00109000812

General . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . Engine Lubrication . . . . . . . . . . . . . Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .

00 11 12 13 14 15 16 17 21 22 23 26 27 31 32 33 34 35 36 37 42 51 52 54 55

WORKSHOP MANUALFOREWORDThis Workshop Manual contains procedures for service mechanics, including removal, disassembly, inspection, adjustment, reassembly and installation. Use the following manuals in combination with this manual as required. TECHNICAL INFORMATION MANUAL PYDE9604 WORKSHOP MANUAL ENGINE GROUP PWEEjjjj (Looseleaf edition) ELECTRICAL WIRING PHDE9608 BODY REPAIR MANUAL PBDE9609 PARTS CATALOGUE Sedan B608S107Aj Wagon B608T507Aj

Engine Cooling . . . . . . . . . . . . . . . . . Intake and Exhaust ............

Engine Electrical . . . . . . . . . . . . . . . Engine and Emission Control . . . . Clutch . . . . . . . . . . . . . . . . . . . . . . . . . Manual Transmission . . . . . . . . . . . Automatic Transmission . . . . . . . . Front Axle . . . . . . . . . . . . . . . . . . . . . . Rear Axle . . . . . . . . . . . . . . . . . . . . . . Wheel and Tyre . . . . . . . . . . . . . . . . . Power Plant Mount . . . . . . . . . . . . . . Front Suspension . . . . . . . . . . . . . . . Rear Suspension . . . . . . . . . . . . . . .

All information, illustrations and product descriptions contained in this manual are current as at the time of publication. We, however, reserve the right to make changes at any time without prior notice or obligation.

Service Brakes . . . . . . . . . . . . . . . . . Parking Brakes . . . . . . . . . . . . . . . . . Steering . . . . . . . . . . . . . . . . . . . . . . . . Body . . . . . . . . . . . . . . . . . . . . . . . . . . . Exterior . . . . . . . . . . . . . . . . . . . . . . . . Interior and Supplemental Restraint System (SRS) . . . . . . . . . Chassis Electrical . . . . . . . . . . . . . . Heater, Air Conditioner and Ventilation . . . . . . . . . . . . . . . . . . . . . .

E Mitsubishi Motors Corporation

Dec. 1996

WARNING! (1) Improper service or maintenance of any component of the SRS and seat belt with pre-tensioner, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag and seat belt with pre-tensioner) or to the driver and passenger (from rendering the SRS inoperative). (2) SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the SRS-ECU, air bag module (drivers side and front passengers side), clock spring, side impact sensor, front seat assembly (side air bag module) and seat belt with pre-tensioner before drying or baking the vehicle after painting. SRS-ECU, air bag module, clock spring and side impact sensor: 93_C or more Seat belt with pre-tensioner: 90_C or more (3) Service or maintenance of any SRS component and seat belt with pre-tensioner or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of the SRS and seat belt with pre-tensioner or any SRS-related component. NOTE Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.

00-1

GENERALCONTENTSHOW TO USE THIS MANUAL . . . . . . . . . . . . . . 2Scope of Maintenance, Repair and Servicing Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Indication of Tightening Torque . . . . . . . . . . . . . . . . 2 Model Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Explanation of Manual Contents . . . . . . . . . . . . . . . 400109000829

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Model Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Chassis Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Engine Model Number . . . . . . . . . . . . . . . . . . . . . . . 17

MAJOR SPECIFICATIONS . . . . . . . . . . . . . . . . 18 PRECAUTIONS BEFORE SERVICE . . . . . . . 20 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH PRE-TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . 24 SUPPORT LOCATIONS FOR LIFTING AND JACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Support Positions for a Garage Jack and Axle Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Support Positions for a Single-Post Lift or Double-Post Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Support Positions and Support Method for an H-Bar Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Troubleshooting Contents . . . . . . . . . . . . . . . . . . . . . 6 Diagnosis Function . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 How to Use the Inspection Procedures . . . . . . . . 9 Connector Measurement Service Points . . . . . . . 10 Connector Inspection . . . . . . . . . . . . . . . . . . . . . . . . 11 Inspection Service Points for a Blown Fuse . . . 12 Points to Note for Intermittent Malfunctions . . . . 12

VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . 13Vehicle Information Code Plate . . . . . . . . . . . . . . . 13

STANDARD PART/TIGHTENING-TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

00-2

GENERAL - How to Use This Manual00100010302

HOW TO USE THIS MANUALSCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONSThis manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair and servicing of the subject model. Note, however, that for engine and transmission-related component parts, this manual covers only on-vehicle inspections, adjustments, and the removal and installation procedures for major components. For detailed information concerning the inspection, checking, adjustment, disassembly and reassembly of the engine, transmission and major components after they have been removed from the vehicle, please refer to separate manuals covering the engine and the transmission. ON-VEHICLE SERVICE On-vehicle Service is procedures for performing inspections and adjustments of particularly important locations with regard to the construction and for maintenance and servicing, but other inspection (for looseness, play, cracking, damage, etc.) must also be performed. INSPECTION Under this title are presented inspection and checking procedures to be performed by using special tools and measuring instruments and by feeling, but, for actual maintenance and servicing procedures, visual inspections should always be performed as well.

DEFINITION OF TERMSSTANDARD VALUE Indicates the value used as the standard for judging the quality of a part or assembly on inspection or the value to which the part or assembly is corrected and adjusted. It is given by tolerance. LIMIT Shows the standard for judging the quality of a part or assembly on inspection and means the maximum or minimum value within which the part or assembly must be kept functionally or in strength. It is a value established outside the range of standard value. REFERENCE VALUE Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly and adjustment procedures, and so they can be completed in a shorter time). CAUTION Indicates the presentation of information particularly vital to the worker during the performance of maintenance and servicing procedures in order to avoid the possibility of injury to the worker, or damage to component parts, or a reduction of component or vehicle function or performance, etc.

INDICATION OF TIGHTENING TORQUEThe tightening torque shown in this manual is a basic value with a tolerance of 10% except the following cases when the upper and lower limits of tightening torque are given. (1) The tolerance of the basic value is within 10%. (2) Special bolts or the like are in use. (3) Special tightening methods are used.

GENERAL - How to Use This Manual MODEL INDICATIONSThe following abbreviations are used in this manual for classification of model types.

00-3

2000: Indicates models equipped with the 2,000 mL petrol engine. 2500: Indicates models equipped with the 2,500 mL petrol engine. 2000D: Indicates models equipped with the 2,000 mL diesel engine. MPI: Indicates the multi-point injection, or engine equipped with the multi-point injection. SOHC: Indicates an engine with the single overhead camshaft, or models equipped with such an engine. M/T: Indicates the manual transmission, or models equipped with the manual transmission. A/T: Indicates the automatic transmission, or models equipped with the automatic transmission. A/C: Indicates the air conditioner.

00-4

GENERAL - How to Use This Manual

EXPLANATION OF MANUAL CONTENTS

Indicates procedures to be performed before the work in that section is started, and procedures to be performed after the work in that section is finished. Component Diagram A diagram of the component parts is provided near the front of each section in order to give a reader a better understanding of the installed condition of component parts. Indicates (by symbols) where lubrication is necessary.

Maintenance and Servicing Procedures The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures. D Removal steps: The part designation number corresponds to the number in the illustration to indicate removal steps. D Disassembly steps: The part designation number corresponds to the number in the illustration to indicate disassembly steps.

D Installation steps: Specified in case installation is impossible in reverse order of removal steps. Omitted if installation is possible in reverse order of removal steps. D Reassembly steps: Specified in case reassembly is impossible in reverse order of disassembly steps. Omitted if reassemby is possible in reverse order of disassembly steps.

Classifications of Major Maintenance/Service Points When there are major points relative to maintenance and servicing procedures (such as essential maintenance and service points, maintenance and service standard values, information regarding the use of special tools, etc.), these are arranged together as major maintenance and service points and explained in detail. AA" "AA : Indicates that there are essential points for removal or disassembly. : Indicates that there are essential points for installation or reassembly.

Symbols for Lubrication, Sealants and Adhesives Information concerning the locations for lubrication and for application of sealants and adhesives is provided, by using symbols, in the diagram of component parts or on the page following the component parts page, and explained. : Grease (multipurpose grease unless there is a brand or type specified) : Sealant or adhesive : Brake fluid or automatic transmission fluid : Engine oil, gear oil or air conditioner compressor oil : Adhesive tape or butyl rubber tape

GENERAL - How to Use This ManualIndicates the group title. Indicates the section title. Indicates the group number. Indicates the page number.

00-5

Denotes able part.

non-reus-

Denotes tightening torque. For bolts and nuts which do not have a tightening torque listed, refer to the Standard Partstightening-torque Table. Repair kit or set parts are shown. (Only very frequently used parts are shown.)

Operating procedures, cautions, etc. on removal, installation, disassembly and reassembly are described.

indicates that there is a continuity between the terminals. indicates terminals to which battery voltage is applied.

The title of the page (following the page on which the diagram of component parts is presented) indicating the locations of lubrication and sealing procedures.

00-6

GENERAL - How to Use Troubleshooting/Inspection Service Points

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

00100020152

Troubleshooting of electronic control systems for which the MUT-II can be used follows the basic outline described below. Furthermore, even in systems for which the MUT-II cannot be used, part of these systems still follow this outline.

TROUBLESHOOTING CONTENTS1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING The troubleshooting sections follow the basic diagnosis flow which is given below. If the diagnosis flow is different from that given below, or if additional explanation is required, the details of such differences or additions will also be listed. Diagnosis methodGathering information from the customer.

Check trouble symptom. Reoccurs Does not reoccur.

Read the diagnosis code No diagnosis code or communication with MUT-II not possible Refer to the INSPECTION CHART FOR TROUBLE SYMPTOMS (Refer to applicable group.) Diagnosis code displayed.

Read the diagnosis code Diagnosis code displayed. No diagnosis code

After taking note of the malfunction code, erase the diagnosis code memory

Recheck trouble symptom.

Read the diagnosis codes. Diagnosis code displayed. No diagnosis code

Refer to the INSPECTION CHART FOR DIAGNOSIS CODES (Refer to applicable group.)

INTERMITTENT MALFUNCTIONS (Refer to P.00-12.)

2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS If verification of the trouble symptoms is difficult, procedures for checking operation and verifying trouble symptoms are shown. 3. DIAGNOSIS FUNCTION Details which are different from those in the Diagnosis Function section on the next page are listed.

GENERAL - How to Use Troubleshooting/Inspection Service Points4. INSPECTION CHART FOR DIAGNOSIS CODES

00-7

5. INSPECTION PROCEDURE FOR DIAGNOSIS CODES Indicates the inspection procedures corresponding to each diagnosis code. (Refer to P.00-9 for how to read the inspection procedures.) 6. INSPECTION CHART FOR TROUBLE SYMPTOMS If there are trouble symptoms even though the results of inspection using the MUT-II show that all diagnosis codes are normal, inspection procedures for each trouble symptom will be found by means of this chart. 7. INSPECTION PROCEDURE FOR TROUBLE SYMPTOM Indicates the inspection procedures corresponding to each trouble symptoms classified in the Inspection Chart for Trouble Symptoms. (Refer to P.00-9 for how to read the inspection procedures.) 8. SERVICE DATA REFERENCE TABLE Inspection items and normal judgement values have been provided in this chart as reference information. 9. CHECK AT ECU TERMINALS Terminal numbers for the ECU connectors, inspection items and standard values have been provided in this chart as reference information. 10. INSPECTION PROCEDURES USING AN OSCILLOSCOPE When there are inspection procedures using an oscilloscope, these are listed here.

DIAGNOSIS FUNCTIONMETHOD OF READING DIAGNOSIS CODES WHEN USING THE MUT-II Connect the MUT-II to the diagnosis connector and take a reading of the diagnosis codes. Caution Turn off the ignition switch before connecting or disconnecting the MUT-II.

MUT-II

00-8

GENERAL - How to Use Troubleshooting/Inspection Service PointsWHEN USING THE WARNING LAMP 1. Use the special tool to earth No.1 terminal (diagnosis control terminal) of the diagnosis connector. 2. To check ABS system, remove the valve relay.MB991529

Diagnosis connector

NOTE That is because the valve relay is off and the warning lamp remains illuminated if there is a fault in the ABS system. 3. Turn off the ignition switch. 4. Read out a diagnosis code by observing how the warning lamp flashes. Applicable systemsSystem name MPI A/T ABS TCL Warning lamp name Engine warning lamp Neutral position indicator lamp ABS warning lamp TCL-OFF indicator lamp

Indication of diagnosis code by warning lampWhen the diagnosis code No.24 is output1.5 secs. 0.5 sec. 0.5 sec.

When no diagnosis code is output*0.5 sec. 0.25 sec. On Off

On Off

Pause time 3 secs.

Tens signal

Place division 2 secs.

Units signal

NOTE *: Even if the ABS system is normal, removing the valve relay causes the diagnosis code No.52 to be output. METHOD OF ERASING DIAGNOSIS CODES WHEN USING THE MUT-II Connect the MUT-II to the diagnosis connector and erase the diagnosis code. Caution Turn off the ignition switch before connecting or disconnecting the MUT-II. WHEN NOT USING THE MUT-II (1) Turn the ignition switch to OFF. (2) After disconnecting the battery cable from the battery ( - ) terminal for 10 seconds or more, reconnect the cable. (3) After the engine has warmed up, run it at idle for about 15 minutes.

GENERAL - How to Use Troubleshooting/Inspection Service Points HOW TO USE THE INSPECTION PROCEDURES

00-9

The causes of a high frequency of problems occurring in electronic circuitry are generally the connectors, components, the ECU and the harnesses between connectors, in that order. These inspection procedures follow this order, and they first try to discover a problem with a connector or a defective component.1. Comments on the diagnosis code or trouble symptom above.

CHECKING PROCEDURE 4D Indicator does not turn on or off even if control mode switch is pressed. D Indicator switch should not be illuminated is illuminated.In the above cases, the ECS switch circuit is defective or the indicator circuit is defective.

Probable cause2. Indicates inspection carried out using the MUT-II. Indicates the operation and inspection procedures. Indicates the OK judgement conditions. Detailed inspection procedures (methods) such as component inspection and circuit inspection are listed on a separate page, and are given here for reference.

3. OK

MUT-II Data list 17 Control mode selection switch OK: Voltage changes between approx. 0V approx. 2.5V approx. 5V when the switch is operated.

4. Indicates voltage and resistance to be measured at a particular NG connector. (Refer to Connector Measurement Service Points.) OK The connector position can be located in the wiring diagram in the OK electrical wiring manual by means of this symbol. Measure at switch connector A-44 Indicates operation and inspection procedures, inspection terminals D Disconnect the connector, and measure at the harness and inspection conditions. side. Indicates the OK judgement conditions. D Voltage between terminal 6 - earth and terminal 8 ECU switch component inspection (Refer to P.3-44.) earth OK: Approx. 5V

NG

OKCheck the following connector. A-44

NG 5.

Repair

OKCheck trouble symptom. Replace the ECS-ECU.

Inspect the contact condition at each connector terminal. (Refer to Connector Inspection Service Points.) The connector position can be located in the wiring diagram in the electrical wiring manual by means of this symbol. Caution After carrying out connector inspection, always be sure to reconnect the connector as it was before.

6.

Confirm that there are trouble symptoms. If trouble symptoms have disappeared, the connector may have been inserted incorrectly and the trouble symptom may have disappeared during inspection. If it seems that trouble symptoms still remain, proceed to the next page of instructions.

7.

If trouble symptoms still remain up to this stage, there is a possibility that there is an open or short circuit in the harness between the connectors, so check the harness. Alternatively, the cause may be a defective ECU, so try replacing the ECU and check if the trouble symptom disappears.

HARNESS INSPECTION Check for an open or short circuit in the harness between the terminals which were defective according to the connector measurements. Carry out this inspection while referring to the electrical wiring manual. Here, Check harness between power supply and terminal xx also includes checking for blown fuses. For inspection service points when there is a blown fuse, refer to Inspection Service Points for a Blown Fuse. MEASURES TO TAKE AFTER REPLACING THE ECU If the trouble symptoms have not disappeared even after replacing the ECU, repeat the inspection procedure from the beginning.

00-10

GENERAL - How to Use Troubleshooting/Inspection Service Points CONNECTOR MEASUREMENT SERVICE POINTSTurn the ignition switch to OFF when connecting disconnecting the connectors, and turn the ignition switch to ON when measuring if there are no instructions to be contrary.

Harness connector

IF INSPECTING WITH THE CONNECTOR CONNECTED (WITH CIRCUIT IN A CONDITION OF CONTINUITY) Waterproof Connectors Be sure to use the special tool (harness connector). Never insert a test bar from the harness side, because to do so will reduce the waterproof performance and result in corrosion.

Extra-thin probe

Test bar Connector

Ordinary (non-waterproof) Connectors Check by inserting the test bar from the harness side. Note that if the connector (control unit, etc.) is too small to permit insertion of the test bar, it should not be forced; use a special tool (the extra-thin probe in the harness set for checking for this purpose.

Inspection harness for connector pin contact pressure

IF INSPECTING WITH THE CONNECTOR DISCONNECTED Use the special tool (inspection harness for connector pin contact pressure in the harness set for inspection). The inspection harness for connector pin contact pressure should be used. the test bar should never be forcibly inserted, as it may cause a defective contact.

Touch the pin directly with the test bar. Caution At this time, be careful not to short the connector pins with the test bars. To do so may damage the circuits inside the ECU.

GENERAL - How to Use Troubleshooting/Inspection Service PointsConnector disconnected or improperly connected

00-11

CONNECTOR INSPECTIONVISUAL INSPECTION D Connector is disconnected or improperly connected D Connector pins are pulled out D Due to harness tension at terminal section D Low contact pressure between male and female terminals D Low connection pressure due to rusted terminals or foreign matter lodged in terminals

Defective connector contact

Harness wire breakage at terminal section Low contact pressure

CONNECTOR PIN INSPECTION If the connector pin stopper is damaged, the terminal connections (male and female pins) will not be perfect even if the connector body is connected, and the pins may pull out of the reverse side of the connector. Therefore, gently pull the harnesses one by one to make sure that no pins pull out of the connector.

MB991219

CONNECTOR ENGAGEMENT INSPECTION Use the special tool (connector pin connection pressure inspection harness of the inspection harness set) to inspect the engagement of the male pins and females pins. (Pin drawing force : 1 N or more)

00-12

GENERAL - How to Use Troubleshooting/Inspection Service Points INSPECTION SERVICE POINTS FOR A BLOWN FUSE0W

Battery

Remove the fuse and measure the resistance between the load side of the fuse and the earth. Set the switches of all circuits which are connected to this fuse to a condition of continuity. If the resistance is almost 0 W at this time, there is a short somewhere between these switches and the load. If the resistance is not 0 W, there is no short at the present time, but a momentary short has probably caused the fuse to blow. The main causes of a short circuit are the following. D Harness being clamped by the vehicle body D Damage to the outer casing of the harness due to wear or heat D Water getting into the connector or circuitry D Human error (mistakenly shorting a circuit, etc.)

Fuse Connector inspection

Load switch Load

POINTS TO NOTE FOR INTERMITTENT MALFUNCTIONSIntermittent malfunctions often occur under certain conditions, and if these conditions can be ascertained, determining the cause becomes simple. In order to ascertain the conditions under which an intermittent malfunction occurs, first ask the customer for details about the driving conditions, weather conditions, frequency of occurrence and trouble symptoms, and then try to recreate the trouble symptoms. Next, ascertain whether the reason why the trouble symptom occurred under these conditions is due to vibration, temperature or some other factor. If vibration is thought to be the cause, carry out the following checks with the connectors and components to confirm whether the trouble symptom occurs. The objects to be checked are connectors and components which are indicated by inspection procedures or given as probable causes (which generates diagnosis codes or trouble symptoms.) D Gently shake the connector up, down and to the left and right. D Gently shake the wiring harness up, down and to the left and right. D Gently rock each sensor and relay, etc. by hand. D Gently shake the wiring harness at suspensions and other moving parts. NOTE If determining the cause is difficult, the flight recorder function of the MUT-II can also be used.

GENERAL - Vehicle Identification

00-1300100540085

VEHICLE IDENTIFICATIONVEHICLE INFORMATION CODE PLATE

LOCATION Vehicle information code plate is riveted on the toeboard inside the engine compartment.

1 2 3 4 5

CODE PLATE DESCRIPTION The plate shows model code, engine model, transmission model, and body colour code.No. 1 Item MODEL Contents EA2A SNHEQL6 4G63 B60B F5M42 B60 41H 03V EA2A: Vehicle model SNHEQL6: Model series Engine model Exterior code Transmission code B60: Body colour code 41H: Interior code 03V: Equipment code

2 3 4 5

ENGINE EXT TRANS AXLE COLOR INT OPT

For monotone colour vehicles, the body colour code shall be indicated. For two-tone or three-way two-tone colour vehicles, each colour code only shall be indicated in series.

MODELS

Model code EA2A SNJEQL6 SNHEQL6 SRHEQL6 EA5A SNGEQL6 SRGEQL6 EA6A SNHFQL6 4D68-SOHC (1,998 mL) 6A13-SOHC (2,497 mL) F4A42 (2WD-4A/T) F5M42 (2WD-5M/T) F4A42 (2WD-4A/T) F5M42 (2WD-5M/T) MPI Engine model 4G63-SOHC (1,997 mL) Transmission model F5M42 (2WD-5M/T)

00100030223

Fuel supply system MPI

Electronically controlled injection pump MPI

EA2A

SNJEQL6C SNHEQL6C SRHEQL6C

4G63-SOHC (1,997 mL)

F5M42 (2WD-5M/T)

F4A42 (2WD-4A/T)

00-14Model code EA5A

GENERAL - Vehicle IdentificationEngine model SNGEQL6C SRGEQL6C 6A13-SOHC (2,497 mL) Transmission model F5M42 (2WD-5M/T) F4A42 (2WD-4A/T) 4D68-SOHC (1,998 mL) F5M42 (2WD-5M/T) Electronically controlled injection pump MPI Fuel supply system MPI

EA6A

SNHFQL6C

EA2A

SNHEQR6 SRHEQR6

4G63-SOHC (1,997 mL)

F5M42 (2WD-5M/T) F4A42 (2WD-4A/T)

EA5A

SNGEQR6 SRGEQR6

6A13-SOHC (2,497 mL)

F5M42 (2WD-5M/T) F4A42 (2WD-4A/T)

MPI

EA6A

SNHFQR6

4D68-SOHC (1,998 mL)

F5M42 (2WD-5M/T)

Electronically controlled injection pump

Model code EA2W LNJEQL6 LNHEQL6 LRHEQL6 EA5W LNGEQL6 LRGEQL6 EA6W LNHFQL6 4D68-SOHC (1,998 mL) 6A13-SOHC (2,497 mL) F4A42 (2WD-4A/T) F5M42 (2WD-5M/T) F4A42 (2WD-4A/T) F5M42 (2WD-5M/T) Electronically controlled injection pump MPI MPI Engine model 4G63-SOHC (1,997 mL) Transmission model F5M42 (2WD-5M/T) Fuel supply system MPI

EA2W

LNJEQL6C LNHEQL6C LRHEQL6C

4G63-SOHC (1,997 mL)

F5M42 (2WD-5M/T)

F4A42 (2WD-4A/T) 6A13-SOHC (2,497 mL) F5M42 (2WD-5M/T) F4A42 (2WD-4A/T) 4D68-SOHC (1,998 mL) F5M42 (2WD-5M/T) Electronically controlled injection pump MPI MPI

EA5W

LNGEQL6C LRGEQL6C

EA6W

LNHFQL6C

EA2W

LNHEQR6 LRHEQR6

4G63-SOHC (1,997 mL)

F5M42 (2WD-5M/T) F4A42 (2WD-4A/T)

EA5W

LNGEQR6 LRGEQR6

6A13-SOHC (2,497 mL)

F5M42 (2WD-5M/T) F4A42 (2WD-4A/T)

MPI

EA6W

LNHFQR6

4D68-SOHC (1,998 mL)

F5M42 (2WD-5M/T)

Electronically controlled injection pump

GENERAL - Vehicle Identification MODEL CODENo. 1 Items Development Engine type Contents

00-1500100040257

EA: MITSUBISHI GALANT 2: 2,000 mL petrol engine 5: 2,500 mL petrol engine 6: 2,000 mL diesel engine A: Passenger car W: Wagon S: 4-door sedan L: 4-door station wagon N: 5-speed manual transmission R: 4-speed automatic transmission J: GLX H: GLS G: V6-24 E: MPI-SOHC F: Turbocharger with intercooler Q: With catalytic converter None: Without catalytic converter L: Left hand R: Right hand 6: For Europe C: Central Europe

1 2 3 4 5 6 7 8 9 10

2

3 4 5

Sort Body style Transmission type

6

Trim level

7

Specification engine feature Exhaust system specification Steering wheel location Destination

8

9 10

00-16

GENERAL - Vehicle Identification CHASSIS NUMBER00100560104

The chassis number is stamped on the toeboard inside the engine compartment.

1

2

3

4

5

6

7

8

9

10

11

No. 1 2 3

Items Fixed figure Distribution channel Destination J M A B

Contents Asia Japan channel For Europe, right hand drive For Europe, left hand drive 4-door sedan 4-door station wagon 5-speed manual transmission 4-speed automatic transmission GALANT 4G63: 1,997 mL petrol engine 6A13: 2,498 mL petrol engine 4D68: 1,998 mL diesel engine Passenger car 1997 Okazaki Motor Vehicle Works -

4

Body style

S L

5

Transmission type

N R

6 7

Development order Engine

EA 2 5 6

8 9 10 11

Sort Model year Plant Serial number

A V Z -

GENERAL - Vehicle Identification

00-1700100570107

ENGINE MODEL NUMBER

1. The engine model number is stamped at the cylinder block as shown in the following.Engine model 4G63 6A13 4D68 Engine displacement mL 1,997 2,498 1,998

Front of vehicle

2. The engine serial number is stamped near the engine model number.Engine serial number AA0201 to YY9999

Front of vehicle

Front of vehicle

00-18

GENERAL - Major Specifications00100080143

MAJOR SPECIFICATIONS

3

9 5 2 7 4 1 8 6

Items

EA2AS NJEQL6, NJEQL6C

EA2AS NHEQL6, NHEQL6C, NHEQR6

EA2AS RHEQL6, RHEQL6C, RHEQR6

EA5AS NGEQL6, NGEQL6C, NGEQR6

EA5AS RGEQL6, RGEQL6C, RGEQR6

EA6AS NHFQL6, NHFQL6C, NHFQR6

Vehicle dimensions mm

Overall length Overall width Overall height (unladen) Wheelbase Track-front Track-rear Overhang-front Overhang-rear Ground clearance (unladen)

1 4,630 2 1,740 3 1,415 4 2,635 5 1,510 6 1,505 7 930 8 1,065 9 150 1,260 1,775 925 850 5 4G63 1,997 F5M42

4,630 1,740 1,415 2,635 1,510 1,505 930 1,065 150

4,630 1,740 1,415 2,635 1,510 1,505 930 1,065 150 1,280

4,630 1,740 1,415 2,635 1,510 1,505 930 1,065 150 1,290 1,805 955 850

4,630 1,740 1,415 2,635 1,510 1,505 930 1,065 150 1,310

4,630 1,740 1,415 2,635 1,510 1,505 930 1,065 150 1,300 1,795 955 840

Vehicle weight kg

Kerb weight Max. gross vehicle weight Max. axle weight rating-front Max. axle weight rating-rear

Seating capacity Engine Model No. Total displacement mL Transmission Fuel system Model No. Type Fuel supply system

6A13 2,498 F4A42 4-speed automatic F5M42 5-speed manual F4A42 4-speed automatic

4D68 1,998 F5M42 5-speed manual Electronically controlled fuel injection

5-speed manual

Electronically controlled multi-point injection

GENERAL - Major Specifications

00-19

3

5 2

9

7

4 1

8

6

Items

EA2WL NJEQL6, NJEQL6C

EA2WL NHEQL6, NHEQL6C, NHEQR6

EA2WL RHEQL6, RHEQL6C, RHEQR6

EA5WL NGEQL6, NGEQL6C, NGEQR6

EA5WL RGEQL6, RGEQL6C, RGEQR6

EA6WL NHFQL6, NHFQL6C, NHFQR6

Vehicle dimensions mm

Overall length Overall width Overall height (unladen) Wheelbase Track-front Track-rear Overhang-front Overhang-rear Ground clearance (unladen)

1 4,680 2 1,740 3 1,495 4 2,635 5 1,510 6 1,505 7 930 8 1,115 9 150 1,310 1,830 920 910 5 4G63 1,997 F5M42

4,680 1,740 1,495 2,635 1,510 1,505 930 1,115 150 1,310

4,680 1,740 1,495 2,635 1,510 1,505 930 1,115 150 1,330

4,680 1,740 1,495 2,635 1,510 1,505 930 1,115 150 1,340 1,860 950 910

4,680 1,740 1,495 2,635 1,510 1,505 930 1,115 150 1,360

4,680 1,740 1,495 2,635 1,510 1,505 930 1,115 150 1,350 1,850

Vehicle weight kg

Kerb weight Max. gross vehicle weight Max. axle weight rating-front Max. axle weight rating-rear

900

Seating capacity Engine Model No. Total displacement mL Transmission Fuel system Model No. Type Fuel supply system

6A13 2,498 F4A42 4-speed automatic F5M42 5-speed manual F4A42 4-speed automatic

4D68 1,998 F5M42 5-speed manual Electronically controlled fuel injection

5-speed manual

Electronically controlled multi-point injection

00-20

GENERAL - Precautions Before Service00100050229

PRECAUTIONS BEFORE SERVICE

SUPPLEMENTAL RESTRAINT SYSTEM (SRS), SEAT BELT WITH PRE-TENSIONER1. Items to follow when servicing SRS (1) Be sure to read GROUP 52B - Supplemental Restraint System (SRS). For safe operations, please follow the directions and heed all warnings. (2) Wait at least 60 seconds after disconnecting the battery cable before doing any further work. The SRS system is designed to retain enough voltage to deploy the air bag even after the battery has been disconnected. Serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cable is disconnected. (3) Warning labels must be heeded when servicing or handling SRS components and seat belt with pre-tensioner. Warning labels are located in the following locations. D Sun visor D Glove box D SRS air bag control unit D Steering wheel D Steering gear and linkage D Air bag module (drivers side and front passengers side) D Clock spring D Seat belt with pre-tensioner D Side air bag module D Side impact sensor (4) Always use the designated special tools and test equipment. (5) Store components removed from the SRS and seat belt with pre-tensioner in a clean and dry place. The air bag module and seat belt with pre-tensioner should be stored on a flat surface and placed so that the pad surface is facing upward. Do not place anything on top of it. (6) Never attempt to disassemble or repair the SRS components (SRS air bag control unit, air bag module, clock spring and side impact sensor) and seat belt with pre-tensioner. (7) Whenever you finish servicing the SRS and seat belt with pre-tensioner, check the SRS warning lamp operation to make sure that the system functions properly. (8) Be sure to deploy the air bag and seat belt with pre-tensioner before disposing of the air bag module and seat belt with pre-tensioner or disposing of a vehicle equipped with an air bag and seat belt with pre-tensioner. (Refer to GROUP 52B - Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures.) 2. Observe the following when carrying out operations on places where SRS components and seat belt with pre-tensioner are installed, including operations not directly related to the SRS air bag and seat belt with pre-tensioner. (1) When removing or installing parts do not allow any impact or shock to the SRS components and seat belt with pre-tensioner. (2) SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the SRS components and seat belt with pre-tensioner before drying or baking the vehicle after painting. D SRS air bag control unit, air bag module, clock spring and side impact sensor: 93_C or more D Seat belt with pre-tensioner 90_C or more After re-installing them, check the SRS warning lamp operation to make sure that the system functions properly.

GENERAL - Precautions Before Service SERVICING THE ELECTRICAL SYSTEM

00-21

Before replacing a component related to the electrical system and before undertaking any repair procedures involving the electrical system, be sure to first disconnect the negative ( - ) cable from the battery in order to avoid damage caused by short-circuiting. Caution Before connecting or disconnecting the negative ( - ) cable, be sure to turn off the ignition switch and the lighting switch. (If this is not done, there is the possibility of semiconductor parts being damaged.)

APPLICATION OF ANTI-CORROSION AGENTS AND UNDERCOATSIf oil or grease gets onto the oxygen sensor, it will cause a drop in the performance of the sensor. Cover the oxygen sensor with a protective cover when applying anti-corrosion agents and undercoats.

PRE-INSPECTION CONDITIONPre-inspection condition refers to the condition that the vehicle must be in before proper engine inspection can be carried out. If you see the words Set the vehicle to the pre-inspection condition. in this manual, it means to set the vehicle to the following condition. D Engine coolant temperature: 80 - 90_C D Lamps, electric cooling fan and all accessories: OFF D M/T: Neutral D A/T: P range

VEHICLE WASHINGApprox. 40 cm

If high-pressure car-washing equipment or steam car-washing equipment is used to wash the vehicle, be sure to note the following information in order to avoid damage to plastic components, etc. D Spray nozzle distance: Approx. 40 cm or more D Spray pressure: 3,900 kPa or less D Spray temperature: 82_C or less D Time of concentrated spray to one point: within 30 sec.

00-22MUT-II sub-assembly

GENERAL - Precautions Before Service MUT-IIRefer to the MUT-II INSTRUCTION MANUAL for instructions on handling the MUT-II.

ROM pack

Connect the MUT-II to the diagnosis connector as shown in the illustration.MUT-II

Caution Connection and disconnection of the MUT-II should always be made with the ignition switch in the OFF position.

IN ORDER TO PREVENT VEHICLES FROM FIREImproper installation of electrical or fuel related parts could cause a fire. In order to retain the high quality and safety of the vehicle, it is important that any accessories that may be fitted or modifications/repairs that may be carried out which involve the electrical or fuel systems, MUST be carried out in accordance with MMCs information/Instructions.

ENGINE OILS Health WarningProlonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitits. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities must be provided.

Recommended PrecautionsThe most effective precaution is to adapt working practices which prevent, as far as practicable, the risk of skin contact with mineral oils, for example by using enclosed systems for handling used engine oil and by degreasing components, where practicable, before handling them.

GENERAL - Precautions Before Service

00-23

Other precautions: D Avoid prolonged and repeated contact with oils, particularly used engine oils. D Wear protective clothing, including impervious gloves where practicable. D Avoid contaminating clothes, particularly underpants, with oil. D Do not put oily rags in pockets, the use of overalls without pockets will avoid this. D Do not wear heavily soiled clothing and oil-impregnated foot-wear. Overalls must be cleaned regularly and kept separately from personal clothing. D Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. D Obtain First Aid treatment immediately for open cuts and wounds. D Wash regularly with soap and water to ensure all oil is removed, especially before meals (skin cleansers and nail brushes will help). After cleaning, the application of preparations containing lanolin to replace the natural skin oils is advised. D Do not use petrol, kerosine, diesel fuel, gas oil, thinners or solvents for cleaning skin. D Use barrier creams, applying them before each work period, to help the removal of oil from the skin after work. D If skin disorders develop, obtain medical advice without delay.

00-24

GENERAL -

Supplemental Restraint System (SRS) and Seatbelts with Pre-tensioner

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEATBELTS 00100590073 WITH PRE-TENSIONERTo improve safety, the SRS and seat belts with pre-tensioner are available as optional parts. These systems enhance collision safety by restraining the front passengers in case of an accident. The SRS works with the pre-tensioner simultaneously when a collision is detected. The SRS consists of four air bag modules, SRS air bag control unit (SRS-ECU), side impact sensor, SRS warning lamp and clock spring. The air bags are located in the centre of the steering wheel, above the glove box, and built into the front seat back assemblies. Each air bag has a folded air bag and an inflator unit. The SRS-ECU under the floor console monitors the system and has a safing G sensor and an analog G sensor. The side impact sensor inside the center pillar monitors any shocks coming from the side of the vehicle. The warning lamp on the instrument panel indicates the operational status of the SRS. The clock spring is installed in the steering column. The SRS side air bag deploys if an impact received at the side of the vehicle is stronger than a certain set value, in order to protect the upper bodies of front seat passengers in the event of a collision. The seat belt pre-tensioner is built into the front seat belt retractor. Only authorized service personnel should do work on or around the SRS components and seat belt with pre-tensioner. Those service personnel should read this manual carefully before starting any such work. Extreme care must be used when servicing the SRS to avoid injury to the service personnel (by inadvertent deployment of the air bags or inadvertent operation of the seat belt with pre-tensioner) or the driver (by rendering the SRS or the seat belt with pre-tensioner inoperative).

Side impact sensor Side air bag module Clock spring Air bag module (Drivers side)

Air bag module (Front passengers side)

Diagnosis connector

SRS-ECU Seat belt with pre-tensioner SRS warning lamp

GENERAL -

Supplemental Restraint System (SRS) and Seatbelts with Pre-tensioner

00-25

SEAT BELT WITH PRE-TENSIONER The seat belt with pre-tensioner has a pre-tensioner operating mechanism and a G-sensor which detects the force from an impact built into the seat belt retractor. The G-sensor is a mechanical-type sensor which includes components such as a weight which moves as a result of the impact from a collision, and a spike which strikes a charge and causes it to detonate. Thus the pre-tensioner is equipped with a safety mechanism to prevent mis-operation during maintenance operations such as removal and installation of the seat belt.

The safety mechanism operates automatically when the retractor top mounting screw is removed during removal of the seat belt. When the retractor top mounting screw is removed, the force of the spring plate causes the tab at the lower edge of plate (A) to push in the pin of the G-sensor, which prevents the weight inside the G-sensor from moving. At the same time, the retractor bracket and the top of plate (A) become separated. A stopper is inserted into the gap thus formed by the force from a spring to prevent the tab from being removed from the pin if an outside force is applied to plate (A).

Plate (A) Spring Stopper Retractor bracket Plate (A) (when safety mechanism is disengaged) Plate (A) (when safety mechanism is engaged) Stopper

Spring plate

Tab

Tab

G-sensor structure Charge

Spike

Pin Pin (when safety mechanism is engaged)

Tab

Sensor weight

00-26

GENERAL -

Supplemental Restraint System (SRS) and Seatbelts with Pre-tensioner00100600073

SRS SERVICE PRECAUTIONS1. In order to avoid injury to yourself or others from accidental deployment of the air bag and accidental operation of the seat belt with pre-tensioner during servicing, read and carefully follow all the precautions and procedures described in this manual. 2. Do not use any electrical test equipment on or near SRS components, except those specified on GROUP 52B. 3. Never Attempt to Repair the Following Components: D SRS air bag control unit (SRS-ECU) D Clock Spring D Air bag module (Drivers side or front passengers side) D Side air bag module D Side impact sensor D Seat belt with Pre-tensioner

NOTE If any of these components are diagnosed as faulty, they should only be replaced, in accordance with the INDIVIDUAL COMPONENTS SERVICE procedures in this manual, starting at page GROUP 52B.

Insulating tape

Battery

4. After disconnecting the battery cable, wait 60 seconds or more before proceeding with the following work. The SRS system is designed to retain enough voltage to deploy the air bag for a short time even after the battery has been disconnected, so serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cables are disconnected.

SRS-ECU connector

5. Do not attempt to repair the wiring harness connectors of the SRS. If any of the connectors are diagnosed as faulty, replace the wiring harness. If the wires are diagnosed as faulty, replace or repair the wiring harness according to the following table.

GENERAL SRS-ECU Terminal No. 1 to 4 5, 6 7, 8 9, 10 11 12 13 14 15 16 to 19 20, 21 Destination of harness -

Supplemental Restraint System (SRS) and Seatbelts with Pre-tensioner

00-27

Corrective action Correct or replace the dash wiring harness. Replace the clock spring. Correct or replace the dash wiring harness.

Dash wiring harness Clock spring Air bag module (Drivers side) Dash wiring harness Air bag module (Front passengers side) Dash wiring harness Diagnosis connector Dash wiring harness Junction block (fuse No.4) Dash wiring harness Junction block (fuse No.13) Dash wiring harness Instrument panel wiring harness SRS warning lamp Dash wiring harness Earth

Correct or replace each wiring harness. Correct or replace the dash wring harness.

SRS-ECU Terminal No. 1, 2 3 4 5, 6 7, 8 9 10, 11 12 13 14, 15 16 17 to 20 21, 22 23, 24 Destination of harness Dash wiring harness Earth Dash wiring harness Instrument panel wiring harness SRS warning lamp Dash wiring harness Air bag module (Front Passengers side) Dash wiring harness Clock spring Air bag module (Drivers side) Dash wiring harness Junction block (fuse No.4) Dash wiring harness Junction block (fuse No.13) Dash wiring harness Earth Dash wiring harness Diagnosis connector Dash wiring harness Side air bag module (LH) Dash wiring harness Side air bag module (RH) Corrective action Correct or replace the dash wiring harness Correct or replace each wiring harness. Correct or replace the dash wiring harness. Correct or replace the dash wiring harness. Replace the clock spring. Correct or replace the dash wiring harness.

00-28SRS-ECU Terminal No. 25 to 33 34, 35, 36 37 to 39 40, 41, 42

GENERAL Destination of harness -

Supplemental Restraint System (SRS) and Seatbelts with Pre-tensioner Corrective action Correct or replace the dash wiring harness. Correct or replace each wiring harness

Dash wiring harness Floor wiring harness Side impact sensor (LH) Dash wiring harness Floor wiring harness Side impact sensor (RH)

6. Inspection of the SRS-ECU harness connector should be carried out by the following procedure. Insert the special tool (narrow probe in the harness set) into connector from harness side (rear side), and connect the tester to this probe. If any to other than the special tool is used, it may cause damage to the harness and other components. Furthermore, measurement should not be carried out by touching the probe directly against the terminals from the front of the connector. The terminals are plated to increase their conductivity, so that if they are touched directly by the probe, the plating may break, which will cause drops in reliability.MB991222 SRS-ECU harness connector SRS-ECU harness connector (rear side)

7. SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the SRS-ECU, air bag module (drivers side and front passengers side), clock spring, side impact sensor, front seat assembly (side air bag module), and seat belt with pre-tensioner before drying or baking the vehicle after painting. D SRS-ECU, air bag module, clock spring, side impact sensor: 93_C or more D Seat belt with pre-tensioner: 90_C or more 8. Whenever you finish servicing the SRS, check warning lamp operation to make sure that the system functions properly. (Refer to GROUP 52B.) 9. Make certain that the ignition switch is OFF when the MUT-II is connected or disconnected. 10. If you have any questions about the SRS, please contact your local distributor. NOTE SERIOUS INJURY CAN RESULT FROM UNINTENDED AIR BAG DEPLOYMENT, SO USE ONLY THE PROCEDURES AND EQUIPMENT SPECIFIED IN THIS MANUAL.

GENERAL - Support Locations for Lifting and Jacking

00-2900100070065

SUPPORT LOCATIONS FOR LIFTING AND JACKING

Caution Do not support the vehicles at locations other than specified supporting points. If do so, this will cause damage, etc.

SUPPORT POSITIONS FOR A GARAGE JACK AND AXLE STANDSGARAGE JACK Caution Never support any point other than the specified one, or it will be deformed.

Caution Never support the rear floor crossmember.

AXLE STANDSNotch Notch

Rubber

Rubber

00-30

GENERAL - Support Locations for Lifting and JackingCaution When service procedures require removing rear suspension, spare tyre and rear bumper, place additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of centre of gravity changes.

SUPPORT POSITIONS FOR A SINGLE-POST LIFT OR DOUBLE-POST LIFT

DOUBLE-POST LIFT Notch Notch

SINGLE-POST LIFT

GENERAL - Support Locations for Lifting and JackingH-bar lift H-bar lift

00-31

SUPPORT POSITIONS AND SUPPORT METHOD FOR AN H-BAR LIFTCaution When service procedures require removing rear suspension, fuel tank, spare tyre and rear bumper, place additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of centre of gravity changes. When H-bar lift is used to lift up vehicles, use of metallic attachment attached to the H-bar lift may cause damage to the suspension arm etc. Therefore, lift up the vehicle by the following procedure.

Chassis-support position (side sill) Attachment

1. Place the vehicle on the H-bar lift (same direction). 2. Place attachments on the H-bar lift at the designated chassis-support positions. When making the attachments, refer to the section concerning making them.Section A-A Side sill

H-bar lift Attachment

Caution If support is at any location other than the designated positions, the body or suspension might be deformed or otherwise damaged, so care should be taken to support only at the correct (designated) positions. 3. Raise the H-bar lift to the height at which the vehicle is slightly raised and check to be sure that the vehicle is correctly and sufficiently secured; then raise the vehicle.

H-bar lift

A

A

00-32Block (A) 1,800 90 95 Block (B) 15 40 60 40 20

GENERAL - Support Locations for Lifting and Jackingmm

PREPARATION OF ATTACHMENTS 1. Prepare the blocks (wooden) and nails as shown in the figure.Item Block (A) Block (B) Block (C) Dimensions mm 90 95 1,800 60 100 95 140 40 95 70 or more Quantity 2 4 8 32

Block (C) 15 40 40

Nail

20

Caution The wood selected for the blocks must be hard. 2. For the (B) blocks and (C) blocks, use a saw and chisel or similar tool to make grooves of the dimensions shown in the figure. 3. Make four ATTACHMENTS such as shown in the figure nailing (B) and (C) blocks so that each (B) blocks is sandwiches between (C) blocks.

140 100 40

Block (C) 100 Block (C) 140 Nail

Block (B) Finished attachment

Movable according to vehicle width

GENERAL - Standard Part/Tightening-Torque Table

00-3300100110033

STANDARD PART/TIGHTENING-TORQUE TABLEEach torque value in the table is a standard value for tightening under the following conditions. (1) Bolts, nuts and washers are all made of steel and plated with zinc. (2) The threads and bearing surface of bolts and nuts are all in dry condition. Standard bolt and nut tightening torqueThread size Bolt nominal diameter (mm) M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 Pitch (mm) 0.8 1.0 1.25 1.25 1.25 1.5 1.5 1.5 1.5 1.5 1.5 Torque Nm Head mark 4 2.5 4.9 12 24 41 72 111 167 226 304 392 Head mark 7 4.9 8.8 22 44 81 137 206 304 412 559 735

The values in the table are not applicable: (1) If toothed washers are inserted. (2) If plastic parts are fastened. (3) If bolts are tightened to plastic or die-cast inserted nuts. (4) If self-tapping screws or self-locking nuts are used.

Head mark 8 5.9 9.8 25 52 96 157 235 343 481 647 853

Flange bolt and nut tightening torqueThread size Bolt nominal diameter (mm) M6 M8 M10 M10 M12 M12 Pitch (mm) 1.0 1.25 1.25 1.5 1.25 1.75 Torque Nm Head mark 4 4.9 13 26 24 46 42 Head mark 7 9.8 24 49 44 93 81 Head mark 8 12 28 57 54 103 96

NOTES

11A-1

ENGINECONTENTS11109000276

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11C

11A-2

ENGINE CONTENTSGENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 3 SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6Drive Belt Tension Check and Adjustment . . . . . . 6 Ignition Timing Check . . . . . . . . . . . . . . . . . . . . . . . . . 7 Idle Speed Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Idle Mixture Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Compression Pressure Check . . . . . . . . . . . . . . . . . 9 Manifold Vacuum Check . . . . . . . . . . . . . . . . . . . . . 1011109000603

Lash Adjuster Check . . . . . . . . . . . . . . . . . . . . . . . . 11

CRANKSHAFT PULLEY . . . . . . . . . . . . . . . . . . . 15 CAMSHAFT AND CAMSHAFT OIL SEAL . . . 16 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 CRANKSHAFT OIL SEAL . . . . . . . . . . . . . . . . . . 20 CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . 22 TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 TIMING BELT B . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 33

ENGINE - General Information/Service Specifications

11A-311100010469

GENERAL INFORMATIONItems Total displacement mL Bore Stroke mm Compression ratio Combustion chamber Camshaft arrangement Number of valve Intake Exhaust Intake Valve timing Exhaust Fuel system Rocker arm Auto-lash adjuster Opening Closing Opening Closing 4G63 1,997 85.0 88.0 10.0 Pentroof type SOHC 8 8 BTDC 11_ ABDC 53_ BBDC 63_ ATDC 21_

Electronically controlled multipoint fuel injection Roller type Equipped11100030489

SERVICE SPECIFICATIONSItems When checked Tension N Alternator drive belt tension When a used belt is installed When a new belt is installed Deflection (Reference value) mm When checked When a used belt is installed When a new belt is installed When checked Power steering oil pump and A/C compressor drive belt tension Tension N When a used belt is installed When a new belt is installed When checked Deflection mm When a used belt is installed When a new belt is installed Basic ignition timing Ignition timing Standard value 294 - 490 343 - 441 490 - 686 7.7 - 12.3 8.4 - 10.6 5.9 - 7.7 392 - 588 441 - 539 637 - 833 11.7 - 15.3 12.5 - 14.3 8.8 - 11.0 5_ BTDC2_ Approx. 10_BTDC Limit -

11A-4Items

ENGINE - Service Specifications/Sealants/Special ToolsStandard value 750 100 0.5 or less 100 or less 1,400 Within 1 3.5 3.8 - 4.5 5-7 Limit Min. 1,060 Max. 100 Min. 69 99.4 11100050201

Idle speed r/min CO contents % HC contents ppm Compression pressure (250 - 400 r/min) kPa Compression pressure difference of all cylinder kPa Intake manifold vacuum kPa Cylinder head bolt shank length mm Auto-tensioner push rod movement mm Timing belt tension torque Nm (Reference value) Auto-tensioner rod protrusion amount mm Timing belt B tension mm

SEALANTSItems Rocker cover and cylinder head Semi-circular packing Oil pan Thermostat case Flywheel bolt Specified sealants 3M ATD Part No.8660 or equivalent MITSUBISHI GENUINE MD970389 or equivalent PART Remarks Semi-drying sealant -

3M Stud Locking 4170 or equivalent

SPECIAL TOOLSTool Number MB991502 Name MUT-II sub assembly Use D D Checking the idle speed Erasing diagnosis code

11100060457

MB990767

End yoke holder

D D

Holding the camshaft sprocket Holding the crankshaft sprocket

MD998719 MD998754

or

Crankshaft pulley holder pin

D D

Holding the camshaft sprocket Holding the crankshaft sprocket

ENGINE - Special ToolsTool Number MD998713 Name Camshaft oil seal installer Use Press-in of the camshaft oil seal

11A-5

MD998443

Auto-lash adjuster holder

Supporting of auto-lash adjuster

MD998727

Oil pan remover

Removal of oil pan

MD998781

Flywheel stopper

Securing the flywheel

MD998776

Crankshaft rear oil seal installer

Press-in of the crankshaft rear oil seal

MB990938

Handle

Press-in of the crankshaft rear oil seal

MD998767

Tension pulley socket wrench

Timing belt tension adjustment

GENERAL SERVICE TOOL MZ203827

Engine lifter

Supporting the engine assembly during removal and installation of the transmission

MB991453

Engine hanger assembly

11A-6Alternator pulley

ENGINE - On-vehicle ServiceWater pump pulley

ON-VEHICLE SERVICEDRIVE BELT TENSION CHECK AND ADJUSTMENT

11100090432

Crankshaft pulley

ALTERNATOR DRIVE BELT TENSION CHECK Use a belt tension gauge to check that the belt tension is at the standard value at a point half-way between the two pulleys as shown in the illustration. In addition, press this section with a force of 98 N and check that the amount of belt deflection is at the standard value. Standard value:Tension N Deflection (Reference value) mm 294 - 490 7.7 - 12.3

ALTERNATOR DRIVE BELT TENSION ADJUSTMENT 1. Loosen the nut of the alternator pivot bolt. 2. Loosen the lock bolt. 3. Use the adjusting bolt to adjust the belt tension and belt deflection to the standard values. Standard value:Adjusting bolt Lock bolt

Items Tension N

When a used belt is installed 343 - 441

When a new belt is installed 490 - 686 5.9 - 7.7

Deflection (Reference 8.4 - 10.6 value) mm

4. Tighten the nut of the alternator pivot bolt. Tightening torque: 44 Nm 5. Tighten the lock bolt. Tightening torque: 22 Nm 6. Tighten the adjusting bolt. Tightening torque: 10 Nm

ENGINE - On-vehicle Service Oil pump pulley 98 N A Crankshaft pulley Tensioner pulley B

11A-7

POWER STEERING OIL PUMP AND AIR CONDITIONER COMPRESSOR DRIVE BELT TENSION CHECK AND ADJUSTMENT 11100130127 1. Use a belt tension gauge to check that the belt tension is at the standard value at a point half-way between the two pulleys (indicated by an arrow in the illustration). In addition, press this section with a force of 98 N and check that the amount of belt deflection is at the standard value. Standard value:Items When checked 392 - 588 11.7 - 15.3 When a used belt is installed 441 - 539 12.5 - 14.3 When a new belt is installed 637 - 833 8.8 - 11.0

Oil pump pulley 98 N Crankshaft pulley A Tensioner pulley B A/C compressor pulley

Tension N Deflection (Reference value) mm

2. If the tension or deflection is outside the standard value, adjust by the following procedure. (1) Loosen tensioner pulley fixing nut A. (2) Adjust the amount of belt deflection using adjusting bolt B. (3) Tighten fixing nut A. Tightening torque: 25 Nm (4) Check the belt deflection amount and tension, and readjust if necessary. Caution Check after turning the crankshaft once or more clockwise (right turn).

IGNITION TIMING CHECK

11100170297

1. Before inspection, set the vehicle to the pre-inspection condition. 2. Connect the MUT-II to the diagnosis connector. 3. Set up a timing light. 4. Start the engine and run at idle. 5. Check that engine idle speed is within the standard value. Standard value: 750 100 r/min 6. Select No.17 of the MUT-II Actuator test.

11A-8

ENGINE - On-vehicle Service7. Check that basic ignition timing is within the standard value. Standard value: 5_ BTDC2_ 8. If the basic ignition timing is outside the standard value, inspect the MPI system while referring to GROUP 13A - Troubleshooting. 9. Press the MUT-II clear key (Select a forced driving cancel mode) to release the Actuator test. Caution If the test is not cancelled, a forced driving will continue for 27 minutes. Driving under this condition may damage the engine. 10. Check that ignition timing is at the standard value. Standard value: approx. 10_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 standard value at higher altitudes.

IDLE SPEED CHECK

11100350066

1. Before inspection, set the vehicle to the pre-inspection condition. 2. Turn the ignition switch to OFF and connect the MUT-II to the diagnosis connector. 3. Check the basic ignition timing. Standard value: 5_ BTDC2_ 4. Run the engine at idle for 2 minutes. 5. Check the idle speed. Select item No. 22 and take a reading of the idle speed. Standard value: 750 100 r/min NOTE The idle speed is controlled automatically by the idle speed control (ISC) system. 6. If the idle speed is outside the standard value, inspect the MPI components by referring to GROUP 13A Troubleshooting.

IDLE MIXTURE CHECK

11100210418

1. Before inspection, set the vehicle to the pre-inspection condition. 2. Turn the ignition switch to OFF and connect the MUT-II to the diagnosis connector. 3. Check that the basic ignition timing is within the standard value. Standard value: 5_ BTDC2_ 4. Run the engine at 2,500 r/min for 2 minutes.

ENGINE - On-vehicle Service

11A-9

5. Set the CO, HC tester. 6. Check the CO contents and the HC contents at idle. Standard value CO contents: 0.5% or less HC contents: 100 ppm or less 7. If there is a deviation from the standard value, check the following items: D Diagnosis output D Closed-loop control (When the closed-loop control is normal, the output signal of the oxygen sensor changes between 0 - 400 mV and 600 - 1,000 mV at idle.) D Fuel pressure D Injector D Ignition coil, spark plug cable, spark plug D Leak in the EGR system and in the EGR valve D Evaporative emission control system D Compression pressure NOTE Replace the three way catalyst when the CO and HC contents are not within the standard value, even though the result of the inspection is normal on all items.

COMPRESSION PRESSURE CHECK

11100260499

1. Before inspection, check that the engine oil, starter and battery are normal. In addition, set the vehicle to the pre-inspection condition. 2. Disconnect the spark plug cables. 3. Remove all of the spark plugs. 4. Disconnect the crank angle sensor connector. NOTE Doing this will prevent the engine-ECU from carrying out ignition and fuel injection. 5. Cover the spark plug hole with a shop towel etc., and after the engine has been cranked, check that no foreign material is adhering to the shop towel. Caution 1. Keep away from the spark plug hole when cranking. 2. If compression is measured with water, oil, fuel, etc., that has come from cracks inside the cylinder, these materials will become heated and will gush out from the spark plug hole, which is dangerous.

11A-10

ENGINE - On-vehicle Service6. Set compression gauge to one of the spark plug holes. 7. Crank the engine with the throttle valve fully open and measure the compression pressure.

Compression gauge

Standard value (at engine speed of 250 - 400 r/min): 1,400 kPa Limit (at engine speed of 250 - 400 r/min): Min. 1,060 kPa 8. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit. Limit: Max. 100 kPa 9. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps 7 and 8. (1) If the compression increases after oil is added, the cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface. (2) 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 crank angle sensor connector. 11. Install the spark plugs and spark plug cables. 12. Use the MUT-II to erase the diagnosis codes. NOTE This will erase the diagnosis code resulting from the crank angle sensor connector being disconnected.

MANIFOLD VACUUM CHECKVacuum gage

11100270409

1. Start the engine and allow it to warm up until the temperature of the engine coolant reaches 80 to 95_C. 2. Connect a tachometer. 3. Attach a three-way union to the vacuum hose between the fuel pressure regulator and the air intake plenum, and connect a vacuum gauge. 4. Start the engine and check that idle speed is within standard value. Then read off the vacuum gauge. Limit: Min. 69 kPa

ENGINE - On-vehicle Service LASH ADJUSTER CHECK

11A-1111100290344

If an abnormal noise (knocking) that seems to be coming from the lash adjuster is heard after starting the engine and does not stop, carry out the following check. NOTE (1) The abnormal noise which is caused by a problem with the lash adjusters is generated after the engine is started, and will vary according to the engine speed. However, this noise is not related to the actual engine load. Because of this, if the noise does not occur immediately after the engine is started, if it does not change in accordance with the engine speed, or if it changes in accordance with the engine load, the source of the noise is not the lash adjusters. (2) If there is a problem with the lash adjusters, the noise will almost never disappear, even if the engine has been run at idle to let it warm up. The only case where the noise might disappear is if the oil in the engine has not been looked after properly and oil sludge has caused the lash adjusters to stick. 1. Start the engine. 2. Check that the noise occurs immediately after the engine is started, and that the noise changes in accordance with changes in the engine speed. If the noise does not occur immediately after the engine is started, or if it does not change in accordance with the engine speed, the problem is not being caused y the lash adjusters, so check for some other cause of the problem. Moreover, if the noise does not change in accordance with the engine speed, the cause of the problem is probably not with the engine. (In these cases, the lash adjusters are normal.) 3. While the engine is idling, check that the noise level does not change when the engine load is varied (for example, by shifting from N D). If the noise level changes, the cause of the noise is probably parts striking because of worn crankshaft bearings or connecting rod bearings. (In such cases, the lash adjusters are normal.) 4. After the engine has warmed up, run it at idle and check if any noise can be heard. If the noise has become smaller or has disappeared, the cause of the noise was probably that oil sludge had caused the lash adjusters to become stuck. If this happens, carry out the following check. If the noise level does not change, go to step 5. (1) Let the engine cool down sufficiently. (2) Turn the crankshaft two full revolutions.

11A-12

ENGINE - On-vehicle Service(3) Carry out lash adjuster simple check. (Refer to P.11A-13.) D If any of the rocker arms can be pushed down easily during the lash adjuster simple check, replace the corresponding lash adjusters. D If the lash adjuster simple check has been carried out but all lash adjusters are normal (if none of the rocker arms could be pushed down easily), check for some other cause of the problem. NOTE You can check whether the lash adjusters are normal or not by carrying out a leak-down test. (Refer to the Engine Workshop Manual.) Caution Make sure that the air has been fully bled before installation of a new lash adjuster. (Refer to the Engine Workshop Manual.) 5. Bleed the air from the lash adjusters. (Refer to P.11A-13.) 6. If the noise does not disappear even after the air has been bled from the lash adjusters, carry out the following check. Carry out lash adjuster simple check. (Refer to P.11A-13.) D If one of the rocker arms can be pushed down easily during the lash adjuster simple check, replace the corresponding lash adjuster. D If two or more of the rocker arms can be pushed down easily during the lash adjuster simple check, the cause may be that the oil passage to the cylinder head is blocked. Check for blockages in the oil passage, and clear the blockages if any are found. If there are no blockages, replace the lash adjusters. D If the lash adjuster simple check has been carried out but all lash adjusters are normal (if none of the rocker arms could be pushed down easily), check for some other cause of the problem. NOTE You can check whether the lash adjusters are normal or not by carrying out a leak-down test. (Refer to the Engine Workshop Manual.) Caution Make sure that the air has been fully bled before installation of a new lash adjuster. (Refer to the Engine Workshop Manual.) 7. Start the engine and check that the abnormal noise has disappeared. If necessary, bleed the air from the lash adjusters. (Refer to P.11A-13.)

ENGINE - On-vehicle Service

11A-13

1. Stop the engine. 2. Remove the rocker cover. 3. Set the No.1 cylinder to the compression top dead centre position. 4. Check the rocker arms indicated by white arrows in the illustration by the procedures given below. Check whether the rocker arm moves downwards when the part of the rocker arm which touches the top of the lash adjuster is pushed. D If the rocker arm moves down easily when it is pushed, make a note of which is the corresponding lash adjuster. D If the rocker arm feels extremely stiff when it is pushed and does not move down, the lash adjuster is normal, so check for some other cause of the problem. NOTE It will not be possible to depress the Y-shaped rocker arm at the exhaust valve side if one lash adjuster is defective but the other one is normal. In such cases, carry out the following procedure using a thickness gauge. (1) Check that a thickness gauge with a thickness of 0.1 - 0.2 mm can be inserted easily between the valve and the lash adjuster. (2) If the thickness gauge can be inserted easily, make a note of which is the corresponding lash adjuster. (3) If the thickness gauge cannot be inserted easily, the lash adjuster is normal, so check for some other cause of the problem. 5. Slowly turn the crankshaft 360_ in the clockwise direction. 6. Check the rocker arms indicated by black arrows in the illustration in the same way as explained in step 4. NOTE (1) If the vehicle is parked on a slope for a long period of time, the amount of oil inside the lash adjuster will decrease, and air may get into the high pressure chamber when starting the engine. (2) After parking the vehicle for long periods, the oil drains out of the oil passage, and it takes time for the oil to be supplied to the lash adjuster, so air can get into the high pressure chamber. (3) If either of the above situations occur, the abnormal noise can be eliminated by bleeding the air from inside the lash adjusters.

11A-14

ENGINE - On-vehicle Service1. Check the engine oil and replenish or replace the oil if necessary. NOTE (1) If there is a only small amount of oil, air will be drawn in through the oil screen and will get into the oil passage. (2) If the amount of oil is greater than normal, then the oil will being mixed by the crankshaft and a large amount of air may get mixed into the oil. (3) If the oil is degenerated, air and oil will not separate easily in oil, and the amount of air mixed into the oil will increase.

Good

High pressure chamber

(4) If the air which has been mixed in with the oil due to any of the above reasons gets into the high pressure chamber of the lash adjuster, the air inside the high pressure chamber will be compressed when the valve is open and the lash adjuster will over-compress, resulting in abnormal noise when the valve closes. This is the same effect as if the valve clearance is adjusted to be too large by mistake. If the air inside the lash adjusters is then released, the operation of the lash adjusters will return to normal. 2. Run the engine at idle for 1 - 3 minutes to let it warm up. 3. With no load on the engine, repeat the drive pattern shown in the illustration at left and check if the abnormal noise disappears. (The noise should normally disappear after 10 - 30 repetitions, but if there is no change in the noise level after 30 repetitions or more, the problem is probably not due to air inside the lash adjusters.) 4. After the noise has disappeared, repeat the drive pattern shown in the illustration at left a further 5 times. 5. Run the engine at idle for 1 - 3 minutes and check that the noise has disappeared.

Drive pattern for air bleeding Gradually open the Close the throttle throttle valve. valve. Approx. 3,000 r/min. Idle speed15 seconds 15 seconds

Once

ENGINE - Crankshaft Pulley

11A-1511200160303

CRANKSHAFT PULLEYREMOVAL AND INSTALLATIONPre-removal Operation D Under Cover Removal

Post-installation Operation D Drive Belt Tension Adjustment (Refer to P.11A-6.) D Under Cover Installation

2 3

25 Nm

1

Removal steps 1. Drive belt (Power steering and A/C)

2. Drive belt (Alternator) 3. Crankshaft pulley

11A-16

ENGINE - Camshaft and Camshaft Oil Seal11200190418

CAMSHAFT AND CAMSHAFT OIL SEALREMOVAL AND INSTALLATIONPre-removal and Post-installation Operation D Air Cleaner Removal and Installation D Timing Belt Removal and Installation (Refer to P.11A-26.) D Relay Box Removal and Installation

10 Nm

1 2

5

(f 3 1 mm)

414 Nm 3.4 Nm

322 Nm

Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

528 - 34 Nm

8Lip section

9 5 6 12 10

11

88 Nm

Cam section and journal section

12 8 7Engine oil

Removal steps 1. Control harness connection 2. Spark plug cable 3. PCV hose connection 4. Rocker cover 5. Camshaft position sensor support 6. Camshaft position sensing cylinder AA" "CA 7. Camshaft sprocket

"BA 8. Camshaft oil seal 9. Spark plug guide oil seal AB" "AA 10. Rocker arm and shaft assembly (intake side) AB" "AA 11. Rocker arm and shaft assembly (exhaust side) 12. Camshaft

ENGINE - Camshaft and Camshaft Oil Seal REMOVAL SERVICE POINTSMB990767

11A-17

AA" CAMSHAFT SPROCKET REMOVAL

MD998719 or MD998754

MD998443

AB" ROCKER ARM AND SHAFT ASSEMBLY REMOVAL Before removing the rocker arm and shaft assembly, install the special tools as shown in the illustration so that the lash adjusters will not fall out.

INSTALLATION SERVICE POINTS"AA ROCKER ARM AND SHAFT ASSEMBLY

INSTALLATION 1. Temporarily tighten the rocker shaft with the bolt so that all rocker arms on the inlet valve side do not push the valves. 2. Fit the rocker shaft spring from the above and position it so that it is right angles to the plug guide. NOTE Install the rocker shaft spring before installing the rocker arm and rocker arm shaft on the exhaust side. 3. Remove the special tool for fixing the lash adjuster.

4. Confirm that the rocker shaft notch is in the direction shown in the diagram.

11A-18

ENGINE - Camshaft and Camshaft Oil Seal"BA CAMSHAFT OIL SEAL INSTALLATION 1. Apply engine oil to the camshaft oil seal lip. 2. Use the special tool to press-fit the camshaft oil seal.

MD998713

"CA CAMSHAFT SPROCKET INSTALLATION Use the special tool to stop the camshaft sprocket from turning in the same way as was done during removal, and then tighten the bolts to the specified torque.

ENGINE - Oil Pan

11A-1911200280207

OIL PANREMOVAL AND INSTALLATIONPre-removal and Post-installation Operation D Engine Oil Draining and Supplying (Refer to GROUP 12 - On-vehicle Service.) D Oil Level Gauge Removal and Installation D

Front Exhaust Pipe Removal and Installation (Refer to GROUP 15.)

5f 4 1 mm Groove Bolt hole

3Sealant: MITSUBISHI GENUINE MD970389 or equivalent PART

5

4

7 Nm 9 Nm

2 19 Nm

Removal steps 1. Drain plug "AA 2. Drain plug gasket 3. Bell housing coverMD998727 MD998727

AA"

4. Oil level sensor 5. Oil pan

REMOVAL SERVICE POINTAA" OIL PAN REMOVAL 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 flange.

INSTALLATION SERVICE POINTOil pan side Drain plug gasket

"AA DRAIN PLUG GASKET INSTALLATION Install the drain plug gasket in the direction so that it faces as shown in the illustration.

11A-20

ENGINE - Crankshaft Oil Seal11200310135

CRANKSHAFT OIL SEALREMOVAL AND INSTALLATION127 - 137 Nm

7 8

9 11 12

127 - 137 Nm

6 2 8 10 1 Crankshaft Crankshaft

4

5

3

(Engine oil: bolt washer surface)

(Engine oil: bolt washer surface)

12

5

9 10

Lip section

Lip section

Sealant: 3M Stud locking 4170 or equivalent

Engine oil

Crankshaft front oil seal removal steps D Timing belt (Refer to P.11A-26.) D Crank angle sensor (Refer to GROUP 16.) 1. Crankshaft sprocket 2. Flange 3. Crankshaft sprocket B 4. Key "CA 5. Crankshaft front oil seal

AA" AB" AB" AB" AB" AB" "BA "BA "BA "BA "BA "AA

Crankshaft rear oil seal removal steps D Oil pan (Refer to P.11A-19.) D Transmission assembly D Clutch cover and disc 6. Crankshaft bushing 7. Plate 8. Adapter plate 9. Flywheel 10. Drive plate 11. Adapter plate 12. Crankshaft rear oil seal

ENGINE - Crankshaft Oil Seal

11A-21

REMOVAL SERVICE POINTSAA" TRANSMISSION ASSEMBLY REMOVAL : Refer to GROUP 22. Caution Do not remove the flywheel mounting bolt shown by the arrow. If this bolt Is removed, the flywheel will become out of balance and damaged. : Refer to GROUP 23. AB" PLATE /ADAPTER PLATE/FLYWHEEL /DRIVE PLATE REMOVAL Use the special tool to secure the flywheel or drive plate, and remove the bolts.

Flywheel Bolt

MD998781

Crankshaft rear oil seal MD990938

INSTALLATION SERVICE POINTSCrankshaft

"AA CRANKSHAFT REAR OIL SEAL INSTALLATION 1. Apply a small mount of engine oil to the entire circumference 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.

MD998776

"BA DRIVE PLATE /FLYWHEEL /ADAPTER PLATE/PLATE INSTALLATION 1. Clean off all sealant, oil and other substances which are adhering to the threaded bolts, crankshaft thread holes and the flywheel or drive plate. 2. Apply oil to the bearing surface of the flywheel or drive plate bolts. 3. Apply oil to the crankshaft thread holes. 4. Apply sealant to the threaded mounting holes. Specified sealant: 3M Stud locking 4170 or equivalent 5. Use the special tool to hold the flywheel or drive plate in the same manner as removal, and install the bolt. "CA CRANKSHAFT FRONT OIL SEAL INSTALLATION 1. Apply a small amount of engine oil to the entire circumference of the oil seal lip. 2. Press-fit the oil seal unit it is flush with the oil seal case.

11A-22

ENGINE - Cylinder Head Gasket11200400542

CYLINDER HEAD GASKETREMOVAL AND INSTALLATIONPre-removal Operation D Fuel Discharge Prevention (Refer to GROUP 13A - On-vehicle Service.) D Engine Oil Draining (Refer to GROUP 12 On-vehicle Service.) D Thermostat Case Assembly Removal (Refer to GROUP 14 - Water Hose and Water Pipe.)

Post-installation Operation D Thermostat Case Assembly Installation (Refer to GROUP 14 - Water Hose and Water Pipe.) D Engine Oil Supplying (Refer to GROUP 12 On-vehicle Service.) D Accelerator Cable Adjustment (Refer to GROUP 17 - On-vehicle Service.)

Delivery pipe

O-ring

1 9 10 10

7 5 2

Engine oil

8 6 4

3 11

Removal steps 1. Accelerator cable connection 2. Vacuum hose connection 3. Brake booster vacuum hose connection 4. Vacuum hose connection 5. Throttle position sensor connector 6. Idle speed control connector

7. Injector connector 8. Purge control solenoid valve connector 9. EGR solenoid valve connector "CA 10. High-pressure fuel hose connection 11. Fuel return hose connection

ENGINE - Cylinder Head Gasket10 Nm

11A-23

15 78 Nm 0 Nm 20 Nm + 90_ + 90_ 16 27(Engine oil) 3.4 Nm

14

12 26

17

19 28 13

22 20 21

29 18

49 Nm

24

24 Nm 44 Nm

25 2331 Nm 34 Nm

12. 13. 14. 15. 16. 17.

Radiator upper hose connection PCV hose Ignition coil connector Ignition coil assembly Breather hose Engine coolant temperature sensor connector 18. Engine coolant temperature gauge unit connector 19. Camshaft position sensor 20. Water hose connection

AA"

21. 22. 23. 24.

25. 26. D AB" "BA 27. 28. "AA 29.

Heater hose connection Thermostat case assembly Water hose connection Power steering oil pump and bracket assembly Front exhaust pipe connection Rocker cover Timing belt (Refer to P.11A-26.) Cylinder head bolt Cylinder head assembly Cylinder head gasket

11A-24

ENGINE - Cylinder Head Gasket REMOVAL SERVICE POINTSAA" POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL Remove the power steering oil pump and bracket assembly from the engine with the hose attached. NOTE Place the removed power steering oil pump in a place where it will not be a hindrance when removing and installing the cylinder head assembly, and tie it with a cord. AB" CYLINDER HEAD BOLT REMOVAL Loosen the bolts in 2 or 3 steps in order of the numbers shown in the illustration, and remove the cylinder head assembly. Caution Because the plug guides cannot be replaced by themselves, be careful not to damage or deform the plug guides when removing the cylinder head bolts.

Intake side

Front of engine

3

5

10

8

2

1

7

9

6

4

Exhaust side

INSTALLATION SERVICE POINTS"AA CYLINDER HEAD GASKET INSTALLATION 1. Wipe off all oil and grease from the gasket mounting surface. 2. Install so that the shapes of the cylinder head holes match the shapes of the respective cylinder head gasket holes.

Burred side Head bolt washer Cylinder head

Head bolt (Engine oil)

"BA CYLINDER HEAD BOLT INSTALLATION 1. When installing the cylinder head bolts, the length below the head of the bolts should be within the limit. If it is outside the limit, replace the bolts. Limit (A): 99.4 mm 2. The head bolt washer should be installed with the burred side caused by tapping out facing upwards. 3. Apply a small amount of engine oil to the thread section and the washer of the cylinder head bolt.

A

ENGINE - Cylinder Head GasketIntake side Front of engine

11A-25Remarks Carry out in the order shown in the illustration. Carry out in the reverse order of that shown in the illustration. Carry out in the order shown in the illustration. In the order shown in the illustration. Mark the head of the cylinder head bolt and cylinder head by paint. In the order shown in the illustration. Check that the painted mark of the head bolt is lined up with that of the cylinder head.

4. Tighten the bolts by the following procedure.Step 19

Operation Tighten to 78 Nm. Fully loosen.

8

6

1

3

210 4 2 5 7

3Exhaust side

Tighten to 20 Nm. Tighten 90_ of a turn.

4Step 4 90_ Step 5 90_

5

Tighten 90_ of a turn.

Painted mark

Painted mark

Caution 1. Always make a tightening angle just 90_. If it is less than 90_, the head bolt will be loosened. 2. If it is more than 90_, remove the head bolt and repeat the procedure from step 1.

"CA HIGH-PRESSURE FUEL HOSE INSTALLATION 1. Apply a small amount of new engine oil to the O-ring. Caution Do not let any engine oil get into the delivery pipe. 2. While turning the high-pressure fuel hose to the right and left, install the delivery pipe, while being careful not to damage the O-ring. After installing, check that the hose turns smoothly. 3. If the hose does not turn smoothly, the O-ring is probably being clamped. Disconnect the high-pressure fuel hose and check the O-ring for damage. After this, re-insert the delivery pipe and check that the hose turns smoothly.

11A-26 TIMING BELT

ENGINE - Timing Belt11200430473

REMOVAL AND INSTALLATIONPre-removal and Post-installation Operation D Crankshaft Pulley Removal and Installation (Refer to P.11A-15.) D Engine Mount Bracket Removal and Installation (Refer to GROUP 32 - Engine Mounting.)

3

110 - 12 Nm

48 Nm

5

424 Nm

9 Nm

2

Removal steps 1. Timing belt upper cover 2. Timing belt lower cover "CA D Timing belt tension adjustment AA" "BA 3. Timing belt 4. Tension pulley "AA 5. Auto tensioner

ENGINE - Timing BeltTiming mark (Top of cylinder head) Timing mark Camshaft sprocket

11A-27

REMOVAL SERVICE POINTAA" TIMING BELT REMOVAL 1. Turn 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 clockwise.

Timing mark Timing mark Crankshaft sprocket

Timing mark Oil pump sprocket

2. Loosen the tension pulley centre bolt. 3. Move the tension pulley to the water pump side, and then remove the timing belt.Centre bolt

Caution If the timing belt is to be re-used, use chalk to mark (on its flat side) an arrow indicating the clockwise direction.

INSTALLATION SERVICE POINTS98N - 196N

A

B

Movement Push rod

"AA AUTO TENSIONER INSTALLATION 1. Apply 98 - 196 N force to the auto tensioner by pressing it against a metal (cylinder block, etc.), and measure the movement of the push rod. Standard value: Within 1 mm A: Length when it is free (not pressed) B: Length when it is pressed A - B: Movement 2. If it is out of the standard value, replace the auto tensioner.

Auto tensioner

A

B

3. Use a press or vice to gently compress the auto tensioner push rod until pin hole A of the push rod and pin hole B of the tensioner cylinder are aligned. Caution If the compression speed is too fast, the rod may become damaged, so be sure to carry out this operation slowly.

11A-28Set pin

ENGINE - Timing Belt4. Once the holes are aligned, insert the set pin. NOTE When replacing the auto tensioner with a new part, the pin will be in the auto tensioner. 5. Install the auto tensioner to the engine.

Timing mark (Top of cylinder head)

Timing mark Camshaft sprocket

"BA TIMING BELT INSTALLATION 1. Align the timing marks on the camshaft sprocket, crankshaft sprocket and oil pump sprocket.

Timing mark Timing mark Crankshaft sprocket

Timing mark Oil pump sprocket

Plug

60 mm or more

8 mm

Screwdriver Counterbalance shaft

Cylinder block

2. After aligning the timing mark on the oil pump sprocket, remove the cylinder block plug and insert a Phillips screwdriver with a diameter of 8 mm, and check to be sure that the screwdriver goes in 60 mm or more. If the screwdriver will only go in 20 - 25 mm before striking the counterbalance shaft, turn the sprocket once, realign the timing mark and check that the screwdriver goes in 60 mm or more. The screwdriver should not be taken out until the timing b