MITSUBISHI ENGINE 6A1 SERIES (E-W) WORKSHOP MANUAL FOREWORD This Workshop Manual contains procedures for Engine .. removal, disassembly, inspection, adjustment, reassembly and installation, etc. for service mechanics. All information, illustrations and product descriptions contained in this manual are current as at the time of publication, We, however, reserve the right to make changes at any time without prior notice or obligation. FILING INSTRUCTION Please keep these manual pages in the binder No. BN890001. File these pages according to the signs “Added”, “Revised” and “Deleted” on the “List of effective pages” which are interpreted below. ‘Added: File the pages with this sign additionally in your manual. Revised, Deleted: Replace the existing pages with the corresponding pages with this sign. Missing sheets will be supplied upon request. ate MITSUBISHI MOTORS CORPORATION Pub. No. PWEE9622 © wnaubieht Motora Corporation Feb. 1067INTRODUCTION EXPLANATION OF MANUAL CONTENTS Maintenance and Servicing Procedures (1) A diagram of the component parts is © Removal steps: provided near the front of each section in ‘The part designation number corresponds order to give the reader a better under- to the number in the illustration to indicate standing of the installed condition of removal steps. component parts. @ Disassembly steps: (2) The numbers provided within the diagram The part designation number corresponds indicate the sequence for maintenance and to the number in the illustration to indicate servicing procedures. disassembly steps. BB: indicates a non-reusable part. ‘© Installation steps: ‘The tightening torque is provided where Specified in case installation is impossible applicable. in reverse order of removal steps. Omitted if installation is possible in reverse order of removal steps. Reassombly steps: Specified in case reassembly is impossible in reverse order of disassembly steps. Omitted if reassembly is possible in reverse order of disassembly steps. Classification of Major Maintenance/Service Points When there are major points relative to maintenance and servicing procedures (such as essential maintenance and service points, maintenance and service stan- dard values, information regarding the use of special tools, etc.), these are arranged together a8 major maintenance and service points and explained In tall <4AD- = Indicates that there are essential points for removal or disassembly. DPA-¢ = Indicates that there are essential points for installation or reassembly. ‘Symbols for Lubrication, Sealants and Adhesives Information concerning the locations for lubrication and for application of sealants and adhesives is provided, by using sym- bols, in the diagram of component parts, or (on the page following the component parts page, and explained. Grease (multipurpose grease unless there is a brand or type specified) : Sealant or adhesive : Brake fluid, automatic transmission fluid or air conditioner compressor oll ami ht Engine oil or gear oil ‘© Miteubiahi Motors Corporation Feb. 1997 PweesezeINTRODUCTION Indicates the section num- ber. Indicates the section title, Indicates the group number. Indicates the page number. GAY ENGINE (E-W) Water Purp and Water Pipe 11A-7-1 7. WATER PUMP AND WATER PIPE REMOVAL AND INSTALLATION Denotes tightening torque. —| Denotes non-reusable part ] This number corresponds to the number appearing in “Removal steps’, “Disassembly steps”, “installation steps” of “Reassembly steps”. Ee pea cree cst mpegs et Bed JEG Stn lonpoause Soar roa Operating procedures, _cau- tions, etc. on removal, installa- INSTALLATION SERVICE POINTS: tion,” disassembly and reas- Ad SEALANT APPLICATION TO WATER PUMP sembly are described. ‘Sota str: "reel anne Pat No, MOSER or equa [ebteaionrumberRevon cose (© Mitnubiaht Motors Corporation Feb, 1057 PwEED62211A-0-1 GENERAL INFORMATION 1. SPECIFICATIONS SERVICE SPECIFICATIONS . REWORK DIMENSIONS ..... TORQUE SPECIFICATION . 6A1 SERIES SEALANTS... FORM-IN-PLACE GASKET (FiPG) 2.SPECIAL TOOLS ... 3.DRIVE BELT 4, TIMING BELT ... 5.FUEL AND EMISSION CONTROL PARTS ... 6.IGNITION SYSTEM . 7.WATER PUMP AND WATER PIPE . . 8.INTAKE MANIFOLD AND EXHAUST MANIFOLD 9, ROCKER ARM AND CAMSHAFT ... 10. ROCKER COVER AND CAMSHAFT ......... ENGINE CONTENTS 11. ROCKER ARM AND ROCKER SHAFT CAP 12. CYLINDER HEAD AND VALVES .... 13. OIL PUMP CASE AND OIL PAN . 14. PISTON AND CONNECTING ROD... 15, CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL ‘AND DRIVE PLATE . 11A0-3, AAA WAT AAS TA AAT TAB A241 110-34 TAM TAS T1A-6-1 MATA 11A-8-1 11A-9-41 cee HAO 2 WA WAN24 | WA-13-4 A144 WA15-4 © Mitaubia Motors Corporation Feb. 1097 Pweeseaa11A-0-2 NOTES (© nataubant Motors Corporation Feb. 10976A1 ENGINE (E-W) — General GENERAL INFORMATION GENERAL SPECIFICATIONS Descriptions eat2 BAt3 Type 60° V, OHV, DOHC (for each bank) | 60° V, OHV, SOHC (for each bank) Number of oyinders 6 6 Combustion chamber Pentroof type | Pentroot type a Total displacement dm? 1,998 2.498 Oylinder bore mm 78.4 81.0 Piston stroke mm 69.0 e008 ‘Compression ratio. 10.0 9.5" oF 9.02 : Valve timing | intake | Opens | 15° (Low-speed cam) 18° 7 valve | (BTDC) | 37.5° (High-speed cam) Closes | 41° (Low-speed cam) 53° 7 (ABDC) | 82.5° (High-speed cam) Exhaust | Opens | 41° (Low-speed cam) 53° ” | valve (BBDC) | 75° (High-speed cam) Closes | 15° (Low-speed cam) 15° (ATDC) | 30° (High-speed cam) Lubrication system Pressure feed, full-fow fitration Pressure feed, ful-flow fitration | ll pump type Trochoid type | Trochoid type Cooling system Water-cooled forced circulation Water-cooled forced circulation _| Water pump type Centritugal impeller type | Centitugal impeller type NOTE *': Europe and Hong Kong GEC and Export (© Miaubishi Motors Corporation eb. 1907 PweEssze6A1 ENGINE (E-W) — Speci 11A-1-1 1. SPECIFICATIONS SERVICE SPECIFICATIONS tems ‘Standard value Limit Timing belt - ‘Auto tensioner rod projection mm 120 = {Auto tensioner rod pushed-in amount (when pushed with a force | 1.0 or less - of 98 - 196 N) mm Rocker arm and camshaft - Camshaft cam height mm | Intake - | 35.20 34.70 - Exhaust _ 34.70 34.20 Camshaft joumal diameter mm [ 45 - - | Rocker cover and camshaft Camshaftcam heightmm | Intake | (Low-speed cam) | 34.94 33.64 (High-speed cam) [96.46 35.96 [exhaust | (Low-speed cam) | 94.40 33.90 (High-speed cam) [35.86 3535 | Camshaft journal diameter mm 26 ~ Valve clearance mm Intake 040 = Exhaust 013 - | Cylinder heed andvalve 7 7 Flatness of cylinder head gasket surface mm - = | Cylinder head gasket surface grinding limit (including grinding of | Less than 0.03 = cylinder block gasket surface) mm Cylinder head overall height | SOHC 1199-120. = ™ MIVEC 1196-1198 = Cylinder head bolt nominal length mm = 64 Valve margin mm Intake [10 os Exhaust 13 08 Valve stem diameter mm [60 - Valve sterto-guide clearance | Intake | 0.02-0.05 0.10 - ™ Exhaust 0.04 - 0.07 0.18 Valve face angle mm a 45° — 45.5° - Valve stem projection mm | SOHC 48.45 48.95 MIVEC 48.40 48.00 {© MitaubehiMotore Corporation Feb. 1067 PwEEv6z211A-1-2 6A1 ENGINE (E-W) - Specifications tems Standard value Limit “Overall valve length mm Intake | SOHC 113.02 112.52 MIVEC 112.37 meri Exhaust | SOHC 116.32 [ wives nore 110.74 Valve spring free height mm | SOHC 499 48.9 MIVEC 515 505 Valve spring loadinstalled | SOHC | 2683.4 = neigh Nin MIVEC 256/445 = Valve spring squareness 2 * Valve seat contact width mm 09-13 - ‘Valve guide internal diameter mm 66 = Valve guide projection mm | SOHC 140 - Mivec - 190 = Oil pump case and oil pan - | Oi pump tip clearance mm 0.06 0.18 = il pump side clearance mm = 0.04 -0.10 = il pump body clearance mm 0.10 -0.18 0.36 Piston and connecting rod - Piston outside diameter mm | 6A12 7a4 = 6A13 a0 = Piston ring side clearance mm | No.1 ring 0.02- 0.06 = No.2 ring | 002-006 - Piston ring end gap mm No.t ring 0.20 -0:35 08 No2ring 0.35 - 0.50 08 “No ring (020 -0.50 10 Piston pin outside diameter mm 190 = Piston pin press-in oad (at room temperature) N_ 4,900 - 14,700 - Crankshaft pin oil clearance mm 0.02 - 0.05 on Connecting rod big end side clearance mm 040-025 04 ~ Crankshaft, cylinder block, flywheel and drive plate “Crankshaft end playmm 0.05 — 0.25 04 (© miteubehi Motore Corporation Feb. 1907 PweEDe226A1 ENGINE (E-W) — Specificatior 11A-1 tems Standard valve Limit Crankshaft journal diameter | 6A12 53.0 - =m [eas 560 - Crankshaft pin diameter mm | 6A12 430 = [eats 51.0 = | Crankshaft journal oll clearance mm ~ [0020.04 04 Cylinder block gasket surface flatness mm 0.05 - “| yinder block gasket surtace grinding limit (inluding grinding of | ~ 02 oylinder head gasket surface) mm | Gyinder Bock overal height | 6At2 1900 [- eA13 209.0 = ylinderbiock eylincricty mm 0.01 or less = Gylinder block internal diame- | 6A12 73.4 - termm | 6A13 810 = Bearing cap bolt nominal length mm = 714 Piston-to-cylinder clearance mm 0.02 - 0.04 = REWORK DIMENSIONS item ‘Standard Cylinder head and valves Cylinder head oversize valve guide hole diameter mm | 0.05 0.8, | 1.05- 11.07 | 0.2508. 1125-1127 05008, 11.50- 11.52 | Oversize intake valve seat | SOHC 0305. 29.80 - 29.82 fing hole diameter mm - 0605. 30.10 30.12 MIvec 0308. 32.30 - 23.32 0608 32.60 - 62.62 | ‘Oversize exhaust valve | SOHC losos. 27.80 ~ 27.82 seat ring clameter mm 0608. 28.10 28.12 MIVEC Josos. 29.60 -29.82 060: | 30.10 -90.12 (© mitaublahi Motor Corporation Feb. 1967 Pweevece11A-1-4 6A1 ENGINE (E-W) - Specifications TORQUE SPECIFICATION Teme Nm ‘Alternator and drive belt - Altemator pivot nut 4 | ‘iterator bolt at Ci level gauge guide 23 Tensioner pulley 15 | Engine hanger 23 Tensioner pulley bracket A 45 (Crankshaft bolt 182 Engine cover 3 Timing bett | | Timing belt front cover 1" | Engine suppor bracket 49 ‘Angle sensor 9 ‘Angle sensor connector bracket - " Tensionerpuley 48 ‘Tensioner arm 24 Auto tensioner 21 Camshaft sprocket bolt 88 Idler pulley - 35 Timing belt rear cover 1" | ‘Angle sensor connector bracket 1 | Fuel and emission control parts Air intake plenum stay 18 | Connector bracket 7 1" EGR valve 22 Throttle body 12 Ar intake plenum : 18 Delivery pipe 12 Fuel pipe 9 Fuel pressure regulator " ~ 9 ‘Alternator bracket 23 ‘| (© Mitaubeht Motors Corporation Feb. 1087 PweEve226A1 ENGINE (E-W) — Specifications 11A-1-5 items Nm Ignition system 7 Spark plug 7 25 ~ Water cover (SOHC) 1 7 Distributor (SOHO) 13 ~ lonition failure sensor (MIVEC) 10 _ Condenser bracket assembly (MIVEC) - Ignition col (MIVEC) _ ; Water pump and water pipe Engine hanger (MIVEC) 1" Engine coolant temperature gauge unit |n | Engine coolant temperature sensor [29 - Heater pipe (SOHC) 3 7 Water init fiting je Water outlet fiting 18 Thermostat housing 23 Water pipe 13 - Water pump fe Intake manifold and exhaust manifold Intake manifold 7 | Heat protector 18 — Exhaust manifold stay “4 - Exhaust manifold 49 Rocker arm and camahaft ; Rockercover 7 4 Rocker arm and rocker shaft 31 Thrust case 24 7 Rocker arm and camshaft ~ — Rocker cover — 4 Oil control valve holder ° ; Cam cap [24 Bearing cap M6 _ 1" Bearing cap M8 24 7 (© mitaublahi Motors Corporation Feb. 1957 Pweesez211A-1-6 6A1 ENGINE (E-W) — Specifications Items ‘Arm spring holder Rocker arm and rocker shaft cap Nm 1" Rocker shaft cap 1" Cylinder head and valves Cylinder head bolt 20 + 120° + 120° il pan and oi! pump Oil pressure switch il fiter cover 2 Water hose 30 Bolt 68 | Drain plug 9 | Oit evel sensor @ il pan 7 Oil screen 19 7 Battle plate ° —_ Reliet plug — 44 Oil pump case 14 il pump case cover 12 | Piston and connecting rod Connecting rod 18 + 90° — 100° Crankshaft, cylinder block, flywheel and drive plate Detonation sensor 23 idler pulley bracket 35 Flywheel bolt 98 Drive plate bolt — 98 — Rear plate in Bell housing cover 9 Oil seal case 1" Bearing cap bolt | 28+ 90° = 100° | (© mitsubishi Motors Corporation Feb 1987 PweEssz26A1 ENGINE (E-W) — Specifications 114-1-7 NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA ‘A new type of bolts, to be tightened in plastic area, is currently used in some parts of the engine. The tightening method for the bolts is different from the conventional one. Be sure to observe the method described in the text when tightening the bolts. Service limits are provided for the bolts. Make sure that the service limits described in the text are strictly observed. © Areas where the bolts are in use: (1) Cylinder head bolts (2) Main bearing cap bolts (3) Connecting tod cap bolts © Tightening Method After tightening the bolts to the specified torque, tighten them another 90° to 100°, or 240° (twice 120°). The tightening method varies on different areas. Observe the tightening method described in the text. SEALANTS tiem Specified sealant Quantity Water pump Mitsubishi Genuine Part No. MD970389 or equivalent | As required Water outlet fiting® Mitsubishi Genuine Part No. MD970389 or equivalent | As required Engine coolant temperature sensor | 3M Nut Locking Part No. 4171 or equivalent ‘As required Engine coolant temperature gauge unit | 3M ATD Part No. 8660 or equivalent ‘As required ‘Camshaft bearing ~ | 8M ATD Part No. 8660 or equivalent ‘As required ‘Cam cap ~~ | 3M ATD Part No. 8660 or equivalent ‘As required Oilcontrolvave 3M ATD Part No. 8660 or equivalent ‘As required Camshaft holder* Mitsubishi Genuine Part No. MD970389 or equivalent | As required Rocker cover 3M ATD Part No, 8660 or equivalent ‘As required il pump case" Mitsubishi Genuine Part No. MD970389 or equivalent | As required Oil pant a Mitsubishi Genuine Part No. MD970389 or equivalent | As required Oil pressure switch ‘3M ATD Part No. 8660 or equivalent ‘As required Oil seal case" Mitsubishi Genuine Part No. MD970389 or equivalent | As required Drive plate bolt “8M Nut Locking Part No. 4171 or equivalent ‘As required Flywheel bolt ~| 3M Nut Looking Part No. 4171 or equivalent ‘As required *: parts sealed by foam-in-place gasket (FIPG) ‘©mnaubih Motore Corporation Feb. 1007 PweEve2211A-1-8 6A1_ ENGINE (E-W) — Specifications FORM-IN-PLACE GASKET (FIPG) The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to apply the gasket ‘evenly without a break, while observing the correct bead The FIPG used in the engine is a room temperature vulcanisation (RTV) type and is supplied in a 100-gram tube (Part No. MD970389 or MD997110). Since the RTV hardens as it reacts with the moisture in the atmospheric air, it is normally used in the metallic flange areas. The FIPG, Part No. MD970389, can be used for sealing both engine oil and coolant, while Part No. MD997110 can only be used for engine oil sealing. Disassembly The parts assembled with the FIPG can be easily disassembled without use of a special method. In some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking with @ mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces, For removal of the oll pan, the special tool “Oil Pan Remover” (MD998727) is available. Be sure to use the special tool to remove the oll pan. Surface Preparation Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure that there are no oils, greases and foreign substances deposited on the application surfaces. Do not forget to remove the old sealant remained in the bolt holes. Form-in-Place Gasket Application When assembiing parts with the FIPG, you must observe some precautions, but the procedures is very simple as in the case of a conventional precut gasket, Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time (about one hour) has passed after installation is completed. The FIPG application procedure may vary on different areas. Observe the procedure described in the text when applying the FIPG. {© Mitaubiaht Motors Corporation Feb. 1067 Pweesez2