Mitsubishi 6A1 SERIES manual

1 1A-0-1 ENGINE 6A1 SERIES CONTENTS GENERAL INFORMA TION ........................................... 1 1A-0-3 1. SPECIFICA TIONS ............................................... 1 1A-1-1 SERVICE SPECIFICA TIONS .................................. 1 1A-1-1 REWORK DIMENSIONS ....................................... 1 1A-1-3 T ORQUE SPECIFICA TION ......[...]

1 1A-0-2 NOTES K Mitsubishi Motors Corporation Feb. 1997 PWEE9622[...]

6A1 ENGINE (E - W) - General Information 1 1A-0-3 GENERAL INFORMA TION GENERAL SPECIFICA TIONS Descriptions 6A12 6A13 60 è V , OHV , DOHC (for each bank) Pentroof type T ype 60 è V , OHV , SOHC (for each bank) Number of cylinders 6 6 Combustion chamber Pentroof type T otal displacement dm 3 1,998 2,498 78.4 81.0 69.0 80.8 10.0 9.5* 1 2 Intake val[...]

6A1 ENGINE (E - W) - Specifications 1 1A-1-1 1. SPECIFICA TIONS SERVICE SPECIFICA TIONS Items Standard value Limit Timing belt 1.0 or less Auto tensioner rod projection mm 12.0 - Auto tensioner rod pushed-in amount (when pushed with a force - of 98 - 196 N) mm Rocker arm and camshaft <SOHC> Intake 35.20 34.70 Exhaust 34.70 34.20 45 - Camshaft[...]

1 1A-1-2 6A1 ENGINE (E - W) - Specifications Items Limit Intake SOHC MIVEC Exhaust SOHC MIVEC SOHC 49.9 48.9 MIVEC 51.5 50.5 spring load/installed SOHC 265/43.4 - MIVEC 255/44.5 - 2 è 4 è 0.9 - 1.3 - 6.6 - SOHC 14.0 - MIVEC 19.0 - Standard value Overall valve length mm 1 13.02 1 12.52 1 12.37 1 1 1.87 1 15.32 1 14.82 1 10.74 1 10.74 V alve spring[...]

6A1 ENGINE (E - W) - Specifications 1 1A-1-3 Items Limit Crankshaft journal diameter 6A12 53.0 - mm 6A13 56.0 - 6A12 43.0 - 6A13 51.0 - 0.02 - 0.04 0.1 0.05 - - 0.2 6A12 190.0 - mm 6A13 209.0 - - Standard value Crankshaft pin diameter mm Crankshaft journal oil clearance mm Cylinder block gasket surface flatness mm Cylinder block gasket surface grin[...]

1 1A-1-4 6A1 ENGINE (E - W) - Specifications TORQUE SPECIFICA TION Items Nm Alternator and drive belt Alternator pivot nut 44 Alternator bolt 21 Oil level gauge guide 23 T ensioner pulley 15 Engine hanger 23 T ensioner pulley bracket A 45 Crankshaft bolt 182 Engine cover 3 Timing belt T iming belt front cover 11 Engine support bracket 49 Angle sens[...]

6A1 ENGINE (E - W) - Specifications 1 1A-1-5 Items Nm Ignition system Spark plug 25 W ater cover (SOHC) 11 Distributor (SOHC) 13 Ignition failure sensor (MIVEC) 10 Condenser bracket assembly (MIVEC) 5 Ignition coil (MIVEC) 10 W ater pump and water pipe Engine hanger (MIVEC) 11 Engine coolant temperature gauge unit 11 Engine coolant temperature sens[...]

1 1A-1-6 6A1 ENGINE (E - W) - Specifications Items Nm Arm spring holder 11 Rocker arm and rocker shaft cap <MIVEC> Rocker shaft cap 11 Cylinder head and valves Cylinder head bolt 20 + 120 è + 120 è Oil pan and oil pump Oil pressure switch 10 Oil filter cover 21 W ater hose 30 Bolt 68 Drain plug 39 Oil level sensor 9 Oil pan 7 Oil screen 19 [...]

6A1 ENGINE (E - W) - Specifications 1 1A-1-7 NEW TIGHTENING METHOD - BY USE OF BOL TS TO BE TIGHTENED IN PLASTIC AREA A new type of bolts, to be tightened in plastic area, is currently used in some parts of the engine. The tightening method for the bolts is different from the conventional one. Be sure to observe the method described in the text whe[...]

1 1A-1-8 6A1 ENGINE (E - W) - Specifications FORM-IN-PLACE GASKET (FIPG) The engine has several areas where the form-in-place gasket (FIPG) is in use. T o 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. T oo thin a [...]

6A1 ENGINE (E - W) - Special T ools 1 1A-2-1 2. SPECIAL T OOLS Number Name Use MB990685 MB990938 Handle MB990767 Crankshaft pulley holder MB991477 wrench MB991478 MB991479 MB991614 MB991653 wrench MB991659 T ool T orque wrench Adjustment of timing belt tension Use with MD998776 Holding camshaft sprocket when loosening and tightening of bolt. Use wi[...]

1 1A-2-2 6A1 ENGINE (E - W) - Special T ools Name Number MD998440 MD998441 retainer Ai MD998442 Ai Ai MD998443 holder MD998713 installer MD998716 MD998717 il MD998719 Pulley holder pin (2) MD998727 T ool U se Leak-down tester Leak-down test of lash adjuster Lash adjuster r bleeding of lash adjuster r bleed wire r bleeding of lash adjuster Lash adju[...]

6A1 ENGINE (E - W) - Special T ools 1 1A-2-3 Name Number MD998735 compressor MD998754 Pin MD998767 MD998772 compressor parts MD998774 stem seal installer MD998775 stem seal installer MD998776 il MD998777 T ool U se V alve spring Compression of valve spring Use with MB990767 T ensioner pulley socket wrench Adjustment of timing belt tension V alve sp[...]

1 1A-2-4 6A1 ENGINE (E - W) - Special T ools Name Number MD998780 in MD998781 MD998784 compressor adapter T ool U se SETTING TOOL Piston p Removal and installation of piston pin Flywheel stopper Holding flywheel and drive plate V alve spring Compression of valve spring (MIVEC) (Use with MD998772) K Mitsubishi Motors Corporation Feb. 1997 PWEE9622[...]

6A1 ENGINE (E - W) - Drive Belt 1 1A-3-1 3. DRIVE BEL T REMOV AL AND INST ALLA TION <SOHC> 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 21 Nm 15 Nm 23 Nm 3N m 23 Nm 44 Nm 44 Nm 44 Nm 182 N m Removal steps 1. Drive belt 9. T ensioner pulley bracket B 2. Alternator 10. Adjusting stud 3. Oil level gauge (dipstick) 1 1. Adjusting bolt 4. Oil level gaug[...]

1 1A-3-2 6A1 ENGINE (E - W) - Drive Belt REMOV AL AND INST ALLA TION <MIVEC> 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 21 Nm 15 Nm 23 Nm 44 Nm 23 Nm 44 Nm 3N m 44 Nm 182 N m Removal steps 1. Drive belt 9. T ensioner pulley bracket B 2. Alternator 10. Adjusting stud 3. Oil level gauge (dipstick) 1 1. Adjusting bolt 4. Oil level gauge guide G A ++[...]

6A1 ENGINE (E - W) - Drive Belt 1 1A-3-3 6AE0039 MD998781 REMOV AL SERVICE POINTS G A + CRANKSHAFT PULLEY BOL T REMOV AL (1) Hold the flywheel or drive plate in position with the special tool before removing the crankshaft pulley bolts. INST ALLA TION SERVICE POINTS + A G CRANKSHAFT PULLEY BOL T INST ALLA TION (1) Hold the flywheel or drive plate i[...]

6A1 ENGINE (E - W) - Timing Belt 1 1A-4-1 4. TIMING BEL T REMOV AL AND INST ALLA TION <SOHC> 11 N m 17 35 Nm 88 Nm 6 16 15 14 48 Nm 8 24 Nm 13 12 18 11 11 N m 9 7 5 11 N m 1 21 Nm 3 10 2 4 9N m 49 Nm 11 N m 11 N m Removal steps 1. T iming belt front cover , upper right + B G 10. Auto tensioner 2. T iming belt front cover , upper left 1 1. Cra[...]

1 1A-4-2 6A1 ENGINE (E - W) - Timing Belt REMOV AL AND INST ALLA TION <MIVEC> 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 17 19 20 21 22 23 18 11 N m 12 Nm 9N m 48 Nm 44 Nm 49 Nm 35 Nm 88 Nm 11 N m 11 N m 11 N m 11 N m 22 Nm 9N m 9N m G A ++ D G Removal steps 1. T iming belt front cover , upper right 2. T iming belt front cover , upper left 3. [...]

6A1 ENGINE (E - W) - Timing Belt 1 1A-4-3 6AE0135 6AE0044 6AE0137 MB990767 MD998719 6AE0045 MB990767 MD998754 6AE0138 MB990767 MD998719 REMOV AL SERVICE POINTS G A + TIMING BEL T REMOV AL (1) Mark the belt running direction for reference in reinstallation. (2) Loosen the bolt that secures the tensioner pulley to remove the timing belt. G B + CAMSHA[...]

1 1A-4-4 6A1 ENGINE (E - W) - Timing Belt 6AE0048 MB990767 MD998754 6AE0049 (A) (B) 6AE0050 6AE0329 6AE0358 Timing mark + B G AUTO TENSIONER SETTING (1) Set the auto tensioner in a vice, while making sure it is not tilted. (2) Slowly close the vice to force the rod in until the set hole (A) of the rod is lined up with the set hole (B) of the cylind[...]

6A1 ENGINE (E - W) - Timing Belt 1 1A-4-5 6AE0331 (3) Align the timing mark on the crankshaft sprocket with that on the cylinder block side. (4) Fit the timing belt on the sprockets in the following order: 1) Fit the timing belt on the crankshaft sprocket and then, while giving tension to the belt, fit it on the water pump sprocket. 2) Fit the belt[...]

1 1A-4-6 6A1 ENGINE (E - W) - Timing Belt 6AE0051 MD998716 + D G TIMING BEL T INST ALLA TION (1) T urn the crankshaft sprocket so that its timing mark will be away from the mating timing mark by approx. three teeth. Caution J If the timing ma rks are aligned, the piston is brought to the TDC. When the camshaft is turned under this condition, the va[...]

6A1 ENGINE (E - W) - Timing Belt 1 1A-4-7 4) On the left bank, make sure that the timing marks of the camshaft sprockets are aligned and then hold the timing belt on these sprockets with paper clips. 5) Place the timing belt around the water pump pulley . 6) Place the timing belt around the crankshaft sprocket. 7) Place the timing belt around the t[...]

1 1A-4-8 6A1 ENGINE (E - W) - Timing Belt (2) Cracks on rubber back. (3) Cracks or peeling of canvas. (4) Cracks on tooth bottom. (5) Cracks or belt sides. 1EN0249 Cracks Cracks Cracks Peeling 8EN0067 Abnormal wear 8EN0068 and canvas 6AE0046 “L” 6EN1033 - Stroke Rounded edge (Fluffy strand) Rubber exposed T ooth missing fiber exposed 98 196 N ([...]

6A1 ENGINE (E - W) - Fuel and Emission Control Parts 1 1A-5-1 5. FUEL AND EMISSION CONTROL P ARTS REMOV AL AND INST ALLA TION <SOHC> 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 7 18 Nm 9N m 22 Nm 23 Nm 12 Nm 18 Nm 9N m 12 Nm 18 Nm 18 Nm 18 Nm + C G Removal steps 1. Air intake plenum stay , front 2. Air intake plenum stay , rear 3. [...]

1 1A-5-2 6A1 ENGINE (E - W) - Fuel and Emission Control Parts REMOV AL AND INST ALLA TION <MIVEC> 2 3 4 5 6 7 8 10 12 13 14 15 16 17 18 19 20 21 22 24 23 26 1 11 25 9 18 Nm 23 Nm 12 Nm 14 Nm 9N m 9N m 18 Nm 12 Nm 11 N m 11 N m 18 Nm 8.8 Nm 18 Nm + C G Removal steps 1. Air intake plenum stay , front 2. Air intake plenum stay , rear 3. V acuum [...]

6A1 ENGINE (E - W) - Fuel and Emission Control Parts 1 1A-5-3 6AE0061 INST ALLA TION SERVICE POINTS + A G FUEL PRESSURE REGULA TOR INST ALLA TION (1) Apply spindle oil or gasoline to the new O-ring installed on the fuel pressure regulator . (2) Insert the fuel pressure regulator in the delivery pipe. (3) Make sure that the fuel pressure regulator t[...]

6A1 ENGINE (E - W) - Ignition System 1 1A-6-1 6. IGNITION SYSTEM REMOV AL AND INST ALLA TION <SOHC> 1 2 3 4 25 Nm 11 N m 13 Nm Removal steps 1. Spark plug cable 2. Spark plug 3. W ater cover + A G 4. Distributor K Mitsubishi Motors Corporation Feb. 1997 PWEE9622[...]

1 1A-6-2 6A1 ENGINE (E - W) - Ignition System REMOV AL AND INST ALLA TION <MIVEC> 1 2 3 25 Nm 1.0 Nm Removal steps 1. Spark plug cable 2. Ignition coil 3. Spark plug 6AE0151 Alignment mark INST ALLA TION SERVICE POINT + A G DISTRIBUTOR INST ALLA TION (1) T urn the crankshaft clockwise to bring the No. 1 cylinder piston to the compression stro[...]

6A1 ENGINE (E - W) - W ater Pump an d W ater Pipe 1 1A-7-1 7. W A TER PUMP AND W A TER PIPE REMOV AL AND INST ALLA TION <SOHC> 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 13 Nm 18 Nm 23 Nm 29 Nm 11 N m 23 Nm 23 Nm 18 Nm Removal steps + F G + E G 1. Engine coolant temperature gauge unit 2. Engine coolant temperature sensor 3. W ater hose + D G 8. Ther[...]

1 1A-7-2 6A1 ENGINE (E - W) - W ater Pump an d W ater Pipe REMOV AL AND INST ALLA TION <MIVEC> 1 2 4 5 6 7 8 9 10 11 12 13 14 3 13 Nm 18 Nm 23 Nm 29 Nm 18 Nm 18 Nm 11 N m 23 Nm Removal steps + F G 1. Engine hanger 2. Engine coolant temperature gauge unit + C G 8. W ater outlet fitting 9. Thermostat housing 10. Gasket + E G + D G 3. Engine coo[...]

6A1 ENGINE (E - W) - W ater Pump an d W ater Pipe 1 1A-7-3 6AE0067 diameter 3m m bead sealant INST ALLA TION SERVICE POINTS + A G SEALANT APPLICA TION T O W A TER PUMP Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent 6AE0068 diameter 6AE0069 6AE0070 3m m bead sealant Jiggle valve + B G W A TER PIPE / O-RING INST ALLA TION (1) W[...]

1 1A-7-4 6A1 ENGINE (E - W) - W ater Pump an d W ater Pipe + F G SEALANT APPLICA TION TO ENGINE COOLANT TEMPERA TURE GAUGE UNIT Specified sealant: 3M A TD Part No. 8660 or equivalent 6AE0071 K Mitsubishi Motors Corporation Feb. 1997 PWEE9622[...]

6A1 ENGINE (E - W) - Intake Manifold and Exhaust Manifold 1 1A-8-1 8. INT AKE MANIFOLD AND EXHAUST MANIFOLD REMOV AL AND INST ALLA TION <SOHC> 1 2 3 4 5 6 7 8 9 13 Nm 17 Nm 44 Nm 49 Nm 49 Nm 13 Nm Removal steps 1. Intake manifold 2. Gasket 3. Heat protector , right 4. Exhaust manifold stay 5. Exhaust manifold, right 6. Gasket 7. Heat protecto[...]

1 1A-8-2 6A1 ENGINE (E - W) - Intake Manifold and Exhaust Manifold REMOV AL AND INST ALLA TION <MIVEC> 1 2 3 4 5 6 7 8 9 13 Nm 17 Nm 44 Nm 49 Nm 49 Nm 13 Nm Removal steps 1. Intake manifold 2. Gasket 3. Heat protector , right 4. Exhaust manifold stay 5. Exhaust manifold, right 6. Gasket 7. Heat protector , left 8. Exhaust manifold, left 9. Ga[...]

6A1 ENGINE (E - W) - Rocker Arm and Camshaft <SOHC> 1 1A-9-1 9. ROCKER ARM AND CAMSHAFT <SOHC> REMOV AL AND INST ALLA TION installation. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 12 12 9 9 8 8 7 7 Apply engine oil to all moving parts before 4N m 24 Nm 31 Nm Removal steps 1. Rocker cover 10. Rocker arm shaft 2. Rocker cover gasket 3. Oil[...]

1 1A-9-2 6A1 ENGINE (E - W) - Rocker Arm and Camshaft <SOHC> 6AE0160 MD998443 6AE0180 6EN0421 Diesel fuel MD998442 6AE0161 MD998443 For right bank For left bank Lash adjuster REMOV AL SERVICE POINT G A + ROCKER ARMS AND ROCKER ARM SHAFTS REMOV AL (1) Before removing rocker arms and shafts assembly , install the special tool as illustrated to [...]

6A1 ENGINE (E - W) - Rocker Arm and Camshaft <SOHC> 1 1A-9-3 NOTE Install the rocker shaft spring before installing the exhaust side rocker arms and rocker arm shaft. (3) Remove the special tool for securing the lash adjuster . (4) Make sure that the notch in the rocker arm shaft is in the direction as illustrated. 6AE0163 6AE0164 MD998713 6A[...]

1 1A-9-4 6A1 ENGINE (E - W) - Rocker Arm and Camshaft <SOHC> 6EN0186 MD998442 MD998441 Diesel fuel LASH ADJUSTER LEAK DOWN TEST Caution J The lash adjuster is a precision part. Keep it free from dust and other foreign matters. J Do not disassemble lash adjuster . J When cleaning lash adjuster , use clean diesel fuel only . (1) Immerse the las[...]

6A1 ENGINE (E - W) - Rocker Cover and Camshaft <MIVEC> 1 1A-10-1 10. ROCKER COVER AND CAMSHAFT <MIVEC> REMOV AL AND INST ALLA TION installation. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 9 Apply engine oil to all moving parts before 4N m 24 Nm 11 N m 11 N m 11 N m 24 Nm 24 Nm 24 Nm 9N m Removal steps + G G 1. Rocker cover + C G 8. Oil control va[...]

1 1A-10-2 6A1 ENGINE (E - W) - Rocker Cover and Camshaft <MIVEC> Left bank camshaft Right bank camshaft 6AE0229 6AE0230 Right bank in Left bank in EX EX IN IN 6AE0233 Dowel p Dowel p INST ALLA TION SERVICE POINT + A G CAMSHAFT INST ALLA TION (1) Intake valve camshaft and exhaust valve camshaft can be identified by their diameters at the porti[...]

6A1 ENGINE (E - W) - Rocker Cover and Camshaft <MIVEC> 1 1A-10-3 + C G OIL CONTROL V AL VE INST ALLA TION (1) Apply the specified sealant to the area shown. Specified sealant: 3M A TD Part No. 8660 or equivalent 6AE0236 6AE0237 Protrusion Groove Screw Retainer Pad 6AE0238 + D G SEMI-CIRCULAR P ACKING / CAMSHAFT HOLDER INST ALLA TION (1) Make [...]

1 1A-10-4 6A1 ENGINE (E - W) - Rocker Cover and Camshaft <MIVEC> + E G CAMSHAFT OIL SEAL INST ALLA TION (1) When installing the left bank camshaft oil seal, use the special tool to prevent interference with the knock pin. 6AE0306 MD998713 6AE0307 MD998713 MD998777 6AE0241 MD998713 Right bank Left bank + F G CIRCULAR P ACKING INST ALLA TION + [...]

6A1 ENGINE (E - W) - Rocker Cover and Camshaft <MIVEC> 1 1A-10-5 6AE0227 9N0058 Identification Low-speed V alve 21 mm 16 mm High-speed cam (H) mark location cam (L) CAMSHAFT (1) Measure the cam heights. If the specified limit is exceeded, replace the camshaft. NOTE Each camshaft has an identification mark on its rear end surface. ( ) Limit L [...]

1 1A-10-6 6A1 ENGINE (E - W) - Rocker Cover and Camshaft <MIVEC> 6AE0286 Piston MB991479 (5) Screw in the other adjusting screw until it comes into contact with the valve (when the turning torque changes), and then tighten the lock nut. (6) Loosen the adjusting screw that was screwed in first slightly (until the turning torque becomes almost [...]

6A1 ENGINE (E - W) - Rocker Arm and Rocker Shaft Cap <MIVEC> 1 1A-1 1-1 1 1. ROCKER ARM AND ROCKER SHAFT CAP <MIVEC> REMOV AL AND INST ALLA TION installation. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 22 20 21 13 20 21 20 21 13 19 18 4 11 12 11 12 4 Apply engine oil to all moving parts before 11 N m Removal steps + B G 1. Rocker shaft c[...]

1 1A-1 1-2 6A1 ENGINE (E - W) - Rocker Arm and Rocker Shaft Cap <MIVEC> INST ALLA TION SERVICE POINTS + A G SPRING GUIDE INST ALLA TION (1) Install the spring guide with the concave side toward the rocker arm. The waved washer may be installed with either side out. 6AE0247 Concave side Spring guide W aved washer T -lever Either side may be ou[...]

6A1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-12-1 12. CYLINDER HEAD AND V AL VES REMOV AL AND INST ALLA TION <SOHC> installation. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Apply engine oil to all moving parts before Removal steps G A ++ D G 1. Cylinder head bolt 1 1. Exhaust valve 2. Cylinder head G C ++ A G 12. V alve stem se[...]

1 1A-12-2 6A1 ENGINE (E - W) - Cylinder Head a nd V alves REMOV AL AND INST ALLA TION <MIVEC> installation. 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 20 19 11 18 Apply engine oil to all moving parts before Removal steps G A ++ D G 1. Cylinder head bolt G D + 1 1. Exhaust valve 2. Cylinder head G C ++ A G 12. V alve stem seal 3. Cylinder head gas[...]

6A1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-12-3 6AE0166 <SOHC> MB991653 6AE0408 <MIVEC> MB991653 6AE0167 <SOHC> MD998772 6AE0253 <MIVEC> MD998784 MD998772 6EN1068 MD998735 REMOV AL SERVICE POINTS PRECAUTION FOR REMOVED P ARTS Keep removed parts in order according to the cylinder number and intake/exhaust side. G A +[...]

1 1A-12-4 6A1 ENGINE (E - W) - Cylinder Head a nd V alves G C + V AL VE STEM SEAL REMOV AL (1) Do not reuse removed valve stem seals. 6AE0082 G D + V AL VE 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 con[...]

6A1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-12-5 Stem seals for exhaust Stem seals for intake valves: Silver valves: Black 7EN0763 6AE0169 <SOHC> MD998774 6AE0409 <MIVEC> MD998775 6EN0437 Painted end Spring retainer Spring seat 6AE0167 <SOHC> MD998772 Stem seal INST ALLA TION SERVICE POINTS + A G V AL VE STEM SEAL INST ALL[...]

1 1A-12-6 6A1 ENGINE (E - W) - Cylinder Head a nd V alves 6AE0253 MD998784 <MIVEC> MD998772 6EN1068 MD998735 9EN0251 6AE0392 Length of shank + D G CYLINDER HEAD BOL T INST ALLA TION (1) When installing the cylinder head bolts, check that the shank length of each bolt meets the limit. If the limit is exceeded, replace the bolts. Limit: max. 96[...]

6A1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-12-7 6AE0083 INSPECTION CYLINDER HEAD (1) Check the cylinder head gasket surface for flatness by using a straightedge and thickness gauge. Standard value: 0.03 mm Limit: 0 .2 mm (2) If the service limit is exceeded, correct to meet the specification. Grinding limit: *0.2 mm *Includes/combined with[...]

1 1A-12-8 6A1 ENGINE (E - W) - Cylinder Head a nd V alves V AL VE SPRING (1) Measure the valve spring’s free height. If the measurement is less than specified, replace the spring. 1EN0264 Free height Out of square V alve stem end V alve stem projection Spring seating surface DEN0212 1EN0279 guide V alve Standard value mm Limit mm SOHC 49.9 48.9 M[...]

6A1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-12-9 1EN0105 0.9 - 0.9 - 65 b 65 b 44 b 44 b 15 b 15 b 1EN0274 0.5 - 0.5 - 1EN0275 height 1.3 mm 1.3 mm 1.0 mm Cut away 1.0 mm V alve seat Oversize valve seat hole diameter V AL VE SEA T RECONDITIONING PROCEDURE (1) Before correcting the valve seat, check the clearance between the valve guide and [...]

1 1A-12-10 6A1 ENGINE (E - W) - Cylinder Head and V alves 1EN0106 <SOHC> 6AE0254 <DOHC> 14 mm 19 mm 19 mm (3) Press-fit the valve guide until it protrude specified value (SOHC: 14 mm, DOHC: 19 mm) as shown in the illustration. Caution J Press the valve guide from the cylinder head top surface. J V alve guide for intake valve and that fo[...]

6A1 ENGINE (E - W) - Oil Pump Case and Oil Pan 1 1A-13-1 13. OIL PUMP CASE AND OIL P AN REMOV AL AND INST ALLA TION <SOHC> installation. 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 23 3 21 24 25 26 22 Apply engine oil to all moving parts before 19 Nm 44 Nm 10 Nm 9N m 7N m 7N m 7N m 9N m 39 Nm 21 Nm 68 Nm 14 Nm 12 Nm 30 Nm Removal steps +[...]

1 1A-13-2 6A1 ENGINE (E - W) - Oil Pump Case and Oil Pan REMOV AL AND INST ALLA TION <MIVEC> installation. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Apply engine oil to all moving parts before 19 Nm 39 Nm 21 Nm 44 Nm 7N m 7N m 10 Nm 14 Nm 12 Nm Removal steps + I G + H G + F G G A ++ E G 1. Oil pressure switch 2. Oil filter 3. Oil filter co[...]

6A1 ENGINE (E - W) - Oil Pump Case and Oil Pan 1 1A-13-3 6AE0087 MD998727 6AE0091 REMOV AL SERVICE POINT G A + OIL P AN REMOV AL (1) Knock the special tool deeply between the oil pan and the cylinder block. (2) Hitting the side of the special tool, slide the special tool along the oil pan to remove it. INST ALLA TION SERVICE POINTS + A G INNER ROTO[...]

1 1A-13-4 6A1 ENGINE (E - W) - Oil Pump Case and Oil Pan + D G OIL P AN INST ALLA TION <SOHC> (1) Clean the cylinder block and oil pan gasket application surfaces. (2) Install the oil pan within 15 minutes after FIPG has been applied to the entire flange surfaces of the oil pan. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equiv[...]

6A1 ENGINE (E - W) - Oil Pump Case and Oil Pan 1 1A-13-5 + G G OIL COOLER INST ALLA TION (1) Install the oil cooler , with the oil cooler ’s positioning projection positioned against the rib on cylinder block. 6AE0172 + H G OIL FIL TER INST ALLA TION (1) Clean the surfaces of the cylinder block on which the oil filter is to be mounted. (2) Apply [...]

1 1A-13-6 6A1 ENGINE (E - W) - Oil Pump Case and Oil Pan (3) Check the body clearance. Standard value: 0.10 - 0.18 mm Limit: 0.35 mm 6AE0090 6AE0192 OIL LEVEL SENSOR (FOR EUROPE) (1) Put the oil level sensor in the oil, then move the float up and down with the oil at a temperature either lower than 40 è C or higher than 80 è C, and check for cont[...]

6A1 ENGINE (E - W) - Piston and Connecting Rod 1 1A-14-1 14. PISTON AND CONNECTING ROD REMOV AL AND INST ALLA TION installation. Apply engine oil to all moving parts before 6AE0095 Removal steps + G G 1. Nut + C G 7. Piston ring No.2 G A ++ F G 2. Connecting rod ca p + B G 8. Oil ring + E G 3. Connecting rod bearing G B ++ A G 9. Piston pin + D G 4[...]

1 1A-14-2 6A1 ENGINE (E - W) - Piston and Connecting Rod REMOV AL SERVICE POINTS G A + CONNECTING ROD CAP REMOV AL (1) Mark the large end of the connecting rod with the cylinder Cylinder No. number for use during reassembly . DEN0050 Piston pin setting tool MD998780 Push rod Guide A : 17.9 mm Guide B Guide A: 18.9 mm Guide C Guide A: 20.9 mm Guide [...]

6A1 ENGINE (E - W) - Piston and Connecting Rod 1 1A-14-3 Piston A B C D Connecting rod Piston pin 7EN0432 7EN0433 3m m+L Guide B Guide A INST ALLA TION SERVICE POINTS + A G PISTON PIN INST ALLA TION (1) Measure the following dimensions of the piston, piston pin and connecting rod. A: Piston pin insertion hole length B: Distance between piston bosse[...]

1 1A-14-4 6A1 ENGINE (E - W) - Piston and Connecting Rod 6AE0194 1EN0269 7EN0452 9EN0524 No.1 No.2 Side rail gap Piston ring expander Size mark Identification mark Identification mark Upper ring Lower in side rail No. 1 gap side rail Piston p No. 2 and spacer gap 6EN0549 K Mitsubishi Motors Corporation Feb. 1997 + B G OIL RING INST ALLA TION (1) Fi[...]

6A1 ENGINE (E - W) - Piston and Connecting Rod 1 1A-14-5 6AE0097 in Check digit No.1 No.3 No.5 No.2 No.4 No.6 Crankshaft p identification mark (4) Use suitable thread protectors on connecting rod bolts before inserting piston and connecting rod assembly into cylinder block. Care must be taken not to nick crank pin. (5) Using a suitable piston ring [...]

1 1A-14-6 6A1 ENGINE (E - W) - Piston and Connecting Rod (2) Check if the thrust clearance in the connecting rod big end is correct. Standard value: 0.10 - 0.25 mm Limit: 0 .4 mm 9EN0073 + G G CONNECTING ROD CAP NUT INST ALLA TION (1) Since the connecting rod bolts and nuts are torqued using a new procedure they should be examined BEFORE reuse. If [...]

6A1 ENGINE (E - W) - Piston and Connecting Rod 1 1A-14-7 7EN0475 Push in by the piston Piston Piston ring ring gap 7EN0476 1EN0246 Plastic gauge INSPECTION PISTON RING (1) Check the side clearance between the piston ring and ring groove. If the limit is exceeded, replace the ring or piston, or both. Standard value: No. 1 0.03 - 0.07 mm No. 2 0.02 -[...]

Crankshaft, Cylinder Block, Flywheel and 6A1 ENGINE (E - W) - Drive Plate 1 1A-15-1 15. CRANKSHAFT , CYLINDER BLOCK, FL YWHEEL AND DRIVE PLA TE REMOV AL AND INST ALLA TION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 20 19 18 21 A installation. 23 Nm 35 Nm 9N m 11 N m 98 Nm 98 Nm 11 N m Apply engine oil to all moving parts before Removal steps 1. Deto[...]

Crankshaft, Cylinder Block, Flywheel and 1 1A-15-2 6A1 ENGINE (E - W) - Drive Plate Crankshaft journal Check No.1 No.3 No.2 No.4 identification mark INST ALLA TION SERVICE POINTS + A G CRANKSHAFT BEARING INST ALLA TION (1) When replacing bearing, select a one of proper size according to the identification marks stamped on both crankshaft and cylind[...]

Crankshaft, Cylinder Block, Flywheel and 6A1 ENGINE (E - W) - Drive Plate 1 1A-15-3 9EN0477 6AE0108 Arrow Shank length 90 è - 100 è Paint marks Paint marks 6EN0955 6AE0109 + B G BEARING CAP / BEARING CAP BOL T INST ALLA TION (1) Install the bearing caps so that their arrows are positioned on the timing belt side. (2) When installing the bearing c[...]

Crankshaft, Cylinder Block, Flywheel and 1 1A-15-4 6A1 ENGINE (E - W) - Drive Plate + C G OIL SEAL INST ALLA TION (1) Apply engine oil to oil seal lip. 9EN0077 MB990938 MD998776 9EN0102 6AE0101 6AE0102 6AE01 10 + D G APPLICA TION OF OIL SEAL CASE Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent + E G DRIVE PLA TE BOL T / FL YWH[...]

Crankshaft, Cylinder Block, Flywheel and 6A1 ENGINE (E - W) - Drive Plate 1 1A-15-5 6AE0103 A B C D E F G 6AE0104 6AE0105 12 mm CYLINDER BLOCK (1) Using a straightedge and feeler gauge, check the block top surface for warpage. Make sure that the surface is free from gasket chips and other foreign matter . Standard value: 0.05 mm or less Limit: 0 .1[...]

Crankshaft, Cylinder Block, Flywheel and 1 1A-15-6 6A1 ENGINE (E - W) - Drive Plate (4) Bore all cylinders to calculated boring finish dimension. Caution J T o prevent distortion that may result from temperature rise during honing, bore cylinders, working from No. 1, No. 2, No. 3, No. 4, No. 5 and No. 6 (5) Hone to final finish dimension (piston O.[...]

NOTES[...]

Service Bulletins Click on the applicable bookmark to select the Service Bulletin.[...]

SERVICE BULLETIN QUALITY INFORMATION ANALYSIS OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION SERVICE BULLETIN No.: MSB-01 E11-0 01 Date : 2001-07- 25 <Model> <M/Y> (EC) GALANT(EA0) 01-10 Subject: ADDITION OF 6A1 ENGINE WATER PUMP INSTALLATION PROCEDURES Group: ENGINE D INFORMATION ENGINE 6A1 (W-E) Workshop Ma nual ENGINE 6A1 (E-W)[...]

ENGINE 6A1 (E-W) Workshop Manual 6A1 ENGINE (E-W) – Water Pump and Water Pipe 11A-7-3 4 th A ◄ ► INSTALLATI ON SERVICE POINTS SEALANT APPLICATIO N TO WATER PUMP Specified sealant: Mitsubishi Genuine Part No. MD970389 or equ ivale nt 6AE0067 3 mm diameter bead sealant page adde d here. ► B ◄ WATER PIPE / O-RING INSTALLATION (1) Wet th e O-[...]

<Added> (1) Install the water pump and tighten the bolts 1 and 2 i n that order. (2) Turn the pulley by hand and ensure that the impeller does not interfere with the cylinder block. (3) Tighten the bolts other than bolts 1 and 2. Water pump 6AE0415 4[...]