ENGINE OVERHAUL Specifications

Main
Index

SPECIFICATIONS
GENERAL SPECIFICATIONS
Descriptions

Specifications

Type

60_ V, SOHC (per bank)

Number of cylinders

Combustion chamber

Pentroof type

Total displacement cc

6G72 2,972 / 6G74 3,497

Cylinder bore mm

6G72 91.1 / 6G74 93.0

Piston stroke mm

6G72 76 / 6G74 85.8

Valve timing

Intake valve

Exhaust valve

Opens (BTDC)

9_

Closes (ABDC)

59_

Opens (BBDC)

47_

Closes (ATDC)

21_

Lubrication system

Pressure feed, full-flow filtration

Oil pump type

Trochoid type

Cooling system

Water-cooled forced circulation

Water pump type

Centrifugal impeller type

EGR type

Single type

Injector type and number

Electromagnetic, 6

Injector identification mark

CDH210

Throttle bore mm

65

Throttle position sensor

Variable resistor type

Closed throttle position switch

Movable contact type, within throttle position sensor

11B
Index

ENGINE OVERHAUL Specifications

Main
Index

SERVICE SPECIFICATIONS
Items

Standard value

Limit

11B
Index

Alternator
Drive belt

Tension N

New belt

784980

Used belt

539637

New belt

6.07.2

Used belt

8.29.3

1316 at 20_C

Intake

37.58

37.08

Exhaust

36.95

36.45

44.93 44.94

Flatness of gasket surface mm

0.03

0.2

Grinding limit of gasket surface

*Includes/combined with cylinder block
grinding mm

*0.2

Overall height mm

120

Intake

1.0

0.5

Exhaust

1.2

0.7

Intake

6.0

Exhaust

6.0

Intake

0.020.05

0.10

Exhaust

0.040.07

0.15

45_45.5_

Free height mm

51.0

50.0

Load/installed height N/mm

267/44.2

Out of squareness

2_ or less

Max. 4_

Valve seat

Valve contact width mm

0.91.3

Valve guide

Inner diameter mm

6.0

Outer diameter mm

11.0

Deflection mm
(Reference value)
Fuel and emission parts
Injector coil resistance
Rocker arms and camshaft
Camshaft

Camshaft

Cam height mm

Journal diameter mm

Cylinder head and valve

Cylinder head

Valve

Thickness of valve head

(margin) mm
Stem diameter mm

Stem to guide clearance

mm
Valve face angle
Valve spring

ENGINE OVERHAUL Specifications

Standard value

Limit

Main
Index

Tip clearance mm

0.060.18

Side clearance mm

0.040.10

11B
Index

Body clearance mm

0.100.18

0.35

Outer diameter mm

6G72 91.1 / 6G74 93.0

Piston to cylinder clearance mm

0.020.04

Ring to ring groove clearance No. 1 ring

mm

0.030.07

0.1

Ring to ring groove clearance No. 2 ring

mm

0.020.06

0.1

End gap No. 1 ring mm

0.300.45

0.8

End gap No. 2 ring mm

0.450.60

0.8

End gap oil ring mm

6G72 0.200.60
6G74 0.100.35

1.0

Outer diameter mm

22.0

Press-in load

6G72 7,350 17,200 N

6G74 Finger pressure

Press-in temperature

6G72 Room Temp

6G74 70_C

Crankshaft

Oil clearance of pin mm

0.020.05

0.1

Connecting rod

Big end side clearance mm

0.100.25

0.4

End play mm

0.050.25

0.3

Journal outer diameter mm

60

Pin outer diameter mm

50

Oil clearance of journal mm

0.020.04

0.1

Runout mm

0.13

Flatness of gasket surface mm

0.05

0.1

Grinding limit of gasket surface

*Includes/combined with cylinder block
grinding mm

*0.2

Overall height mm

210.4210.6

Cylinder bore inner diameter mm

6G72 91.9 / 6G74 93.0

Items
Front case, oil pump and oil pan
Oil pump

Piston and connecting rod

Piston

Piston ring

Piston pin

Crankshaft, Flywheel and drive plate

Crankshaft

Drive plate and

Flywheel
Cylinder Block
Cylinder block

ENGINE OVERHAUL Specifications

Main
Index

REWORK DIMENSIONS
Items

Standard value

Limit

Cylinder head and valve

Cylinder head

Oversize valve guide hole

(both intake and exhaust)

Oversize intake valve seat ring

hole mm
Oversize exhaust valve seat
ring hole mm

0.05

11.0511.07

0.25

11.2513.32

0.50

11.5011.52

0.3

34.3034.33

0.6

34.6034.63

0.3

31.8032.83

0.6

32.1032.13

0.005

Crankshaft
Crankshaft

Out of roundness and taper of journal and pin

mm

11B
Index

ENGINE OVERHAUL Specifications

Main
Index

TORQUE SPECIFICATIONS
Items

Nm

Alternator and drive belt

Alternator bolt

21

Tensioner pulley nut

50

Alternator bracket bolt

M8

48

M10

23

Alternator pivot nut

44

Crankshaft bolt

180-190

Intake manifold plenum and throttle body

Manifold differential pressure sensor bolt

4.9

Intake manifold plenum bolt and nut

18

Vacuum hose assembly bolt

9.8

Water outlet fitting bracket bolt

19

EGR pipe bolt

18

EGR pipe flare nut

59

Intake manifold plenum stay bolt

M8

18

M10

36

EGR valve bolt

22

Bracket bolt

24

Throttle body bolt

12

Ignition system
Spark plug

25

Distributor nut

23

Timing belt
Crank angle sensor bolt

Auto tensioner bolt

24

Tensioner pulley bolt

49

Tensioner arm bolt

44

Idler pulley bolt

44

Camshaft sprocket bolt

88

Intake manifold and fuel parts

Injector and fuel rail bolt

12

Fuel pressure regulator bolt

Fuel pipe bolt

Heat pipe bolt

18

Engine coolant temperature gauge unit

11

Engine coolant temperature sensor

30

Water outlet fitting bolt

19

Water inlet fitting bolt

19

Thermostat case bolt

19

Water (outlet) pipe bolt

14

Intake manifold nut

21

11B
Index

ENGINE OVERHAUL Specifications

Items

Nm

Exhaust manifold
Oil level gauge guide bolt

14

Heat protector bolt

14

Exhaust manifold nut

29

Water pump bolt

M8

24

M10

41

Rocker arms and camshafts

Rocker cover bolt

3.5

Distributor adaptor bolt

23

Thrust case bolt

13

Rocker arm, rocker arm shaft bolt

31

Cylinder head and valve

Cylinder head bolt

108

Oil pan and oil pump

Oil pressure switch
Oil filter bracket bolt

10
M8

24

M10

40

Drain plug

40

Oil pan (upper) bolt

Oil pan lower bolt

11

Cover bolt

11

Baffle plate bolt

M6

11

M8

Oil screen bolt

19

Plug

45

Oil pump case bolt

14

Oil pump cover bolt

10

Piston and connecting rod

Connecting rod cap nut

52

Crankshaft, Flywheel and drive plate

Drive plate bolt

75

Flywheel bolt

98

Bell housing cover bolt

Oil seal case bolt

11

Bearing cap bolt

93

Bracket
Bracket bolt

M8

22

M10

41

M12

75

Main
Index
11B
Index

ENGINE OVERHAUL Specifications

Main
Index

SEALANTS
Items

Specified sealant

Quantity

Engine coolant temperature sensor

Loctite 577

As required

Engine coolant temperature gauge unit

Loctite 577

As required

Oil pressure switch / gauge unit

Loctite 577

As required

Oil pump case

MD970389 / Loctite 587

As required

Oil pan

MD970389 / Loctite 587

As required

Rear main oil seal

MD970389 / Loctite 587

As required

Welsh plugs and spark plug sleeves

Loctite 262

As required

Water outlet fitting

Loctite 577

As required

11B
Index

ENGINE OVERHAUL Special Tools

Main
Index

SPECIAL TOOLS
Tool

Tool number and name

Supersession

Application

MB990767
End yoke holder

EMB990767

Holding camshaft sprocket

when loosening bolt.

MD991559
Camshaft oil seal
installer adaptor

EMD991559

Installation of camshaft oil seal

(Left bank)
(Use with MD998713)

MD998051
Cylinder head bolt
wrench

E1139

Loosening and tightening

cylinder head bolts

MD998440
Leak-down tester

49U012005

Leak-down test of lash adjuster

MD998441
Lash adjuster retainer

EMD998441

Bleeding of air inside adjuster

MD998442
Air bleed wire

E9M401

Air bleeding of auto lash

adjuster

MD998443
Lash adjuster holder
(8)

E9M402

Supporting lash adjuster to

prevent it from falling when
rocker shaft assembly is
removed or installed

MD998713
Camshaft oil seal
installer

EMD998713

Installation of camshaft oil seal

MD998717
Crankshaft front oil
seal installer

EMD998717

Installation of crankshaft front

oil seal

11B
Index

ENGINE OVERHAUL Special Tools

Tool

Main
Index

Tool number and name

Supersession

Application

MD998718
Crankshaft rear oil seal
installer

EMD998718

Installation of crankshaft rear oil

seal

MD998715
Pulley holding pins (2)

EMD998715

Holding camshaft sprocket when

loosening or torquing bolt

MD998715
Valve spring compressor

J8062

Removal and installation of valve

and related parts

MD998767
Tension pulley wrench

EMD998767

Adjustment of timing belt tension

MD998769
Crankshaft spacer

Rotation of crankshaft when

installing piston and timing belt

MD998772
Valve spring compressor

Compression of valve spring

MD998774
Valve stem seal installer

EMD998774

Installation of valve stem seal

MD998780
Piston pin setting tool

Removal and
piston pin

MD998781
Flywheel stopper

Loosening and tightening

crankshaft bolts

installation

of

11B
Index

ENGINE OVERHAUL Alternator and Drive Belt

Main
Index

ALTERNATOR AND DRIVE BELT

REMOVAL AND INSTALLATION

11B
Index
13
14
15
13 Nm

16

7
21 Nm
48 Nm

23 Nm

49 Nm
180-190
Nm

12

44 Nm

6
11

9
10
1

Removal steps
"BA 1. Drive belt
2. Tensioner pulley
AA" "AA 3. Crankshaft bolt
4. Washer
5. Crankshaft pulley
6. Alternator
7. Alternator bracket
8. Harness connector

9.
10.
11.
12.
13.
14.
15.
16.

Suction hose connection

Discharge hose connection
Compressor
Compressor bracket
Dip stick
O-ring
Dip stick tube
O-ring

REMOVAL SERVICE POINT

AA" CRANKSHAFT BOLT LOOSENING
1. Using the special tool, hold the drive plate.
2. Remove the crankshaft bolt.

MB998781

ENGINE OVERHAUL Alternator and Drive Belt

INSTALLATION SERVICE POINT

"AA CRANKSHAFT BOLT TIGHTENING
1. Using the special tool, hold the drive plate or flywheel.
2. Install the crankshaft bolt.

MB998781

"BA DRIVE BELT TENSION ADJUSTMENT

1. Use a belt tension gauge to check belt tension, or check
deflection by applying 98 N to the shown point.
Standard value:
Alternator drive belt

Tension N

New

784 980

Used

539 637

Tension
pulley

Fixing
nut
Adjusting bolt

Standard value:

Alternator pulley
Tension pulley

A/C
pulley
Crankshaft
pulley

100 N

Alternator drive belt

Deflection (Reference value)

mm

New

6.0 7.2

Used

8.2 9.3

Main
Index
11B
Index

ENGINE OVERHAUL Intake Manifold Plenum and Throttle Body

Main
Index

INTAKE MANIFOLD PLENUM AND THROTTLE BODY

REMOVAL AND INSTALLATION

11B
Index

10 Nm

2
1

3 Nm

11 Nm

11
12
13
17 Nm

9 Nm
17 Nm

17 Nm

4
10 Nm

6
7
14

35 Nm
17 Nm

15
9

10
11 Nm

Removal steps
1. Engine cover
2. Clamp
3. Accelerator cable bracket
4. Intake plenum stay, front
5. Intake plenum stay, rear
6. EGR valve
7. EGR valve gasket
8. EGR pipe

9.
10.
11.
12.
13.
14.
15.

EGR pipe gasket

Connector bracket
Vacuum pipe
Throttle body
Throttle body gasket
Intake plenum
Intake plenum gasket

ENGINE OVERHAUL Ignition System

Main
Index

IGNITION SYSTEM
REMOVAL AND INSTALLATION

11B
Index

Pre-removal and Post-installation Operation

Removal and installation
D Intake manifold plenum (Refer to P.11B-14)

1
3
23 Nm

4
1
25 Nm

Removal steps
1. Spark plug cables
2. Spark plugs
"AA 3. Distributor
4. O-ring

ENGINE OVERHAUL Ignition System

INSTALLATION SERVICE POINT

Aligning
marks

Main
Index

"AA DISTRIBUTOR INSTALLATION

1. Align the mark on the distributor housing with that of
11B
the coupling and install the distributor.
2. Once the engine has been started verify that the ignition Index
timing is correct.

ENGINE OVERHAUL Timing Belt

Main
Index

TIMING BELT
REMOVAL AND INSTALLATION

11B
Index

Pre-removal and Post-installation Operation

Removal and installation
D Crankshaft pulley (Refer to P.11B-12)

21

23 Nm

22

20
13 Nm

19
88 Nm
23 Nm

7
9

10

14
44 Nm

12
11

17
48 Nm

18 16

8
15

13

44 Nm

8 Nm

13 Nm
9 Nm
8 Nm

3
44 Nm

Removal steps
1. Timing belt front upper cover, rear
2. Timing belt front upper cover, front
3. Timing belt front lower cover
"DA 4. Engine support bracket
5. Crank angle sensor
AA" "CA 6. Timing belt
"BA 7. Automatic tensioner
8. Tensioner pulley
9. Tensioner arm
10. Shaft
11. Idler pulley

12.
13.
14.
15.
16.
17.
18.
AB" "AA 19.
20.
21.
22.

Idler pulley adjusting bracket

Adjusting bolt
Adjusting stud
Crankshaft sprocket
Sensing blade
Crankshaft spacer
Crankshaft key
Camshaft sprocket bolt
Camshaft sprocket
Bracket
Timing belt rear cover

ENGINE OVERHAUL Timing Belt

REMOVAL SERVICE POINTS

AA" TIMING BELT REMOVAL
1. Mark the belt running direction for reference in
reinstallation.
NOTE
1. Water or oil on the belt shortens its life drastically,
so the removed timing belt, sprocket, and tensioner
must be kept free from oil and water. Do not immerse
parts in cleaning solvent.
2. If there is oil or water on any part, check the front
case oil seal, camshaft oil seal and water pump for
leaks.

AB" CAMSHAFT SPROCKET BOLT LOOSENING

EMD998715
EMB990767

INSTALLATION SERVICE POINTS

"AA CAMSHAFT SPROCKET BOLT TIGHTENING
EMD998715
EMB990767

"BA AUTO-TENSIONER INSTALLATION

If the auto-tensioner rod is fully extended, set it in the retracted
position with the following procedure.
1. Set the auto-tensioner in a vice.

Main
Index
11B
Index

ENGINE OVERHAUL Timing Belt

2. Slowly close the vice to force the rod in until the set Main
hole (A) of the rod is lined up with the set hole (B) of Index
the cylinder.
3. Insert a wire [1.4 mm in diameter] into the set holes.
11B
4. Remove the auto-tensioner from the vice.

Index

"CA TIMING BELT INSTALLATION

1. Move the timing mark of the crankshaft sprocket three
teeth to slightly lower the piston below the top dead centre
on the compression stroke of the No. 1 cylinder.

Timing marks

Caution
If the camshaft sprocket is rotated with the piston
at the top dead centre on the compression stroke
of the No. 1 cylinder, the valve and piston might
interfere.
Crankshaft sprocket

Right bank

Timing marks

Left bank

2. Line up the timing marks of the left bank camshaft

sprockets.
3. Line up the timing marks of the right bank camshaft
sprockets.
Caution
Since the camshaft sprocket readily turns because
of spring action, use care to make sure that your
finger is not caught.

Camshaft sprocket

Timing marks

Camshaft
sprocket

4. Line up the timing marks of the crankshaft sprockets.

5. Install the timing belt on each sprocket in the following
sequence.
(1) Install the timing belt on the crankshaft sprocket and
then on the idler pulley, while tightening it to prevent
slackness.
(2) Install the timing belt on the left bank camshaft
sprocket.
(3) Install the timing belt on the water pump pulley, while
taking up the slack.
(4) Install the timing belt on the right bank camshaft
sprocket.
(5) Install the timing belt on the tensioner pulley.

ENGINE OVERHAUL Timing Belt

6. Lightly press the tensioner pulley against the belt and Main
Index
temporarily tighten the centre bolt.
7. Check to see that the timing marks of all the sprockets
are in alignment.

Tensioner pulley

11B
Index

8. Using a special tool, rotate the crankshaft a quarter of

a turn counter-clockwise. Then rotate it back clockwise
to verify that all the timing marks are in alignment.

MD998769

Right bank

Left bank

Timing mark

Water pump pulley

Camshaft sprocket
Camshaft sprocket
Tensioner pulley
Idler pulley
Auto-tensioner

Crankshaft sprocket

Timing mark

ENGINE OVERHAUL Timing Belt

EMD998767

9. Mount a special tool and torque wrench on the tensioner Main

Index
pulley.
10. Torque it to 4.4 Nm with the torque wrench.
11. While holding the tensioner pulley in position, tighten the
11B
centre bolt to the specified torque.

Index

12. Remove the metal wire inserted when the auto-tensioner

was installed.
13. Rotate the crankshaft two turns clockwise and let it stand
for approx. 5 minutes. In this condition, check that the
projection of the rod of the auto-tensioner is within the
standard value.
Standard value: 3.8 5.0 mm
14. Ensure the timing marks of the sprockets are still aligned
correctly.

"DA ENGINE SUPPORT BRACKET

1. Tighten bolts to specified torque in the sequence shown.

ENGINE OVERHAUL Timing Belt

INSPECTION

Main
Index

TIMING BELT
Replace belt if any of the following conditions exist.
1. Hardening of backing rubber, backing rubber is glossy, 11B
without resilience and leaves no indent when pressed Index
with fingernail.

Cracks

2.
3.
4.
5.

Cracks
Cracks
Cracks
Cracks

on backing rubber
or peeling of canvas
on tooth bottom
on side of belt

Peeling
Cracks

Cracks

6. Abnormal wear of belt sides. The sides are normal if they

are sharp as if cut by a knife.
Rounded edge

Abnormal wear
(Fluffy strand)

7. Abnormal wear on teeth

8. Tooth missing and canvas fibre exposed.
Rubber exposed
Tooth missing
and canvas
fibre exposed

ENGINE OVERHAUL Timing Belt

Main
TENSIONER PULLEY AND IDLER PULLEY
Index
1. Turn the pulley. If pulley does not rotate smoothly,
develops noise or excessive play, replace the pulley.
11B
Index

AUTO-TENSIONER
1. Check for oil leaks. If oil leaks are evident, replace the
auto-tensioner.
2. Check the rod end for wear or damage and replace the
auto-tensioner if necessary.
3. Measure the rod projection length. If the reading is outside
the standard value, replace the auto-tensioner.
Standard value: 11.712.3 mm

11.712.3 mm

98196 N

Movement

4. Press the rod with a force of 98 to 196 N and measure

the movement of rod.
If the measured value is out of the standard value, replace
the auto-tensioner.
Standard value:

1 mm or less.

ENGINE OVERHAUL Intake Manifold and Fuel Parts

Main
Index

INTAKE MANIFOLD AND FUEL PARTS

REMOVAL AND INSTALLATION
1

17
11 Nm

11B
Index

18 Nm

19
20
18 Nm

9 Nm

18
23

12

18 Nm

21

11

24 18 Nm
26

8
9
7
9 Nm

10

25
22

15

27

11 Nm

16
13
21 Nm

29 Nm

14
18 Nm

30
14

"HA
"GA

"FA
"EA
"DA

31

Removal steps
1. Engine harness
2. Injector and fuel rail
3. Insulator
4. Fuel pressure regulator
5. O-ring
6. Insulator
7. Injector
8. O-ring
9. Grommet
10. Fuel pipe
11. O-ring
12. Delivery pipe
13. Intake manifold
14. Intake manifold gasket
15. Engine coolant temperature gauge
unit
16. Engine coolant temperature sensor

13 Nm

29

28

"CA
"AA
"CA
"AA

"BA
"AA
"AA

17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.

Water hose
Water hose
Heater inlet pipe
O-ring
Heater inlet pipe
O-ring
Water outlet fitting
Water outlet fitting gasket
Water inlet fitting
Thermostat
Thermostat housing
Thermostat housing gasket
O-ring
Water pipe
O-ring

ENGINE OVERHAUL Intake Manifold and Fuel Parts

O-ring

INSTALLATION SERVICE POINTS

"AA O-RING AND WATER PIPE INSTALLATION
1. Wet the O-ring (with water) to facilitate assembly.
Caution
Keep the O-ring free of oil or grease.

Water inlet pipe

Jiggle valve

Outlet pipe

"BA THERMOSTAT INSTALLATION

1. Install the thermostat in the thermostat housing with its
jiggle valve located at the top position.

"CA HEATER INLET AND OUTLET PIPES

1. Attach the outlet and inlet pipes in this order, one on
the top of the other.

Inlet pipe
Surge tank stay

"DA SEALANT APPLICATION TO ENGINE COOLANT

TEMPERATURE SENSOR
Specified sealant:
Loctite 577 or equivalent

"EA SEALANT APPLICATION TO ENGINE COOLANT

TEMPERATURE GAUGE UNIT
Specified sealant:
Loctite 577 or equivalent

Main
Index
11B
Index

ENGINE OVERHAUL Intake Manifold and Fuel Parts

Main
"FA INTAKE MANIFOLD INSTALLATION
Index
1. Tighten the nuts on the right bank to 5 8 Nm.
2. Tighten the nuts on the left bank to the specified torque.
Then tighten the nuts on right bank to the specified torque. 11B
3. Tighten the nuts on the left bank and those on the right
Index
bank again in that order.

Front

"GA INJECTOR INSTALLATION

1. Before installing the injector, the rubber O-ring must be
lubricated with a drop of new engine oil for easy
installation.
Caution
Use care not to let the engine oil enter the fuel rail.
2. Insert the injector top end into the fuel rail. Be careful
not to damage O-ring during installation.
Fuel rail
Injector

"HA FUEL PRESSURE REGULATOR INSTALLATION

1. Before installing the pressure regulator, the O-ring must
be lubricated with a drop of new engine oil for easy
installation.
Caution
Use care not to let the engine oil enter the fuel rail.

ENGINE OVERHAUL Exhaust Manifold and Water Pump

Main
Index

EXHAUST MANIFOLD AND WATER PUMP

REMOVAL AND INSTALLATION

11B
Index

13 Nm

4
5

6
8

13 Nm

49 Nm

11

10

12

41 Nm

1
2
9
49 Nm
13 Nm

23 Nm

Removal steps
1. Oil level gauge
2. Oil level gauge guide
3. O-ring
4. Heat protector, rear
5. Exhaust manifold, rear
"BA 6. Exhaust manifold gasket, rear
7. Heat protector, front
8. Engine lift bracket
9. Exhaust manifold, front
"BA 10. Exhaust manifold gasket, front
"AA 11. Water pump
12. Water pump gasket

ENGINE OVERHAUL Exhaust Manifold and Water Pump

O-ring

Water pump

INSTALLATION SERVICE POINTS

"AA O-RING AND WATER PIPE INSTALLATION
1. Wet the O-ring (with water) to facilitate assembly.
Caution
Keep the O-ring free of oil or grease.

Water inlet pipe

Cylinder No.
For right bank

Front

Front

For left bank

Cylinder No.

"BA EXHAUST MANIFOLD GASKET INSTALLATION

1. Install gaskets with cylinder number 1, 3 and 5 embossed
on their top side to the right bank and install those with
cylinder number 2, 4 and 6 to the left bank.

Main
Index
11B
Index

ENGINE OVERHAUL Rocker Arms and Camshaft

Main
Index

ROCKER ARMS AND CAMSHAFT

REMOVAL AND INSTALLATION

11B
Index

3.5 Nm
31 Nm

2
10
6

3
8

7 9

8
5

11
7

13

12

12 Nm

12
14

12
16

15

17

4
Lubricate all internal
parts with engine oil
during reassembly.

Removal steps
1. Rocker cover
2. Rocker cover gasket
3. Oil seal
"EA 4. Camshaft oil seal
AA"
5. Rocker arm, rocker arm shaft
AA"
6. Rocker arm, rocker arm shaft
"DA 7. Rocker shaft spring
8. Rocker arm A
9. Rocker arm B

"CA 10. Rocker arm shaft

"BA 11. Lash adjuster
12. Rocker arm C
"CA 13. Rocker arm shaft
"BA 14. Lash adjuster
15. Thrust case
16. O-ring
"AA 17. Camshaft

ENGINE OVERHAUL Rocker Arms and Camshaft

REMOVAL SERVICE POINT

Main
Index

AA" ROCKER ARM, ROCKER ARM SHAFT REMOVAL

1. Install the special tools to the rocker arm to hold the
11B
lash adjuster.
2. Loosen the camshaft bearing cap bolt. Do not remove Index
the bolts from the cap.
3. Remove the rocker arm, shaft and bearing cap as an
assembly.
E9M402

NOTE
If the lash adjuster is to be re-used, it must be cleaned and
checked before installation, refer to Lash Adjuster Cleaning
and Checking.

INSTALLATION SERVICE POINTS

"AA CAMSHAFT INSTALLATION
1. Apply engine oil to the camshaft journals and cams and
then install the camshafts.
Use care to prevent confusion of the right and left bank
camshafts.

Slit

Right bank
Approx.
60

Left bank

2. Check to see that the dowel pin of the camshaft is located

at the position shown.

Approx.
71

E9M402

Lash
adjuster

NOTE
The right bank camshaft is identified by a slit 4 mm wide
at the rear end of the camshaft.

"BA LASH ADJUSTER INSTALLATION

NOTE
If the lash adjuster is to be re-used, it must be cleaned and
checked before installation. refer to Lash adjuster cleaning
and checking.
1. Fit the lash adjuster onto the rocker arm without allowing
diesel fuel to spill out. Fit special tool E9M40 2 to prevent
the lash adjuster coming free and falling to the floor.

ENGINE OVERHAUL Rocker Arms and Camshaft

Main
"CA ROCKER ARM SHAFT
Index
1. The end with the larger chamfer is at the right on the
left bank and at the left on the right bank.

Timing belt side

11B
NOTE
Before installing the exhaust rocker arms and rocker arm Index
shaft, mount the rocker shaft spring.

Chamfered

Oil hole

2. The side with the oil holes is on the lower side (cylinder
head side).

"DA ROCKER SHAFT SPRING

1. Insert the rocker shaft spring at a slant with respect to
the spark plug guide and install it normal to the guide.

Rocker shaft
spring

"EA CAMSHAFT OIL SEAL INSTALLATION

<Right bank side>

EMD998713

<Left bank side>

EMD998713

EMB991559

ENGINE OVERHAUL Rocker Arms and Camshaft

INSPECTION
ROCKER ARM SHAFT
1. Check the rocker arm mounting portions of the rocker
arm shafts for wear or damage. Replace as necessary.
ROCKER ARM
1. Check the roller surface and replace the rocker arm if
recesses, damage or heat seizure is observed.
2. Check roller rotation and replace the rocker arm if uneven
rotation or roller backlash is observed.
3. Check the inside diameter and replace the rocker arm
if damage or seizure is observed.
CAMSHAFT
1. Inspect the camshaft bearing journals for damage and
binding. If the journals are binding, also check the cylinder
head for damage. Also check the cylinder head oil holes
for clogging.
2. Check the cam surface for abnormal wear and damage
and replace if defective. Also measure the cam height
and replace if out of limit.
Standard value

Limit

Intake mm

37.58

37.08

Exhaust mm

36.95

36.45

Main
Index
11B
Index

ENGINE OVERHAUL Lash Adjuster Cleaning and Checking

LASH ADJUSTER CLEANING AND CHECKING
Outside
cleaning

Inside
cleaning

Filling
diesel fuel

Caution
D The lash adjusters are precision-engineered
mechanisms. Do not allow them to become 11B
contaminated by dirt or other foreign substances. Index
D Do not attempt to disassemble the lash adjusters.
D Use only fresh diesel fuel to clean the lash
adjusters.
1. Prepare three containers and approximately five litres
of diesel fuel. Into each container, pour enough diesel
fuel to completely cover a lash adjuster when it is standing
upright. Then, perform the following steps with each lash
adjuster.
2. Place the lash adjuster in container A and clean its outside
surface.
NOTE
Use a nylon brush if deposits are hard to remove.

3. Fit special tool EMD998441 onto the lash adjuster.

EMD998441

Diesel
fuel

E9M40 1

Caution
The steel ball spring is extremely weak, so the lash
adjusters functionality may be lost if the air bleed
wire is pushed in hard.
4. While gently pushing down the internal steel ball using
special tool E9M40 1, move the plunger through five
to ten strokes until it slides smoothly. In addition to
eliminating stiffness in the plunger, this operation will
remove dirty oil.
NOTE
If the plunger remains stiff or the mechanism appears
otherwise abnormal, replace the lash adjuster.

5. Remove the lash adjuster from the container. Then, push

down the steel ball gently and push the plunger to eliminate
diesel fuel from the pressure chamber.

EMD998441

E9M40 1
Diesel fuel

Main
Index

ENGINE OVERHAUL Lash Adjuster Cleaning and Checking

6. Fit special tool EMD998441 onto the lash adjuster.

EMD998441

Diesel
fuel

E9M40 1

Caution
The steel ball spring is extremely weak, so the lash
adjusters functionality may be lost if the air bleed 11B
wire is pushed in hard.
Index
7. Place the lash adjuster in container B. Then, gently push
down the internal steel ball using special tool
E9M40 1 and move the plunger through five to ten
strokes until it slides smoothly. This operation will clean
the lash adjusters pressure chamber.
8. Remove the lash adjuster from the container. Then, push
down the steel ball gently and push the plunger to eliminate
diesel fuel from the pressure chamber.

EMD998441

E9M40 1
Diesel fuel

E9M40 1

Diesel fuel
EMD998441

EMD998441

Caution
Do not use container C for cleaning. If cleaning is
performed in container C, foreign matter could enter
the pressure chamber when the chamber is filled with
diesel fuel.
9. Place the lash adjuster in container C. Then, gently push
down the internal steel ball using special tool
E9M40 1.

10. Stand the lash adjuster with its plunger at the top, then
push the plunger downward firmly until it moves through
its greatest possible stroke. Return the plunger slowly,
then release the steel ball and allow the pressure chamber
to fill with diesel fuel.
11. Remove special tool EMD998441.

E9M40 1

Main
Index

Diesel fuel

12. Remove the lash adjuster from the container, then stand
the lash adjuster with its plunger at the top. Push the
plunger firmly and check that it does not move. Also,
check that the lash adjusters height matches that of a
new lash adjuster.
NOTE
If lash adjuster contracts, perform the operations (9)
through (12) again to fill it with diesel fuel completely.
Replace the lash adjuster if it still contracts after performing
these steps.

ENGINE OVERHAUL Lash Adjuster Cleaning and Checking

Division = 1mm
49U012005

Lash Adjuster

13. Set the lash adjuster on the special tool 49U012005 (leak Main
Index
down tester).
14. After the plunger has moved downward slightly [ 0.2 to
0.5mm ], measure the time taken for it to move downward
11B
by a further 1 mm.
Standard value: 5 20 seconds/1mm [with diesel fuel
at 15 to 20_C]
NOTE
Replace the lash adjuster if the time measurement is
out of specification.

E9M40 1

EMD998441

Diesel fuel

15. Fit special tool EMD998441 onto the lash adjuster.

16. Place the lash adjuster in container C again, then gently
push down the internal steel ball using special tool
E9M40 1.
17. Stand the lash adjuster with its plunger at the top, then
push the plunger downward firmly until it moves through
its greatest possible stroke. Return the plunger slowly,
then release the steel ball and allow the pressure chamber
to fill with diesel fuel.
18. Remove special tool EMD998441.
19. Remove the lash adjuster from the container, then stand
the lash adjuster with its plunger at the top. Push the
plunger firmly and check that it does not move. Also,
check that the lash adjusters height matches that of a
new lash adjuster.
NOTE
If lash adjuster contracts, perform the operations (15)
through (19) again to fill it with diesel fuel completely.
Replace the lash adjuster if it still contracts after performing
these steps.
20. Stand the lash adjuster upright to prevent diesel fuel
spilling out. Do not allow the lash adjuster to become
contaminated by dirt or other foreign matter. Fit the lash
adjuster onto the engine as soon as possible.

Index

ENGINE OVERHAUL Cylinder Head and Valve

Main
Index

CYLINDER HEAD AND VALVE

REMOVAL AND INSTALLATION
1
108 Nm

2
5

Lubricate all internal

parts with engine oil
during reassembly.

6
7
13
14
17

19 16

11

22
18 15

21

10

12

20
8
3

Removal steps
AA" "DA 1. Cylinder head bolt
2. Washer
3. Cylinder head assembly
4. Cylinder head gasket
AB" "CA 5. Retainer lock
6. Valve spring retainer
"BA 7. Valve spring
8. Intake valve
AB" "CA 9. Retainer lock
10. Valve spring retainer
"BA 11. Valve spring

12.
AC" "AA 13.
14.
AC" "AA 15.
16.
17.
18.
19.
20.
21.
22.

Exhaust valve
Valve stem seal
Valve spring seat
Valve stem seal
Valve spring seat
Intake valve guide
Snap ring
Exhaust valve guide
Intake valve seat
Exhaust valve seat
Cylinder head

11B
Index

ENGINE OVERHAUL Cylinder Head and Valve

REMOVAL SERVICE POINTS

PRECAUTION FOR REMOVED PARTS
1. Keep removed parts in order according to the cylinder
number and intake/exhaust.

AA" CYLINDER HEAD BOLT REMOVAL

E1139

J8062

AB" RETAINER LOCK REMOVAL

1. Using the special tool, compress the spring.
2. Remove the retainer locks.

MD998772

AC" VALVE STEM SEAL REMOVAL

1. Do not re-use removed valve stem seals.

Main
Index
11B
Index

ENGINE OVERHAUL Cylinder Head and Valve

Identification colour: Silver or White

Intake

Identification
our: Black

col-

INSTALLATION SERVICE POINTS

"AA VALVE STEM SEAL INSTALLATION
1. Install the valve spring seat.

Exhaust

EMD998774

2. Using the special tool, install a new stem seal to the

valve guide.
Caution
1. Valve stem seals for intake valve and for exhaust
valve are different. Be sure to install the correct
ones.
Valve stem seal identification colour
Intake: Silver or White
Exhaust: Black
2. Do not re-use removed valve stem seal.
3. Always use the special tool to install the valve
stem seal. Improperly installed valve stem seal
may cause oil leak.

Identification
colour

Spring
retainer

Stem seal

Spring seat

"BA VALVE SPRING INSTALLATION

1. Direct the valve spring end with identification colour toward
the spring retainer.

Main
Index
11B
Index

ENGINE OVERHAUL Cylinder Head and Valve

Main
"CA RETAINER LOCK INSTALLATION
Index
1. Using the special tool, compress the valve spring and
insert the retainer lock into position.

J8062

11B
Index

MD998772

Exhaust side

<Left bank>
Rounded side

6
5

2
1

3
4

Intake side
Cylinder head
bolt washer
<Right bank>

8
7

4
3

1
2

Exhaust side

7
8
Engine
front

5
6

"DA CYLINDER HEAD BOLT INSTALLATION

1. Tighten the cylinder head bolts using the special tool
in the sequence shown. Each bolt should be tightened
in two to three steps, torquing progressively. Tighten to
the specified torque in the final sequence.

ENGINE OVERHAUL Cylinder Head and Valve

INSPECTION

Main
Index

CYLINDER HEAD
1. Check the cylinder head gasket surface for flatness by
using a straightedge in the directions of A through G 11B
shown in the illustration.
Index
Standard value
0.03 mm
Limit: 0.2 mm
2. If the service limit is exceeded, correct to meet the
specification.
Grinding limit: *0.2 mm
* Total resurfacing depth of both cylinder head and cylinder
block.
Overall height
120 mm

VALVE
1. If the valve stem is worn (ridge wear) or otherwise
damaged, replace. Also replace the valve if the stem
end (that contacts the rocker arm lash adjuster) has an
indentation.

Ridge
wear

2. Check the valve face for correct contact. If incorrect, reface

using a valve refacer. Valve should make a uniform contact
with the seat at the centre of valve face.
3. If the margin exceeds the service limit, replace the valve.
Standard value
Valve seat
contact

Margin

<Intake>
1.0 mm
<Exhaust>
1.2 mm
Limit
<Intake>
0.5 mm
<Exhaust>
1.2 mm

ENGINE OVERHAUL Cylinder Head and Valve

Main
VALVE SPRINGS
Index
1. Measure the free height of the spring and, if it is smaller
than the limit, replace.

Standard value
51.0 mm

Free
height

Limit
50.0 mm
2. Measure the squareness of the spring and, if the limit
is exceeded, replace.
Standard value: 2
Limit: Max. 4

VALVE GUIDES
1. Measure the clearance between the valve guide and valve
stem. If the limit is exceeded, replace the valve guide
or valve, or both.

Valve stem O.D.

Standard value

Valve
guide

<Intake>
0.020.05 mm
<Exhaust>
0.040.07 mm

Guide I.D.

Limit
<Intake>
0.10 mm
<Exhaust>
0.15 mm

0.91.3 mm
0.91.3 mm
65

65
15

15
44

44

VALVE SEAT RECONDITIONING PROCEDURE

1. Before correcting the valve seat, check for clearance
between the valve guide and valve and, if necessary,
replace the valve guide.
2. Using the special tool or seat grinder, correct to obtain
the specified seat width and angle.
3. After correction, valve and valve seat should be lapped
with a lapping compound.

11B
Index

ENGINE OVERHAUL Cylinder Head and Valve

VALVE SEAT REPLACEMENT PROCEDURE

0.51 mm

1. Cut the valve seat to be replaced from the inside to thin

the wall thickness. Then, remove the valve seat.

11B
Index

Cut
away
0.51 mm

2. Rebore the valve seat hole in the cylinder head to a

selected oversize valve seat diameter.
Seat ring hole diameter:
See Rework Dimensions.
Height of
seat ring

Oversize I.D.

3. Before fitting the valve seat, either heat the cylinder head
up to approximately 250C or cool the valve seat in liquid
nitrogen, to prevent the cylinder head bore from galling.
4. Using a valve seat cutter, correct the valve seat to the
specified width and angle.
See VALVE SEAT RECONDITIONING PROCEDURE.

VALVE GUIDE REPLACEMENT PROCEDURE

1. Remove the snap ring from the exhaust valve guide.
2. Using the press, remove the valve guide toward the
cylinder block.
3. Rebore the valve guide hole of the cylinder head so that
it may fit to the press-fitted oversize valve guide.
Caution
Do not install a valve guide of the same size again.
Valve guide hole diameter:
See Rework Dimensions.
4. Press-fit the valve guide until it protrudes 14 mm from
the cylinder head top surface as shown in the illustration.

14 mm

Main
Index

NOTE
1. When press-fitting the valve guide, work from the
cylinder head top surface.
2. Pay attention to the difference in length of the valve
guides. [intake side: 45.5 mm; exhaust side: 50.5
mm]
3. After installing the valve guides, insert new valves
in them to check for sliding condition.

ENGINE OVERHAUL Oil Pan and Oil Pump

Main
Index

OIL PAN AND OIL PUMP

REMOVAL AND INSTALLATION

11B
Index

20
21

18

22
13
9.8 Nm

13 Nm

12
19
3
41 Nm

16
15
14

17

44 Nm

9.8 Nm

11
10

18 Nm

11 Nm
9.8 Nm

9.8 Nm
23 Nm
23 Nm

11 Nm

5
39 Nm

Lubricate all internal

parts with engine oil
during reassembly.

Removal steps
"HA 1. Oil pressure gauge unit
"GA 2. Oil filter
3. Oil filter bracket
4. Oil filter bracket gasket
5. Drain plug
"FA 6. Drain plug gasket
AA" "EA 7. Oil pan, lower
8. Cover
AB" "DA 9. Oil pan, upper
10. Baffle plate
11. Oil screen

5.9 Nm

6
11 Nm

"CA
"BA
AC" "AA
AC" "AA

12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.

Oil screen gasket

Baffle plate
Plug
Relief spring
Relief plunger
Crankshaft oil seal
Oil pump case
O-ring
Oil pump cover
Oil pump outer rotor
Oil pump inner rotor

ENGINE OVERHAUL Oil Pan and Oil Pump

REMOVAL SERVICE POINT

AA" OIL PAN, LOWER REMOVAL
1. Apply wood to the oil pan side and remove the oil pan
lower with a plastic hammer.
Caution
Do not use a scraper or special tool to remove the
oil pan.

Timing belt side

AB" OIL PAN, UPPER REMOVAL

1. Remove the bolts 1 shown in the illustration.
2. Remove all other bolts.

3. Thread the bolt into the illustrated bolt hole A (at each
end) to float and remove the oil pan.
Caution
Do not use a scraper or special tool to remove the
oil pan.

Alignment dots

AC" OUTER ROTOR/INNER ROTOR REMOVAL

1. Make alignment dots on the outer and inner rotors for
reference in reassembly.

Main
Index
11B
Index

ENGINE OVERHAUL Oil Pan and Oil Pump

INSTALLATION SERVICE POINTS

Alignment dots

"AA INNER ROTOR/OUTER ROTOR INSTALLATION

1. Apply engine oil to the rotors. Then, install the rotors
ensuring that the alignment dots made at disassembly 11B
are properly aligned.
Index

"BA OIL PUMP CASE INSTALLATION

1. Remove the sealant from the cylinder block (oil pump
mounting plane) and oil pump
2. Apply a 3 mm diameter bead of sealant to the oil pump
case. Be sure to install the oil pan quickly while the
sealant is wet (within 15 minutes).
3. After installation, keep the sealed area away from the
oil and coolant for approx. 1 hour.
Specified sealant:
MITSUBISHI GENUINE Part No. MD970389 / Loctite
587 Ultra blue or equivalent
"CA CRANKSHAFT FRONT OIL SEAL INSTALLATION
1. Using the special tool, knock the oil seal into the oil pump
case.
NOTE
Knock the seal in until it is fully based.

EMD998717

EMD998717 Crankshaft

Guide
Oil seal

Oil pump case

Main
Index

ENGINE OVERHAUL Oil Pan and Oil Pump

Main
"DA OIL PAN, UPPER INSTALLATION
Index
1. Clean the gasket surfaces of the cylinder block and upper
oil pan.
2. Apply a 4 mm diameter bead of sealant to the oil pump 11B
case. Be sure to install the oil pan quickly while the
Index
sealant is wet (within 15 minutes).
3. After installation, keep the sealed area away from the
oil and coolant for approx. 1 hour.
Caution
When installing the upper oil pan, be sure not to expel
the sealant from the oil pan flange at portion A in
the illustration.
Specified sealant:
MITSUBISHI GENUINE Part No. MD970389 / Loctite
587 Ultra blue or equivalent

"EA OIL PAN, LOWER INSTALLATION

1. Clean the gasket surfaces of the upper and lower oil
pans.
2. Apply a 4 mm diameter bead of sealant to the oil pump
case. Be sure to install the oil pan quickly while the
sealant is wet (within 15 minutes).
3. After installation, keep the sealed area away from the
oil and coolant for approx. 1 hour.

View from above

oil pan, lower

Flange bolt tightening sequence

10
9
8

7
5

View from the bottom of the oil pan, lower

Specified sealant:
MITSUBISHI GENUINE Part No. MD970389 / Loctite
587 Ultra blue or equivalent

ENGINE OVERHAUL Oil Pan and Oil Pump

"FA DRAIN PLUG GASKET INSTALLATION
1. Install the drain plug gasket as illustrated.
Drain plug

Gasket

Main
Index
11B
Index

Oil pan

Oil pan
side

Bracket
side
Apply
engine oil

"GA OIL FILTER INSTALLATION

1. Clean the installation surface of the filter bracket.
2. Apply engine oil to the O-ring of the oil filter.
3. Screw the oil filter on until the O-ring contacts the bracket.
Then tighten approximately one turn [14 Nm].

"HA SEALANT APPLICATION TO OIL PRESSURE

SWITCH
1. Coat the threads of the switch with sealant and install
the switch using the special tool.
Specified sealant:
Loctite 577 or equivalent
Caution
1. Keep the end of threaded portion clear of sealant.
2. Avoid over tightening.

ENGINE OVERHAUL Oil Pan and Oil Pump

INSPECTION
OIL PUMP
1. Check the tip clearance.
Standard value: 0.060.18 mm

2. Check the side clearance.

Standard value: 0.040.10 mm

3. Check the body clearance.

Standard value: 0.100.18 mm
Limit: 0.35 mm

Main
Index
11B
Index

ENGINE OVERHAUL Piston and Connecting Rod

Main
Index

PISTON AND CONNECTING ROD

REMOVAL AND INSTALLATION <6G72>

11B
Index
6
Lubricate all internal
parts with engine oil
during reassembly.

7
10

12

11

3
2
1
52 Nm

Removal steps
1. Nut
AA" "EA 2. Connecting rod cap
3. Connecting rod bearing, lower
"DA 4. Piston and connecting rod
assembly
5. Connecting rod bearing, upper
"CA 6. Piston ring No.1

"CA 7. Piston ring No.2

"BA 8. Oil ring
AB" "AA 9. Piston pin
10. Piston
11. Connecting rod
12. Bolt

ENGINE OVERHAUL Piston and Connecting Rod

Main
Index

REMOVAL AND INSTALLATION <6G74>

Lubricate all internal

parts with engine oil
during reassembly.

11B
Index

7
8
12

10
11

4
14

13

3
2
1
52 Nm

AA" "EA
"DA
"CA
"CA

Removal steps
1. Nut
2. Connecting rod cap
3. Connecting rod bearing, lower
4. Piston and connecting rod
assembly
5. Connecting rod bearing, upper
6. Piston ring No.1
7. Piston ring No.2

"BA 8.
9.
AB" "AA 10.
11.
12.
13.
14.

Oil ring
Snap ring
Piston pin
Snap ring
Piston
Connecting rod
Bolt

ENGINE OVERHAUL Piston and Connecting Rod

REMOVAL SERVICE POINTS

Cylinder number

Push rod

Guide A:
17.9mm

Guide B

AA" CONNECTING ROD CAP REMOVAL

1. Mark the cylinder number on the side of the connecting
11B
rod big end for correct reassembly.
2. Keep the removed connecting rods, caps, and bearings Index
in order according to the cylinder number.

AB" REMOVAL OF PISTON PIN<6G72>

The special piston pin setting tool (MD998780) consists of
the parts shown at left.

Guide A:
18.9mm

Guide C

Guide A:
20.9mm

Base

Guide A:
21.9mm

Push rod

Front
mark

Front mark

Guide C

Base

Main
Index

1. Insert the special push rod tool from the front marked
(arrow) side of the piston and attach guide C.
2. Set the piston and connecting rod assembly to the special
tool piston pin setting base such that the front mark on
the piston faces upward.
3. Remove the piston pin with a press.
NOTE:
After removing the piston pin, place the piston, the piston
pin, and the connecting rod in order for each cylinder
number.

ENGINE OVERHAUL Piston and Connecting Rod

70_C

Main
AB" REMOVAL OF PISTON PIN<6G74>
Index
1. Remove the snap rings.
2. Heat the piston to approximately 70_C and pull out the
piston pin.
11B

Index

Caution

The clearance between the piston and the piston pin

is an almost tight fit at normal temperature. Therefore,
be sure to heat the piston before pulling out the piston
pin. In addition, note that the piston is hot after heating.

INSTALLATION SERVICE POINTS

"AA PISTON PIN INSTALLATION<6G72>

1. Measure the dimensions of the following parts and
portions.
A: Piston pin mounting portion
B: Distance between piston bosses
C: Piston pin
D: Connecting rod

Connecting rod
Piston pin
Piston

2. Calculate by subtracting each measured value into the

following equation.
L = (A C) (B D)
2

3mm + L

3. Insert the special push rod tool into the piston pin and
attach guide A to it.
4. Combine the piston and connecting rod, matching their
front marks.
5. Apply engine oil to the outer periphery of the piston pin.
6. Insert the side of the piston pin guide A attached per
step (3) into the pin hole from the side of the piston
containing the front mark.
7. Screw guide B into guide A until they are distance L
(obtained per step (2) above) plus 3 mm apart as shown.
8. Use special tools to set the piston pin to a special tool
piston base with the front mark of the piston facing up.
9. Press fit the piston pin with a press. When the load required
for press fitting the piston pin is below the standard value,
change the piston pin (piston assembly) or connecting
rod or both.
Standard value: 7,350 17,200 N

Guide A

Guide B

ENGINE OVERHAUL Piston and Connecting Rod

Main
Index

Push rod

11B
Index

Piston pin
Front
mark

Front mark

Guide A

Base
Guide B

Front mark
74
Front mark

"AA PISTON PIN INSTALLATION<6G74>

1. Heat the piston to approximately 70_C and set the snap
ring on one side first. Be sure to install the snap ring
with the shear droop directed toward the inside.
2. With the front mark of the connecting rod and that of
the piston located on the same side, insert the piston
pin.
3. After insertion of the piston pin, set the other snap ring.
Caution
Apply an ample coat of engine oil to the periphery
of the piston pin and the hole of the connecting rod
small end.
The clearance between the piston and the piston pin
is an almost tight fit at normal temperature. Therefore,
be sure to heat the piston before inserting the piston
pin.
In addition, note that the piston is hot after heating.

ENGINE OVERHAUL Piston and Connecting Rod

"BA OIL RING INSTALLATION
1. Fit the oil ring spacer into the piston ring groove.

Main
Index

NOTE
The side rails and spacer may be installed in either 11B
direction.
Index

Side rail gap

2. Install the upper side rail

To install the side rail, first fit one end of the rail into
the piston groove, then press the remaining portion into
the position by finger. See illustration.
Use of a ring expander to expand the side rail end gap
can break the side rail, unlike other piston rings.
NOTE
Do not use any piston ring expander when installing the
side rail.
3. Install the lower side rail in the same procedure as
described in step (2).
4. Make sure that the side rails move smoothly in either
direction.

"CA PISTON RING NO.2/PISTON RING NO.1

INSTALLATION
1. Using a piston ring expander, fit No.2 and then No.1
piston ring into position.
NOTE
1. The ring end is provided with the identification mark.
Identification mark
No. 1 ring

No. 2 ring

T2

2. Install piston rings with identification mark facing up,

to the piston crown side.

ENGINE OVERHAUL Piston and Connecting Rod

Upper
side rail

No.1

Piston pin

No.2 ring gap

and spacer gap

Main
"DA PISTON AND CONNECTING ROD INSTALLATION
Index
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 11B
spacer) as shown in the illustration.
3. Rotate the crankshaft so that the crank pin is on the Index
centre of the cylinder bore.

Lower
side rail

4. Use suitable thread protectors on the connecting rod bolts

before inserting the piston and connecting rod assembly
into the cylinder block.
Care must be taken not to nick the crank pin.
5. Using a suitable piston ring compressor tool, install the
piston and connecting rod assembly into the cylinder block.
Caution
Install the piston with the front mark (arrow mark)
on the top of the piston directed towards the engine
front (timing belt side).

Cylinder No.

"EA CONNECTING ROD CAP INSTALLATION

1. Mate the correct bearing cap with the correct connecting
rod by checking with the alignment marks marked during
disassembly. If a new connecting rod is used which has
no alignment mark, position the notches for locking the
bearing on the same side.

Notches

2. Check if the thrust clearance in the connecting rod big

end is correct.
Standard value: 0.100.25 mm
Limit: 0.4 mm

ENGINE OVERHAUL Piston and Connecting Rod

INSPECTION

Main
Index

CYLINDER BLOCK
1. Visually check for scratches, rust, and corrosion. Also
use a flaw detecting agent for the check. If defects are 11B
evident, correct, or replace.
Index
2. Using a straightedge and feeler gauge, check the flatness
of the block top surface. Make sure that the surface is
free from gasket pieces and other foreign matter.
Standard value: 0.05 mm
Limit: 0.1 mm
3. If distortion is excessive, correct within the allowable limit
or replace.
Grinding limit: 0.2 mm
*Includes/combined with cylinder head grinding.
Cylinder block height (when new):
210.4210.6 mm

12 mm
Centre
Bottom

4. Check the cylinder walls for scratches and seizure. If

defects are evident, correct (rebore to an oversize) or
replace.
5. Using a cylinder gauge, measure the cylinder bore and
cylindricality. If worn badly, correct by boring the cylinders
to an oversize and replace pistons and piston rings.
Measure at the points shown in the illustration.
Standard value:
6G72 Cylinder I.D.: 91.1 mm
6G74 Cylinder I.D.: 93.0 mm
Cylindricality: 0.01 mm

ENGINE OVERHAUL Piston and Connecting Rod

Main
BORING CYLINDER
Index
1. Oversize pistons to be used should be determined on
the basis of the largest bore cylinder.
Piston size identification
Thrust
direction
Piston O.D.

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 the outside diameter of the piston to be used.
Measure it in the thrust direction as shown.
3. Based on the measured piston O.D., calculate the boring
finish dimension.
Boring finish dimension =
Piston O.D. + (clearance between piston O.D. and
cylinder) 0.02 mm (honing margin)
4. Bore all cylinders to the calculated boring finish dimension.
Caution
To prevent distortion that may result from temperature
rise during honing, bore cylinders in the order of No.2,
No.4, No.6, No.1, No.3 and No.5.
5. Hone to the final finish dimension (piston O.D. + clearance
between piston O.D. and cylinder).
6. Check the clearance between the piston and cylinder.
Clearance between piston and cylinder:
0.020.04 mm
NOTE
When boring cylinders, finish all of six cylinders to the
same oversize. Do not bore only one cylinder to an
oversize.
PISTON
1. Replace the piston if scratches or seizure are evident
on its surfaces (especially the thrust surface). Replace
the piston if it is cracked.
PISTON PIN
1. Insert the piston pin into the piston pin hole with a thumb.
You should feel a slight resistance. Replace the piston
pin if it can be easily inserted or there is an excessive
play.
2. The piston and piston pin must be replaced as an
assembly.
PISTON RING
1. Check the piston ring for damage, excessive wear, and
breakage and replace if defects are evident. If the piston
has been replaced with a new one, the piston rings must
also be replaced with new ones.

11B
Index

ENGINE OVERHAUL Piston and Connecting Rod

2. Check for clearance between the piston ring and ring Main
groove. If the limit is exceeded, replace the ring or piston, Index
or both.
Standard value:
No. 1 0.030.07 mm
No. 2 0.020.06 mm
Limit: 0.1 mm

Push in by piston

Piston ring

Piston
ring gap

3. Insert the piston ring into the cylinder bore. Force the
ring down with a piston, the piston crown being in contact
with the ring, to correctly position it at right angles to
the cylinder wall. Then, measure the end gap with a feeler
gauge.
If the ring gap is excessive, replace the piston ring.
Standard value:
No. 1: 0.300.45 mm
No. 2: 0.450.60 mm
Oil: 0.200.60 mm
Limit:
No. 1, No. 2: 0.8 mm
Oil: 1.0 mm

Plastigauge

CRANKSHAFT PIN OIL CLEARANCE (PLASTIGAUGE

METHOD)
The crankshaft oil clearance can be measured easily by using
Plastigauge, as follows:
1. Remove oil and grease and any other foreign matters
from the crankshaft pin and the bearing inner surface.
2. Install the crankshaft.
3. Cut Plastigauge to the same length as the width of the
bearing and place it on the pin in parallel with its axis.
4. Gently place the crankshaft bearing cap over it and tighten
the bolts to the specified torque.
5. Remove the bolts and gently remove the crankshaft
bearing cap.
6. Measure the width of the crushed Plastigauge at its widest
section by using a scale printed on the Plastigauge bag.
Standard value: 0.020.05 mm
Limit: 0.1 mm

11B
Index

ENGINE OVERHAUL Crankshaft, Flywheel and Drive Plate

Main
Index

CRANKSHAFT, FLYWHEEL AND DRIVE PLATE

REMOVAL AND INSTALLATION
2

11B
Index

75 Nm

11 Nm

11 Nm

7
5

98 Nm

18
16

15
17

14

12 <6G72>

11 <6G72>
13

Lubricate all internal

parts with engine oil
during reassembly.

10
<6G72>
9

10
<6G74>

93 Nm

9
7080 Nm

Removal steps
1. Adaptor plate
2. Drive plate
3. Plate
4. Adaptor plate
5. Flywheel
6. Rear plate
"DA 7. Oil seal case
"CA 8. Crankshaft rear oil seal
"BA 9. Bearing cap bolt

"BA
"AA
"AA
"AA

10.
11.
12.
13.
14.
"AA 15.
"AA 16.
"AA 17.
18.

Bearing cap
Thrust bearing A <6G72>
Thrust bearing B <6G72>
Crankshaft bearing, lower
Crankshaft
Thrust bearing B
Thrust bearing A
Crankshaft bearing, upper
Cylinder block

ENGINE OVERHAUL Crankshaft, Flywheel and Drive Plate

Location of Identification colour No. 4 journal
No. 2 journal No. 3 journal

No. 1 journal

Cylinder block bore

size mark (reference)

Main
"AA CRANKSHAFT BEARING INSTALLATION
Index
MAIN BEARINGS
When bearing replacement is required, select and install the
correct bearing by the following procedure.
11B
1. Measure the crankshaft journal diameter and confirm its
Index
classification from the following table. In the case of a
crankshaft supplied as a service part, identification colours
of its journals are painted at the positions shown in the
illustration.
2. The cylinder block bearing bore diameter identification
marks are stamped at the position shown in the illustration
from left to right, beginning at No. 1.
<6G72>
Combination of crankshaft journal diameter
and cylinder block bearing bore diameter
Crankshaft journal

Cylinder block
bearing bore
diameter
identification mark

Classification

Identification
colour
Produc- Service
tion part
part

Identification mark

None

None

Yellow

None

Identification colour

3
Oil groove

Groove

None

White

O.D.
mm
59.994

60.000
59.988

59.994
59.982

59.988

Bearing
identification
Cylincolour or
der
identiblock
fication
bearing
mark (for
bore diservice
ameter
part)
identification
mark
l
Pink(1)
ll

Red(2)

lll

Green(3)

Red(2)

lll

Green(3)

lll

Black(4)

Green(3)

ll

Black(4)

lll

Brown(5)

ENGINE OVERHAUL Crankshaft, Flywheel and Drive Plate

Main
Index

<6G74>
Bearing
identification
Cylincolour or
der
identiblock
fication
bearing
mark (for
bore diservice
ameter
part)
identification
mark
l
Pink(1)

Combination of crankshaft journal diameter

and cylinder block bearing bore diameter
Crankshaft journal

Classification

Identification
colour
Produc- Service
tion part
part

None

None

None

Yellow

None

White

O.D.
mm
63.994

64.000
63.988

63.994
63.982

63.988

ll

Red(2)

lll

Green(3)

Red(2)

lll

Green(3)

lll

Black(4)

Green(3)

ll

Black(4)

lll

Brown(5)

3. Select the correct bearing from the above tables on the

basis of the identification data confirmed at steps 1 and
2.
Example <6G72>
1. 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 also replaced by a spare
part, check the identification colours of the journals
painted on the new crankshaft. If the colour is yellow,
for example, the journal is classified as 1 .
2. Next, check the cylinder block bearing bore
identification mark stamped on the cylinder block.
If it is 1, read the Bearing identification colour
column to find the identification colour of the bearing
to be used. In this case, it is pink.
4. Install the bearing halves with oil groove in the cylinder
block side.
5. Install the bearing halves without oil groove on the bearing
cap side.
6. Install the thrust bearings on both sides of the No.3 bearing
with the grooves facing outward.

11B
Index

ENGINE OVERHAUL Crankshaft, Flywheel and Drive Plate

Location of Identification colour
No. 4 journal
No. 1 journal
No. 2 journal

No. 3 journal
No. 5 journal

No. 6 journal

Main
Index

INSTALLATION SERVICE POINTS

"AA CRANKSHAFT BEARING INSTALLATION

CONNECTING ROD <6G74>
When the bearing needs replacing, select and install a proper 11B
bearing by the following procedure.
Index
1. Measure the crankshaft journal diameter and confirm its
classification from the following table. In the case of
a bearing supplied as a service part, its identification
colour is painted at the position shown in the illustration.
2. The connecting rod identification mark is stamped at the
position shown in the illustration.
3. Select a suitable bearing from the following table on the
basis of the identification data confirmed under Items
1. and 2.

Identification mark

Identification colour

Items

Standard value

Crankshaft
Identification mark
(colour)
Production part
None

None

None

Spare
part
Yellow

None

White

Limit

Connecting rod
Big end

Journal O.D.
mm

54.99455.000

54.99854.994

54.98254.988

Identification mark

Bearing

I.D. mm

Identification colour

Thickness mm

58.00058.006

Pink

1.4831.486

58.00658.012

Red

1.4861.489

58.01258.018

Green

1.4891.492

58.00058.006

Red

1.4861.489

58.00658.012

Green

1.4891.492

58.01258.018

Black

1.4921.495

58.00058.006

Green

1.4891.492

58.00658.012

Black

1.4921.495

58.01258.018

Brown

1.4951.498

ENGINE OVERHAUL Crankshaft, Flywheel and Drive Plate

Main
"BA BEARING CAP/BEARING BOLT INSTALLATION
Index
1. Attach the bearing cap on the cylinder block as shown
in the illustration.
2. Tighten the bearing cap bolts to the specified torque in 11B
the sequence shown in the illustration.
Index
3. Check that the crankshaft rotates smoothly.

Crankshaft
Front mark

15 7

8 16

Bearing cap
Bearing cap bolt
3

11 3

14 12

10 2

14 6

5 13

Cylinder block

<6G74>

<6G72>

4. Check the end plate. If it exceeds the limit value, replace

the thrust bearing.
Standard value : 0.050.25 mm
Limit: 0.3 mm

ENGINE OVERHAUL Crankshaft, Flywheel and Drive Plate

Main
"CA CRANKSHAFT REAR OIL SEAL INSTALLATION
Index
1. Using the special tool, press-fit a new crankshaft rear
oil seal into the oil seal case.
11B
Index

EMD998718
Oil seal
case

EMD998718

"DA OIL SEAL CASE INSTALLATION

1. Apply specified sealant to the area shown in the illustration.
Specified sealant:
MITSUBISHI GENUINE Part No. MD970389 / Loctite
587 Ultra blue or equivalent
2. Apply a small amount of engine oil to the entire
circumference of the oil seal lip section, and place the
oil seal on the cylinder block.

INSPECTION
CRANKSHAFT
If the oil clearance exceeds the limit, replace the bearing,
and crankshaft if necessary.
1. Measure the outside diameter of the journals and the
inside diameter of the crankshaft bearings.
If the
difference between them (oil clearance) exceeds the limit,
replace the crankshaft bearing and, if necessary,
crankshaft.
Standard value: 0.020.04 mm
Limit: 0.1 mm
Caution
Do not attempt an undersize machining of the
crankshaft with special surface treatment. This
crankshaft can be identified by its dull gray
appearance.

ENGINE OVERHAUL Crankshaft, Flywheel and Drive Plate

Main
CRANKSHAFT JOURNAL OIL CLEARANCE
Index
<PLASTIGAUGE METHOD>
The crankshaft oil clearance can be measured easily by using
Plastigauge, as follows:
11B
1. Remove oil and grease and any other foreign matters
Index
from the crankshaft journal and bearing inner surface.
2. Install the crankshaft.
3. Cut Plastigauge to the same length as the width of the
bearing and place it on the journal in parallel with its
axis.

Plastigauge

4. Gently place the crankshaft bearing cap over it and tighten

the bolts to the specified torque.
5. Remove the bolts and gently remove the crankshaft
bearing cap.
6. Measure the width of the crushed Plastigauge at its widest
section by using a scale printed on the Plastigauge
package.

FLYWHEEL
1. Check the clutch disc friction surface for ridge wear, cracks
and seizure.
2. If the runout of the flywheel exceeds the limit, replace
the flywheel assembly.
Limit: 0.13 mm

Bolts

Caution
The flywheel mounting bolts shown must not be
removed. If the bolts are removed, the flywheel will
lose its original balance and could break during
operation.