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Mitsubishi 4G6 manual

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Table of contents for the manual

  • Page 1

    ENGINE <4G6> 1 1A ............................................ ENGINE <6A1> 1 1B ............................................ ENGINE <4D6> 1 1C ............................................ 1 1A-1 ENGINE CONTENTS 1 1 109000276[...]

  • Page 2

    1 1A-2 ENGINE <4G6> CONTENTS 1 1 109000603 GENERAL INFORMA TION 3 .................. SER VICE SPECIFICA TIONS 3 ................. SEALANTS 4 ................................ SPECIAL TOOLS 4 ........................... ON-VEHICLE SER VICE 6 ..................... Drive Belt T ension Check and Adjustment 6 ...... Ignition T iming Check 7 .......[...]

  • Page 3

    ENGINE <4G6> - General Information/Service Specifications 1 1A-3 GENERAL INFORMA TION 1 1 100010469 Items 4G63 T otal displacement mL 1,997 Bore ´ Stroke mm 85.0 ´ 88.0 Compression ratio 10.0 Combustion chamber Pentroof type Camshaft arrangement SOHC Intake 8 Number of valve Exhaust 8 Opening BTDC 1 1 _ Intake Closing ABDC 53 _ V alve timin[...]

  • Page 4

    ENGINE <4G6> - Service Specifications/Sealants/Special T ools 1 1A-4 Items Limit Standard value Idle speed r/min 750 ± 100 - CO contents % 0.5 or less - HC contents ppm 100 or less - Compression pressure (250 - 400 r/min) kPa 1,400 Min. 1,060 Compression pressure difference of all cylinder kPa - Max. 100 Intake manifold vacuum kPa - Min. 69 [...]

  • Page 5

    ENGINE <4G6> - Special T ools 1 1A-5 T ool Use Name Number MD998713 Camshaft oil seal installer Press-in of the camshaft oil seal 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 o[...]

  • Page 6

    ENGINE <4G6> - On-vehicle Service 1 1A-6 ON-VEHICLE SERVICE 1 1 100090432 DRIVE BEL T TENSION CHECK AND ADJUSTMENT AL TERNA T OR DRIVE BEL T 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 wi[...]

  • Page 7

    ENGINE <4G6> - On-vehicle Service 1 1A-7 POWER STEERING OIL PUMP AND AIR CONDITIONER COMPRESSOR DRIVE BEL T TENSION CHECK AND ADJUSTMENT 1 1 100130127 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 t[...]

  • Page 8

    ENGINE <4G6> - On-vehicle Service 1 1A-8 7. Check that basic ignition timing is within the standard value. Standard value: 5 _ BTDC ± 2 _ 8. If the basic ignition timing is outside the standard value, inspect the MPI system while referring to GROUP 13A - T roubleshooting. 9. Press the MUT - II clear key (Select a forced driving cancel mode) [...]

  • Page 9

    ENGINE <4G6> - On-vehicle Service ENGINE <4G6> - On-vehicle Service 1 1A-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 [...]

  • Page 10

    ENGINE <4G6> - On-vehicle Service 1 1A-10 6. 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. 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 pre[...]

  • Page 11

    ENGINE <4G6> - On-vehicle Service 1 1A-1 1 LASH ADJUSTER CHECK 1 1 100290344 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[...]

  • Page 12

    ENGINE <4G6> - On-vehicle Service 1 1A-12 (3) Carry out lash adjuster simple check. (Refer to P .1 1A-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[...]

  • Page 13

    ENGINE <4G6> - On-vehicle Service 1 1A-13 <LASH ADJUSTER SIMPLE CHECK> 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 . <Checking an intake-side rocker arm> Ch[...]

  • Page 14

    ENGINE <4G6> - On-vehicle Service ENGINE <4G6> - On-vehicle Service 1 1A-14 1. 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 [...]

  • Page 15

    ENGINE <4G6> - Crankshaft Pulley 1 1A-15 CRANKSHAFT PULLEY 1 1200160303 REMOV AL AND INST ALLA TION Pre-removal Operation D Under Cover Removal Post-installation Operation D Drive Belt T ension Adjustment (Refer to P .1 1A-6.) D Under Cover Installation 1 2 3 25 Nm Removal steps 1. Drive belt (Power steering and A/C) 2. Drive belt (Alternator[...]

  • Page 16

    ENGINE <4G6> - Camshaft and Camshaft Oil Seal 1 1A-16 CAMSHAFT AND CAMSHAFT OIL SEAL 1 1200190418 REMOV AL AND INST ALLA TION Pre-removal and Post-installation Operation D Air Cleaner Removal and Installation D T iming Belt Removal and Installation (Refer to P .1 1A-26.) D Relay Box Removal and Installation 8 10 Nm 28 - 34 Nm 88 Nm 1 2 5 3 4 [...]

  • Page 17

    ENGINE <4G6> - Camshaft and Camshaft Oil Seal 1 1A-17 REMOV AL SERVICE POINTS A A " CAMSHAFT SPROCKET REMOV AL A B " ROCKER ARM AND SHAFT ASSEMBL Y REMOV AL 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. INST ALLA TION SERVICE P[...]

  • Page 18

    ENGINE <4G6> - Camshaft and Camshaft Oil Seal 1 1A-18 " B A CAMSHAFT OIL SEAL INST ALLA TION 1. Apply engine oil to the camshaft oil seal lip. 2. Use the special tool to press-fit the camshaft oil seal. " C A CAMSHAFT SPROCKET INST ALLA TION Use the special tool to stop the camshaft sprocket from turning in the same way as was done [...]

  • Page 19

    ENGINE <4G6> - Oil Pan 1 1A-19 OIL P AN 1 1200280207 REMOV AL AND INST ALLA TION Pre-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.) f 4 ± 1m m Bolt hole Groove 5 [...]

  • Page 20

    ENGINE <4G6> - Crankshaft Oil Seal 1 1A-20 CRANKSHAFT OIL SEAL 1 1200310135 REMOV AL AND INST ALLA TION (Engine oil: bolt wash- er surface) 127 - 137 Nm 10 5 4 3 2 1 <M/T> <A/T> 7 9 12 8 11 <M/T> <A/T> Crankshaft (Engine oil: bolt washer surface) Crankshaft 9 10 12 5 Sealant: 3M Stud locking 4170 or equivalent Lip sect[...]

  • Page 21

    ENGINE <4G6> - Crankshaft Oil Seal 1 1A-21 REMOV AL SERVICE POINTS A A " TRANSMISSION ASSEMBL Y REMOV AL <M/T>: 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. <A/T>: Refer to GROUP 23. A B " PLA TE <[...]

  • Page 22

    ENGINE <4G6> - Cylinder Head Gasket 1 1A-22 CYLINDER HEAD GASKET 1 1200400542 REMOV AL AND INST ALLA TION Pre-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 W ater Pip[...]

  • Page 23

    ENGINE <4G6> - Cylinder Head Gasket 1 1A-23 (Engine oil) 31 Nm <Cold engine> 78 Nm ® 0N m ® 20 Nm ® +9 0 _ ® +9 0 _ 3.4 Nm 26 29 34 Nm 24 Nm 44 Nm 12 13 14 15 16 17 20 21 22 23 24 25 27 28 49 Nm 10 Nm 19 18 12. Radiator upper hose connection 13. PCV hose 14. Ignition coil connector 15. Ignition coil assembly 16. Breather hose 17. En[...]

  • Page 24

    ENGINE <4G6> - Cylinder Head Gasket 1 1A-24 REMOV AL SERVICE POINTS A A " POWER STEERING OIL PUMP AND BRACKET ASSEMBL Y REMOV AL 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 insta[...]

  • Page 25

    ENGINE <4G6> - Cylinder Head Gasket 1 1A-25 4. T ighten the bolts by the following procedure. Step Operation Remarks 1 T ighten to 78 Nm. Carry out in the order shown in the illustration. 2 Fully loosen. Carry out in the reverse order of that shown in the illustration. 3 T ighten to 20 Nm. Carry out in the order shown in the illustration. 4 T[...]

  • Page 26

    ENGINE <4G6> - T iming Belt 1 1A-26 TIMING BEL T 1 1200430473 REMOV AL AND INST ALLA TION Pre-removal and Post-installation Operation D Crankshaft Pulley Removal and Installation (Refer to P .1 1A-15.) D Engine Mount Bracket Removal and Installation (Refer to GROUP 32 - Engine Mounting.) 10 - 12 Nm 48 Nm 1 2 5 24 Nm 4 3 9N m Removal steps 1. [...]

  • Page 27

    ENGINE <4G6> - T iming Belt 1 1A-27 REMOV AL SERVICE POINT A A " TIMING BEL T REMOV AL 1. T urn 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. 2. Loosen the tension pulley centre bolt. 3. Move the [...]

  • Page 28

    ENGINE <4G6> - T iming Belt 1 1A-28 4. 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. " B A TIMING BEL T INST ALLA TION 1. Align the timing marks on the camshaft sprocket, crankshaft sprocket and o[...]

  • Page 29

    ENGINE <4G6> - T iming Belt 1 1A-29 " C A TIMING BEL T TENSION ADJUSTMENT 1. After turning the crankshaft 1/4 of a revolution in the anticlockwise direction, turn it in the clockwise direction until the timing marks are aligned. 2. Loosen the tension pulley fixing bolt, and then use the special tool and a torque wrench to tighten the fix[...]

  • Page 30

    ENGINE <4G6> - T iming Belt B 1 1A-30 TIMING BEL T B 1 1200460106 REMOV AL AND INST ALLA TION 19 Nm 108 - 127 Nm 1 2 3 4 5 Removal steps 1. Timing belt (Refer to P .1 1A-26.) A A "" C A 2. Crankshaft sprocket " B A 3. Flange 4. Timing belt B tensioner A B "" A A 5. Timing belt B REMOV AL SERVICE POINTS A A " CRAN[...]

  • Page 31

    ENGINE <4G6> - T iming Belt B 1 1A-31 INST ALLA TION SERVICE POINTS " A A TIMING BEL T B INST ALLA TION, ADJUSTMENT 1. Install timing belt “B” by the following procedure. (1) Ensure that crankshaft sprocket “B” timing mark and the counterbalance shaft sprocket timing mark are aligned. (2) Fit timing belt “B” over crankshaft s[...]

  • Page 32

    ENGINE <4G6> - T iming Belt B 1 1A-32 " C A CRANKSHAFT SPROCKET INST ALLA TION NOTE Apply the minimum amount of engine oil to the bearing surface and thread of the crankshaft bolt. MD998719 or MD998754 MB990767 Crankshaft sprocket[...]

  • Page 33

    ENGINE <4G6> - Engine Assembly 1 1A-33 ENGINE ASSEMBL Y 1 1200090015 REMOV AL AND INST ALLA TION Pre-removal Operation D Fuel Discharge Prevention (Refer to GROUP 13A - On-vehicle Service.) D Engine Coolant Draining D Thermostat Case Assembly Removal (Refer to GROUP 14 - Water Hose and W ater Pipe.) D Front Exhaust Pipe Removal (Refer to GROU[...]

  • Page 34

    ENGINE <4G6> - Engine Assembly 1 1A-34 13 14 15 16 17 18 19 20 21 22 23 24 25 26 49 Nm 57 Nm* 25 98 Nm 13. Drive belt (Alternator) 14. Drive belt (Power steering and A/C) A A " 15. Power steering oil pump and bracket assembly A B " 16. A/C compressor 17. Alternator connector 18. Oil pressure switch connector 19. Heater hose connecti[...]

  • Page 35

    ENGINE <4G6> - Engine Assembly 1 1A-35 REMOV AL SERVICE POINTS A A " POWER STEERING OIL PUMP AND BRACKET ASSEMBL Y REMOV AL 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[...]

  • Page 36

    ENGINE <4G6> - Engine Assembly 1 1A-36 INST ALLA TION SERVICE POINTS " A A ENGINE ASSEMBL Y INST ALLA TION Install the engine assembly , checking that the cables, hoses, and harness connectors are not clamped. " B A ENGINE MOUNT ST OPPER INST ALLA TION Clamp the engine mount stopper so that the arrow points in the direction as shown[...]

  • Page 37

    1 1B-1 ENGINE <6A1> CONTENTS 1 1 109000610 GENERAL INFORMA TION 2 .................. SER VICE SPECIFICA TIONS 2 ................. SEALANTS 3 ................................ SPECIAL TOOLS 3 ........................... ON-VEHICLE SER VICE 5 ..................... Drive Belt T ension Check and Adjustment 5 ...... Ignition T iming Check 6 .......[...]

  • Page 38

    ENGINE <6A1> - General Information/Service Specifications 1 1B-2 GENERAL INFORMA TION 1 1 100010452 Items 6A13 T otal displacement mL 2,498 Bore ´ Stroke mm 81.0 ´ 80.8 Compression ratio 9.5 Combustion chamber Pentroof type Camshaft arrangement SOHC Intake 12 Number of valve Exhaust 12 Opening BTDC 15 _ Intake Closing ABDC 53 _ V alve timin[...]

  • Page 39

    ENGINE <6A1> - Service Specifications/Sealants/Special T ools 1 1B-3 Items Limit Standard value Idle speed r/min 650 ± 100 - CO contents % 0.2 or less - HC contents ppm 100 or less - Compression pressure (250 - 400 r/min) kPa 1 177 Min. 875 Compression pressure difference of all cylinder kPa - Max. 98 Intake manifold vacuum kPa - Min. 60 Cyl[...]

  • Page 40

    ENGINE <6A1> - Special T ools 1 1B-4 T ool Use Name Number MD998443 Auto-lash adjuster holder Supporting of auto-lash adjuster MD998713 Camshaft oil seal installer Press-in of the camshaft oil seal MD998776 Crankshaft rear oil seal installer Press-in of the crankshaft rear oil seal MB990938 Handle Press-in of the crankshaft rear oil seal MD99[...]

  • Page 41

    ENGINE <6A1> - Special T ools/On-vehicle Service 1 1B-5 T ool Use Name Number MB991453 Engine hanger assembly Supporting the engine assembly during removal and installation of the transmission ON-VEHICLE SERVICE 1 1 100090425 DRIVE BEL T TENSION CHECK AND ADJUSTMENT AL TERNA T OR DRIVE BEL T TENSION CHECK Use a belt tension gauge to check tha[...]

  • Page 42

    ENGINE <6A1> - On-vehicle Service 1 1B-6 POWER STEERING OIL PUMP AND AIR CONDITIONER COMPRESSOR DRIVE BEL T TENSION CHECK AND ADJUSTMENT 1 1 100130134 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 t[...]

  • Page 43

    ENGINE <6A1> - On-vehicle Service 1 1B-7 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 [...]

  • Page 44

    ENGINE <6A1> - On-vehicle Service 1 1B-8 5. Set the CO, HC tester . 6. Check the CO contents and the HC contents at idle. Standard value CO contents: 0.2% 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[...]

  • Page 45

    ENGINE <6A1> - On-vehicle Service 1 1B-9 6. 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. Standard value (at engine speed of 250 - 400 r/min): 1,177 kPa Limit (at engine speed of 250 - 400 r/min): Min. 875 kPa 8. Measure the compression pressu[...]

  • Page 46

    ENGINE <6A1> - On-vehicle Service 1 1B-10 LASH ADJUSTER CHECK 1 1 100290337 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 [...]

  • Page 47

    ENGINE <6A1> - On-vehicle Service 1 1B-1 1 (3) Carry out lash adjuster simple check. (Refer to P .1 1B-12.) 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 o[...]

  • Page 48

    ENGINE <6A1> - On-vehicle Service 1 1B-12 <LASH ADJUSTER SIMPLE CHECK> 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 . <Checking an intake-side rocker arm> Ch[...]

  • Page 49

    ENGINE <6A1> - On-vehicle Service ENGINE <6A1> - On-vehicle Service 1 1B-13 1. 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 [...]

  • Page 50

    ENGINE <6A1> - Crankshaft Pulley 1 1B-14 CRANKSHAFT PULLEY 1 1200160310 REMOV AL AND INST ALLA TION Pre-removal Operation D Under Cover Removal Post-installation Operation D Drive Belt T ension Adjustment (Refer to P .1 1B-5.) D Under Cover Installation 177 - 186 Nm 1 2 3 (Engine oil) 4 5 Removal steps 1. Drive belt (Power steering oil pump, [...]

  • Page 51

    ENGINE <6A1> - Camshaft and Camshaft Oil Seal 1 1B-15 CAMSHAFT AND CAMSHAFT OIL SEAL 1 1200220124 REMOV AL AND INST ALLA TION <Front bank> Pre-removal and Post-installation Operation D Engine Coolant Draining and Refilling (Refer to GROUP 14 - On-vehicle Service.) D Air Intake Hose Assembly Removal and Installation D T iming Belt Remova[...]

  • Page 52

    ENGINE <6A1> - Camshaft and Camshaft Oil Seal 1 1B-16 <Rear bank> Pre-removal and Post-installation Operation D Air Intake Plenum Removal and Installation (Refer to GROUP 15.) D T iming Belt Removal and Installation (Refer to P .1 1B-26.) D Distributor Removal and Installation (Refer to GROUP 16.) D Drive Belt T ension Adjustment (Refer[...]

  • Page 53

    ENGINE <6A1> - Camshaft and Camshaft Oil Seal 1 1B-17 A B " CAMSHAFT SPROCKET REMOV AL A C " ROCKER ARM AND SHAFT ASSEMBL Y REMOV AL 1. Install the special tools as shown in the illustration so that the lash adjusters will not fall out. 2. Loosen the rocker arm and shaft assembly mounting bolt, and then remove the rocker arm and sha[...]

  • Page 54

    ENGINE <6A1> - Camshaft and Camshaft Oil Seal 1 1B-18 " C A CAMSHAFT SPROCKET INST ALLA TION 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. T ightening torque: 88 Nm " D A RADIA TOR LOWER HOSE/RADIA TOR UPPER HOSE CONNECT[...]

  • Page 55

    ENGINE <6A1> - Oil Pan 1 1B-19 OIL P A N 1 1200280214 REMOV AL AND INST ALLA TION Pre-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.) D Under Cover Removal and Inst[...]

  • Page 56

    ENGINE <6A1> - Oil Pan 1 1B-20 REMOV AL SERVICE POINT A A " LOWER OIL P AN/UPPER OIL P AN REMOV AL 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. INST ALLA TION SERVICE POINT " A A DRAIN PLUG GASKET INST ALL[...]

  • Page 57

    ENGINE <6A1> - Crankshaft Oil Seal 1 1B-21 CRANKSHAFT OIL SEAL 1 1200310142 REMOV AL AND INST ALLA TION 1 2 3 4 5 6 7 8 9 10 11 <M/T> <A/T> <M/T> (Engine oil: bolt wash- er surface) Crankshaft <A/T> (Engine oil: bolt washer surface) Crankshaft Sealant: 3M Stud Locking 4170 or equivalent Lip section Lip section 7 8 10 5[...]

  • Page 58

    ENGINE <6A1> - Crankshaft Oil Seal 1 1B-22 REMOV AL SERVICE POINTS A A " TRANSMISSION ASSEMBL Y REMOV AL <M/T>: 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. <A/T>: Refer to GROUP 23. A B " PLA TE <[...]

  • Page 59

    ENGINE <6A1> - Crankshaft Oil Seal 1 1B-23 " C A CRANKSHAFT FRONT OIL SEAL INST ALLA TION 1. Apply a small amount of engine oil to the entire circumference of the oil seal lip. 2. T ap the oil seal unit it is flush with the oil seal case. Crankshaft MD998717 MD998717 Oil seal[...]

  • Page 60

    ENGINE <6A1> - Cylinder Head Gasket 1 1B-24 CYLINDER HEAD GASKET 1 1200400559 REMOV AL AND INST ALLA TION Pre-removal and Post-installation Operation D Engine Coolant Draining and Refilling (Refer to GROUP 14 - On-vehicle Service.) D Air Intake Hose Assembly Removal and Installation D Radiator Assembly Removal and Installation (Refer to GROUP[...]

  • Page 61

    ENGINE <6A1> - Cylinder Head Gasket 1 1B-25 REMOV AL SERVICE POINT A A " CYLINDER HEAD BOL T REMOV AL Loosen the bolts in 2 or 3 steps in order of the numbers shown in the illustration, and remove the cylinder head assembly . INST ALLA TION SERVICE POINTS " A A CYLINDER HEAD GASKET INST ALLA TION 1. Wipe off all oil and grease from [...]

  • Page 62

    ENGINE <6A1> - Timing Belt 1 1B-26 TIMING BEL T 1 1200430480 REMOV AL AND INST ALLA TION Pre-removal and Post-installation Operation D Under Cover Removal and Installation D Crankshaft Pulley Removal and Installation D Alternator Removal and Installation (Refer to GROUP 16.) D Drive Belt T ension Adjustment (Refer to P .1 1B-5.) 10 - 12 Nm 10[...]

  • Page 63

    ENGINE <6A1> - Timing Belt 1 1B-27 REMOV AL SERVICE POINT A A " TIMING BEL T REMOV AL 1. Align each of the timing marks. 2. Loosen the centre bolt of the tension pulley and remove the timing belt. Caution (1) If the timing belt is to be reused, use chalk to mark it with an arrow on its flat side indicating the turning direction. (2) If t[...]

  • Page 64

    ENGINE <6A1> - Timing Belt 1 1B-28 " B A TIMING BEL T INST ALLA TION 1. Check that the timing marks of the both camshaft sprockets and the crankshaft sprocket are aligned. NOTE In this condition, t he No.1 cylinder will be in th e compression top dead centre position. 2. Install the timing belt so that there is no slackness on the tensio[...]

  • Page 65

    ENGINE <6A1> - Timing Belt 1 1B-29 " C A TIMING BEL T TENSION ADJUSTMENT 1. After turning the crankshaft 1/4 of a revolution in the anticlockwise direction, turn it in the clockwise direction until the timing marks are aligned. 2. Loosen the tensioner pulley fixing bolt, and then use the special tool and a torque wrench to tighten the fi[...]

  • Page 66

    ENGINE <6A1> - Engine Assembly 1 1B-30 ENGINE ASSEMBL Y 1 1200100558 REMOV AL AND INST ALLA TION Pre-removal Operation D Fuel Discharge Prevention (Refer to GROUP 13A - On-vehicle Service.) D Under Cover Removal D Hood Removal (Refer to GROUP 42.) D Air Cleaner Removal D Radiator Removal (Refer to GROUP 14.) D Front Exhaust Pipe Removal (Refe[...]

  • Page 67

    ENGINE <6A1> - Engine Assembly 1 1B-31 12 Nm 57 Nm 25 26 27 28 29 30 31 32 34 33 39 Nm 67 Nm 35 Nm 27 33 98 - 1 18 Nm* 12 Nm 27 25. Drive belt (Alternator) 26. Drive belt (Power steering and A/C) 27. Clamp bolt (Power steering hose and pipe) A A " 28. Power steering oil pump assembly A B " 29. A/C compressor 30. Heater hose connecti[...]

  • Page 68

    ENGINE <6A1> - Engine Assembly 1 1B-32 REMOV AL SERVICE POINTS A A " POWER STEERING OIL PUMP AND BRACKET ASSEMBL Y REMOV AL 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[...]

  • Page 69

    ENGINE <6A1> - Engine Assembly 1 1B-33 INST ALLA TION SERVICE POINTS " A A ENGINE ASSEMBL Y INST ALLA TION Install the engine assembly , checking that the cables, hoses, and harness connectors are not clamped. " B A ENGINE MOUNT ST OPPER INST ALLA TION Clamp the engine mount stopper so that the arrow points in the direction as shown[...]

  • Page 70

    NOTES[...]

  • Page 71

    1 1C-1 ENGINE <4D6> CONTENTS 1 1 109000627 GENERAL INFORMA TION 2 .................. SER VICE SPECIFICA TIONS 2 ................. SEALANTS 3 ................................ SPECIAL TOOLS 4 ........................... ON-VEHICLE SER VICE 6 ..................... Drive Belt T ension Check and Adjustment 6 ...... V alve Clearance Check and Adjus[...]

  • Page 72

    ENGINE <4D6> - General Information/Service Specifications 1 1C-2 GENERAL INFORMA TION 1 1 100010476 Items 4D68 T otal displacement mL 1,998 Bore ´ Stroke mm 82.7 ´ 93.0 Compression ratio 22.4 Combustion chamber V ortex chamber type Camshaft arrangement SOHC Number of valve Intake 4 Exhaust 4 V alve timing Intake Opening BTDC 20 _ Closing AB[...]

  • Page 73

    ENGINE <4D6> - Service Specifications/Sealants 1 1C-3 Items Limit Standard value Power T ension N When checked 294 - 490 - steering oil pump drive When a used belt is installed 343 - 441 - belt tension When a new belt is installed 490 - 686 - Deflection When checked 12.6 - 16.3 - mm When a used belt is installed 13.4 - 15.3 - When a new belt [...]

  • Page 74

    ENGINE <4D6> - Special T ools 1 1C-4 SPECIAL T OOLS 1 1 100060471 T ool Number Name Use MB991502 MUT - II sub assembly Idle speed check MB998720 Prestroke measuring adapter Adjustment of the injection timing MB990767 End yoke holder Holding the camshaft sprocket MD998719 Crankshaft pulley holder pin MD998754 Crankshaft pulley holder pin MD998[...]

  • Page 75

    ENGINE <4D6> - Special T ools 1 1C-5 T ool Use Name Number MD998382 Crankshaft front oil seal installer Installing the crankshaft front oil seal MD998383 Crankshaft front oil seal guide MD998781 Flywheel stopper Securing the flywheel <M/T> or drive plate <A/T> GENERAL SERVICE TOOL MZ203827 Engine lifter Supporting the engine assem[...]

  • Page 76

    ENGINE <4D6> - On-vehicle Service ENGINE <4D6> - On-vehicle Service 1 1C-6 ON-VEHICLE SERVICE 1 1 100090449 DRIVE BEL T TENSION CHECK AND ADJUSTMENT AL TERNA TOR DRIVE BEL T 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 illustrat[...]

  • Page 77

    ENGINE <4D6> - On-vehicle Service 1 1C-7 POWER STEERING OIL PUMP DRIVE BEL T TENSION CHECK AND ADJUSTMENT 11 100110183 1. Check the tension by pulling or pushing at the centre of the belt between pulleys with a force of 98 N as shown in the figure. Measure drive belt deflection amount. Standard value: Items When checked When a used belt is in[...]

  • Page 78

    ENGINE <4D6> - On-vehicle Service 1 1C-8 COMPRESSOR DRIVE BEL T TENSION CHECK AND ADJUSTMENT 1 1 100100203 1. Check the tension by pulling or pushing at the centre of the belt between pulleys with a force of 98 N as shown in the figure. Measure drive belt deflection amount. Standard value: Items When checked When a used belt is installed When[...]

  • Page 79

    ENGINE <4D6> - On-vehicle Service 1 1C-9 6. Measure the valve clearance in the places indicated by arrows in the illustration. Arrow A: When the No.1 cylinder is at compression top dead centre Arrow B: When the No.4 cylinder is at compression top dead centre Standard value: When warm When cold (NOTE) Intake 0.35 mm 0.25 mm Exhaust 0.45 mm 0.3[...]

  • Page 80

    ENGINE <4D6> - On-vehicle Service 1 1C-10 8. T ighten the lock nut while holding the adjusting screw with a screwdriver so that it doesn’t turn. 9. T urn the crankshaft one full revolution to align the crankshaft pulley timing mark. 10. Adjust the remaining valves by the same procedure as in steps 7. - 9. above. 1 1. Install the glow plugs [...]

  • Page 81

    ENGINE <4D6> - On-vehicle Service 1 1C-1 1 7. T urn the crankshaft clockwise to move th e No.1 cylinder approximately 30 _ before compression top dead centre. 8. Set the needle of the dial gauge to 0. 9. Check that the needle doesn’t move even if the crankshaft is turned slightly (2 - 3 _ ) in both clockwise and anti-clockwise direction. NO[...]

  • Page 82

    ENGINE <4D6> - On-vehicle Service 1 1C-12 IDLE SPEED CHECK 1 1 100350073 NOTE Check that the injection timing is normal, and then perform this check. 1. Before inspection, set the vehicle to the pre-inspection condition. 2. Connect the MUT - II to the diagnosis connector . 3. Start the engine and check that the idle speed is at the standard v[...]

  • Page 83

    ENGINE <4D6> - On-vehicle Service 1 1C-13 5. Set compression gauge to one of the glow plug holes. 6. Crank the engine and measure the compression pressure. Standard value: 3,500 kPa (at engine speed of 280 r/min) Limit: Min. 2,560 kPa (at engine speed of 280 r/min) 7. Measure the compression pressure for all cylinders, and check that the pres[...]

  • Page 84

    ENGINE <4D6> - On-vehicle Service 1 1C-14 5. T urn the crankshaft anti-clockwise by 1/2 the width of a camshaft sprocket tooth in order to take up the slack in the idler pulley belt (the side where th e belt is slack). 6. Loosen the timing belt tensioner mounting bolt by 1/4 - 1/3 a turn, and use the force of the tensioner spring to apply ten[...]

  • Page 85

    ENGINE <4D6> - Crankshaft Pulley 1 1C-15 CRANKSHAFT PULLEY 1 1200160327 REMOV AL AND INST ALLA TION Pre-removal Operation D Under Cover Removal Post-installation Operation D Drive Belt T ension Adjustment (Refer to P .1 1C-6.) D Under Cover Installation 25 Nm 1 2 3 4 Removal steps 1. Drive belt (Power steering) 2. Drive belt (A/C) 3. Drive be[...]

  • Page 86

    ENGINE <4D6> - Camshaft and Camshaft Oil Seal 1 1C-16 CAMSHAFT AND CAMSHAFT OIL SEAL 1 1200190425 REMOV AL AND INST ALLA TION Pre-removal and Post-installation Operation D T iming Belt Removal and Installation (Refer to P .1 1C-26.) D Air Pipe A Removal and Installation D V acuum Pump Removal and Installation (Refer to GROUP 14.) Cam section [...]

  • Page 87

    ENGINE <4D6> - Camshaft and Camshaft Oil Seal 1 1C-17 REMOV AL SERVICE POINT A A " CAMSHAFT SPROCKET REMOV AL INST ALLA TION SERVICE POINTS " A A CAMSHAFT BEARING CAP INST ALLA TION The cap numbers are embossed on the top surface of the bearing caps, so install in the order of the numbers. However , no numbers are embossed on bearin[...]

  • Page 88

    ENGINE <4D6> - Oil Pan 1 1C-18 OIL P A N 1 1200280221 REMOV AL AND INST ALLA TION Pre-removal and Post-installation Operation D Under Cover Removal and Installation D Front Exhaust Pipe Removal and Installation (Refer to GROUP 15.) D Engine Oil Level Gauge Removal and Insertion D Engine Oil Draining and Refilling (Refer to GROUP 12 - On-vehic[...]

  • Page 89

    ENGINE <4D6> - Oil Pan 1 1C-19 REMOV AL SERVICE POINT A A " OIL P AN REMOV AL 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. INST ALLA TION SERVICE POINT " A A DRAIN PLUG GASKET INST ALLA TION Install the dr[...]

  • Page 90

    ENGINE <4D6> - Crankshaft Oil Seal 1 1C-20 CRANKSHAFT OIL SEAL 1 1200310159 REMOV AL AND INST ALLA TION (Engine oil: bolt washer surface) (Engine oil: bolt washer surface) <M/T> <A/T> (Engine oil) Lip section Lip section Engine oil Crankshaft Crankshaft Sealant: 3M Stud Locking 4170 or equivalent 1 2 3 4 5 6 7 8 9 10 11 127 - 137 [...]

  • Page 91

    ENGINE <4D6> - Crankshaft Oil Seal 1 1C-21 REMOV AL SERVICE POINT A A " TRANSMISSION ASSEMBL Y REMOV AL <M/T>: 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. <A/T>: Refer to GROUP 23. A B " ADAPTER PLA [...]

  • Page 92

    ENGINE <4D6> - Crankshaft Oil Seal 1 1C-22 " C A CRANKSHAFT FRONT OIL SEAL INST ALLA TION 1. Apply a small amount of engine oil to the entire circumference of the oil seal lip. 2. T ap the oil seal unit it is flush with the oil seal case. Crankshaft Oil seal MD998382 MD998383 Front lower case[...]

  • Page 93

    ENGINE <4D6> - Cylinder Head Gasket ENGINE <4D6> - Cylinder Head Gasket 1 1C-23 CYLINDER HEAD GASKET 1 1200400566 REMOV AL AND INST ALLA TION Pre-removal and Post-installation Operation D Engine Coolant Draining and Refilling (Refer to GROUP 14 - On-vehicle Service.) D Air Pipe A Removal and Installation (Refer to GROUP 15 - Intercooler[...]

  • Page 94

    1 1C-24 A A " FUEL INJECTION PIPE REMOV AL When loosening nuts at injection pipe ends, hold the nut at other side (delivery holder nut for pump side, nozzle holder nut at nozzle side) with wrench. Caution After disconnecting the injection pipe, plug the opening so that no foreign particles get inside the pump or into the injection nozzle. A B [...]

  • Page 95

    ENGINE <4D6> - Cylinder Head Gasket 1 1C-25 4. T ighten the bolts by the following procedure. Step Operation Remarks 1 T ighten to 88 Nm. Carry out in the order shown in the illustration. 2 Fully loosen. Carry out in the reverse order of that shown in the illustration. 3 T ighten to 39 Nm. Carry out in the order shown in the illustration. 4 T[...]

  • Page 96

    ENGINE <4D6> - Timing Belt 1 1C-26 TIMING BEL T 1 1200430497 REMOV AL AND INST ALLA TION Pre-removal and Post-installation Operation D Crankshaft Pulley Removal and Installation (Refer to P .1 1C-15.) D Engine Mount Bracket Removal and Installation (Refer to GROUP 32.) 10 - 12 Nm 9N m 25 Nm 23 Nm 19 Nm 10 - 12 Nm 10 - 12 Nm 10 - 12 Nm 9N m 10[...]

  • Page 97

    ENGINE <4D6> - Timing Belt 1 1C-27 REMOV AL SERVICE POINTS A A " TIMING BEL T FRONT UPPER COVER INST ALLA TION Attach protective tape to the engine mount bracket, and then remove the timing belt front upper cover . A B " TIMING BEL T REMOV AL 1. Align th e timing marks. 2. Loosen the installation bolt of the timing belt tensioner . [...]

  • Page 98

    ENGINE <4D6> - Timing Belt 1 1C-28 INST ALLA TION SERVICE POINTS " A A TIMING BEL T INST ALLA TION 1. Ensure that the timing marks of the camshaft sprocket, the injection pump sprocket, the crankshaft sprocket, and the oil pump sprocket are all aligned. 2. Move the timing belt tensioner downward and loosely tighten the bolt so that the t[...]

  • Page 99

    ENGINE <4D6> - Timing Belt 1 1C-29 6. Using the index finger , press between the camshaft sprocket and the injection pump sprocket, and check whether or not the amount of flexion is within the standard value range. Standard value: 4 - 5 mm Injection pump sprocket Camshaft sprocket[...]

  • Page 100

    ENGINE <4D6> - T iming Belt B 1 1C-30 TIMING BEL T B 1 12004601 13 REMOV AL AND INST ALLA TION Pre-removal and Post-installation Operation D Crankshaft Pulley Removal and Installation (Refer to P .1 1C-15.) D Engine Mount Bracket Removal and Installation (Refer to GROUP 32.) D T iming Belt Removal and Installation (Refer to P .1 1C-26.) (Engi[...]

  • Page 101

    ENGINE <4D6> - T iming Belt B 1 1C-31 A B " TIMING BEL T B REMOV AL Caution If the timing belt “B” is to be re-used, use chalk to mark (on its flat side) an arrow indicating the clockwise direction. INST ALLA TION SERVICE POINTS " A A TIMING BEL T B INST ALLA TION 1. Install the timing belt “B” by the following procedure. (1[...]

  • Page 102

    ENGINE <4D6> - T iming Belt B 1 1C-32 " B A CRANKSHAFT SPROCKET INST ALLA TION 1. Apply as little engine oil as possible to the seat and the thread of the crankshaft bolt. 2. Secure the crankshaft sprocket in the same way as during removal, and then tighten the bolt to the specified torque. T ightening torque: 108 - 127 Nm[...]

  • Page 103

    ENGINE <4D6> - Engine Assembly 1 1C-33 ENGINE ASSEMBL Y 1 1200100565 REMOV AL AND INST ALLA TION Pre-removal Operation D Hood Removal (Refer to GROUP 42.) D Air Cleaner Assembly Removal D Engine Coolant Draining D Radiator Assembly Removal (Refer to GROUP 14.) D Under Cover Removal D Front Exhaust Pipe Removal (Refer to GROUP 15.) Post-instal[...]

  • Page 104

    ENGINE <4D6> - Engine Assembly 1 1C-34 18 19 20 21 22 23 24 25 26 27 28 29 29 - 34 Nm 98 Nm 12 Nm 57 Nm* 39 Nm 22 Nm 28 18. Heater hose connection 19. Drive belt (Power steering) 20. Drive belt (A/C) 21. Oil pump brace A A " 22. Power steering oil pump and bracket assembly A B " 23. A/C compressor 24. Engine oil cooler pipe connecti[...]

  • Page 105

    ENGINE <4D6> - Engine Assembly 1 1C-35 REMOV AL SERVICE POINTS A A " POWER STEERING OIL PUMP AND BRACKET ASSEMBL Y REMOV AL 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[...]

  • Page 106

    ENGINE <4D6> - Engine Assembly 1 1C-36 INST ALLA TION SERVICE POINTS " A A ENGINE ASSEMBL Y INST ALLA TION Install the engine assembly , checking that the cables, hoses, and harness connectors are not clamped. " B A ENGINE MOUNT ST OPPER INST ALLA TION Clamp the engine mount stopper so that the arrow points in the direction as shown[...]