ENGINE 6672

CONTENTS
BRACKET ................................................................ 122 CAMSHAFT, ROCKER ARMS AND BEARING CAPS .................................................... 87 CRANKSHAFT, FLYWHEEL AND DRIVE PLATE ........... . ............................................ 115 CYLINDER HEAD AND VALVES - SOHC ........ 91 CYLINDER HEAD AND VALVES - DOHC ........ 98 EXHAUST MANIFOLD ........................................ 67 2 GENERAL INFORMATION ... ............................. GENERAL SPECIFICATIONS ............................ 12 GENERATOR AND DRIVE BELT ........................ 27 IGNITION SYSTEM ........................... . ................ 44 INTAKE MANIFOLD AND FUEL PARTS ........ 62 INTAKE MANIFOLD PLENUM AND THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PAN AND OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . ROCKER ARMS AND CAMSHAFTS . . . . . . . . . . . . . . . . . SEALANT . . . . .. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THROTTLE BODY . . .. . . . . . . . . . . . . . . . . . . . . . . ...*..... . . . . . . . . . . . . . 32 102 108 77 23 14 24 37 TIMING BELT - SOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 TIMING BELT- DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

‘HE-2

6G7 ENGINE - General Information

GENERAL INFORMATION
SECTIONAL VIEW - SOHC ENGINE for DIAMANTE

7EN0323

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6G7 ENGINE - General Information

llE-3

TEN0324

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IIE-4

6G7 ENGINE - General Information

SECTIONAL VIEW - SOHC ENGINE for MONTERO AND TRUCK

7EN0135

TSB Revision I

667 ENGINE - General Information

7EN0120

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I

WE-6

6G7 ENGINE - General Information

SECTIONAL VIEW - DOHC NON-TURBO ENGINE

7EN0325

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DOHC TURBO ENGINE 7EN0335 1 TSB Revision .General Information SECTIONAL VIEW .IIE-8 6G7 ENGINE .

General Information IIE-9 7EN0334 TSB Revision .667 ENGINE .

General Information JJBRICATION SYSTEM .SOHC / Oil pressure switch \ Oil pressure gauge unit n t Oil cooler by-pass valve .MONTERO only Rocke Lash adjuster 7LUOO34 TSB Revision .IIE-10 6G7 ENGINE .

DOHC llE41 is Oil pressure switch \ Oil pressure gauge unit To turbocharger -turbo only Las To oil cooler Turbo only II Oil cooler by-pass valve -Turbo only Relief valve TSB Revision .667 ENGINE .General Information UBRICATION SYSTEM .

WE-12 SOHC Description 6G7 ENGINE .0 (3.in.9 Type Number of cylinders Combustion chamber Total displacement cm3 (cu.99) 10.1 Cylinder bore x stroke mm (in.59 x 2.972 (181. SOHC (per bank) 6 Compact type 2.General Specifications GENERAL SPECIFICATIONS Specifications 6O”V.) Compression ratio Front wheel drive vehicle Rear wheel drive vehicle Valve timing: Front wheel drive Intake valve Opens Closes Exhaust valve Opens Closes Valve timing: Rear wheel drive Intake valve Opens Closes Exhaust valve Opens Closes Lubrication system 3il pump type Cooling system JVater pump type EG R type njector type and number njector identification mark For MONTERO and TRUCK For DIAMANTE and TRUCK mm (in.I x 76.362) Variable resistor type Movable contact type TSB Revision .4) 91 .) Throttle bore rhrottle position sensor Iosed throttle position switch 16” BTDC 66” ABDC 56” BBDC 26” ATDC 19” BTDC 59” ABDC 59” BBDC 19” ATDC Pressure feed. full-flow filtration Trochoid type Water-cooled forced circulation Centrifugal impeller type Single type Electromagnetic. 6 B210H N21 OH 60 (2.0 8.

972 (181.667 ENGINE . full-flow filtration Trochoid type Water-cooled forced circulation Centrifugal impeller type Single type Electromagnetic.362) Variable resistor type Movable contact type 1 TSB Revision I .1 Cylinder bore x stroke mm (in.0 16” BTDC 55” ABDC 48” BBDC 15” ATDC 16” BTDC 55” ABDC 50” BBDC 17” ATDC Pressure feed.59 x 2.0 8.0 (3.99) 10. 6 BDH210 BDL360 60 (2.1 x 76.) Throttle position sensor Closed throttle position switch Specifications 6O”V.) Compression ratio Non-turbo Turbo Valve timing-Non-turbo Intake valve Opens Closes Exhaust valve Opens Closes Valve timing -Turbo Intake valve Opens Closes Exhaust valve Opens Closes Lubrication system Oil pump type Cooling system tiater pump type EGR type Injector type njector identification mark Non-turbo Turbo Throttle bore mm (in.in.4) 91. DOHC (per bank) 6 Compact type 2.General Specifications DOHC Description Type Number of cylinders Combustion chamber Total displacement cm3 (cu.

4421) 33.4291 .13.2 (.60 38..63 (1.7559 .4929) 36.25 .33 (1.50 .09 (.3 (.5079 .OlO) 0..30 .33 (1.33.3 (.012) 0.1.05 (.27 (4823 .05 .03 (.6 (.0019) 84 (3.1.012) 0.6 (.002) 0.05 .2 (..12.34) 0.024) Camshaft.05 (.36.SOHC Zam height Intake Exhaust lournal diameter Iii clearance dentification mark Limit 0.7441 .008) “0.7453) 44.5209) Less than 0.25 (1.4409 .50 (.6 (.13.002) 0.024) Exhaust 0.6240) 41.3228 .6240) 34 (1.30 44.4921 .020) 3versize rework dimension of valve seat hole Intake 0.SOHC Flatness of gasket surface Grinding limit of gasket surface * Total resurfacing depth of both cylinder head and cylinder block Overall height Oversize rework dimensions of valve guide hole (both intake and exhaust) 0.25 .50 (.5197 .4744.0012) 0.5147) 13.2 (.3122) 33.008) *0.3240) 41.IIE-14 6G7 ENGINE .63 (1.6043) TSB Revision .52 (.75 (1.0020 .0035) for DIAMANTE for MONTERO and TRUCK ! 40.20) 12.07 (.4303) 36.Service Specifications SERVICE SPECIFICATIONS mm (in..27 (5217 .3 (.1.5138.) Standard Cylinder head .024) Exhaust 0.63 (1.05 (.2 (008).5315 .7571) 38.31) 13.12.4831) 12.6043) 40.020) Oversize rework dimension of valve seat hole Intake 0.5091) 38.60 44.012) 0.07 (.3110-1.30-33.1.012) 0.13.5224) 13.1.33(1.25 (.63 (1.3 (.05.12.024) Cylinder head ..52 l.25 (.60 .008) Less than 0.75 (1.5323) 44.0.50 .30 38.DOHC Flatness of gasket surface Grinding limit of gasket surface * Total resurfacing depth of both cylinder head and cylinder block 3verall height Dversize rework dimensions of valve guide hole Iboth intake and exhaust) 0. 132 (5.6 (.60 ..1.1.4752) 12.36..25 (1.33 (1.OlO) 0.

020-.0059) 0.3134-.3858)*'.28(4.10 i.41 (1.09(.97 (4.3661)"' 34.3972)*‘.004)' 102. Rocker arm-to-shaft clearance Rocker shaft .Service SDecifications mm (in.0035) 1.5(.93(.41 (1.91 (1.49(1.01 -0.SOHC I.039) 1.7441) 333.57-6.7453) 0.0012-.667 ENGINE .10 (.3142) 7. Dverall length Valve .34.95 (.98(.05-0.67 (4.05(.0035) 34.15 (. 5 (.0 i.20(1.SOHC 3.0024) 0.7445-.7437-.02-0.03-0.059) 0.3547)"' 34.3776)*' 34. 7 (.0059) 0 .3!%7)"2 18.53-6.0421) 7.039) TSB Revision I .2587-.0020) 0.05-0.1496) 6.06(.019) 1 .1842) 105.5(13.0008-.0039) 0.55(.o i.09 (.059) .91 -18.70 (1.99(1.2 (.5" 0.2591) 6.SOHC 3verall length Intake Exhaust jtem diameter Intake Exhaust -ace angle stem-to guide clearance Intake Exhaust -hickness of valve head (Margin) Intake Exhaust lalve .0016) 18.02) 0.0020-.DOHC Iverall length Intake Exhaust item diameter Intake Exhaust ace angle item-to guide clearance Intake Exhaust hickness of valve head (Margin) Intake Exhaust NOTE *I = Up to 1992 models “2 = from 1993 models Limit 35.3744)** 35.D.09(.96-7.130) 0.89-18.) Standard Camshaft .3130) 45"-45.0035) 1 .o l.047) 2.2579) 45"-45.34.2571 -.D.05-0.15 i.3744)*' 26(1. 106.5 (.0039) 0.0004-.DOHC Cam height Intake Exhaust Journal diameter Oil clearance Rocker arm .3122-.91 (1.079) 0.58(.93-7.5" 0.90 (.10(.04(.0020-.0539) 102.40(4.028) 1 .

.25 LOlO).315 .02 i.SOHC Free length Load/Installed height Out-of-squareness Valve spring .I (3.740)*’ 45.75 (.44.5142-. Service size Valve seat Seat angle valve contact width Sinkage Service size N/mm (Ibs.D. 1 .62 (.DOHC Free length Load/installed height Out-of-squareness Valve guide .4 (1..587) 0. 0.4748 .024) Oversize 91 .12.D.020) Oversize 44.50 f. 0.00 ./in.DOHC Overall length Intake Exhaust I.039) Oversize 91 .0.9 (52.60 .13.D.06 .25 LO1 0) 0.051) 0.25 LO1 0) 0.012).50 (.0008 .591) Less than 2” 45.2 (1.030).316) 13.492) Less than 2” 44.587) 0. = Outer Diameter I.020) 0.50 (.921) 4” Valve spring .780)*‘.2598 .0008 .89) 8.07 (.9 .002).911.Service SDecifications mm (in.D.02 .50 (.) 49.5(1.4 (725/l .988) 6.30 (.73) 48 (1.D. 0.1 240/37.5” 0.2 (1... O.6.D.OO l.OlO). ‘iston-to-cylinder clearance Service size NOTE O.2 0.04 (.05 (.06.0016) 0.75 (..SOHC Overall length Intake Exhaust I. 0.02 . O.in.961) 329/40. ‘iston-to-cylinder clearance Service size ‘iston .002).60 t.3 (035 . 1 .4752) 0.07 (.030).I (3.) Standard Limit 48.791) 50.04 (.0016) 0.020) 0.827)“’ N/mm (Ibs. 46.IIE-16 667 ENGINE . Service size Valve guide .OO (039) Oversize Piston .DOHC 3.8 (1. = Inner Diameter *I = Up to 1992 models “2 = From 1993 models 1 TSB Revision .D.5 (1.8.1.SOHC 3.5146) 0.05 (.2607) 12.787)“’ 4” 44 (1. 0.4 (1..020) Oversize 45.25 (.8 (1.D.0.

0118 .039) 0.1 (.0098) 0.8 (.1 (004) 0.8 (.0028) 0.45 .004) 0.0020) 0.45 LOO98 .20 .0236) 0.0177 .0028) 0.09 (0020 .0.0012 .03 .6G7 ENGINE .D..97) Less than 0. ‘Tess-in load N (Ibs.031) 1 .05 .25 (0020 ..0..039) 1 .005 (.06 (.0. ‘in O.012) 0.8 (.0.3 (.004) 140.02 .22.0008 .70 (.20 .1 ring Front wheel drive vehicle Rear wheel drive vehicle No.) ‘Tess-in temperature Connecting rod 3ig end center-to-small end center length 3end ‘wist jig end side clearance Crankshaft !nd play ournal O..D.0.0.039) 1 .0098) 60 (2.003 (.0008 ..007 (8662 .031) 0.0177) 0.25 (.20 .00 (1.1 (.05 (0020) or less 0.175. 1 ring No.0276) 0.00 ..0.0.30-0.0177) 0.60 (.02 .0236) 0.4 (. = Outer Diameter 0.016) 0.1 (.0177 ..020 ..o (.. 2 ring Front wheel drive vehicle Rear wheel drive vehicle Oil ring Front wheel drive vehicle Rear wheel drive vehicle Ring to ring groove clearance No.004) 0.03 .653 .3.0079 .60 LOO79 ..DOHC End gap No.o 0.0118-.0. jut-of-roundness of journal and pin Two-camshaft engine Four-camshaft engine aper of journal and pin )il clearance of journal )il clearance of pin NOTE O.0008 .858) Room temperature 0.8 (.45(..10 .0276) 0.) Limit Standard Piston ring . 1 ring No.llE-17 mm (in.OOOl) Less than 0.020 .D.25 .07 LOOI 2 .1 (004) or less 0.o (.D.0079 .1 (. 2 ring Oil ring ?ing to ring groove clearance No..0024) 22.0020) 0.0.2 ring Piston ring .031) ‘I .o (039) 0.9.0024) 0.07 (.45 .005 (.0.Service Specifications .SOHC End gap No.0177) 0..0236) 0.050 t.0.o (.0002) 0.141 .06 (.36) 50 (I .0...0035) 0.70 (.45 (.0039 .050 (0008 .004) 0.0002) Less than 0..05 .1 (004) 0.001 .30 .8664) 75.031) 0. 2 ring ‘iston pin I.1 (.004) 1 TSB Revision ..0.60 (.0.0. 1 ring No.

0(.198) 500 (I IO) 6.05 (.1 (3.197) 650 .197) 7.16 at 20°C (68°F) 2 .354) 500-700(110-154) 400 (88) 3.5 ..008) 0..2 (.5 5 .6.IIE-18 6G7 ENGINE .138-.DOHC Ieflection New belt Used belt rension N (Ibs.0 (.35 (0138) 4.002) “0.) New belt Used belt njector Zoil resistance Non-turbo R Turbo R dle air control motor Ioil resistance R -hrottle position sensor tesistance kS1 rccelerator pedal position sensor lesistance kR ‘ariable induction control motor (esistance fi 91.0 (.04-0.500 (99 .0 (276) 700 .Service SDecifications mm (in.10 (.5 ..3 at 20°C (68°F) 28 .18 (0040 .) New belt Used belt Irive belt .0016.315) 9.8.08 (0012 .33 at 20°C (68°F) 3.850 (143 .0031) 0.0(.SOHC for DIAMANTE Deflection New belt Used belt Tension gauge N (Ibs.900 (154 .10 .5-6.) Standard Limit Cylinder block Cylinder bore Flatness of gasket surface Grinding limit of top surface * Total resurfacing depth of both cylinder head and cylinder block Oil pump Tip clearance Side clearance Body clearance Drive belt .0.132) 13 .5-4.187) 450 .0-5.0039) 0.35 at 20°C (68°F) TSB Revision .) New belt Used belt Drive belt .157-.0-5.157-.157) 4.0(..0070) 0.5 3.0.SOHC for MONTERO and TRUCK Deflection New belt Used belt Tension gauge N (Ibs.03 .587) 0.256 .

< .Exhaust manifold tightening side bolt Generator bracket bolt lrankshaft bolt SOHC DOHC ntake manifold plenum and throttle body iGR pipe bolt ntake manifold plenum stay bolt !GR valve bolt -hrottle body bolt SOHC MONTERO AND TRUCK gnition coil bolt gnition power transistor bolt -hrottle body ‘hrottle position sensor bolt Ye air control motor bolt SOHC DIAMANTE DOHC Non-TURBO \ccelerator pedal position sensor bolt ‘acuum actuator bolt 1 TSB Revision .8 3.4 2.5 2 3.5 5 2 3.667’ ENGINE . DOHC SOHC MONTERO AND TRUCK Tensioner bracket bolt SOHC DIAMANTE SOHC MONTERO AND TRUCK Ml0 Ml2 DOHC Idler pulley bolt SOHC MONTERO AND TRUCK DOHC Cooling fan bracket bolt Tensioner bracket stay bolt Generator pivot nut Generator brace bolt ftlbs..’ 33 36 30 17 17 IO 7 9 17 33 122 134.5 1. 11 11 50 45 42 24 42 19 45 50 42 24 23 .5 2.F-’ 14 10 13 24 45 155 185 18 18 22 12 14 2. 30 14 .5 8 8 36 33 30 17.Side bolt .8 1. 13 13 16 8 10 1.’ SOHC DIAMANTE SOHC MONTERO AND TRUCK.6 1.5 .Torque Specifications TORQUE SPECIFICATIONS Nm Generator and drive belt Cooling fan bolt Fan pulley bolt Tensioner pulley nut SOHC DIAMANTE..4 2.

DOHC Ml0 Ml2 ZrankshaftKamshaft position sensor bolts 4uto tensioner bolt rensioner pulley bolt rensioner arm assembly bolt dler pulley bolt dler pulley bracket bolt jocker cover bolt Camshaft sprocket bolt ntake manifold and fuel parts njector and fuel rail bolt :uel pressure regulator bolt -uel pipe bolt leat pipe bolt ngine coolant temperature gauge unit ngine coolant temperature sensor SOHC DIAMANTE hermo switch dater outlet fitting bolt ltake manifold nut Jater inlet fitting bolt hermostat housing bolt Engine support bracket bolt . 2 18 10 18 9 16 9 7 Ignition system Center cover bolt Spark plug Distributor nut Ignition coil bolt SOHC MONTERO AND TRUCK DOHC Ignition power transistor bolt DIAMANTE 3000GT Crankshaft position sensor nut Timing belt . 3 25 14 25 13 22 13 12 60 110 29 90 25 25 70 110 9 24 49 42 55 42 3 90 12 9 9 12 30 11 8 8 19 18 19 19 43 80 19 65 18 18 ‘51 80 7 17 35 30 40 30 2 65 9 7 7 9 22 8 6 6 14 13 14 14 ITSB Revision 1 .SOHC Engine support bracket bolt Ml0 Ml2 Tensioner lock bolt Camshaft sprocket bolt Zenerator stay bolt 3enerator bracket bolt riming belt .Ibs.IIE-20 6G7 ENGINE .Torque Specifications Nm ft.

ENGlNE .Torque Specifications Nm Exhaust manifold Oil levelgauge guide bolt Heat protector bolt Engine hanger bolt SOHC DIAMANTE SOHC MONTERO AND TRUCK DOHC NON-TURBO Exhaust manifold nut SOHC DOHC NON-TURBO DOHC TURBO Heater pipe bolt dater pipe bolt SOHC MONTERO AND TRUCK dater pump bolt ieat protector C Turbocharger stay bolt ixhaust fitting bolt eye 3il pipe bolt Yare nut Nater pipe eye bolt Xl return pipe bolt rurbocharger ‘urbocharger waste gate actuator bolt locker arms and camshafts .lbs. front and rear bolt rearing cap bolts No. rocker arms and bearing caps.DOHC lrankshaft position sensor adaptor bolt learing caps. 3.4 lylinder head and valve. 2.SOHC >il filler bolt locker cover bolt Iistributor adaptor bolt locker arm shaft and bearing cap bolt Camshafts.6G7 .--* 90 TSB Revision I .SOHC :ylinder head bolt :ylinder head and valve . 10 10 17 14 9 14 33 22 9 10 9 17 22 43 10 12 18 22 7 12 9 9 9 13 20 24 20 11 110 7 7 9 14 17 14 8 80 110 125 + Back off + 125 80 90 + Back off .DOHC :ylinder head bolt NON-TURBO TURBO 14 14 24 19 13 19 45 30 12 14 12 24 30 60 14 17 25 31 9 ft.

11 E-22 667 ENGINE .DIAMANTE and 3000GT knock sensor bracket bolt . Oil pan and oil pump Transmission stay bolt Oil pressure switch DIAMANTE AND 3000GT MONTERO AND TRUCK Oil pressure gauge unit DIAMANTE AND 3000GT MONTERO Oil cooler by-pass valve Oil filter bracket stay bolt (10x20) (8x20) Oil filter bracket bolt DIAMANTE AND 3000GT MONTERO AND TRUCK mark 4 mark 7 Drain plug Oil pan bolt Oil screen bolt Plug Oil pump case bolt Oil pump cover bolt Piston and connecting rod Connecting rod cap nut Crankshaft. flywheel and drive plate +wheel bolt Irive plate bolt 3ear plate bolt 3ell housing cover bolt 3il seal case bolt 3earing cap stay bolt 3earing cap bolt .Torque Specifications Nm ft.DIAMANTE and 3000GT loll stopper bracket .M 10 Ml2 75 19 IO 10 55 55 23 13 24 24 14 40 6 19 45 14 10 54 14 7 7 40 40 17 IO 17 17 10 29 4 14 33 10 7 52 38 75 75 11 9 11 48 79 93 74 29 23 23 29 42 75 54 54 8 7 8 35 57 67 54 21 17 17 21 30 54 TSB Revision .lbs.SOHC DOHC 1993 models DOHC -TURBO knock sensor bracket bolt knock sensor Bracket Knock sensor .

8660 3M NUT Locking Part No.8660 3M ATD Part No.8660 3M NUT Locking Part No. ‘” ) Quantity As required As required As required As required As required As required As required As required As required .Sealant SEALANT Items Auto tensioner bolt -Turbo Engine coolant temperature sensor Engine coolant temperature gauge unit Rocker cover Bearing cap Oil pressure switch Oil pressure gauge unit Oil pan Oil seal case Specified sealant 3M ATD Part No.41 71 3M ATD Part No. TSB Revision .MD970389 .8660 MITSUBISHI GENUINE Part No..MD970389 MITSUBISHI GENUINE Part No.41 71 3M ATD Part No.667 ENGINE .8660 3M ATD Part No.

11 E-24 6G7 ENGINE .SDecial Tools SPECIAL TOOLS SOHC engine only MD99871 9 or Leak-down tester Air bleed wire Camshaft oil seal installer For SOHC engine only ton and timing belt For SOHC engine only TSB Revision .

8G7 ENGINE .Special Tools Tool Number and tool name MD99871 7 Crankshaft front oil seal installer Supersession MD99871 7-01 Application Installation of crankshaft front oil seal I MD99871 8 Crankshaft rear oil seal installer MD998718-01 Use with MB990938. 01 IInstallation of crankshaft rear oil seal MD998719 Pulley holding pins (2) MIT308239 iolding camshaft sprocket when loosening x torquing bolt -or SOHC engine only MD998727 Oil pan remover fqemoval of oil pan M D998729 Valve stem seal installer nstallation of valve stem seal :or SOHC engine only MD998735 Valve spring compressor MD998735-01 lemoval and installation of valve and rejted parts M D998754 Pulley holding pins (2) M IT308239 l-lolding crankshaft sprocket when loosenirlg or torquing bolt MD998761 Camshaft oil seal installer MD998761-01 lstallation of camshaft oil seal or DOHC engine only M D998762 Circular packing installer M D998762-01 Installation of circular packing For DOHC engine only TSB Revision .

11 E-26 6G7 ENGINE .Special Tools seal installer compressor Installation of flywheel TSB Revision .

lbs.667 ENGINE . Adjusting stud 5. Crankshaft bolt 10. 23 Nm 30 ft. Tensioner bracket 6. Adjusting bolt 4. Removal steps +A4 I. Pivot bolt 7.lbs. Tensioner pulley 3. I 7EN0487 1 TSB Revision I . Special washer 11. Generator 8. Generator brace QArJ +B4 9.Generator and Drive Belt GENERATOR AND DRIVE BELT REMOVAL AND INSTALLATION .SOHC for DIAMANTE 1 3 2 il 7 155 Nm 112 ft.lbs. Drive belt 2. Crankshaft pulley 8 14 Nm 10 ft.

SOHC for MONTERO and TRUCK 13 Nm 9 ftlbs. Generator brace 3. I 12 I IONm 7 ftlbs. Fan clutch 4. Generator 4. Adjusting bolt 8. Cooling fan 3. Crankshaft pulley 7EN0488 TSB Revision . Special washer 6. Tensioner pulley 7. Idler pulley 6. Cooling fan bracket assembly 1. Tensioner bracket stay 2. Crankshaft bolt 5.IIE-28 6G7 ENGINE . Adjusting stud 9. Tensioner bracket 0.Generator and Drive Belt tEMOVAL AND INSTALLATION . 13 13 Nm 9 ftlbs. Removal steps 1. Fan pulley 5. Drive belt 2.

I 4 45 Nm 33 ft. Crankshaft bolt 11. 24 Nm 17 ft. Adjusting stud 6. \ 2 8 I 50 Nm I 165 Nm 134ft. Generator bracket 9. Crankshaft pulley 7EN0489 TSB Revision .lbs.Generator and Drive Belt IEMOVAL AND INSTALLATION i DOHC 23 Nm 17 ft. Adjusting bolt 5.lbs. Idler pulley 3. Generator 8. Special washer 12. 50 Nm 36 klbs. Removal steps #A4 1. Tensioner bracket 7. Bracket (IA(J #64 IO.6G7 ENGINE . Drive belt 2.lby 24 Nm 17 ftlbs.lbs. Tensioner pulley 4.

5-8. (2) Tighten the adjusting bolt to adjust the belt deflectbn to the specification shown in the chart.26-.uge I 700-900(154-198) 500 (110) 500-700(110-154) 400(88) 650-850(143-187) 450-600(99-132) SOHC for New MONTERO USed and TRUCK NTERO and TRUCK DOHC New Used I 3. (2) Remove the crankshaft bolt.5 (.bt.0(.TENSION CHART Generator drive belt SOHC for DIAMANTE New USed Deflection mm (in. 7EN0349 TSB Revision .14-.16) 4-5(.0(.28) 6.16-. SOHC for DIAMANTE INSTALLATION SERVICE POINT #A4 DRIVE BELT TENSION ADJUSTMENT DRIVE BELT .Generator and Drive Belt REMOVAL SERVICE POINT (JAO CRANKSHAFT BOLT LOOSENING (1) Using the special tool. hold the drive plate or flywheel.WE-30 6G7 ENGINE .32) 9(.16-.35) TenEo.20) 7 l.20) DOHC IOON (1) Loosen the tensioner pulley locking nut.5-4.) 4.

chart.Generator and Drive Belt SOHC for DIAMANTE- (3) If you use a tension gauge. SOHC for MONTERO and TRUCK w gauge Tension’ w 7EN0399 7EL0070 DOHC I)B4 CRANKSHAFT BOLT TIGHTENING (1) Using the special tool.:. TSB Revision 1 .6G7 ENGINE . tighten the adjusting bblt to adjust the belt tension to the specification shown in the . hold the drive plate or flywheel. (2) Install the crankshaft bolt.

lbs. Intake manifold plenum stay. Ignition power transistor 11. front 6. rear 5. EGRpipe 2. EGR valve aasket 1 For California 8. Intake manifold plenum 12.11 E-32 6G7 ENGINE . Intake manifold plenum gasket 7EN0405 TSB Revision . Throttle body gasket 10.6 ft.lbs. Removal steps For California 1. I 22 Nm 16 ftlbs.SOHC for DIAMANTE 8 12 Nm 8 ft. EGR valve 7. Throttle body 9.Intake Manifold Plenum and Throttle Body INTAKE MANIFOLD PLENUM AND THROTTLE BODY REMOVAL AND INSTALLATION . Ignition coil 3. 18Nm 13 ft.lbs. High tension cable 4. Intake manifold plenum stay. 18 Nm 5Nm 3.

Throttle body 8.Intake Manifold Plenum and Throttle Body IEMOVAL AND INSTALLATION .SOHC for MONTERO and TRUCK 14 Nm 10 ft. front 5. Throttle body gasket 9. EGR valve gasket > For California 7. 18 Nm 22 Nm 16 ft. Intake manifold plenum 10. Removal steps 1.lbs. tr- 18 Nm 13 ft.lbs.lbs. EGR pipe gasket I 3. rear 4.6G7 ENGINE . EGR valve 6. Intake inariifold plenum stay. EGR pipe For California 2. Intake manifold plenum stay. Intake manifold plenum gasket 7EN0408 TSB Revision .

11 E-34

6G7 ENGINE - Intake Manifold Plenum and Throttle Body

{EMOVAL AND INSTALLATION - DOHC NON-TURBO

6

12 Nm 8 ft.lbs. I

8Nm 3 ftlbs.

22 Nm 16 ft.lbs.

18Nm 13 ft.lbs.

3

18Nm 13 ftlbs.

Cb,18Nm 13 fklbs. Removal steps 1. EGR pipe For California 2. Intake manifold plenum stay, rear 3. Intake manifold plenum stay, front 5. EGR valve For California 6. EGR valve gasket I 7. Throttle body 8. Intake manifold plenum 9. Intake manifold plenum gasket
7EN0411

TSB Revision

6G7 ENGINE - Intake Manifold Plenum and Throtiib B’ijdy IEMOVAL AND FUEL SYSTEM - DOHC TURBO

qq-ps5

m2-?&

18hm 13 ftlbs.

18Nm 13 ft.lbs.

18 Nm 13 ftlbs. Removal steps 1. EGRpipe For California j 2. EGR pipe gasket 3. Intake manifold plenum stay, rear 4. Intake manifold plenum stay, front 5. EGR valve For California I 6. EGR valve aasket 7. Throttle bo?iy 8. Throttle body gasket 9. Intake manifold plenum 10. Intake manifold plenum gasket

1 TSB Revision I.

I1

11 E-36

6G7 ENGINE - Intake Manifold Plenum and Throttle Body INSPECTION EGR VALVE
(1) Check the EGR valve for sticking or carbon deposits. If such conditions exist, clean or replace the EGR valve. (2) Connect a hand vacuum pump to the nipple of the EGR valve and plug other nipple. (3) If there is vacuum leakage, replace the EGR valve. (4) Blow air in from one passage of the EGR to check its condition as follows.
6EM0384

TSB Revision

SOHC for DIAMANTE. !Nm 1.lbs.8 ft. DOHC NON-TURBO 2.5 Nm 2.5 ft.5 Nm 1. Throttle position sensor 2.4 ft.5 ftlbs.lbs. Idle air control motor 3. Throttle body @O 7FU1282 DISASSEMBLY AND REASSEMBLY . Water hose sensor #B4 6.lbs.lbs.5 Disassembly steps 1. Throttle body 1. 3.For VEHICLES with TRACTION CONTROL 4 I ii+-- 3.Throttle Body n-E-37 THROTTLE BODY DISASSEMBLY AND REASSEMBLY . Disassembly steps QArJ +A4 1.lbs. 7FU1283 TSB Revision .5 Nm 2.4 ft.667 ENGINE . 2Nin 1.4ft.

lbs. Idle air control motor 0 7.5 ftlbs. Idle air control motor assembly 3. Throttle position sensor (Within closed throttle position switch) 2.5 Nm 2.Throttle Body DISASSEMBLY AND REASSEMBLY . Throttle position sensor 6.4 ft. 7FUO532 . Vacuum valve 4.SOHC for MONTERO and TRUCK 3.DOHC TURBO Disassembly steps Up to 1992 models 3. Dash pot.11 E-38 6G7 ENGINE . Throttle body 1 TSB Revision 1 /T’ cz!J I 2Nm 1.From 1993 models (IAO )A4 5. Throttle body DISASSEMBLY AND REASSEMBLY . 3 I n Disassembly steps OAO )B4 1.

(2) Do not clean the sensor and motor by dipping them into the solvent. Therefore. (2) Check if the vacuum port or passage is clogged. INSPECTION DASH POT . (3) If the rod protrudes. Use compressed air to clean the vacuum passage. Resistance increases as the rod is pushed harder.6G7 ENGINE . a broken diaphragm is suspected. NOTE If the rod returns slowly.DOHC TURBO Up to 1992 models (1) Push the rod of the dash pot all the way in and close the nipple with the fingers. the check valve is faulty. 2. (2) Release finger and confirm that the rod returns to its original position quickly. If the rod can be pushed in with no resistance. replace the dash pot. Clean them with shop towel. (2) If the rod does not protrude after releasing it. ACCELERATOR PEDAL POSITION SENSOR AND IDLE AIR CONTROL MOTOR REMOVAL (1) Do not d’rsassemble the sensor and motor. (%r) THROlTLE BODY REMOVAL (1) Do not remove the throttle valve. NOTE 1. \ 7FU105i From 1993 models (1) Push the dash pot rod in lightly and confirm the resistance. either the diaphragm or check valve is faulty. the dash pot is functioning normally.Throttle Body DISASSEMBLY SERVICE POINTS OAo THROlTLE POSITION SENSOR. TSB Revision .

7 in. (8) Install the filter onto the black nipple of the valve. (2) Measure the resistance between the white clip of Test Harness and the red clip or blue clip. (6) Make sure that the negative pressure leaks out as soon as it is applied. (2) Connect a hand vacuum pump to the black nipple of the vacuum valve. 6EM069 Red IDLE AIR CONTROL MOTOR Checking the Coil Resistance (1) Connect Test Harness to the motor connector.DOHC TURBO Up to 1992 models (1) Remove the filter from the vacuum valve. apply a negative pressure of 500 mmHg (19.IIE-40 6G7 ENGINE . (3) With the other nipple closed by the finger.Throttle Bodv VACUUM VALVE . Standard value: 28 . (4) Let go your finger and make sure that the negative pressure leaks out gradually. Standard value: 28 .33 LR at 20°C (68°F) M D998463 7FUO29( Operational Check (1) Connect Test Harness to the idle air control motor connector. Idle air mot01 MD998463 7FUOO71 1 TSB Revision I .33 LR at 20°C (68°F) (3) Measure the resistance between the green clip of Test Harness and the yellow clip or black clip. (7) Remove the hand vacuum pump from the valve.Hg. (5) Disconnect the hand vacuum pump and connect it to the green nipple.) to make sure that the negative pressure is maintained. (2) Connect the positive 0 terminal of 6 volt battery to the white clip and the green clip of Test Harness.

and tighten the screws. TSB Revision . apply a vacuum of 200 mmHg (7. @ Connect the negative 0 terminal of the power supply to the blue and black clip.) to the vacuum actuator to make sure that the throttle valve closes. (2) Then lower the level of vacuum gradually to make sure that the vacuum actuator opens.SOHC for DIAMANTE. vibration is detected. @ Connect the negative 0 terminal of the power supply to the blue and yellow clip.Hg. REASSEMBLY SERVICE POINTS I)A4 THROTTLE POSITION SENSOR (TPS) INSTALLATION . @ Repeat the tests in sequence from @ to 0.Throttle Body 1 gs41 7FUO29f (3) Hold the idle air control motor as shown in the illustration.6G7 ENGINE . @ Connect the negative 0 terminal of the power supply to the red and black clip. @ Connect the negative 0 terminal of the power supply to the red and black clip. @ Connect the negative 0 terminal of the power supply to the red and yellow clip. DOHC (1) Install the throttle position sensor to the throttle body as shown in the illustration.9 in. (4) If. w 7FUlb3Z “’ I (2) Turn the throttle position sensor 90” clockwise to set it. as a result of these tests. the stepper motor can be considered to be normal. connect the negative 0 terminal of the power supply to each clip as described in the following steps.VEHICLES with TRACTION CONTROL (1) With the throttle valve opened. CHECKING VACUUM ACTUATOR . and check whether or not a vibrating feeling (a feeling of very slight vibration of the stepper motor) is generated as a result of the activation of the stepper motor.

In that case. the check described in step (4) cannot be accomplished.SOHC for MONTERO and TRUCK (1) Install the throttle position sensor to the throttle body as shown in the illustration. Throttle valve position Fully closed Fully open I Continuity Conductive Non-conductive I I Throttle position sensor output Closed throttle position switch 7FU053E If there is no continuity with the throttle valve fully closed.rNHslA~-EP$tSITION SENSOR (TPS) . replace TPS. or between 2 (output) and 1 (power). turn TPS counterclockwise. I)B4 .Throttle Bodv (3) Connect a circuit tester between 4 (ground) and 2 (output). make sure that the resistance changes smoothly when the throttle valve is slowly moved to the fully open position.11 E-42 Throttle position Ground 6G7 ENGINE . make sure that the resistance changes smoothly when the throttle valve is slowly moved to the fully open position. and then check again. 7FUO53: (2) Turn the throttle position sensor 90” counterclockwise to set it. and tighten the screws. NOTE Some throttle position sensors are not provided with the position switch. (4) Check for continuity across terminals 3 (closed throttle position switch) and 4 (ground) with the throttle valve both fully closed and fully open. (5) If the above specifications are not met. (4) Check for continuity across terminals @ (closed throttle position switch) and @ (ground) with the throttle valve both fully closed and fully open. I I I 7FUO53L !I (3) Connect a circuit tester between @ (ground) and @ (output). Ground \ Throttle position sensor outmt Closed throttle position switch \ Throttle position sensor power 7FU053E TSB Revision 1 . or between @ (output) and @ (power). Then. Then.

6G7 ENGINE - Throttle Body

w43

)r”““-’
If there is no continuity with throttle valve fully closed, turn the throttle position sensor clockwise, and then check again. (5) If the above specifications are not met, replace TPS. I)c4 ACCELERATOR PEDAL POSITION SENSOR (APS) INSTALLATION (1) Install the accelerator pedal position sensor to the throttle body as shown in the illustration.

7FU1071

(2) Turn the accelerator pedal position sensor 90” clockwise to set it, and tighten the screws.

7FU107:

Closed throttle

Accelerator

(3) Connect a circuit tester between (ground) and (output), or between (output) and (power). Then, make sure that the resistance changes smoothly when the throttle valve is slowly moved to the fully open position. (4) Check for continuity across terminals (closed throttle position switch) and (ground) with the throttle valve both fully closed and fully open.
Throttle valve position Continuity

pedal position sensor output

7~~053~

Fully closed Fully open

Conductive
Non-conductive

If there is no continuity with the throttle valve fully closed, turn APS counterclockwise, and then check again. (5) If the above specifications are not met, rep!ace APS.

1 TSB Revision

11 E-44 IGNITION SYSTEM
SOHC for DIAMANTE

6G7 ENGINE - Ignition System

25 Nm 18 ft.lbs.

Removal steps 1. Spark plug cables 2. Spark plug 3. Distributor 4. O-ring
7EN0406

TSB Revision

I

6G7 ENGINE - Ignition Svstem ;OHC for MONTERO AND TRUCK

25 Nm 18 ft.lbs.

Removal steps 1. Spark plug cables 2. Spark plugs 3. High tension cable *A4 4. Distributor 5. O-ring 6. Ignition coil
7EN0409

\ TSB Revision
I

DIAMANTE 8.11 E-46 667 ENGINE . Engine hanger 7. Crankshaft position sensor. Ciamp’ um From 1993 models 5. Center cover 2. Ignition power transistor. Spark plug cables 3.Up to 1992 models 10.Ignition System IOHC for DIAMANTE A N D 3000GT 13 Nm 9 ft.lbs. O-ring I 7EN0492 1 TSB Revision L II . ignition power transistor _ 3000GT eB4 9. Removal steps 1. Soark oluas 4. Ignition coil 6.

lining up the matchmarks on the crankshaft position sensor housing and the coupling.6G7 ENGINE .RAFKSHAFT POSITION SENSOR INSTALLATION - (1) Turn the crankshaft so that the No.Ignition Svstem WE-47 INSTALLATION SERVICE POINTS I)A4 DISTRIBUTOR INSTALLATION . install the distributor. 1 cylinder is at compression top dead center. (2) Install.SOljC (1) Turn the crankshaft so that the No. Mating mark 7FI OOWi I TSB Revision . (2) Align the distributor housing and gear mating marks. I)B4 . (3) With the stud located in the center of the adjusting slot at the distributor.on top dead center. 1 cylinder is at compressi..

Access cover 3. Tensioner spring 11.lbs. 110 Nm 80 ftlbs. Timing belt rear cover. Flange 4AO &CC 8. Timing belt front upper cover. Camshaft sprocket bolt 13. Timing belt front lower cover 7. Engine support bracket 2. left 15. Timing belt front upper cover. Timing belt rear cover.DIAMANTE 26 Nm 19 ft. Timing belt cover cap 5.SOHC TIMING BELT . Tensioner 10.Timing Belt . Crankshaft sprocket QBrJ #A4 12. 4F 6 I Removal steps +D4 1.11 E-48 6G7 ENGINE . Timing belt iB4 9. left 6. right 7EN0493 TSB Revision . right 4. Camshaft sprocket 14.SOHC REMOVAL AND INSTALLATION .

Generator bracket 7EN0494 TSB Revision . Tensioner 8. right 3. left 13.SOHC IEMOVAL AND INSTALLATION .MONTERO AND TRUCK 25 Nm 18 ft. Timing belt front lower cover 5. Camshaft sprocket bolt 11. Flange @IO #C4 6.lbs. Timing belt eB4 7. Camshaft sprocket 12. left 4. Generator stay 14. Access cover 2. Tensioner spring 9.Timing Belt . Crankshaft sprocket (IBIJ +A4 10.6G7 ENGINE . Timing belt front upper cover.lbs. 19 ft. 4 Removal steps 1. Timing belt front upper cover. 14 I 11 Nm 8 ftlbs. Timing belt rear upper cover.

The sides are normal if they are sharp as if cut by a knife.SOHC REMOVAL SERVICE POINTS TIMING BELT REMOVAL (1) Mark the belt running direction for reference in reinstallation. camshaft oil seal and water pump for leaks. and tensioner must be kept free from oil and water. (2) If there is oil or water on any part. check the front case oil seal. EJ 0 0 008 G (2) (3) (4) (5) Cracks Cracks Cracks Cracks on rubber back or peeling of canvas on tooth bottom on belt (6) Abnormal wear of belt sides. ~BI) CAMSHAFT SPROCKET BOLT REMOVAL MB990775-01 INSPECTION TIMING BELT Replace belt if any of the following conditions exist. so the removed timing belt. sprocket. Abnormal wear (Fluffy strand) TSB Revision . (1) Hardening of back rubber-back side is glossy without resilience and leaves no indent when pressed with fingernail.Timing Belt .WE-50 6G7 ENGINE . (IAO . Do not immerse parts in cleaning solvent. NOTE (1) Water or oil on the belt shortens its life drastically.

Timing Belt .6G7 ENGINE . Rubber exposed Tooth missing and canvas fiber exposed INSTALLATION SERVICE POINTS +A4 CAMSHAFT SPROCKET BOLT INSTALLATION 01w70: I)B4 TIMING BELT TENSIONER INSTALLATION (1) Insert a screwdriver into the hole of the timing belt tensioner arm.SOHC (7) Abnormal wear on teeth (8) Tooth missing and canvas fiber exposed. move it all the way in the direction of the arrow. 1 TSB Revision I . and tighten the tensioner lock bolt to temporarily hold this position.

(2) Install the timing belt on the crankshaft sprocket first and while keeping the belt tight on the tension side. (3) Then. Timing mark (on belt cover) Timing mark (on rear cover or generator bracket) I ImIng maw (on sprocket) / Camshaft sprocket (wht) \ Camshaft sprocket (left) side Timing belt tensioner (on front case) Crankshaft sprocket (on sprocket) (4) Install the flange onto the front end of the crankshaft. (6) Loosen the tensioner lock bolt one or two turns and allow the spring to tension the timing belt. Turn smoothly and in clockwise direction only. TSB Revision . (5) Install the special tool onto the crankshaft.Timina Belt . install the belt on the left camshaft sprocket. install on the water pump pulley and on the right camshaft sprocket and finally on the timing belt tensioner.SOHC I)cg TIMING BELT INSTALLATION (1) Align the timing marks of the camshaft sprockets and the crankshaft sprocket.11 E-52 6G7 ENGINE . (8) Again line up the timing marks on the sprockets and tighten the tensioner lock bolt to the specified torque. (7) Turn the crankshaft two full turns clockwise.

SOHC I)D4 ENGINE SUPPORT BRACKET INSTALLATION .I 7EN024: il \ TSB Revision .DIAMANTE (I) Tighten the engine support bracket bolts in the order shown in the illustration.6G7 ENGINE . NOTE The bolt used at the location shown in the illustration is a reamer bolt (head mark “R”).Timing Belt . ad mark .

Bracket 20. Rocker cover gasket. left 19. Timing belt rear cover. Timing belt front lower cover 4AO $04 5. Tensioner pulley 8. Timing belt rear cover. Timing belt rear cover. Removal steps I)E4 1. Timing belt front upper cover.Timing Belt . / 6 15 A 49 Nm 35 ft.lbs.DOHC REMOVAL AND INSTALLATION . i 55 Nm 40 ftlbs. 30 ft.lbs. Crankshaft sprocket #B4 12. Timing belt +C4 6. Tensioner arm assembly 9. left 4. Rocker cover gasket. center I 7EN0497 TSB Revision .11 E-54 6G7 ENGINE . Idler pulley 10. Camshaft sprocket 17. Timing belt front upper cover.Up to 1992 models 3Nm 2 ft. right 18. 90 Nm 65 ftlbs.DOHC TIMING BELT . A 14. Engine support bracket 2. Auto tensioner 7.lbs. Idler pulley bracket 11. Camshaft sprocket bolt 16. Rocker cover 13. right 3. 24 17 RS. B (IB~J *A4 15.

Timing belt rear cover. A 19. Rocker cover gasket. Timing belt 7. right 4. Timing belt rear cover.lbs. Tensioner arm assembly 12.lbs.DOHC tEMOVAL AND INSTALLATION . 3Nm 2 ft. Idler pulley bracket 14. Bracket 26. Sensing plate 16. Engine support bracket 2.lbs. 1 42 Nm 30 ft. Washer #B4 17. Timing belt front upper cover. Rocker cover gasket. left 5.lbs. Camshaft position sensor 1 TSB Revision +C4 9.667 ENGINE . B (rBr) +A4 20. 15 14 r 55 Nm 40 ft. Idler pulley 13. 10 46Nm 35 ft. right 24. Auto tensioner IO. center 7ENO498 . Timing belt front lower cover OAo eD4 6. Crankshaft position sensor 8. left 25. Crankshaft sprocket 15. Tensioner nrrllev 11.lbs. Camshaft sprocket 23. Timing belt rear cover. Crankshaft position sensor bracket 3. Rocker cover 18. Camshaft sprocket 22. Camshaft sprocket bolt 21. r ap 5 2 IlONm 60 ft.From 1993 models 3Nm 2 klbs.lbs. Removal steps eE4 1. 25 24 Nm 17 ft.Timing Belt . Timing belt front upper cover.

so the removed timing belt. Do not immerse parts in cleaning solvent.. NOTE (1) Water or oil on the belt shortens its life drastically. If the reading is outside the standard value. If oil leaks are evident.) 7EN0224 (4) Use a vice to force the auto tensioner rod in. replace the auto tensioner.7 . (3) Measure the rod projection length. when removing the camshaft sprocket bolt.12. AUTO-TENSIONER (1) Check for oil leaks.461 .3 mm (.Timina Belt . the rod will offer considerable resistance. If there is nothing wrong. If the rod slides in easily.484 in. camshaft oil seal and water pump for leaks. INSPECTION TIMING BELT Refer to “INSPECTION” on page IIE-50.DOHC REMOVAL SERVICE POINTS aA0 TIMING BELT REMOVAL (1) Mark the belt running direction for reference in reinstallation. 7ENO775 TSB Revision . replace the auto-tensioner. Standard value: 11. and tensioner must be kept free from oil and water. (2) Check the rod end for wear or damage and replace the auto-tensioner if necessary. OBr) CAMSHAFT SPROCKET BOLT REMOVAL (1) Hold the hexagonal portion of the camshaft with a wrench. sprocket. replace the tensioner. check the front case oil seal. (2) If there is oil or water on any part.6G7 ENGINE .

Timing Belt . II I 7EN022E (2) Slowly close the vice to force the rod in until the set hole (A) of the rod is lined up with the set hole (B) of the cylinder.DOHC ljl51 .4 mm (. 7EN024’ I I)c4 AUTO-TENSIONER INSTALLATION If the auto-tensioner rod is fully extended. INSTALLATION SERVICE POINTS I)A4 CAMSHAFT SPROCKET BOLT TIGHTENING (1) Hold the hexagonal portion of the camshaft with a wrench when tightening the camshaft sprocket bolt. 7EN022i TSB Revision . Specified sealant: 3M ATD Part No.055 in.8660 or equivalent. (3) Insert a wire [I . +B4 ROCKER COVER INSTALLATION (1) Apply sealant to the areas shown in the illustration. Tighten the bolt to the specified torque. (4) Remove the auto tensioner from the vice. set it in the retracted position with the following procedure. (1) Set the auto tensioner in a vice. (5) On engines with turbocharger. apply sealant to the threads of the auto tensioner mounting bolt. Apply sealant 7-G 7EN024 Spark plug holes (2) Tighten the rocker cover bolts in the sequence shown in the illustration.) in diameter] into the set holes. Specified sealant: 3M ATD Part No._.6G7 ENGINE .8660 or equivalent.

be careful not to catch your finger. (5) Install the timing belt on the intake side camshaft sprocket and hold it with a paper clip at the positions shown in the illustration.Timing Belt . TSB Revision . the intake and exhaust valves might interfere. (4) Install the timing belt on the exhaust side camshaft sprocket for right bank and hold it with a paper clip at the position shown in the illustration. and then rotate the sprocket one tooth counterclockwise. avoid excessive pulling on the timing belt. 2. (3) Using two wrenches. line up the timing marks of the camshaft sprockets for right bank. Caution Since the camshaft sprocket turns easily. if a camshaft sprocket was turned too far in lining up the timing marks. (2) Line up the timing marks of the camshaft sprockets for left bank. be sure to rotate it back from that position to line up again the timing marks. Caution 1. If either camshaft sprocket is rotated one complete turn clockwise or counterclockwise after lining up the timing marks of the other camshaft sprocket. line up the crankshaft sprocket timing marks.DOHC I)04 TIMING BELT INSTALLATION (1) Using the special tool. Since valve spring force can turn the camshaft sprocket.11 E-58 6G7 ENGINE . Consequently.

Then rotate it clockwise to line up the timing marks and check that all the timing marks are in alignment. (7) Install the timing belt on the idler pulley. (1 l)Remove the four paper clips. 1 TSB Revision .6G7 ENGINE . Then install the timing belt on these sprockets and hold it with a paper clip at the positions shown in the illustration. rotate the tensioner pulley clockwise to tighten the center bolt.Timing Belt . (8) Install the timing belt on the crankshaft sprocket. (12)Using the special tool. (9) Install the timing belt on the tensioner pulley. (1O)Using the special tool.DOHC (6) Check that the timing marks of the camshaft sprockets for left bank are in alignment. turn the crankshaft a quarter turn counterclockwise.

) torque to prevent it from turning.DOHC Timing marks (on right rocker cover) Camshaft sprocket Timing marks (on left rocker cover) Timing mark (on sprocket) Auto tensioner Timing mark (on oil pump case) (on sprocket) Crankshaft sprocket ’ 7EN0235 (13)Loosen the center bolt of the auto-tensioner pulley. repeat step (12) until it does move smoothly.11 E-60 6G7 ENGINE . Then move in and out the auto-tensioner setting metal wire to check that the wire moves smoothly. and leave it alone for about five minutes. While holding the pulley with approximately 10 Nm (7 ftlbs. NOTE If the metal wire does not move smoothly. TSB Revision . tighten the center bolt to the specified torque. (15)Remove the auto tensioner setting metal wire. (14)Turn the crankshaft two turns clockwise. and install the special tool and a torque wrench on the pull’ey.Timing Belt .

4.. Standard value: 3.6G7 ENGINE . r)E4 ENGINE SUPPORT BRACKET INSTALLATION (1) Tighten the engine support bracket bolts in the order shown in the illustration. ad mark I. 7EN024: TSB Revision I .I77 ‘in.8 . NOTE The bolt used at the location shown in the illustration is a reamer bolt (head mark “R”).5 mm (.) *.Timing Belt .I50 .DOHC (16)Check that the spacing between the tensioner arm antfaulo tensioner is within the standard limit.

Injector and fuel rail 3. Intake manifold 20. Fuel rail *D4 13. Engrne coolant temperature sensor *I34 15. lnj.SOHC for DIAMANTE I/ 9Nm 7 ftlbs. 19 Nm 14 ftlbs. Fuel pressure regulator 5. injector harness 2. Engjne coolant temperature gauge unit +C4 14.I5 8Nm 8 ftlbs. O-ring 6.e.rs 9: Gromet 10. Water outlet fitting gasket 18. Fuel pipe 11. O-ring 12. insulator eG4 4. Intake manifold gasket 7EN0499 1 TSB Revision 7 . Insulator eF4 87. Thermostat 19. Water outlet fitting 17. Therm0 switch 16.11 E-62 6G7 ENGINE .Intake Manifold and Fuel Parts INTAKE MANIFOLD AND FUEL PARTS REMOVAL AND INSTALLATION . 16 18 Removal steps 1. -@-I10 I2 __/J c1 / .

Heat pipe 13. Intake manifold gasket 7EN0500 . Water hose A Il.476lklbs.lbs. Water hose eD4 15. Water outlet fitting 19. Engine coolant temperature gauge unit eC4 16. Engine coolant temperature sensor eB4 17. Thermostat 21. Therm0 switch 18. Insulator )F4 6. Fuel rail 10. Injector and fuel rail 2. Fuel pressure regulator 4. 18 11 Nm 8 ftlbs. Insulator eG4 3.6G7 ENGINE . Heat pipe gasket 14.Intake Manifold and Fuel Parts IEMOVAL AND INSTALLATION . O-ring 8. d Removal steps 1. Intake manifold 22.lbs. O-ring 5. Water outlet fitting gasket 20. Gromet 9.SOHC for MONTERO AND TRUCK 12Nm g )f~~bs~ 19Nm 14 ft. 8Nm . 30 Nm 22 c. Injectors 7. Water hose B 1 TSB Revision 12.

Insulator +G4 4. Thermostat housing gasket 7EN0501 . Fuel pipe 12. Water hose A 21. Water hose 20.Intake Manifold and Fuel Parts {EMOVAL AND INSTALLATION . Gromet 11. Intake manifold TSB Revision 15.lbs. Injector clip eF4 8. Water inlet fitting #A4 25. Engine coolant temperature gauge unit eC4 17.lbs. Thermostat 26.DIAMAN TE 23. O-ring 13. 11 Nm 8 ftlbs.lbs. --$j Removal steps 1. Fuel pressure regulator 5. -3 18 Nm 13 ft. O-ring 6. Water outlet fitting. 19 Nm 14 ft. Therm0 switch 19. Water outlet fitting . Engine coolant temperature sensor +B4 18. Injector harness 2. O-ring 10. Intake manifold gasket I)Dg 16. Fuel rail *E4 14. Thermostat housing 27.11 E-64 6G7 ENGINE .DOHC IY Nrn ldft Ihe 19 Nm 14 ft. Injector and fuel rail 3.3000GT 22. Water outlet fitting gasket 24. Injectors 9. Insulator 7.

Intake Manifold and Fuel Parts INSPECTION INJECTORS (1) Measure the resistance between the terminals of the injectors using a circuit tester.16 R at 20°C (68°F) Non Turbo 2 .3 IR at 20°C (68°F) Turbo 6FU192C I Alignment mark \ Jiggle valve INSTALLATION SERVICE POINTS +A4 THERMOSTAT INSTALLATION . Standard value: 13 . 8660 or equivalent .DOHC (1) install the thermostat and line up the jiggle valve with the alignment mark on the thermostat housing. If the resistance is out of?he specification. 4171 or equivalent 9cooo91 Sealant eD4 SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE GAUGE UNIT Specified sealant: 3M Part No. replace the injector.667 ENGINE . 8660 or equivalent 1 EN0338 Sealant +c+ SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE SENSOR Specified sealant: 3M Nut Locking No. II Sealant II 7COOO42 I)B4 SEALANT APPLICATION TO THERM0 SWITCH Specified sealant: 3M Part No.

I)G4 FUEL PRESSURE REGULATOR INSTALLATION (1) Before installing the pressure regulator. (2) Tighten the nuts on the left bank to the specified torque. the rubber O-ring must be lubricated with a drop of clean engine oil for easy installation. Then tighten the nuts on right bank to the specified torque. TSB Revision . 71 NO090 I)Fg INSTALLATION OF INJECTOR (1) Before installing the injector. (3) Install the injector clip by sliding the open ends onto both injector and fuel rail.IIE-66 _ Front 6G7 ENGINE . 7FUO61' (2) Insert the injector top end into the fuel rail.DOHC (1) Tighten the nuts on the right bank to 4 Nm (2.2 ft.lbs. the O-ring must be lubricated with a drop of clean engine oil for easy installation. Be careful not to damage O-ring during installation.Intake Manifold and Fuel Parts r)E4 INTAKE MANIFOLD INSTALLATION . (3) Tighten the nuts on the left bank and those on the right bbnk again in that order.).

Removal steps 1. m -I’” /(/ 24 Nm l7 ft-‘?m 14 Nm IO ft.4 & &- 14 D @---1SNm 14 ft. Water inlet pipe B +A4 16. Water hose 14. Water pump 21. 1 6 III 5--K-a . Engine hanger.lbs.Exhaust Manifold yfip@7 EXHAUST MANIFOLD REMOVAL AND INSTALLATION . right 6. left +B4 11. Exhaust manifold gasket 12. Water by-pass hose TSB Revision +A4 15. Heat protector.667 ENGINE . right )BC 7. O-ring )A4 17. Water pump gasket For M/l For A/T 7EN0502 I . Exhaust manifold. Water inlet pipe *A4 19. Water inlet pipe A *A4 18. O-ring 4. Exhaust manifold. O-ring 20. Water hose 13. right 9. Oil level gauge guide 3. Heat protector 5.SOHC for DIAMANTE 14 Nm IOfLlbs. Exhaust manifold gasket 8. Oil level gauge 2. 6.lbs. Bracket 10.

Water pipe +A4 17.SOHC for MONTERO AND TRUCK 19 Nm 6 - I/‘. right 5. O-ring *A4 18. left 9. Heat protector.lbs. Oil level gauge guide 3. O-ring 4. Water hose 13. Engine hanger 6. Exhaust manifold.6G7 ENGINE .lbs. Water inlet fitting gasket 20. Oil level gauge 2. Water pump gasket TSB Revision 14 Nm 10 ft.Exhaust Manifold IEMOVAL AND INSTALLATION . 7ENO360 . Exhaust manifold gasket 8. I 18 Removal steps 1. Bracket 10. Water hose A 14. Heater pipe gasket 16.“/ I 12Nm 9 ft. Heat protector. left $B4 11. right eB4 7. Water inlet pipe 19. Exhaust manifold. Exhaust manifold gasket 12. Water pump 21. Heater pipe 15.

lbs. Heat protector. Water inlet pipe 3.IEMOVAL AND INSTALLATION . left 0. 45 Nm 33 ft. Removal steps 1. right 5. O-ring 4. 9 c 13 Nm 9 ft. Exhaust manifold. Engine hanger 6. Heat protector. Water pump gasket 7EN0503 . left 9.lbs. Oil level gauge guide 3. Exhaust manifold gasket 8. Exhaust manifold gasket 1. 667 ENGINE .Exhaust Manifold 12 14 10 1 ft.DOHC NON-TURBO 14 Nm 10 ft. right 7. Exhaust manifold. O-ring 2.lbs. Nm 9 11m 14 Nm IO ftlbs. Water pump 15. Oil level gauge 2.lbs. O-ring 4.

Oil level gauge guide 3. Water pump gasket 7EN0504 TSB Revision I . Water inlet pipe #A4 6. O-ring 7. O-ring +A4 5.IIE-70 667 ENGINE . Water pump 8.Exhaust Manifold REMOVAL AND INSTALLATION . O-ring *A4 4. Oil level gauge 2. Removal steps 1.DOHC TURBO 14 Nm 10 ftlbs. - 17 ftlbs.

a 9.lbs. Oil return pipe gasket 24. Exhaust fitting 13. 31 Nm 22 ft Ibs.lbs. Exhaust manifold gasket 71N0120 TSB Revision . 60 Nm 43 ftlbs. rig):t 26.Exhaust Manifold 60 Nm 44 ft. Heat protector A 11. Turbocharger gasket 21. TIE-71 14Nm __B IO ft. Heat protector B 10. Water pipe B. Water hose 17. Oil pipe 15. Exhaust fitting gasket 14. right 16. right 23. Oil return pipe. Water pipe A. right 18. right 20. right +C4 25. Exhaust manifold. Turbocharger stay 12. Exhaust manifold sta . Water hose 19. 14 Nm 10 ftlbs. “Nm klbs.6G7 ENGINE . Turbocharger. Ring 22.

lbs. Exhaust fitting gasket. 10 Nm 28 14Nm & IO ft.11 E-72 6G7 ENGINE . Heat protector C 31. Oil return pipe 32. Water hose 7lN0121 i TSB Revision /’ . left 29. Water pipe 6. / 14 Nm IO ftlbs. -9 ---ml m V 31 Nm 22 ftlbs. Oil pipe 34.Exhaust Manifold 4 %4% 35 IlNm 8 klbs. Exhaust fitting. Heat protector D 28. Oil return pipe gasket 33. left 35.lbs. 25 Nm 18 ft. 27 3im 27. left 30.

Water in’let pipe 6EN0594 I I)B4 Cylinder No. Groove 7lNOl l! TSB Revision . (2) Install the nut.lbs. Caution Keep the O-ring free of oil or grease. @ and @ embossed on their top side to the right bank and install those with cylinder number 0. (3) Back off nuts @I until a torque value of 10 Nm (7 ft.). (1) Tighten five nuts @ to 30 Nm (22 ftlbs.). EXHAUST MANIFOLD GASKET IDENTIFICATION SOHC (1) Install gaskets with cylinder number 0.Exhaust Manifold I WE-73 O-ring I Water pump I INSTALLATION SERVICE POINTS +A4 O-RING AND WATER PIPE INSTALLATION (I) Wet the O-ring (with water) to facilitate assembly.). (4) Tighten nuts @ to 30 Nm (22 ft.) is achieved. @ and @J to the left bank.lbs. (2) Tighten nuts @ to 50 Nm (36 ft. NOTE (1) Fit the cone disc spring with the grooved side facing the nut. cone disc spring and washer in the order shown in the illustration. 7FNWi11 E I)c4 RIGHT EXHAUST MANIFOLD INSTALLATION DOHC TURBO Tighten the nuts in the following order.6G7 ENGINE . For right bank Front c3 7lNOOlCI Front e For left bank Cylinder No.lbs.

. cone disc spring and washer in the order shown in the illustration.). NOTE (1) Fit the cone disc spring with the grooved side facing the nut.) is achieved.).lbs.). (4) Tighten nuts @ and @ to 50 Nm (36 ftlbs. (6) Tighten nuts @ and @ to 30 Nm (22 ftlbs. (2) Install the nut.11 E-74 6G7 ENGINE . (5) Back off nuts @ and @ until a torque value of 10 Nm (7 ft. (1) Tighten four nuts @ to 30 Nm (22 ft.poranly tighten the turbocharger to the exhaust man(3) Tighten nut @ to 30 Nm (22 ft.lbs.Exhaust Manifold I)D4 LEFT EXHAUST MANIFOLD INSTALLATION . (2) -TT. I Groove / 7lNOll TSB Revision .DOHC TURBO Tighten the nuts in the following order.lbs.).

Combressor cover 71N0098 eD4 *C4 *Bg bAC r 1 INSPECTION TURBOCHARGER (1) Manually open and close the waste gate valve to make sure it operates freely.Turbocharger TURBOCHARGER DISASSEMBLY AND REASSEMBLY Xsassembly steps 1. Turbocharger waste gate actuator 3.6G7 ENGINE . Turbine wheel assembly 7. 0-rina 8. Snap pin 2. (3) Clean the inlet section of the compressor cover with a rag. O-ring 3EN019C TSB Revision I . Snap ring 6. If worn. Coupling 4. REASSEMBLY SERVICE POINTS #A4 O-RING INSTALLATION (1) Apply a light coat of engine oil to a new O-ring and fit it in the groove of the turbine wheel assembly. (2) Inspect the oil passage in the cartridge for signs of deposits or blockage. replace it. Turbine housing 5. Inspect it for signs of contact with the compressor turbine.

11 E-76 6G7 ENGINE . TSB Revision -I .Turbocharger 664 TURBINE WHEEL ASSEMBLY INSTALLATION ) Install the turbine wheel assembly to the compressor cover while aligning the dowel pin and the hole. il Chamfered +cg SNAP RING INSTALLATION (1) Fit the snap ring with its chamfered side facing up. Caution Use care not to damage the blades of the turbine wheel. T&ink wheel assembly I CompressoB cover I)04 TURBINE HOUSING INSTALLATION (1) Install the turbine housing while aligning the dowel pin and the hole. Caution Use care not to damage the blades of the turbine wheel and compressor wheel.

O-ring #B4 7. shafts and bebring caps OAO +A4 98: pa. Circular packing +C4 4. 9 @ 7 30 7 Removal steps #E4 . Fi.DIAMANTE 9Nm 7 ft.lbs.Rocker Arms and Camshaft ..667 ENGINE .. Camshaft oil seal 5. cover elII4 3.SOHC “14 E~77 ROCKER ARMS ANI) CAMSHAFTS . Rocker arms.Smhs.. Distributor adaptor 6.c:.W$er 7EN0362 TSB Revision .SOHC REMOVAL AND INSTALLATION .

Distributor adaptor 8.SOHC REMOVAL AND INSTALLATION . shafts and bearing caps aA0 *A4 .lbs.lbs.7 ft. ------d t Removal steps 1 Oil filler 2. I 0 8 - 13Nm 9 ft. Circular packing I)C4 6. Rocker arms. Gasket #D4 5.MONTERO AND TRUCK 9Nm Q. Camshaft oil seal 7.Rocker Arms and Camshaft . 7: p&dfutster 7EN0363 TSB Revision . 9Nm 7 ft. Oil filler tube eE4 3.lbs. Rocker cover 4.IIE-78 6G7 ENGINE . O-ring ’ #B4 9.

(3) Check the cam surface for abnormal wear and damage and replace if defective. Also measure the cam height and replace if out of limit. (2) Check the tooth surface of the distributor drive gear teeth of the camshaft and replace if abnormal wear is evident. use clean diesel fuel only.) LASH ADJUSTER LEAK DOWN TEST Caution 1.Rocker Arms and Camshaft . Keep it free from dust and other foreign matters.6240 in.25 mm (1. (3) Remove the rocker arm.SOHC REMOVAL SERVICE POINT 1 TE39 ROCKER ARM.75 mm (1. The lash adjuster is a precision part. SHAFT AND BEARING CAP REMOVAL (1) Install the special tools to the rocker arm to hold the lash adjuster. (2) Loosen the camshaft bearing cap bolt. shaft and bearing cap as an assembly. also check the cylinder head for damage.6643 in. If the journals are binding. Do not disassemble the lash adjusters. 2.6G7 ENGINE . 3. Do not remove the bolts from the cap. TSB Revision .) Limit: 40. Also check the cylinder head oil holes for clogging. Standard value: 41. When cleaning the lash adjusters. flo INSPECTION CAMSHAFT (1) Inspect the camshaft bearing journals for damage and binding.

11 E-80 667 ENGINE .) [Diesel fuel at 15 . move the plunger up and down 4 or 5 times while pushing down lightly on the check ball in order to bleed out the air.2 . being careful not to spill the diesel fuel.Rocker Arms and Camshaft . hold the lash adjuster upright to prevents the inside diesel fuel from spilling.04 in. bleed the lash adjuster again and test again.008 . the lash adjuster is normal. Caution Upon completion of air bleeding. replace the lash adjuster.5 mm (. Use of the Retainer facilitates the air bleeding of the rocker arm mounted type lash adjuster.20°C (50 . If the plunger is hard to be pushed in.).SOHC (1) Immerse the lash adjuster in clean diesel fuel.68”F)] 3 7EN043t INSTALLATION SERVICE POINTS *A4 LASH ADJUSTER INSTALLATION (1) Immerse the lash adjuster in clean diesel fuel. If the plunger is still loose. move the plunger up and down four or five times to bleed air. 6EN057 Division = 1 mm (.0. (2) Using a small wire.). (5) After the plunger has gone down somewhat 0. (2) While lightly pushing down the inner steel ball using the small wire. measure the time taken for it to go down 1 mm (. Replace if the measured time is out of specification. 6EN0421 M D998443-0 1 1 (3) Insert the lash adjuster to rocker arm.020 in. Standard value: 4 . Lash adjust& 7EN0174 !I ‘I TSB Revision .04 in. (3) Remove the small wire and press the plunger.) I (4) After air bleeding.20 seconds / 1 mm (.04 in. Then use the special tool to prevent the adjuster from falling while installing it. If the plunger can be pushed in all the way readily.. set the lash adjuster on the special tool (Leak down tester MD998440).

Specified sealant: 3M NUT Locking No. SHAFT AND BEARING CAP INSTALLATION (1) Apply a minimum amount of the specified sealant on the four places of the cylinder head.667 ENGINE . NOTE Be sure the sealing agent does not swell out onto the cam journal surface of the cylinder head. If it swells out. immediately wipe it off before it can dry. shafts and bearing caps such that the arrow mark on the bearing cap faces in the same direction as the arrow mark on the cylinder head.SOHC +64 ROCKER ARM. TSB Revision .4 bearing cap mating surface of cylinder head (2) Install the rocker arms. 1 and No.Rocker Arms and Camshaft . 4171 or equivalent Apply sealant Apply sealant * No.

(2) Using the special tool. (4) Remove the special tools from all rocker arms.Rocker Arms and Camshaft .11 E-82 667 ENGINE . ec4 CAMSHAFT OIL SEAL INSTALLATION (1) Apply a slight amount of engine oil all over the circumference of the camshaft oil seal lip. TSB Revision I . insert the oil seal.SOHC Arrow mark (bearing cap) Rocker arm shaft assembly(B) c7 Timing belt side Arrow mark (cylinder head) Rocker arm shaft ----assembly (A) Arrow mark-(bearing cap) 7EN0176 (3) Tighten the bearing cap bolts to the specified torque.

Specified sealant: 3M ATD Part No. / \\/ \/ 0.) thick spacer to the special tool and drive in the circular packing.052 to .5 mm (.Rocker Arms and Camshaft .667 ENGINE .3 to 1. - MD998714-01 / I 7EN0131 I)E4 ROCKER COVER INSTALLATION (1) Apply specified sealant on the area specified in the illustration. 6660 or equivalent 1 TSB Revision .SOHC MD998714-01 #D4 C I R C U L A R P A C K I N G I N S T A L L A T I O N (1) Install a 1. NOTE Use of MD724328 spacer for transmission is recommended.059 in.) 7EN0441 Spacer 7 I Caution The packing is overdriven if no spacer is fitted to the special tool.5 mm (020 in.

identify the original location of each rocker arm by a symbol.4 0 2. Rocker arm shaft “B” $A4 7. Rocker arm 3. 1 DISASSEMBLY SERVICE POINT OAo ROCKER ARM REMOVAL (1) Before disassembly.6 cylinder exhaust __ TSB Revision . Spring 4. For example.IIE-84 6G7 ENGINE . 2 *A4 6. 1 IN: For No.SOHC DISASSEMBLY AND REASSEMBLY Disassembly steps 1. Bearing cap No. Bearing cap No. put symbols as shown below. Bearing cap No.Rocker Arms and Rocker Shafts . Rocker arm shaft “A” 8. 3 5.1 cylinder intake 6EX: For No. Bearing cap No.

(2) Install the rocker arm shafts with the notched side facing the bearing cap No. #A4 Rocker arm shaft “A” Cap No.SOHC INSPECTION ROCKER ARM (1) Check the roller surface and replace the rocker arm if recesses.Rocker Arms and Rocker Shafts . Replace as necessary. damage or heat seizure is observed.667 ENGINE .---- Rocker arm shaft (B) 7ENOOlE r&B Revision I . (2) Check to ensure that the oil holes are clear.1 and the oil grooved side facing downward. (2) Check roller rotation and replace the rocker arm if uneven rotation or roller backlash is observed. 7EN006r ROCKER ARM SHAFT (1) Check the rocker arm mounting portions of the rocker arm shafts for wear or damage. The shaft with a smaller oil hole is the rocker arm shaft “A”. (3) Check the inside diameter and replace the rocker arm if damage or seizure is observed.1 and insert the bolts into the holes of the bearing cap and shafts. Notch Rocker arm shaft “6” REASSEMBLY SERVICE POINT ROCKER ARM SHAFT INSTALLATION (1) Install the rocker arm shafts “A” and “B” to the camshaft bearing cap No. Jiew P P 7EN0015 \ Rocker arm Oil hole shaft (A) \ ----/ ‘ao’& -.

(3) Install the lash adjuster to the cylinder head.) Exhaust side From 1993 models 34.41 mm (1.3778 in.3744 in.039 in.41 mm (1.70 mm (1.91 mm (1.49 mm (1.) Intake side 34.) Intake side 35.) Exhaust side MD998440 Scale = 1 mm l. Rocker Arms and Bearing Caps .3858 in. If it exceeds the limit.) Exhaust side Limit: Up to 1992 models 34.) Exhaust side From 1993 models 34.3547 in. \ 6EN035: INSTALLATION SERVICE POINTS I)A4 LASH ADJUSTER INSTALLATION Small wire (1) Immerse the lash adjuster in clean diesel fuel. remove the adjusting screw of the tester and adjust it to the height of the lash adjuster as shown in the illustration.) Intake side 34.IIE-88 6G7 ENGINE .) I n LASH ADJUSTER LEAK DOWN TEST Refer to “LASH ADJUSTER LEAK DOWN TEST” on pages 11 E-79 and 11 E-80.3661 in.99 mm (1.Camshafts.3972 in. TSB Revision .3547 in. (2) Using a small wire.20 mm (1. replace the camshaft. Also note the following: When the lash adjuster is set on a tester.DOHC INSPECTION CAMSHAFT Measure the cam height (longer diameter of the cam).91 mm (1. move the plunger up and down 4 or 5 times while lightly pushing down the check ball in order to bleed out the air. Standard value: Up to 1992 models 35.) Intake side 34.3744 in.

TSB Revision . 3 and 4 bearing caps bear the front mark. Rocker Arms and Bearing Caps . Identification mark: Up to 1992 From 1993 models mpdeis Turbo Intake side J E Exhaust side Non-turbo Intake side J” Exhaust side ii K (4) Install the camshafts with their dowel pins positioned as shown in the illustration.1 cylinder to the top dead center. I Identification mark: Intake side Exhaust side E Front mark Identification 7EN031 t (2) Gradually tighten the bearing caps in two or three steps.Camshafts.6G7 ENGINE . Right bank KY ApproFi Left bank ec4 BEARING CAP INSTALLATION (1) Install the bearing caps according to the identification mark and cap number. In the final step. No.2. (3) Install the camshaft while noting the identification mark (stamped on the hexagon section). (2) Check that the rocker arm is installed correctly on the lash adjuster and valve. tighten to the specified torque. Install these caps with the front mark directed in the same direction as that on the cylinder head.DOHC 17E439 Identification mark 7EN024S +64 C A M S H A F T INSTALLATlON (1) Turn the crankshaft to bring No.

I)D4 Rocker Arms and Bearing Caps . +E4 CIRCULAR PACKING (1) Install the circular packing with the special tool. TSB Revision .IIE-90 6G7 ENGINE . (2) Using the special tool.c amshafts.DOHC CAMSHAFT OIL SEAL (1) Apply engine oil sparingly all around the lip of the camshaft oil seal. install the oil seal.

Snap ring 3. Valve spring retainer #B4 7.Cylinder Head and Valve . \ b. Exhaust valve 3. Valve stem seal 6.SOHC REMOVAL AND INSTALLATION 0+5 W6 ce-130 g -0Q 10 -4 7 @E---14 IlONm 80 ft. Cylinder head 7EN0522 TSB Revision I . Exhaust valve seat 2. Exhaust valve guide I. Valve spring seat 7. fyks$~.lbs.SOHC l-l E-91 CYLINDER HEAD AND VALVE . Valve spring seat 5. Inlet valve guide 3. Inlet valve ~BI) $C4 9. Retainer lock 10. Valve stem seal 4. Retainer lock 6.6G7 ENGINE . Valve spring 8. head bolt 3: Cylinder head assembly #D4 4. Cylinder head gasket ~BI) eC4 5. Inlet valve seat I. Valve spring retainer 1. Valve spring 2.170 : Removal steps QAIJ +E4 12.

~BI) RETAINER LOCK REMOVAL (1) Using the special tool.11 E-92 6G7 ENGINE . OAo CYLINDER HEAD BOLT REMOVAL (1) Using the special tool. 7FNflM4 1 I TSB Revision I . little by little.Cylinder Head and Valve .SOHC REMOVAL SERVICE POINTS PRECAUTION FOR REMOVED PARTS (1) Keep removed parts in order according to the cylinder number and intake/exhaust. @o VALVE STEM SEAL REMOVAL (I) Do not reuse removed valve stem seals. (2) Remove the retainer locks. Loosen evenly. loosen the cylinder head bolts. compress the spring.

Ridge wear 1 EN026: (2) Check the valve face for correct contact.008 in.) Limit: 0. Grinding limit: “0.0020 in.05 mm (. Also replace the valve if the stem end (that contacts the rocker arm adjusting screw) has a dent. Standard value: 0.5 Exhaust 6ENOW mm (.028 in. (3) If the margin exceeds the service limit.7 1.079 in.31 in.2 mm (.2 mm (.) * Total resurfacing depth of both cylinder head and cylinder block.008 in.) mm (.2 Intake 2.) VALVE (1) If the valve stem is worn (ridge wear) or otherwise damaged. correct to meet the specification. If incorrect.) TSB Revision .0 Exhaust Limit: Intake 0.047 in. replace the valve. Standard value: 1. reface using a valve refacer. Overall height: 84 mm (3.) mm (.059 in. replace.6G7 ENGINE .Cylinder Head and Valve .) (2) If the service limit is exceeded. Valve should make a uniform contact with the seat at the center of valve face.SOHC INSPECTION CYLINDER HEAD (1) Check the cylinder head gasket surface for flatness by using a straightedge in the directions of A through G shown in the illustration.) mm (.

if the limit is exceeded.10 mm (.0.921 in. If the blue is transferred to the bottom edge of the valve face.) Exhaust Limit 0. Standard value: SOHC 49.) (3) The valve and valve seat should be lapped with lapping compound.0059 in.) Intake 0. (2) Recondition the valve seat with a seat grinder or cutter.878 in.3 mm (.827 in.) Limit: SOHC 48.06 mm (.780 in.) (2) Measure the squareness of the spring and. To do this.0. The valve seat width should be the specified value at the center of the valve face. replace the valve guide or valve. If the limit is exceeded. Standard value: 2” Limit: 4” 1 EN0264 1 EN027: VALVE GUIDES (1) Measure the clearance between the valve guide and valve stem.0020 .) Exhaust VALVE SEAT RECONDITIONING PROCEDURES (1) Before valve seat reconditioning.0039 in.1. replace. and then set the valve in place.09 mm (.0024 in.05 .4 mm (1.73 in.) Exhaust Seat width: 0.11 E-94 6G7 ENGINE .0035 in. Standard value: 0. If the blue is transferred to the center of the valve face. Rotate the valve with a light pressure.8 mm (1.2 mm (1.50 in.) DOHC up to 1992 models 45.035 . if it is smaller than the limit. check the valve stem-toguide clearance. Inspect the valve seat with prussian blue to determine where the valve contacts the seat.051 in.961 in. or both.03 . lower the valve seat with a 30 degrees stone or cutter.) From 1993 models 46.0012 .2 mm (1. replace. If the blue is transferred to the top edge of the valve face..Cvlinder Head and Valve . coat the valve 6EN0491 seat lightly with prussian blue. contact is satisfactory.9 .8 mm (1.740 in.SOHC VALVE SPRINGS (1 ) Measure the free height of the spring and. Valve seat diameter: Intake 44 mm (1.) Intake 0.4 mm (1. 1 TSB Revision ...) 38 mm (1.) From 1993 models 45.15 mm (.) DOHC up to 1992 models 44. raise the valve seat with a 65 degrees stone or cutter.

05 .4 mm (1.05 O.) If the valve spring’s installed height exceeds the service limit. Removal a Press Installation 0 Press Valve guide 6EN054: VALVE GUIDE REPLACEMENT PROCEDURE (1) Remove the snap ring from the exhaust valve.38.1.7571 in. Intake valve seat hole diameter 0.44.30 O.30 .) 0.44.591 in. to prevent the cylinder head bore from galling.SOHC (4) Check the valve seat sinkage.: 13.) 1 I Installed height 6EN043: 0.S. either heat the cylinder head up to approximately 250°C (482°F) or cool the valve seat in liquid nitrogen. Valve guide hole diameter 0.4 mm (1.1 mm (.5197 .13.1.: 38.60 O.S.38.25 OS.45 in. remove the valve seat.020 . The valve seat sinkage can be determined by measuring the valve spring’s installed height.5091 in.13.27 mm (.: 38.5138 . guide.50 O.) (3) Before fitting the valve seat. (2) Using the push rod and a press.. (3) Rebore the valve guide hole to the new oversize valve guide outside diameter.) I.) TSB Revision .S.60 O. remove the valve guide toward the cylinder head gasket surface. correct the valve seat to the specified width and angle.039 in.63 mm (1.52 mm (.: 44..: 44..25 .) Limit: 41.S. I 0.33 mm (1. (If the valve seat sinkage is great.Cylinder Head and Valve .1 mm LO20 .1.630 in.: 13.S.039 in.) VALVE SEAT REPLACEMENT PROCEDURE (1) Cut the valve seat to be replaced from the inside to thin the wall thickness.S. Then. the valve seat’s installed height also is great.33 mm (1.50 .63 mm (1.13.: 13.7559 .5315 . replace the insert with an oversize part as described below.60 .5.30 O.5.66 . See “VALVE SEAT RECONDITIONING PROCEDU’RE”.07 mm (.) 0.1.) 0. (4) Using a valve seat cutter.5’1.. 1 EN0274 1 EN027E (2) Rebore the valve seat hole in the cylinder head to a selected oversize valve seat diameter.5209 in..5079 .7441 .) Exhaust valve seat hole diameter 0.7453 in. Installed height of spring (both intake and exhaust) Standard value: 40.30 .5322 in.) 0.6G7 ENGINE .5217 .5224 in.

6EN0544i #c4 RETAINER LOCK INSTALLATION (1) Using the special tool. (5) After installing valve guides. working from the cylinder head top surface. Caution Do not reuse removed valve stem seals. 7EN0081 I)64 VALVE SPRING INSTALLATION (1) Direct the valve spring end with identification color toward the spring retainer. (2) Using the special tool. check for valve contact and correct the valve seats as necessary. INSTALLATION SERVICE POINTS I)A4 VALVE STEM SEAL INSTALLATION MD998729-01 (1) Install the valve spring seat. press-fit the valve guide. insert new valves in them to check for sliding condition.11 E-96 6G7 ENGINE .Cylinder Head and Valve . install a new stem seal to the valve guide. (6) When valve guides have been replaced. compress the valve spring and insert the retainer lock into position.SOHC NOTE Do not install a valve guide of the same size again. (4) Using the special tool. TSB Revision .

Each bolt should be tightened in two to three steps.6G7 ENGINE . Identification mark: DIAMANTE a n d M O N T E R O 7 2 72W TRUCK Identification mark #E4 CYLINDER HEAD BOLT INSTALLATION (1) Tighten the cylinder head bolts in the sequence shown.Cylinder Head and Valve . torquing progressively. Tighten to the specified torque in the final sequence.SOHC +D4 CYLINDER HEAD GASKET IDENTIFlCATl6N’ Caution Do not apply sealant to the cylinder head gasket. MD998051-01 TSB Revision .

Valve spring retainer eB4 11. Valve spring retainer 7. .lbs. 90 ft. Valve spring 8. Exhaust valve guide 19. Retainer lock 6. Retainer lock 1 0. Removal steps I. Intake valve seat 20. Valve spring seat (Gr) +A4 15.DOHC REMOVAL OF INSTALLATION Non-turbo IlONm 80 ft.DOHC CYLINDER HEAD AND VALVES . Intake valve 9.lbs. Intake valve guide 18. Cylinder head gasket 5. Washer 3. Valve stem seal 16. Valve spring seat 17. Turbo 125 Nm-+ Back off .+ lg\yE . Cylinder head 7EN0254 TSB Revision . Exhaust valve QCr$ *A4 13. Cylinder head assembly 4.Cvlinder Head and Valves .IIE-98 6G7 ENGINE . Cylinder head bolt 2. Exhaust valve seat 21. Valve stem seal 14. Valve spring 12.

95 and 96) TSB Revision I . (Refer to page 11 E-93. compress the spring. (2) Remove the retainer locks.6G7 ENGINE . loosen the cylinder head bolts.DOHC REMOVAL SERVICE POINTS gA0 CYLINDER HEAD BOLT REMOVAL qqp99 (1) Using the special tool. Loosen evenly. INSPECTION For inspection.Cylinder Head and Valves . 94. (‘IBM RETAINER LOCK REMOVAL (1) Using the special tool. @I) VALVE STEM SEAL REMOVAL (1) Do not reuse removed stem seals. only variations from the SOHC engine are described below. little by little.

5.193 . (2) Using the special tool.IIE-100 6G7 ENGINE .132.1 mm (5.9 .Cylinder Head and Valves . Caution Do not reuse removed valve stem seal. Stem seal I 6EN05A4 +c4 INSTALLATION OF RETAINER LOCKS (1) Using the special tool. II II 6EN0205 Valve seat I)B4 VALVE SPRING INSTALLATION Identification color Spring retainer (1) Install the valve spring so that the end with identification color is positioned on the rocker arm end. TSB Revision .) 252 INSTALLATION SERVICE POINTS I)A4 VALVE STEM SEAL INSTALLATION (1) Install the valve spring seat.201 in.DOHC CYLINDER HEAD Cylinder head height (when new): 131. install a new stem seal to the valve guide. compress the valve spring and insert the retainer lock into position.

(2) Back off the bolts once and tighten them to the specified torque in the same procedure as shown in step (1).6G7 ENGINE .Cylinder Head and Valves . Intake side p-y-y-q Exhaust side 7EN026: TSB Revision .DOHC 1 TE-‘MN I)D4 CYLINDER HEAD GASKET IDENTIFICATION Identifi- Identification mark 2DN Non-turbo Turbo 2DT 7EN026 I)E4 CYLINDER HEAD BOLT INSTALLATION 3 <Turbo engine> (1) Tighten the bolts in two to three stages in the illustrated sequence.

DIAMANTE and 3000GT 23 Nm 17 ft. Oil filter bracket stay 8.Oil Pan and Oil Pump OIL PAN AND OIL PUMP REMOVAL AND INSTALLATION . left eG4 3. Oil pump gasket 21. Crankshaft oil seal 19. Oil screen 14.lbs.IIE-102 6G7 ENGINE .lbs. Removal steps I. Transmission stay.lbs. Oil pump case 20. I 1. Plug 16. Drain plug gasket c)ArJ eC4 12. Oil pump cover ~BI) #A4 22. ~~ __ 1 55 Nm 40 ft. Oil pressure switch #F4 4. Relief plunger )Bg 18. 40 Nm 29 ft.lbs. Oil cooler by-pass valve*** 7. Oil pressure gauge unit +E4 5. UJ 14 Nm 10 klbs. ) 75 Nm 54 ft. right 2.lbs. Oil pan 13. 14ft. Oil screen gasket 15. Drain plug eO4 11. 6Nm 4 ft. 11 Nm 7 ** 24 Nm 17 ftlbs.lbs. Oil filter bracket gasket 10. 7 ft. Relief spring 17. Oil filter bracket 9.lbs. Oil pump inner rotor NOTE *: SOHC **: DOHC ***: DOHC Turbo 7EN0422 TSB Revision .lbs. Oil filter 6. Oil pump outer rotor (IB~J #A4 23. 33 ft. Transmission stay.

lbs.Oil Pan and Oil Pump {EMOVAL AND INSTALLATION . 19Nm 14 ft.lbs. Oil filter 4. Drain plug #III4 8.MONTEBO 5. Plug 13. Removal steps #G4 1. Oil filter bracket gasket 7.lbs.lbs.lbs.lbs. Oil pump gasket 18. 14 Nm 11 ft.lbs. Oil screen Il.lbs. Oil filter bracket 6.MONTERO and TRUCK Bolt with head mark “4” 24 Nm 17 ft. Oil pump cover (IBI) )A4 19. 5 in& Ihc 11!Emw3 55 Nm 10 Nm 7 ft. Oil pump case 17. Oil pan 10. 40 Nm 29 ft.lbs. Relief plunger )B4 15. 7EN0423 . Oil pressure switch #F4 2. Oil screen gasket 12. Relief spring 14.MONTERO +E4 3.lbs. Oil pressure gauge unit . Bolt with head mark “7” 14 Nm 10 ft. Oil pump outer rotor @I) @A4 20.6G7 ENGINE . \ m I< 55 Nm 40 ft. Drain plug gasket (IAI) eC4 9. Crankshaft oil seal 16. Oil cooler by-pass valve . 10 Nm I 7 ft. \ I 45 Nm 33 ft. Oil pump Inner rotor TSB Revision I 6 N’m 4 ft.

0.04 . Standard value: 0.03 .0012 .Oil Pan and Oil Pumn REMOVAL SERVICE POINT gA0 O I L P A N R E M O V A L (1) Knock the special tool deeply between the oil pan and the cylinder block.) (2) Check the side clearance.0031 in.. Standard value: 0.0070) Limit: 0.35 mm (.0039) (3) Check the body clearance.0016 .08 mm (. ~BI) OUTER ROTOR / INNER ROTOR REMOVAL (1) Make alignment dots on the outer and inner rotors for reference in reassembly.0... slide it along the oil pan to remove it. Standard value: 0.0. INSPECTION OIL PUMP (1) Check the tip clearance.IIE-104 6G7 ENGINE .0138) TSB Revision .10 .0040 .10 mm (. (2) Hitting the special tool on the side.18 mm (.

6G7 ENGINE . (2) Ensure that the dimension L measures the standard value under normal temperature and humidity.Oil Pan and Oil Pump OIL COOLER BYPASS VALVE (1) Make sure that the valve moves smoothly. knock the oil seal into the oil pump case. install the rotors ensuring that the alignment dots made at disassembly are properly aligned. Dimension L: 40 mm (1.358 in.) (3) The dimension must be the standard value when measured after the valve has been dipped in 100°C (212°F) oil. Dimension L: 34.5 mm (1. Then. MD99871 7-01 Oil bump case 7FNOld I 7EN046t TSB Revision .) or more 6EN0589 INSTALLATION SERVICE POINTS #A$ INNER ROTOR / OUTER ROTOR INSTALLATION (1) Apply engine oil to the rotors. NOTE Knock it as far as it goes.57 in. I)B4 CRANKSHAFT FRONT OIL SEAL INSTALLATION (1) Using the special tool.

I6 in. (4) Tighten the flange bolts in the sequence shown in the illustration. Specified sealant: Mitsubishi Genuine Part No. Bolt hole area (=7 Timing belt side Tightening sequence of flange bolts (bottom view) a Timing belt side TSB Revision . MD970389 or equivalent (3) The oil pan should be installed within 15 minutes after the application of sealant.) diameter bead of sealant to the oil pan flange.Oil Pan and Oil Pump I)c4 OIL PAN INSTALLATION (1) Remove all the remaining gasket from the mating surfaces using a scraper or a wire brush. See “Form In-Place Gasket” in introduction.IIE-106 6G7 ENGINE . (2) Apply a 4 mm (.

Keep the end of threaded portion clear of sealant. Avoid an overtightening.6G7 ENGINE .8660 or equivalent Caution 1.Oil Pan and Oil Pump +04 DRAIN PLUG GASKET INSTALLATION (1) Install the drain plug gasket as illustrated.T A P P L I C A T I O N T O O I L P R E S S U R E (1) Coat the threads of the switch with sealant and install the switch using the special tool. 2. (3) Screw the oil filter on until the O-ring contacts the bracket. 2. Keep the end of threaded portion clear of sealant. 9EN009 4 TSB Revision . Avoid an overtightening. Specified sealant: 3M ATD Part No. 6EN059 1 I)F4 SEALANT APPLICATION TO OIL PRESSURE GAUGE UNIT (1) Coat the threads of the gauge unit with sealant and install it using the special tool. Then tighten 3/4 turn. Specified sealant: 3M ATD Part No. 1 ~@q’@!! I)E4 OIL FILTER INSTALLATION m l v$ket \ APPLY engine oil (1) Clean the installation surface of the filter bracket. (2) Apply engine oil to the O-ring of the oil filter.8660 or equivalent Caution 1. 3EN022’ I +G4 APP~ %AEA.

Piston and Connecting Rod PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION ! 4 52 Nm 38 ft. Piston. Piston rini No. Piston pin 1 0. Piston rina No.2 8. Piston 1 1. connecting rod assembly 5. Connecting rod bearing (upper) 6.? 7. Oil ring 9.lbs. Bolt 7EN0424 TSB Revision . Connecting rod bearing (lower) eD4 4. Connecting rod 1 2.IIE-108 6G7 ENGINE . Connecting rod cap 3. Nut GAO #E4 2. Removal steps 1.

l The piston support must seat squarely against the piston.) Thread the guide pin onto the threaded portion of the press pin.(2) Select the correct piston support for your application. 0 Verify that the piston pin will slide through the hole in the piston support. . With the press pin up as shown in the illustration. Place the base on the press support blocks. and bearings in order according to the cylinder number. caps. Select the correct connecting rod guide pin.6G7 ENGINE . (6) Remove the piston pin from the piston pin. (See above. Part No. Piston pin setting tool MIT21 6941 1 Q2 @J e 3 \ 3 7EN044E 060 PISTON PIN REMOVAL Item No. (See above) Fit the piston support onto the base. (5) Press the piston pin out of the assembly.. insert the guide pin through the hole in the piston and through the hole in the piston support. (4) Position the piston assembly on the piston support in the press. 1 2 3 4 5 6 7 8 9 10 11 MIT310134 MIT310136 MIT310137 MIT310138 MIT310139 MIT310140 MIT310141 MIT310142 MIT48143 216943 10396 Description Base Piston Support Connecting Rod Guide Connecting Rod Guide Connecting Rod Guide Piston Support Connecting Rod Guide Piston Support Press Pin Stop Screw Nut d/ Pin Pin Pin Pin II cl 6O Q 7EN0426 Press pin Piston pin (1) Remove the stop screw from the base.Piston and Connecting Rod REMOVAL SERVICE POINTS OAr) CONNECTING ROD CAP REMOVAL llEJl69 (1) Mark the cylinder numberdon the side of the connecting rod big end for correct reassembly. IMPORTANT: To avoid piston damage. (3) Insert the press pin through the piston pin hole. (2) Keep the removed connecting rods. 7ENO426 ITss .

0.0079 .0035 in...0.0098 . PISTON PIN (1) Insert the piston pin into the piston pin hole with a thumb.) MONTERO and TRUCK 0. Replace the piston if it is cracked.0026 in. (2) The piston and piston pin must be replaced as an assembly. If the limit is exceeded. 2 0.) MONTERO and TRUCK 0. measure the end gap with a feeler gauge. Replace the piston pin if it can be easily inserted or there is an excessive play.IIE-110 6G7 ENGINE .0.039 in.0236 in. replace the piston ring. 2 Oil 1.45 m m (.06 m m (.0177 in.70 (.09 mm (.45 m m (.) No. 1 DIAMANTE and 3000GT 0. replace the ring or piston.0 mm (. and breakage and replace if defects are evident. the piston crown being in contact with the ring.) \r/ 5EN0066 Push in by piston (3) Insert the piston ring into the cylinder bore.) MONTERO and TRUCK 0. to correctly position it at right angles to the cylinder wall.) Limit: 0.60 m m (.30 .0.) TSB Revision I .0..0236 in. Standard value: No.05 . PISTON RING (1) Check the piston ring for damage.0..004 in.0118 .0020 . You should feel a slight resistance. Force the ring down with a piston. No..8 mm (. If the ring gap is excessive.. Then.60 m m (.25 .0177 in.0.03 ..031 in.OOOS .0012 .Piston and Connecting Rod INSPECTION PISTON (1) Replace the piston if scratches or seizure is evident on its surfaces (especially the thrust surface).0177 .45 . or both.20 . the piston rings must also be replaced with new ones.0024 in.) No.) Limit: 0.) Oil DIAMANTE and 3000GT 0.0276 in.1 mm (. 1.02 .0079 . excessive wear. Standard value: No. 2 Piston ring’ ring gap DIAMANTE and 3000GT 0. (2) Check for clearance between the piston ring and ring groove. 1 0. If the piston has been replaced with a new one.07 m m (..0.20 .) No.

1 mm (.02 . (5) Remove the bolts and gently remove the crankshaft bearing cap.. 3000GT scrkw Pin depth set 7EN042C 3 1 TSB Revision 1 .004 in.6G7 ENGINE . into the hole in the piston support until the press pin touches the stop screw. (2) Install the crankshaft.) 1 EN0271 INSTALLATION SERVICE POINTS +A4 PISTON PIN INSTALLATION Base F t A * Press Pin + / Piston SUPPOrt (1) Thread the stop screw and lock nut assembly into the base. (4) Gently place the crankshaft bearing cap over it and tighten the bolts to the specified torque. as follows: (1) Remove oil and grease and any other foreign matters from the crankshaft pin and the bearing inner surface. Standard value: 0.0. threaded end up. (2) Using the graduations on the press pin.OOOS .Piston and Connecting Rod CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE METHOD) The crankshaft oil clearance can be measured easily by using a plastic gauge. Fit the correct piston support on the top of the base. Inset-t the press pin.) Limit: 0. (6) Measure the width of the smashed plastic gauge at its widest section by using a scale printed on the plastic gauge bag. Depth: MONTERO and TRUCK 60 mm 62 mm DIAMANTE. adjust the stop screw to the depth.0020 in. (3) Cut the plastic gauge to the same length as the width of the bearing and place it on the pin in parallel with its axis.05 mm (.

unlike other piston rings. (4) Make sure that the side rails move smoothly in either direction. (3) Install the lower side rail in the same procedure as described in step (2). 6EN058 1 EN026E (2) Install the upper side rail To install the side rail. then press the remaining portion into the position by finger. NOTE Do not use any piston ring expander when installing the side rail. (4) Slide the piston pin over the threaded end of the press pin. IMPORTANT: Due to production tolerance variations. NOTE The side rails and spacer may be installed in either direction.6G7 ENGINE . and thread the correct guide pin up against it. (6) Press the piston pin through the. slide the guide pin through the piston and connecting rod. first fit one end of the rail into the piston groove.Piston and Connectinn Rod (3) Place the base on the press support blocks. and with the connecting rod held in position. Adjust if necessary. (7) Remove the piston assembly from the base. connecting rod until the guide pin contacts the stop screw. (5) Coat the piston pin with oil. Remove the guide pin and press pin from the assembly. it is necessary to visually inspect the piston pin depth after installation to verify that the piston pin is centered. Use of a ring expander to expand the side rail end gap can break the side rail. 7EN042E #B4 OIL RING INSTALLATION (1) Fit the oil ring spacer into the piston ring groove. TSB Revision . See illustration.

fit No.1 piston ring into position. Install piston rings No. Caution Install the piston with the front mark (arrow mark) on the top of the piston directed towards the engine front (timing belt side). install the piston and connecting rod assembly into the cylinder block. Note the difference in shape between No. (2) Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in the illustration. Care must be taken not to nick the crank pin. MONTERO and TRUCK NOTE For MONTERO and TRUCK.1 (1) Liberally coat the circumference of the piston. 3 and 5 Piston with L: For cylinders 2. Piston with R: For cylinders 1.1 INSTALLATION (1) Using a piston ring expander. and oil ring with engine oil. 3 and 5 and the other for cylinders 2.Piston and Connecting Rod bc4 llE=IA3 \ 7ENO452 PISTON RING NO.2 piston rings.2 and then No.2 / PISTON RING NO.6G7 ENGINE . and spacer gap 6EN0541 (4) Use suitable thread protectors on the connecting rod bolts before inserting the piston and connecting rod assembly into the cylinder block. 4 and 6. (3) Rotate the crankshaft so that the crank pin is on the center of the cylinder bore.1 and No. have been used.) 7EN0369 Upper side rail +D4 PISTON AND CONNECTING ROD INSTALLATION No. 2. one for cylinders 1. piston ring. (5) Using a suitable piston ring compressor tool. two types of pistons.1 and No. NOTE 1.2 with their side having marks facing up (on the piston crown side. 4 and 6 .

/ CONNECTING ROD CAP INSTALLATION (1) Mate the correct bearing cap with the correct connecting rod by checking with the alignment marks marked during disassembly.10 .Piston and Connectinn Rod I)E4 Cylinder No.) 7EN0454 TSB Revision .4 mm (.IIE-114 6G7 ENGINE . Standard value: 0.) Limit: 0.0.25 mm (. Notches 7EN045: 3 (2) Check if the thrust clearance in the connecting rod big end is correct. position the notches for locking the bearing on the same side.0157 in..0039 .0098 in. If a new connecting rod is used which has no alignment mark.

16 Removal steps 1. Oil seal case TSB Revision eE4 eD4 eC4 eC4 +C4 +C4 *I34 +B4 eB4 #B4 #B4 eB4 +A4 11. Knock sensor 25. Crankshaft adaptor 1 6. Drive elate 1 For 4WD A/T 5. 6 14SOHC 79 Nm 57 ft. Flywheel For MIT 2. Bell housing cover eF4 IO.Crankshaft. Thrust bearing A 23.lbs. Thrust bearing B 19. Crankshaft rear oil seal 12. DOHC 93 Nm 67 ftlbs. Adaptor plate 7. Bearing cap 15. Cylinder block 7EN0514 .lbs. Flywheel and Drive Plate 1 l’E415 CRANKSHAFT. Bearing cap 17. Drive plate For FWD A/T 8.6G7 ENGINE . Thrust bearing B 22. Bearing cap bolt 14.lbs. Rear plate 9. Knock sensor bracket 26. Crankshaft 21. Ball bearing > 3. Crankshaft bearing (lower) 20. Crankshaft bearing (upper) 24. 48Nm 35 ft. Thrust beanng A 18. Adaptor plate 4. Bearing cap stay __ 1992 models-Turbo 13. 26 75 Nm 54 ft. FLYWHEEL AND DRIVE PLATE REMOVAL AND INSTALLATION 23 Nm 17 ftlbs. I 74 1 7k Nm 54 ft. Bearing cap bolt I 1993 models-Turbo 16.lbs.

.004 in. (2) Install the crankshaft. (5) Remove the bolts and gently remove the crankshaft bearing cap. (3) Check the oil seal case for cracks and damage. Flywheel and Drive Plate INSPECTION CRANKSHAFT If the oil clearance exceeds the limit.0020 in. (3) Cut the plastic gauge to the same length as the width of the bearing and place it on the journal in parallel with its axis. This crankshaft can be identified by its dull gray appearance. If the difference between them (oil clearance) exceeds the limit. (1) Measure the outside diameter of the journals and the inside diameter of the crankshaft bearings.1 mm (. crankshaft. Standard value: 0. if necessary.) Caution Do not attempt an undersize machining of the crankshaft with special surface treatment.0008 . and crankshaft if necessary. replace the crankshaft bearing and. TSB Revision I . as follows: (1) Remove oil and grease and any other foreign matters from the crankshaft journal and bearing inner surface. (4) Gently place the crankshaft bearing cap over it and tighten the bolts to the specified torque. replace the bearing. (6) Measure the width of the smashed plastic gauge at its widest section by using a scale printed on the plastic gauge bag.05 mm (. CRANKSHAFT JOURNAL OIL CLEARANCE (PLASTIC GAUGE METHOD) The crankshaft oil clearance can be measured easily by using a plastic gauge. 7ENOl41 CRANKSHAFT REAR OIL SEAL (1) Check the oil seal lip for wear and damage.) Limit: 0.Crankshaft.6G7 ENGINE .02 . (2) Check rubber for deterioration or hardening.0.

(2) Measure the outside diameter of the piston to be used.008 in. Cylinder block height (when new): 210.) (3) If the distortion is excessive.02 mm (. measure the cylinder bore and cylindricity.5 mm (8. If worn badly.01 (.5878 in. If defects are evident.D.) at maximum. calculate the boring finish dimension. Make sure that the surface is free from gasket chips and other foreign matter. and cylinder) .) Cylindricity: 0.) (4) Check the cylinder walls for scratches and seizure.0039 in. (5) Using a cylinder gauge. Flywheel and Drive Plate INSPECTION ll&-1-17 CYLINDER BLOCK (I\ VisuaUy check for scratches. Grinding limit: 0. correct.2 mm (.2 mm (008 in.6G7 ENGINE . Standard value: 0.10 .) (honing margin) TSB Revision . correct by boring the cylinders to an oversize and replace pistons and piston rings. Piston size identification m -Thrust direction 7EN0462 NOTE Size mark is stamped on the piston top. Measure at the points shown in the illustration.91. correct within the allowable limit or replace.) Limit: 0.. and corrosion. Boring finish dimension = Piston O.0. If defects are evident.D.1 mm (.D. correct (rebore to an oversize) or replace. (2) Using a straightedge and feeler gauge.Crankshaft.0020 in.OOOS in.D. + (clearance between piston O.5866 .0004 in. Use also a flaw detecting agent for the check. or replace.13 mm (3. (3) Based on the measured piston O.: 91. Standard value: Cylinder I.05 mm (.) BORING CYLINDER (1) Oversize pistons to be used should be determined on the basis of the largest bore cylinder. rust.) The total thickness of the stock allowed to be removed from cylinder block and mating cylinder head is 0. Measure it in the thrust direction as shown.29 in.3. check the block top surface for warpage.

5.IIE-118 6G7 ENGINE . Caution To prevent distortion that may result from temperature rise during honing.01 .3 a n d No. No.) NOTE When boring cylinders.4. + clearance between piston 0-D.2. 1 TSB Revision .6. bore cylinders in the order of No.. No. and cylinder). Clearance between piston and cylinder: 0.Crankshaft. No. finish all of six cylinders to the same oversize.0016 in. No.D.04 m m (-0004 .0.1. Flywheel and Drive Plate (4) Bore all cylinders to the calculated boring finish dimension. INSTALLATION SERVICE POINTS I)A4 DETONATION SENSOR BRACKET INSTALLATION (1) Check that the bracket is in intimate contact with the cylinder block boss and tighten to specified torque in the order shown. Do not bore only one cylinder to an oversize. (6) Check the clearance between the piston and cylinder. (5) Hone to the final finish dimension (piston O.

assemble as shown in the illustration. Caution Install them with the groove side facing outward. Flywheel and Drive Plate I)B4 CRANKSHAFT BEARING (UPPER) / IfE-m THRUST BEARING A / THRUST BEARING B / CRANKSHAFT BEARING (LOWER) INSTALLATION (1) Classify the crankshaft bearings (upper and lower) by whether there is an oil groove or not. Then.3 journal area as shown.6G7 ENGINE .Crankshaft. Oil groove Crankshaft bearing (upper) No oil groove Timing belt side Timing belt side 7EN0463 TSB Revision . (2) Assemble the thrust bearings (A and B) on the No.

012 in.: tighten the bolts on the cylinder block side to the specified torque. replace the thrust bearing. Flywheel and Drive Plate BEARING CAP / BEARING BOLT INSTALLATION I)c4 (1) Attach the bearing cap on the cylinder block as shown in the illustration. Standard value : 0.0098 in.IIE-120 6G7 ENGINE .) I)Dg BEARING CAP STAY INSTALLATION .05 . (2) Tighten the bearing cap bolts to the specified torque in the sequence shown in the illustration.Crankshaft. Install correct ones on correct sides.3 mm (.) Limit: 0.0. (2) Temporarily tighten the bolts on the cylinder block side. If it exceeds the limit value. (3) Check that the crankshaft rotates smoothly. (3) Tighten the bolts on the bearing cap side to the specified (4) Frr%. NOTE The bearing cap stays A and B differ in shape.0020 .. Cylinder (4) Check the end plate.25 mm (. 1 TSB Revision .DOHC TURBO (1) Apply engine oil to the thread and bearing surface of each bolt.

and place the oil seal on the cylinder block. press-fit a new crankshaft rear oil seal into the oil seal case. Flywheel and Drive Plate IIE-121 CRANKSHAFT REAR OIL SEAL INSTALLATION (1) Using the special tool. Specified sealant: MITSUBISHI GENUINE Part No.Crankshaft. I)E4 7EN046! i -I M 8990938-01 I I MD99871 8-01 7EN0466 Sealing agent OIL SEAL CASE INSTALLATION (1) Apply specified sealant to the area shown in the illustration.6G7 ENGINE . I)F4 7EN0467 I 1 TSB Revision II . MD970389 or equivalent (2) Apply a small amount of engine oil to the entire circuinference of the oil seal lip section.

right 2. I Removal steps 1.lbs. 25 Nm 18 ft.lbs. Engine support bracket.Bracket REMOVAL AND INSTALLATION .llE-122 BRACKET 6G7 ENGINE . Roll stopper bracket. Engine support bracket. front 2. rear 1 TSB Revision . Removal steps 1. left 7EN0521 REMOVAL AND INSTALLATION .MONTERO and TRUCK 30 ft.DIAMANTE and 3000GT 2 42Nm 30 ft. Roll stopper bracket.lbs.