ENGINE 6672

ENGINE

6672

CONTENTS

BRACKET

................................................................

122

CAMSHAFT, ROCKER ARMS AND

BEARING CAPS

....................................................

CRANKSHAFT, FLYWHEEL AND

DRIVE

PLATE

........

...

............................................

115

CYLINDER HEAD AND VALVES

SOHC

........

CYLINDER HEAD AND VALVES

DOHC

........

EXHAUST MANIFOLD

........................................

GENERAL INFORMATION

...

.............................

GENERAL SPECIFICATIONS

............................

GENERATOR AND DRIVE BELT

........................

IGNITION SYSTEM

...........................

................

INTAKE MANIFOLD AND FUEL PARTS

........

INTAKE MANIFOLD PLENUM AND

THROTTLE BODY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . .

OIL PAN AND OIL PUMP

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102

PISTON AND CONNECTING ROD

. . . . . . . . . . . . . . . . . . . .

108

ROCKER ARMS AND CAMSHAFTS

. . . . . . . . . . . . . . . .

SEALANT . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . .. . . . .. . .

SERVICE SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THROTTLE BODY .

. . . . . . . . . . . . . . . . . . . . . . ...*.....

. . . . . . . . . . . . .

. . .

TIMING BELT

SOHC

. . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIMING

BELT- DOHC

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TORQUE SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TURBOCHARGER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘HE-2

6G7

ENGINE

General Information

GENERAL INFORMATION

SECTIONAL VIEW

SOHC ENGINE for

DIAMANTE

7EN0323

TSB Revision

6G7

ENGINE

General Information

llE-3

TEN0324

Revision

IIE-4

6G7

ENGINE

General Information

SECTIONAL VIEW

SOHC ENGINE for MONTERO AND TRUCK

TSB Revision

7EN0135

667

ENGINE

General Information

TSB Revision

7EN0120

WE-6

6G7

ENGINE

General Information

SECTIONAL VIEW

DOHC NON-TURBO ENGINE

TSB Revision

7EN0325

IIE-8

6G7

ENGINE

General Information

SECTIONAL VIEW

DOHC TURBO ENGINE

TSB Revision

7EN0335

667

ENGINE

General Information

IIE-9

TSB Revision

7EN0334

IIE-10

6G7

ENGINE

General Information

JJBRICATION

SYSTEM

SOHC

Oil pressure

switch

Oil pressure

gauge unit

Oil cooler by-pass

valve

MONTERO only

Rocke

Lash adjuster

7LUOO34

TSB Revision

667

ENGINE

General Information

llE41

UBRICATION

SYSTEM

DOHC

turbo-

Oil pressure switch

charger

-turbo

only

Oil pressure

gauge unit

Las

To oil cooler

Turbo only

Oil cooler by-pass

valve -Turbo only

Relief valve

TSB Revision

WE-12

6G7

ENGINE

General Specifications

GENERAL SPECIFICATIONS

SOHC

Description

Specifications

Type

6O”V,

SOHC (per bank)

Number of cylinders

Combustion chamber

Compact type

Total displacement

cm3

(cu.in.1

2,972 (181.4)

Cylinder bore

stroke

mm (in.)

76.0 (3.59

2.99)

Compression ratio

Front wheel drive vehicle

10.0

Rear wheel drive vehicle

8.9

Valve timing: Front wheel drive

Intake valve

Opens

16” BTDC

Closes

66” ABDC

Exhaust valve

Opens 56” BBDC

Closes

26”

ATDC

Valve timing: Rear wheel drive

Intake valve

Opens

19” BTDC

Closes

59” ABDC

Exhaust valve

Opens

59” BBDC

Closes 19” ATDC

Lubrication system Pressure feed, full-flow filtration

3il pump type

Trochoid type

Cooling system

Water-cooled forced circulation

JVater

pump type

Centrifugal impeller type

type

Single type

njector type and number Electromagnetic, 6

njector

identification mark For MONTERO and TRUCK

B210H

For DIAMANTE and TRUCK

N21

Throttle bore

mm (in.) 60 (2.362)

rhrottle position sensor

Variable resistor type

Iosed

throttle position switch Movable contact type

TSB Revision

667

ENGINE

General Specifications

DOHC

Description

Type

Number of cylinders

Combustion chamber

Total displacement

cm3

(cu.in.1

Cylinder bore

stroke

mm (in.)

Compression ratio Non-turbo

Turbo

Valve timing-Non-turbo

Intake valve

Opens

Closes

Exhaust valve

Opens

Closes

Valve timing -Turbo

Intake valve

Opens

Closes

Exhaust valve

Opens

Closes

Lubrication system

Oil pump type

Cooling system

tiater

pump type

EGR type

Injector type

njector identification mark Non-turbo

Turbo

Throttle bore

mm (in.)

Throttle position sensor

Closed

throttle position switch

Specifications

6O”V.

DOHC (per bank)

Compact type

2,972 (181.4)

91.1

76.0 (3.59

2.99)

10.0

8.0

16” BTDC

55” ABDC

48” BBDC

15” ATDC

16” BTDC

55” ABDC

50” BBDC

17” ATDC

Pressure feed, full-flow filtration

Trochoid type

Water-cooled forced circulation

Centrifugal impeller type

Single type

Electromagnetic, 6

BDH210

BDL360

60 (2.362)

Variable resistor type

Movable contact type

TSB Revision

IIE-14

6G7

ENGINE

Service Specifications

SERVICE SPECIFICATIONS

mm (in.)

Standard

Limit

Cylinder head

SOHC

Flatness of gasket surface

Less than 0.05

(.0019)

0.2

(.008)

Grinding limit of gasket surface

*0.2

(.008)

Total resurfacing depth of both

cylinder head and cylinder block

Overall height

84 (3.31)

Oversize rework dimensions of valve guide hole

(both intake and exhaust)

0.05

(.002)

13.05-

13.07

(.5138-

.5147)

0.25

(.OlO)

13.25

13.27

(5217

.5224)

0.50

(.020)

13.50

13.52

(.5315

.5323)

Oversize rework dimension of valve seat hole

Intake 0.3

(.012)

44.30

44.33 (1.7441

1.7453)

0.6

(.024)

44.60

44.63 (1.7559

1.7571)

Exhaust 0.3

(.012)

38.30

38.33 (1.5079

1.5091)

0.6

(.024)

38.60

38.63 (1.5197

1.5209)

Cylinder head

DOHC

Flatness of gasket surface

Less than 0.03

(.0012)

0.2

(.008)

Grinding limit of gasket surface

“0.2

(008).

Total resurfacing depth of both

cylinder head and cylinder block

3verall

height

132

(5.20)

Dversize rework dimensions of valve guide hole

Iboth

intake and exhaust)

0.05

(.002)

12.05

12.07

(.4744-

.4752)

0.25

(.OlO)

12.25

12.27

(4823

.4831)

0.50

(.020)

12.50

12.52

l.4921

.4929)

3versize rework dimension of valve seat hole

Intake 0.3

(.012)

36.30

36.33 (1.4291

1.4303)

0.6

(.024)

36.60

36.63

(1.4409

1.4421)

Exhaust 0.3

(.012)

33.30-33.33(1.3110-1.3122)

0.6

(.024)

33.60

33.63 (1.3228

1.3240)

Camshaft-

SOHC

Zam

height

Intake

41.25 (1.6240)

40.75

(1.6043)

Exhaust

41.25 (1.6240)

40.75

(1.6043)

lournal

diameter

34 (1.34)

Iii

clearance

0.05

0.09

(.0020

.0035)

dentification mark

for

DIAMANTE

for MONTERO and TRUCK

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667

ENGINE

Service

SDecifications

mm (in.)

Camshaft

DOHC

Cam height

Intake

Exhaust

Journal diameter

Oil clearance

Rocker arm

SOHC

I.D.

Rocker arm-to-shaft clearance

Rocker

shaft

SOHC

3.D.

Dverall

length

Valve

SOHC

3verall

length

Intake

Exhaust

jtem

diameter

Intake

Exhaust

-ace

angle

stem-to

guide clearance

Intake

Exhaust

-hickness

of valve head (Margin)

Intake

Exhaust

lalve

DOHC

Iverall

length

Intake

Exhaust

item

diameter

Intake

Exhaust

ace angle

item-to guide clearance

Intake

Exhaust

hickness of valve head (Margin)

Intake

Exhaust

Standard

35.49(1.3972)*‘,34.91

(1.3744)**

35.20(1.3858)*',34.91 (1.3744)*'

26(1.02)

0.05-0.09(.020-.0035)

18.91

-18.93(.7445-.7453)

0.01

-0.04(.0004-.0016)

18.89-18.90

(.7437-.7441)

333.5(13.130)

102.97 (4.0539)

102.67 (4.0421)

7.96-7.98(.3134-.3142)

7.93-7.95

(.3122-.3130)

45"-45.5"

0.03-0.06(.0012-.0024)

0.05-0.09(.0020-.0035)

1.2

(.047)

2.0

i.079)

106.28(4.1842)

105.40(4.1496)

6.57-6.58(.2587-.2591)

6.53-6.55(.2571

-.2579)

45"-45.5"

0.02-0.05(.0008-.0020)

0.05-0.09

(.0020-.0035)

l.039)

1.5

(.059)

Limit

34.99(1.3776)*'

34.41 (1.3547)"'

34.70 (1.3661)"'

34.41

(1.3!%7)"2

0.10(.004)'

0.10

(.0039)

0.15

(.0059)

0.7

(.028)

1.5

(.059)

0.10

i.0039)

0.15

i.0059)

0.5(.019)

i.039)

NOTE

Up to 1992 models

“2 = from 1993 models

TSB Revision

IIE-16

667

ENGINE

Service

SDecifications

mm (in.)

Standard

Limit

Valve spring

SOHC

Free length 49.8 (1.961)

48.8 (1.921)

Load/Installed height

N/mm

(Ibs./in.)

329/40.4

(725/l

.591)

Out-of-squareness Less than 2”

4”

Valve spring - DOHC

Free length

45.2

(1.780)*‘,

46.4 (1.827)“’

44.2 (1.740)*’

45.4 (1.787)“’

Load/installed height

N/mm

(Ibs.in.1

240/37.9

(52.911.492)

Out-of-squareness Less than 2”

4”

Valve guide

SOHC

Overall length

Intake

44 (1.73)

Exhaust

48 (1.89)

I.D.

8.00

8.02 i.315

.316)

O.D.

13.06-

13.07

(.5142-.5146)

Service size

0.05

(.002),

0.25

LO1

0.50

(.020)

Oversize

Valve guide

DOHC

Overall length

Intake

Exhaust

I.D.

O.D.

Service size

45.5(1.791)

50.5 (1.988)

6.60

6.62

(.2598

.2607)

12.06

12.07

(.4748

.4752)

0.05

(.002),

0.25

LO1

0.50

(.020)

Oversize

Valve seat

Seat angle

valve

contact width

Sinkage

Service size

Piston

SOHC

3.D.

‘iston-to-cylinder

clearance

Service

size

44-

44.5”

0.9

1.3

(035

,051)

0.30

(.012),

0.60

t.024)

Oversize

(3.587)

0.02

0.04

(.0008

.0016)

0.25

(.OlO),

0.50

(.020)

0.75

(.030),

.OO

l.039)

Oversize

0.2

‘iston

DOHC

3.D.

‘iston-to-cylinder

clearance

Service size

91 .I (3.587)

0.02

0.04

(.0008

.0016)

0.25

LOlO),

0.50

f.020)

0.75

(.030),

.OO

(039) Oversize

NOTE

O.D. = Outer Diameter

I.D. = Inner Diameter

= Up to 1992 models

“2

From 1993 models

TSB Revision

6G7

ENGINE

Service Specifications

,llE-17

mm (in.)

Piston ring

SOHC

End gap

No. 1 ring

No. 2 ring

Front wheel drive vehicle

Rear wheel drive vehicle

Oil ring

Front wheel drive vehicle

Rear wheel drive vehicle

Ring to ring groove clearance

No.1

ring

Front wheel drive vehicle

Rear wheel drive vehicle

No.2

ring

Piston ring

DOHC

End gap

No.

ring

No. 2 ring

Oil ring

?ing

to ring groove clearance

No. 1 ring

No. 2 ring

‘iston

I.D.

‘Tess-in

load

(Ibs.)

‘Tess-in

temperature

Connecting

rod

3ig

end center-to-small end center length

3end

‘wist

jig end side clearance

Crankshaft

!nd

play

ournal O.D.

‘in O.D.

jut-of-roundness of journal and pin

Two-camshaft engine

Four-camshaft engine

aper

of journal and pin

)il

clearance of journal

)il

clearance of pin

NOTE

O.D.

Outer Diameter

Standard

0.30-0.45(.0118-.0177)

0.45

0.60

(.0177

.0236)

0.25

0.45

LOO98

.0177)

0.20

0.60

LOO79

.0236)

0.20

0.70

(.0079

.0276)

0.03

0.07

LOOI

.0028)

0.05

0.09

(0020

.0035)

0.02

0.06

(.0008

.0024)

0.30

0.45

(.0118

.0177)

0.45

0.60

(.0177

.0236)

0.20

0.70

(.0079

.0276)

0.03

0.07

(.0012

.0028)

0.02

0.06

(.0008

.0024)

22.001

22.007

(8662

.8664)

75.00

175.00 (1,653

3,858)

Room temperature

Limit

0.8

(.031)

0.8

(.031)

0.8

(.031)

‘I

(.039)

0.1

(004)

0.1

(004)

0.1

(.004)

0.8

(.031)

(.039)

(039)

0.1

(.004)

0.1

(.004)

140.9-

141

0.05

(0020)

or less

0.1

(004)

or less

0.10

0.25

(.0039

.0098)

0.05

0.25

(0020

.0098)

60 (2.36)

50 (I

.97)

Less than 0.005

(.0002)

Less than 0.003

(.OOOl)

Less than 0.005

(.0002)

0.020

0.050 t.0008

.0020)

0.020

0.050

(0008

.0020)

0.4

(.016)

0.3

(.012)

0.1

(.004)

0.1

(.004)

TSB Revision

IIE-18

6G7

ENGINE

Service

SDecifications

mm (in.)

Cylinder block

Cylinder bore

Flatness of gasket surface

Grinding limit of top surface

Total resurfacing depth of both

cylinder head and cylinder block

Standard

91.1 (3.587)

0.05

(.002)

Limit

“0.2

(.008)

Oil pump

Tip clearance

0.03

0.08

(0012

.0031)

0.35 (0138)

Side clearance

0.04-0.10

(.0016-

.0039)

Body clearance 0.10

0.18

(0040

.0070)

Drive belt

SOHC for

DIAMANTE

Deflection

New belt

4.0-5.0(.157-,197)

Used belt 7.0

(276)

Tension gauge

(Ibs.)

New belt 700

900 (154

198)

Used belt 500 (I

IO)

Drive belt

SOHC for MONTERO and TRUCK

Deflection

New belt

6.5

8.0

(.256

,315)

Used belt

9.0

(.354)

Tension gauge

(Ibs.)

New belt

500-700(110-154)

Used belt

400 (88)

Irive

belt

DOHC

Ieflection

New belt

3.5-4.0(.138-,157)

Used belt

4.0-5.0(.157-,197)

rension

(Ibs.)

New belt

650

850 (143

187)

Used belt

450

500 (99

132)

njector

Zoil

resistance

Non-turbo R

16 at

20°C

(68°F)

Turbo

3 at

20°C

(68°F)

dle

air control motor

Ioil

resistance

33 at

20°C

(68°F)

-hrottle

position sensor

tesistance

kS1

3.5

6.5

rccelerator

pedal position sensor

lesistance

3.5-6.5

‘ariable

induction control motor

(esistance

35 at

20°C

(68°F)

TSB Revision

667’

ENGINE

Torque Specifications

TORQUE

SPECIFICATIONS

Generator and drive belt

Cooling fan bolt

ftlbs.

Fan pulley bolt

Tensioner pulley nut

SOHC DIAMANTE, DOHC

SOHC MONTERO AND TRUCK

Tensioner bracket bolt

SOHC DIAMANTE

SOHC MONTERO AND TRUCK

Ml0

17.

Ml2

DOHC

,,.’

Idler pulley bolt

,’

SOHC MONTERO AND TRUCK

DOHC

Cooling fan bracket bolt

Tensioner bracket stay bolt

Generator pivot nut

Generator brace bolt

.F-’

SOHC DIAMANTE

SOHC MONTERO AND TRUCK- Side bolt

Exhaust

manifold

tightening side

bolt

Generator bracket bolt

lrankshaft bolt SOHC

155

122

DOHC

185

134.

ntake manifold plenum and throttle body

iGR

pipe bolt

ntake manifold plenum stay bolt

!GR

valve bolt

-hrottle

body bolt

SOHC MONTERO AND TRUCK

gnition coil bolt

2.5

1.8

gnition

power transistor bolt

3.6

-hrottle body

‘hrottle

position sensor bolt

1.4

air control motor bolt

3.5

2.5

SOHC DIAMANTE DOHC Non-TURBO

2.5

1.8

\ccelerator pedal position sensor bolt

1.4

‘acuum

actuator bolt

3.5

2.5

TSB Revision

IIE-20

6G7

ENGINE

Torque Specifications

Ignition system

Center

cover bolt

Spark plug

Distributor nut

Ignition coil bolt

SOHC MONTERO AND TRUCK

DOHC

Ignition power transistor bolt

DIAMANTE

3000GT

Crankshaft position sensor nut

Timing belt

SOHC

Engine support bracket bolt

Ml0

Ml2

Tensioner lock bolt

Camshaft

sprocket bolt

Zenerator stay bolt

3enerator bracket bolt

riming belt - DOHC

Engine

support bracket bolt

Ml0

Ml2

ZrankshaftKamshaft position sensor bolts

4uto

tensioner bolt

rensioner pulley bolt

rensioner arm assembly bolt

dler pulley bolt

dler pulley bracket bolt

jocker

cover bolt

Camshaft

sprocket bolt

ntake manifold and fuel parts

njector

and fuel rail bolt

:uel

regulator bolt

pressure

-uel

pipe bolt

leat

pipe bolt

ngine coolant temperature gauge unit

ngine coolant temperature sensor

SOHC DIAMANTE

hermo

switch

dater outlet fitting bolt

ltake

manifold nut

Jater inlet fitting bolt

hermostat housing bolt

. .

ft.Ibs.

110

70 ‘51

110

ITSB Revision

6G7

,ENGlNE

Torque Specifications

Exhaust manifold

Oil level guide bolt

gauge

Heat protector bolt

Engine hanger bolt

SOHC DIAMANTE

SOHC MONTERO AND TRUCK

DOHC NON-TURBO

Exhaust manifold nut

SOHC

DOHC NON-TURBO

DOHC TURBO

Heater pipe bolt

dater

pipe bolt

SOHC MONTERO AND TRUCK

dater

bolt

pump

ieat

protector

Turbocharger stay bolt

ixhaust

fitting bolt

3il

pipe bolt

eye

Yare

nut

Nater pipe eye bolt

return pipe bolt

rurbocharger

‘urbocharger waste gate actuator bolt

locker arms and camshafts - SOHC

>il

filler bolt

locker cover bolt

Iistributor

adaptor bolt

locker arm shaft and bearing cap bolt

Camshafts,

rocker arms and bearing caps- DOHC

lrankshaft position sensor adaptor bolt

learing

caps, front and rear bolt

rearing cap bolts No. 2,

3,4

lylinder

head and valve- SOHC

:ylinder head bolt

:ylinder

head and valve

DOHC

:ylinder

head bolt

NON-TURBO

TURBO

ft.lbs.

20 14

110

125

Back off

125

.--*

TSB

Revision

E-22

667

ENGINE

Torque Specifications

ft.lbs.

Oil pan and oil pump

Transmission stay bolt

75 54

Oil pressure switch

DIAMANTE AND

3000GT

19 14

MONTERO AND TRUCK

Oil pressure gauge unit

DIAMANTE AND

3000GT

MONTERO

Oil cooler by-pass valve

55 40

Oil filter bracket stay bolt

(10x20)

(8x20)

Oil filter bracket bolt

DIAMANTE AND

3000GT

MONTERO AND TRUCK mark 4 24

mark 7

14 10

Drain plug

Oil bolt

pan

Oil screen bolt

19 14

Plug

45 33

Oil case bolt

pump

Oil cover bolt

pump

Piston and connecting rod

Connecting rod cap nut

52 38

Crankshaft,

flywheel and drive plate

+wheel

bolt

75 54

Irive

plate bolt

75 54

3ear

plate bolt

3ell

housing cover bolt

9 7

3il

seal case bolt

3earing

cap stay bolt 48

3earing

cap bolt

SOHC

79 57

DOHC 93 67

1993

models DOHC -TURBO

74 54

knock

sensor bracket bolt

knock

sensor

Bracket

Knock

sensor

DIAMANTE and

3000GT

knock

sensor bracket bolt

DIAMANTE and

3000GT

loll stopper bracket

42 30

Ml2

TSB Revision

667

ENGINE

Sealant

SEALANT

‘”

,. )

Items

Specified sealant

Auto tensioner bolt -Turbo

ATD Part No. 8660

Engine coolant temperature sensor

NUT Locking Part

No.41

Engine coolant temperature gauge unit

ATD Part No.8660

Rocker cover

ATD Part No.8660

Bearing cap

3M NUT Locking Part

No.41

Oil pressure switch

ATD Part No.8660

Oil pressure gauge unit

ATD Part No.8660

Oil pan

MITSUBISHI GENUINE Part No.MD970389

Oil seal case

MITSUBISHI GENUINE Part No.MD970389

Quantity

As required

TSB Revision

E-24

6G7

ENGINE

SDecial

Tools

SPECIAL

TOOLS

MD99871

9 or

SOHC engine only

Leak-down tester

Air bleed wire

Camshaft oil

seal installer

For SOHC

engine only

ton and timing

belt

For SOHC engine only

TSB Revision

8G7

ENGINE

Special Tools

Tool

Number and

tool name

Supersession

MD99871

Crankshaft

front oil seal

installer

MD99871

Crankshaft

rear oil seal

installer

MD998719

Pulley holding

pins (2)

MD998727

Oil pan

remover

M D998729

Valve stem

seal installer

MD998735

Valve spring

compressor

M D998754

Pulley holding

pins

(2)

MD998761 MD998761-01

Camshaft oil

seal installer

D998762

Circular packing

installer

MD99871

7-01

MD998718-01

Use with

MB990938,

MIT308239

MD998735-01

IT308239

Installation of crankshaft rear oil seal

iolding

camshaft sprocket when loosening

torquing bolt

-or

SOHC engine only

qemoval

of oil pan

nstallation of valve stem seal

:or

SOHC engine only

lemoval and installation of valve and

re-

jted

parts

lolding

crankshaft sprocket when

loosen-

or torquing bolt

lstallation of camshaft oil seal

or DOHC engine only

Application

Installation of crankshaft front oil seal

D998762-01

Installation of circular packing

For DOHC engine only

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E-26

6G7

ENGINE

Special Tools

seal installer

compressor

Installation of flywheel

TSB Revision

667

ENGINE

Generator and Drive Belt

GENERATOR AND DRIVE BELT

REMOVAL AND INSTALLATION

SOHC for

DIAMANTE

ft.lbs.

155

112

ft.lbs.

Removal steps

+A4

Drive belt

Tensioner pulley

Adjusting bolt

Adjusting stud

Tensioner bracket

Pivot bolt

Generator

Generator brace

QArJ

+B4

9. Crankshaft bolt

10.

Special washer

11.

Crankshaft pulley

7EN0487

TSB Revision

IIE-28

6G7

ENGINE

Generator and Drive Belt

tEMOVAL

AND INSTALLATION

SOHC for MONTERO and TRUCK

ftlbs.

IONm

7 ftlbs.

Removal steps

ftlbs.

Drive belt

Cooling fan

Fan clutch

4. Fan pulley

Idler pulley

Tensioner pulley

Adjusting bolt

Adjusting stud

Tensioner bracket

0. Cooling fan bracket assembly

1. Tensioner bracket stay

Generator brace

Generator

Crankshaft bolt

Special washer

Crankshaft pulley

7EN0488

TSB Revision

6G7

ENGINE

Generator and Drive Belt

IEMOVAL

AND INSTALLATION

DOHC

ft.lby

24 Nm

17 ftlbs.

ft.lbs.

45 Nm

ft.lbs.

klbs.

165

134ft.lbs.

Removal steps

#A4

Drive belt

Idler pulley

Tensioner pulley

Adjusting bolt

Adjusting stud

Tensioner bracket

Generator

Generator bracket

Bracket

(IA(J

#64

IO.

Crankshaft bolt

11.

Special washer

12.

Crankshaft pulley

7EN0489

TSB Revision

WE-30

6G7

ENGINE

Generator and Drive Belt

SOHC for

DIAMANTE

NTERO and TRUCK

DOHC

IOON

7EN0349

REMOVAL SERVICE POINT

(JAO

CRANKSHAFT BOLT LOOSENING

(1) Using the special tool, hold the drive plate or flywheel.

(2)

Remove the crankshaft bolt.

INSTALLATION SERVICE POINT

#A4

DRIVE BELT TENSION ADJUSTMENT

DRIVE BELT

TENSION CHART

Generator

drive belt

SOHC for

New

DIAMANTE

USed

SOHC for

New

MONTERO

USed

and TRUCK

DOHC

New

Used

Deflection

mm (in.)

TenEo;bt;uge

4.5

(.16-.20)

700-900(154-198)

l.28)

500 (110)

6.5-8.0(.26-.32)

500-700(110-154)

9(.35)

400(88)

3.5-4.0(.14-.16)

650-850(143-187)

4-5(.16-.20)

450-600(99-132)

TSB Revision

(1)

Loosen the tensioner pulley locking nut.

(2) Tighten the adjusting bolt to adjust the belt

deflectbn

to the

specification shown in the chart.

6G7

ENGINE

Generator and Drive Belt

SOHC

for

DIAMANTE-

gauge

Tension’

7EN0399

SOHC

for MONTERO and TRUCK

7EL0070

DOHC

(3) If you use a tension gauge, tighten the adjusting

bblt

adjust the belt tension to the specification shown in the

chart.

.:.

I)B4

CRANKSHAFT BOLT TIGHTENING

(1)

Using the special tool, hold the drive plate or flywheel.

(2) Install the crankshaft bolt.

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E-32

6G7

ENGINE

Intake Manifold Plenum and Throttle Body

INTAKE MANIFOLD PLENUM AND THROTTLE BODY

REMOVAL AND INSTALLATION

SOHC for

DIAMANTE

ft.lbs.

5Nm

3.6

ft.lbs.

ftlbs.

18Nm

ft.lbs.

Removal steps

EGRpipe

2. Ignition coil

For California

3. High tension cable

4. Intake manifold plenum stay, rear

5. Intake manifold plenum

stay,

front

EGR valve

7. EGR valve aasket

For California

Throttle body

9. Throttle body gasket

10.

Ignition power transistor

11. Intake manifold plenum

12. Intake manifold plenum gasket

7EN0405

TSB Revision

6G7

ENGINE

Intake Manifold Plenum and Throttle Body

IEMOVAL

AND INSTALLATION

SOHC for MONTERO and TRUCK

ft.lbs.

tr-

ft.lbs.

Removal steps

1. EGR pipe

EGR pipe gasket

For California

Intake

inariifold plenum stay, rear

4. Intake manifold plenum stay, front

EGR valve

6. EGR valve gasket

For California

7. Throttle body

8. Throttle body gasket

9. Intake

manifold

plenum

10. Intake manifold plenum gasket

ft.lbs.

7EN0408

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E-34

6G7

ENGINE

Intake Manifold Plenum and Throttle Body

{EMOVAL

AND INSTALLATION

DOHC NON-TURBO

12 Nm

ft.lbs.

8Nm

3 ftlbs.

22 Nm

ft.lbs.

18Nm

ft.lbs.

18Nm

13 ftlbs.

Removal steps

EGR pipe

For California

2. Intake manifold plenum stay, rear

3. Intake manifold plenum stay, front

EGR valve

6. EGR valve gasket

For California

7. Throttle body

8. Intake manifold plenum

9. Intake manifold plenum gasket

Cb,18Nm

fklbs.

TSB Revision

7EN0411

IEMOVAL

AND FUEL SYSTEM

DOHC TURBO

m2-?&

18hm

13 ftlbs.

18Nm

ft.lbs.

Removal steps

EGRpipe

2. EGR pipe gasket

For California

3. Intake manifold plenum stay, rear

4. Intake manifold plenum stay, front

EGR valve

6. EGR valve aasket

For California

7. Throttle

bo?iy

8. Throttle body gasket

Intake

manifold plenum

10.

Intake manifold plenum gasket

18 Nm

ftlbs.

6G7

ENGINE

Intake Manifold Plenum and Throtiib

B’ijdy

qq-ps5

TSB

Revision

I .

E-36

6G7

ENGINE

Intake Manifold Plenum and Throttle Body

6EM0384

INSPECTION

EGR VALVE

(1)

Check the EGR valve for sticking or carbon deposits.

If such conditions exist, clean or replace the EGR valve.

(2) Connect a hand vacuum pump to the nipple of the EGR

valve and plug other nipple.

(3) If there is vacuum leakage, replace the EGR valve.

(4) Blow air in from one passage of the EGR to check its

condition as follows.

TSB Revision

THROTTLE BODY

667 ENGINE

Throttle Body

n-E-37

DISASSEMBLY AND REASSEMBLY

SOHC for DIAMANTE, DOHC NON-TURBO

2Nin

1.4ft.lbs.

2.5 Nm

1.8

ft.lbs.

Disassembly steps

QArJ

+A4

1. Throttle position sensor

2. Idle air control motor

3. Throttle body

7FU1282

DISASSEMBLY AND REASSEMBLY

For VEHICLES with TRACTION CONTROL

!Nm

1.4

ft.lbs.-

ii+--

3.5 Nm

2.5 ftlbs.

3.5 Nm

2.5

ft.lbs.

Disassembly steps

1. Water hose

#B4

6. Throttle body

1.4

ft.lbs.

sensor

7FU1283

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E-38

6G7

ENGINE

Throttle Body

DISASSEMBLY AND REASSEMBLY

DOHC TURBO

Disassembly steps

Up to 1992 models

Vacuum valve

Dash

pot-

From 1993

models

(IAO

)A4

5. Throttle position sensor

Idle

air control motor

Throttle body

DISASSEMBLY AND REASSEMBLY

SOHC for MONTERO and TRUCK

cz!J

/T’

Disassembly steps

OAO

)B4

Throttle position sensor

(Within closed throttle position switch)

2. Idle air control motor assembly

3. Throttle body

3.5

2.5 ftlbs.

2Nm

1.4

ft.lbs.

TSB Revision

7FUO532

6G7

ENGINE

Throttle Body

DISASSEMBLY SERVICE POINTS

OAo

THROlTLE

POSITION SENSOR, ACCELERATOR

PEDAL POSITION SENSOR AND IDLE AIR CONTROL

MOTOR REMOVAL

(1)

Do not

d’

rsassemble

the sensor and motor.

(2)

Do not clean the sensor and motor by dipping them into the

solvent. Clean them with shop towel.

7FU105i

(%r)

THROlTLE

BODY REMOVAL

(1) Do not remove the throttle valve.

(2) Check if the vacuum port or passage is clogged. Use

compressed air to clean the vacuum passage.

INSPECTION

DASH POT

DOHC TURBO

Up to 1992 models

(1) Push the rod of the dash pot all the way in and close the

nipple with the fingers,

(2)

If the rod does not protrude after releasing it, the dash pot is

functioning normally.

(3) If the rod protrudes, a broken diaphragm is suspected.

Therefore, replace the dash pot.

From 1993 models

(1) Push the dash pot rod in lightly and confirm the resistance.

NOTE

Resistance increases as the rod is pushed harder.

2. If the rod can be pushed in with no resistance, either

the diaphragm or check valve is faulty.

(2) Release finger and confirm that the rod returns to its

original position quickly.

NOTE

If the rod returns slowly, the check valve is faulty.

TSB Revision

IIE-40

6G7

ENGINE

Throttle Bodv

6EM069

Red

D998463

7FUO29(

Idle

air

mot01

MD998463

7FUOO71

VACUUM VALVE

DOHC TURBO

Up to 1992 models

(1)

Remove the filter from the vacuum valve.

(2) Connect a hand vacuum pump to the black nipple of the

vacuum valve.

(3) With the other nipple closed by the finger, apply a negative

pressure of 500

mmHg

(19.7

in.Hg.)

to make sure that the

negative pressure is maintained.

(4)

Let go your finger and make sure that the negative pressure

leaks out gradually.

(5) Disconnect the hand vacuum pump and connect it to the

green nipple.

(6) Make sure that the negative pressure leaks out as soon as it

is applied.

(7) Remove the hand vacuum pump from the valve.

(8) Install the filter onto the black nipple of the valve.

IDLE AIR CONTROL MOTOR

Checking the Coil Resistance

(1) Connect Test Harness to the motor connector.

(2) Measure the resistance between the white clip of Test

Harness and the red clip or blue clip.

Standard value: 28

20°C

(68°F)

(3)

Measure the resistance between the green clip of Test

Harness and the yellow clip or black clip.

Standard value: 28

20°C

(68°F)

Operational Check

(1)

Connect Test Harness to the idle air control motor

connector.

(2) Connect the positive

terminal of 6 volt battery to the

white clip and the green clip of Test Harness.

TSB Revision

6G7

ENGINE

Throttle Body

gs41

7FUO29f

“’

7FUlb3Z

(3) Hold the idle air control motor as shown in the illustration,

connect the negative

terminal of the power supply to

each clip as described in the following steps, and check

whether or not a vibrating feeling (a feeling of very slight

vibration of the stepper motor) is generated as a result of

the activation of the stepper motor.

Connect the negative

terminal of the power supply to

the red and black clip.

@ Connect the negative

terminal of the power supply to

the blue and black clip.

@ Connect the negative

terminal of the power supply to

the blue and yellow clip.

@ Connect the negative

terminal of the power supply to

the red and yellow clip.

@ Connect the negative

terminal of the power supply to

the red and black clip.

@ Repeat the tests in sequence from @ to

(4) If, as a result of these tests, vibration is detected, the

stepper motor can be considered to be normal.

CHECKING VACUUM ACTUATOR

VEHICLES with TRACTION CONTROL

(1)

With the throttle valve opened, apply a vacuum of 200

mmHg (7.9

in.Hg.)

to the vacuum actuator to make sure

that the throttle valve closes.

(2) Then lower the level of vacuum gradually to make sure that

the vacuum actuator opens.

REASSEMBLY SERVICE POINTS

I)A4

THROTTLE POSITION SENSOR

(TPS)

INSTALLATION

SOHC for DIAMANTE, DOHC

(1)

Install the throttle position sensor to the throttle body as

shown in the illustration.

(2) Turn the throttle position sensor 90” clockwise to set it, and

tighten the screws.

TSB Revision

E-42

6G7

ENGINE

Throttle Bodv

Throttle position

Ground

Throttle position

sensor

output

Closed throttle

position switch

7FU053E

7FUO53:

7FUO53L

Ground

Throttle position

sensor

outmt

Closed throttle

position switch

Throttle position

sensor power

7FU053E

(3) Connect a circuit tester between 4 (ground) and 2 (output),

or between 2 (output) and 1 (power). Then, make sure that

the resistance changes smoothly when the throttle valve is

slowly moved to the fully open position.

(4) Check for continuity across terminals 3 (closed throttle

position switch) and 4 (ground) with the throttle valve both

fully closed and fully open.

Throttle valve position

Fully closed

Continuity

Conductive

Fully open

Non-conductive

If there is no continuity with the throttle valve fully closed,

turn TPS counterclockwise, and then check again.

NOTE

Some throttle position sensors are not provided with the

position switch. In that case, the check described in step (4)

cannot be accomplished.

(5) If the above specifications are not met, replace TPS.

I)B4

;rNHslA~-EP$tSITION SENSOR (TPS)

SOHC for MONTERO and TRUCK

(1)

Install the throttle position sensor to the throttle body as

shown in the illustration.

(2) Turn the throttle position sensor 90” counterclockwise to

set it, and tighten the screws.

(3) Connect a circuit tester between

(ground) and

(output), or between @ (output) and @ (power). Then,

make sure that the resistance changes smoothly when the

throttle valve is slowly moved to the fully open position.

(4) Check for continuity across terminals @ (closed throttle

position switch) and @ (ground) with the throttle valve both

fully closed and fully open.

TSB Revision

6G7

ENGINE

Throttle Body

w43

7FU1071

7FU107:

Closed throttle

Accelerator

pedal position

sensor output

7~~053~

)r”““-’

If there is no continuity with throttle valve fully closed, turn

the throttle position sensor clockwise, and then check

again.

(5) If the above specifications are not met, replace TPS.

I)c4

ACCELERATOR PEDAL POSITION SENSOR

(APS)

INSTALLATION

(1)

Install the accelerator pedal position sensor to the throttle

body as shown in the illustration.

(2) Turn the accelerator pedal position sensor 90” clockwise to

set it, and tighten the screws.

(3) Connect a circuit tester between (ground) and (output), or

between (output) and (power). Then, make sure that the

resistance changes smoothly when the throttle valve is

slowly moved to the fully open position.

(4) Check for continuity across terminals (closed throttle

position switch) and (ground) with the throttle valve both

fully closed and fully open.

Throttle valve position

Continuity

Fully closed

Conductive

Fully open

Non-conductive

If there is no continuity with the throttle valve fully closed,

turn APS counterclockwise, and then check again.

(5) If the above specifications are not met,

rep!ace

APS.

TSB Revision

E-44

6G7

ENGINE

Ignition System

IGNITION SYSTEM

SOHC for

DIAMANTE

25 Nm

ft.lbs.

Removal steps

1. Spark plug cables

2. Spark plug

3. Distributor

4. O-ring

7EN0406

TSB Revision

6G7

ENGINE

Ignition Svstem

;OHC

for MONTERO AND TRUCK

ft.lbs.

Removal steps

1. Spark plug cables

Spark plugs

3. High tension cable

*A4

Distributor

O-ring

Ignition coil

7EN0409

TSB

Revision

E-46

667

ENGINE

Ignition System

IOHC

for

DIAMANTE

AND

3000GT

ft.lbs.

Removal steps

Center cover

2. Spark plug cables

Soark

oluas

Ciamp’

From

Ignition

1993

coil

models

Engine hanger

Ignition

power transistor-

DIAMANTE

eB4

8. ignition power transistor

3000GT

9. Crankshaft position sensor- Up to 1992 models

10.

O-ring

7EN0492

TSB Revision

6G7

ENGINE

Ignition Svstem

WE-47

INSTALLATION SERVICE POINTS

I)A4

DISTRIBUTOR INSTALLATION

SOljC

(1) Turn the crankshaft so that the No. 1 cylinder is at

compression top dead center.

(2) Align the distributor housing and gear mating marks.

(3) With the stud located in the center of the adjusting slot at

the distributor, install the distributor.

Mating mark

7FI

OOWi

I)B4

;;RAFKSHAFT

POSITION SENSOR INSTALLATION

(1) Turn the crankshaft so that the No.

cylinder is at

compressi,on

top dead center.

(2) Install, lining up the matchmarks on the crankshaft position

sensor housing and the coupling.

TSB Revision

E-48

6G7

ENGINE

Timing Belt

SOHC

TIMING BELT

SOHC

REMOVAL AND INSTALLATION

DIAMANTE

110

80 ftlbs.

ft.lbs.

Removal steps

+D4

1. Engine support bracket

2. Access cover

3. Timing belt front upper cover, right

4. Timing belt cover cap

5. Timing belt front upper cover, left

6. Timing belt front lower cover

7. Flange

4AO

&CC

8. Timing belt

iB4

9. Tensioner

10. Tensioner spring

11. Crankshaft sprocket

QBrJ

#A4

12. Camshaft sprocket bolt

13. Camshaft sprocket

14. Timing belt rear cover, left

15. Timing belt rear cover, right

7EN0493

TSB Revision

6G7

ENGINE

Timing

Belt

SOHC

IEMOVAL

AND INSTALLATION

MONTERO AND TRUCK

8 ftlbs.

ft.lbs.

Removal steps

1. Access cover

2. Timing belt front upper cover, right

3. Timing belt front upper cover, left

4. Timing belt front lower cover

5. Flange

@IO

#C4

6. Timing belt

eB4

Tensioner

8. Tensioner spring

9. Crankshaft sprocket

(IBIJ

+A4

10.

Camshaft sprocket bolt

11.

Camshaft sprocket

12. Timing belt rear upper cover, left

13. Generator stay

14. Generator bracket

7EN0494

TSB

Revision

WE-50

6G7

ENGINE

Timing Belt

SOHC

MB990775-01

000

008

REMOVAL SERVICE POINTS

(IAO

TIMING BELT REMOVAL

(1)

Mark the belt running direction for reference in reinstalla-

tion.

NOTE

(1)

Water or oil on the belt shortens its life drastically, so

the removed timing belt, sprocket, and tensioner must

be kept free from oil and water. Do not immerse parts in

cleaning solvent.

(2) If there is oil or water on any part, check the front case

oil seal, camshaft oil seal and water pump for leaks.

~BI)

CAMSHAFT SPROCKET BOLT REMOVAL

Abnormal wear

(Fluffy strand)

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 finger-

nail.

(2) Cracks on rubber back

(3) Cracks or peeling of canvas

(4) Cracks on tooth bottom

(5) Cracks on belt

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

are sharp as if cut by a knife.

TSB Revision

6G7

ENGINE

Timing Belt

SOHC

Rubber exposed

Tooth missing and

canvas fiber exposed

01w70:

(7) Abnormal wear on teeth

(8) Tooth missing and canvas fiber exposed.

INSTALLATION SERVICE POINTS

+A4

CAMSHAFT SPROCKET BOLT INSTALLATION

I)B4

TIMING BELT TENSIONER INSTALLATION

(1) Insert a screwdriver into the hole of the timing belt

tensioner arm, move it all the way in the direction of the

arrow, and tighten the tensioner lock bolt to temporarily

hold this position.

TSB Revision

E-52

6G7

ENGINE

Timina Belt

SOHC

I)cg

TIMING BELT INSTALLATION

(1)

Align the timing marks of the camshaft sprockets and the

crankshaft sprocket.

(2) Install the timing belt on the crankshaft sprocket first and

while keeping the belt tight on the tension side, install the

belt on the left camshaft sprocket.

(3) Then, install on the water pump pulley and on the right

camshaft sprocket and finally on the timing belt tensioner.

Timing mark

(on belt cover)

Timing mark

(on rear cover or

generator bracket)

Camshaft sprocket

(wht)

Timing belt tensioner

(on front

case)

Crankshaft sprocket

(on sprocket)

side

ImIng

maw

(on sprocket)

Camshaft

(left)

sprocket

(4) Install the flange onto the front end of the crankshaft.

(5) Install the special tool onto the crankshaft.

(6) Loosen the tensioner lock bolt one or two turns and allow

the spring to tension the timing belt.

(7) Turn the crankshaft two full turns clockwise. Turn smoothly

and in clockwise direction only.

(8) Again line up the timing marks on the sprockets and tighten

the tensioner lock bolt to the specified torque.

TSB Revision

6G7

ENGINE

Timing Belt

SOHC

mark

7EN024:

I)D4

ENGINE SUPPORT BRACKET INSTALLATION

DIAMANTE

(I)

Tighten the engine support bracket bolts in the order shown

in the illustration.

NOTE

The bolt used at the location shown in the illustration is a

reamer bolt (head mark

“R”).

TSB

Revision

E-54

6G7

ENGINE

Timing Belt

DOHC

TIMING BELT

DOHC

REMOVAL AND INSTALLATION

Up to 1992 models

3Nm

ft.lbs.

90 Nm

65 ftlbs.

RS.

ft.lbs.

55 Nm

40 ftlbs.

Removal steps

I)E4

1. Engine support bracket

2. Timing belt front upper cover, right

3. Timing belt front upper cover, left

4. Timing belt front lower cover

4AO

$04

5. Timing belt

+C4

6. Auto tensioner

7. Tensioner pulley

8. Tensioner arm assembly

9. Idler pulley

10.

Idler pulley bracket

11. Crankshaft sprocket

#B4

12. Rocker cover

13. Rocker cover gasket, A

14. Rocker cover gasket,

(IB~J

*A4

15. Camshaft sprocket bolt

16. Camshaft sprocket

17. Timing belt rear cover, right

18. Timing belt rear cover, left

19. Bracket

20. Timing belt rear cover, center

7EN0497

TSB

Revision

667

ENGINE

Timing Belt

DOHC

tEMOVAL

AND INSTALLATION

From 1993 models

3Nm

klbs.

3Nm

ft.lbs.

24 Nm

ft.lbs.

42 Nm

46Nm

30 ft.lbs.

ft.lbs.

40 ft.lbs.

IlONm

60 ft.lbs.

+C4

9. Auto tensioner

IO.

Tensioner

nrrllev

11.

Tensioner arm assembly

12.

Idler pulley

13. Idler pulley bracket

14.

Crankshaft

sprocket

15. Sensing plate

16.

Washer

Removal steps

eE4

1. Engine support bracket

2. Crankshaft position sensor bracket

3. Timing belt front upper cover, right

4. Timing belt front upper cover, left

5. Timing belt front lower cover

OAo

eD4

6. Timing belt

7. Crankshaft position sensor

8. Camshaft position sensor

#B4

17. Rocker cover

18. Rocker cover gasket, A

19. Rocker cover gasket,

(rBr)

+A4

20. Camshaft sprocket bolt

21. Camshaft sprocket

22. Camshaft sprocket

23. Timing belt rear cover, right

24. Timing belt rear cover, left

25. Bracket

26. Timing belt rear cover, center

7ENO498

TSB Revision

6G7

ENGINE

Timina Belt

DOHC

7EN0224

7ENO775

REMOVAL SERVICE POINTS

aA0

TIMING BELT REMOVAL

(1)

Mark the belt running direction for reference in reinstalla-

tion.

NOTE

(1) Water or oil on the belt shortens its life drastically, so

the removed timing belt, sprocket, and tensioner must

be kept free from oil and water. Do not immerse parts in

cleaning solvent.

(2) If there is oil or water on any part, check the front case

oil seal, camshaft oil seal and water pump for leaks.

OBr)

CAMSHAFT SPROCKET BOLT REMOVAL

(1)

Hold the hexagonal portion of the camshaft with a wrench,

when removing the camshaft sprocket bolt.

INSPECTION

TIMING BELT

Refer to “INSPECTION” on page

IIE-50.

AUTO-TENSIONER

(1)

Check for oil leaks. If oil leaks are evident, replace the

auto-tensioner.

(2) Check the rod end for wear or damage and replace the

auto-tensioner if necessary.

(3)

Measure the rod projection length. If the reading is outside

the standard value, replace the auto tensioner.

Standard value: 11.7

12.3 mm

(.461

.484

in.)

(4) Use a vice to force the auto tensioner rod in. If the rod

slides in easily, replace the tensioner. If there is nothing

wrong, the rod will offer considerable resistance.

TSB Revision

6G7

ENGINE

Timing Belt

DOHC

ljl51

;_,

Apply sealant

7-G

7EN024

7EN024’

7EN022E

Spark plug holes

7EN022i

INSTALLATION SERVICE POINTS

I)A4

CAMSHAFT SPROCKET BOLT TIGHTENING

(1)

Hold the hexagonal portion of the camshaft with a wrench

when tightening the camshaft sprocket bolt. Tighten the

bolt to the specified torque.

+B4

ROCKER COVER INSTALLATION

(1)

Apply sealant to the areas shown in the illustration.

Specified sealant: 3M ATD Part

No.8660

or equivalent.

(2) Tighten the rocker cover bolts in the sequence shown in the

illustration.

I)c4 AUTO-TENSIONER INSTALLATION

If the auto-tensioner rod is fully extended, set it in the retracted

position with the following procedure.

(1)

Set the auto tensioner in a vice.

(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.

(3) Insert a wire [I

(.055

in.) in diameter] into the set

holes.

(4)

Remove the auto tensioner from the vice.

(5) On engines with turbocharger, apply sealant to the threads

of the auto tensioner mounting bolt.

Specified sealant:

ATD Part No.8660 or equivalent.

TSB Revision

E-58

6G7

ENGINE

Timing Belt

DOHC

I)04

TIMING BELT INSTALLATION

(1) Using the special tool, line up the crankshaft sprocket

timing marks, and then rotate the sprocket one tooth

counterclockwise.

(2) Line up the timing marks of the camshaft sprockets for left

bank.

(3) Using two wrenches, line up the timing marks of the

camshaft sprockets for right bank.

Caution

1. Since valve spring force can turn the camshaft

sprocket, be careful not to catch your finger.

If either camshaft sprocket is rotated one complete

turn clockwise or counterclockwise after lining up

the timing marks of the other camshaft sprocket,

the intake and exhaust valves might interfere.

Consequently, if a camshaft sprocket was turned

too far in lining up the timing marks, be sure to

rotate it back from that position to line up again the

timing marks.

(4) Install the timing belt on the exhaust side camshaft

sprocket for right bank and hold it with a paper clip at the

position shown in the illustration.

(5) Install the timing belt on the intake side camshaft sprocket

and hold it with a paper clip at the positions shown in the

illustration.

Caution

Since the camshaft sprocket turns easily, avoid exces-

sive pulling on the timing belt.

TSB Revision

6G7

ENGINE

Timing Belt

DOHC

(6) Check that the timing marks of the camshaft sprockets for

left bank are in alignment. Then install the timing belt on

these sprockets and hold it with a paper clip at the positions

shown in the illustration.

(7) Install the timing belt on the idler pulley.

(8) Install the timing belt on the crankshaft sprocket.

(9) Install the timing belt on the tensioner pulley.

(1O)Using

the special tool, rotate the tensioner pulley clockwise

to tighten the center bolt.

(1 l)Remove the four paper clips.

(12)Using

the special tool, turn the crankshaft a quarter turn

counterclockwise. Then rotate it clockwise to line up the

timing marks and check that all the timing marks are in

alignment.

TSB Revision

E-60

6G7

ENGINE

Timing Belt

DOHC

Timing marks

(on right

rocker cover)

Camshaft sprocket

Timing marks

(on left rocker cover)

Auto tensioner

Timing mark (on oil pump case)

(on sprocket)

Timing mark

(on sprocket)

Crankshaft sprocket

’

7EN0235

(13)Loosen

the center bolt of the auto-tensioner pulley, and

install the special tool and a torque wrench on the

pull’ey.

While holding the pulley with approximately

Nm (7

ftlbs.)

torque to prevent it from turning, tighten the center

bolt to the specified torque.

(14)Turn

the crankshaft two turns clockwise, and leave it alone

for about five minutes. Then move in and out the

auto-tensioner setting metal wire to check that the wire

moves smoothly.

NOTE

If the metal wire does not move smoothly, repeat step (12)

until it does move smoothly.

(15)Remove

the auto tensioner setting metal wire.

TSB Revision

6G7

ENGINE

Timing Belt

DOHC

ad mark

7EN024:

(16)Check

that the spacing between the tensioner

arm

antfaulo

tensioner is within the standard limit.

Standard value: 3.8

4.5 mm

(.I50

.I77

‘in.)

r)E4

ENGINE SUPPORT BRACKET INSTALLATION

(1)

Tighten the engine support bracket bolts in the order shown

in the illustration.

NOTE

The bolt used at the location shown in the illustration is a

reamer bolt (head mark

“R”).

TSB

Revision

E-62

6G7 ENGINE

Intake Manifold and Fuel

Parts

INTAKE MANIFOLD AND FUEL PARTS

REMOVAL AND INSTALLATION

SOHC for

DIAMANTE

9Nm

7 ftlbs.

-@-I-

__/J

8Nm

ftlbs.

,I5

19 Nm

14 ftlbs.

Removal steps

injector harness

2. Injector and fuel rail

insulator

eG4

4. Fuel pressure regulator

5. O-ring

6. Insulator

eF4

87.

lnj;e;rs

Gromet

10.

Fuel pipe

11. O-ring

12. Fuel rail

*D4

13.

Engjne

coolant temperature gauge unit

+C4

14.

Engrne

coolant temperature sensor

*I34

15.

Therm0

switch

16. Water outlet fitting

17. Water outlet fitting gasket

18. Thermostat

19. Intake manifold

20. Intake manifold gasket

7EN0499

TSB Revision

6G7

ENGINE

Intake Manifold and Fuel Parts

IEMOVAL

AND INSTALLATION

SOHC for MONTERO AND TRUCK

19Nm

ft.lbs.

c.lbs.

11 Nm

8 ftlbs.

8Nm

47-

6lklbs.

12Nm

)f~~bs~

Removal steps

1. Injector and fuel rail

12. Heat pipe

Insulator

13.

Heat pipe gasket

eG4

3. Fuel pressure regulator

14. Water hose

4. O-ring

eD4

15. Engine coolant temperature gauge unit

5. Insulator

eC4

16. Engine coolant temperature sensor

)F4

Injectors

eB4 17.

Therm0

switch

O-ring

18.

Water outlet fitting

Gromet

19.

Water outlet fitting

gasket

Fuel rail

20.

Thermostat

10.

Water hose

21.

Intake manifold

Il.

Water hose

22.

Intake

manifold gasket

7EN0500

TSB

Revision

E-64

6G7

ENGINE

Intake Manifold and Fuel Parts

{EMOVAL

AND INSTALLATION

DOHC

Nrn

ldft

Ihe

-3

18 Nm

ft.lbs.

--$j

ft.lbs.

ftlbs.

19 Nm

ft.lbs.

Removal steps

1. Injector harness

2. Injector and fuel rail

3. Insulator

+G4

4. Fuel pressure regulator

5. O-ring

Insulator

eF4

Injector clip

Injectors

O-ring

10.

Gromet

11.

Fuel pipe

12.

O-ring

13.

Fuel rail

*E4

14. Intake manifold

15. Intake manifold gasket

I)Dg

16. Engine coolant temperature gauge unit

eC4

17. Engine coolant temperature sensor

+B4

18.

Therm0

switch

19. Water hose

20. Water hose A

21.

Water outlet fitting

3000GT

22. Water outlet

fitting-

23. Water outlet fitting gasket

DIAMAN

24. Water inlet fitting

#A4

25. Thermostat

26. Thermostat housing

27. Thermostat housing gasket

7EN0501

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667

ENGINE

Intake Manifold and Fuel Parts

6FU192C

Alignment mark

Jiggle valve

7COOO42

Sealant

1 EN0338

Sealant

9cooo91

Sealant

INSPECTION

INJECTORS

(1) Measure the resistance between the terminals of the

injectors using a circuit tester. If the resistance is out

of?he

specification, replace the injector.

Standard value:

Non Turbo

20°C

(68°F)

Turbo

20°C

(68°F)

INSTALLATION SERVICE POINTS

+A4

THERMOSTAT INSTALLATION

DOHC

(1)

install the thermostat and line up the jiggle valve with the

alignment mark on the thermostat housing.

I)B4

SEALANT APPLICATION TO

THERM0

SWITCH

Specified sealant:

Part No. 8660 or equivalent

+c+

SEALANT APPLICATION TO ENGINE COOLANT

TEMPERATURE SENSOR

Specified sealant:

Nut Locking No. 4171 or equivalent

eD4

SEALANT APPLICATION TO ENGINE COOLANT

TEMPERATURE GAUGE UNIT

Specified sealant:

Part No. 8660 or equivalent

IIE-66

6G7

ENGINE

Intake Manifold and Fuel

Parts

Front

NO090

7FUO61'

r)E4

INTAKE MANIFOLD INSTALLATION

DOHC

(1)

Tighten the nuts on the right bank to 4 Nm (2.2

ft.lbs.).

(2) Tighten the nuts on the left bank to the specified torque.

Then tighten the nuts on right bank to the specified torque.

(3) Tighten the nuts on the left bank and those on the right

bbnk

again in that order.

I)Fg

INSTALLATION OF INJECTOR

(1)

Before installing the injector, the rubber O-ring must be

lubricated with a drop of clean engine oil for easy

installation.

(2) Insert the injector top end into the fuel rail. Be careful not to

damage O-ring during installation.

(3) Install the injector clip by sliding the open ends onto both

injector and fuel rail.

I)G4

FUEL PRESSURE REGULATOR INSTALLATION

(1)

Before installing the pressure regulator, the O-ring must be

lubricated with a drop of clean engine oil for easy

installation.

TSB Revision

667

ENGINE

Exhaust Manifold

yfip@7

EXHAUST MANIFOLD

REMOVAL AND INSTALLATION

SOHC for

DIAMANTE

14 Nm

IOfLlbs.

-I’”

/(/

III

24 Nm

ft-‘?m

14 Nm

ft.lbs.

6.4

5--K-a

Removal steps

Oil level gauge

2. Oil level gauge guide

O-ring

Heat protector

5. Engine hanger, right

6. Exhaust manifold, right

)BC

7. Exhaust manifold gasket

8. Heat protector, right

Bracket

10.

Exhaust manifold, left

+B4

11. Exhaust manifold gasket

12.

Water hose

13.

Water hose

14. Water by-pass hose

@---1SNm

ft.lbs.

+A4

15. Water inlet pipe

+A4

16. O-ring

For

M/l

)A4

17. Water inlet pipe A

*A4

18. Water inlet pipe

*A4

19. O-ring

For A/T

20. Water pump

21.

Water pump gasket

7EN0502

TSB Revision

6G7

ENGINE

Exhaust Manifold

IEMOVAL

AND INSTALLATION

SOHC for MONTERO AND TRUCK

I/‘,“/

12Nm

ft.lbs.

Removal steps

1. Oil level gauge

2. Oil level gauge guide

O-ring

4. Heat protector, right

Engine hanger

6. Exhaust manifold, right

eB4

7. Exhaust manifold gasket

8. Heat protector, left

Bracket

10. Exhaust manifold, left

$B4

11. Exhaust manifold gasket

12.

Water hose

13. Water hose A

14.

Heater pipe

15. Heater pipe gasket

16.

Water pipe

+A4

17.

O-ring

*A4

18. Water inlet pipe

19. Water inlet fitting gasket

20.

Water

pump

21.

Water pump gasket

7ENO360

TSB Revision

667

ENGINE

Exhaust Manifold

IEMOVAL

AND INSTALLATION

DOHC NON-TURBO

1 2

ft.lbs.

11m

ft.lbs.

13 Nm

ft.lbs.

14 Nm

ftlbs.

45 Nm

ft.lbs.

Removal steps

1. Oil level gauge

2. Oil level gauge guide

O-ring

4. Heat protector, right

Engine hanger

6. Exhaust manifold, right

7. Exhaust manifold gasket

8. Heat protector, left

9. Exhaust manifold, left

0. Exhaust manifold gasket

1. O-ring

2. Water inlet pipe

3. O-ring

4. Water pump

15. Water pump gasket

7EN0503

IIE-70

667

ENGINE

Exhaust Manifold

REMOVAL AND INSTALLATION

DOHC TURBO

14 Nm

ftlbs.

Removal steps

1. Oil level gauge

Oil level gauge guide

O-ring

*A4

O-ring

+A4

5. Water inlet pipe

ftlbs.

#A4

O-ring

Water

pump

8. Water pump gasket

7EN0504

TSB Revision

6G7

ENGINE

Exhaust Manifold

TIE-71

14 Nm

ftlbs.

ft.lbs.

14Nm

__B

ft.lbs.

31 Nm

Ibs.

“Nm

klbs.

43 ftlbs.

9. Heat protector

10.

Heat protector A

11.

Turbocharger stay

12.

Exhaust fitting

13. Exhaust fitting gasket

14.

Oil pipe

15. Water pipe A, right

16.

Water hose

17. Water pipe

right

18.

Water hose

19. Turbocharger, right

20. Turbocharger gasket

21. Ring

22. Oil return pipe, right

23. Oil return pipe gasket

24. Exhaust manifold sta

, right

+C4

25. Exhaust manifold, rig

26. Exhaust manifold gasket

71N0120

TSB Revision

E-72

6G7

ENGINE

Exhaust Manifold

IlNm

klbs.

31 Nm

22 ftlbs.

14 Nm

ftlbs.

25 Nm

ft.lbs.

-9

---ml

14Nm

ft.lbs.

3im

27. Heat protector

28. Exhaust fitting, left

29. Exhaust fitting gasket, left

30. Heat protector

31.

Oil return pipe

32. Oil return pipe gasket

33.

Oil pipe

34.

Water pipe

left

35.

Water hose

7lN0121

TSB Revision

/’

6G7

ENGINE

Exhaust Manifold

WE-73

O-ring

Water pump

Water

in’let

pipe

6EN0594

For right bank

Front

7lNOOlC

Front

For left bank

Cylinder No.

7FNWi11

Cylinder No.

Groove

INSTALLATION SERVICE POINTS

+A4

O-RING AND WATER PIPE INSTALLATION

(I)

Wet the O-ring (with water) to facilitate assembly.

Caution

Keep the O-ring free of oil or grease.

I)B4

EXHAUST MANIFOLD GASKET IDENTIFICATION

SOHC

(1) Install gaskets with cylinder number

@ and @ embos-

sed on their top side to the right bank and install those with

cylinder number

@ and

to the left bank.

I)c4

RIGHT EXHAUST MANIFOLD INSTALLATION

DOHC TURBO

Tighten the nuts in the following order.

(1) Tighten five nuts

to 30 Nm (22

ftlbs.).

(2) Tighten nuts

to 50 Nm (36

ft.lbs.).

(3) Back off nuts

until a torque value of

Nm (7

ft.lbs.)

achieved.

(4) Tighten nuts

to 30 Nm (22

ft.lbs.).

NOTE

(1) Fit the cone disc spring with the grooved side facing the

nut.

(2) Install the nut, cone disc spring and washer in the order

shown in the illustration.

7lNOl

TSB Revision

E-74

6G7

ENGINE

Exhaust

Manifold

Groove

7lNOll

I)D4 LEFT EXHAUST MANIFOLD INSTALLATION

DOHC

TURBO

Tighten the nuts in the following order.

(1) Tighten four nuts @ to 30 Nm (22

ft.lbs.).

(2)

-TT;.poranly

tighten the turbocharger to the

exhaust

man-

(3) Tighten nut @ to 30 Nm (22

ft.lbs.).

(4) Tighten nuts

and @ to 50 Nm (36

ftlbs.).

(5) Back off nuts @ and @ until a torque value of

Nm (7

ft.lbs.)

is achieved.

(6) Tighten nuts

and

to 30 Nm (22

ftlbs.).

NOTE

(1)

Fit the cone disc spring with the grooved side facing the

nut.

(2) Install the nut, cone disc spring and washer in the order

shown in the illustration.

TSB Revision

6G7

ENGINE

Turbocharger

TURBOCHARGER

DISASSEMBLY AND REASSEMBLY

Xsassembly steps

Snap pin

2. Turbocharger waste gate actuator

3. Coupling

eD4

4. Turbine housing

*C4

5. Snap ring

*Bg

6. Turbine wheel assembly

bAC

0-rina

Combressor

cover

71N0098

O-ring

3EN019C

INSPECTION

TURBOCHARGER

(1)

Manually open and close the waste gate valve to make sure

it operates freely.

(2)

Inspect the oil passage in the cartridge for signs of deposits

or blockage.

(3) Clean the inlet section of the compressor cover with a rag.

Inspect it for signs of contact with the compressor turbine.

If worn, replace it.

REASSEMBLY SERVICE POINTS

#A4

O-RING INSTALLATION

(1) Apply a light coat of engine oil to a new O-ring and fit it in

the groove of the turbine wheel assembly.

TSB Revision

E-76

6G7

ENGINE

Turbocharger

Chamfered

T&ink

wheel

assembly

CompressoB

cover

664

TURBINE WHEEL ASSEMBLY INSTALLATION

)

Install the turbine wheel assembly to the compressor cover

while aligning the dowel pin and the hole.

Caution

Use care not to damage the blades of the turbine wheel

and compressor wheel.

+cg SNAP RING INSTALLATION

(1)

Fit the snap ring with its chamfered side facing up.

I)04

TURBINE HOUSING INSTALLATION

(1)

Install the turbine housing while aligning the dowel pin and

the hole.

Caution

Use care not to damage the blades of the turbine

wheel.

TSB

Revision

-I

667

ENGINE

Rocker Arms and Camshaft

SOHC

“14

E~77

ROCKER ARMS ANI) CAMSHAFTS

SOHC

REMOVAL AND INSTALLATION

DIAMANTE

9Nm

ft.lbs.

Removal steps

#E4

Fi;,c:;;

cover

elII4

3. Circular packing

+C4

4. Camshaft oil seal

5. Distributor adaptor

6. O-ring

#B4

7. Rocker

arms,

shafts and

bebring

caps

OAO

+A4

98:

pa,Smhs;W$er

7EN0362

TSB

Revision

IIE-78

6G7

ENGINE

Rocker Arms and Camshaft

SOHC

REMOVAL AND INSTALLATION

MONTERO AND TRUCK

13Nm

ft.lbs.

------d

9Nm

Q-

ft.lbs.

9Nm

I--

ft.lbs.

Removal steps

1 Oil filler

2. Oil filler tube

eE4

3. Rocker cover

4. Gasket

#D4

5. Circular packing

I)C4

6. Camshaft oil seal

7. Distributor adaptor

8. O-ring

’

#B4

9. Rocker

arms,

shafts and bearing caps

aA0

*A4

;

p&dfutster

7EN0363

TSB

Revision

6G7

ENGINE

Rocker Arms and Camshaft

SOHC

TE39

REMOVAL SERVICE POINT

flo

ROCKER ARM,

SHAFT

AND BEARING CAP

REMOVAL

(1) Install the special tools to the rocker arm to hold the lash

adjuster.

(2) Loosen the camshaft bearing cap bolt. Do not remove the

bolts from the cap.

(3) Remove the rocker arm, shaft and bearing cap as an

assembly.

INSPECTION

CAMSHAFT

(1)

Inspect the camshaft bearing journals for damage and

binding. If the journals are binding, also check the cylinder

head for damage. Also check the cylinder head oil holes for

clogging.

(2) Check the tooth surface of the distributor drive gear teeth

of the camshaft and replace if abnormal wear is evident.

(3) Check the cam surface for abnormal wear and damage and

replace if defective. Also measure the cam height and

replace if out of limit.

Standard value: 41.25 mm (1.6240 in.)

Limit: 40.75 mm (1.6643 in.)

LASH ADJUSTER LEAK DOWN TEST

Caution

1. The lash adjuster is a precision part. Keep it free

from dust and other foreign matters.

2. Do not disassemble the lash adjusters.

3. When cleaning the lash adjusters, use clean diesel

fuel only.

TSB

Revision

E-80

667

ENGINE

Rocker Arms and Camshaft

SOHC

6EN057

Division = 1 mm

(.04

in.)

7EN043t

6EN0421

D998443-0

Lash

adjust&

7EN0174

(1)

Immerse the lash adjuster in clean diesel fuel.

(2) While lightly pushing down the inner steel ball using the

small wire, move the plunger up and down four or five

times to bleed air.

Use of the Retainer facilitates the air bleeding of the rocker

arm mounted type lash adjuster.

(3)

Remove the small wire 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. If the plunger is still loose,

replace the lash adjuster.

Caution

Upon completion of air bleeding, hold

the lash adjuster

upright to prevents the inside diesel fuel from spilling.

(4) After air bleeding, set the lash adjuster on the special tool

(Leak down tester

MD998440).

(5) After the plunger has gone down somewhat 0.2

0.5 mm

(.008

.020

in.), measure the time taken for it to go down

(.04

in.). Replace if the measured time is out of

specification.

Standard value: 4

20 seconds

1 mm

(.04

in.)

[Diesel fuel at 15

20°C

(50

68”F)]

INSTALLATION SERVICE POINTS

*A4

LASH ADJUSTER INSTALLATION

(1)

Immerse the lash adjuster in clean diesel fuel.

(2) Using a small 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.

(3) Insert the lash adjuster to rocker arm, being careful not to

spill the diesel fuel. Then use the special tool to prevent the

adjuster from falling while installing it.

TSB Revision

‘I

667

ENGINE

Rocker Arms and Camshaft

SOHC

+64

ROCKER ARM, SHAFT AND BEARING CAP

INSTALLATION

(1) Apply a minimum amount of the specified sealant on the

four places of the cylinder head.

NOTE

Be sure the sealing agent does not swell out onto the cam

journal surface of the cylinder head. If it swells out,

immediately wipe it off before it can dry.

Specified sealant:

NUT Locking No. 4171 or equivalent

Apply sealant

No.

and

No.4

bearing cap mating surface

of cylinder head

(2) Install the rocker arms, shafts and bearing caps such that

the arrow mark on the bearing cap faces in the same

direction as the arrow mark on the cylinder head.

TSB Revision

E-82

667

ENGINE

Rocker Arms and Camshaft

SOHC

Rocker arm shaft

assembly(B)

Arrow mark (bearing cap)

Arrow mark (cylinder head)

Timing belt side

Rocker arm shaft -----

assembly (A)

Arrow

mark-(bearing

cap)

7EN0176

(3) Tighten the bearing cap bolts to the specified torque.

(4) Remove the special tools from all rocker arms.

ec4

CAMSHAFT OIL SEAL INSTALLATION

(1) Apply a slight amount of engine oil all over the circumfer-

ence of the camshaft oil seal lip.

(2) Using the special tool, insert the oil seal.

TSB Revision

667

ENGINE

Rocker Arms and Camshaft

SOHC

MD998714-01

\\/

7EN0441

0.5 mm

(020

in.)

I--

Spacer

MD998714-01

7EN0131

#D4 CIRCULAR PACKING INSTALLATION

(1)

Install a 1.3 to 1.5 mm

(.052

.059

in.) thick spacer to the

special tool and drive in the circular packing.

NOTE

Use of MD724328 spacer for transmission is recom-

mended.

Caution

The packing is overdriven if no spacer is fitted to the

special tool.

I)E4

ROCKER COVER INSTALLATION

(1) Apply specified sealant on the area specified in the

illustration.

Specified sealant:

ATD

Part

No. 6660 or equivalent

TSB Revision

IIE-84

6G7

ENGINE

Rocker Arms and Rocker Shafts

SOHC

DISASSEMBLY AND REASSEMBLY

Disassembly steps

1. Bearing cap

No.4

Rocker arm

Spring

Bearing cap No.

Bearing cap

No.

*A4

6. Rocker arm shaft “B”

$A4

7. Rocker arm shaft “A”

Bearing cap No.

DISASSEMBLY SERVICE POINT

OAo

ROCKER ARM REMOVAL

(1)

Before disassembly, identify the original location of each

rocker arm by a symbol.

For example, put symbols as shown below.

1 IN: For

No.1

cylinder intake

6EX:

For

No.6

cylinder exhaust

TSB Revision

667

ENGINE

Rocker Arms and Rocker Shafts

SOHC

7EN006r

Notch

Rocker arm shaft “6”

Cap No.

Rocker

arm

shaft

“A”

7EN0015

Jiew

Rocker arm

Oil hole

shaft (A)

-----

‘ao’&

-,----

Rocker arm shaft

(B)

7ENOOlE

INSPECTION

ROCKER ARM

(1) Check the roller surface and replace the rocker arm if

recesses, damage or heat seizure is observed.

(2) Check roller rotation and replace the rocker arm if uneven

rotation or roller backlash is observed.

(3) Check the inside diameter and replace the rocker arm if

damage or seizure is observed.

ROCKER ARM SHAFT

(1) Check the rocker arm mounting portions of the rocker arm

shafts for wear or damage. Replace as necessary.

(2) Check to ensure that the oil holes are clear.

REASSEMBLY SERVICE POINT

#A4

ROCKER ARM SHAFT INSTALLATION

(1) Install the rocker arm shafts “A” and “B” to the camshaft

bearing cap

No.1

and insert the bolts into the holes of the

bearing cap and shafts.

(2) Install the rocker arm shafts with the notched side facing

the bearing cap

No.1

and the oil grooved side facing

downward. The shaft with a smaller oil hole is the rocker

arm shaft “A”.

r&B

Revision

IIE-88

6G7

ENGINE

Camshafts, Rocker Arms and Bearing Caps

DOHC

MD998440

Scale

1 mm l.039 in.)

6EN035:

Small wire

INSPECTION

CAMSHAFT

Measure the cam height (longer diameter of the cam). If it

exceeds the limit, replace the camshaft.

Standard value:

Up to 1992 models

Intake side

35.49 mm (1.3972 in.)

Exhaust side

35.20 mm (1.3858 in.)

From 1993 models

Intake side

34.91 mm (1.3744 in.)

Exhaust side

34.91 mm (1.3744 in.)

Limit:

Up to 1992 models

Intake side

34.99 mm (1.3778 in.)

Exhaust side

34.70 mm (1.3661 in.)

From 1993 models

Intake side

34.41 mm (1.3547 in.)

Exhaust side

34.41 mm (1.3547 in.)

LASH ADJUSTER LEAK DOWN TEST

Refer to “LASH ADJUSTER LEAK DOWN TEST” on pages

E-79

and 11

E-80.

Also note the following:

When the lash adjuster is set on a tester, remove the adjusting

screw of the tester and adjust it to the height of the lash

adjuster as shown in the illustration.

INSTALLATION SERVICE POINTS

I)A4

LASH ADJUSTER INSTALLATION

(1) Immerse the lash adjuster in clean diesel fuel.

(2) Using a small wire, move the plunger up and down 4 or 5

times while lightly pushing down the check ball in order to

bleed out the air.

(3) Install the lash adjuster to the cylinder head.

TSB Revision

6G7

ENGINE

Camshafts, Rocker Arms and Bearing Caps

DOHC

17E439

Identification mark

7EN024S

+64

CAMSHAFT INSTALLATlON

(1)

Turn the crankshaft to bring

No.1

cylinder to the top dead

center.

(2) Check that the rocker arm is installed correctly on the lash

adjuster and valve.

(3) Install the camshaft while noting the identification mark

(stamped on the hexagon section).

Identification mark:

Up to 1992 From 1993

models

mpdeis

Turbo

Intake side

Exhaust side

Non-turbo Intake side

Exhaust side

J”

(4) Install the camshafts with their dowel pins positioned as

shown in the illustration.

Left bank

Right bank

ApproFi

Front mark

Identification

7EN031

ec4

BEARING CAP INSTALLATION

(1) Install the bearing caps according to the identification mark

and cap number.

No.2,

3 and 4 bearing caps bear the front

mark. Install these caps with the front mark directed in the

same direction as that on the cylinder head.

Identification mark: Intake side

Exhaust side

(2) Gradually tighten the bearing caps in two or three steps. In

the final step, tighten to the specified torque.

TSB Revision

IIE-88

6G7

ENGINE

Camshafts, Rocker Arms and Bearing Caps

DOHC

MD998440

Scale

1 mm l.039 in.)

6EN035:

Small wire

INSPECTION

CAMSHAFT

Measure the cam height (longer diameter of the cam). If it

exceeds the limit, replace the camshaft.

Standard value:

Up to 1992 models

Intake side

35.49 mm (1.3972 in.)

Exhaust side

35.20 mm (1.3858 in.)

From 1993 models

Intake side

34.91 mm (1.3744 in.)

Exhaust side

34.91 mm (1.3744 in.)

Limit:

Up to 1992 models

Intake side

34.99 mm (1.3778 in.)

Exhaust side

34.70 mm (1.3661 in.)

From 1993 models

Intake side

34.41 mm (1.3547 in.)

Exhaust side

34.41 mm (1.3547 in.)

LASH ADJUSTER LEAK DOWN TEST

Refer to “LASH ADJUSTER LEAK DOWN TEST” on pages

E-79

and 11

E-80.

Also note the following:

When the lash adjuster is set on a tester, remove the adjusting

screw of the tester and adjust it to the height of the lash

adjuster as shown in the illustration.

INSTALLATION SERVICE POINTS

I)A4

LASH ADJUSTER INSTALLATION

(1) Immerse the lash adjuster in clean diesel fuel.

(2) Using a small wire, move the plunger up and down 4 or 5

times while lightly pushing down the check ball in order to

bleed out the air.

(3) Install the lash adjuster to the cylinder head.

TSB Revision

6G7

ENGINE

Camshafts, Rocker Arms and Bearing Caps

DOHC

17E439

Identification mark

7EN024S

+64

CAMSHAFT INSTALLATlON

(1)

Turn the crankshaft to bring

No.1

cylinder to the top dead

center.

(2) Check that the rocker arm is installed correctly on the lash

adjuster and valve.

(3) Install the camshaft while noting the identification mark

(stamped on the hexagon section).

Identification mark:

Up to 1992 From 1993

models

mpdeis

Turbo

Intake side

Exhaust side

Non-turbo Intake side

Exhaust side

J”

(4) Install the camshafts with their dowel pins positioned as

shown in the illustration.

Left bank

Right bank

ApproFi

Front mark

Identification

7EN031

ec4

BEARING CAP INSTALLATION

(1) Install the bearing caps according to the identification mark

and cap number.

No.2,

3 and 4 bearing caps bear the front

mark. Install these caps with the front mark directed in the

same direction as that on the cylinder head.

Identification mark: Intake side

Exhaust side

(2) Gradually tighten the bearing caps in two or three steps. In

the final step, tighten to the specified torque.

TSB Revision

IIE-90

6G7

ENGINE

amshafts,

Rocker Arms and Bearing Caps

DOHC

I)D4

CAMSHAFT OIL SEAL

(1)

Apply engine oil sparingly all around the lip of the camshaft

oil seal.

(2)

Using the special tool, install the oil seal.

+E4

CIRCULAR PACKING

(1)

Install the circular packing with the special tool.

TSB Revision

6G7

ENGINE

Cylinder Head and Valve

SOHC

CYLINDER HEAD AND VALVE

SOHC

REMOVAL AND INSTALLATION

l-l

E-91

0+5

ce-130

-0Q

-4

@E---14

170

IlONm

ft.lbs.

Removal steps

QAIJ

+E4

12.

fyks$~;

head bolt

Cylinder head assembly

#D4

4. Cylinder head gasket

~BI)

eC4

5. Retainer lock

6. Valve spring retainer

#B4

7. Valve spring

8. Inlet valve

~BI)

$C4

9. Retainer lock

10.

Valve spring retainer

1. Valve spring

2. Exhaust valve

3. Valve stem seal

4. Valve spring seat

5. Valve stem seal

6. Valve spring seat

7. Inlet valve guide

3. Snap ring

3. Exhaust valve guide

I. Inlet valve seat

I. Exhaust valve seat

Cylinder head

7EN0522

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E-92

6G7

ENGINE

Cylinder Head and Valve

SOHC

7FNflM4

REMOVAL SERVICE POINTS

PRECAUTION FOR REMOVED PARTS

(1)

Keep removed parts in order according to the cylinder

number and intake/exhaust.

OAo

CYLINDER HEAD BOLT REMOVAL

(1)

Using the special tool, loosen the cylinder head bolts.

Loosen evenly, little by little.

~BI)

RETAINER LOCK REMOVAL

(1)

Using the special tool, compress the spring.

(2)

Remove the retainer locks.

VALVE STEM SEAL REMOVAL

(I)

Do not reuse removed valve stem seals.

TSB Revision

6G7

ENGINE

Cylinder Head and Valve

SOHC

Ridge

wear

EN026:

6ENOW

INSPECTION

CYLINDER HEAD

(1)

Check the cylinder head gasket surface for flatness by

using a straightedge in the directions of A through

shown

in the illustration.

Standard value: 0.05 mm

(.0020

in.)

Limit: 0.2 mm

(.008

in.)

(2) If the service limit is exceeded, correct to meet the

specification.

Grinding limit:

“0.2

(.008

in.)

Total resurfacing depth of both cylinder head and cylinder

block.

Overall height: 84 mm (3.31 in.)

VALVE

(1)

If the valve stem is worn (ridge wear) or otherwise

damaged, replace. Also replace the valve if the stem end

(that contacts the rocker arm adjusting screw) has a dent.

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

using a valve

refacer.

Valve should make a uniform contact

with the seat at the center of valve face.

(3) If the margin exceeds the service limit, replace the valve.

Standard value:

Intake

1.2 mm

(.047

in.)

Exhaust

2.0 mm

(.079

in.)

Limit:

Intake 0.7 mm

(.028

in.)

Exhaust

1.5 mm

(.059

in.)

TSB

Revision

E-94

6G7

ENGINE

Cvlinder Head and Valve

SOHC

EN0264

EN027:

6EN0491

VALVE SPRINGS

)

Measure the free height of the spring and, if it is smaller

than the limit, replace.

Standard value:

SOHC

49.8 mm (1.961 in.)

DOHC

up to 1992 models

45.2 mm (1.780 in.)

From

1993 models

46.4 mm (1.827 in.)

Limit:

SOHC

48.8 mm (1.921 in.)

DOHC

up to 1992 models

44.2 mm

(1.740

in.)

From

1993 models

45.4 mm (1.878 in.)

(2) Measure the squareness of the spring and, if the limit is

exceeded, replace.

Standard value:

2”

Limit: 4”

VALVE GUIDES

(1) Measure the clearance between the valve guide and valve

stem. If the limit is exceeded, replace the valve guide or

valve, or both.

Standard value:

Intake

0.03

0.06 mm

(.0012

.0024

in.)

Exhaust

0.05

0.09 mm

(.0020

.0035

in.)

Limit

Intake

0.10 mm

(.0039

in.)

Exhaust

0.15 mm

(.0059

in.)

VALVE SEAT RECONDITIONING PROCEDURES

(1) Before valve seat reconditioning, check the valve

stem-to-

guide clearance.

(2)

Recondition the valve seat with a seat grinder or cutter. The

valve seat width should be the specified value at the center

of the valve face.

Inspect the valve seat with prussian blue to determine

where the valve contacts the seat. To do this, coat the valve

seat lightly with prussian blue, and then set the valve in

place.

Rotate the valve with a light pressure. If the blue is

transferred to the center of the valve face, contact is

satisfactory.

If the blue is transferred to the top edge of the valve face,

lower the valve seat with a 30 degrees stone or cutter. If

the blue is transferred to the bottom edge of the valve face,

raise the valve seat with a 65 degrees stone or cutter.

Valve seat diameter:

Intake 44 mm (1.73 in.)

Exhaust

38 mm (1.50 in.)

Seat width: 0.9

1.3 mm

(.035

.051

in.)

(3) The valve and valve seat should be lapped with lapping

compound.

TSB Revision

6G7

ENGINE

Cylinder Head and Valve

SOHC

Installed

height

6EN043:

0.5-

LO20

.039

in.)

0.5-

1 mm

(.020

,039

in.)

EN0274

EN027E

Removal

Installation

Press

Valve

guide

6EN054:

(4) Check the valve seat

sinkage.

The valve seat

sinkage

can be determined by measuring the

valve spring’s installed height. (If the valve seat

sinkage

great, the valve seat’s installed height also is great.)

If the valve spring’s installed height exceeds the service

limit, replace the insert with an oversize part as described

below.

Installed height of spring (both intake and exhaust)

Standard value: 40.4 mm (1.591 in.)

Limit: 41.4 mm

(1.630

in.)

VALVE SEAT REPLACEMENT PROCEDURE

(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.

Intake valve seat hole diameter

0.30 O.S.: 44.30

44.33 mm (1.7441

1.7453 in.)

0.60 O.S.: 44.66

44.63 mm (1.7559

1.7571 in.)

Exhaust valve seat hole diameter

0.30 O.S.: 38.30

38.33 mm

(1.5079

1.5091

in.)

0.60 O.S.: 38.60

38.63 mm (1.5197

1.5209 in.)

(3) Before fitting the valve seat, either heat the cylinder head

up to approximately

250°C

(482°F)

or cool the valve seat in

liquid nitrogen, to prevent the cylinder head bore from

galling.

(4)

Using a valve seat cutter, correct the valve seat to the

specified width and angle.

See “VALVE SEAT RECONDITIONING

PROCEDU’RE”.

VALVE GUIDE REPLACEMENT PROCEDURE

(1)

Remove the snap ring from the exhaust valve; guide.

(2) Using the push rod and a press, remove the valve guide

toward the cylinder head gasket surface.

(3)

Rebore the valve guide hole to the new oversize valve guide

outside diameter.

Valve guide hole diameter

0.05 O.S.: 13.05

13.07

(.5138

.5’1;45

in.)

0.25

OS.:

13.25

13.27

(.5217

.5224

in.)

0.50

O.S.: 13.50

13.52

(.5315

.5322

in.)

TSB Revision

E-96

6G7

ENGINE

Cylinder Head and Valve

SOHC

MD998729-01

7EN0081

6EN0544

NOTE

Do not install a valve guide of the same size again.

(4) Using the special tool, press-fit the valve guide, working

from the cylinder head top surface.

(5) After installing valve guides, insert new valves in them to

check for sliding condition.

(6) When valve guides have been replaced, check for valve

contact and correct the valve seats as necessary.

INSTALLATION SERVICE POINTS

I)A4

VALVE STEM SEAL INSTALLATION

(1) Install the valve spring seat.

(2) Using the special tool, install a new stem seal to the valve

guide.

Caution

Do not reuse removed valve stem seals.

I)64 VALVE SPRING INSTALLATION

(1) Direct the valve spring end with identification color toward

the spring retainer.

#c4

RETAINER LOCK INSTALLATION

(1)

Using the special tool, compress the valve spring and insert

the retainer lock into position.

TSB Revision

6G7

ENGINE

Cylinder Head and Valve

SOHC

Identification mark

MD998051-01

+D4 CYLINDER HEAD GASKET IDENTIFlCATl6N’

Caution

Do not apply sealant to the cylinder head gasket.

Identification mark:

DIAMANTE and MONTERO 72

TRUCK

72W

#E4

CYLINDER HEAD BOLT INSTALLATION

(1)

Tighten the cylinder head bolts in the sequence shown.

Each bolt should be tightened in two to three steps,

torquing progressively. Tighten to the specified torque in

the final sequence.

TSB Revision

IIE-98

6G7

ENGINE

Cvlinder

Head and Valves

DOHC

CYLINDER HEAD AND VALVES

DOHC

REMOVAL OF INSTALLATION

Removal steps

Non-turbo

IlONm

ft.lbs.

Turbo

125

Nm-+ Back off

lg\yE

ft.lbs.

. .

Cylinder head bolt

Washer

3. Cylinder head assembly

4. Cylinder head gasket

Retainer lock

6. Valve spring retainer

Valve spring

Intake valve

Retainer lock

0. Valve spring retainer

eB4

11. Valve spring

12. Exhaust valve

QCr$

*A4

13. Valve stem seal

14. Valve spring seat

(Gr)

+A4

15. Valve stem seal

16. Valve spring seat

17. Intake valve guide

18. Exhaust valve guide

19. Intake valve seat

20. Exhaust valve seat

21. Cylinder head

7EN0254

TSB Revision

6G7

ENGINE

Cylinder Head and Valves

DOHC

qqp99

REMOVAL SERVICE POINTS

gA0

CYLINDER HEAD BOLT REMOVAL

(1)

Using the special tool, loosen the cylinder head bolts.

Loosen evenly, little by little.

(‘IBM

RETAINER LOCK REMOVAL

(1) Using the special tool, compress the spring.

(2) Remove the retainer locks.

@I)

VALVE STEM SEAL REMOVAL

(1) Do not reuse removed stem seals.

INSPECTION

For inspection, only variations from the SOHC engine are

described below.

(Refer to page

E-93,

94, 95 and 96)

TSB Revision

IIE-100

6G7

ENGINE

Cylinder Head and Valves

DOHC

252

Valve

seat

6EN0205

Identification -

color

Spring

retainer

Stem seal

6EN05A4

CYLINDER HEAD

Cylinder head height (when new):

131.9

132.1 mm (5.193

5.201 in.)

INSTALLATION SERVICE POINTS

I)A4

VALVE STEM SEAL INSTALLATION

(1)

Install the valve spring seat.

(2) Using the special tool, install a new stem seal to the valve

guide.

Caution

Do not reuse removed valve stem seal.

I)B4

VALVE SPRING INSTALLATION

(1) Install the valve spring so that the end with identification

color is positioned on the rocker arm end.

+c4

INSTALLATION OF RETAINER LOCKS

(1) Using the special tool, compress the valve spring and insert

the retainer lock into position.

TSB Revision

6G7

ENGINE

Cylinder Head and Valves

DOHC

TE-‘MN

Identifi-

7EN026

I)D4

CYLINDER HEAD GASKET IDENTIFICATION

Identification mark

Non-turbo 2DN

Turbo 2DT

I)E4

CYLINDER HEAD BOLT INSTALLATION

(1) Tighten the bolts in two to three stages in the illustrated

sequence.

(2) Back off the bolts once and tighten them to the specified

torque in the same procedure as shown in step (1).

Intake side

p-y-y-q

Exhaust side

7EN026:

TSB

Revision

IIE-102

6G7

ENGINE

Oil Pan and Oil Pump

OIL PAN AND OIL PUMP

REMOVAL AND INSTALLATION

DIAMANTE

and

3000GT

ft.lbs.

ftlbs.

ft.lbs.

)

ft.lbs.

14ft.lbs.

ft.lbs.

14 Nm

klbs.

ft.lbs.

6Nm

ft.lbs.

Removal steps

Transmission stay, right

2. Transmission stay, left

eG4

3. Oil pressure switch

#F4

4. Oil pressure gauge unit

+E4

5. Oil filter

6. Oil cooler by-pass valve***

7. Oil filter bracket stay

8. Oil filter bracket

9. Oil filter bracket gasket

10.

Drain plug

eO4

11.

Drain plug gasket

c)ArJ

eC4

12. Oil pan

13. Oil screen

14. Oil screen gasket

15.

Plug

16. Relief spring

17. Relief plunger

)Bg

18.

Crankshaft oil seal

19. Oil pump case

20. Oil pump gasket

21.

Oil pump cover

~BI)

#A4

22. Oil pump outer rotor

(IB~J

#A4

23. Oil pump inner rotor

NOTE

SOHC

**:

DOHC

***:

DOHC Turbo

7EN0422

TSB Revision

6G7

ENGINE

Oil Pan and Oil Pump

{EMOVAL

AND INSTALLATION

MONTERO and TRUCK

11!Emw3

Bolt with head mark “4” 24 Nm

ft.lbs.

Bolt with head mark “7”

ft.lbs.

55 Nm

in&

Ihc

55 Nm

ft.lbs.

45 Nm

ft.lbs.

40 Nm

ft.lbs.

Removal steps

#G4

Oil pressure switch

#F4

2. Oil pressure gauge unit

MONTERO

+E4

3. Oil filter

4. Oil cooler by-pass valve

MONTEBO

5. Oil filter bracket

6. Oil filter bracket gasket

7. Drain plug

#III4

8. Drain plug gasket

(IAI)

eC4

9. Oil pan

10.

Oil screen

Il.

Oil screen gasket

12. Plug

13. Relief spring

14. Relief plunger

)B4

15. Crankshaft oil seal

16. Oil pump case

17. Oil pump gasket

18. Oil pump cover

(IBI)

)A4

19. Oil pump outer rotor

@I)

@A4

20. Oil pump

Inner

rotor

19Nm

ft.lbs.

N’m

ft.lbs.

7EN0423

TSB Revision

IIE-104

6G7

ENGINE

Oil Pan and Oil

Pumn

REMOVAL SERVICE POINT

gA0

OIL PAN REMOVAL

(1)

Knock the special tool deeply between the oil pan and the

cylinder block.

(2)

Hitting the special tool on the side, slide it along the oil pan

to remove it.

~BI)

OUTER ROTOR

INNER ROTOR REMOVAL

(1)

Make alignment dots on the outer and inner rotors for

reference in reassembly.

INSPECTION

OIL PUMP

(1)

Check the tip clearance.

Standard value: 0.03

0.08 mm

(.0012

.0031

in.)

(2) Check the side clearance.

Standard value: 0.04

0.10 mm

(.0016

.0039)

(3) Check the body clearance.

Standard value: 0.10

0.18 mm

(.0040

.0070)

Limit: 0.35 mm

(.0138)

TSB Revision

6G7

ENGINE

Oil Pan and Oil Pump

6EN0589

MD99871

7-01

Oil bump

case

7FNOld

7EN046t

OIL COOLER BYPASS VALVE

(1)

Make sure that the valve moves smoothly.

(2) Ensure that the dimension

measures the standard value

under normal temperature and humidity.

Dimension L: 34.5 mm (1.358 in.)

(3) The dimension must be the standard value when measured

after the valve has been dipped in

100°C

(212°F)

oil.

Dimension L: 40 mm (1.57 in.) or more

INSTALLATION SERVICE POINTS

#A$

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.

I)B4

CRANKSHAFT FRONT OIL SEAL INSTALLATION

(1) Using the special tool, knock the oil seal into the oil pump

case.

NOTE

Knock it as far as it goes.

TSB Revision

IIE-106

6G7

ENGINE

Oil Pan and Oil Pump

I)c4

OIL PAN INSTALLATION

(1) Remove all the remaining gasket from the mating surfaces

using a scraper or a wire brush.

(2) Apply a 4 mm

(.I6

in.) diameter bead of sealant to the oil

pan flange.

See “Form In-Place Gasket” in introduction.

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or

equivalent

(3) The oil pan should be installed within 15 minutes after the

application of sealant.

(4) Tighten the flange bolts in the sequence shown in the

illustration.

Bolt

hole

area

(=7

Timing

belt

side

Tightening sequence of flange bolts

(bottom view)

Timing

belt side

TSB

Revision

6G7

ENGINE

Oil Pan and Oil Pump

~@q’@!!

+04

DRAIN PLUG GASKET INSTALLATION

(1) Install the drain plug gasket as illustrated.

v$ket

APPLY

engine oil

6EN059

3EN022’

+G4

%AEA;T

APPLICATION TO OIL PRESSURE

(1) Coat the threads of the switch with sealant and install the

switch using the special tool.

Specified sealant:

ATD Part No.8660

or equivalent

Caution

1. Keep the end of threaded portion clear of sealant.

2. Avoid an overtightening.

9EN009

TSB

Revision

APP~

I)E4

OIL FILTER INSTALLATION

(1) Clean the installation surface of the filter bracket.

(2) Apply engine oil to the O-ring of the oil filter.

(3) Screw the oil filter on until the O-ring contacts the bracket.

Then tighten

3/4

turn.

I)F4

SEALANT APPLICATION TO OIL PRESSURE GAUGE

UNIT

(1) Coat the threads of the gauge unit with sealant and install it

using the special tool.

Specified sealant:

ATD Part No.8660 or equivalent

Caution

1. Keep the end of threaded portion clear of sealant.

2. Avoid an overtightening.

IIE-108

6G7

ENGINE

Piston and Connecting Rod

PISTON AND CONNECTING

REMOVAL AND INSTALLATION

ROD

ft.lbs.

Removal steps

1. Nut

GAO

#E4

2. Connecting rod cap

3. Connecting rod bearing (lower)

eD4

4. Piston, connecting rod assembly

5. Connecting rod bearing (upper)

6. Piston rina No.?

7. Piston

rini

No.2

Oil ring

Piston pin

Piston

Connecting

rod

Bolt

7EN0424

TSB Revision

6G7

ENGINE

Piston and Connecting Rod

llEJl69

7EN044E

Piston pin setting tool

MIT21

6941

7EN0426

Press pin

Piston pin

7ENO42

ITss

REMOVAL SERVICE POINTS

OAr)

CONNECTING ROD CAP REMOVAL

(1) Mark the cylinder

numberdon

the side of the connecting rod

big end for correct reassembly.

(2) Keep the removed connecting rods, caps, and

bearings

order according to the cylinder number..

060

PISTON PIN REMOVAL

Item No.

Part No.

MIT310134

MIT310136

MIT310137

4 MIT310138

MIT310139

MIT310140

MIT310141

MIT310142

MIT48143

216943

10396

Description

Base

Piston Support

Connecting Rod

Guide Pin

Connecting Rod Guide Pin

Piston Support

Connecting Rod Guide Pin

Piston Support

Press Pin

Stop Screw

Nut

(1) Remove the stop screw from the base.

(2)

Select the correct piston support for your application. (See

above) Fit the piston support onto the base. Place the base

on the press support blocks.

(3)

Insert

the press pin through the piston pin hole. Select the

correct connecting rod guide pin. (See above.) Thread the

guide pin onto the threaded portion of the press pin.

(4) Position the piston assembly on the piston support in the

press. With the press pin up as shown in the illustration,

insert the guide pin through the hole in the piston and

through the hole in the piston support.

(5) Press the piston pin out of the assembly.

IMPORTANT: To avoid piston damage,

The piston support must seat squarely against the

piston.

Verify that the piston pin will slide through the hole

in the piston support.

(6) Remove the piston pin from the piston pin.

IIE-110

6G7

ENGINE

Piston and Connecting Rod

\r/

5EN0066

Push in by piston

Piston ring’

ring gap

INSPECTION

PISTON

(1) Replace the piston if scratches or seizure is evident on its

surfaces (especially the thrust surface). Replace the piston

if it is cracked.

PISTON PIN

(1)

Insert

the piston pin into the piston pin hole with a thumb.

You should feel a slight resistance. Replace the piston pin if

it can be easily inserted or there is an excessive play.

(2) The piston and piston pin must be replaced as an assembly.

PISTON RING

(1) Check the piston ring for damage, excessive wear, and

breakage and replace if defects are evident. If the piston

has been replaced with a new one, the piston rings must

also be replaced with new ones.

(2) Check for clearance between the piston ring and ring

groove. If the limit is exceeded, replace the ring or piston, or

both.

Standard value:

No. 1

DIAMANTE and

3000GT

0.03

0.07 mm

(.0012

.0026

in.)

MONTERO and TRUCK

0.05

0.09 mm

(.0020

.0035

in.)

No. 2

0.02

0.06 mm

(.OOOS

.0024

in.)

Limit: 0.1 mm

(.004

in.)

(3) Insert the piston ring into the cylinder bore. Force the ring

down with a piston, the piston crown being in contact with

the ring, to correctly position it at right angles to the cylinder

wall. Then, measure the end gap with a feeler gauge.

If the ring gap is excessive, replace the piston ring.

Standard value:

No. 1

0.30

0.45 mm

(.0118

.0177

in.)

No. 2

DIAMANTE and

3000GT

0.45

0.60 mm

(.0177

.0236

in.)

MONTERO and TRUCK

0.25

0.45 mm

(.0098

.0177

in.)

Oil

DIAMANTE and

3000GT

0.20

0.60 mm

(.0079

.0236

in.)

MONTERO and TRUCK

0.20

0.70

(.0079

.0276

in.)

Limit:

No. 1, No. 2

0.8 mm

(.031

in.)

Oil

1.0 mm

(.039

in.)

TSB Revision

6G7

ENGINE

Piston and

Connecting

Rod

EN0271

Base

Press Pin

Piston

SUPPOrt

scrkw

Pin depth set

7EN042C

CRANKSHAFT PIN OIL CLEARANCE

(PLASTIC GAUGE

METHOD)

The crankshaft oil clearance can be measured easily by using a

plastic gauge, as follows:

(1)

Remove oil and grease and any other foreign matters from

the crankshaft pin and the bearing inner surface.

(2) Install the crankshaft.

(3)

Cut the plastic gauge to the same length as the width of the

bearing and place it on the pin in parallel with its axis.

(4) Gently place the crankshaft bearing cap over it and tighten

the bolts to the specified torque.

(5)

Remove the bolts and gently remove the crankshaft bearing

cap.

(6) Measure the width of the smashed plastic gauge at its

widest section by using a scale printed on the plastic gauge

bag.

Standard value: 0.02

0.05 mm

(.OOOS

.0020

in.)

Limit: 0.1 mm

(.004

in.)

INSTALLATION SERVICE POINTS

+A4

PISTON PIN INSTALLATION

(1)

Thread the stop screw and lock nut assembly into the base.

Fit the correct piston support on the top of the base.

Inset-t

the press pin, threaded end up, into the hole in the piston

support until the press pin touches the stop screw.

(2) Using the graduations on the press pin, adjust the stop

screw to the depth.

Depth: MONTERO and TRUCK 60 mm

DIAMANTE,

3000GT

62 mm

TSB

Revision

6G7

ENGINE

Piston and

Connectinn

Rod

7EN042E

6EN058

EN026E

(3) Place the base on the press support blocks.

(4) Slide the piston pin over the threaded end of the press pin,

and thread the correct guide pin up against it.

(5) Coat the piston pin with oil, and with the connecting rod

held in position, slide the guide pin through the piston and

connecting rod.

(6) Press the piston pin through

the.

connecting rod until the

guide pin contacts the stop screw.

(7) Remove the piston assembly from the base. Remove the

guide pin and press pin from the assembly.

IMPORTANT: Due to production tolerance variations, it

is necessary to visually inspect the piston pin depth

after installation to verify that the piston pin is

centered. Adjust if necessary.

#B4

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 the

position by finger. See illustration.

Use of a ring expander to expand the side rail end gap can

break the side rail, unlike other piston rings.

NOTE

Do not use any piston ring expander when installing the

side rail.

(3) Install the lower side rail in the same procedure as

described in step (2).

(4) Make sure that the side rails move smoothly in either

direction.

TSB

Revision

6G7

ENGINE

Piston and Connecting Rod

llE=IA3

7ENO452

7EN0369

Upper side

rail

No.1

and spacer gap

6EN0541

MONTERO and TRUCK

bc4

PISTON RING

NO.2

PISTON RING

NO.1

INSTALLATION

(1) Using a piston ring expander, fit

No.2

and then

No.1

piston

ring into position.

NOTE

1. Note the difference in shape between

No.1

and

No.2

piston rings.

Install piston rings

No.1

and

No.2

with their side having

marks facing up (on the piston crown side.)

+D4

PISTON AND CONNECTING ROD INSTALLATION

(1) Liberally coat the circumference of the piston, piston ring,

and oil ring with engine oil.

(2) Arrange the piston ring and oil ring gaps (side rail and

spacer) as shown in the illustration.

(3) Rotate the crankshaft so that the crank pin is on the center

of the cylinder bore.

(4) Use suitable thread protectors on the connecting rod bolts

before inserting the piston and connecting rod assembly

into the cylinder block.

Care must be taken not to nick the crank pin.

(5) Using a suitable piston ring compressor tool, install the

piston and connecting rod assembly into the cylinder block.

Caution

Install the piston with the front mark (arrow mark) on

the top of the piston directed towards the engine front

(timing belt side).

NOTE

For MONTERO and TRUCK, two types of pistons, one for

cylinders 1,

3 and 5

and the other for cylinders

2, 4

and

have been used.

Piston with

R: For cylinders 1, 3 and 5

Piston with

L: For cylinders 2, 4 and 6

IIE-114

6G7

ENGINE

Piston and Connectinn Rod

Notches

Cylinder No.

7EN045:

7EN0454

I)E4

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.

(2) Check if the thrust clearance in the connecting rod big end

is correct.

Standard value: 0.10

0.25 mm

(.0039

.0098

in.)

Limit: 0.4 mm

(.0157

in.)

TSB Revision

6G7

ENGINE

Crankshaft, Flywheel and Drive

Plate

1 l’E415

CRANKSHAFT, FLYWHEEL AND DRIVE PLATE

REMOVAL AND INSTALLATION

17 ftlbs.

14-

SOHC

ft.lbs.

DOHC

ftlbs.

Removal steps

Flywheel

2. Ball bearing

Adaptor plate

Drive

elate

For MIT

For

4WD

A/T

5. Crankshaft adaptor

6. Adaptor plate

7. Drive plate

For FWD

A/T

8. Rear plate

9. Bell housing cover

eF4

IO.

Oil seal case

ft.lbs.

48Nm

ft.lbs.

eE4

11. Crankshaft rear oil seal

eD4

12. Bearing cap stay

1992

models-Turbo

eC4

13. Bearing cap bolt

eC4

14. Bearing cap

+C4

15. Bearing cap bolt

+C4

16. Bearing

cap

1993

models-Turbo

*I34

17. Thrust

beanng

+B4

18. Thrust bearing

eB4

19. Crankshaft bearing (lower)

20. Crankshaft

#B4

21.

Thrust bearing

#B4

22. Thrust bearing A

eB4

23. Crankshaft bearing (upper)

24. Knock sensor

+A4

25. Knock sensor bracket

26. Cylinder block

7EN0514

TSB Revision

6G7

ENGINE

Crankshaft, Flywheel and Drive Plate

7ENOl41

INSPECTION

CRANKSHAFT

If the oil clearance exceeds the limit, replace the bearing, and

crankshaft if necessary.

(1) Measure the outside diameter of the journals and the inside

diameter of the crankshaft bearings. If the difference

between them (oil clearance) exceeds the limit, replace the

crankshaft bearing and, if necessary, crankshaft.

Standard value: 0.02

0.05 mm

(.0008

.0020

in.)

Limit: 0.1 mm

(.004

in.)

Caution

Do not attempt an undersize machining of the crank-

shaft with special

surface

treatment. This crankshaft

can be identified by its dull gray appearance.

CRANKSHAFT JOURNAL OIL CLEARANCE (PLASTIC

GAUGE METHOD)

The crankshaft oil clearance can be measured easily by using a

plastic gauge, as follows:

(1) Remove oil and grease and any other foreign matters from

the crankshaft journal and bearing inner surface.

(2) Install the crankshaft.

(3)

Cut the plastic gauge to the same length as the width of the

bearing and place it on the journal in parallel with its axis.

(4) Gently place the crankshaft bearing cap over it and tighten

the bolts to the specified torque.

(5)

Remove the bolts and gently remove the crankshaft bearing

cap.

(6) Measure the width of the smashed plastic gauge at its

widest section by using a scale printed on the plastic gauge

bag.

CRANKSHAFT REAR OIL SEAL

(1) Check the oil seal lip for wear and damage.

(2) Check rubber for deterioration or hardening.

(3) Check the oil seal case for cracks and damage.

TSB

Revision

6G7

ENGINE

Crankshaft, Flywheel and Drive Plate

INSPECTION

CYLINDER BLOCK

ll&-1-17

(I\

VisuaUy

check

for scratches, rust, and corrosion. Use

also

flaw detecting agent for the check. If defects are evident,

correct, or replace.

(2)

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

(.0020

in.)

Limit: 0.1 mm

(.0039

in.)

(3)

If the distortion is excessive, correct within the allowable

limit or replace.

Grinding limit: 0.2 mm

(.008

in.)

The total thickness of the stock allowed to be

removed from cylinder block and mating cylinder

head is 0.2 mm

(008

in.) at maximum.

Cylinder block height (when new): 210.5 mm (8.29 in.)

-Thrust

direction

7EN0462

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

defects are evident, correct (rebore to an oversize) or

replace.

(5) Using a cylinder gauge, measure the cylinder bore and

cylindricity. If worn badly, correct by boring the cylinders to

an oversize and replace pistons and piston rings. Measure

at the points shown in the illustration.

Standard value:

Cylinder I.D.: 91.10

91.13 mm (3.5866

3.5878

in.)

Cylindricity: 0.01

(.0004

in.)

BORING CYLINDER

(1)

Oversize pistons to be used should be determined on the

basis of the largest bore cylinder.

Piston size identification

NOTE

Size mark is stamped on the piston top.

(2) Measure the outside diameter of the piston to be used.

Measure it in the thrust direction as shown.

(3) Based on the measured piston O.D., calculate the boring

finish dimension.

Boring finish dimension

Piston O.D. + (clearance

between piston O.D. and cylinder)

0.02 mm

(.OOOS

in.)

(honing margin)

TSB Revision

IIE-118

6G7

ENGINE

Crankshaft, Flywheel and Drive Plate

(4)

Bore all cylinders to the calculated boring finish dimension.

Caution

To prevent distortion that may result from temperature

rise during honing, bore cylinders in the order of

No.2,

No.4,

No.6,

No.1,

No.3 and

No.5.

(5) Hone to the final finish dimension (piston O.D.

clearance

between piston 0-D. and cylinder).

(6) Check the clearance between the piston and cylinder.

Clearance between piston and cylinder:

0.01

0.04 mm

(-0004

.0016

in.)

NOTE

When boring cylinders, finish all of six cylinders to the same

oversize. Do not bore only one cylinder to an oversize.

INSTALLATION SERVICE POINTS

I)A4

DETONATION SENSOR BRACKET

INSTALLATION

(1) Check that the bracket is in intimate contact with the

cylinder block boss and tighten to specified torque in the

order shown.

TSB Revision

6G7

ENGINE

Crankshaft, Flywheel and Drive Plate

IfE-m

I)B4

CRANKSHAFT BEARING (UPPER)

THRUST BEARING A

THRUST BEARING

CRANKSHAFT BEARING (LOWER) INSTALLATION

(1)

Classify the crankshaft bearings (upper and

lower)

whether there is an oil groove or not. Then, assemble as

shown in the illustration.

(2) Assemble the thrust bearings (A and B) on the

No.3

journal

area as shown.

Caution

Install them with the groove side facing outward.

7EN0463

TSB

Revision

Oil groove

Crankshaft

bearing (upper)

No oil groove

Timing belt side

IIE-120

6G7

ENGINE

Crankshaft, Flywheel and Drive Plate

I)c4

BEARING CAP

BEARING BOLT INSTALLATION

(1) Attach the bearing cap on the cylinder block as shown in the

illustration.

(2) Tighten the bearing cap bolts to the specified torque in the

sequence shown in the illustration.

(3) Check that the crankshaft rotates smoothly.

Cylinder

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

the thrust bearing.

Standard value

0.05

0.25 mm

(.0020

.0098

in.)

Limit: 0.3 mm

(.012

in.)

I)Dg

BEARING CAP STAY INSTALLATION

DOHC TURBO

(1)

Apply engine oil to the thread and bearing surface of each

bolt.

(2) Temporarily tighten the bolts on the cylinder block side.

(3) Tighten the bolts on the bearing cap side to the specified

(4)

Frr%;:

tighten the bolts on the cylinder block side to the

specified torque.

NOTE

The bearing cap stays A and

differ in shape. Install correct

ones on correct sides.

TSB Revision

6G7

ENGINE

Crankshaft, Flywheel and Drive Plate

IIE-121

7EN046!

7EN0466

8990938-01

MD99871

8-01

Sealing agent

7EN0467

-I

I)E4

CRANKSHAFT REAR OIL SEAL INSTALLATION

(1)

Using the special tool, press-fit a new crankshaft rear oil

seal into the oil seal case.

I)F4

OIL SEAL CASE INSTALLATION

(1)

Apply specified sealant to the area shown in the illustration.

Specified sealant:

MITSUBISHI GENUINE Part No. MD970389 or

equivalent

(2) Apply a small amount of engine oil to the entire circuinfer-

ence of the oil seal lip section, and place the oil seal on the

cylinder block.

TSB Revision

llE-122

BRACKET

6G7

ENGINE

Bracket

REMOVAL AND INSTALLATION

DIAMANTE

and

3000GT

42Nm

ft.lbs.

Removal steps

1. Engine support bracket, right

2. Engine support bracket, left

7EN0521

REMOVAL AND INSTALLATION

MONTERO and TRUCK

ft.lbs.

Removal steps

Roll stopper bracket, front

2. Roll stopper bracket, rear

TSB Revision

ft.lbs.