Mitsubishi 6A1 manual

GENERAL INFORMA TION 1 1A-0-3 ........................................... 1. SPECIFICA TIONS 1 1A-1-1 ............................................... SERVICE SPECIFICA TIONS 1 1A-1-1 .................................. REWORK DIMENSIONS 1 1A-1-3 ....................................... T ORQUE SPECIFICA TION 1 1A-1-4 .................................[...]

1 1A-0-2 PWEE9622 E Feb. 1997 Mitsubishi Motors Corporation NOTES[...]

6A1 ENGINE (E - W) - General Information 1 1A-0-3 GENERAL INFORMA TION GENERAL SPECIFICA TIONS Descriptions 6A12 6A13 T ype 60 ° V , OHV , DOHC (for each bank) 60 ° V , OHV , SOHC (for each bank) Number of cylinders 6 6 Combustion chamber Pentroof type Pentroof type T otal displacement dm 3 1,998 2,498 Cylinder bore mm 78.4 81.0 Piston stroke mm [...]

6A1 ENGINE (E - W) - Specifications 1 1A-1-1 1. SPECIFICA TIONS SERVICE SPECIFICA TIONS Items Standard value Limit Timing belt Auto tensioner rod projection mm 12.0 - Auto tensioner rod pushed-in amount (when pushed with a force of 98 - 19 6 N) mm 1.0 or less - Rocker arm and camshaft <SOHC> Camshaft cam height mm Intake 35.20 34.70 Exhaust 3[...]

6A1 ENGINE (E - W) - Specifications 1 1A-1-2 Items Limit Standard value Overall valve length mm Intake SOHC 1 13.02 1 12.52 MIVEC 1 12.37 1 1 1.87 Exhaust SOHC 1 15.32 1 14.82 MIVEC 1 10.74 1 10.74 V alve spring free height mm SOHC 49.9 48.9 MIVEC 51.5 50.5 V alve spring load/installed SOHC 265/43.4 - height N/mm MIVEC 255/44.5 - V alve spring squa[...]

6A1 ENGINE (E - W) - Specifications 1 1A-1-3 Items Limit Standard value Crankshaft journal diameter 6A12 53.0 - mm 6A13 56.0 - Crankshaft pin diameter mm 6A12 43.0 - 6A13 51.0 - Crankshaft journal oil clearance mm 0.02 - 0.04 0.1 Cylinder block gasket surface flatness mm 0.05 - Cylinder block gasket surface grinding limit (including grinding of cyl[...]

6A1 ENGINE (E - W) - Specifications 1 1A-1-4 TORQUE SPECIFICA TION Items Nm Alternator and drive belt Alternator pivot nut 44 Alternator bolt 21 Oil level gauge guide 23 T ensioner pulley 15 Engine hanger 23 T ensioner pulley bracket A 45 Crankshaft bolt 182 Engine cover 3 Timing belt T iming belt front cover 11 Engine support bracket 49 Angle sens[...]

6A1 ENGINE (E - W) - Specifications 1 1A-1-5 Items Nm Ignition system Spark plug 25 W ater cover (SOHC) 11 Distributor (SOHC) 13 Ignition failure sensor (MIVEC) 10 Condenser bracket assembly (MIVEC) 5 Ignition coil (MIVEC) 10 W ater pump and water pipe Engine hanger (MIVEC) 11 Engine coolant temperature gauge unit 11 Engine coolant temperature sens[...]

6A1 ENGINE (E - W) - Specifications 1 1A-1-6 Items Nm Arm spring holder 11 Rocker arm and rocker shaft cap <MIVEC> Rocker shaft cap 11 Cylinder head and valves Cylinder head bolt 20 + 120 ° + 120 ° Oil pan and oil pump Oil pressure switch 10 Oil filter cover 21 W ater hose 30 Bolt 68 Drain plug 39 Oil level sensor 9 Oil pan 7 Oil screen 19 [...]

6A1 ENGINE (E - W) - Specifications 1 1A-1-7 NEW TIGHTENING METHOD - BY USE OF BOL TS T O 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 dif ferent from the conventional one. Be sure to observe the method described in the text w[...]

6A1 ENGINE (E - W) - Specifications 1 1A-1-8 FORM-IN-PLACE GASKET (FIPG) The engine has several areas where the form-in-place gasket (FIPG) is in use. T o ensure that the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size, continuity and location are of paramount importance. T oo thin a [...]

6A1 ENGINE (E - W) - Special T ools 1 1A-2-1 2. SPECIAL TOOLS T ool Number Name Use MB990685 T orque wrench Adjustment of timing belt tension MB990938 Handle Use with MD998776 MB990767 Crankshaft pulley holder Holding camshaft sprocket when loosening and tightening of bolt. Use with MD998719 MB991477 V alve adjusting wrench Adjustment of valve clea[...]

6A1 ENGINE (E - W) - Special T ools 1 1A-2-2 T ool Use Name Number MD998440 Leak-down tester Leak-down test of lash adjuster MD998441 Lash adjuster retainer Air bleeding of lash adjuster MD998442 A ir bleed wire Air bleeding of lash adjuster MD998443 Lash adjuster holder Retainer for holding lash adjuster in rocker arm at time of removal and instal[...]

6A1 ENGINE (E - W) - Special T ools 1 1A-2-3 T ool Use Name Number MD998735 V alve spring compressor Compression of valve spring MD998754 Pin Use with MB990767 MD998767 T ensioner pulley socket wrench Adjustment of timing belt tension MD998772 V alve spring compressor Removal and installation of valve and related parts MD998774 V alve stem seal ins[...]

6A1 ENGINE (E - W) - Special T ools 1 1A-2-4 T ool Use Name Number MD998780 SETTING TOOL Piston pin Removal and installation of piston pin MD998781 Flywheel stopper Holding flywheel and drive plate MD998784 V alve spring compressor adapter Compression of valve spring (MIVEC) (Use with MD998772) PWEE9622 E Feb. 1997 Mitsubishi Motors Corporation[...]

6A1 ENGINE (E - W) - Drive Belt 1 1A-3-1 3. DRIVE BEL T REMOV AL AND INST ALLA TION <SOHC> 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 21 Nm 15 Nm 23 Nm 3N m 23 Nm 44 Nm 44 Nm 44 Nm 182 Nm Removal steps 1. Drive belt 2. Alternator 3. Oil level gauge (dipstick) 4. O il level gauge guide 5. O-ring 6. T ensioner pulley 7. Engine hanger 8. T ensioner [...]

6A1 ENGINE (E - W) - Drive Belt 1 1A-3-2 REMOV AL AND INST ALLA TION <MIVEC> 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 21 Nm 15 Nm 23 Nm 44 Nm 23 Nm 44 Nm 3N m 44 Nm 182 Nm Removal steps 1. Drive belt 2. Alternator 3. Oil level gauge (dipstick) 4. O il level gauge guide 5. O-ring 6. T ensioner pulley 7. Engine hanger 8. T ensioner pulley bracket[...]

6A1 ENGINE (E - W) - Drive Belt 1 1A-3-3 REMOV AL SER VICE POINTS A A " CRANKSHAFT PULLEY BOL T REMOV AL (1) Hold t he flywheel or drive plate in position with the special tool before removing the crankshaft pulley bolts. INST ALLA TION SER VICE POINTS " A A CRANKSHAFT PULLEY BOL T INST ALLA TION (1) Hold t he flywheel or drive plate in p[...]

6A1 ENGINE (E - W) - Timing Belt 1 1A-4-1 4. TIMING BEL T REMOV AL AND INST ALLA TION <SOHC> 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 11 N m 21 Nm 9N m 48 Nm 24 Nm 49 Nm 35 Nm 88 Nm 17 18 11 N m 11 N m 11 N m 11 N m Removal steps 1. T iming belt front cover , upper right 2. T iming belt front cover , upper left 3. T iming belt front cover , low[...]

6A1 ENGINE (E - W) - Timing Belt 1 1A-4-2 REMOV AL AND INST ALLA TION <MIVEC> 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 11 N m 12 Nm 9N m 48 Nm 44 Nm 49 Nm 35 Nm 88 Nm 17 17 11 N m 11 N m 11 N m 11 N m 19 20 21 22 23 22 Nm 18 9N m 9N m Removal steps 1. T iming belt front cover , upper right 2. T iming belt front cover , upper left 3. T iming bel[...]

6A1 ENGINE (E - W) - Timing Belt 1 1A-4-3 REMOV AL SER VICE POINTS A A " TIMING BEL T REMOV AL (1) Mark the belt running direction for reference in reinstallation. (2) Loosen the bolt that secures the tensioner pulley to remove the timing belt. A B " CAMSHAFT SPROCKET BOL T REMOV AL INST ALLA TION SER VICE POINTS " A A CAMSHAFT SPROC[...]

6A1 ENGINE (E - W) - Timing Belt 1 1A-4-4 " B A AUT O TENSIONER SETTING (1) Set the auto tensioner in a vice, while making sure it is not tilted. (2) Slowly close t he 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 . (3) Insert a 1.4 mm wire in th e set hole. (4) Remove the auto ten[...]

6A1 ENGINE (E - W) - Timing Belt 1 1A-4-5 (3) Align t he timing mark on th e crankshaft sprocket with that on the cylinder block side. (4) Fit the timing belt on th e sprockets in the following order: 1) Fit th e timing belt on the crankshaft sprocket and then, while giving tension to the belt, fit it on the water pump sprocket. 2) Fit the belt on [...]

6A1 ENGINE (E - W) - Timing Belt 1 1A-4-6 " D A TIMING BEL T INST ALLA TION (1) T urn the crankshaft sprocket so that its timing mark will be away from th e mating timing mark by approx. three teeth. Caution D If the timing marks are aligned, the piston is brought to the TDC. When the camshaft is turned under this condition, the v alv es may i[...]

6A1 ENGINE (E - W) - Timing Belt 1 1A-4-7 4) On the left bank, make sure that the timing marks of the camshaft sprockets are aligned and then hold the timing belt on these sprockets with paper clips. 5) Place the timing belt around the water pump pulley . 6) Place the timing belt around the crankshaft sprocket. 7) Place the timing belt around the t[...]

6A1 ENGINE (E - W) - Timing Belt 1 1A-4-8 (2) Cracks on rubber back. (3) Cracks or peeling of canvas. (4) Cracks on tooth bottom. (5) Cracks or belt sides. (6) Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife. (7) Abnormal wear on teeth. (8) Missing tooth. AUT O-TENSIONER (1) Check for oil leaks. If oil leaks[...]

6A1 ENGINE (E - W) - Fuel and Emission Control Parts 1 1A-5-1 5. FUEL AND EMISSION CONTROL P ARTS REMOV AL AND INST ALLA TION <SOHC> 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 18 Nm 9N m 22 Nm 23 Nm 12 Nm 18 Nm 9N m 12 Nm 18 Nm 18 Nm 18 Nm 7 Removal steps 1. Air intake plenum stay , front 2. Air intake plenum stay , rear 3. EGR va[...]

6A1 ENGINE (E - W) - Fuel and Emission Control Parts 1 1A-5-2 REMOV AL AND INST ALLA TION <MIVEC> 2 3 4 5 6 7 8 10 12 13 14 15 16 17 18 19 20 21 22 24 18 Nm 23 Nm 12 Nm 14 Nm 9N m 9N m 23 26 1 18 Nm 11 12 Nm 11 N m 11 N m 18 Nm 8.8 Nm 18 Nm 25 9 Removal steps 1. Air intake plenum stay , front 2. Air intake plenum stay , rear 3. V acuum pipe 4[...]

6A1 ENGINE (E - W) - Fuel and Emission Control Parts 1 1A-5-3 INST ALLA TION SER VICE POINTS " A A FUEL PRESSURE REGULA TOR INST ALLA TION (1) Apply spindle oil or gasoline to th e new O-ring installed on the fuel pressure regulator . (2) Insert the fuel pressure regulator in the delivery pipe. (3) Make sure that the fuel pressure regulator tu[...]

6A1 ENGINE (E - W) - Ignition System 1 1A-6-1 6. IGNITION SYSTEM REMOV AL AND INST ALLA TION <SOHC> 1 2 3 4 25 Nm 11 N m 13 Nm Removal steps 1. Spark plug cable 2. Spark plug 3. W ater cover " A A 4. Distributor PWEE9622 E Feb. 1997 Mitsubishi Motors Corporation[...]

6A1 ENGINE (E - W) - Ignition System 1 1A-6-2 REMOV AL AND INST ALLA TION <MIVEC> 1 2 3 25 Nm 1.0 Nm Removal steps 1. Spark plug cable 2. Ignition coil 3. Spark plug INST ALLA TION SER VICE POINT " A A DISTRIBUT OR INST ALLA TION (1) T urn the crankshaft clockwise to bring t he No. 1 cylinder piston to the compression stroke top dead cen[...]

6A1 ENGINE (E - W) - W ater Pump and W ater Pipe 1 1A-7-1 7. W A TER PUMP AND W A TER PIPE REMOV AL AND INST ALLA TION <SOHC> 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 13 Nm 18 Nm 23 Nm 29 Nm 11 N m 23 Nm 23 Nm 18 Nm Removal steps " F A 1. Engine coolant temperature gauge unit " E A 2. Engine coolant temperature sensor 3. W ater hose 4. W[...]

6A1 ENGINE (E - W) - W ater Pump and W ater Pipe 1 1A-7-2 REMOV AL AND INST ALLA TION <MIVEC> 1 2 4 5 6 7 8 9 10 11 12 13 14 13 Nm 18 Nm 23 Nm 29 Nm 18 Nm 18 Nm 3 11 N m 23 Nm Removal steps 1. Engine hanger " F A 2. Engine coolant temperature gauge unit " E A 3. Engine coolant temperature sensor 4. W ater hose 5. W ater hose 6. W at[...]

6A1 ENGINE (E - W) - W ater Pump and W ater Pipe 1 1A-7-3 INST ALLA TION SER VICE POINTS " A A SEALANT APPLICA TION TO W A TER PUMP Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent " B A W A TER PIPE / O-RING INST ALLA TION (1) Wet the O-ring (with water) to facilitate assembly . Caution D Keep the O-ring free of oil [...]

6A1 ENGINE (E - W) - W ater Pump and W ater Pipe 1 1A-7-4 " F A SEALANT APPLICA TION TO ENGINE COOLANT TEMPERA TURE GAUGE UNIT Specified sealant: 3M A TD Part No. 8660 or equivalent PWEE9622 E Feb. 1997 Mitsubishi Motors Corporation 6AE0071[...]

6A1 ENGINE (E - W) - Intake Manifold and Exhaust Manifold 1 1A-8-1 8. INT AKE MANIFOLD AN D EXHAUST MANIFOLD REMOV AL AND INST ALLA TION <SOHC> 1 2 3 4 5 6 7 8 9 13 Nm 17 Nm 44 Nm 49 Nm 49 Nm 13 Nm Removal steps 1. Intake manifold 2. Gasket 3. Heat protector , right 4. Exhaust manifold stay 5. Exhaust manifold, right 6. Gasket 7. Heat protect[...]

6A1 ENGINE (E - W) - Intake Manifold and Exhaust Manifold 1 1A-8-2 REMOV AL AND INST ALLA TION <MIVEC> 1 2 3 4 5 6 7 8 9 13 Nm 17 Nm 44 Nm 49 Nm 49 Nm 13 Nm Removal steps 1. Intake manifold 2. Gasket 3. Heat protector , right 4. Exhaust manifold stay 5. Exhaust manifold, right 6. Gasket 7. Heat protector , left 8. Exhaust manifold, left 9. Ga[...]

6A1 ENGINE (E - W) - Rocker Arm and Camshaft <SOHC> 1 1A-9-1 9. ROCKER ARM AND CAMSHAFT <SOHC> REMOV AL AND INST ALLA TION Apply engine oil to all moving parts before installation. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4N m 24 Nm 31 Nm 12 12 9 9 8 8 7 7 Removal steps 1. Rocker cover 2. Rocker cover gasket 3. Oil seal " D A 4. O[...]

6A1 ENGINE (E - W) - Rocker Arm and Camshaft <SOHC> 1 1A-9-2 REMOV AL SER VICE POINT A A " ROCKER ARMS AND ROCKER ARM SHAFTS REMOV AL (1) Before removing rocker arms a nd shafts assembly , install the special tool as illustrated to prevent adjuster from dropping. INST ALLA TION SER VICE POINTS " A A CAMSHAFT INST ALLA TION (1) Apply[...]

6A1 ENGINE (E - W) - Rocker Arm and Camshaft <SOHC> 1 1A-9-3 NOTE Install the rocker shaft spring before installing the exhaust side rocker arms a nd rocker arm shaft. (3) Remove the special tool for securing the lash adjuster . (4) Make sure that the notch in the rocker arm shaft is in the direction as illustrated. " D A CAMSHAFT OIL SE[...]

6A1 ENGINE (E - W) - Rocker Arm and Camshaft <SOHC> 1 1A-9-4 LASH ADJUSTER LEAK DOWN TEST Caution D The lash adjuster is a precision part. Keep it free from dust and other foreign matters. D Do not disassemble lash adjuster . D When cleaning lash adjuster , use clean diesel fuel only . (1) Immerse th e lash adjuster in clean diesel fuel. (2) [...]

6A1 ENGINE (E - W) - Rocker Cover an d Camshaft <MIVEC> 1 1A-10-1 10. ROCKER COVER AND CAMSHAFT <MIVEC> REMOV AL AND INST ALLA TION Apply engine oil to all moving parts before installation. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 4N m 24 Nm 11 N m 11 N m 11 N m 9 24 Nm 24 Nm 24 Nm 9N m Removal steps " G A 1. Rocker cover 2. Rocker cover g[...]

6A1 ENGINE (E - W) - Rocker Cover an d Camshaft <MIVEC> 1 1A-10-2 INST ALLA TION SER VICE POINT " A A CAMSHAFT INST ALLA TION (1) Intake valve camshaft and exhaust valve camshaft can be identified by their diameters at the portions indicated in the illustration. Intake valve camshaft: 25 mm Exhaust valve camshaft: 30 mm (2) Before instal[...]

6A1 ENGINE (E - W) - Rocker Cover an d Camshaft <MIVEC> 1 1A-10-3 " C A OIL CONTROL V AL VE INST ALLA TION (1) Apply the specified sealant to the area shown. Specified sealant: 3M A TD Part No. 8660 or equivalent " D A SEMI-CIRCULAR P ACKING / CAMSHAFT HOLDER INST ALLA TION (1) Make sure that the retainer of each adjusting screw is [...]

6A1 ENGINE (E - W) - Rocker Cover an d Camshaft <MIVEC> 1 1A-10-4 " E A CAMSHAFT OIL SEAL INST ALLA TION (1) When installing the left bank camshaft oil seal, use the special tool to prevent interference with th e knock pin. " F A CIRCULAR P ACKING INST ALLA TION " G A ROCKER COVER INST ALLA TION (1) Apply the specified sealant [...]

6A1 ENGINE (E - W) - Rocker Cover an d Camshaft <MIVEC> 1 1A-10-5 CAMSHAFT (1) Measure the cam heights. If the specified limit is exceeded, replace the camshaft. NOTE Each camshaft has an identification mark on its rear en d surface. ( ): Identification mark Standard value Limit IN (3) L 34.34 mm 33.84 mm H 36.46 mm 35.96 mm EX (C) L 34.40 mm[...]

6A1 ENGINE (E - W) - Rocker Cover an d Camshaft <MIVEC> 1 1A-10-6 (5) Screw in th e other adjusting screw until it comes into contact with the valve (when the turning torque changes), and then tighten the lock nut. (6) Loosen the adjusting screw that was screwed in first slightly (until the turning torque becomes almost zero). Screw in the ad[...]

6A1 ENGINE (E - W) - Rocker Arm and Rocker Shaft Cap <MIVEC> 1 1A-1 1-1 1 1. ROCKER ARM AND ROCKER SHAFT CAP <MIVEC> REMOV AL AND INST ALLA TION Apply engine oil to all moving parts before installation. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 11 N m 22 20 21 13 20 21 20 21 13 19 18 4 11 12 11 12 4 Removal steps " B A 1. Rocker sh[...]

6A1 ENGINE (E - W) - Rocker Arm and Rocker Shaft Cap <MIVEC> 1 1A-1 1-2 INST ALLA TION SER VICE POINTS " A A SPRING GUIDE INST ALLA TION (1) Install the spring guide with the concave side toward the rocker arm. The waved washer may be installed with either side out. " B A ROCKER SHAFT CAP INST ALLA TION (1) T ighten the bolts in the[...]

6A1 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-12-1 12. CYLINDER HEAD AN D V AL VES REMOV AL AND INST ALLA TION <SOHC> Apply engine oil to all moving parts before installation. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Removal steps A A "" D A 1. Cylinder head bolt 2. Cylinder head 3. Cylinder head gasket A B "&q[...]

6A1 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-12-2 REMOV AL AND INST ALLA TION <MIVEC> Apply engine oil to all moving parts before installation. 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 20 19 11 18 Removal steps A A "" D A 1. Cylinder head bolt 2. Cylinder head 3. Cylinder head gasket A B "" C A 4. Retainer lock 5. V [...]

6A1 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-12-3 REMOV AL SER VICE POINTS PRECAUTION FOR REMOVED P ARTS Keep removed parts in order according to the cylinder number and intake/exhaust side. A A " CYLINDER HEAD BOL T REMOV AL (1) Using the special tool, loosen the cylinder head bolts. Loosen evenly , little by little. A B " RET AI[...]

6A1 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-12-4 A C " V AL VE STEM SEAL REMOV AL (1) Do n ot reuse removed valve stem seals. A D " V AL VE HANDLING PRECAUTIONS (1) Sodium reacts violently with water or moisture generation heat and liberating hydrogen. It must be handled with utmost care because otherwise the following dangerous [...]

6A1 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-12-5 INST ALLA TION SER VICE POINTS " A A V AL VE STEM SEAL INST ALLA TION (1) Install the valve spring seat. (2) Use th e special tool to fit a new stem seal on the valve guide. NOTE V alve stem seals for intake valves are different from those for exhaust valves. They are identified by colo[...]

6A1 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-12-6 " D A CYLINDER HEAD BOL T INST ALLA TION (1) When installing the cylinder head bolts, check that the shank length of each bolt meets the limit. If the limit is exceeded, replace the bolts. Limit: max. 96.4 mm (2) Install the washers as illustrated. (3) Apply engine oil to the bolt threa[...]

6A1 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-12-7 INSPECTION CYLINDER HEAD (1) Check the cylinder head gasket surface for flatness by using a straightedge and thickness gauge. Standard value: 0.03 mm Limit: 0.2 mm (2) If the service limit is exceeded, correct to meet the specification. Grinding limit: *0.2 mm *Includes/combined with cylinde[...]

6A1 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-12-8 V AL VE SPRING (1) Measure the valve spring’s free height. If the measurement is less than specified, replace the spring. Standard value mm Limit mm SOHC 49.9 48.9 MIVEC 51.5 50.5 (2) Measure the squareness of the spring. If the measurement exceeds the specified limit, replace the spring. [...]

6A1 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-12-9 V AL VE SEA T RECONDITIONING PROCEDURE (1) Before correcting the valve seat, check the clearance between the valve guide and valve. If necessary , replace the valve and/or valve guide. (2) Using the appropriate special tool or seat grinder , correct the valve seat to achieve the specified se[...]

6A1 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-12-10 (3) Press-fit the valve guide until it protrude specified value (SOHC: 14 mm, DOHC: 19 mm) as shown in the illustration. Caution D Press the valve guide from the cylinder head top surface. D V alve guide for intake valve and that for exhaust valve are different in length. (45.5 mm for intak[...]

6A1 ENGINE (E - W) - Oil Pump Case and Oil Pan 1 1A-13-1 13. OIL PUMP CASE AND OIL P AN REMOV AL AND INST ALLA TION <SOHC> Apply engine oil to all moving parts before installation. 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 Nm 44 Nm 10 Nm 18 19 20 23 9N m 7N m 7N m 7N m 3 9N m 39 Nm 21 Nm 68 Nm 21 24 25 26 22 14 Nm 12 Nm 30 Nm Removal steps &[...]

6A1 ENGINE (E - W) - Oil Pump Case and Oil Pan 1 1A-13-2 REMOV AL AND INST ALLA TION <MIVEC> Apply engine oil to all moving parts before installation. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 Nm 39 Nm 21 Nm 44 Nm 7N m 7N m 10 Nm 14 Nm 18 12 Nm Removal steps " I A 1. Oil pressure switch " H A 2. Oil filter 3. Oil filter cover 4. [...]

6A1 ENGINE (E - W) - Oil Pump Case and Oil Pan 1 1A-13-3 REMOV AL SER VICE POINT A A " OIL P AN REMOV AL (1) Knock the special tool deeply between the oil pan a nd the cylinder block. (2) Hitting th e side of the special tool, slide the special tool along the oil pan to remove it. INST ALLA TION SER VICE POINTS " A A INNER ROT OR / OUTER [...]

6A1 ENGINE (E - W) - Oil Pump Case and Oil Pan 1 1A-13-4 " D A OIL P AN INST ALLA TION <SOHC> (1) Clean the cylinder block and oil pan gasket application surfaces. (2) Install the oil pan within 15 minutes after FIPG has been applied to the entire flange surfaces of the oil pan. Specified sealant: Mitsubishi Genuine Part No. MD970389 or [...]

6A1 ENGINE (E - W) - Oil Pump Case and Oil Pan 1 1A-13-5 " G A OIL COOLER INST ALLA TION (1) Install t he oil cooler , with th e oil cooler ’s positioning projection positioned against the rib on cylinder block. " H A OIL FIL TER INST ALLA TION (1) Clean the surfaces of the cylinder block on which the oil filter is to be mounted. (2) Ap[...]

6A1 ENGINE (E - W) - Oil Pump Case and Oil Pan 1 1A-13-6 (3) Check the body clearance. Standard value: 0.10 - 0.18 mm Limit: 0.35 mm OIL LEVEL SENSOR (FOR EUROPE) (1) Put the oil level sensor in the oil, then move the float up an d down with the oil at a temperature either lower than 40 ° C or higher than 80 ° C, a nd check for continuity . 40 °[...]

6A1 ENGINE (E - W) - Piston and Connecting Rod 1 1A-14-1 14. PISTON AN D CONNECTING ROD REMOV AL AND INST ALLA TION Apply engine oil to all moving parts before installation. 6AE0095 Removal steps " G A 1. Nut A A "" F A 2. Connecting rod cap " E A 3. Connecting rod bearing " D A 4. Piston and connecting rod " E A 5. Co[...]

6A1 ENGINE (E - W) - Piston and Connecting Rod 1 1A-14-2 REMOV AL SER VICE POINTS A A " CONNECTING ROD CAP REMOV AL (1) Mark the large end of the connecting rod with the cylinder number for use during reassembly . A B " PISTON PIN REMOV AL Piston pin setting tool (MD998780) consists of th e parts shown in the illustration at left. T o rem[...]

6A1 ENGINE (E - W) - Piston and Connecting Rod 1 1A-14-3 INST ALLA TION SER VICE POINTS " A A PISTON PIN INST ALLA TION (1) Measure the following dimensions of the piston, piston pin and connecting rod. A: Piston pin insertion hole length B: Distance between piston bosses C: Piston pin length D: Connecting rod small end width (2) Calculate th [...]

6A1 ENGINE (E - W) - Piston and Connecting Rod 1 1A-14-4 " B A OIL RING INST ALLA TION (1) Fit the oil ring spacer into the piston ring groove. NOTE The side rails a nd spacer may be installed in either direction. (2) Install the upper side rail. T o install th e side rail, first fit one end of the rail into the piston groove, then press the r[...]

6A1 ENGINE (E - W) - Piston and Connecting Rod 1 1A-14-5 (4) Use suitable thread protectors on connecting rod bolts before inserting piston and connecting rod assembly into cylinder block. Care must be taken not to nick crank pin. (5) Using a suitable piston ring compressor tool, install piston and connecting rod assembly into t he cylinder block. [...]

6A1 ENGINE (E - W) - Piston and Connecting Rod 1 1A-14-6 (2) Check if t he thrust clearance in t he connecting rod big end is correct. Standard value: 0.10 - 0.25 mm Limit: 0.4 mm " G A CONNECTING ROD CAP NUT INST ALLA TION (1) Since the connecting rod bolts and nuts are torqued using a new procedure they should be examined BEFORE reuse. If th[...]

6A1 ENGINE (E - W) - Piston and Connecting Rod 1 1A-14-7 INSPECTION PISTON RING (1) Check the side clearance between the piston ring and ring groove. If the limit is exceeded, replace the ring or piston, or both. Standard value: No. 1 0.03 - 0.07 mm No. 2 0.02 - 0.06 mm Limit: No. 1 0.1 mm No. 2 0.1 mm Install the piston ring into the cylinder bore[...]

6A1 ENGINE (E - W) - Crankshaft, Cylinder Block, Flywheel and Drive Plate 1 1A-15-1 15. CRANKSHAFT , CYLINDER BLOCK, FL YWHEEL AND DRIVE PLA TE REMOV AL AND INST ALLA TION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 23 Nm 35 Nm 20 19 18 21 9N m 11 N m 98 Nm 98 Nm A 11 N m Apply engine oil to all moving parts before installation. Removal steps 1. Deto[...]

6A1 ENGINE (E - W) - Crankshaft, Cylinder Block, Flywheel and Drive Plate 1 1A-15-2 INST ALLA TION SER VICE POINTS " A A CRANKSHAFT BEARING INST ALLA TION (1) When replacing bearing, select a one of proper size according to the identification marks stamped on both crankshaft and cylinder block. <6A12> Crankshaft Journal Cylinder Block Be[...]

6A1 ENGINE (E - W) - Crankshaft, Cylinder Block, Flywheel and Drive Plate 1 1A-15-3 " B A BEARING CAP / BEARING CAP BOL T INST ALLA TION (1) Install the bearing caps so that their arrows are positioned on the timing belt side. (2) When installing the bearing cap bolts, check that the shank length of each bolt meets the limit. If the limit is e[...]

6A1 ENGINE (E - W) - Crankshaft, Cylinder Block, Flywheel and Drive Plate 1 1A-15-4 " C A OIL SEAL INST ALLA TION (1) Apply engine oil to oil seal lip. " D A APPLICA TION OF OIL SEAL CASE Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent " E A DRIVE PLA TE BOL T / FL YWHEEL BOL T INST ALLA TION (1) Remove all the [...]

6A1 ENGINE (E - W) - Crankshaft, Cylinder Block, Flywheel and Drive Plate 1 1A-15-5 CYLINDER BLOCK (1) Using a straightedge and feeler gauge, check the block top surface for warpage. Make sure that the surface is free from gasket chips and other foreign matter . Standard value: 0.05 mm or less Limit: 0.1 mm (2) If th e distortion is excessive, corr[...]

6A1 ENGINE (E - W) - Crankshaft, Cylinder Block, Flywheel and Drive Plate 1 1A-15-6 (4) Bore all cylinders to calculated boring finish dimension. Caution D T o prevent distortion that may result from temperature rise during honing, bore cylinders, working from No. 1, No. 2, No. 3, No. 4, No. 5 and No. 6 (5) Hone to final finish dimension (piston O.[...]

NOTES[...]

Service Bulletins Click on the applicable bookmark to select the Service Bulletin.[...]

SERVICE BULLETIN QUALITY INFORMATION ANALYSIS OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION SERVICE BULLETIN No.: MS B-01 E11-0 01 Date : 2001-07-25 <Model> <M/Y> Subject: ADDITION OF 6A1 ENGINE WATER PUMP INSTALLATION PROCEDURES (EC)GALAN T(EA0) 01-10 Group: ENGINE Draft No.: 00 EN620 614 INFORMATION INTERNAT IONAL CAR ADMINIS T[...]

3 INSTALLATI ON SERVICE POIN TS SEALANT APPLICATIO N TO WATER PUMP Specified sealant: Mitsubishi Genuine Part No. MD970389 or equ ivalent WATER PIPE / O-RING INSTALLATION (1) Wet th e O-ring (wit h water) to f acilitate assembly. Caution • Keep the O-ring free of oil or grease. • Secure the water pipe after the the rmostat housing has been inst[...]

4 (1) Install the water pump and tighten the bolts 1 and 2 in that order. (2) Turn the pulley by hand and en sure that the impeller does not interfere with the cylinder block. (3) Tighten the bolts other than bolts 1 and 2 . <Added> 6AE0415 Water pump[...]