11A-0-1
ENGINE
6A1 SERIES
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-0-3
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1
REWORK DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-3
TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-4
NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE
TIGHTENED IN PLASTIC AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-7
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-7
FORM-IN-PLACE GASKET (FIPG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-8
2. SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-2-1
3. DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-3-1
4. TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-4-1
5. FUEL AND EMISSION CONTROL PARTS . . . . . . . . . . . . . . . . . . . . . . 11A-5-1
6. IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-6-1
7. WATER PUMP AND WATER PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-7-1
8. INTAKE MANIFOLD AND EXHAUST MANIFOLD . . . . . . . . . . . . . . 11A-8-1
9. ROCKER ARM AND CAMSHAFT <SOHC> . . . . . . . . . . . . . . . . . . . . 11A-9-1
10. ROCKER COVER AND CAMSHAFT <MIVEC> . . . . . . . . . . . . . . . . . 11A-10-1
11. ROCKER ARM AND ROCKER SHAFT CAP <MIVEC> . . . . . . . . 11A-11-1
12. CYLINDER HEAD AND VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-12-1
13. OIL PUMP CASE AND OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-13-1
14. PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-14-1
15. CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL
AND DRIVE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-15-1
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-0-3
6A1 ENGINE (E-W) - General Information
GENERAL INFORMATION
GENERAL SPECIFICATIONS
Descriptions
6A12
6A13
Type
60° V, OHV, DOHC (for each bank)
60° V, OHV, SOHC (for each bank)
Number of cylinders
Combustion chamber
Total displacement dm3
Cylinder bore mm
Piston stroke mm
6
6
Pentroof type
1,998
Pentroof type
2,498
78.4
81.0
69.0
80.8
Compression ratio
10.0
9.5*1 or 9.0*2
15°
Valve timing
Intake
valve
Opens
(BTDC)
15° (Low-speed cam)
37.5° (High-speed cam)
Closes
41° (Low-speed cam)
82.5° (High-speed cam)
53°
53°
15°
(ABDC)
Exhaust Opens
41° (Low-speed cam)
75° (High-speed cam)
valve
(BBDC)
Closes
(ATDC)
15° (Low-speed cam)
30° (High-speed cam)
Lubrication system
Oil pump type
Pressure feed, full-flow filtration
Trochoid type
Pressure feed, full-flow filtration
Trochoid type
Cooling system
Water pump type
Water-cooled forced circulation
Centrifugal impeller type
Water-cooled forced circulation
Centrifugal impeller type
NOTE
*1: Europe and Hong Kong
*2: GCC and Export
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-1-1
6A1 ENGINE (E-W) - Specifications
1. SPECIFICATIONS
SERVICE SPECIFICATIONS
Items
Standard value
12.0
Limit
Timing belt
Auto tensioner rod projection mm
-
-
Auto tensioner rod pushed-in amount (when pushed with a force 1.0 or less
of 98 - 196 N) mm
Rocker arm and camshaft <SOHC>
Camshaft cam height mm
Intake
35.20
34.70
45
34.70
34.20
-
Exhaust
Camshaft journal diameter mm
Rocker cover and camshaft <MIVEC>
Camshaft cam height mm
Intake
(Low-speed cam)
34.34
33.84
(High-speed cam) 36.46
(Low-speed cam) 34.40
35.96
Exhaust
33.90
(High-speed cam) 35.86
35.36
Camshaft journal diameter mm
Valve clearance mm
26
-
-
-
Intake
0.10
0.13
Exhaust
Cylinder head and valve
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
119.9 - 120.1
119.6 - 119.8
-
-
mm
MIVEC
-
Cylinder head bolt nominal length mm
96.4
0.5
0.8
-
Valve margin mm
Intake
1.0
Exhaust
1.3
Valve stem diameter mm
6.0
Valve stem-to-guide clearance Intake
0.02 - 0.05
0.04 - 0.07
45° - 45.5°
48.45
0.10
0.15
-
mm
Exhaust
Valve face angle
Valve stem projection mm
SOHC
MIVEC
48.95
48.90
48.40
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-1-2
6A1 ENGINE (E-W) - Specifications
Items
Standard value
Limit
Overall valve length mm
Intake
SOHC
MIVEC
SOHC
MIVEC
113.02
112.37
115.32
110.74
49.9
112.52
111.87
Exhaust
114.82
110.74
Valve spring free height mm
SOHC
MIVEC
48.9
51.5
50.5
Valve spring load/installed SOHC
265/43.4
255/44.5
2°
-
-
height N/mm
MIVEC
Valve spring squareness
4°
-
Valve seat contact width mm
Valve guide internal diameter mm
0.9 - 1.3
6.6
-
Valve guide projection mm
SOHC
MIVEC
14.0
-
19.0
-
Oil pump case and oil pan
Oil pump tip clearance mm
Oil pump side clearance mm
Oil pump body clearance mm
Piston and connecting rod
Piston outside diameter mm
0.06 - 0.18
0.04 - 0.10
0.10 - 0.18
-
-
0.35
6A12
6A13
78.4
-
81.0
-
Piston ring side clearance mm No.1 ring
No.2 ring
0.02 - 0.06
0.02 - 0.06
0.20 - 0.35
0.35 - 0.50
0.20 - 0.50
19.0
-
-
Piston ring end gap mm
No.1 ring
No.2 ring
Oil ring
0.8
0.8
1.0
-
Piston pin outside diameter mm
Piston pin press-in load (at room temperature) N
Crankshaft pin oil clearance mm
4,900 - 14,700
0.02 - 0.05
0.10 - 0.25
-
0.1
0.4
Connecting rod big end side clearance mm
Crankshaft, cylinder block, flywheel and drive plate
Crankshaft end play mm
0.05 - 0.25
0.4
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-1-3
6A1 ENGINE (E-W) - Specifications
Items
Standard value
Limit
Crankshaft journal diameter 6A12
53.0
-
mm
6A13
56.0
-
Crankshaft pin diameter mm
6A12
6A13
43.0
-
51.0
-
Crankshaft journal oil clearance mm
0.02 - 0.04
0.05
0.1
-
Cylinder block gasket surface flatness mm
Cylinder block gasket surface grinding limit (including grinding of
cylinder head gasket surface) mm
-
0.2
Cylinder block overall height 6A12
190.0
-
mm
6A13
209.0
-
Cylinder block cylindricity mm
0.01 or less
78.4
-
Cylinder block internal diame- 6A12
ter mm
-
6A13
81.0
-
Bearing cap bolt nominal length mm
Piston-to-cylinder clearance mm
-
71.1
-
0.02 - 0.04
REWORK DIMENSIONS
Item
Standard
Cylinder head and valves
Cylinder head oversize valve guide hole diameter mm
0.05 O.S.
0.25 O.S.
11.05 - 11.07
11.25 - 11.27
11.50 - 11.52
29.80 - 29.82
30.10 - 30.12
32.30 - 32.32
32.60 - 32.62
27.80 - 27.82
28.10 - 28.12
29.80 - 29.82
30.10 - 30.12
0.50 O.S.
0.3 O.S.
0.6 O.S.
0.3 O.S.
0.6 O.S.
0.3 O.S.
0.6 O.S.
0.3 O.S.
0.6 O.S.
Oversize intake valve seat SOHC
ring hole diameter mm
MIVEC
Oversize exhaust valve SOHC
seat ring diameter mm
MIVEC
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-1-4
6A1 ENGINE (E-W) - Specifications
TORQUE SPECIFICATION
Items
Nm
Alternator and drive belt
Alternator pivot nut
Alternator bolt
44
21
23
15
23
45
182
3
Oil level gauge guide
Tensioner pulley
Engine hanger
Tensioner pulley bracket A
Crankshaft bolt
Engine cover
Timing belt
Timing belt front cover
Engine support bracket
Angle sensor
11
49
9
Angle sensor connector bracket
Tensioner pulley
11
48
24
21
88
35
11
11
Tensioner arm
Auto tensioner
Camshaft sprocket bolt
Idler pulley
Timing belt rear cover
Angle sensor connector bracket
Fuel and emission control parts
Air intake plenum stay
Connector bracket
EGR valve
18
11
22
12
18
12
9
Throttle body
Air intake plenum
Delivery pipe
Fuel pipe
Fuel pressure regulator
Alternator bracket
9
23
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-1-5
6A1 ENGINE (E-W) - Specifications
Items
Nm
Ignition system
Spark plug
25
11
13
10
Water cover (SOHC)
Distributor (SOHC)
Ignition failure sensor (MIVEC)
Condenser bracket assembly (MIVEC)
Ignition coil (MIVEC)
Water pump and water pipe
Engine hanger (MIVEC)
Engine coolant temperature gauge unit
Engine coolant temperature sensor
Heater pipe (SOHC)
Water inlet fitting
5
10
11
11
29
23
18
18
23
13
23
Water outlet fitting
Thermostat housing
Water pipe
Water pump
Intake manifold and exhaust manifold
Intake manifold
17
13
44
49
Heat protector
Exhaust manifold stay
Exhaust manifold
Rocker arm and camshaft <SOHC>
Rocker cover
4
Rocker arm and rocker shaft
Thrust case
31
24
Rocker arm and camshaft <MIVEC>
Rocker cover
4
Oil control valve holder
Cam cap
9
24
11
24
Bearing cap M6
Bearing cap M8
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-1-6
6A1 ENGINE (E-W) - Specifications
Items
Nm
11
Arm spring holder
Rocker arm and rocker shaft cap <MIVEC>
Rocker shaft cap
Cylinder head and valves
Cylinder head bolt
Oil pan and oil pump
Oil pressure switch
Oil filter cover
11
20 + 120° + 120°
10
21
30
68
39
9
Water hose
Bolt
Drain plug
Oil level sensor
Oil pan
7
Oil screen
19
9
Baffle plate
Relief plug
44
14
12
Oil pump case
Oil pump case cover
Piston and connecting rod
Connecting rod
18 + 90° - 100°
Crankshaft, cylinder block, flywheel and drive plate
Detonation sensor
Idler pulley bracket
Flywheel bolt
23
35
98
Drive plate bolt
98
Rear plate
11
Bell housing cover
Oil seal case
9
11
Bearing cap bolt
25 + 90° - 100°
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-1-7
6A1 ENGINE (E-W) - Specifications
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.
D
Areas where the bolts are in use:
(1) Cylinder head bolts
(2) Main bearing cap bolts
(3) Connecting rod cap bolts
D
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
Item
Specified sealant
Quantity
Water pump*
Mitsubishi Genuine Part No. MD970389 or equivalent
Mitsubishi Genuine Part No. MD970389 or equivalent
3M Nut Locking Part No. 4171 or equivalent
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
Water outlet fitting*
Engine coolant temperature sensor
Engine coolant temperature gauge unit 3M ATD Part No. 8660 or equivalent
Camshaft bearing
Cam cap
3M ATD Part No. 8660 or equivalent
3M ATD Part No. 8660 or equivalent
Oil control valve
Camshaft holder*
Rocker cover
Oil pump case*
Oil pan*
3M ATD Part No. 8660 or equivalent
Mitsubishi Genuine Part No. MD970389 or equivalent
3M ATD Part No. 8660 or equivalent
Mitsubishi Genuine Part No. MD970389 or equivalent
Mitsubishi Genuine Part No. MD970389 or equivalent
3M ATD Part No. 8660 or equivalent
Oil pressure switch
Oil seal case*
Drive plate bolt
Flywheel bolt
Mitsubishi Genuine Part No. MD970389 or equivalent
3M Nut Locking Part No. 4171 or equivalent
3M Nut Locking Part No. 4171 or equivalent
*: parts sealed by foam-in-place gasket (FIPG)
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
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 size.
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 a 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 oil pan, the special tool “Oil Pan Remover” (MD998727) is available. Be sure to use
the special tool to remove the oil 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 assembling 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.
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-2-1
6A1 ENGINE (E-W) - Special Tools
2. SPECIAL TOOLS
Tool
Number
Name
Use
MB990685
MB990938
MB990767
MB991477
MB991478
MB991479
MB991614
MB991653
MB991659
Torque wrench
Adjustment of timing belt tension
Handle
Use with MD998776
Crankshaft pulley Holding camshaft sprocket when loosening
holder
and tightening of bolt.
Use with MD998719
Valve adjusting
wrench
Adjustment of valve clearance (MIVEC)
Adjustment of valve clearance (MIVEC)
Adjustment of valve clearance (MIVEC)
Tightening cylinder head bolt
Valve adjusting
wrench feeler
gauge set
Rocker arm
piston checker
Angle gauge
Cylinder head bolt Tightening and loosening of cylinder head bolt
wrench
Guide D
Removal of piston pin (Use with MD998780)
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-2-2
6A1 ENGINE (E-W) - Special Tools
Tool
Number
Name
Use
MD998440
Leak-down tester
Leak-down test of lash adjuster
MD998441
MD998442
MD998443
MD998713
MD998716
MD998717
MD998719
MD998727
Lash adjuster
retainer
Air bleeding of lash adjuster
Air bleeding of lash adjuster
Air bleed wire
Lash adjuster
holder
Retainer for holding lash adjuster in rocker arm
at time of removal and installation of rocker arm
and rocker shaft assembly
Camshaft oil seal Installation of camshaft oil seal
installer
Crankshaft wrench Rotation of crankshaft when installing piston
and timing belt.
Crankshaft front oil Installation of crankshaft front oil seal
seal installer
Pulley holder pin Use with MB990767
(2)
Oil pan remover
Removal of oil pan
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-2-3
6A1 ENGINE (E-W) - Special Tools
Tool
Number
Name
Use
MD998735
Valve spring
compressor
Compression of valve spring
MD998754
MD998767
MD998772
MD998774
MD998775
MD998776
MD998777
Pin
Use with MB990767
Tensioner pulley
socket wrench
Adjustment of timing belt tension
Valve spring
compressor
Removal and installation of valve and related
parts
Valve stem seal Installation of valve stem seal
installer
Valve stem seal Installation of valve stem seal
installer
Crankshaft rear oil Installation of crankshaft rear oil seal
seal installer
Use with MB990938
Camshaft oil seal Installation of camshaft oil seal
installer adapter
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-2-4
6A1 ENGINE (E-W) - Special Tools
Tool
Number
Name
Use
MD998780
SETTING TOOL
Piston pin
Removal and installation of piston pin
MD998781
MD998784
Flywheel stopper
Holding flywheel and drive plate
Valve spring
compressor
adapter
Compression of valve spring (MIVEC)
(Use with MD998772)
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-3-1
6A1 ENGINE (E-W) - Drive Belt
3. DRIVE BELT
REMOVAL AND INSTALLATION <SOHC>
3 Nm
16
44 Nm
21 Nm
2
44 Nm
11
9
1
23 Nm
3
23 Nm
15
7
6
12
14
13
10
44 Nm
8
182 Nm
4
15 Nm
5
Removal steps
1. Drive belt
2. Alternator
9. Tensioner pulley bracket B
10. Adjusting stud
3. Oil level gauge (dipstick)
4. Oil level gauge guide
5. O-ring
11. Adjusting bolt
AA" "AA 12. Crankshaft bolt
13. Special washer
14. Crankshaft pulley
15. Flange
6. Tensioner pulley
7. Engine hanger
8. Tensioner pulley bracket A
16. Engine cover
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-3-2
6A1 ENGINE (E-W) - Drive Belt
REMOVAL AND INSTALLATION <MIVEC>
3 Nm
16
21 Nm
44 Nm
2
1
11
44 Nm
9
3
23 Nm
13
23 Nm
7
15
6
12
10
14
44 Nm
8
182 Nm
4
15 Nm
5
Removal steps
1. Drive belt
2. Alternator
9. Tensioner pulley bracket B
10. Adjusting stud
11. Adjusting bolt
3. Oil level gauge (dipstick)
4. Oil level gauge guide
5. O-ring
AA" "AA 12. Crankshaft bolt
13. Special washer
14. Crankshaft pulley
15. Flange
6. Tensioner pulley
7. Engine hanger
8. Tensioner pulley bracket A
16. Engine cover
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-3-3
6A1 ENGINE (E-W) - Drive Belt
REMOVAL SERVICE POINTS
AA" CRANKSHAFT PULLEY BOLT REMOVAL
(1) Hold the flywheel or drive plate in position with the special
tool before removing the crankshaft pulley bolts.
INSTALLATION SERVICE POINTS
"AA CRANKSHAFT PULLEY BOLT INSTALLATION
(1) Hold the flywheel or drive plate in position with the special
tool before installing the crankshaft pulley bolts.
MD998781
6AE0039
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-4-1
6A1 ENGINE (E-W) - Timing Belt
4. TIMING BELT
REMOVAL AND INSTALLATION <SOHC>
17
11 Nm
35 Nm
16
6
88 Nm
15
14
48 Nm
8
24 Nm
13
12
18
11
3
11 Nm
9
7
5
1
11 Nm
21 Nm
10
2
4
9 Nm
49 Nm
11 Nm
11 Nm
Removal steps
1. Timing belt front cover, upper right
2. Timing belt front cover, upper left
3. Timing belt front cover, lower
4. Engine support bracket
"BA 10. Auto tensioner
11. Crankshaft sprocket
12. Sensing plate
13. Crankshaft spacer
5. Angle sensor
AB" "AA 14. Camshaft sprocket bolt
15. Camshaft sprocket
AA" "CA 6. Timing belt
7. Tensioner pulley
16. Idler pulley
8. Tensioner arm
17. Timing belt rear cover, center
18. Connector bracket
9. Tensioner spacer
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-4-2
6A1 ENGINE (E-W) - Timing Belt
REMOVAL AND INSTALLATION <MIVEC>
12 Nm
23
21
11 Nm
11 Nm
88 Nm
17
16
22
18
48 Nm
9
10
19
8
5
6
35 Nm
11
17
20
44 Nm
11 Nm
15
1
14
13
12
22 Nm
2
7
11 Nm
9 Nm
9 Nm
49 Nm
9 Nm
4
3
11 Nm
Removal steps
1. Timing belt front cover, upper right
2. Timing belt front cover, upper left
3. Timing belt front cover, lower
4. Engine support bracket
5. Angle sensor
13. Crankshaft sprocket
14. Sensing plate
15. Washer
AB" "AA 16. Camshaft sprocket bolt
17. Camshaft sprocket
6. Angle sensor
18. Camshaft sprocket with sensing
plate
7. Spacer
AA" "DA 8. Timing belt
19. Idler pulley
9. Tensioner pulley
20. Timing belt rear cover, left
21. Timing belt rear cover, right
22. Timing belt rear cover, center
23. Connector bracket
10. Tensioner arm
11. Tensioner spacer
"BA 12. Auto tensioner
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-4-3
6A1 ENGINE (E-W) - Timing Belt
REMOVAL SERVICE POINTS
AA" TIMING BELT REMOVAL
(1) Mark the belt running direction for reference in
reinstallation.
(2) Loosen the bolt that secures the tensioner pulley to
remove the timing belt.
6AE0135
6AE0044
6AE0137
6AE0045
6AE0138
AB" CAMSHAFT SPROCKET BOLT REMOVAL
MB990767
MD998719
MB990767
MD998754
INSTALLATION SERVICE POINTS
"AA CAMSHAFT SPROCKET BOLT INSTALLATION
MD998719
MB990767
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-4-4
6A1 ENGINE (E-W) - Timing Belt
MD998754
MB990767
6AE0048
"BA AUTO TENSIONER SETTING
(1) Set the auto tensioner in a vice, while making sure it
is not tilted.
(B)
(A)
(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.
6AE0049
6AE0050
6AE0329
6AE0358
(3) Insert a 1.4 mm wire in the set hole.
(4) Remove the auto tensioner from the vice.
"CA TIMING BELT INSTALLATION
(1) Turn the crankshaft sprocket so that its timing mark will
be away from the 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 valves may interfere with
the piston.
(2) Bring the timing marks of the camshaft sprockets as shown
in the illustration.
Timing mark
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-4-5
6A1 ENGINE (E-W) - Timing Belt
(3) Align the timing mark on the crankshaft sprocket with
that on the cylinder block side.
(4) Fit the timing belt on the sprockets in the following order:
1) Fit the 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 the left bank camshaft sprocket.
3) Fit the belt on the idler pulley while keeping it tight.
4) Align the timing mark on the right bank camshaft
sprocket with the mark on the cylinder block, and
then fit the belt on the camshaft sprocket.
6AE0331
Caution
D
The camshaft sprockets are prone to rotate. Avoid
giving excessive tension to the timing belt when
it is fitted.
5) Make sure that the left bank portion of the belt is
not slack when the belt is fitted on the tensioner pulley.
If it is slack, remove the belt and fit it again beginning
with the first step.
6AE0143
6AE0057
6AE0058
(5) Move the tensioner pulley in the direction of the arrow
and hold it in raised position by tightening the tensioner
pulley bolt.
(6) Check that all timing marks are aligned correctly.
(7) Turn the crankshaft counterclockwise a quarter turn.
(8) Turn back the crankshaft clockwise until the timing marks
align again.
(9) Install the special tool and a torque wrench of 0 - 5
Nm to the tensioner pulley.
MD998767
(10)Torque the tensioner pulley to 3 Nm with the torque
wrench.
(11)While holding the tensioner pulley, tighten the center bolt
to specification.
(12)Turn the crankshaft clockwise 2 turns and let it stand
for about 5 minutes.
MB990685
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-4-6
6A1 ENGINE (E-W) - Timing Belt
"DA TIMING BELT INSTALLATION
(1) Turn the crankshaft sprocket so that its timing mark will
be away from the 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 valves may interfere with
the piston.
MD998716
6AE0051
(2) Bring the timing marks of the camshaft sprockets as shown
in the illustration.
Caution
D
If one of the camshaft sprockets on the right bank
is turned with the timing mark on the other
sprocket aligned, there may be danger for the
intake and exhaust valves to interfere with each
other.
6AE0311
6AE0053
6AE0054
6AE0055
(3) Align the timing mark on the crankshaft sprocket with
the mating timing mark, and then turn the crankshaft
counterclockwise by one tooth.
(4) Place the timing belt over the sprockets in the following
method.
Caution
D
The camshaft sprockets on the right bank can
turn very easily because of the valve spring
tension. Use care not to allow your fingers to get
caught between the sprockets.
Paper clip
1) Align the timing mark of the right bank exhaust
camshaft sprocket with the mating timing mark and
hold the timing belt on the sprocket with a paper
clip.
2) Align the timing mark of the intake camshaft sprocket
and place the timing belt around that sprocket. Then,
clip the belt at the location shown.
Caution
D
The camshaft sprockets can turn easily and
do not give excessive tension to the timing
belt.
3) Place the timing belt around the idler pulley.
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-4-7
6A1 ENGINE (E-W) - Timing Belt
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 tensioner pulley.
6AE0056
6AE0057
6AE0058
6AE0059
8EN0066
(5) Move the tensioner pulley in the direction of the arrow
and hold it in raised position by tightening the tensioner
pulley bolt.
(6) Check that all timing marks are aligned correctly.
(7) Turn the crankshaft counterclockwise a quarter turn.
(8) Turn back the crankshaft clockwise until the timing marks
align again.
(9) Install the special tool and a torque wrench of 0 - 5
Nm to the tensioner pulley.
MD998767
(10)Torque the tensioner pulley to 3 Nm with the torque
wrench.
(11)While holding the tensioner pulley, tighten the center bolt
to specification.
(12)Turn the crankshaft clockwise 2 turns and let it stand
for about 5 minutes.
MB990685
(13)Make sure that the wire, which has been inserted when
installing the auto tensioner, can be removed easily.
Belt tension should be acceptable if the wire can be easily
removed. Remove the wrench. The belt tension can also
be verified by checking the protrusion amount of the auto
tensioner rod which should conform to the following.
Standard value: 3.8 - 4.5 mm
(14)If the wire cannot be removed easily or the rod protrusion
is not up to specification, repeat steps (9) through (12)
to obtain the correct tension.
INSPECTION
TIMING BELT
Replace belt if any of the following conditions exist.
(1) Hardening of back rubber.
Back side is glossy without resilience and leaves no indent
when pressed with fingernail.
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-4-8
6A1 ENGINE (E-W) - Timing Belt
(2) Cracks on rubber back.
Cracks
(3) Cracks or peeling of canvas.
(4) Cracks on tooth bottom.
(5) Cracks or belt sides.
Peeling
Cracks
Cracks
1EN0249
(6) Abnormal wear of belt sides. The sides are normal if
they are sharp as if cut by a knife.
Rounded edge
Abnormal wear
(Fluffy strand)
8EN0067
8EN0068
6AE0046
(7) Abnormal wear on teeth.
(8) Missing tooth.
Rubber exposed
Tooth missing
and canvas
fiber exposed
AUTO-TENSIONER
“L”
(1) Check for oil leaks. If oil leaks are evident, replace the
auto-tensioner.
(2) Check the rod end for wear or damage and replace the
auto-tensioner if necessary.
(3) Measure the rod projection length “L”. If the reading is
outside the standard value, replace the auto tensioner.
Standard value “L”: 12 mm
(4) Press the rod by a force of 98 to 196 N and measure
the rod stroke. If the measured value exceeds the standard
value, replace the tensioner.
98 - 196 N
Stroke
Standard value: 1 mm or less
6EN1033
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-5-1
6A1 ENGINE (E-W) - Fuel and Emission Control Parts
5. FUEL AND EMISSION CONTROL PARTS
REMOVAL AND INSTALLATION <SOHC>
12 Nm
6
18 Nm
18 Nm
7
22 Nm
18 Nm
2
5
3
4
8
9
18 Nm
18 Nm
1
9 Nm
12 Nm
20
10
19
11
16
15
14
13
21
17
18
23 Nm
9 Nm
22
12
Removal steps
1. Air intake plenum stay, front
2. Air intake plenum stay, rear
3. EGR valve
12. Insulator
13. Insulator
"BA 14. Injector
15. Grommet
16. O-ring
4. Gasket
5. Vacuum pipe
6. Throttle body
17. Fuel pipe
18. O-ring
"CA 7. Gasket
8. Air intake plenum
9. Gasket
"AA 19. Fuel pressure regulator
20. O-ring
10. Control harness
11. Delivery pipe and injector
21. Delivery pipe
22. Alternator bracket
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-5-2
6A1 ENGINE (E-W) - Fuel and Emission Control Parts
REMOVAL AND INSTALLATION <MIVEC>
11 Nm
12 Nm
11 Nm
18 Nm
7
6
18 Nm
3
9
18 Nm
8.8 Nm
8
18 Nm
4
5
12
1
2
13
9 Nm
11
12 Nm
14
10
24
14 Nm
25
23
22
19
18
20
21
16
17
15
9 Nm
23 Nm
26
Removal steps
1. Air intake plenum stay, front
2. Air intake plenum stay, rear
3. Vacuum pipe
14. Control harness
15. Delivery pipe and injector
16. Insulator
4. Throttle body
17. Insulator
"CA 5. Gasket
"BA 18. Injector
6. Connector bracket
7. Connector bracket
8. Accelerator cable bracket
9. Ignition failure sensor
10. Air temperature sensor
11. Gasket
19. Grommet
20. O-ring
21. Fuel pipe
22. O-ring
"AA 23. Fuel pressure regulator
24. O-ring
12. Air intake plenum
13. Gasket
25. Delivery pipe
26. Alternator bracket
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-5-3
6A1 ENGINE (E-W) - Fuel and Emission Control Parts
INSTALLATION SERVICE POINTS
"AA FUEL PRESSURE REGULATOR INSTALLATION
(1) Apply spindle oil or gasoline to the 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 turns smoothly;
then align the threaded holes and tighten the regulator
bolts to specification.
Caution
6AE0061
6AE0062
6AE0277
D
If the regulator does not turn smoothly, the O-ring
probably gets caught somewhere in the delivery
pipe. In such a case, remove the fuel pressure
regulator and reinsert it into the delivery pipe.
Check it again for smooth rotation before securing.
"BA INJECTOR INSTALLATION
(1) Install new grommet and O-ring on the injector.
(2) Apply spindle oil or gasoline to the O-ring of the injector.
(3) While turning the injector in both directions, install it in
the delivery pipe.
(4) Make sure that the injector turns smoothly.
Caution
D
If the injector does not turn smoothly, the O-ring
probably gets caught somewhere in the delivery
pipe. In such a case, remove the injector and
reinsert it into the delivery pipe. Check it again
for smooth rotation.
(5) On the right bank, align the marks on the injector and
delivery pipe.
"CA GASKET INSTALLATION
Projection
(1) Locate the projection on the gasket as shown.
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-6-1
6A1 ENGINE (E-W) - Ignition System
6. IGNITION SYSTEM
REMOVAL AND INSTALLATION <SOHC>
1
13 Nm
4
25 Nm
2
11 Nm
3
Removal steps
1. Spark plug cable
2. Spark plug
3. Water cover
"AA 4. Distributor
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-6-2
6A1 ENGINE (E-W) - Ignition System
REMOVAL AND INSTALLATION <MIVEC>
1.0 Nm
25 Nm
1
3
2
Removal steps
1. Spark plug cable
2. Ignition coil
3. Spark plug
INSTALLATION SERVICE POINT
"AA DISTRIBUTOR INSTALLATION
(1) Turn the crankshaft clockwise to bring the No. 1 cylinder
piston to the compression stroke top dead center.
(2) Align the mark on the distributor housing with the mark
on the coupling.
(3) Install the distributor while aligning the coupling key with
the keyway in the camshaft end.
Alignment mark
6AE0151
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-7-1
6A1 ENGINE (E-W) - Water Pump and Water Pipe
7. WATER PUMP AND WATER PIPE
REMOVAL AND INSTALLATION <SOHC>
18 Nm
4
9
23 Nm
18 Nm
29 Nm
3
5
2
10
6
7
8
13 Nm
1
14
11 Nm
23 Nm
12
11
13
23 Nm
15
Removal steps
"FA 1. Engine coolant temperature gauge
"DA 8. Thermostat
unit
"CA 9. Water outlet fitting
10. Thermostat housing
11. Gasket
"EA 2. Engine coolant temperature sensor
3. Water hose
4. Water hose
"BA 12. O-ring
5. Heater pipe
"BA 13. Water pipe
"BA 14. O-ring
6. O-ring
7. Water inlet fitting
"AA 15. Water pump
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-7-2
6A1 ENGINE (E-W) - Water Pump and Water Pipe
REMOVAL AND INSTALLATION <MIVEC>
8
18 Nm
29 Nm
6
18 Nm
7
3
23 Nm
4
5
2
11 Nm
13 Nm
13
10
9
11
12
1
18 Nm
23 Nm
14
Removal steps
1. Engine hanger
"FA 2. Engine coolant temperature gauge
unit
"CA 8. Water outlet fitting
9. Thermostat housing
10. Gasket
"EA 3. Engine coolant temperature sensor
4. Water hose
"BA 11. O-ring
"BA 12. Water pipe
"BA 13. O-ring
5. Water hose
6. Water inlet fitting
"AA 14. Water pump
"DA 7. Thermostat
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-7-3
6A1 ENGINE (E-W) - Water Pump and Water Pipe
INSTALLATION SERVICE POINTS
"AA SEALANT APPLICATION TO WATER PUMP
3 mm
diameter
bead sealant
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or
equivalent
6AE0067
"BA WATER PIPE / O-RING INSTALLATION
(1) Wet the O-ring (with water) to facilitate assembly.
Caution
D
D
Keep the O-ring free of oil or grease.
Secure the water pipe after the thermostat housing
has been installed.
"CA SEALANT APPLICATION TO WATER OUTLET
3 mm
diameter
bead sealant
FITTING
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or
equivalent
6AE0068
6AE0069
6AE0070
"DA THERMOSTAT INSTALLATION
(1) Install the thermostat so that the jiggle valve will be located
in the thermostat housing as shown.
Jiggle valve
"EA SEALANT APPLICATION TO ENGINE COOLANT
TEMPERATURE SENSOR
Specified sealant:
3M Nut locking Part No. 4171 or equivalent
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-7-4
6A1 ENGINE (E-W) - Water Pump and Water Pipe
"FA SEALANT APPLICATION TO ENGINE COOLANT
TEMPERATURE GAUGE UNIT
Specified sealant:
3M ATD Part No. 8660 or equivalent
6AE0071
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-8-1
6A1 ENGINE (E-W) - Intake Manifold and Exhaust Manifold
8. INTAKE MANIFOLD AND EXHAUST MANIFOLD
REMOVAL AND INSTALLATION <SOHC>
1
17 Nm
3
2
13 Nm
6
5
7
9
44 Nm
49 Nm
13 Nm
4
8
49 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. Gasket
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-8-2
6A1 ENGINE (E-W) - Intake Manifold and Exhaust Manifold
REMOVAL AND INSTALLATION <MIVEC>
1
2
17 Nm
3
13 Nm
6
5
7
9
44 Nm
49 Nm
4
13 Nm
8
49 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. Gasket
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-9-1
6A1 ENGINE (E-W) - Rocker Arm and Camshaft <SOHC>
9. ROCKER ARM AND CAMSHAFT <SOHC>
REMOVAL AND INSTALLATION
4 Nm
31 Nm
1
2
6
3
10
9
7
9
5
8
13
7
8
9
7
8
12
24 Nm
12
11
12
15
14
16
17
Apply engine oil to all
moving parts before
installation.
4
Removal steps
1. Rocker cover
10. Rocker arm shaft
2. Rocker cover gasket
3. Oil seal
"BA 11. Lash adjuster
12. Rocker arm C
13. Rocker arm shaft
"BA 14. Lash adjuster
15. Thrust case
"DA 4. Oil seal
AA" "CA 5. Rocker arm and rocker shaft
AA" "CA 6. Rocker arm and rocker shaft
"CA 7. Rocker shaft spring
8. Rocker arm A
16. O-ring
"AA 17. Camshaft
9. Rocker arm B
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-9-2
6A1 ENGINE (E-W) - Rocker Arm and Camshaft <SOHC>
REMOVAL SERVICE POINT
AA" ROCKER ARMS AND ROCKER ARM SHAFTS
MD998443
REMOVAL
(1) Before removing rocker arms and shafts assembly, install
the special tool as illustrated to prevent adjuster from
dropping.
6AE0160
6AE0180
6EN0421
6AE0161
6AE0162
INSTALLATION SERVICE POINTS
"AA CAMSHAFT INSTALLATION
(1) Apply engine oil to journals and cams of the camshaft
before installation.
Be sure to install the correct camshafts on the correct
bank.
For right bank
Do not confuse the intake camshaft with the exhaust
one.
For left bank
"BA LASH ADJUSTER INSTALLATION
(1) Immerse the lash adjuster in clean diesel fuel.
(2) Using the special tool (air bleed wire), 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.
MD998442
Diesel
fuel
(3) Insert the lash adjuster to rocker arm, being careful not
to spill the diesel fuel. Then use the special tool to prevent
adjuster from falling while installing it.
MD998443
Lash adjuster
"CA ROCKER SHAFT SPRING / ROCKER ARMS AND
ROCKER ARM SHAFT INSTALLATION
(1) Temporarily tighten the rocker shaft with the bolt so that
all rocker arms on the inlet valve side do not push the
valves.
(2) Fit the rocker shaft spring from the above and position
it so that it is right angles to the plug guide.
NOTE
Install the rocker shaft spring before installing the exhaust
side rocker arms and rocker arm shaft.
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-9-3
6A1 ENGINE (E-W) - Rocker Arm and Camshaft <SOHC>
NOTE
Install the rocker shaft spring before installing the exhaust
side rocker arms and 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.
6AE0163
"DA CAMSHAFT OIL SEAL INSTALLATION
Right bank
(1) When installing the left bank camshaft oil seal, use the
special tool to prevent interference with the knock pin.
MD998713
6AE0164
Left bank
MD998713
MD998777
6AE0181
INSPECTION
CAMSHAFT
(1) Measure the cam height (lobe diameter) and, if the limit
is exceeded, replace the camshaft.
Standard value:
35.20 mm
34.91 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake side
Exhaust side
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limit:
34.70 mm
34.41 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake side
Exhaust side
9EN0058
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-9-4
6A1 ENGINE (E-W) - Rocker Arm and Camshaft <SOHC>
LASH ADJUSTER LEAK DOWN TEST
Caution
D
The lash adjuster is a precision part. Keep it free
from dust and other foreign matters.
Do not disassemble lash adjuster.
When cleaning lash adjuster, use clean diesel fuel
only.
D
D
(1) Immerse the lash adjuster in clean diesel fuel.
(2) While lightly pushing down inner steel ball using the special
tool (Air bleed wire MD998442), move the plunger up
and down four or five times to bleed air.
MD998442
Use of the special tool (Retainer MD998441) helps
facilitate the air bleeding of the rocker arm mounted type
lash adjuster.
Diesel fuel
(3) Remove the special tool (Air bleed wire MD998442) and
press the plunger. If the plunger is hard to be pushed
in, the lash adjuster is normal. If the plunger can be pushed
in all the way readily, bleed the lash adjuster again and
test again.
MD998441
6EN0186
If the plunger is still loose, replace the lash adjuster.
Caution
D
Upon completion of air bleeding, hold lash
adjuster upright to prevent inside diesel fuel from
spilling.
(4) After air bleeding, set lash adjuster on the special tool
(Leak down tester MD998440).
(5) After plunger has gone down somewhat [0.2 - 0.5 mm],
measure time taken for it to go down 1 mm. Replace
if measured time is out of specification.
Graduations = 1 mm
MD998440
Standard value: 4 - 20 seconds/1 mm
(Diesel fuel at 15 - 20°C)
Lash adjuster
6EN0187
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-10-1
6A1 ENGINE (E-W) - Rocker Cover and Camshaft <MIVEC>
10. ROCKER COVER AND CAMSHAFT <MIVEC>
REMOVAL AND INSTALLATION
4 Nm
1
11 Nm
24 Nm
2
9 Nm
24 Nm
8
3
10
9
11 Nm
24 Nm
11
24 Nm
4
11 Nm
9
Apply engine oil to all
moving parts before
installation.
12
13
6
14
5
7
Removal steps
"GA 1. Rocker cover
"CA 8. Oil control valve
2. Rocker cover gasket
3. Oil seal
"BA 9. Cam cap
10. Oil control valve holder
"BA 11. Camshaft bearing cap
12. Arm spring holder
13. Arm spring
"AA 14. Camshaft
"FA 4. Circuit packing
"EA 5. Oil seal
"DA 6. Camshaft holder
"DA 7. Semi-circular packing
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-10-2
6A1 ENGINE (E-W) - Rocker Cover and Camshaft <MIVEC>
INSTALLATION SERVICE POINT
"AA CAMSHAFT INSTALLATION
Left bank
camshaft
(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
Right bank
camshaft
6AE0229
(2) Before installing each camshaft, apply engine oil to its
journals and cams.
(3) The camshaft dowel pins must be positioned as shown
in the illustration.
IN
EX
IN
Right
bank
Dowel pin
EX
Left
bank
Dowel pin
6AE0230
"BA CAMSHAFT BEARING CAP / CAM CAP
INSTALLATION
(1) Apply sealant to the illustrated points of the camshaft
holders.
Specified sealant:
3M ATD part No. 8660 or equivalent
(2) Install the bearing caps and cam caps correctly according
to the “I” (intake) and “E” (exhaust) marks as well as
the stamped cap numbers and front marks.
(3) Tighten the bolts in the sequence of the numbers shown
in the illustration.
6AE0233
Cap No.
Intake
Front mark
Exhaust
Cap No.
6AE0308
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-10-3
6A1 ENGINE (E-W) - Rocker Cover and Camshaft <MIVEC>
"CA OIL CONTROL VALVE INSTALLATION
(1) Apply the specified sealant to the area shown.
Specified sealant:
3M ATD Part No. 8660 or equivalent
6AE0236
6AE0237
6AE0238
"DA SEMI-CIRCULAR PACKING / CAMSHAFT
HOLDER INSTALLATION
(1) Make sure that the retainer of each adjusting screw is
fitted correctly.
Screw
Protrusion
Caution
Groove
D
If the protrusion on the retainer is not correctly
fitted in the groove of the screw, the pad could
slip off the retainer.
Retainer
Pad
(2) Apply 3 mm thick bead of foam-in-place gasket (FIPG)
to the gasket surface of the camshaft holder.
Caution
D
Since the FIPG could cause blocking of engine
oil passages, be careful not to apply FIPG to other
locations than specified.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or
equivalent
(3) Install the semi-circular packings.
(4) Raise the rocker arms until the rollers come into contact
with the cams, and install the camshaft holder.
(5) Tighten the bolts in the order indicated in the illustration.
(6) Check the torque of the K-marked bolts. See section "BA
for the checking order.
8
7
4
2
6
10
(7) Verify that the pad of each adjusting screw is in place.
3
1
5
9
6AE0239
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-10-4
6A1 ENGINE (E-W) - Rocker Cover and Camshaft <MIVEC>
"EA CAMSHAFT OIL SEAL INSTALLATION
Right bank
(1) When installing the left bank camshaft oil seal, use the
special tool to prevent interference with the knock pin.
MD998713
6AE0306
Left bank
MD998777
MD998713
6AE0307
"FA CIRCULAR PACKING INSTALLATION
MD998713
6AE0241
"GAROCKER COVER INSTALLATION
(1) Apply the specified sealant to the area shown.
Specified sealant:
3M ATD Part No. 8660 or equivalent
Sealant application
areas
10 mm
10 mm
10 mm
6AE0242
INSPECTION
OIL CONTROL VALVE
1
2
(1) Connect a 12VDC power supply between terminals (1)
and (2) of the oil control valve and check if the valve
operates smoothly.
+
-
6AE0206
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-10-5
6A1 ENGINE (E-W) - Rocker Cover and Camshaft <MIVEC>
Valve
6AE0227
CAMSHAFT
(1) Measure the cam heights. If the specified limit isexceeded,
replace the camshaft.
NOTE
Each camshaft has an identification mark on its rear end
surface.
( ): Identification mark
Standard value
34.34 mm
Limit
IN (3)
L
33.84 mm
35.96 mm
33.90 mm
35.36 mm
9N0058
H
L
36.46 mm
EX (C)
34.40 mm
High-speed cam (H)
H
35.86 mm
16 mm
Identification
mark location
Low-speed
cam (L)
21 mm
6AE0228
VALVE CLEARANCE ADJUSTMENT
NOTE
Adjust the valve clearance for each cylinder and for both
intake and exhaust valves with the piston at the compression
stroke top dead center.
(1) Bring the No. 1 cylinder piston into the compression stroke
top dead center.
(2) Use the special tool to loosen the adjusting screw.
(3) Insert a thickness gauge of the thickness specified below
between the low-speed cam (narrow cam) and roller.
Thickness gauge
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13 mm
(4) Screw in one of the two adjusting screws until it comes
into contact with the valve (when the turning torque
changes).
MB991477
6AE0285
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-10-6
6A1 ENGINE (E-W) - Rocker Cover and Camshaft <MIVEC>
(5) Screw in the 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 adjusting screw until it comes into contact
with the valve again (when the turning torque changes)
and tighten the lock nut.
(7) Remove the thickness gauge.
(8) Screw the special tool into the top of piston of the rocker
arm “H”, and pull up the tool to make sure that the piston
can be lifted smoothly by hand.
(9) Perform valve clearance adjustments for other cylinders
by turning every time the crankshaft through 120° (60°
in camshaft sprocket angle) and following the above steps
(2) through (8). Perform the adjustments in the following
order of cylinder number:
MB991479
No. 2 ® No. 3 ® No. 4 ® No. 5 ® No. 6
Piston
6AE0286
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-11-1
6A1 ENGINE (E-W) - Rocker Arm and Rocker Shaft Cap <MIVEC>
11. ROCKER ARM AND ROCKER SHAFT CAP <MIVEC>
REMOVAL AND INSTALLATION
22
20
21
13
20
13
21
13
14
19
20
21
11
12
15
4
18
17
11
3
12
16
4
5
11
10
1
2
12
7
6
11 Nm
9
8
Apply engine oil to all
moving parts before
installation.
4
Removal steps
"BA 1. Rocker shaft cap
2. Seal cap A
12. Wave washer
13. Exhaust rocker arm assembly A
14. Nut
3. Seal cap C
4. Intake rocker arm assembly A
5. Nut
15. Adjusting screw
16. Exhaust rocker arm H
17. Piston H
6. Adjusting screw
7. Intake rocker arm H
8. Piston H
18. Piston spring H
19. Exhaust T-lever L
9. Piston spring H
10. Intake T-lever
"AA 20. Spring guide
21. Wave washer
"AA 11. Spring guide
22. Camshaft holder
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-11-2
6A1 ENGINE (E-W) - Rocker Arm and Rocker Shaft Cap <MIVEC>
INSTALLATION SERVICE POINTS
"AA SPRING GUIDE INSTALLATION
Spring guide
Waved washer
T-lever
(1) Install the spring guide with the concave side toward
the rocker arm. The waved washer may be installed with
either side out.
Concave
side
Either side may be out
6AE0247
"BA ROCKER SHAFT CAP INSTALLATION
(1) Tighten the bolts in the sequence shown.
(2) Make sure that each rocker arm moves smoothly.
10
2
1
4
3
8
7
9
6
5
6AE0249
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-12-1
6A1 ENGINE (E-W) - Cylinder Head and Valves
12. CYLINDER HEAD AND VALVES
REMOVAL AND INSTALLATION <SOHC>
1
4
6
5
12
20
13
16
8
14
17
9
19
11
2
10
15
18
7
3
Apply engine oil to all
moving parts before
installation.
Removal steps
AA" "DA 1. Cylinder head bolt
2. Cylinder head
11. Exhaust valve
AC" "AA 12. Valve stem seal
13. Valve spring seat
3. Cylinder head gasket
AB" "CA 4. Retainer lock
5. Valve spring retainer
"BA 6. Valve spring
7. Intake valve
AC" "AA 14. Valve stem seal
15. Valve spring seat
16. Intake valve guide
17. Exhaust valve guide
18. Intake valve seat
AB" "CA 8. Retainer lock
9. Valve spring retainer
"BA 10. Valve spring
19. Exhaust valve seat
20. Cylinder head
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-12-2
6A1 ENGINE (E-W) - Cylinder Head and Valves
REMOVAL AND INSTALLATION <MIVEC>
1
4
5
8
12
6
9
14
13
10
15
16
17
2
20
19
18
7
11
3
Apply engine oil to all
moving parts before
installation.
Removal steps
AA" "DA 1. Cylinder head bolt
2. Cylinder head
AD"
11. Exhaust valve
AC" "AA 12. Valve stem seal
13. Valve spring seat
3. Cylinder head gasket
AB" "CA 4. Retainer lock
5. Valve spring retainer
"BA 6. Valve spring
7. Intake valve
AC" "AA 14. Valve stem seal
15. Valve spring seat
16. Intake valve guide
17. Exhaust valve guide
18. Intake valve seat
19. Exhaust valve seat
20. Cylinder head
AB" "CA 8. Retainer lock
9. Valve spring retainer
"BA 10. Valve spring
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-12-3
6A1 ENGINE (E-W) - Cylinder Head and Valves
REMOVAL SERVICE POINTS
<SOHC>
PRECAUTION FOR REMOVED PARTS
Keep removed parts in order according to the cylinder number
and intake/exhaust side.
MB991653
AA" CYLINDER HEAD BOLT REMOVAL
(1) Using the special tool, loosen the cylinder head bolts.
Loosen evenly, little by little.
6AE0166
<MIVEC>
MB991653
6AE0408
AB" RETAINER LOCK REMOVAL
<SOHC>
(1) Store removed valves, springs and other parts, tagged
to indicate their cylinder Nos. and location for reassembly.
MD998772
6AE0167
<MIVEC>
MD998784
MD998772
MD998735
6AE0253
6EN1068
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-12-4
6A1 ENGINE (E-W) - Cylinder Head and Valves
AC" VALVE STEM SEAL REMOVAL
(1) Do not reuse removed valve stem seals.
6AE0082
AD" VALVE 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
conditions may result:
Loss of eyesight if sodium gets in eyes.
Burns if sodium contact skin.
Fire hazard.
(2) Handling of Sodium-filled Exhaust Valves
Sodium-filled exhaust valves are not dangerous and may
be handled in the same way as ordinary valves unless
they are broken.
Never try to break the valves and expose sodium to the
air. When worn exhaust valves are to be discarded, have
them disposed of by a salvage company equipped with
special disposal system, notifying them that the valves
contain sodium.
Should the exhaust valves be broken, neutralize sodium
using the method described below, and discard the valves
in the same way as ordinary valves.
(3) How to Neutralize Sodium
Place a container filled with more than 10 liters of water
in a well ventilated large space.
Wear rubber gloves and goggles, and carefully take out
broken valves from the cylinder head.
Put a broken valve in the water-filled container and quickly
get away from the container at least 2 or 3 m.
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-12-5
6A1 ENGINE (E-W) - Cylinder Head and Valves
INSTALLATION SERVICE POINTS
Stem seals
"AA VALVE STEM SEAL INSTALLATION
for exhaust
Stem seals for intake
valves: Silver
valves: Black
(1) Install the valve spring seat.
(2) Use the special tool to fit a new stem seal on the valve
guide.
NOTE
Valve stem seals for intake valves are different from those
for exhaust valves. They are identified by colors of their
spring sections as follows:
7EN0763
Stem seals for intake valves: Silver
Stem seals for exhaust valves: Black
<SOHC>
Caution
MD998774
D
D
Do not reuse the valve stem seal.
Always use the special tool to install the valve
stem seal. If the seal is improperly fitted, engine
oil may work its way down along the valve stem.
6AE0169
<MIVEC>
MD998775
6AE0409
"BA VALVE SPRING INSTALLATION
Spring
retainer
(1) Install the valve spring with the painted end on the rocker
arm side.
Painted
end
Stem seal
Spring
seat
6EN0437
"CA RETAINER LOCK INSTALLATION
<SOHC>
(1) The valve spring, if excessively compressed, causes the
bottom end of retainer to be in contact with, and damage,
the stem seal.
MD998772
6AE0167
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-12-6
6A1 ENGINE (E-W) - Cylinder Head and Valves
<MIVEC>
MD998784
MD998772
MD998735
6AE0253
6EN1068
9EN0251
6AE0392
"DA CYLINDER HEAD BOLT INSTALLATION
(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 threads and washers.
Length of shank
(4) Retighten the loosened bolts to a torque of 20 Nm in
the specified tightening sequence.
(5) Make paint marks on the cylinder head bolts and cylinder
MB991614
head.
(6) Give a 120° turn to the bolts in the specified tightening
sequence.
Caution
120°
D
D
If the bolts are tightened by an angle of less than
120°, they may not hold the cylinder head with
sufficient strength.
If a bolt is overtightened, completely remove all
the bolts and carry out the installation procedure
again from step (1).
6AE0339
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-12-7
6A1 ENGINE (E-W) - Cylinder Head and Valves
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.
6AE0083
Grinding limit: *0.2 mm
*Includes/combined with cylinder block grinding
Cylinder head height (Specification when new):
119.9 - 120.1 mm <SOHC>
119.6 - 119.8 mm <MIVEC>
VALVE
(1) Check the valve face for correct contact. If incorrect, reface
using a valve refacer. Valve should make a uniform contact
with the seat at the centre of valve face.
(2) If the margin is smaller than the service limit, replace
the valve.
Valve seat
contact
Margin
Standard value mm
Limit mm
Intake
1.0
1.3
0.5
0.8
Exhaust
6EN0542
(3) Measure the overall height of the valve. If the specified
limit is exceeded, replace the valve.
Standard value Limit mm
mm
Intake
SOHC
MIVEC
SOHC
MIVEC
113.02
112.37
115.32
110.74
112.52
111.87
114.82
110.74
Exhaust
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-12-8
6A1 ENGINE (E-W) - Cylinder Head and Valves
VALVE SPRING
Out of square
(1) Measure the valve spring’s free height. If the measurement
is less than specified, replace the spring.
Standard
mm
value Limit mm
Free
height
SOHC
MIVEC
49.9
51.5
48.9
50.5
(2) Measure the squareness of the spring. If the measurement
exceeds the specified limit, replace the spring.
1EN0264
Standard value: 2_ or less
Limit: 4_
VALVE SEAT
Valve stem end
(1) Assemble the valve, then measure the valve stem
projection between the end of the valve stem and the
spring seating surface. If the measurement exceeds the
specified limit, replace the valve seat.
Valve stem
projection
Spring seating
surface
Standard
mm
value Limit mm
SOHC
MIVEC
48.45
48.40
48.95
48.90
DEN0212
VALVE GUIDE
(1) Measure the clearance between the valve guide and valve
stem. If the limit is exceeded, replace the valve guide
or valve, or both.
Valve
guide
Standard value:
Intake: 0.02 - 0.05 mm
Exhaust: 0.04 - 0.07 mm
Limit:
Intake: 0.10 mm
Exhaust: 0.15 mm
1EN0279
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-12-9
6A1 ENGINE (E-W) - Cylinder Head and Valves
VALVE SEAT RECONDITIONING PROCEDURE
0.9 - 1.3 mm
0.9 - 1.3 mm
65_
(1) Before correcting the valve seat, check the clearance
between the valve guide and valve. If necessary, replace
the valve and/or valve guide.
65_
(2) Using the appropriate special tool or seat grinder, correct
the valve seat to achieve the specified seat width and
angle.
(3) After correcting the valve seat, lap the valve and valve
seat using lapping compound. Then, check the valve
stem projection (refer to VALVE SEAT in INSPECTION).
15_
15_
44_
44_
1EN0105
VALVE SEAT REPLACEMENT PROCEDURE
0.5 - 1.0 mm
(1) Cut the valve seat to be replaced from the inside to thin
the wall thickness. Then, remove the valve seat.
(2) Rebore the valve seat hole in the cylinder head to a
selected oversize valve seat diameter.
Cut away
Intake valve seat hole diameter
0.3 O.S. <SOHC>: 29.80 - 29.82 mm
<MIVEC>: 32.30 - 32.32 mm
0.5 - 1.0 mm
0.6 O.S. <SOHC>: 30.10 - 30.12 mm
<MIVEC>: 32.60 - 32.62 mm
1EN0274
Exhaust valve seat hole diameter
0.3 O.S. <SOHC>: 27.80 - 27.82 mm
<MIVEC>: 29.80 - 29.82 mm
0.6 O.S. <SOHC>: 28.10 - 28.12 mm
<MIVEC>: 30.10 - 30.12 mm
Valve seat
height
Oversize valve seat
hole diameter
1EN0275
(3) Before fitting the valve seat, either heat the cylinder head
up to approximately 250_C or cool the valve seat in liquid
nitrogen, to prevent the cylinder head bore from galling.
(4) Correct the valve seat to the specified width and angle.
VALVE GUIDE REPLACEMENT
(1) Force the valve guide out toward the cylinder block using
a press.
(2) Machine the valve guide hole in the cylinder head to
the size of the oversize valve guide to be installed.
Caution
D
Do not use the valve guide of the same size as
the removed one.
Valve guide hole diameters in cylinder head
0.05 O.S.: 11.05 - 11.07 mm
0.25 O.S.: 11.25 - 11.27 mm
0.50 O.S.: 11.50 - 11.52 mm
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-12-10
6A1 ENGINE (E-W) - Cylinder Head and Valves
(3) Press-fit the valve guide until it protrude specified value
<SOHC>
(SOHC: 14 mm, DOHC: 19 mm) as shown in the
illustration.
Caution
D
Press the valve guide from the cylinder head top
surface.
Valve guide for intake valve and that for exhaust
valve are different in length. (45.5 mm for intake
valve; 50.5 mm for exhaust valve)
D
14 mm
(4) After the valve guide has been installed, insert a new
valve to check for smooth sliding motion.
1EN0106
<DOHC>
19 mm
19 mm
6AE0254
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-13-1
6A1 ENGINE (E-W) - Oil Pump Case and Oil Pan
13. OIL PUMP CASE AND OIL PAN
REMOVAL AND INSTALLATION <SOHC>
6
Apply engine oil to all
moving parts before
installation.
12 Nm
24
25
26
2
22
14 Nm
8
17
16
7
23
19 Nm
20
21
4
21 Nm
5
19
68 Nm
15
30 Nm
1
9 Nm
18
10 Nm
44 Nm
3
7 Nm
14
12
10
39 Nm
7 Nm
9
13
9 Nm
7 Nm
11
Removal steps
"IA 1. Oil pressure switch
"HA 2. Oil filter
"DA 14. Oil pan upper
15. Buffle plate
16. Oil screen
3. Oil filter cover
4. Water hose (for Europe and GCC)
5. Water pipe (for Europe and GCC)
6. Water pipe (for Europe and GCC)
7. Bolt (for Europe and GCC)
"GA 8. Oil cooler (for Europe and GCC)
9. Drain plug
17. Gasket
18. Relief plug
19. Relief spring
20. Relief plunger
"CA 21. Oil seal
"BA 22. Oil pump case
23. O-ring
"FA 10. Gasket
11. Oil level sensor (For Europe)
12. Cover
24. Oil pump case cover
"AA 25. Outer rotor
"AA 26. Inner rotor
"DA 13. Oil pan lower
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-13-2
6A1 ENGINE (E-W) - Oil Pump Case and Oil Pan
REMOVAL AND INSTALLATION <MIVEC>
2
17
18
21 Nm
14
14 Nm
9
3
12 Nm
16
15
7 Nm
12
11
8
44 Nm
10
1
13
7
19 Nm
10 Nm
7 Nm
6
39 Nm
4
5
Apply engine oil to all
moving parts before
installation.
Removal steps
"IA 1. Oil pressure switch
"HA 2. Oil filter
3. Oil filter cover
10. Relief plug
11. Relief spring
12. Relief plunger
4. Drain plug
"CA 13. Oil seal
"BA 14. Oil pump case
15. O-ring
"FA 5. Gasket
AA" "EA 6. Oil pan
7. Oil screen
8. Gasket
16. Oil pump case cover
"AA 17. Outer rotor
9. Buffle plate
"AA 18. Inner rotor
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-13-3
6A1 ENGINE (E-W) - Oil Pump Case and Oil Pan
REMOVAL SERVICE POINT
AA" OIL PAN REMOVAL
MD998727
(1) Knock the special tool deeply between the oil pan and
the cylinder block.
(2) Hitting the side of the special tool, slide the special tool
along the oil pan to remove it.
6AE0087
6AE0091
6AE0092
6AE0093
INSTALLATION SERVICE POINTS
"AA INNER ROTOR / OUTER ROTOR INSTALLATION
(1) Apply engine oil to the rotors. Then, install the rotors
ensuring that the alignment dots made at disassembly
are properly aligned.
"BA SEALANT APPLICATION TO OIL PUMP CASE
3 mm diameter
bead sealant
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or
equivalent
"CA OIL SEAL INSTALLATION
(1) Apply engine oil to the oil seal lip.
Using the special tool, knock the oil seal into the oil pump
case.
MD998717
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-13-4
6A1 ENGINE (E-W) - Oil Pump Case and Oil Pan
"DA OIL PAN INSTALLATION <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
equivalent
f 4
Groove
Bolt
hole
"EA OIL PAN INSTALLATION <MIVEC>
4 mm diameter
bead sealant
(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
equivalent
6AE0094
"FA DRAIN PLUG GASKET INSTALLATION
(1) Install the drain plug gasket in the shown direction.
Oil pan
side
Drain plug
gasket
7EN0307
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-13-5
6A1 ENGINE (E-W) - Oil Pump Case and Oil Pan
"GAOIL COOLER INSTALLATION
(1) Install the oil cooler, with the oil cooler’s positioning
projection positioned against the rib on cylinder block.
6AE0172
"HA OIL FILTER INSTALLATION
(1) Clean the surfaces of the cylinder block on which the
oil filter is to be mounted.
(2) Apply engine oil to the O-ring of the oil filter.
(3) Turn down the oil filter until the O-ring contacts the cylinder
block surface, and then give the oil filter one more turn
(or tighten with a 16 Nm torque).
NOTE
For MD135737 oil filter, the tightening torque should be
14 Nm.
"IA SEALANT APPLICATION TO SEALANT TO OIL
PRESSURE SWITCH
(1) Apply sealant to the threads of the switch.
Specified sealant:
3M ATD Part No. 8660 or equivalent
Caution
D
Use care not to allow the sealant to plug the oil
passage.
Oil passage
9EN0094
6AE0088
6AE0089
INSPECTION
OIL PUMP
(1) Check the tip clearance.
Standard value: 0.06 - 0.18 mm
(2) Check the side clearance.
Standard value: 0.04 - 0.10 mm
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-13-6
6A1 ENGINE (E-W) - Oil Pump Case and Oil Pan
(3) Check the body clearance.
Standard value: 0.10 - 0.18 mm
Limit: 0.35 mm
6AE0090
OIL LEVEL SENSOR (FOR EUROPE)
(1) Put the oil level sensor in the oil, then move the float
up and down with the oil at a temperature either lower
than 40°C or higher than 80°C, and check for continuity.
40°C
Float position
Switch ON/OFF
ON (continuity)
ON (continuity)
Condition when down
Condition when up
6AE0192
80°C
Float position
Switch ON/OFF
OFF (no continuity)
ON (continuity)
Condition when down
Condition when up
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-14-1
6A1 ENGINE (E-W) - Piston and Connecting Rod
14. PISTON AND CONNECTING ROD
REMOVAL AND INSTALLATION
Apply engine oil to all
moving parts before
installation.
6AE0095
Removal steps
"GA 1. Nut
"CA 7. Piston ring No.2
"BA 8. Oil ring
AB" "AA 9. Piston pin
10. Piston
AA" "FA 2. Connecting rod cap
"EA 3. Connecting rod bearing
"DA 4. Piston and connecting rod
"EA 5. Connecting rod bearing
"CA 6. Piston ring No.1
11. Connecting rod
12. Bolt
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-14-2
6A1 ENGINE (E-W) - Piston and Connecting Rod
REMOVAL SERVICE POINTS
AA" CONNECTING ROD CAP REMOVAL
(1) Mark the large end of the connecting rod with the cylinder
number for use during reassembly.
Cylinder No.
DEN0050
AB" PISTON PIN REMOVAL
Piston pin setting tool MD998780
Piston pin setting tool (MD998780) consists of the parts shown
in the illustration at left.
To remove the piston pin, Guide D (MB991659) is also used
in combination with the Piston pin setting tool.
Push rod
Guide A:
17.9 mm
Guide B
Guide C
Guide A:
18.9 mm
Guide A:
20.9 mm
Guide D
MB991659
Guide A:
21.9 mm
Base
9EN0780
(1) Insert the Push Rod (special tool) into the piston from
the side on which the front mark is stamped in the piston
head, and attach the guide D to the push rod end.
(2) Place the piston and connecting rod assembly on the
Piston Pin Setting Base (special tool) with the front mark
facing upward.
Push rod
(3) Using a press, remove the piston pin.
Front mark
NOTE
Front
mark
Keep the disassembled pistons, piston pins and
connecting rods in order according to the cylinder number.
Guide D
Base
7EN0390
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-14-3
6A1 ENGINE (E-W) - Piston and Connecting Rod
INSTALLATION SERVICE POINTS
"AA PISTON PIN INSTALLATION
Piston
(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
B
A
D: Connecting rod small end width
(2) Calculate the following formula by substituting the
measured values.
(A - C) - (B - D)
L =
2
(3) Insert the Push Rod (special tool) into the piston pin and
attach the guide A to the push rod end.
(4) Assemble the connecting rod in the piston with their front
marks facing the same direction.
(5) Apply engine oil to the entire periphery of the piston pin.
(6) Insert the piston pin, push rod and guide A assembly
having assembled in step (3) from the guide A side into
the piston pin hole on the front marked side.
D
C
Connecting rod
Piston pin
7EN0432
(7) Screw the guide B into the guide A until the gap between
both guides amounts to the value L obtained in step
(2) plus 3 mm.
3 mm + L
Guide B
Guide A
7EN0433
(8) Place the piston and connecting rod assembly onto the
piston setting base with the front marks directed upward.
(9) Press-fit the piston pin using a press.
Push rod
Piston pin
If the press-fitting force required is less than the standard
value, replace the piston and piston pin set or/and the
connecting rod.
Standard value: 5,000 - 15,000 N
Front mark
Front
mark
Guide A
Base
Guide B
7EN0391
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-14-4
6A1 ENGINE (E-W) - Piston and Connecting Rod
"BA OIL RING INSTALLATION
(1) Fit the oil ring spacer into the piston ring groove.
NOTE
The side rails and spacer may be installed in either
direction.
(2) Install the upper side rail.
To install the side rail, first fit one end of the rail into
the piston groove, then press the remaining portion into
position by finger. See illustration.
6AE0194
NOTE
Side rail gap
Do not use piston ring expander when installing side
rail. Use of ring expander to expand the side rail end
gap can break the side rail, unlike other piston rings.
(3) Install the lower side rail in the same procedure as
described in step (2).
(4) Make sure that the side rails move smoothly in either
direction.
1EN0269
"CA PISTON RING NO. 2 / PISTON RING NO. 1
INSTALLATION
(1) Using piston ring expander, install the piston rings with
their side having identification marks facing up.
Identification mark:
No. 1 ring: T
Piston ring expander
No. 2 ring: 2T
7EN0452
NOTE
Identification mark
Identification mark
The piston ring is stamped with the following size mark.
Size mark
Size
Size mark
None
50
Standard size
0.50 mm O.S.
1.00 mm O.S.
No.1
No.2
100
9EN0524
"DA PISTON AND CONNECTING ROD INSTALLATION
Upper
side rail
No. 1
(1) Liberally coat engine oil on the circumference of the piston,
piston ring, and oil ring.
(2) Arrange the piston ring and oil ring gaps (side rail and
spacer) as shown in the figure.
Piston pin
(3) Rotate crankshaft so that the crank pin is on center of
the cylinder bore.
Lower
No. 2 ring gap
and spacer gap
side rail
6EN0549
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-14-5
6A1 ENGINE (E-W) - Piston and Connecting Rod
(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 the cylinder block.
Caution
D
Insert the front mark (arrow) on the top of the
piston so it faces the engine front (timing belt
side).
6AE0097
"EA CONNECTING ROD BEARINGS INSTALLATION
Crankshaft pin
identification mark
(1) When the bearings are to be replaced, select correct
ones and install them in the correct positions according
to the identification marks stamped on the crankshaft.
No.2
No.4
No.1
No.3
No.5
<6A12>
Crankshaft pin
Connecting rod
bearing
No.6
Check
digit
Identification mark
Outer diameter mm Identification mark
I
42.995 - 43.000
42.985 - 42.995
42.980 - 42.985
1
2
3
6AE0341
II
III
<6A13>
Crankshaft pin
Connecting rod
bearing
Identification mark
Outer diameter mm Identification mark
I
50.995 - 51.000
50.985 - 50.995
50.980 - 50.985
1
2
3
Identification mark
II
III
"FA CONNECTING ROD CAP INSTALLATION
(1) Mate the correct bearing cap with the correct connecting
rod by checking with the alignment marks marked during
disassembly. If a new connecting rod is used which has
no alignment mark, position the notches for locking the
bearing on the same side.
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-14-6
6A1 ENGINE (E-W) - Piston and Connecting Rod
(2) Check if the thrust clearance in the connecting rod big
end is correct.
Standard value: 0.10 - 0.25 mm
Limit: 0.4 mm
9EN0073
"GACONNECTING ROD CAP NUT INSTALLATION
(1) Since the connecting rod bolts and nuts are torqued using
a new procedure they should be examined BEFORE
reuse. If the bolt threads are “necked down” the bolts
should be replaced.
Necking can be checked by running a nut with fingers
to the full length of the bolt’s thread. If the nut does not
run down smoothly, the bolt should be replaced.
(2) Before installation of each nut, apply engine oil to the
threaded portion and bearing surface of the nut.
(3) Install each nut to the bolt and tighten it finger tight. Then
tighten the nuts alternately to install the cap properly.
(4) Tighten the nuts to a torque of 18 Nm.
(5) Make a paint mark on the head of each nut.
(6) Make a paint mark on the bolt at the position 90° to
100° from the paint mark made on the nut in the direction
of tightening the nut.
90° - 100°
Bolt
Nut
Paint
marks
Paint
marks
(7) Give a 90° to 100° turn to the nut and make sure that
the paint mark on the nut and that on the bolt are in
alignment.
6EN0954
Caution
D
If the nuts are tightened by an angle of less than
90°, they may not hold the caps with sufficient
strength.
D
If a nut is tightened by an angle exceeding 100°,
completely remove all the nuts and carry out the
installation procedure again from step (1).
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
11A-14-7
6A1 ENGINE (E-W) - Piston and Connecting Rod
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
No. 2
0.03 - 0.07 mm
0.02 - 0.06 mm
Limit:
7EN0475
No. 1
No. 2
0.1 mm
0.1 mm
Push in
by the piston
Install the piston ring into the cylinder bore. Force it down
with a piston, its crown being in contact with the ring,
to correctly position it at right angles to the cylinder wall.
Then, measure the end gap with a feeler gauge.
If the ring gap is excessive, replace piston ring.
Standard value:
No. 1
No. 2
Oil
0.25 - 0.40 mm
0.40 - 0.55 mm
0.10 - 0.35 mm
Piston
ring gap
Piston ring
7EN0476
Limit:
No. 1, No. 2
Oil
0.8 mm
1.0 mm
CRANKSHAFT PIN OIL CLEARANCE (PLASTIC
GAUGE METHOD)
(1) Remove oil from crankshaft pin and connecting rod
bearing.
(2) Cut the plastic gauge to the same length as the width
of bearing and place it on crankshaft pin in parallel with
its axis.
(3) Install the connecting rod cap carefully and tighten the
bolts to specified torque.
(4) Carefully remove the connecting rod cap.
(5) Measure the width of the plastic gauge at its widest part
by using a scale printed on the plastic gauge package.
Plastic gauge
1EN0246
Standard value: 0.02 - 0.05 mm
Limit: 0.1 mm
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
Crankshaft, Cylinder Block, Flywheel and
6A1 ENGINE (E-W) - Drive Plate
11A-15-1
15. CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE
PLATE
REMOVAL AND INSTALLATION
5
4
6
11 Nm
A
35 Nm
23 Nm
2
11
3
1
14
98 Nm
13
7
21
8
12
98 Nm
9
11 Nm
10
9 Nm
19
18
16
20
Apply engine oil to all
moving parts before
installation.
17
15
Removal steps
1. Detonation sensor
"BA 16. Bearing cap
2. Idler pulley bracket <M/T>
"AA 17. Crankshaft bearing, lower
18. Crankshaft
"EA 3. Flywheel bolt <M/T>
4. Plate <M/T>
"AA 19. Thrust bearing
"AA 20. Crankshaft bearing, upper
21. Cylinder block
5. Adapter plate <M/T>
6. Flexible flywheel <M/T>
7. Adapter plate <M/T>
"EA 8. Drive plate bolt <A/T>
9. Adapter plate <A/T>
10. Drive plate <A/T>
11. Rear plate
Caution
On the flexible wheel equipped engines, do not
remove any of the bolts “A” of the flywheel shown
in the illustration.
12. Bell housing cover <MIVEC>
The balance of the flexible flywheel is adjusted in
an assembled condition. Removing the bolt,
therefore, can cause the flexible flywheel to be out
of balance, giving damage to the flywheel.
"DA 13. Oil seal case
"CA 14. Oil seal
"BA 15. Bearing cap bolt
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
Crankshaft, Cylinder Block, Flywheel and
6A1 ENGINE (E-W) - Drive Plate
11A-15-2
INSTALLATION SERVICE POINTS
"AA CRANKSHAFT BEARING INSTALLATION
Crankshaft journal
identification mark
(1) When replacing bearing, select a one of proper size
according to the identification marks stamped on both
crankshaft and cylinder block.
No.1
No.2
No.4
<6A12>
No.3
Cylinder Block Bearing
Bore
Crankshaft
Bearing
Crankshaft Journal
Check
digit
Identi-
Identifi-
Inner diameter
cation
6AE0343
Outer diameter
Identifica-
tion mark
fication
mark
mm
mm
mark
Cylinder bore size
mark (reference)
0
1
2
0
1
2
0
1
2
57.000 - 57.006
57.006 - 57.012
57.012 - 57.018
57.000 - 57.006
57.006 - 57.012
57.012 - 57.018
57.000 - 57.006
57.006 - 57.012
57.012 - 57.018
1
2
3
2
3
4
3
4
5
No.4 No.2
1
2
52.994 - 53.000
No.3
No.1
Cylinder block
bearing bore
identification
mark
52.988 - 52.994
52.982 - 52.988
3
Timing belt side
6AE0344
<6A13>
Cylinder Block Bearing
Bore
Crankshaft
Bearing
Crankshaft Journal
Identi-
fication
mark
Identifi-
Inner diameter
cation
Outer diameter
mm
Identifica-
tion mark
mm
mark
0
1
2
0
1
2
0
1
2
60.000 - 60.006
60.006 - 60.012
60.012 - 60.018
60.000 - 60.006
60.006 - 60.012
60.012 - 60.018
60.000 - 60.006
60.006 - 60.012
60.012 - 60.018
1
2
3
2
3
4
3
4
5
1
2
3
55.994 - 56.000
55.988 - 55.994
55.982 - 55.988
(2) Install the bearings having an oil groove to the cylinder
block.
Oil groove
Groove
(3) Install the bearings having no oil groove to the bearing
caps.
(4) Install the thrust bearings at the No. 3 upper bearing
with the grooved side toward the crank web.
Identification
mark
Identification
mark
6AE0116
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
Crankshaft, Cylinder Block, Flywheel and
6A1 ENGINE (E-W) - Drive Plate
11A-15-3
"BA BEARING CAP / BEARING CAP BOLT
INSTALLATION
(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
exceeded, replace the bolt.
Shank length
Limit: max. 71.1 mm
9EN0477
6AE0108
6EN0955
(3) Apply engine oil to the threaded portion and bearing
surface of the bolt.
(4) Tighten the bearing cap bolts to 25 Nm torque in the
tightening sequence.
Arrow
(5) Make a paint mark on the head of each nut.
(6) Make a paint mark on the area around the bolt bearing
surface at location 90° to 100° in the direction of tightening
the bolt.
(7) Give a 90° to 100° turn to the bolts in the tightening
sequence. Make sure that the paint mark on the bolt
and that on the area around the bolt bearing surface
are in alignment.
Paint marks
90° - 100°
Caution
D
If the bolts are tightened by an angle of less than
90°, they may not hold the cap with sufficient
strength.
Paint marks
D
If a bolt is tightened by an angle exceeding 100°,
completely remove all the bolts and carry out the
installation procedure again from step (1).
(8) After installing the bearing caps, make sure that the
crankshaft turns smoothly and the end play is correct.
If the end play exceeds the limit, replace crankshaft
bearings.
Standard value: 0.05 - 0.25 mm
Limit: 0.4 mm
6AE0109
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
Crankshaft, Cylinder Block, Flywheel and
6A1 ENGINE (E-W) - Drive Plate
11A-15-4
"CA OIL SEAL INSTALLATION
(1) Apply engine oil to oil seal lip.
MB990938
MD998776
9EN0077
"DA APPLICATION OF OIL SEAL CASE
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or
equivalent
6AE0110
9EN0102
6AE0101
6AE0102
"EA DRIVE PLATE BOLT / FLYWHEEL BOLT
INSTALLATION
(1) Remove all the remaining sealant from bolts and thread
holes of crankshaft.
(2) Apply engine oil to the flange of bolt.
(3) Apply engine oil into the thread holes of crankshaft.
(4) Apply specified sealant to the thread of bolts.
Specified sealant:
3M Nut Locking Part No. 4171 or equivalent
(5) Tighten the bolts to specified torque.
INSPECTION
CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE
METHOD)
(1) Remove oil from crankshaft journal and crankshaft
bearing.
(2) Install the crankshaft.
(3) Cut the plastic gauge to the same length as the width
of bearing and place it on journal in parallel with its axis.
(4) Install the crankshaft bearing cap carefully and tighten
the bolts to specified torque.
(5) Carefully remove the crankshaft bearing cap.
(6) Measure the width of the plastic gauge at its widest part
by using a scale printed on the plastic gauge package.
Standard value: 0.02 - 0.04 mm
Limit: 0.1 mm
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
Crankshaft, Cylinder Block, Flywheel and
6A1 ENGINE (E-W) - Drive Plate
11A-15-5
CYLINDER BLOCK
C
D
E
F
A
B
(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.
G
Standard value: 0.05 mm or less
Limit: 0.1 mm
(2) If the distortion is excessive, correct within the allowable
limit or replace.
Grinding limit: 0.2 mm
6AE0103
The total thickness of the stock allowed to be
removed from cylinder block and mating cylinder
head is 0.2 mm at maximum.
Cylinder block height (when new):
6A12
6A13
190 mm
209 mm
(3) Check cylinder walls for scratches and seizure. If defects
are evident, correct (bored to oversize) or replace.
(4) Using cylinder gauge, measure the cylinder bore and
cylindricity. If worn badly, correct cylinder to an oversize
and replace piston and piston rings. Measure at the points
shown in illustration.
Standard value:
Cylinder I.D.:
12 mm
6A12
6A13
78.40 - 78.43 mm
81.00 - 81.03 mm
Out-of-roundness and taper of cylinder bore:
0.01 mm or less
6AE0104
BORING CYLINDER
(1) Oversize pistons to be used should be determined on
the basis of the largest bore cylinder.
Piston size identification
Size
Identification mark
0.50 mm O.S.
1.00 mm O.S.
0.50
1.00
6AE0105
NOTE
Size mark is stamped on piston top.
(2) Measure outside diameter of piston to be used. Measure
it in thrust direction as shown.
(3) Based on measured piston O.D. calculate boring finish
dimension.
Boring finish dimension = Piston O.D. + (Clearance
between piston O.D. and cylinder) - 0.02 mm (honing
margin)
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
Crankshaft, Cylinder Block, Flywheel and
6A1 ENGINE (E-W) - Drive Plate
11A-15-6
(4) Bore all cylinders to calculated boring finish dimension.
Caution
D
To 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.D. + clearance
between piston O.D. and cylinder.)
(6) Check clearance between piston and cylinder.
Clearance between piston and cylinder:
0.02 - 0.04 mm
NOTE
When boring cylinders, finish all of four cylinders to same
oversize. Do not bore only one cylinder to an oversize.
Mitsubishi Motors Corporation
Feb. 1997
PWEE9622
E
NOTES
Service Bulletins
Click on the applicable bookmark to select the Service Bulletin.
SERVICE BULLETIN
QUALITY INFORMATION ANALYSIS
OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION
No.: MSB-01E11-001
SERVICE BULLETIN
Date: 2001-07-25
<Model>
<M/Y>
ADDITION OF 6A1 ENGINE WATER PUMP
INSTALLATION PROCEDURES
(EC)GALANT(EA0)
01-10
Subject:
Group:
ENGINE
Draft No.: 00EN620614
INTERNATIONAL
CAR
INFORMATION
ADMINISTRATION
OFFICE
T.MASAKI-MANAGER
TECHNICAL SERVICE PLANNING
1. Description:
It has been found that when the 6A1 engine is installed, the water pump impeller interferes with
the cylinder block. Therefore, the procedures for positioning the water pump that are to be
followed when the water pump is installed, have been introduced.
2. Applicable Manuals:
Manual
ENGINE 6A1 (W-E)
Workshop Manual
Pub. No.
PWEE9202
PWES9203
PWEF9204
PWEG9205
PWED9206
PWEW9207
PWEE9622
PWES9623
PWEF9624
PWEG9625
PWED9626
PWEW9627
Language
Page(s)
(English) 11A-7-2
(Spanish)
(French)
(German)
(Dutch)
(Swedish)
(English) 11A-7-3
(Spanish)
(French)
(German)
(Dutch)
(Swedish)
ENGINE 6A1 (E-W)
Workshop Manual
ENGINE 6A1 (E-W) Workshop Manual
6A1 ENGINE (E-W) – Water Pump and Water Pipe
11A-7-3
INSTALLATION SERVICE POINTS
3 mm diameter
bead sealant
A
►
◄
SEALANT APPLICATION TO WATER PUMP
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or equivalent
4th page added here.
6AE0067
B WATER PIPE / O-RING INSTALLATION
► ◄
(1) Wet the O-ring (with water) to facilitate assembly.
Caution
•
•
Keep the O-ring free of oil or grease.
Secure the water pipe after the thermostat housing
has been installed.
C SEALANT APPLICATION TO WATER OUTLET FITTING
► ◄
3 mm diameter
bead sealant
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or equivalent
6AE0068
THERMOSTAT INSTALLATION
D
► ◄
Jiggle valve
(1) Install the thermostat so that the jiggle valve will be located in
the thermostat housing as shown.
6AE0069
E SEALANT APPLICATION TO ENGINE COOLANT
► ◄
TEMPERATURE SENSOR
Specified sealant:
3M Nut locking Part No. 4171 or equivalent
6AE0070
3
<Added>
(1) Install the water pump and tighten the bolts 1 and 2 in that
order.
(2) Turn the pulley by hand and ensure that the impeller does not
interfere with the cylinder block.
(3) Tighten the bolts other than bolts 1 and 2.
Water pump
6AE0415
4
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