removal steps
1. Drain plug AC" "JA 18. Flange bolt
"NA 2. Drain plug gasket "HA 19. Front case
"MA 3. Oil filter 20. Front case gasket
AA" "LA 4. Oil pan 21. Oil pump cover
5. Oil screen "GA 22. Oil pump driven gear
6. Oil screen gasket "GA 23. Oil pump drive gear
7. Buffle plate "FA 24. Crankshaft oil seal
"IA 8. Oil pressure switch "EA 25. Oil pump oil seal
9. Oil cooler by-pass valve "DA 26. Counterbalance shaft oil seal
10. Relief plug 27. Counterbalance shaft left
11. Relief plug gasket 28. Counterbalance shaft right
12. Relief spring AD" "CA 29. Counterbalance shaft front bearing
13. Relief plunger AE" "BA 30. Counterbalance shaft rear bearing
14. Oil filter bracket left
15. Oil filter bracket gasket AE" "AA 31. Counterbalance shaft rear bearing
AB" "KA 16. Plug right
17. O-ring
11-52 ENGINE – Front Case, Counterbalance Shaft and Oil Pan

MD998727
AA" OIL PAN REMOVAL
(1) Remove all oil pan bolts.
(2) Drive in the special tool between the cylinder block and
oil pan.
NOTE
Never use a screwdriver or chisel, instead of the service
tool, as a deformed oil pan flange will result in oil leakage.
6EN0698
AB" PLUG REMOVAL

MD998162 (1) Fit special tool MD998162 on the plug, and then hold
it in position with special tool MD998783.
(2) Loosen the plug.
(3) Remove the special tools MD998783 and MD998162 and
then the plug.
cardiagn.com
MD998783
AC" FLANGE BOLT REMOVAL

(1) Remove the plug on the side of cylinder block.
(2) Insert a Phillips screwdriver (shank diameter 8 mm) into
the plug hole to lock the counterbalance shaft.
Plug
Screwdriver
6EN1026
(3) Loosen the flange bolt.
6EN0565
AD" COUNTERBALANCE SHAFT FRONT BEARING

REMOVAL
Using the special tool, remove the counterbalance shaft front
bearing from the cylinder block.
NOTE
Be sure to remove the front bearing first.
If it has not been removed, the Rear Bearing Puller cannot
be used.
AE" COUNTERBALANCE SHAFT REAR BEARING
REMOVAL
MB991603
Using the special tool, remove the left counterbalance shaft
rear bearing from the cylinder block.
NOTE
When removing the left counterbalance shaft rear bearing,
install the special tool (MB991603) in front of the cylinder
block.

"AA RIGHT COUNTERBALANCE SHAFT REAR
BEARING INSTALLATION
(1) Apply engine oil to the outer surface of bearing.
(2) Using special tools, install right rear bearing. Make sure
that oil hole of bearing is aligned with oil hole of cylinder
block.
cardiagn.com
MD998705
6EN1034
"BA LEFT COUNTERBALANCE SHAFT REAR

BEARING INSTALLATION
MB991603 (1) Install the special tool (Guide Plate) to the cylinder block.
(2) Apply engine oil to the rear bearing outer circumference
and bearing hole in the cylinder block.
(3) Using the special tool, install the rear bearing.
NOTE
The left rear bearing has no oil holes.
MB991603 Rear bearing
MD998705
6EN0557
"CA COUNTERBALANCE SHAFT FRONT BEARING

INSTALLATION
Using special tools, install front bearing.
MD998705
MD998705
Bearing
cardiagn.com
Cylinder block
6EN1035
"DA COUNTERBALANCE SHAFT OIL SEAL

INSTALLATION
Using a suitable socket wrench, install the counterbalance
shaft oil seal into the front case.
"EA OIL PUMP OIL SEAL INSTALLATION

Using a suitable socket wrench, install the oil pump oil seal
into the front case.
"FA CRANKSHAFT FRONT OIL SEAL INSTALLATION

Using the special tool, install the crankshaft front oil seal
into the front case.
"GA OIL PUMP DRIVEN GEAR / OIL PUMP DRIVE
GEAR INSTALLATION
Apply engine oil amply to the gears and line up the alignment
marks.
"HA FRONT CASE ASSEMBLY INSTALLATION

(1) Set the special tool on the front end of crankshaft and
apply a thin coat of engine oil to the outer circumference
of the special tool to install the front case.
cardiagn.com
(2) Install the front case assembly through a new front case
gasket and temporarily tighten the flange bolts (other
than those for tightening the filter bracket).
"IA SEALANT APPLICATION TO OIL PRESSURE

SWITCH
Coat the threads of switch with sealant and install the switch
using the special tool.
Caution
(1) Keep the end of the thread portion clear or sealant.
(2) Avoid an overtightening.
"JA FLANGE BOLT INSTALLATION

(1) Insert a Phillips screwdriver into a hole in the left side
of the cylinder block to lock the silent shaft.
6EN0564
(2) Secure the oil pump driven gear onto the left
counterbalance shaft by tightening the flange bolt to
specified torque.
"KA PLUG INSTALLATION

MD998162 (1) Install a new O-ring to the groove of the front case.
(2) Install the plug to the front case.
(3) Fit the special tool MD998162 on the plug, and then
hold it in position with special tool MD998783.
(4) Tighten the plug to the specified torque.
(5) Remove the special tools MD998783 and MD998162.
cardiagn.com
MD998783
"LA OIL PAN INSTALLATION

(1) Clean both mating surfaces of oil pan and cylinder block.
(2) Apply a 4 mm wide bead of sealant to the entire
circumference of the oil pan flange.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or
equivalent
Groove
Bolt hole portion
portion 6EN0213
NOTE
1. Be sure to install the oil pan quickly while the sealant
is wet (within 15 minutes).
2. After installation, keep the sealed area away from
the oil and coolant for approx. one hour.
(3) Note the difference in bolt lengths at the location shown.

"MAOIL FILTER INSTALLATION
Bracket side (1) Clean the installation surfaces of the filter bracket.
(2) Apply engine oil to the O-ring of the oil filter.
(3) Screw the oil filter in until the O-ring contacts the bracket.
Then tighten 3/4 turn (tightening torque: 16 Nm).
6EN0591
"NA DRAIN PLUG GASKET INSTALLATION

Caution
Fitting the gasket in a wrong way will result in oil leakage.
Drain plug
Install the drain plug gasket in the direction shown.
cardiagn.com
Gasket Oil pan
Oil pan
side
INSPECTION
FRONT CASE
(1) Check oil holes for clogging and clean if necessary.
(2) Check the left counterbalance shaft front bearing section
for wear, damage and seizure. If there is anything wrong
with the section, replace the front case.
(3) Check the front case for cracks and other damage.
Replace cracked or damaged front case.
OIL SEAL
(1) Check the oil seal lip for wear and damage. Replace
oil seal if necessary.
(2) Check the oil seal lip for deterioration. Replace oil seal
if necessary.
COUNTERBALANCE SHAFT
(1) Check oil holes for clogging.
(2) Check journals for seizure, damage and contact with
bearing. If there is anything wrong with the journal, replace
the counterbalance shaft, bearing or front case assembly.
OIL COOLER BY-PASS VALVE (ENGINE WITH AIR

COOLING TYPE OIL COOLER)
(1) Make sure that the valve moves smoothly.
(2) Ensure that the dimension (L) measures the standard
valve under normal temperature and humidity.
Standard value (L): 34.5 mm
(3) The dimension must be the standard value when
Valve measured after the valve has been dipped in 100°C oil.
cardiagn.com
Standard value (L): 40 mm or more
OIL PUMP
(1) Assemble the oil pump gear to the front case and rotate
it to ensure smooth rotation with no looseness.
(2) Ensure that there is no ridge wear on the contact surface
between the front case and the gear surface of the oil
pump cover.
(3) Check the side clearance.
Standard value:
Drive gear 0.08 – 0.14 mm
Driven gear 0.06 – 0.12 mm
ENGINE – Piston and Connecting Rod 11-59
PISTON AND CONNECTING ROD
6
7
Apply engine oil to all 8
moving parts before
installation. 10 4
12
9
11
cardiagn.com
5
2
20 Nm + 90_ to 94_
1
Removal steps
"GA 1. Connecting rod nut "CA 7. Piston ring No. 2
AA" "FA 2. Connecting rod cap "BA 8. Oil ring
"EA 3. Connecting rod bearing AB" "AA 9. Piston pin
"DA 4. Piston and connecting rod assem- 10. Piston
bly 11. Connecting rod
5. Connecting rod bearing 12. Bolt
"CA 6. Piston ring No. 1
11-60 ENGINE – Piston and Connecting Rod

AA" CONNECTING ROD CAP REMOVAL
(1) Mark the cylinder number on the side of the connecting
rod big end for correct reassembly.
(2) Keep the removed connecting rods, caps, and bearings
in order according to the cylinder number.
AB" PISTON PIN REMOVAL
cardiagn.com
(1) Insert the special tool, Push Rod, into the piston from
the side on which the front mark is stamped in the piston
head, and attach the guide C to the push rod end.
(2) Place the piston and connecting rod assembly on the
special tool, Piston Pin Setting Base, with the front mark
facing upward.
(3) Using a press, remove the piston pin.
NOTE
Keep the disassembled pistons, piston pins and
connecting rods in order according to the cylinder number.
"AA PISTON PIN INSTALLATION
(1) Measure the following dimensions of the piston, piston
pin and connecting rod.
A: Piston pin insertion hole length
B: Distance between piston bosses
C: Piston pin length
D: Connecting rod small end width
(2) Obtain dimension L (to be used later) from the above
measurements by using by following formula.
(A – C) – (B – D)
L =
2
(3) Insert the special tool, Push Rod, into the piston pin and
attach the guide A to the push rod end.
(4) Assemble the connecting rod in the piston with their front
marks facing the same direction.
(5) Apply engine oil to the entire periphery of the piston pin.
(6) Insert the piston pin, push rod and guide A assembly
having assembled in step (3) from the guide A side into
cardiagn.com
the piston pin hole on the front marked side.
3 mm + L (7) Screw the guide B into the guide A until the gap between
both guides amounts to the value L obtained in step
(2) plus 3 mm.
(8) Place the piston and connecting rod assembly onto the
piston setting base with the front marks directed upward.
(9) Press-fit the piston pin using a press.
If the press-fitting force required is less than the standard
value, replace the piston and piston pin set or/and the
connecting rod.
Standard value: 7,350 – 17,200 N
(10)Check that the piston moves smoothly
"BA OIL RING INSTALLATION

Upper
side rail (1) Fit the oil ring spacer into the piston ring groove.
NOTE
1. The side rails and spacer may be installed in either
Spacer direction.
2. New spacers and side rails are colored for
identification of their sizes.
cardiagn.com
Size Identification color
Lower side rail
6EN1237 Standard None
0.50 mm oversize Red
1.00 mm oversize Yellow
Side rail gap (2) Install the upper side rail.

To install the side rail, first fit one end of the rail into
the piston groove, then press the remaining portion into
position by finger. See illustration.
Use of ring expander to expand the side rail end gap
can break the side rail, unlike other piston rings.
Caution
Do not use piston ring expander when installing side
rail.
1EN0269 (3) Install the lower side rail in the same procedure as
described in step (2).
(4) Make sure that the side rails move smoothly in either
direction.
"CA PISTON RING NO. 2 / PISTON RING NO. 1
INSTALLATION
(1) Using piston ring expander, fit No. 2 and then No. 1 piston
ring into position.
NOTE
1. The ring end is provided with identification mark.
Item Identification mark
No. 1 ring 1R
No. 2 ring 2R
Identification mark
2. Install piston rings with identification mark facing up,
to the piston crown side.
Identification mark Side mark 3. Size marks on position rings are as follows.
Size Size mark
Standard None
No. 1
0.50 mm oversize 50
No. 2
1.00 mm oversize 100
cardiagn.com
9EN0524
"DA PISTON AND CONNECTING ROD ASSEMBLY

INSTALLATION
(1) Liberally coat engine oil on the circumference of the piston,
piston ring, and oil ring.
(2) Arrange the piston ring and oil ring gaps (side rail and
spacer) as shown in the figure.
(3) Rotate the crankshaft so that crank pin is on the center
of cylinder bore.
(4) Use suitable thread protectors on the connecting rod bolts

before inserting piston and connecting rod assembly into
Timing belt side
the cylinder block.
Care must be taken not to nick the crank pin.
(5) Using a suitable piston ring compressor tool, install the
piston and connecting rod assembly into the cylinder block.
"EA CONNECTING ROD BEARINGS INSTALLATION

When the bearing needs replacing, select and install a proper
bearing by the following procedure.
(1) Measure the crankshaft pin diameter and confirm its
classification from the following table. In the case of a
crankshaft supplied as a service part, identification colors
of its pins are painted at the positions shown in the
illustration.
(2) The connecting rod bearing identification mark is stamped

at the position shown in the illustration.
Crankshaft pin Connecting rod bearing
Classi- Identifica- Identifi- O. D. mm Identi- Thickness mm
fication tion mark cation fication
color mark
Produc- Service
tion part part
Identification mark
1 None Yellow 44.995 – 45.000 0 1.483 – 1.487
2 None None 44.985 – 44.995 1 1.487 – 1.491
3 None White 44.980 – 44.985 2 1.491 – 1.495
Connecting rod I.D.: 48.000 – 48.015 mm

(3) Select a proper bearing from the above table on the basic
of the identification data confirmed under items (1) and
(2).
[Example]
If the measured value of a crankshaft pin outer diameter
is 44.996 mm, the pin is classified as “1” in the table.
cardiagn.com
In case the crankshaft is also replaced by a spare part,
check the identification colors of the pins painted on the
new crankshaft. If the color is yellow, for example, the
pin is classified as “1”. In the above cases, select the
connection rod bearing having identification mark “0”.
"FA CONNECTING ROD CAP INSTALLATION

(1) Verifying the mark made during disassembly, install the
bearing cap to the connecting rod. If the connecting rod
is new with no index mark, make sure that the bearing
locking notches come on the same side as shown.
(2) Make sure that the connecting rod big end side clearance
meets the specification.
Limit: 0.4 mm
"GA CONNECTING ROD CAP NUT INSTALLATION
Caution
If the cylinder head has been installed before installing
the connecting rod cap nut, be sure to remove the spark
plugs.
(1) Since the connecting rod cap bolts and nuts are torqued
using the plastic area tightening method, the bolts should
be examined BEFORE reuse. If the bolt threads are
“necked down”, the bolt should be replaced.
Necking can be checked by running a nut with fingers
to the full length of the bolt threads. If the nut does not
Paint mark run down smoothly, the bolt should be replaced.
90° to 94° (2) Before installation of each nut, apply engine oil to the
Paint thread portion and bearing surface of the nut.
mark
(3) Install each nut to the bolt and tighten it with fingers.
Then tighten the nuts alternately to install the cap properly.
(4) Tighten the nuts to a torque of 20 Nm.
(5) Make a paint mark on the head of each nut.
Bolt (6) Make a paint mark on the bolt end at the position 90°
Nut
to 94° from the paint mark made on the nut in the direction
cardiagn.com
of tightening the nut.
6AE0298 (7) Give a 90° to 94° turn to the nut and make sure that
the paint mark on the nut and that on the bolt are in
alignment.
Caution
1. If the nut is turned less than 90°, proper fastening
performance may not be expected. When
tightening the nut, therefore, be careful to give
a sufficient turn to it.
2. If the nut is overtightened (exceeding 94°), loosen
the nut completely and then retighten it by
repeating the tightening procedure from step (1).
INSPECTION
PISTON RING
(1) Check the piston ring for damage, excessive wear, and
breakage and replace if defects are evident. If the piston
has been replaced with a new one, the piston rings must
also be replaced with new ones.
(2) Check for the clearance between the piston ring and
ring groove. If the limit is exceeded, replace the ring or
piston, or both.
Standard value:
No. 1 ring 0.04 – 0.075 mm
No. 2 ring 0.02 – 0.06 mm
Limit: 0.1 mm
(3) Install the piston ring into the cylinder bore. Force it down
with a piston, its crown being in contact with the ring,
to correctly position it at right angles to the cylinder wall.
Then, measure the end gap with a feeler gauge. If the
ring gap is excessive, replace the piston ring.
Standard value:
No. 1 ring 0.25 – 0.35 mm
No. 2 ring 0.40 – 0.55 mm
Oil ring 0.10 – 0.40 mm
Limit:
No. 1, No. 2 ring 0.8 mm
Oil ring 1.0 mm
cardiagn.com
CRANKSHAFT PIN OIL CLEARANCE
(PLASTIC GAUGE METHOD)
(1) Remove oil from the crankshaft pin and connecting rod
bearing.
(2) Cut the Plastigage to the same length as the width of
the bearing and place it on the crankshaft pin in parallel
with its axis.
Plastigage
(3) Install the connecting rod cap carefully and tighten the
nuts to specified torque.
(4) Carefully remove the connecting rod cap.
(5) Measure the width of the Plastigage at its widest part
by using a scale printed on the Plastigage package.
Limit: 0.1 mm
ENGINE – Crankshaft and Flywheel 11-67
CRANKSHAFT AND FLYWHEEL
2
1
15 5 6
4 132 Nm
11 Nm
cardiagn.com
9 Nm
11 Nm
11 Nm
14
12
13
11
32 Nm
10
9
moving parts before
8 installation.
25 Nm + 90_
7
Removal steps
1. Flywheel bolt "BA 9. Crankshaft bearing lower
2. Flywheel 10. Crankshaft
3. Rear plate "BA 11. Crankshaft bearing upper
4. Bell housing cover "AA 12. Crankshaft thrust bearing
"EA 5. Oil seal case 13. Check valve
"DA 6. Oil seal 14. Oil jet
"CA 7. Beam bearing cap bolt 15. Cylinder block
"CA 8. Beam bearing cap
11-68 ENGINE – Crankshaft and Flywheel

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

Identification color of crankshaft journal
(1) From the following table, select a bearing whose size
is appropriate for the crankshaft journal outside diameter.
cardiagn.com
Bearing bore size
identification mark
No. 1 No. 2 No. 3 No. 4 No. 5
Bearing bore
identification
mark
Cylinder inner
diameter size
mark
Bottom of Rear face of

cylinder block cylinder block
Crankshaft journal outside diameter Cylinder block bearing bore Crankshaft bearing
Identification color Size mm Identification mark Identification mark or color
Yellow 56.994 – 57.000 0 0 or Black
1 1 or Green
2 2 or Yellow
None 56.988 – 56.994 0 1 or Green
1 2 or Yellow
2 3 or None
White 56.982 – 56.988 0 2 or Yellow
1 3 or None
2 4 or Blue
cardiagn.com
Crankshaft bearing size For example, if the crankshaft journal outside diameter
identification mark or color ID color is “yellow” and cylinder block bearing bore ID
mark is “1”, select a bearing whose ID mark is “1”.
If there is no ID color paint on the crankshaft, measure
the journal outside diameter and select a bearing
appropriate for the measured value.
Identification
mark or color
(2) Install the bearings having an oil groove to the cylinder

block.
Groove (3) Install the bearings having no oil groove to the bearing
cap.
Upper
Lower
"CA BEARING CAP / BEARING CAP BOLT

INSTALLATION
(1) Install the bearing caps so the arrow points to the timing
belt side.
(2) Before installing the bearing cap bolts, check that the
shank length of each bolt meets the limit. If the limit is
exceeded, replace the bolt.
Shank length Limit: Max. 71.1 mm
(3) Apply engine oil to the threaded portion and bearing
9EN0477 surface of the bolt.
(4) Tighten the bolts to 25 Nm in the specified tightening

sequence.
Arrow mark
(5) Make a paint mark on the head of each bolt.

(6) Make a paint mark on the bearing cap at the position
Paint mark Paint mark
90° from the paint mark made on the bolt in the direction
of tightening the bolt.
(7) According to the specified tightening sequence, give a
90° turn to each bolt and make sure that the paint mark
on the bolt and that on the cap are in alignment.
90° Caution
If the bolt is turned less than 90°, proper fastening
cardiagn.com
performance may not be expected. When tightening
6AE0299
the bolt, therefore, be careful to give a sufficient turn
to it.
(8) After installing the bearing caps, make sure that the
crankshaft turns smoothly and the end play is correct.
If the end play exceeds the limit, replace No. 3 crankshaft
bearings.
Limit: 0.4 mm
"DA OIL SEAL INSTALLATION

Using the special tool, knock the oil seal into the oil seal
case.
"EA SEALANT APPLICATION TO OIL SEAL CASE
Specified sealant:
NOTE
(1) Be sure to install the case quickly while the sealant is
wet (within 15 minutes).
(2) After installation, keep the sealed area away from the
oil and coolant for approx. one hour.
Plastigage
INSPECTION
CRANKSHAFT OIL CLEARANCE (PLASTIGAGE
METHOD)
(1) Remove oil from the crankshaft journal and the crankshaft
bearing.
(2) Install the crankshaft.
(3) Cut the Plastigage to the same length as the width of
the bearing and place it on the journal in parallel with
cardiagn.com
its axis.
(4) Install the crankshaft bearing cap carefully and tighten

the bolts to the specified torque.
(5) Carefully remove the crankshaft bearing cap.
(6) Measure the width of the Plastigage at its widest part
by using a scale printed on the Plastigage package.
Limit: 0.1 mm
Plastigage
CYLINDER BLOCK
(1) Visually check for scratches, rust, and corrosion.
Use also a flaw detecting agent for the check. If defects
are evident, correct, or replace.
(2) Using a straightedge and feeler gauge, check the block
top surface for warpage. Make sure that the surface is
free from gasket chips and other foreign matter.
Limit: 0.1 mm
(3) If the distortion is excessive, correct within the allowable

limit or replace.
Grinding limit: 0.2 mm
Includes/combined with cylinder head grinding
Cylinder block height (when new): 284 mm
(4) Check cylinder walls for scratches and seizure. If defects
are evident, correct (bored to oversize) or replace.
(5) Using cylinder gauge, measure the cylinder bore and

cylindricity. If worn badly, correct cylinder to an oversize
and replace piston and piston rings. Measure at the points
shown in illustration.
Standard value:
Cylinder I.D. 85.00 – 85.03 mm
Cylindricity 0.01 mm or less
BORING CYLINDER
(1) Oversize pistons to be used should be determined on
the basis of the largest bore cylinder.
Piston size identification
Size Identification mark
0.50 O.S. 50
1.00 O.S. 100
cardiagn.com
NOTE
Size mark is stamped on the piston top.
(2) Measure outside diameter of piston to be used. Measure
it in thrust direction as shown.
(3) Based on the measured piston O.D. calculate boring finish
dimension.
Boring finish dimension = Piston O.D. + (clearance
between piston O.D. and cylinder) – 0.02 mm
(honing margin)
(4) Bore all cylinders to the calculated boring finish dimension.
Caution
To prevent distortion that may result from temperature
rise during honing, bore cylinders, working from No.
2, No. 4, No. 1 to No. 3.
(5) Hone to final finish dimension (piston O.D. + clearance
between piston O.D. and cylinder).
(6) Check clearance between piston and cylinder.
Clearance between piston and cylinder:
0.02 – 0.04 mm
NOTE
When boring cylinders, finish all of four cylinders to same
oversize. Do not bore only one cylinder to an oversize.
ENGINE – Throttle Body 11-73
THROTTLE BODY
DISASSEMBLY AND REASSEMBLY
3.5 Nm 1
cardiagn.com
2
3.5 Nm
Disassembly steps
AA" "AA 1. Throttle position sensor (with built- NOTE
in closed throttle position switch) 1. The fixed SAS and the speed adjusting screw are
2. Idle speed control body assembly correctly adjusted at the factory and should not be
3. O-ring removed.
AB" 4. Throttle body 2. If the fixed SAS should happen to have been
5. Fixed SAS removed, carry out fixed SAS adjustment.
6. Speed adjusting screw 3. If the speed adjusting screw should happen to have
8. O-ring been removed, carry out speed adjusting screw
adjustment.
11-74 ENGINE – Throttle Body
DISASSEMBLY SERVICE POINTS

AA" THROTTLE POSITION SENSOR AND IDLE AIR
CONTROL MOTOR REMOVAL
(1) Do not disassemble the sensor and motor.
(2) Do not immerse solvent to clean the sensor and motor.
Clean then with shop towel.
AB" THROTTLE BODY REMOVAL
(1) Do not remove the throttle body.
(2) Check if the vacuum port or passage is clogged. Use
compressed air to clean the vacuum passage.
REASSEMBLY SERVICE POINT
"AA THROTTLE POSITION SENSOR INSTALLATION
(1) Install the throttle position sensor to the throttle body
as shown in the diagram.
cardiagn.com
Throttle position sensor
(2) Turn throttle position sensor 90° clockwise to set it, and
tighten screws.
(3) Check the continuity between terminal No. 3 (Idle throttle

TPS power supply Earth position switch) and No. 4 (Earth).
Throttle valve condition Continuity
Fully closed Conductive
Fully open No conductive
If there is no continuity with the throttle valve fully closed,
TPS output Idle position switch turn the throttle position sensor counterclockwise, and
then check again.
ENGINE – Turbocharger 11-75
TURBOCHARGER
cardiagn.com
11 Nm
2
1
Disassembly steps
"FA D Inspection of turbocharger waste gate "DA 4. Turbine housing
actuator operation AA" "CA 5. Snap ring
1. Snap pin AB" "BA 6. Turbine wheel assembly
2. Waste gate actuator 7. Compressor cover
"EA 3. Coupling "AA 8. O-ring
11-76 ENGINE – Turbocharger

AA" SNAP RING REMOVAL
Lay the unit with the compressor cover side facing down
and using snap ring pliers, remove the compressor cover
attaching snap ring.
Caution
When removing the snap ring, hold it with fingers to
Snap ring
prevent it from springing away.
AB" TURBINE WHEEL ASSEMBLY REMOVAL

Remove the turbine wheel assembly, striking the
circumference of the compressor cover with a plastic hammer.
The turbine wheel assembly may be a little hard to remove
due to an O-ring put on the outer circumference.
Turbine
wheel
cardiagn.com
assembly
CLEANING
(1) Use a clean cleaning oil commercially available. Do not
use corrosive cleaning oils as they could damage to some
parts.
(2) Use a plastic scraper or hard brush to clean aluminum
parts.
REASSEMBLY SERVICE POINTS

"AA O-RING INSTALLATION
Apply a light coat of engine oil to a new O-ring and fit in
the turbine wheel assembly groove.
Caution
O-ring When installing the O-ring, use care not to damage it.
A damaged O-ring causes oil leaks.
Dowel pin hole

"BA TURBINE WHEEL ASSEMBLY
(1) Apply a light coat of engine oil to the periphery of the
Dowel pin
O-ring.
(2) Install the turbine wheel assembly to the compressor cover
in relation to the dowel pin.
Caution
Use care not to damage the blades of turbine wheel
and compressor wheel.
ENGINE – Turbocharger 11-77
Chamfered "CA SNAP RING INSTALLATION
Snap ring edge
Lay the assembly with the compressor cover facing down
and fit the snap ring.
Caution
Fit the snap ring with its chamfered side facing up.
Turbine wheel
assembly
Compressor
cover
"DA TURBINE HOUSING INSTALLATION

Install the turbine housing in relation to the dowel pin.
Caution
Use care not to damage the blades of turbine wheel.
Dowel pin
cardiagn.com
Dowel pin hole
"EA COUPLING INSTALLATION

Install the coupling and tighten to the specified torque.
Coupling
"FA WASTE GATE ACTUATOR OPERATION CHECK

Using a tester, apply a pressure of approx. 100.0 kPa to
the actuator and make sure that the rod moves.
Caution
Do not apply a pressure of more than 113.3 kPa to the
actuator. Otherwise, diaphragm may be damaged. Never
attempt to adjust the waste gate valve.
Traces of contact INSPECTION

TURBINE HOUSING
(1) Check the housing for traces of contact with the turbine
wheel, cracks due to overheating, pitching, deformation
and other damage. Replace with a new turbine housing
if cracked.
(2) Operate the waste gate valve lever manually to check
that the gate can be operated and closed smoothly.
11-78 ENGINE – Turbocharger
COMPRESSOR COVER
Oil passage
Check the compressor cover for traces of contact with the
Turbine wheel compressor wheel and other damage.
TURBINE WHEEL ASSEMBLY
(1) Check the turbine and compressor wheel blades for bend,
burr, damage, corrosion and traces of contact on the
back side and replace if defective.
Water passage (2) Check the oil passage of the turbine wheel assembly
Compressor for deposit and clogging.
wheel
(3) In the case of water cooled type, check also the water
passage for deposit and clogging.
(4) Check the turbine wheel and compressor wheel for light
and smooth turning.
cardiagn.com
ENGINE – Alternator 11-79
ALTERNATOR
1 4
3
5
7 6
cardiagn.com
12
10
9
8 14
13
11
Disassembly steps
AA" 1. Front bracket assembly AC" 8. Stator
AB" 2. Alternator pulley 9. Plate
"BA 3. Rotor AC" "AA 10. Regulator assembly
4. Rear bearing 11. Brush
5. Bearing retainer 12. Slinger
6. Front bearing 13. Rectifier
7. Front bracket 14. Rear bracket
11-80 ENGINE – Alternator

AA" FRONT BRACKET ASSEMBLY REMOVAL
Insert a flat tip screwdrivers or the like in the clearance between
the front bracket assembly and stator core, to pry open and
separate the stator and front bracket.
Caution
Do not insert the screwdriver too far, or the stator coil
gets damaged.
AB" ALTERNATOR PULLEY REMOVAL

Face pulley side upward, fix the rotor with a work bench
and remove the pulley.
Caution
Use care not to damage the rotor.
cardiagn.com
AC" STATOR / REGULATOR ASSEMBLY REMOVAL
(1) Unsolder the stator with a soldering iron (180 to 250
Soldered W). Complete this work within four seconds not to transfer
heat to the diode.
(2) When removing rectifier from the regulator assembly,
remove the soldered sections to rectifier.
Caution
1. Use care to make sure that the heat of the soldering
iron is not transmitted to the diodes for a long
period.
2. Use care that no undue force is exerted to the
lead wires of the diodes.

Wire "AA REGULATOR ASSEMBLY INSTALLATION
After installing the regulator assembly, insert a wire into the
hole provided on the rear bracket while pressing in the brush
to fix the brush.
NOTE
The brush is fixed when a wire is inserted, making rotor
installation easier.
Rear bracket
Brush
Wire
ENGINE – Alternator 11-81
"BA ROTOR INSTALLATION
Wire After installing the rotor, remove the wire used to fix the brush.
INSPECTION
ROTOR CHECK
(1) Check the continuity between the rotor coil slip rings,
and replace the rotor if the resistance value is not at
the standard value.
Standard value: 3 – 5 Ω
cardiagn.com
(2) Check the continuity between the slip ring and core, and
if there is continuity, replace the rotor.
STATOR CHECK
(1) Check the continuity between the coil leads, and if there
is continuity, replace the stator.
(2) Check the continuity between the coil and core, and if
there is continuity, replace the stator.
11-82 ENGINE – Alternator
RECTIFIERS CHECK
(1) Inspect the (+) heat sink by checking the continuity
between the (+) heat sink and stator coil lead wire
connection terminal using a tester probe.
If there is a continuity at both, the diode is short circuited,
so replace the rectifier.
(2) Inspect the (–) heat sink by checking the continuity

between the (–) heat sink and stator coil lead wire
connection terminal using a tester probe.
If there is a continuity at both, the diode is short circuited,
so replace the rectifier.
cardiagn.com
(3) Check the diode trio by connecting an ohmmeter to both
ends of each diode and check the continuity of the three
diodes.
If there is a continuity at both ends, or if there is no
continuity, the diode is damaged so replace the recitifier.
BRUSH CHECK
(1) Measure the length of the brush protrusion shown in the
illustration, and replace the brush if the measured value
is below the limit value.
Protrusion Limit: 2 mm or less
length
(2) The brush can be removed if the solder of the brush

Soldered lead wire is removed.
(3) When installing a new brush, insert the brush into the
holder as shown in the illustration, and then solder the
lead wires.
ENGINE – Starter Motor 11-83
STARTER MOTOR
14
15
17
19 13 12
16
2 18
22
cardiagn.com
21 5
20
23
9 1
11
6
8
7
10
Disassembly steps
1. Cover 13. Packing A
2. Screw 14. Packing B
AA" 3. Magnetic switch 15. Plate
4. Screw 16. Planetary gear
5. Through 17. Lever
6. Rear bracket AC" "AA 18. Snap ring
7. Brush holder AC" "AA 19. Stop ring
8. Brush 20. Overrunning clutch
9. Rear bearing 21. Internal gear
AB" 10. Armature 22. Planetary gear holder
11. Yoke assembly 23. Front bracket
AB" 12. Ball
11-84 ENGINE – Starter Motor
Magnetic “S” terminal DISASSEMBLY SERVICE POINTS

switch
AA" MAGNETIC SWITCH REMOVAL
“B” terminal Disconnect field coil wire from “M” terminal of magnetic switch.
“M” terminal
Field coil wire
AB" ARMATURE / BALL REMOVAL

Caution
When removing the armature, take care not to lose the
ball (which is used as a bearing) in the armature end.
cardiagn.com
Socket
AC" SNAP RING / STOP RING REMOVAL
(1) Press stop ring off snap ring with a suitable socket.
Stop ring
Pinion gear
Overrunning
clutch
Armature
(2) Remove snap ring with snap ring pliers and then remove
Snap ring stop ring and overrunning clutch.
Snap ring pliers
Pinion gear
Overrunning
clutch
Armature
STARTER MOTOR PARTS CLEANING

(1) Do not immerse parts in cleaning solvent. Immersing the
yoke and field coil assembly and/or armature will damage
insulation. Wipe motor assembly with a cloth only.
(2) Do not immerse drive unit in cleaning solvent. Overrunning
clutch is pre-lubricated at the factory and solvent will wash
lubrication from clutch.
(3) The drive unit may be cleaned with a brush moistened
with cleaning solvent and wiped dry with a cloth.
"AA STOP RING / SNAP RING INSTALLATION
Using a suitable pulling tool, pull overrunnig clutch stop ring
over snap ring.
Stop ring
Overrunning
Stop ring clutch
Snap ring
INSPECTION
COMMUTATOR CHECK
(1) Place the armature in a pair of “V” blocks and check
the runout with a dial indicator.
Limit: 0.1 mm
cardiagn.com
(2) Measure the commutator outer diameter.
Limit: 31.4 mm
(3) Check the undercut depth between segments.

Undercut Standard value: 0.5 mm
Segment
Mica
BRUSH HOLDER CHECK

Check the continuity between brush holder plate and brush
Brush holder holder.
If there is no continuity, the brush holder is in order.
11-86 ENGINE – Starter Motor
OVERRUNING CLUTCH CHECK

(1) While holding clutch housing, rotate the pinion. Drive
pinion should rotate smoothly in one direction, but should
not rotate in opposite direction. If clutch does not function
Free properly, replace overrunnig clutch assembly.
(2) Inspect pinion for wear or burrs. If pinion is worn or burred,
replace overrunning clutch assembly. If pinion is damaged,
Lock also inspect ring gear for wear or burrs.
FRONT AND REAR BRACKET BUSHING CHECK

Inspect bushing for wear or burrs. If bushing is worn or burred,
replace front bracket assembly or rear bracket assembly.
cardiagn.com
BRUSH AND SPRING REPLACEMENT
(1) Brushes that are worn beyond wear limit line, or oil-soaked,
should be replaced.
(2) When replacing ground brush, slide the brush from brush
holder by prying retaining spring back.
Wear limit line
Growler
ARMATURE TEST
ARMATURE COIL SHORT-CIRCUIT TEST
(1) Place armature in a growler.
(2) Hold a thin steel blade parallel and just above while rotating
armature slowly in growler. A shorted armature will cause
blade to vibrate and be attracted to the core. Replace
shorted armature.
ARMATURE COIL EARTH TEST

Check the insulation between each commutator segment and
armature coil core.
If there is no continuity, the insulation is in order.
ARMATURE COIL OPEN-CIRCUIT INSPECTION
Check the continuity between segments. If there is continuity,
the coil is in order.
cardiagn.com

Ev6 Xe11

Uploaded by

Copyright:

Available Formats

Ev6 Xe11

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Ev6 Xe11

Uploaded by

Copyright:

Available Formats

11-1

GENERAL INFORMATION . . . . . . . . . . . . . . . . 2 EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . 31

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 3 WATER PUMP AND WATER HOSE . . . . . 34

Type In-line OHV, SOHC

Combustion chamber Pentroof + curved top piston type

Total displacement dm3 1,997

Cylinder bore mm 85.0

Piston stroke mm 88.0

Compression ratio 8.8

Valve timing Intake valve Opens (BTDC) 21°

Closes (ABDC) 59°

Exhaust valve Opens (BBDC) 58°

Lubrication system Pressure feed, full-flow filtration

Oil pump type Involute gear type

Auto-tensioner rod projection length mm 12 –

Camshaft cam height mm Intake 35.79 35.29

Exhaust 35.49 34.99

Camshaft journal outer diameter mm 26 –

Cylinder head and valves

Cylinder head flatness of gasket surface mm Less than 0.05 0.2

Valve thickness of valve head (margin) mm Intake 1.0 0.5

Exhaust 1.5 1.0

Overall valve length mm Intake 109.5 109.0

Exhaust 109.7 109.2

Valve thickness to valve guide clearance Intake 0.02 – 0.05 0.10

Valve face angle 45° – 45.5° –

Valve spring free length mm 48.3 47.3

Valve spring out-of-squareness 1.5° or less Maximum 4°

Valve seat contact width mm 0.9 – 1.3 –

Valve guide inner diameter mm 6.6 –

Valve guide projection from cylinder head upper surface mm 20.5 –

Valve stem projection mm Intake 49.20 49.70

Exhaust 48.40 48.90

Oversize rework dimensions of valve guide 0.05 O.S. 12.05 – 12.07 –

Items Standard value Limit

Intake oversize rework dimensions of valve 0.3 O.S. 35.30 – 35.33 –

Exhaust oversize rework dimensions of 0.3 O.S. 33.30 – 33.33 –

Oil pump side clearance mm Drive gear 0.08 – 0.14 –

Driven gear 0.06 – 0.12 –

Piston and connecting rod

Piston outer diameter mm 85.0 –

Piston ring side clearance mm No. 1 ring 0.04 – 0.075 –

Piston ring end gap mm No. 1 ring 0.25 – 0.35 0.8

Oil ring 0.10 – 0.40 1.0

Piston pin outer diameter mm 21.0 –

Piston pin press-in load N (Room temperature) 7,350 – 17,200 –

Crankshaft pin oil clearance mm 0.02 – 0.05 0.1

Connecting rod big end side clearance mm 0.10 – 0.25 0.4

Crankshaft and flywheel

Crankshaft end play mm 0.05 – 0.25 0.40

Crankshaft journal outer diameter mm 57.0 –

Crankshaft journal oil clearance mm 0.02 – 0.04 0.1

Bearing cap bolt shank length mm – Maximum 71.1

Piston to cylinder clearance mm 0.02 – 0.04 –

Cylinder block grinding limit of gasket surface mm – 0.2

Cylinder block inner diameter mm 85.0 –

Cylinder block cylinder mm 0.01 –

Items Standard value Limit

Rotor coil resistance Ω Approx. 3 – 5 –