Mitsubishi 6G7 manual

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-1-2 ....................................... T ORQUE SPECIFICA TIONS 1 1A-1-3 ................................[...]

1 1A-0-2 PWEE9615 E Dec. 1996 Mitsubishi Motors Corporation NOTES[...]

6G7 ENGINE (E - W) - General Information 1 1A-0-3 GENERAL INFORMA TION GENERAL SPECIFICA TIONS Descriptions 6G72-SOHC T ype 60 _ OHV , SOHC Number of cylinders 6 Combustion chamber Compact type T otal displacement dm 3 2.972 Cylinder bore mm 91.1 Piston stroke mm 76.0 Compression ratio 8.9 V alve timing Intake valve Opens (BTDC) 15 ° (Camshaft ide[...]

6G7 ENGINE (E - W) - Specifications 1 1A-1-1 1. SPECIFICA TIONS SERVICE SPECIFICA TIONS Items Standard Limit Timing belt Auto-tensioner rod length mm 3.8 - 5.0 - Auto-tensioner rod projection length mm 12 - Auto-tensioner rod pushed-in amount (when pushed with a force of 98 - 196 N) mm 1.0 or less - Rocker arms and camshaft Camshaft cam height mm ([...]

6G7 ENGINE (E - W) - Specifications 1 1A-1-2 Items Limit Standard Oil pump side clearance mm 0.04 - 0.10 - Oil pump body clearance mm 0.10 - 0.18 0.35 Piston and connecting rod Piston outside diameter mm 91.1 - Piston ring to ring groove clearance mm No. 1 0.03 - 0.07 0.1 No. 2 0.02 - 0.06 0.1 Piston ring end g ap mm No. 1 0.30 - 0.45 0.8 No. 2 0.4[...]

6G7 ENGINE (E - W) - Specifications 1 1A-1-3 TORQUE SPECIFICA TIONS Items Nm Alternator Drive belt tensioner pulley nut 49 Crankshaft bolt 181 Alternator pivot nut 44 Alternator bolt M8 21 Alternator bolt M10 48 Dipstick tube 13 Air intake plenum Air intake plenum stay bolt M8 17 Air intake plenum stay bolt M10 35 Accelerator cable bracket 4 Bracke[...]

6G7 ENGINE (E - W) - Specifications 1 1A-1-4 Items Nm Intake manifold Engine coolant temperature gauge unit 11 Engine coolant temperature sensor 29 Heater pipe bolt 18 W ater outlet fitting bolt 18 W ater inlet fitting bolt 18 Thermostat housing bolt 18 W ater pipe bolt 13 Delivery pipe 11 Intake manifold bolt 21 Fuel pipe bolt 8.8 Fuel pressure re[...]

6G7 ENGINE (E - W) - Specifications 1 1A-1-5 Items Nm Oil pan, upper bolt 5.9 Baffle plate bolt (oil pan side) 11 Baffle plate bolt (cylinder block side) 9.8 Oil screen bolt 18 Relief plug 44 Oil pump case bolt 13 Oil pump cover bolt 9.8 Piston and connecting rod Connecting rod c ap 51 Crankshaft, flywheel and drive plate Flywheel bolt 74 Drive pla[...]

6G7 ENGINE (E - W) - Specifications 1 1A-1-6 FORM-IN-PLACE GASKET 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 bead co[...]

6G7 ENGINE (E - W) - Special T ools 1 1A-2-1 2. SPECIAL TOOLS T ool Number Name Use MB991559 Camshaft oil seal installer adaptor Installation of camshaft oil seal (on left bank) (Used in combination with MD998713) MD998051 Cylinder head bolt wrench Loosening and tightening of cylinder head bolt MD998440 Leak-down tester Leak-down test of lash adjus[...]

6G7 ENGINE (E - W) - Special T ools 1 1A-2-2 T ool Us e Name Number MD998774 V alve stem seal installer Installation of valve stem seal MD998780 Piston pin setting tool Removal and installation of piston pin MD998781 Flywheel stopper Holding flywheel or drive plate MD998767 T ensioner pulley Adjustment of timing belt tension MB990767 End yoke holde[...]

6G7 ENGINE (E - W) - Alternator 1 1A-3-1 3. AL TERNA T OR REMOV AL AND INST ALLA TION 7EN1030 1 2 3 4 5 6 7 8 9 10 13 Nm 21 Nm 48 Nm 44 Nm 49 Nm 181 Nm Removal steps 1. T ensioner pulley A A "" A A 2. Crankshaft bolt 3. W asher 4. Crankshaft pulley 5. Alternator 6. Alternator bracket 7. Dip stick 8. O-ring 9. Dip stick tube 10. O-ring PWE[...]

6G7 ENGINE (E - W) - Alternator 1 1A-3-2 REMOV AL SER VICE POINTS A A " CRANKSHAFT BOL T (1) With th e Special T ool fixed to th e drive plate or flywheel remove the crankshaft bolt. INST ALLA TION SERVICE POINTS " A A CRANKSHAFT BOL T (1) With th e Special T ool fixed to th e drive plate or flywheel install the crankshaft bolt. PWEE9615 [...]

6G7 ENGINE (E - W) - Air Intake Plenum 1 1A-4-1 4. AIR INT AKE PLENUM REMOV AL AND INST ALLA TION 7EN1031 1 2 3 4 5 6 7 8 9 10 11 12 13 4N m 21 Nm 17 Nm 56 Nm 17 Nm 17 Nm 17 Nm 11 N m 11 N m 35 Nm Removal steps 1. Air intake plenum stay , front 2. Air intake plenum stay , rear 3. Accelerator cable bracket 4. EGR valve 5. EGR valve gasket 6. EGR pip[...]

6G7 ENGINE (E - W) - Air Intake Plenum 1 1A-4-2 INST ALLA TION SERVICE POINTS " A A THROTTLE BODY GASKET (1) Install gasket with protrusion as illustrated. PWEE9615 E Dec. 1996 Mitsubishi Motors Corporation Protrusion 6AE0277[...]

6G7 ENGINE (E - W) - Ignition System 1 1A-5-1 5. IGNITION SYSTEM REMOV AL AND INST ALLA TION 7EN0965 1 2 3 4 1 23 Nm 25 Nm Removal steps 1. Spark plug cable 2. Spark plug 3. Distributor 4. O-ring PWEE9615 E Dec. 1996 Mitsubishi Motors Corporation[...]

6G7 ENGINE (E - W) - Timing Belt 1 1A-6-1 6. TIMING BEL T REMOV AL AND INST ALLA TION 7EN0862 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Nm 88 Nm 23 Nm 44 Nm 48 Nm 13 Nm 11 N m 9N m 11 N m 44 Nm 13 Nm 44 Nm Removal steps 1. T iming belt front upper cover , rear 2. T iming belt front upper cover , front 3. Timing belt front lower co[...]

6G7 ENGINE (E - W) - Timing Belt 1 1A-6-2 REMOV AL SER VICE POINTS A A " TIMING BEL T (1) When th e timing belt is to be reused, in order to allow re-installation of the belt so that it travels in the same direction as before it was removed, mark the direction of travel with an arrow before removing it. Caution D As water or oil on the belt ca[...]

6G7 ENGINE (E - W) - Timing Belt 1 1A-6-3 (7) Badly worn teeth. Initial stage: Canvas is worn (fluffy canvas fibres are visible, rubber is gone and colour has changed to white. Canvas texture is not clear). Last stage: Canvas is worn out a nd rubber exposed a nd its width is reduced. (8) Missing tooth. AUT O-TENSIONER (1) Check for oil leaks. If oi[...]

6G7 ENGINE (E - W) - Timing Belt 1 1A-6-4 2 Slowly close the vice to force th e rod in until th e set hole (A) of the rod is lined up with the set hole (B) of the cylinder . 3 Insert a metal wire (1.4 mm in diameter) into the set holes. 4 Remove the auto-tensioner from the vice. (2) Install the auto tensioner on the cylinder block through the oil p[...]

6G7 ENGINE (E - W) - Timing Belt 1 1A-6-5 (8) Using t he Special T ool, turn the crankshaft counter- clockwise a quarter turn, then turn it clockwise and align the timing marks. Make sure that all timing marks are in alignment. Timing mark Crankshaft sprocket Right bank Left bank Timing mark Camshaft sprocket Camshaft sprocket T ensioner pulley Aut[...]

6G7 ENGINE (E - W) - Timing Belt 1 1A-6-6 (9) Set the Special T ool and a torque wrench on the tensioner pulley . (10) T orque the tensioner pulley to 4.4 Nm. (1 1) While holding the tensioner pulley , tighten its centre bolt to the specified torque. (12) T urn the crankshaft 2 turns clockwise and let it stand for approx. 5 minutes. (13) Remove the[...]

6G7 ENGINE (E - W) - Intake Manifold 1 1A-7-1 7. INT AKE MANIFOLD REMOV AL AND INST ALLA TION 7EN0874 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 13 Nm 11 N m 11 N m 29 Nm 18 Nm 18 Nm 18 Nm 18 Nm 21 Nm 9N m 9N m 18 Nm 14 Removal steps 1. Engine harness 2. Injector and delivery pipe 3. Insulator " H A 4. [...]

6G7 ENGINE (E - W) - Intake Manifold 1 1A-7-2 INST ALLA TION SERVICE POINTS " A A O-RING / W A TER PIPE (1) Wet the O-ring (with water) to facilitate assembly . Caution D Keep the O-ring of oil or grease. " B A THERMOST A T (1) Install t he thermostat in th e thermostat case with its jiggle valve located at the t op position. " C A H[...]

6G7 ENGINE (E - W) - Intake Manifold 1 1A-7-3 " F A INT AKE MANIFOLD (1) T ighten the nuts on the right bank to 5 - 8 Nm. (2) T ighten the nuts on the left bank to the specified torque. Then tighten the nuts on right bank to the specified torque. (3) T ighten the nuts on the left bank and those on the right bank again in that order . " G [...]

6G7 ENGINE (E - W) - Exhaust Manifold & W ater Pump 1 1A-8-1 8. EXHAUST MANIFOLD & W A TER PUMP REMOV AL AND INST ALLA TION 7EN0966 1 2 3 4 5 6 7 8 9 49 Nm 13 Nm 35 Nm 13 Nm 49 Nm 41 Nm 23 Nm Removal steps 1. Heat protector , rear 2. Exhaust manifold, rear " B A 3. Exhaust manifold gasket, rear 4. Heat protector , front 5. Engine lift [...]

6G7 ENGINE (E - W) - Exhaust Manifold & W ater Pump 1 1A-8-2 INST ALLA TION SERVICE POINTS " A A O-RING / W A TER PIPE (1) Wet the O-ring (with water) to facilitate assembly . Caution D Keep the O-ring free of oil grease. " B A EXHAUST MANIFOLD GASKET (1) Install gaskets with number 1 , 3 and 5 embossed on their top side to the right [...]

6G7 ENGINE (E - W) - Rocker Arms and Camshaft 1 1A-9-1 9. ROCKER ARMS AND CAMSHAFT REMOV AL AND INST ALLA TION Apply engine oil to all moving parts before installation. 7EN0879 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 12 Nm 31 Nm 3.4 Nm Removal steps 1. Rocker cover 2. Gasket 3. Oil seal " E A 4. Oil seal A A " 5. Rocke[...]

6G7 ENGINE (E - W) - Rocker Arms and Camshaft 1 1A-9-2 REMOV AL SER VICE POINTS A A " LASH ADJUSTER (1) Before removing t he rocker arms a nd rocker arm shafts, install the Special T ools to prevent the lash adjusters from falling off. INSPECTION CAMSHAFT (1) Measure the cam height. Standard value: IN: 37.71 mm EX: 37.14 m m Limit: IN: 37.21 m[...]

6G7 ENGINE (E - W) - Rocker Arms and Camshaft 1 1A-9-3 INST ALLA TION SERVICE POINTS " A A CAMSHAFT (1) Before attaching the camshafts, apply engine oil to the journals an d cams. T ake care not to confuse the right bank and left bank camshafts. NOTE The right bank camshaft has 4-mm-wide slits in the rear end surface. (2) Make sure the camshaf[...]

6G7 ENGINE (E - W) - Rocker Arms and Camshaft 1 1A-9-4 " D A ROCKER SHAFT SPRING (1) Insert the rocker shaft spring at a slant with respect to the spark plug guide a nd install it normal to the guide. " E A OIL SEAL PWEE9615 E Dec. 1996 Mitsubishi Motors Corporation 7EN0723 Rocker shaft spring 6AE0164 MD998713 7EN0724 Left bank side MD998[...]

6G7 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-10-1 10. CYLINDER HEAD AN D V AL VES REMOV AL AND INST ALLA TION Apply engine oil to all moving parts before installation. 7EN0915 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 108 Nm Removal steps A A " 1. Cylinder head bolt 2. W asher 3. Cylinder head assembly 4. Cylinder head g[...]

6G7 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-10-2 REMOV AL SER VICE POINTS A A " CYLINDER HEAD BOL T A B " RET AINER LOCK (1) Attach a tag with the cylinder No. an d mounting location to the detached valves, springs an d other parts an d store them for reassembly . A C " V AL VE STEM SEAL Caution D Do not reuse the stem seal.[...]

6G7 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-10-3 INSPECTION CYLINDER HEAD (1) Check the cylinder head for water leaks, gas leaks, damage or cracks before washing it. (2) Completely remove oil, fur , sealer , carbon and t he like. After washing the oil passages, blow air through them to make sure they are not clogged. (3) T o ensure flatnes[...]

6G7 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-10-4 V AL VE GUIDE (1) Measure the clearance between the valve guide an d the valve stem. When t he clearance exceeds t he specified limit, change the valve guide or the valve or both. Standard value: Intake 0.02 - 0.04 mm Exhaust 0.04 - 0.06 mm Limit: Intake 0.10 mm Exhaust 0.15 mm V AL VE SEA T[...]

6G7 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-10-5 V AL VE GUIDE REPLACEMENT PROCEDURE (1) Remove the snap ring from the exhaust valve guide. (2) Pull out to th e cylinder block side using a press. (3) Machine the valve guide hole in the cylinder head to match the oversize valve guide to be press fitted. Caution D Do not press fit another va[...]

6G7 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-10-6 " B A V AL VE SPRING (1) Install the valve spring painted red side up. " C A V AL VE RET AINER LOCK (1) Using Special T ool install th e valve retainer lock. PWEE9615 E Dec. 1996 Mitsubishi Motors Corporation 6EN0544 Stem seal Spring seal Spring retainer Identification colour 7EN08[...]

6G7 ENGINE (E - W) - Oil Pan and Oil Pump 1 1A-1 1-1 1 1. OIL P AN AND OIL PUMP REMOV AL AND INST ALLA TION Apply engine oil to all moving parts before installation. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Nm 23 Nm 9.8 Nm 41 Nm 13 Nm 18 Nm 9.8 Nm 11 N m 5.9 Nm 11 N m 39 Nm 44 Nm 9.8 Nm 9.8 Nm 11 N m 7EN0893 Removal steps " [...]

6G7 ENGINE (E - W) - Oil Pan and Oil Pump 1 1A-1 1-2 REMOV AL SER VICE POINTS A A " OIL P AN (LOWER) (1) Apply wood to the oil pan side an d remove the oil pa n lower with a plastic hammer . A B " OIL P AN (UPPER) (1) Detach th e bolt (1) shown at left. (2) Detach all other bolts. (3) Screw a bolt into bolt hole A shown (at both ends) to [...]

6G7 ENGINE (E - W) - Oil Pan and Oil Pump 1 1A-1 1-3 (2) Check for side clearance. Standard value: 0.04 - 0.10 mm (3) Check for body clearance. Standard value: 0.10 - 0.18 mm Limit: 0.35 mm INST ALLA TION SERVICE POINTS " A A OIL PUMP INNER AND OUTER ROTORS (1) Install th e oil pump outer rotor in t he proper direction using the setting mark d[...]

6G7 ENGINE (E - W) - Oil Pan and Oil Pump 1 1A-1 1-4 " C A OIL SEAL " D A OIL P AN (UPPER) (1) Clean the gasket coating surfaces of t he cylinder block and the oil pan upper . (2) Squeeze out a 4 mm bead of liquid gasket and coat the coating surface with it. NOTE During attachment of the oil pan upper , the sealer must not be expelled fro[...]

6G7 ENGINE (E - W) - Oil Pan and Oil Pump 1 1A-1 1-5 " E A OIL P AN (LOWER) (1) Clean the gasket coating surfaces of the oil p an upper and t he oil pan lower . (2) Squeeze out a 4 mm bead of liquid gasket and coat the coating surface with it. Liquid gasket: MITSUBISHI GENUINE Part No. MD970389 or equivalent " F A OIL FIL TER (1) Clean th[...]

6G7 ENGINE (E - W) - Piston and Connecting Rod 1 1A-12-1 12. PISTON AN D CONNECTING ROD REMOV AL AND INST ALLA TION 7EN0424 1 2 3 4 5 6 7 8 9 10 11 12 51 Nm Apply engine oil to all moving parts before installation. Removal steps 1. Connecting rod cap n ut A A "" E A 2. Connecting rod cap 3. Connecting rod bearing, lower " D A 4. Pist[...]

6G7 ENGINE (E - W) - Piston and Connecting Rod 1 1A-12-2 REMOV AL SER VICE POINTS A A " CONNECTING ROD CAP (1) Enter th e cylinder No. on the side of t he large end of the connecting rod to facilitate reassembly . A B " PISTON PIN The special piston pin setting tool (MD998780) consists of the parts shown at left. (1) Insert the special pu[...]

6G7 ENGINE (E - W) - Piston and Connecting Rod 1 1A-12-3 INSPECTION PISTON RING (1) Check the clearance between the piston ring and the ring groove. If it exceeds the specified limit, change the ring or the piston and piston ring. Standard values: No. 1 0.03 - 0.07 mm No. 2 0.02 - 0.06 mm Limit: 0.1 mm (2) Place the piston ring in the cylinder bore[...]

6G7 ENGINE (E - W) - Piston and Connecting Rod 1 1A-12-4 INST ALLA TION SERVICE POINTS " A A PISTON PIN (1) Measure the dimensions of t he following parts and portions: A: Piston pin mounting portion B: Distance between piston bosses C: Piston pin D: Connecting rod (2) Calculate by substituting each measured value into the following equation: [...]

6G7 ENGINE (E - W) - Piston and Connecting Rod 1 1A-12-5 " B A OIL RING (1) Install th e oil ring spacer into th e piston ring groove. Next install the upper side rail into the piston ring groove, and then install the lower side rail. NOTE D There is no distinction between the upper and lower surfaces of the side rail and spacer . D The spacer[...]

6G7 ENGINE (E - W) - Piston and Connecting Rod 1 1A-12-6 " D A PISTON AND CONNECTING ROD (1) Liberally coat the circumference of the piston, piston ring, and oil ring with engine oil. (2) Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in th e figure. (3) Rotate the crankshaft so that the crank pin is positioned at th[...]

6G7 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate 1 1A-13-1 13. CRANKSHAFT , FL YWHEEL AND DRIVE PLA TE REMOV AL AND INST ALLA TION Apply engine oil to all moving parts before installation. 7EN1032 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 74 Nm 11 N m 74 Nm 11 N m 93 Nm Removal steps 1. Adaptor plate 2. Drive plate 3. Plate 4. Adaptor p[...]

6G7 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate 1 1A-13-2 INSPECTION CRANKSHAFT OIL CLEARANCE (PLASTIGAUGE METHOD) NOTE If the oil clearance exceeds th e limit, replace t he bearing, and crankshaft if necessary . This crankshaft oil clearance can be measured easily by using a plastic gauge, as follows: 1 Remove oil and grease and any othe[...]

6G7 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate 1 1A-13-3 BORING CYLINDER (1) Oversize pistons to be used should be determined on the basis of th e largest bore cylinder . Piston size identification Size Identification mark 0.50 mm O.S. 0.50 1.00 mm O.S. 1.00 NOTE Size mark is stamped on the piston top. (2) Measure outside diameter of pis[...]

6G7 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate 1 1A-13-4 INST ALLA TION SERVICE POINTS " A A CRANKSHAFT BEARING When bearing replacement is required, select and install the correct bearing by the following procedure. (1) Measure th e crankshaft journal diameter and confirm its classification from the following table. In the case of [...]

6G7 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate 1 1A-13-5 (3) Select the correct bearing from the above table on the basis of the identification data confirmed at steps 1 and 2. Example D If the measured value of a crankshaft journal outer diameter is 59.996 mm, the journal is classified as “1” in the table. In case the crankshaft is [...]

6G7 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate 1 1A-13-6 (4) Check the en d play . If it exceeds th e limit value, replace the thrust bearing. Standard value: 0.05 - 0.25 mm Limit: 0.3 mm " C A CRANKSHAFT REAR OIL SEAL (1) Using the Special T ool, press-fit a new crankshaft rear oil seal into the seal case. " D A OIL SEAL CASE [...]

NOTES[...]