MITSUBISHI L300 WORKSHOP MANUAL FOREWORD This Workshop Manual contains procedures tor removal, disassembly, inspection, adjustment, reassembly and installation, etc, for service mechanics. Use the following manuals in combination with this manual as required WORKSHOP MANUAL ENGINE GROUP) = PWEE OOO (Looseleaf edition} ELECTRICAL WIRING PHWE8916 PARTS CATALOGUE ‘AO131809AC All information, illustrations and product descrip- tions 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 Pe SURLY © Mhsubishi Motors Corporation Mar. 1980 Lubrication Fuel ..... Cooling Intake and Exhaust .... Engine Electrical .. Emission Control Clutch Manual Transmission Propeller Shaft Front Axle ...... Rear Axle .. Wheel and Tyre ..... Power Plant Mount ......... Front Suspen: Rear Suspension ........ Service Brakes .. Parking Brakes .. Steering ... Body Body Repair ... Exterior .. Interior ...... Chassis Electrical... Heater and Ventilation ... * PS : ae} roe) EN) w]wlw]olw]ro G)B/WIN}= qe eae BIN aE)GENERAL HOW TO USE THIS MANUAL .. Scope of Maintenance, Repair and Servicing Explanations .............0+- Definition of Terms ...... Explanation of Manual Contents ... VEHICLE IDENTIFICATION... Vehicle information Code Plate ...... Models Model Code Chassis Number Ye 2e Bww CONTENTS otca-— DIMENSIONAL VIEWS ... MAJOR SPECIFICATIONS ... PRECAUTIONS BEFORE SERVICE ... SUPPORT LOCATIONS FOR LIFTING AND JACKING 7 STANDARD PARTS-TIGHTENING-TORQUE TABLE00-2 NOTESGENERAL - How to Use This Manual 00-3 HOW TO USE THIS MANUAL SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS This manual provides explanations, ete. concerning procedures for the inspection, maintenance, repair and servicing of the subject model. Note, however, that for engine- and transmission-related compo- nent parts, this manual covers only on-vehicle inspections, adjustments, and the removal and installation procedures for major components. For detailed information conceming the inspection checking, adjustment, disassembly and reassem- bly of the engine, transmission and major compo- nents after they have been removed from the vehicle, please refer to the separate manuals covering the engine and the transmission SERVICE ADJUSTMENT PROCEDURES “Service Adjustment Procedures” are procedures for performing inspections and adjustments of particularly important locations with regard to the construction and for maintenance and servicing, but ather inspections {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 TERMS: STANDARD VALUE Indicates the value used as the standard tor judging the quality of a part or assembly on inspection or the value to which the part or assembiy is corrected and adjusted. It is given by tolerance uMIT Shows the standard for judging the quality of a part or assembly on inspection and means the maxi- mum of minimum vaiue 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 com pleted in a shorter time) CAUTION Indicates the presentation of information particu- larly 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.00-4 GENERAL - How to Use This Manual EXPLANATION OF MANUAL CONTENTS Indicates procedures to be per- formed before the work in that section is started, and procedures to be performed after the work in that section is finished, Maintenance and Se icing Procedures ¢ Removal steps. The part designation number cor responds to the number in the illustration to indicate removal steps. © Disassembly steps: The part designation number cor responds to the number in the illustration to indicate disassembly steps. © Installation steps: Specified in case installation is impossi- ble in reverse order of removal steps. Omitted if installation is possible in reverse order of removal steps. © Reassembly steps: Specified in case reassembly is impossible in reverse order of disassembly steps Omitied if reassembly is possible in reverse order of disassembly steps (1) A diagram of the component parts is provided near the frant of each section in order to give the reader a better understanding of the installed cond tion of component parts (2) The numbers provided within the diagram indicate the sequence for maintenance and servicing pro- cedures; the symbol MM indicates a nonreusable part; the tightening tor que is provided where applicable Indicates (by symbols) where lubrication is necessary. In this ‘example, multipurpose grease is to applied (where indicated) to the steering gear box. 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 28 majat maintenance and service points and explained in detail | 4 Indicates that there are essential points for removal or disassembly. 4: Indicates that there are essential points for in. stallation or reassembly. ‘Symbols for Lubrication, Sealants and Adhesives Sy Grease Information concerning the locations for lubrication, (multipurpose grease and for application of sealants and adhesives is pro- unless there is a brand or vided, by using symbols, in the diagram of component type specified) parts or on the page following the component parts page. and explained s@t Sealant or adhesive I Breke fluid oF automatic transmission tu SH Engine oil, gear oil or air conditioner compressor oilGENERAL - How to Use TI Manual 00. Indicates the group umber 37-24. Indicates the page number. STEERING - Power Steering Gott Box POWER STEERING GEAR BOX <———_____ [REMOVAL AND INSTALLATION Indicates the group title Indicates the section tile, This information is applicable for vehicles destined for Europe. This information is also applicable to vehicles (with Specifications for Europe) that are ship ped to General Export destinations ‘Sig ae sl —t ire eens pS Repair kit or set parts are] [shown, (Only very frequently used parts are shown.) Denotes non. su} reusable part H Denotes tighten ing torque. 37-28 [STEERING ~ Power Stewing Gear Box The title of the page (follow cena Operating procedures, cau- Ey ne ions, etc. on removal, in. 6 FSS a rary voce [stallation, disassembly and Spi pn) OSU Tone ae teassembly are described SERVICE POINTS OF REMOVAL" way 5. DISCONNECTION OF JOWT ASSEMBLY AND sere This number corresponds tothe] SOULE LA Ay [umber appearing in “Removal =, steps", “Disassembly steps | ORMOVAL DF ERGO ER BAT VOWS instalation steps" Seaton Feassembly steps’ ‘Te prevant the special tol rom jmng out secure & by ovat 'naaoy pare ing the page on which the iagram of component parts BH 2000 @ como 's presented) indicating. the ee locations of lubrication and sealing procedures,00-6 GENERAL - Vehic! identification VEHICLE IDENTIFICATION VEHICLE INFORMATION CODE PLATE e100 Vehicle identification plate is riveted on the passenger's seat pan. ‘The plate shows model code, engine model, transmission model and body color code. 1. MODEL Lo32P__YZL6 t Model series Vehicle model 2. ENGINE 4G32 ~ -——- Engine model 3. EXT 7 1{_____——— Exterior code. 4. TRANSAXLE R5M21 4625 T Final gear ratio Transmission model 6. COLOR, INT OPT S49 87V 03V — Equipment code Interior colour code Body colour code For monotone colour vehicles, the body colour code shall be indicated. For two-tone or three-tone colour vehicles, each colour code only shall be indicated in series. MODELS towa-— Model code Engine model Transmission model Fuel supply system LO32PYZL6R6 4632 (1598 cc (96 cuin)] | R6M21 (S-speed, manual, | Carburettor ri column shift) LO3PYZL6RE 4056 [2477 oc (151 cu.in} InjectionGENERAL ~ Vehicle Identification 00-7 MODEL CODE eo108—— + * T t t T f 1234567 1. Vehicle line 5, Transmission type L-MITSUBISH! L300 Z—5-speed manual transmission, Column shift 2, Engine displacement 6. Steering wheel location 032 — 1598 oc (96 cu. in.), Petrol L~Left hand 039 - 2477 cc (151 cu. in), Diesel R— Right hand 3. Body type 7. Destination P— With frame 6 For Europe 4. Body style Y~ Cab and Chassis ee CHASSIS NUMBER 1ocAP ‘The chassis number is stamped on the side wall of the frame near the right rear spring hanger. 032 P POL A 4 00001 A alee ieee 8 91011 12 1. Asia 7. Vehicle type 2. Japan 8. Body style 3. A-—For Europe, right hand drive P— Cab and Chassis, B — For Europe, left hand drive 9, Model year 4. Sort L— 1990 L—Commercial car 10, Plant 5. Development order A- Mizushima Motor Vehicle Works 032 - 1598 cc (96 cu. in.), Petrol 11. Transmission type 039 — 2477 cc (161 cu. in.), Diesel 4—5-speed manual transmission 6. Body type 12. Serial number P—With frame00-8 GENERAL — Dimensional Views DIMENSIONAL VIEWS ane 7 A = 8 é [= . I | a oo vais) state et etet ty z aa i jum se] [cesaat_saewes : i ial oe ee wore *1: 4,105 (161.6) petri aas8 pel *? : 920 (36.2) eres eae rece m2 000015GENERAL — Major Specifications 00-9 MAJOR SPECIFICATIONS Items Loa2PYZL6/RE LOaSPYZLB/RB Dimensions mm in.) Dverall length 4,105 (161.6) 4,205 (165.6) Dverall width 1,695 (66.7) 1,695 (66.7) Dyerall height (unladen) 1,795 (70.7) 1,795 (70.7) Wheelbase 2,200 (88.6) 2.200 (86.6) Track-front 1,440 (567) 1,440 (66.7) Track-rear 1,980 64.3) 1,380 (64.3) Overhang Front 985 (38.8) 985 (38.8) Rear 920 (36.2) 1,020 (40.2) Ground clearance (unladen) 195 7.7) 195 7.7) Weight kg tbs.) Ker weight 970 (2.138) 1,065 (2.347) Front axle load 685 (1,510) 745 (1,642) Rear axle load 285 (628) 320 (705) ‘Max, gross vehicle weight 2,208 (4,861) or 2,205 (4,881) or 2/200 (4.850)*" 2200 (4.850)* +? Front axle load 1,150 {2.5351 1,150 (2.535) Rear axle load 1,830 (2,932) 1.990 (2,932) Seating capacity 3 3 Porformance Max. speed kmh (mph) | 130 (80) 120 (75) Min. turning radius m (f.) | 8.9 (29) 89 (29) Engine Mode! 4g32 4056 Total displacement ce (cuin.) | 1,598 (96) 2.477 (181) Fuel System Fuel supply system Carburettor Injection Fuel pump type Mechanical (Diaphragm) | Mechanical (Vane) Fuel tank capacity lit (US.gal. mpgal) | $5 (145, 120) 55 (14.5, 12.0) Cooling Sytem Cooling capacity lit, USats., imp.ats.) | 7.1 (7.5, 6.2) 8.4 183, 7.41) Guten Type Dry singledise clutch with | Dry singledise clutch with diaphragm spring iephragm spring NOTE 1: Vehicles for West Germany +?) Vehicles for Switzerland00-10 GENERAL — Major Specifications items Los2PYZLe/Re Log9Pyz.eine Transmission Type 5.speed manual, column shift Model RBM21 Wheels Tye size T75RI4C-8PR Disc wheel size 14 x 8) Suspension Type Front Rear Double wishbone Parallel leaf spring Steering System Type Recirculating ball and nut Service Brakes Type Hydraulic brake system with servo Front Dise Rear Drum Parking Brake Mechanical type, acting on rear whee's Electrical Syste Battery type — Voltage — Capacity 5SD23R-12V-4B Ah or | 95D31R— 12-64 Ah or 65D23R - 12V—52 An (85B24R — 12 ~ 36 An) x 2GENERAL - Precautions Before Service 00-11 mm fin) 500088 PRECAUTIONS BEFORE SERVICE ena. SERVICING THE ELECTRICAL SYSTEM 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 shortcircuiting. Caution Before connecting or disconnecting the negative (-) cabl. be sure to turn off the ignition switch and the lighting ‘switch. (lf this is not done, there Parts being damaged.) the possibility of semiconductor VEHICLE WASHING It 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 © Spray nozzle distance: 300 mm {11.8 in.) or more © Spray pressure 4 MPa (40 kg/cm, 569 psi) or less © Spray temperature 82°C (180°F) or less @ Time of concentrated spray to one point within 30 sec.00-12 GENERAL — Support Locations for Lifting and Jacking SUPPORT LOCATIONS FOR LIFTING AND JACKING eae == Caution Do not support the vehicle at locations other than specified supporting points. If do so, this will cause damage etc. SUPPORT POSITIONS FOR A GARAGE JACKGENERAL — Support Locations for Lifting and Jacking SUPPORT POSITIONS FOR AXLE STANDS, A SINGLE-POST LIFT OR FREE WHEEL TYPE AUTO LIFT Caution When service procedures require removing rear suspension, fuel tank and spare tyre, place ad- ditional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of centre of gravity changes. 00-13 ‘00001800-14 GENERAL — Support Locations for Lifting and JackingGENERAL STANDARD PARTS-TIGHTENING-TORQUE TABLE Each 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 torque 00-15 The valves 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 selftapping screws or self-locking nuts are used Be ronal | paon | Toraue Nn Ware Fs) eee (rm) tren Head mark @ Ms oa 2-302-03, 14-22) Me 10 | 4-6 104-06, 29-43) 9-14 09-14, 65-10) Head onark @ 4-6 (04-06 29-43 7-1 (7-14, 61-80) 17-26 (1.7-26. 12-10) 55 (35. Heed mark © 8-7 (05-07, 36-51) 8-12 (08-12, 68-87) 20-90 (20-30, 14-22) 19-28 |1.9-28, 14-20 3 | 84-50 (24-50, 25-96) 70-95 (7.0-95, 51-69) 110 5-11, 61-80) wna 18 [60-85 (60-85, 43-61) 120-160 (12-16, 87-116) | 130-180 (13-18, 94-130) | we | 95-190 (05-13, 69-98) | 180240 (18-24, 190-174) | 200-270 20-77, 145-185) | 140-190 (14-19. 101-137) | 260-950 (6-25, 188-253) | 300-400 (90-40, 217-789) 1-26, 137-188) | 360-480 (96-48, 260-347) | 410-560 (41-6, | 68-269) | 480-50 (48-65, 947-470) _ | 560-750 (66-76, Mea Lis | 340-60 (24-46, 246-335) | 690-860 (69-06, 456-622) | 74011 Flange bolt and nut tightening torque Ban rorirat [ayy | Torave Ni (am, fs) : trom jim) Hees mek @ Head mare @) Head mark @) [ws j10.-—«([ 4-6 (04-08, 29-49) 8-12 (08-12, 88-87) 9-14 (09-14, 65-10) M8 ys [30-18 40-15, 72-11) | 19-28 49-28 14-20) 22.93 (2.2433, 16-24 M0 faa [21-a1@ 1-3, 16-22 39-60 (99-60, 28-43) 50-85 (50-65, 36-47) [M0 [a5 [79-29 19-29, 14-21) 26-54 (36-54, 26-29) 45-65 (45-65, 39-47) pwi2 «(125 [38-58 (36-55, 27-40) | a0-110 @0-11, 68-20) 90-120 (90-12, 65-87) Miz | 175 [34-82 (94-52, 25-36) ‘| 70-95 70-95 51-69) _~| 85-110 185-1 Taper thread tightening torque Torque New lkgr, fllbs) Thread size Female thread material: Light alloy 5-8 (05-08, 36-58) 8-22 108-12, 58-87) | 20-30 (20-30. 14-22) 40-55 (40-65, 29-40) NPTF 6 [Female thread materia: Steel 8-12 (08-12, 88-87) 16-20 (16-20, 12-14) 95-45 (35-45, 25-33) 60-75 (60-75, 43-54) NOTE: NPIF is dry seat pipe thread, while PT is pipe thread.NOTESENGINE CONTENTS ENGINE <4G32> SPECIFICATIONS . General Specifications Service Specifications Torque Specifications Lubricants, Sealants and Adhesives SPECIAL TOOLS ENGINE ADJUSTMENT Radiator Cap Valve-opening Pressure Check Battery Inspection Spark Plug Check and Cleaning Drive Belt Tension Inspection and Adjustment Valve Clearance Inspection and Adjustment 7 Ignition Timing Inspection and Adjustment 8 Idling Speed/idle Mixture Inspection and Adjustment 3 Dashpot Inspection and Adjustment 10 Manifold Vacuum Inspection 10 Compression Pressure Inspection W Timing Beit Tension Adjustment 12 CAMSHAFT AND CAMSHAFT OIL SEAL . OIL PAN .. CYLINDER HEAD GASKET 7 TIMING BELT ........ CRANKSHAFT OIL SEAL .... ENGINE AND TRANSMISSION ASSEMBLY ....... BR WOONNNN poses 8 24 ENGINE <4D56> ‘SPECIFICATIONS : General Specifications 28 Service Specifications 28 Torque Specifications 29 Lubricants 23 Sealants and Adhesives ae 29 SPECIAL TOOLS eee 30 ENGINE ADJUSTMENT ......ccssccscceeesss 31 Radiator Cap Valve-opening Pressure Check’ : 2 3 Battery Inspection 31 Drive Belt Tension Inspection and Adjustment 32 Valve Clearance Inspection and Adjustment 32 Injection Timing Inspection and Adjustment 34 Idling Speed Inspection and Adjustment ... 36 Compression Pressure Inspection 37 Timing Belt Tension Adjustment 37 Timing Belt "B” Tension Adjustment 38 CRANKSHAFT PULLEY .. CAMSHAFT AND CAMSHAFT OIL SEAL OIL PAN .. CYLINDER HEAD GASKET . 7 TIMING BELT AND TIMING BELT B CRANKSHAFT OIL SEAL .. ENGINE AND TRANSMISSION ASSEMBLY .. 5011-2 ENGINE <4G32> SPECIFICATIONS GENERAL SPECIFICATIONS ENGINE <4G32> — Specifications hems. Specifications Type. Invine, 4 cylinders Single over head camshaft Bore mm fin) | 769 (3.03) Stroke mm (in) | 86.0 (3:39) Total displacement ce (eu. in) | 1,597 (97.5) Compression ratio eat Firing order 1342 Valve timin Intake valve Opens (BTDC) 20 Closes (ABDC) 48° Exhaust valve Opens (BDC) sr Closes (ATDC) wr SERVICE SPECIFICATIONS ems: Specifications, Standard value Valve clearance at hot engine mm (ind Inlet side Exhaust side Ignition tiring laling speed tien Radiator cap valve-opening pressure kPa (kglcm®, psi) Spark plug gap mm (in.) Drive belt tension ) Limit Radiator cap valve-opening pressure kPa (kgicm’, psi 0.16 (0.0059) 0.25 (0.0088) 5°42" BIDC 80050 78-105 (0.75 1.05, 11-15) 07-08 (0.028 0.031) 9.0- 11.5 10.35 - 0.45) 65 (0.65, 9.2)ENGINE <4G32> — Specifications 11-3 TORQUE SPECIFICATIONS Tem Nn vam Tbs ‘emator Support bot nt m0-% [20-25 | 14-18 Aerator brace bol 18 12-18) fen Rocker cover bot signee asta lads Rocker shaft assembly to cylinder head assembly 19-21 19-21 | 14-15 Rocker shalt assembly to onder heed asserély wiz |ro-ia fre i woz |10-12 fre Rocker er adjusting nut 2-12-18 few Camshaft sprocket s0-100 | 80-100 | 58-72 Distbutor rut jio-13 10-13. | 7-8 soak php 20-2 20-30 | 14-22 Ot pan 5-8 os-o8 | 43-57 Oil pan 57 os-07 | 26-50 Drain pug wea fas—ae | asa Timing bel front upper cover 1-12 19-12. J 7-8 Reed valve w-13 |to-13 fe Air pipe to exhaust manifold 2-30 |20-30 | 15-22 fr pie bracket to exhaust manifold ws fiz-1s foi CVinder head essembly yo-7 [70-75 | 51-58 Cankshatt pulley wae fis-18 | ni Timing bel lower cover wo fore 7-2 ee a0 |22-30 | 18-22 Flywheel assembly 10-140 | 13-14 | a4 101 Exhaust pipe to brecket y-20 [20-30 | 15-22 Transmission rountng bolt wsss [4a_55 | ot—40 Propeller shat so-00 |so-eo | a6 a3 ee go-42 |a0-42 | 22-20 Front gine support assembly mounting bok w-60 [40-80 | 20-26 LUBRICANTS enco- 8 ome Resorymended bbreant Guana (API classification) (U.S.qts., Imp.qts. ) a SE oF igher 4042 88 SEALANTS AND ADHESIVES eNce—& Teme Speci sealant Temas Sembee packing 3M ATO Part No.B660 oF equivalent | Nonalying sealant 0 pan | MUTSUBISH GENUINE PART Semiciyng sealant11-4 SPECIAL TOOLS ENGINE <4G32> — Special Tools/Eng Adjustment I a iz SIRES co tao a oar KX roses rcs toe] eaien ava clase le ee ee Riess crt | ec tu cen oe a pomodoro] Sowa ear ea seal instaler ENGINE ADJUSTMENT RADIATOR CAP VALVE-OPENING PRESSURE CHECK ceaco Standard value: 75-105 kPa {0.75 1.05 kg/em?, 11-15 psi) Limit: 65 kPa (0.65 kg/cm’, 9.2 psi) ENGINE COOLANT INSPECTIONENGINE <4G32> — Engit Indicator Write Green / / Charging Good necessary condition sovs814| Adjustment 11-5 BATTERY INSPECTION erase BATTERY VISUAL INSPECTION (1) The battery contains a visual test indicator which gives green signal when an adequate charge level exists, and white signal when charging is required. BATTERY VISUAL INSPECTION (2) Make sure ignition switch is in Off position and all battery feed accessories are Off. 1. Disconnect earth cable from battery before disconnecting (+) cable. 2, Remove battery from vehicle, Caution Care should be taken in the event battery case is cracked or leaking to protect hands from the electrolyte. A suitable pair of rubber gloves (not the household type) should be worn when removing battery by hand. 3. Inspect battery cartier for darnage caused by loss of acid from battery. If acid damage is present, it will be necessary to clean area with @ solution of clean warm water and baking soda Scrub area with a stiff bristle brush and wipe off with a cloth moistened with ammonia or baking soda in water, 4, Clean top of battery with same solutions as described in Step @). 5. inspect battery case and cover for cracks. If cracks are present, battery must be replaced 6. Clean the battery post with a suitable battery post clesning tool 7. Clean the inside surfaces of the terminal clamps with a suitable battery terminal cleaning tool. Replace damaged or frayed cable and broken terminal clamp. 8. Install the battery in vehicle 9. Connect (+) and (-} cables to battery in the order of mention. 10. Tighten the clamp nut securely ENGINE OIL LEVEL INSPECTION ennenako AIR CLEANER ELEMENT INSPECTION AND CLEANING exterane SPARK PLUG CHECK AND CLEANING ene Standard value: BPGES, BPRGES, W20EP, 0.7-0.8 mm W20EPR, W20EX-U (0.028 - 0.031 in.)ENGINE <4G32> Waster pare pulley { Uy / / Alternator ‘ pulley Crankshaft ulley 100001 20-25 of 20-25. 14-101/ gy No tkom_ttibs | WAR Engine Adjustment DRIVE BELT TENSION INSPECTION AND ADJUST- MENT enaay 1. Check belt for damage or wear. Confirm that belt is set correctly in pulley groove. NOTE If the belt “squeals” or slips, check belt for friction, damage or breaks and check pulley contact surface for damage. 2. Press at 100N [10 kg, 22 Ibs.) mid-point of belt between two pulleys as indicated in the illustration, Measure drive belt flex. Standard value: 7-10 mm (0.28 - 0.39 in.) Caution Measure belt flex between specified pulleys (<=: 3, Adjust alternator drive belt deflection by the following proce: dures {1) Loosen alternator pivot boit nut and brace bolt (2) Adjust belt deflection by using a rod as a lever against the alternator stator pushing it into the proper position, Standard value: 7-10 mm (0.28 - 0.39 in.) (3) Retighten the alternator brace boit and support pivot bolt nut to the specified torque.ENGINE <4G32> Engine Adjustment 11-7 Timing Timing belt mark upper’ cover Camshaft sprocket side VALVE CLEARANCE INSPECTION AND ADJUST- MENT 1, Start the engine and allow it to warm up until the engine coolant temperature reaches 80 to 90°C (176 to 194°F) Remove air hom Remove rocker cover. Remove timing belt front upper cover. AON 5, Tum crankshatt clockwise and align with camshaft sprock- et timing mark. 6. Check that vaive clearance indicated in the diagram is at the standard value Standard value (hot engine): Intake Exhaust 0.15 mm (0.0059 in.) 0.25 mm (0.0098 in.) 7. valve clearance is off the standard value, loosen rocker aim adjusting screw locking nut, Use thickness gauge and adjust valve clearance by turning adjusting screw. 8 Secure rocker arm adjusting screw with screwdriver so that is it will not rotate and tighten locking nut 9. Rotate clockwise the crankshaft one complete tum (360° degree). 10. Check that valve clearance indicated in the diagram is at the standard value. 11. Repeat steps 7. and 8. to adjust the valve clearance of remaining valves.11-8 ENGINE <4G32> — Engine Adjustment DENZ30 —-= Ba 08 Mm, ‘ylinder heas Semicircular packing senooea| Timirg ant [ a _N BSA \ a ) PSA 12, When installing the rocker cover assembly to the cylinder head, apply @ coating of the specified sealant to the semicircular packing and the cylinder head top surface, and then tighten at the specified torque Specified sealant: 3M ATD Part No. 8660 or equivalent Caution If they are overtorqued, a deformed rocker cover or oil leakage could result. IGNITION TIMING INSPECTION AND ADJUST- MENT sentevane 1. Before inspection and adjustment, set vehicle in the following condition. © Engine coolant temperature: 80-90°C (176-194°F) © Lamps and all accessories: OFF © Transmission: Neutral 2, Set timing light and tachometer. 3. Check to make sure the engine speed is between 600 to 900 rnin, 4. Chock that basic ignition timing is within the standard value. Standard value: 5° + 2° BTDC 5. IF not within the standard value, loosen distributor fixing nut and adjust by rotating d distributor body. 6. After adjusting, tighten the fixing nut taking care that the distrbutor does not move. NOTE Sealing tape is attached to all vehicles when new,ENGINE <4G32> — Engine Adjustment 11-9 Vacuum hose se u0s12 0398289 erusis IDLING SPEED/IDLE MIXTURE INSPECTION AND ADJUSTMENT enrxen 1. Before inspection and adjustment, set vehicle in the following condition, (1) Engine coolant temperature: 80 — 90°C (176 - 194°F) (2) Lamps and all accessories: OFF (3) Transmission: Neutral 2. Set timing light and tachometer, 3. Start engine and run at idle. 4. Check the basic ignition timing. (Refer to P. 11-8) Standard value: 5° + 2° BTDC 5. Set catbon monoxide concentration analyzer. 6. Disconnect the vacuum hose (hose with white stripe) from the secondary ait control valve and piug the end of the vacuum hose. 7. Run engine at 2,000 — 3,000 r/min. and race 2~ 9 times, 8. Check the engine idle carbon monoxide concentration is within the standard value. Engine idling speed: 800 + 50 r/min. Carbon monoxide concentration: 1.0 + 0.5 % (at alr cut) If not within the standard values, adjust idle r/min and idle mixture to standard value with speed adjusting screw (SAS) and mixture adjusting screw (MAS), NOTE 1. Adjusting shall be done quickly and efficiently. 2. The carburettor is fitted with an idling limiter eap, so the special tool (MAS drivet) is required for adjusting carbon monoxide concentration. 9. Remove the plug from the end of the vacuum hose (hose with white stripel, and re connect the vacuum hose to the second- ary ait control valve. 10. Run the engine at 2,000 to 3,000 r/min, for 18 to 30 seconds. 11, Check to make sure the engine idiing speed and carbon monoxide concentration ate within the standard values spec- ified below. Engine idling speed: 800 + 50 r/min. Carbon monoxide concentration: 1.0% or less (at air in)11-10 ENGINE <4G32> -— Engine Adjustment Lever 8 adjusting ser owuotse DASHPOT INSPECTION AND ADJUSTMENT NOTE Dashpot inspection and adjustment must be done only after spark timing, engine idling speed and carbon monoxide concentration have been inspected and adjusted. 1. Before inspection and adjustment set vehicle in the following condition © Engine coolant temperature: 80 90°C (176 - 194°F) Lights and accessories: OFF ¢ Transmission: Neutral Set tachometer. Start engine and run at idle. Open throttle lever unti! dashpot rod makes full stroke, 5. Close the throttle valve gradually and locate the point at which cash pot lever A touches the dash pot rod (the point at which the dash pot rod begins to shrink]. Maintain the position of the throttle valve at that point, At this time, dash pot lever B shall be touching the dash pot adjusting screw. 6. Check the engine speed (engine speed at which the dash pot starts to operate). ‘Standard value: 1,600 + 200 r/min. 7. Ifthe engine speed is not within the standard value specified above, adjust the engine speed by turning the dash pot adjusting screw. 8, Starting from the time the throttle valve is released (from the position in which it was maintained), check the time required until the engine speed decreases to the check point engine speed (dash pot operating time) Standard value: Check point 900 r/min. Dash pot operating time 15-45 seconds 9. If the time is not within the standard range specified above. adjust the dash pot operating time by increasing or decreasing the dash pot operation starting speed within the tolerance limit, of the standard value. MANIFOLD VACUUM INSPECTION enewan 1. Start the engine and allow it to warm up until the temperature: of the coolant reaches 80° C to 90°C (176°F to 194°F}. 2. Set an engine tachometer in place. 3. Set the vacuum gauge at illustrated position on the intake manifold, 4. Start the engine and check that the idle speed is within the standard value range. Then read off the vacuum gauge. ‘Standard value: 500 mmHg (19.7 in.Hg) or more 5. If not at standard value, refer to following chart for cause and repairENGINE <4G32> — Engi Adjustment Symptom Probable cause Remedy Vacuum gauge reads under standard value but needle is stable Vecuum gauge needle fluctuates slowly ‘© Delayed ignition timing # Incorrect valve clearance © Aisiuel mixture too rich ‘© Adjust carburettor ‘Adjust ignition timing Adjust valve clearance Vacuum gauge reading decreases inregularty © Air fuel mixture too lean Adjust carburettor Vacuum gauge needle decreases about 30 ~ 160 mmHg (1.26.3 in Hg) inter- rmittently ‘© Improper seating of intake and exhaust valves, (Check, repair valve Vacuum gauge needle suddenly de- ‘creases about 250 mmHg (8 in. Hg) from standard value and then returns © Broken cylinder head gasket Replace cylinder head gasket COMPRESSION PRESSURE INSPECTION (1) Check to be sure that the engine oil, starting motor and battery ate in the normal condition. (2) Start the engine and allow it to warm up until the temperature of the coolant reaches 80° C to 90°C (176*F to 194°F). (3) Disconnect the high-tension cable. (4) Remove all 4 spark plugs. (5) Crank engine to discharge foreign material from cylinder Caution Cover spark plug hole with rag etc., to prevent foreign material scattering when discharged. Keep people away from spark plug hole side. If compression is measured with water, oil, fuel ete., inside cylinder from cracks, hot water, oil, fuel etc., will gush out from spark plug hole, which is very dangerous. (6) Set an engine tachometer in place. (7) Place a compression gauge adaptor and compression gauge in one of the spark plug holes. (8) Crank the engine with the throttle velve fully open, and measure the compression at the place where the compres- sion gauge indicator shows a stabilized reading, Limit (at engine speed of 250 r/min.): . 840 kPa (8.4 kg/cm?, 119 psi) (9) Conduct steps 7, 8 with all cylinders and confirm pressure differences of all cylinders is within the limit. jt: Max. 100 kPa (1.0 kg/cm?, 14 psi.) (10)1f, after the measurement, the compression is below the fimit put a small amount of engine oil through the spark plug hole into the oylinder; then measure the compression once again and determine the cause of the malfunction (T1IF, after oil is added, the compression rises, the cause of the malfunction is a wom or damaged piston ring andor cylinder inner surface. If, however, the compression does not rise, the cause is a bad valve or a bad gasket. For information regarding the servicing procedures for these causes of malfunction, refer to the ENGINE AND TRANSMIS- SION MANUAL.11-12 Timing mark Timing \, we 2reeth Timing mark, Timing ber _ Nut Bott ENGINE <4G32> — Engine Adjustment TIMING BELT TENSION ADJUSTMENT evFFO8 1 2, Remove timing belt front upper cover. Turn the crankshatt clockwise to align the timing mark on the cover with the position the timing mark on the camshaft sprocket, Turn the crankshatt clockwise by two crankshaft sprocket teeth Femove the access covers, Loosen the timing belt tensioner mounting nut and bott, Caution Do not loosen the nut and bolt more than necessary. They could drop in the lower cover. Insert a screwdriver from the top of the timing belt lower cover and push the tensioner in the belt tensioning direction and then release 1g @ screwdriver, use care not to damage Tighten the timing belt tensioner mounting nut and bolt Caution Tighten the tensioner nut (upper) first and then bolt (lower).it 11-13 8. Install access cover. Access cover is easily installed by sliding Mies hook between guide projections. 9. Install timing belt front upper cover. ENGINE <4G32> — Engine Adjust Access cover Guide projections Adjusting hate ~ SENOT711-14 ENGINE <4G32> — Camshaft and Camshaft Oil Seal CAMSHAFT AND CAMSHAFT OIL SEAL ema REMOVAL AND INSTALLATION Post installation Operation Engine Adjustinent (Refer to P. 11-4 ) 10-121Nm 1.0- 1.2 kgm ~ 7 7-3 filbs. Removal steps fe ci 1, Hose, = 2. Breather hose 3. Secondary air supply hose 4 Spare pg cable. 5 Datrbstor Dena 4 8: Rocker cover 5 Semecieulor packing Gaia: 8. Timing belt (eter to P. 11-21.) 5: Camshaft sprocket 18. Timing Det under upper cover er OF seal 12, Rocker arm, rocker shaft assembly 13, Camshaft eae 3M ATD Part No. 8660 or equivalentENGINE <4G32> — Camshaft and Camshaft Oil Seal 11-15 ©, seal ensz ‘Apply a light coating of fongine of to the gasket Surface within this area Front bearing Rocker cover ae SERVICE POINTS OF INSTALLATION 11. INSTALLATION OF OIL SEAL (1) Apply @ small amount of engine oil to the oil seal lip, then insert it to the cylinder head (2) Use the special tool (oil seal installer) to tap the oil seal into the cylinder head. 6. INSTALLATION OF ROCKER COVER (1) Apply a coating of engine oil to the gasket surface of the rocker cover (where shown in the figure}. (2) Install the rocker cover.11-16 ENGINE <4G32> — Oil Pan OIL PAN REMOVAL AND INSTALLATION Fr Removal steps Z Bran pi gasket [BB Post-installation Operation ¢ Removal and Installation of the Under Dearing and Supplying of the Engine Oil 40003. Oil Pan Hole of bott sere hsm | Sealant: = 0.8 kam MITSUBISHI GENUINE PART ~ 5:7 Fe L___Mz100168 or orwocee SERVICE POINTS OF REMOVAL ‘craMsa00 3. REMOVAL OF OIL PAN After removing the oil pan mounting bolts and nuts, remove the oil pan with the special tool and a brass bar Caution Perform this slowly to avoid deformation of the oil pan flange. SERVICE POINTS OF INSTALLATION 3. INSTALLATION OF OIL PAN (1) Remove all sealant from the oil pan and cylinder block with @ scraper, etc. (2) Degrease the areas to be coated with sealant and mating surfaces (3) To squeeze out proper amount of sealant, cut off the nozzle of sealant. This will provide a nozzle 4 mm (0.16 in.) in diameterENGINE <4G32> ~ Cylinder Head Gasket 11-17 CYLINDER HEAD GASKET REMOVAL AND INSTALLATION Preremoval Operation Draining of the Engine Coolant IReter to GROUP 14 ~ Service Adjustment Procedures.} ‘emoval of Seat # Removal of Air Horn Postinstallation Operation Supplying of tho Engine Coolant {Refer to GROUP 14 ~ Service Adjustment Procedures.) Engine Adjustment (Refer to P. 11-4) ‘ installation of Air Hom @ instalation of Seat Removal steps Breather hose Hose Accelerator cable connection Earth cable connection Bolt Distributor connection Engine coolant temperature connection Fuel-cut solenoid valve connection Radiator upper hose connection 10. High tension cable and spark plug cable connection 11. Breather tube 12. Vacuum hose connection 13. Water hose connection 14. Waler by-pass hose connection 15. Fuel tube connection 16. Fuel return tube connection5-7.Nm 05 —0.7 kgm 4-5 ftlbs 17. Front exhaust pipe connection 18. Air cleaner heat duct 19. Vacuum hose connection 21. Timing belt front upper cover @* 22. Camshaft sprocket 23. Timing belt under upper cover ‘ee 24. Rocker cover 25. Semi-circular packing 26. Reed valve and air pipe assembly #0 94 27. Cylinder head assembly © 28. Cylinder head gasket eis oroo019 20. Secondary air supply hose connection Cylinder head’ Sealant: 3M _ATD Part No. 8660 or equivalentENGINE <4G32> — Cylinder Head Gasket aca SERVICE POINTS OF REMOVAL snr 7 22. REMOVAL OF CAMSHAFT SPROCKET wh (1) Rotate crankshaft clockwise (to the right) and align timing o> marks. > Caution eat Always rotate crankshaft clockwise. ovmorsa (2) Remove camshaft sprocket with timing belt and place it on timing belt front lower cover. Caution Do not rotate crankshaft after removing camshaft sprocket. NOTE Secure camshaft sprocket and timing belt with wire etc., to prevent them from slipping out of place. Camshaft sprocket oG0072 27. REMOVAL OF CYLINDER HEAD ASSEMBLY Loosen bolt in the numerical order indicated in the diagram with special tool and remove. Mpgee960 omens = Timing port side Exhaust side Intake side omo300 SERVICE POINTS OF INSTALLATION eros [oot eeeeee aren) 28. INSTALLATION OF CYLINDER HEAD GASKET KO) 1) Scrape of gasket adheres to cyinder back sna 2 Caution Be careful that foreign material does not fall into cyl- inder, or into coolant and oil passage ways.11-20 ENGINE <4G32> Cylinder Head Gasket o1n0415, Nog9s360 o1no419| Ting bot side Exhaust side (fohteontrenatonaio aise en eats | [cesta tsetse eeeees Jeet o © e@ oa of Intake side o1n0390| rosemt A) Yer — (2) Identification mark is provided on cylinder head gasket to ensure correct installation. (3) Mount on cylinder block with mark at top. 27. INSTALLATION OF CYLINDER HEAD ASSEMBLY (1) Scrape off gasket adhered to cylinder head assembly. Caution Be careful that foreign material does not fall into coolant and oil passage ways. (2) Tighten in the numerical order indicated in the diagram in two or three groups with special tool 24, INSTALLATION OF ROCKER COVER (1) Apply a coating of engine oil to the gasket surface of the rocker cover (where shown in the figure) (2) Install the rocker cover.ENGINE <4G32> — Timing Belt TIMING BELT enca-a REMOVAL AND INSTALLATION 0100023, Post installation Operation Engine Adjustment Refer to P. 11-8) Removal steps Cooling fan Alternator V-belt Water pump pulley Crankshaft pulley Timing belt upper cover Timing belt lower cover Timing beltENGINE <4G32> — Timing Belt Bae at ee Tiring mark Timing beit tensioner Timing belt Bot! Nut 2x29 SERVICE POINTS OF REMOVAL errenee 7. REMOVAL OF TIMING BELT (1) Rotate crankshatt clockwise {to the right} and align timing marks Caution Always rotate crankshaft clockwise. (2) Loosen timing belt tensioner bolt and nut (3) Push timing belt tensioner to water pump side and tighten nut. Secure so that tensioner will not move back. (4) Remove timing belt Caution When reinstalling timing belt, mark an arrow at the back of belt with chalk to show rotation direction (ro- tate to right). INSPECTION enrecaso TIMING BELT COVER Cracking, splitting, deterioration of gasketENGINE <4G32> - Timing Belt 11-23 ‘SERVICE POINTS OF INSTALLATION erre0ce 7. INSTALLATION AND ADJUSTMENT OF TIMING BELT (1) Align sprocket timing marks. Timing fn (2) First, put timing belt around crankshaft sprocket. Next, put timing belt around oil pump sprocket and then around Seat pie camshaft sprocket. Install so that tension side has no Li slack yee (3) Push camshatt sprocket counter clockwise (to the left) and stretch belt tension side taut. Reconfirm correct timing : mark alignments. al {4} Tum 1 ~ 2 times tensioner bolt and nut temporarily se- cured on water pump side first, and loosen. Stretch belt using tensioner spring force Timing ] Oi bump mark é Tension sprocket Crankshaft sprocket S#4€ enz20 (5) Rotate crankshaft clockwise {to the right} for two teeth on the camshaft sprocket. This provides appropriate tension to timing belt, so do not rotate crankshaft counter clock- wise [to the left) or check tension by pressing belt. Timing mark (6) Push tensioner in rotation direction (indicated in diagrar) Adjust so that belt does not rise at point (A) and meshes completely with camshaft sprocket. (7) Tighten tensioner installing nut (upper tensioner) to spec- ified torque. Tension side (8) Tighten tensioner installing boit (lower tensioner) to spec- ified torque. Caution It bolt Is tightened first, tensioner will rotate and ten- sion will be too tight, (9) Press center of timing belt tension side (between cam- shaft sprocket and oil pump sprocket) with thumb and pointer from both sides and confirm that gap between belt 6mm back and cover is at the standard value. ean Standard vaiue: 6 mm (0.24 in.) EN017,11-24 CRANKSHAFT OIL SEAL REMOVAL AND INSTALLATION ENGINE <4G32> — Crankshaft Oil S Pre-removal Operation ‘* Removal of the Timing Belt {Refer to P. 17-21) ‘# Removal of the Transmission Post-installation Opore instalaton of the Timing Engine Adjustment (Refer Bett Front Oil Seal> Fear Oil Seal> kshatt Rear Oil to PV. 130-140 Nm 13-14 kgm 947101 felbs. Removal steps 1 wor 3 o Crankshaft sprocket Crankshaft front oil seal Flywheel assembly Oil seal case Gasket Crankshaft rear oil seal i seat 0996011 Oil seal case SERVICE POINTS OF INSTALLATION 6. INSTALLATION OF CRANKSHAFT REAR OIL SEAL Using the special tool, press-fit a new crankshaft rear oil seal into the cil seal case,ENGINE <4G32> — Crankshaft Oil Seal 2. INSTALLATION OF CRANKSHAFT FRONT OIL SEAL (1) Attach the special to0! to the crankshaft and apply engine oil to the outer surface of the tool. (2) Using the special tool, install the front oil seal into the front lower case. Front case, r0001211-26 ENGINE <4G32> ~ Engine and Transmission Assembly ENGINE AND TRANSMISSION ASSEMBLY essa REMOVAL AND INSTALLATION Pre-removal Operation Draining of the Engine Coolant (Rotor to GROUP 14 — Service Adjustment Procedures} f Insialaton of the Ar Hom ‘* Removal of the Seat ‘© Supplying of the Engine Coolant ¢ Removal of the Air Hom (Rofar to GROUP 14~ Service Adjustment iemoval of the Undercover Procedures.) ‘Engine Adjustment Refer to P_11-4) Removal steps 1. Breather hose 10. High tension cable connection 2. Secondary air supply hose connection 11. Vacuum hose connection 3. Engine coolant temperature connection 12, Vacuum hose connection 4. Fuelcut solenoid valve connection 13. Water hose connection 5. Accelerator cable connection 14, Water hose connection 6 Earth cable connection 15. Fuel tube connection 7. Air cleaner heat connection 16. Fuel retu:n tube connection 8. Radiator upper hose connection 17. Radiator lower hase connection 9. Distributor connector 18, Front exhaust pipe connection19, 20, 21 22. 23, 2a. 25, 26. 27. ENGINE <4G32> — Engine and Transmi Cooling fan Alterater connector Gil pressure switch connection Earth cable connection Bolt Clutch contro! cable connection Transmission control cable connection Speedometer cable connection Back-up lamp harness connection 28. 23, 20. 31 22, 33, Earth cable connection Propeller shaft (Refer to GROUP 25 — Propeller shaft} Starter motor connector Transmission mounting nut Front engine support assembly mounting bolt Engine and transmission assembly11-28 ENGINE <4D56> ENGINE <4D56> SPECIFICATIONS GENERAL SPECIFICATIONS Specifications tems. Specifications Type Indine, 4 cylinders. Single Over Head Camshaft Bore rom (in) | 91.4 (3.59) Stroke mm {in} | 95.0 (8.74) Total displacement ce feuin.) | 2.477 (151.1) Compression ratio a4 Injection order 19-42 Counterbalance shaft Equipped Valve timing Intake vaive Opens (TDCi | 20° Closes (ABDC! | 49° Exhaust valve Opens {BBDC) | 55° Closes (ATDC) | 22” SERVICE SPECIFICATIONS tems, Specifications: ‘Standard value Valve clearance at hot engine mm (in) Intake side 0.25 40.0098) Exhaust side 0.25 (0.0098) Injection timing Except vehicles for Switzeriand and Austria 7 aTDC Vehicles for Switzerland and Austria 5° ATOC Idle spe: rimin, | 75030 Radiator cap valve-opening pressure kPa tkalom?, psi) | 75-105 (0.75- 1.05, 11-15) Drive belt tension mm (in) When a new belt is installed When used belt is installed Limit Raciator cap valve-opening pressure kPa {kgicm?, ps) 9-12 (0.35 -0.47) 44-14 (0,430.55) 65 (0.65, 92)ENGINE <4D56> — Specifications 11-29 TORQUE SPECIFICATIONS tems. Nm kan ftlbs, Alternator support bolt nut 20-25 20-25 | 14-18 Alternator brece bolt 12-15 12-18 0 [9-11 Glow plug 18-20 1s-20 0 | 11-15 Glow plug to glow plug plate 10-18 010-015 | 07-10 Adjusting screw locking nut 12-18 12-18 | 85-13 Timing belt tensioner 22-30 22-30 | 16-22 Fue! injection pipe clamp 46 os-06 | 29-43 Fue! injection pipe flare nut 23-37 23-37 | 17-27 Injection timing check plug 8-10 os-10 | 6-7 Crankshaft pulley 170-190 | 17-19 129-137 Rocker cover 5-7 os-07 | 36-51 Rocker aim shaft 36-40 35-40 | 25-29 Camshaft bearing csp 19-21 19-21 14-18 Camshaft sprocket 65-75 65-75 | 47-54 Dil pan 6-8 06-08 | 43-57 Drain plug 35-45 35-45 — | 25-33 Cylinder head assembly yos-118 | 105-115 | 76-83 Timing belt upper cover 10-12 10-12 [7-9 Exheust manifold to exhaust pipe 30-40 30-40 | 22-29 Timing belt lower cover 10-12 wo-12 | 7-9 Flywheel assembly yg0-140 | 13-14 94-101 Dil cooler hose 40-50 40-50 | 29-36 Exhaust pipe to bracket 20-30 | 20-30 | 15-22 Transmission mounting bolt 43-56 43-55 | 31-40 Propeller shaft 50-60 50-60 | 36-43 Transmission mounting aut 30-42 30-42 | 22-30 Clutch release cylinder 30-42 30-42 | 22-30 Front engine support assembly mounting bolt 40-50 [40-50 | 29 ~36 LUBRICANTS. tems Recommended lubricant ‘Quantity it API classification) (USqts.. Impats.) Engine oil CC ar higher 55 68 48) SEALANTS AND ADHESIVES | Specified sealant Remarks Semroreular packing and rocker cover | JM ATD Part No. 8660 or equivalent | Nor-drying sealant Dit pan MITSUBISHI GENUINE PART Mz100168 or | Semidrying sealant ecuivaler11-30 ENGINE <4D56> — Special Tools SPECIAL TOOLS oe Tool Number Name Use 1MD996051 Wrench, eyinder | Loosening and tightening of eylinder head bolt xe head bolt 0998976 Crankshaft rear oi | instalation of crankshaft il seal seal installer M0998381 Camshatt ol seal | Installation of camshaft ol seal 6) installer 998382 Crankshaft front oil | Guide for instalation of crankshaft front ol seal DP seal guide 0986363 Crankshaft front oil | Installation of crankshaft front cil seab oO seal instaler Mbg86384 Prostoke ‘Adjusting iniection timing 3 measuring adapter a MD988721 Crank pulley holder | Removal and instalation of crankshaft pulley es 0998727 (il pan sealer cutter | Removal of oil panENGINE <4D56> — Engine Adjustment 11-31 ENGINE ADJUSTMENT RADIATOR CAP VALVE-OPENING PRESSURE ‘CHECK enw, Standard value: 75- 105 kPa (0.75 - 1.05 kg/em?, 11-15 psi) Limit: 65 kPa (0.65 kg/cm?, 9.2 psi) ENGINE COOLANT INSPECTION BATTERY INSPECTION ‘ennemaac Refer to P. 11-5. ENGINE OIL LEVEL INSPECTION ed AIR CLEANER ELEMENT INSPECTION AND CLEANING enirraNtWater purnp pulley / - VY Fai) LZ Altorator drive bolt Crankshatt puley 100001 Ahemator brace (20-25 14-18) bolt — Engine Adjustment DRIVE BELT TENSION INSPECTION AND ADJUST- MENT 1. Check belt for damage or wear. Confirm that belt is set correctly in pulley groove. NOTE If the belt “squeals” or slips, check belt for friction, damage or breaks and check pulley contact surface for damage. 2. Press at 100N (10 kg, 22 Ibs.) mid-point of belt between pulleys as indicated in the diagram. Measure drive belt deflec- tion Standard value: ‘When equipped with new drive belt 9-12 mm (0.35 - 0.47 in.) When belt currently being used is tightened 11-14 mm (0.43 - 0.55 in.) Caution Measure belt flex between specified pulleys (<=). 3. Adjust altemator drive belt deflection by the following proce- dures (1) Loosen alternator support bolt nut. (2) Adjust belt deflection by using a rod as a level against the alternator stator pushing it into the proper position (3) Retighten the alternator brace bolt and support bolt nut to the specified torque. Standard value: When equipped with new drive belt: 9-12 mm (0.35-0.47 in.) When belt currently being used is tightened: 11-14 mm (0.43-0.55 in.) VALVE CLEARANCE INSPECTION AND ADJUST- MENT 1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80° C to 90°C (176*F to 194°F) 2. Check the injection timing and the iding speed, and adjust if necessary, (Refer to P. 11-34, 36.) 3. Remove the upper timing belt cover Remove the rocker coverENGINE <4D56> — En: Timng a jon carnshal sprocket ome fiming mark lon front upper caso] No No2 Nod Nod Exh Int. Exh nt Exh. Int Exh int Nod No2 No3 Nod Exh In Exh lot Exh lt Exh it Dentes, ‘Apply sealant enz20 5. Tum the crankshatt clockwise and align the timing mark on the carnshaft sprocket with the timing mark on the top of the front upper case. Check that valve clearance indicated in the diagram tes is at the standard value. Standard value (hot engine): 0.25 mm (0.0098 in.) 7. If not within the standard value, loosen the adjusting screw locking nut and, while turning the adjusting screw. use a thickness gauge to adjust the valve clearance to the standard value 2. Block the adjusting screw with a screwdriver, so that it cannot move and tighten the lock nut to the specified torque. Tightening torque: 12— 18 Nm (1.2-1.8 kgm, 8.7-13 ft.lbs.) 9. Rotate clockwise the crankshaft one complete turn (360° de- gree) 10. Check that valve clearance indicated in the diagrarn Hes is at the standard value. Standard value (hot engine): 0.25 mm (0.0098 in.) 11. Ifnot within the standard value, repeat steps (7) to 8) to adjust the valve clearance of remaining valves. 12. When installing the rocker cover assembly to the cylinder head, apply 2 Coating of the specified sealant to the sem- circular packing and cylinder head top surfaces, and then tighten at the speatied torque. ‘Specified sealant: 3M ATD Part No. 8660 or equivalent Tightening torque: 5-7 Nm (0.5— 0.7 kgm, 4-5 ftlbs.) Caution If they are overtorqued, a deformed rocker cover or oil leakage could result.Icvinser head} i Semiereuar NC peking seyo02s aren Jlemearstt sete) Tring mak fon on upper case) \ Ais 180023 Mpesezee Pushed Nut tomm (039 in) pruczs ENGINE <4D56> ~ Engine Adjustment INJECTION TIMING INSPECTION AND ADJUST- MENT 1 2, Remove the glow plugs (four) so that the crankshaft can be tured with greater ease. Turn the crankshaft clockwise and align the two timing marks (located on the camshaft sprocket and on the front upper case). Then set the No.1 cylinder to the top dead center of compression Remove the timing check plug installed on the back of the injection pump. Before installation of special tool, make sure that push rod is protruding by 10 mm (0,39 in.). Protrusion of push rod can be agjusted with an inner nut. After setting the dial gauge, install the special tool on the rear Of the injection pump.ENGINE <4D56> — En: Adjustment Crankshaft pulley 7003 mm (0.0384:0.0012 in) Bolt 2) Fv023 2 Fron view oe Woe 2000 om (asad soa0:2m) Sratove = When 12008 yn foossezaon2 na orb" pGE025 6. Turn crankshaft clockwise to such a position that the notch on pulley is at approximately 30° before top dead center on compression stroke of piston in No.’ cylinder. 7. Set dial indicator to zero. 8, Check to make sure that the indicator needle does not move when the crankshaft is turned slightly clockwise or slighthy anti-clockwise (2 to 3°) 9. If the indicator needle moves, this means that the injection pump plunger is lifted. If so, tum and reset the crankshaft so that the indicator needle does not move, 10. Turn the crankshaft clockwise and set the notch located on the crankshatt pulley to 7° ATDC (set to 5° ATDC for vehicles for ‘Switzerland and Austria). 11, Read the value indicated on the dial gauge. 1 + 0.03 mm (0.0394 + 0.0012 in.) 12. If the indicated value is not within the range specified above, adjust the injection timing by following the procedure below. (1) Loosen the injection pipe union nuts (four) located on the injection pump side. {Do not remove these union nuts.) Be sure to use a spanner to prevent the delivery valve holder from moving while loosening the nuts. (2) Slightly loosen the injection pump installation bolts (two) and nuts {two) (Do not remove these bolts and nuts.) (3) Tit the injection pump to the right or left, and adjust the indicator needle of the dial gauge to the standard value. (4) Temporary tighten the injection pump installation nuts (two) and bolts (two).ENGINE <4D56> — Engine Adjustment {8} Repeat Steps 6 to 11 to check that adjustment has been made correctly {6) Tighten the injection pump instalation nuts (two) and bolts {two} by applying the torque specified below. Tightning torque: Nut 15-22 Nm (1.5 -2.2 kgm, 11-16 ft.lbs.) Bolt 20-27 Nm (2.0-2.7 kgm, 14 20 ftlbs.) (7) Tighten injection pipe union nuts (4) to specified torque. When nuts are tightened, hold delivery valve holder with a spanner to prevent it from rotating with nut. Tightening torque: 23-37 Nm (23-3.7 kgm, 17-27 ftlbs.) 13, Remove the special tool 14. Install new copper gasket, then tighten timing check plug to specified torque, Tightening torque: 8-10 Nm (0.8 -1.0 kgm, 6-7 ftlbs.) IDLE SPEED INSPECTION AND ADJUSTMENT... NOTE Idle speed inspection and adjustment must be done only after normal {uel injection timing has been confirmed. 1, Before inspection and adjustment set vehicle in the following condition. (1) Coolant temperature: 80 90°C (176 194°F) (2) Lights and ail accessories: OFF (3) Transmission: Neutral 2. Connect the tachometer to the injection nozzle or t0 the injection pipe. Caution 7 oruo0se Before connecting the tachometer to the injection pipe, Tachometer be sure to remove all plpe-securing clamps. / {| 3. Check the engine idling speed. Standard value: 750 + 30 r/min. —F Injection nore 4. If not within the standard value, loosen idle adjusting screw lock nut and agjust the standard value by rotating adjusting screw. After adjustment, tighten lack nut securely.ENGINE <4D56> _— En: i 11-37 Tompression COMPRESSION PRESSURE INSPECTION enrcan 1. Check to be sure that the engine oil, starting motor and battery are in the normal condition, 2. Start the engine and allow it to warm up unti the temperature of the coolant reaches 80° C to 90°C (176°F to 194°F), . Loosen the nuts at the nozzle side of the injection pipes, and disconnect the pipes from the nozzle holders Caution Caps must be used to prevent entry of foreign materials into the nozzles. Remove the glow plug plate and all 4 glow plugs. Set an engine tachometer in place. Place @ compression gauge adaptor and compression gauge in the glow plug hole. 7. Crank the engine with the throttle valve fully open, and measure the compression at the piace where the compres- sion gauge indicator shows a stabilized reading, Limit (at engine speed of 250 r/min. Min. 1,920 kPa (19.2 kg/em?, 273 psi) 8. Conduct steps 6, 7 with all cylinders and confirm pressure differences of all elinders is within the limit. Limit: Max. 300 kPa (3.0 kg/cm’, 43 psi) 9. fafter the measurement, the compression is below the limit put 2 small amount of engine oil through the glow plug hole into the cylinder; then measure the compression once again ‘and determine the cause of the malfunction. 10. I, after oil is added, the compression rises, the cause of the malfunction is a wom or damaged piston ring andior cylinder inner surface. If however, the compression does not rise, the cause is a bad valve or a bad gasket For information regarding the servicing procedures for these causes of malfunction. refer to the ENGINE AND TRANSMIS: SION MANUAL. TIMING BELT TENSION ADJUSTMENT eno 1. Remove timing belt upper cover. 2. Tum the crankshaft clockwise to align the timing marks. "Ting aS oce010 3, Loosen the timing belt tensioner mounting bolts. Direction of gay enanae Eeieauutsh Do not loosen the belts more than necessary. They could Back of drop in the lower cover. Tod ums —— Back off 1 urn pce01111-38 ENGINE <4D56> Camshaft sprocket Dacor e017 Engine Adjustment 4, Tum crankshaft clockwise through two camshaft sprocket teeth and hold, 5. Tighten tensioner mounting bolts. Caution Tighten the upper bolts first and then the lower ones. 6. Reverse crankshaft to align timing marks, and push down belt ata point halfway with forefinger to check that tension of belt is up to standard value. Standard value: 4—5 mm (0.16-0.20 7. Mount the timing belt upper cover. ) TIMING BELT “B" TENSION ADJUSTMENT 1. Remove timing belt upper cover and bring piston in No.1 cyt Inder to top dead center on compression stroke. Check that timing marks of sprockets are aligned. 2. Tum the crankshaft clockwise to align timing marks. 3. Remove the access cover. 4. Loosen the timing belt “B” tensioner mounting nut and bolt Caution Do not loosen the bolts (upper) more than necessary. They could drop in the lower cover. 5. Tighten tensioner mounting nut and bolt Caution Tighten the nut (lower) first and then the bolt (upper). Mount the access cover. Mount the timing belt upper cover.