Specifications

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GENERAL INFORMATION 11B-0-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. SPECIFICATIONS 11B-1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE SPECIFICATIONS 11B-1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REWORK DIMENSIONS 11B-1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TORQUE SPECIFICATIONS 11B-1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SEALANTS 11B-1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FORM-IN-PLACE GASKET 11B-1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. SPECIAL TOOLS 11B-2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. ALTERNATOR 11B-3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. CONTROL AND EGR SYSTEM 11B-4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. INTAKE AND IGNITION SYSTEM 11B-5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. TIMING BELT 11B-6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.WATER PIPE AND WATER HOSE 11B-7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. FUEL SYSTEM 11B-8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9. EXHAUST MANIFOLD 11B-9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10. ROCKER ARMS AND CAMSHAFT 11B-10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11. ROCKER ARMS AND CAMSHAFT <GDI> 11B-11-1. . . . . . . . . . . . . . . . . . . . .

12. CYLINDER HEAD AND VALVES 11B-12-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13. OIL PAN AND OIL PUMP 11B-13-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14. PISTON AND CONNECTING ROD 11B-14-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15. CRANKSHAFT, FLYWHEEL AND DRIVE PLATE 11B-15-1. . . . . . . . . . . . . .

11B-0-1

PWEE9520

Nov. 1995Mitsubishi Motors Corporation

ENGINE

6G7 SERIES

CONTENTS

PWEE9061-I

Aug. 2001Mitsubishi Motors Corporation Added

Summary of content (140 pages)

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1B-0-1 ENGINE 6G7 SERIES CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B-0-3 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B-1-1 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B-1-1 REWORK DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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11B-0-2 NOTES E Mitsubishi Motors Corporation Nov. Aug.
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6G7 ENGINE – General Information 11B-0-3 GENERAL INFORMATION 6G72 Descriptions 6G72 12-valve 6G72 24-valve Type 60_ OHV, SOHC 60_ OHV, DOHC Number of cylinders 6 6 Combustion chamber Compact type Pentroof type Total displacement dm3 2,972 2,972 Cylinder bore mm 91.1 91.1 Piston stroke mm 76.0 76.0 Compression ratio 8.9 9.
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11B-0-4 6G7 ENGINE – General Information 6G74 Descriptions 6G74 24-valve 6G74 24-valve-GDI Type 60_ OHV, SOHC 60_ OHV, DOHC Number of cylinders 6 6 Combustion chamber Pentroof type Pentroof+curved top piston type Total displacement dm3 3,497 3,497 Cylinder bore mm 93.0 93.0 Piston stroke mm 85.8 85.8 Compression ratio 9.0 10.
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6G7 ENGINE – General Information 11B-0-5 6G75 Descriptions 6G75 24-valve Type 60_ OHV, SOHC Number of cylinders 6 Combustion chamber Pentroof type Total displacement dm3 3,828 Cylinder bore mm 95.0 Piston stroke mm 90.0 Compression ratio 9.5*1, 10.
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11B-1-1 6G7 ENGINE – Specifications 1. SPECIFICATIONS SERVICE SPECIFICATIONS Item Standard Limit Except PAJERO (V63W, V65W, V67W, V73W, V75W, V77W) 3.8–4.5 – PAJERO (V63W, V65W, V67W, V73W, V75W, V77W) 4.8–5.5 – Auto-tensioner rod projection length mm 12 – Auto-tensioner rod pushed-in amount (when pushed with a force of 98–196N) mm 1.0 or less – 12-valve 41.25 40.75 24-valve Timing belt Auto-tensioner rod length mm Rocker arms and camshaft Camshaft cam height mm Intake 37.58*1, 37.
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11B-1-2 6G7 ENGINE – Specifications Item Standard Limit Intake 0.03–0.06 0.10 Exhaust 0.05–0.09 0.15 Intake 0.02–0.05 0.10 Exhaust 0.04–0.06 0.15 Intake 0.02–0.05 0.10 Exhaust 0.04–0.07 0.15 43.5_–44_ – 12-valve 49.8 48.8 24-valve 51.0 50.0 GDI 47.2 46.2 12-valve 323/40.4 – 24-valve 216/44.2 – GDI 230/37.9 – Valve spring out of squareness 2_ or less 4_ Valve seat contact width mm 0.9–1.3 – 12-valve, GDI 6.6 – 24-valve 6.0 – 14.0 – 12-valve 41.65 42.
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11B-1-3 6G7 ENGINE – Specifications Item Standard Limit 0.25–0.35*1 0.8 0.30–0.45*2 0.8 0.25–0.40*3 0.8 0.30–0.45*4 0.8 6G75 0.25–0.40 0.8 6G72 0.35–0.50*1 0.8 0.45–0.60*2 0.8 0.35–0.50*3 0.8 0.45–0.60*4 0.8 6G75 0.35–0.50 0.8 6G72 (For Hong Kong), 6G74, 6G75 0.10–0.35 1.0 6G72 (Except for Hong Kong) 0.20–0.60 1.0 Piston pin O.D. mm 22.0 – Piston pin press-in load (at room temperature) N 7,350–17,200 – Crankshaft pin oil clearance mm 0.02–0.05 0.
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11B-1-4 6G7 ENGINE – Specifications REWORK DIMENSIONS Item Standard Limit 0.05 O.S. 13.05–13.07 – 0.25 O.S. 13.25–13.27 – 0.50 O.S. 13.50–13.52 – 0.05 O.S. 11.05–11.07 – 0.25 O.S. 11.25–11.27 – 0.50 O.S. 11.50–11.52 – 0.05 O.S. 12.05–12.07 – 0.25 O.S. 12.25–12.27 – 0.50 O.S. 12.50–12.52 – 0.3 O.S. 44.30–44.33 – 0.6 O.S. 44.60–44.63 – 0.3 O.S. 38.30–38.33 – 0.6 O.S. 38.60–38.63 – 0.3 O.S. 34.30–34.33 – 0.6 O.S. 34.60–34.63 – 0.3 O.S. 31.80–31.83 – 0.6 O.S.
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11B-1-5 6G7 ENGINE – Specifications TORQUE SPECIFICATIONS Item Nm Alternator Accessory mount bolt (M10 x 1.25) 44"10 Accessory mount bolt (M10 x 1.
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B-1-6 6G7 ENGINE – Specifications Item Nm EGR pipe flare nut 18"2 Vacuum pipe and hose bolt 10"2 Vacuum pipe and hose bolt 10"2 Solenoid valve bolt 9"1 Intake and ignition system Air intake fitting bolt 18"2 Air intake plenum bolt, nut 18"2 Air intake plenum bolt (M6) <6G75> 9"1 Air intake plenum bolt (M8) <6G75> 18"2 Air intake plenum nut 9"1 Air intake plenum stay bolt (M8) 18"2 Air intake plenum stay bolt (M10) 36"6 Boost sensor bolt 5"1 Bracket bolt 24"3 Cen
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11B-1-7 6G7 ENGINE – Specifications Item Nm Timing belt cover bolt (M6) 11"1 Timing belt cover bolt (M8) 14"1 Timing belt cover nut 5"1 Timing belt tensioner bolt 26"3 Water pipe and water hose Engine coolant temperature gauge unit 10.8"1.
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11B-1-8 6G7 ENGINE – Specifications Item Nm Exhaust manifold bolt <24-valve> 44"5 Exhaust manifold bolt 49"5 Heat protector bolt 14"1 Water inlet fitting bolt 12"1 Water pump bolt 24"3 Rocker arms and camshaft Distributor adaptor bolt 14"1 Rocker arms, rocker arm shaft bolt <12-valve> 20"1 Rocker arms, rocker arm shaft bolt <24-valve> 31"3 Rocker cover bolt <12-valve> 9"1 Rocker cover bolt <24-valve> 3.5"0.
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11B-1-9 6G7 ENGINE – Specifications Item Nm Pistons and connecting rod Connecting rod cap nut <12-valve> 51"1 Connecting rod cap bolt <24-valve> 34"2+90_ Crankshaft, flywheel and drive plate Bearing cap bolt <12-valve> 93"4 Bearing cap bolt <24-valve> 74"4 Bell housing cover bolt 11"2 Detonation sensor bracket bolt 28"2 Drive plate bolt 74"2 Flywheel bolt 74"2 Knock sensor 23"2 Knock sensor bracket bolt 28"2 Oil seal case bolt 11"2 Rear plate bolt 11"2 SEALANTS Item Specified sea
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11B-1-10 6G7 ENGINE – Specifications FORM-IN-PLACE GASKET The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the fluid feed line.
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6G7 ENGINE – Special Tools 11B-2-1 2.
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11B-2-2 Tool E Mitsubishi Motors Corporation 6G7 ENGINE – Special Tools Number Name Use MD998717 Crankshaft front oil seal Installation of crankshaft front oil seal installer MD998718 Crankshaft rear oil seal installer Press fitting crankshaft rear oil seal MD998727 Oil pan remover Removal of oil pan MD998729 Valve stem seal installer Installation of valve stem seal <6G72 12-valve> MD998735 Valve spring compressor Compressing the valve springs MD998761 Camshaft oil seal installer Insta
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6G7 ENGINE – Special Tools Tool E Mitsubishi Motors Corporation 11B-2-3 Number Name Use MD998769 Crank pulley spacer Cranking the crankshaft to install timing belt MD998772 Valve spring compressor Compressing of the valve springs MB991999 Valve stem seal installer Installation of valve stem seal MD998780 Piston pin setting tool Removal and installation of piston pin MD998781 Flywheel stopper Holding flywheel or drive plate Nov. 1995 Feb.
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11B-3-1 6G7 ENGINE – Alternator 3. ALTERNATOR <12-VALVE> 17 14 ± 1 Nm 9 ± 1 Nm 18 13 19 13 ± 2 Nm 12 23 ± 2 Nm 11 24 ± 3 Nm 19 ± 3 Nm 10 ± 2 Nm 7 9 8 44 ± 10 Nm 42 ± 8 Nm 10 6 5 24 ± 3 Nm 44 ± 10 Nm 16 14 185 ± 5 Nm 4 3 15 42 ± 8 Nm 11 ± 1 Nm 75 ± 10 Nm 11 ± 1 Nm 2 1 Removal steps 1. Drive belt 2. Cooling fan 3. Fan clutch 4. Cooling fan pulley 5. Idler pulley 6. Tensioner pulley 7. Adjusting bolt 8. Adjusting stud 9. Tensioner bracket 10.
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11B-3-2 6G7 ENGINE – Alternator REMOVAL AND INSTALLATION <24-VALVE FOR PAJERO (V33V), CHALLENGER, L200> 10 11 22 ± 4 Nm 12 24 ± 4 Nm 9 49 ± 9 Nm 49 ± 5 Nm 14 13 8 17 ± 2 Nm 44 ± 10 Nm 7 23 ± 3 Nm 41 ± 8 Nm 4 11 ± 1 Nm 44 ± 10 Nm 16 15 6 5 49 ± 10 Nm 3 11 ± 1 Nm 11 ± 1 Nm 1 2 19 17 18 185 ± 5 Nm Removal steps 1. Cooling fan 2. Fan clutch 3. Drive belt 4. Cooling fan pulley 5. Cooling fan bracket 6. Drive belt tensioner pulley 7. Timing indicator 8. Alternator 9.
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11B-3-3 6G7 ENGINE – Alternator REMOVAL AND INSTALLATION <24-VALVE FOR PAJERO (V63W, V65W, V67W, V73W, V75W, V77W), GDI> 9 44 ± 10 Nm 24 ± 4 Nm 49 ± 9 Nm 49 ± 5 Nm 6 9 24 ± 4 Nm 11 8 7 12 44 ± 10 Nm 23 ± 3 Nm 74 ± 9 Nm 24 ± 4 Nm 44 ± 10 Nm 41 ± 8 Nm 44 ± 10 Nm 4 44 ± 10 Nm 15 13 5 14 41 ± 8 Nm 185 ± 5 Nm 3 11 ± 1 Nm 10 11 ± 1 Nm 2 1 Removal steps 1. Cooling fan 2. Fan clutch 3. Cooling fan pulley 4. Cooling fan bracket 5. Idler pulley 6. Idler pulley 7. Auto tensioner 8.
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11B-3-4 6G7 ENGINE – Alternator REMOVAL SERVICE POINTS AA" CRANKSHAFT BOLT REMOVAL With the Special Tool fixed to the drive plate or flywheel, remove the crankshaft bolt. 7EN0491 Crankshaft bolt INSTALLATION SERVICE POINTS Damper pulley Washer Inside chamfered side Crankshaft Clean Degrease "AA CRANKSHAFT BOLT / WASHER / CRANKSHAFT PULLEY INSTALLATION 1. Clean the bolt hole in crankshaft bolt and damper pulley’s seating surface. 2. Degrease the cleaned seating surface of the damper pulley. 3.
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11B-4-1 6G7 ENGINE – Control and EGR System 4. CONTROL AND EGR SYSTEM REMOVAL AND INSTALLATION <12-VALVE> 10 ± 2 Nm 2 3 1 5 4 22 ± 4 Nm 7 6 18 ± 2 Nm 7 Removal steps 1. Breather hose 2. Vacuum pipe 3. Vacuum pipe and hose 4. EGR valve 5. EGR valve gasket 6. EGR pipe 7. EGR pipe gasket E Mitsubishi Motors Corporation Apr.
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11B-4-2 6G7 ENGINE – Control and EGR System REMOVAL AND INSTALLATION <24-VALVE WITH VACUUM CONTROL VALVE (PAJERO-6G72)> 11 ± 1 Nm 9 ± 1 Nm 9 11 ± 1 Nm 9 ± 1 Nm 10 5 21 ± 4 Nm 9 11 7 12 8 11 ± 1 Nm 6 2 11 ± 1 Nm 4 3 14 1 59 ± 5 Nm Removal steps 1. PCV hose 2. Breather hose 3. Blow-by hose 4. Vacuum hose 5. Hose 6. Vacuum pipe and hose 7. Vacuum pipe and hose E Mitsubishi Motors Corporation Feb. 2004 18 ± 2 Nm 13 8. 9. 10. 11. 12. 13. 14.
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6G7 ENGINE – Control and EGR System 11B-4-3 REMOVAL AND INSTALLATION <24-VALVE WITH VACUUM CONTROL VALVE (PAJERO-6G74)> 9 ± 1 Nm 21 ± 4 Nm 9 6 10 7 11 ± 1 Nm 8 11 ± 1 Nm 5 11 ± 1 Nm 4 2 3 12 1 18 ± 2 Nm 59 ± 5 Nm Removal steps 1. PCV hose 2. Breather hose 3. Blow-by hose 4. Vacuum hose 5. Vacuum pipe and hose 6. Solenoid valve E Mitsubishi Motors Corporation Feb. 2004 11 7. 8. 9. 10. 11. 12.
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11B-4-4 6G7 ENGINE – Control and EGR System REMOVAL AND INSTALLATION <24-VALVE WITH VACUUM CONTROL VALVE (CHALLENGER)> 9 ± 1 Nm 21 ± 4 Nm 11 12 8 6 7 5 11 ± 1 Nm 9 11 ± 1 Nm 10 11 ± 1 Nm 2 3 4 14 1 59 ± 5 Nm Removal steps 1. PCV hose 2. Breather hose 3. Blow-by hose 4. Vacuum hose 5. Hose 6. Vacuum pipe and hose 7. Vacuum pipe and hose E Mitsubishi Motors Corporation Feb. 2004 18 ± 2 Nm 13 8. 9. 10. 11. 12. 13. 14.
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11B-4-4a 6G7 ENGINE – Control and EGR System REMOVAL AND INSTALLATION <24-VALVE WITHOUT VACUUM CONTROL VALVE (6G75)> 9 ± 1 Nm 9 10 4 12 24 ± 3 Nm (For Taiwan) 21 ± 4 Nm (Except for Taiwan) 11 3 14 18 ± 2 Nm 9 ± 1 Nm 2 8 13 6 59 ± 10 Nm 9 ± 1 Nm 5 9 ± 1 Nm 7 1 Removal steps 1. PCV hose A 2. PCV hose B 3. Blow-by hose 4. Breather and water hose assembly 5. Fuel return pipe 6. Vacuum pipe and hose assembly 7. Vacuum hose E Mitsubishi Motors Corporation Apr. 2003 PWEE9061-K 8. 9. 10. 11. 12.
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11B-4-5 6G7 ENGINE – Control and EGR System REMOVAL AND INSTALLATION <24-VALVE WITHOUT VACUUM CONTROL VALVE (6G72 and 6G74)> 9 ± 1 Nm 4 10 ± 2 Nm 10 9 ± 1 Nm 21 ± 4 Nm 6 11 12 11 ± 1 Nm 11 ± 1 Nm 2 3 11 ± 1 Nm 5 7 9 8 11 ± 1 Nm 11 ± 1 Nm 14 18 ± 2 Nm 1 13 59 ± 5 Nm Removal steps 1. PCV hose 2. Breather hose 3. Blow-by hose 4. Vacuum pipe and hose 5. Vacuum pipe and hose 6.
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11B-4-6 6G7 ENGINE – Control and EGR System REMOVAL AND INSTALLATION <24-VALVE WITHOUT VACUUM CONTROL VALVE (6G75)> 9 ± 1 Nm 11 12 4 13 14 24 ± 3 Nm (For Taiwan) 21 ± 4 Nm (Except for Taiwan) 3 16 18 ± 2 Nm 9 ± 1 Nm 2 10 15 6 59 ± 10 Nm 9 8 5 9 ± 1 Nm 9 ± 1 Nm 7 1 Removal steps 1. PCV hose A 2. PCV hose B 3. Blow-by hose 4. Breather and water hose assembly 5. Fuel return pipe 6. Vacuum pipe and hose assembly 7. Vacuum hose 8. Vacuum hose E Mitsubishi Motors Corporation Feb.
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11B-4-7 6G7 ENGINE – Control and EGR System REMOVAL AND INSTALLATION 5 2 4 6 11 ± 1 Nm 8 5 ± 1 Nm 1 11 3 13 14 ± 1 Nm 9 ± 1 Nm 10 7 9 11 ± 1 Nm 17 18 ± 2 Nm 14 15 16 59 ± 10 Nm 22 ± 4 Nm 12 Removal steps 1. PCV hose A 2. PCV hose B 3. PCV hose C 4. Breather hose 5. Blow-by hose 6. PCV pipe 7. Purge hose 8. Vacuum pipe and hose 9. Solenoid valve E Mitsubishi Motors Corporation Feb. 2004 10. 11. 12. 13. 14. 15. 16. 17.
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6G7 ENGINE – Intake and Ignition System 11B-5-1 5. INTAKE AND IGNITION SYSTEM REMOVAL AND INSTALLATION <12-VALVE> 25 ± 5 Nm 5 1 24 ± 5 Nm 12 ± 1 Nm 2 6 3 14 ± 1 Nm 18 ± 2 Nm 9 4 18 ± 2 Nm 10 18 ± 2 Nm 8 7 11 18 ± 2 Nm 12 13 Removal steps 1. Spark plug cable 2. High tension cable 3. Ignition coil assembly 4. Stay B 5. Spark plug 6. Distributor 7. Air intake plenum stay, front E Mitsubishi Motors Corporation Apr. 2003 8. 9. "BA 10. 11. 12. 13.
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11B-5-2 6G7 ENGINE – Intake and Ignition System REMOVAL AND INSTALLATION <24-VALVE FOR PAJERO (6G72 and 6G74), CHALLENGER, L200 (From 2004 model)> 18 ± 2 Nm 5 ± 1 Nm 5 ± 1 Nm 4 3 12 ± 1 Nm 7 18 ± 2 Nm 8 9 14 ± 1 Nm 6 11 ± 1 Nm 10 1 25 ± 5 Nm 14 2 18 ± 2 Nm 11 13 12 5 18 ± 2 Nm 36 ± 6 Nm Removal steps 1. Ignition coil assembly 2. Ignition power transistor "CA 3. MDP sensor "CA 4. Boost sensor 5. Air intake plenum stay 6. Water outlet fitting bracket 7.
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11B-5-3 6G7 ENGINE – Intake and Ignition System REMOVAL AND INSTALLATION <24-VALVE FOR L200 (Up to 2003 model)> 18 ± 2 Nm 13 ± 2 Nm 11 ± 1 Nm 12 ± 1 Nm 6 7 14 ± 1 Nm 2 8 3 9 4 24 ± 3 Nm 5 18 ± 2 Nm 10 11 12 25 ± 5 Nm 1 18 ± 2 Nm 36 ± 6 Nm Removal steps 1. Air intake plenum stay 2. Ignition coil assembly 3. Water outlet fitting bracket 4. Power transistor 5. Bracket 6. Accel cable bracket E Mitsubishi Motors Corporation Apr. 2003 7. "BA 8. 9. 10. 11. 12.
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11B-5-4 6G7 ENGINE – Intake and Ignition System REMOVAL AND INSTALLATION 3.0 ± 0.5 Nm 8 3.0 ± 0.5 Nm 7 10 ± 2 Nm 12 ± 1 Nm 9 4 3 6 5 ± 1 Nm 5 11 10 ± 2 Nm 9 22 ± 1 Nm 18 ± 2 Nm 10 25 ± 5 Nm 12 14 ± 1 Nm 14 13 2 14 1 17 ± 2 Nm Removal steps 1. Engine hanger 2. Water outlet fitting bracket 3. Throttle body stay 4. Throttle body "BA 5. Throttle body gasket 6. Center cover, left 7. Center cover, right E Mitsubishi Motors Corporation Nov. Aug. 1995 2001 8. 9. 10. 11. 12. "AA 13.
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11B-5-4a 6G7 ENGINE – Intake and Ignition System REMOVAL AND INSTALLATION <24-VALVE (6G75)> 12 ± 1 Nm 5 ± 1 Nm 18 ± 2 Nm 1 5 4 6 9 ± 1 Nm 18 ± 2 Nm 2 10 ± 2 Nm 8 7 36 ± 6 Nm 14 ± 1 Nm 3 11 13 9 12 25 ± 5 Nm 10 Removal steps 1. Boost sensor (For Taiwan) 2. Air intake plenum stay 3. Water outlet fitting bracket 4. Throttle body "BA 5. Throttle body gasket 6. Air intake plenum 7. ICV primary gasket E Mitsubishi Motors Corporation Apr. 2003 8. 9. 10. 11. 12. 13.
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6G7 ENGINE – Intake and Ignition System 11B-5-5 INSTALLATION SERVICE POINTS R "AA INTAKE MANIFOLD INSTALLATION Tighten the intake manifold mounting nuts in the following order. 1. Tighten nut (L) on the left bank side to 7 Nm. 2. Tighten nut (R) on the right bank side to the specified torque. 3. Tighten (L) to the specified torque. 4. Tighten (R) to the specified torque. 5. Tighten (L) to the specified torque.
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6G7 ENGINE – Timing Belt 11B-6-1 6. TIMING BELT REMOVAL AND INSTALLATION <12-VALVE> 25 ± 4 Nm 10 13 12 25 ± 4 Nm 88 ± 10 Nm 9 5 1 11 6 11 ± 1 Nm 4 26 ± 3 Nm 8 7 11 ± 1 Nm 2 3 Removal steps 1. Timing belt front upper cover, right 2. Timing belt front upper cover, left 3. Timing belt front lower cover AA" "HA 4. Timing belt 5. Timing belt tensioner 6. Tensioner spring "FA 7. Front flange E Mitsubishi Motors Corporation Nov. Aug. 1995 2001 "FA 8. Crankshaft sprocket AD" "AA 9.
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11B-6-2 6G7 ENGINE – Timing Belt REMOVAL AND INSTALLATION <24-VALVE FOR PAJERO (V33V), CHALLENGER, L200> 88 ± 10 Nm 14 ± 1 Nm 18 20 17 5 8 11 ± 1 Nm 23 ± 3 Nm 1 10 11 2 44 ± 10 Nm 13 12 15 9 44 ± 5 Nm 14 16 48 ± 6 Nm 14 ± 1 Nm 7 3 5 ± 1 Nm 6 8.5 ± 0.5 Nm 4 19 Removal steps 1. Timing belt cover cap 2. Timing belt front upper cover, right 3. Timing belt front upper cover, left 4. Timing belt front lower cover AA" "IA 5. Timing belt 6. Crankshaft position sensor 7.
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11B-6-3 6G7 ENGINE – Timing Belt REMOVAL AND INSTALLATION <24-VALVE FOR PAJERO (V63W, V65W, V67W, V73W, V75W, V77W)> 11 ± 1 Nm 11 ± 1 Nm 1 14 ± 1 Nm 14 2 15 14 ± 1 Nm 16 11 ± 1 Nm 88 ± 10 Nm 3 22 ± 4 Nm 19 18 4 17 6 5 8 9 23 ± 3 Nm 44 ± 10 Nm 48 ± 6 Nm 12 7 11 13 Removal steps 1. Timing belt front upper cover, right 2. Timing belt front upper cover, left 3. Timing belt front lower cover AA" "IA 4. Timing belt 5. Crankshaft position sensor "GA 6. Auto tensioner 7. Tensioner pulley 8.
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11B-6-4 6G7 ENGINE – Timing Belt REMOVAL AND INSTALLATION 11 ± 1 Nm 14 ± 1 Nm 2 11 ± 1 Nm 14 22 ± 4 Nm 1 11 ± 1 Nm 16 3 88 ± 10 Nm 19 15 11 ± 1 Nm 4 18 17 11 ± 1 Nm 6 9 44 ± 10 Nm 8 5 23 ± 3 Nm 12 13 7 11 10 20 44 ± 5 Nm 11 ± 1 Nm 48 ± 6 Nm Removal steps 1. Timing belt front upper cover, right 2. Timing belt front upper cover, left 3. Timing belt front lower cover AB" "JA 4. Timing belt 5. Crankshaft position sensor "GA 6. Auto tensioner 7. Tensioner pulley 8. Tensioner arm 9.
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6G7 ENGINE – Timing Belt 11B-6-5 REMOVAL SERVICE POINTS AA" TIMING BELT REMOVAL When the timing belt is to be reused, in order to allow re-installation of the belt so that it travels in the same direction as before it was removed, mark the direction of travel with an arrow before removing it. 7EN0145 Caution (1) As water or oil on the belt can seriously reduce its usable life, ensure that the timing belt, sprocket, and tensioner stay clean and dry while removed, and never wash them.
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11B-6-6 6G7 ENGINE – Timing Belt MD998715 AD" CAMSHAFT SPROCKET BOLT REMOVAL 1. Using the Special Tool, hold the camshaft sprocket. 2. Remove the camshaft sprocket bolt. MB990767 7EN0005 MB990767 MD998715 INSTALLATION SERVICE POINTS MD998715 MB990767 "AA CAMSHAFT SPROCKET BOLT INSTALLATION 1. Using the Special Tool, hold the camshaft sprocket. 2. Torque the camshaft sprocket bolt to the specified torque. 7EN0005 MB990767 "BA CAMSHAFT SPROCKET BOLT INSTALLATION 1.
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6G7 ENGINE – Timing Belt 11B-6-7 "DA CAM POSITION SENSOR SUPPORT INSTALLATION Apply a 3 mm bead of form-in-place gasket (FIPG) to the area shown. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent Crankshaft sprocket Crankshaft sensing blade Crankshaft spacer Crankshaft Degrease Oil pump casing Clean "EA CRANKSHAFT SPROCKET / CRANKSHAFT SENSING BLADE / CRANKSHAFT SPACER INSTALLATION 1. Wipe clean the crankshaft fitting surface of the crankshaft sprocket. 2.
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11B-6-8 6G7 ENGINE – Timing Belt "HA TIMING BELT INSTALLATION 1. Align the timing marks of the camshaft sprockets and the crankshaft sprocket. 2. First, route the timing belt on the crankshaft sprocket, then on the camshaft sprocket of the left bank side without slackness in the tension side. 3. Next, run the timing belt onto the water pump pulley, the camshaft sprocket on the right bank side, and the timing belt tensioner.
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6G7 ENGINE – Timing Belt Timing mark 11B-6-9 "IA TIMING BELT INSTALLATION 1. Turn the crankshaft sprocket to position its timing mark 3 teeth away from the timing mark on the crankcase. (That is, slightly lower the No. 1 piston from the top dead center on the compression stroke.) Caution If the camshaft sprocket is turned with the piston at the top dead center on the compression stroke, valves may interfere with the piston.
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11B-6-10 6G7 ENGINE – Timing Belt 6. While pressing the tensioner pulley lightly against the timing belt, temporarily tighten its center bolt. 7. Check that all timing marks are in alignment. Timing mark Crankshaft sprocket 7EN1567 Tensioner pulley 7EN0743 Tensioner pulley 7EN1568 8.
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11B-6-11 6G7 ENGINE – Timing Belt Timing mark Right bank Left bank Water pump pulley Crankshaft sprocket Camshaft sprocket Tensioner pulley Idler pulley Auto tensioner Camshaft sprocket Timing mark 7EN0745 Timing mark Left bank Right bank Water pump pulley Timing mark Camshaft sprocket Camshaft sprocket Tensioner pulley Idler pulley Auto tensioner Timing mark Camshaft sprocket 7EN1569 E Mitsubishi Motors Corpora
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11B-6-12 6G7 ENGINE – Timing Belt 9. Set the special tool and a torque wrench on the tensioner pulley. 10. Torque the tensioner pulley to 4.4 Nm. 11. While holding the tensioner pulley, tighten its center bolt to the specified torque. 12. Turn the crankshaft 2 turns clockwise and let it stand for approx. 5 minutes.
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6G7 ENGINE – Timing Belt Timing marks 11B-6-13 2. Align the timing mark of the camshaft sprocket on the left bank side. Timing marks 7EN1529 3. Align the timing marks of the camshaft sprockets on the right bank side. When the special tool is removed, the sprocket turns by itself, letting the timing mark to deviate. Make necessary corrections, therefore, in step 5. to align the timing mark before installing the belt.
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11B-6-14 6G7 ENGINE – Timing Belt Paper clip 6. Make sure that the timing mark of the exhaust camshaft sprocket on the right bank side is in alignment. Then install the timing belt over the sprocket and secure it with a paper clip. Caution If the old timing belt is to be reused, install it so that the arrow marked during removal procedures points in the turning direction. 7EN1531 Paper clip Paper clip 7. Check that the timing mark is aligned on the intake camshaft sprocket.
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11B-6-15 6G7 ENGINE – Timing Belt Water pump pulley Timing marks Timing marks Idler pulley Auto tensioner Tensioner pulley Timing marks Crankshaft sprocket 7EN1533 18. Loosen the center bolt of the tensioner pulley and install the special tool and torque wrench. Apply a torque of 4.4 Nm to prevent the tensioner pulley from turning together, tighten the center bolt to the specified torque. MD998767 7EN1534 19.
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11B-6-16 6G7 ENGINE – Timing Belt INSPECTION 1. TIMING BELT Check the belt in detail. If the following is evident, replace the belt. (1) Hardened back surface rubber. Back surface glossy, non-elastic and so hard that even if a finger nail is forced into it, no mark is produced. 8EN0066 Cracks Peeling (2) (3) (4) (5) Cracked Cracked Cracked Cracked back surface rubber. or separated canvas. tooth bottom. side of belt. Cracks Cracks 1EN0249 (6) Side of belt badly worn.
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6G7 ENGINE – Timing Belt 11B-6-17 (4) Press the rod by a force of 98 to 196 N and measure the rod stroke. If the measured value exceeds the standard value, replace the tensioner. 98 – 196 N Stroke Standard value: 1 mm or less 6EN1033 E Mitsubishi Motors Corporation Nov. Aug.
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11B-7-1 6G7 ENGINE – Water Pipe and Water Hose 7. WATER PIPE AND WATER HOSE REMOVAL AND INSTALLATION <12-VALVE> 2 19 ± 1 Nm 1 9 14 ± 1 Nm 4 12 ± 1 Nm 10.8 ± 1.0 Nm 10 7 5 11 12 8 ± 1 Nm 13 6 3 8 29 ± 10 Nm Removal steps 1. Water hose 2. Water hose 3. Water by-pass hose 4. Heat pipe 5. Heat pipe gasket "FA 6. Thermo switch "EA 7. Engine coolant temperature gauge unit E Mitsubishi Motors Corporation Nov. Aug. 1995 2001 "DA 8. 9. 10. 11. "AA 12. "AA 13.
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11B-7-2 6G7 ENGINE – Water Pipe and Water Hose REMOVAL AND INSTALLATION <24-VALVE FOR PAJERO (V33V), CHALLENGER, L200> 1 2 14 ± 1 Nm 10 10.8 ± 1.0 Nm 29 ± 10 Nm 8 ± 1 Nm 11 5 6 16 7 18 12 ± 1 Nm 10.8 ± 1.0 Nm 5 29 ± 10 Nm 14 ± 1 Nm 11 19 3 6 19 ± 1 Nm 8 17 9 4 13 12 15 14 19 ± 1 Nm 24 ± 4 Nm Removal steps 1. Water hose 2. Water hose 3. Water hose 4. Water hose "EA 5. Engine coolant temperature gauge unit "DA 6. Engine coolant temperature sensor "FA 7.
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11B-7-3 6G7 ENGINE – Water Pipe and Water Hose REMOVAL AND INSTALLATION <24-VALVE FOR PAJERO (V63W, V65W, V67W, V73W, V75W, V77W)> 14 ± 1 Nm 14 ± 1 Nm 1 2 14 ± 1 Nm 10.8 ± 1.0 Nm 20 5 10 10 17 29 ± 10 Nm 19 6 12 ± 1 Nm 9 19 ± 1 Nm 3 7 4 8 18 12 ± 1 Nm 15 9 ± 1 Nm 11 12 14 13 16 12 ± 1 Nm "EA "DA "CA "CA Removal steps 1. Water hose 2. Water hose 3. Water hose 4. Water hose 5. Engine coolant temperature gauge unit 6. Engine coolant temperature sensor 7. Water outlet fitting 8.
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11B-7-4 6G7 ENGINE – Water Pipe and Water Hose REMOVAL AND INSTALLATION 5 ± 1 Nm 5 ± 1 Nm 25 5 14 ± 1 Nm 14 ± 1 Nm 27 26 6 23 10.8 ± 1.0 Nm 14 ± 1 Nm 24 29 ± 10 Nm 7 1 3 2 6 21 12 ± 1 Nm 12 ± 1 Nm 9 ± 1 Nm 22 19 ± 1 Nm 4 10 8 12 9 13 11 14 19 16 15 12 ± 1 Nm 11 ± 1 Nm 19 ± 3 Nm 20 17 18 14 ± 1 Nm 19 ± 3 Nm "EA "DA "CA "CA "BA Removal steps 1. Engine coolant temperature gauge unit 2. Engine coolant temperature sensor 3. Water outlet fitting 4. Gasket 5.
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6G7 ENGINE – Water Pipe and Water Hose 11B-7-5 INSTALLATION SERVICE POINTS O-ring "AA O-RING / WATER PIPE INSTALLATION 1. Fit a new O-ring in the groove at the front end of the water pipe. 2. Coat the O-ring with water or soapsuds. Water pump Caution Never apply engine oil or any other grease to the O-ring. Water pipe 6EN0594 Jiggle valve 3. Insert the front end of the water pipe in the water pump. "BA THERMOSTAT INSTALLATION Install the thermostat so that the jiggle valve is on the top end.
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11B-7-6 6G7 ENGINE – Water Pipe and Water Hose "FA THERMO SWITCH INSTALLATION If the thermo switch is to be reused, apply the specified sealant to its threads. Specified sealant: 3M Nut Locking Part No. 4171 or equivalent E Mitsubishi Motors Corporation Nov. Aug.
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11B-8-1 6G7 ENGINE – Fuel System 8. FUEL SYSTEM REMOVAL AND INSTALLATION <12-VALVE> 12 ± 1 Nm 3 9 ± 2 Nm 9 1 4 7 8 6 5 18 ± 2 Nm 2 10 11 11 Removal steps 1. Injector and delivery pipe 2. Insulator "BA 3. Fuel pressure regulator 4. O-ring 5. Insulator 6. Injector E Mitsubishi Motors Corporation Nov. Aug. 1995 2001 7. 8. 9. "AA 10. 11.
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11B-8-2 6G7 ENGINE – Fuel System REMOVAL AND INSTALLATION <24-VALVE> 1 12 ± 1 Nm 9 ± 1 Nm 13 4 12 14 2 22 ± 1 Nm 6 5 3 9 ± 1 Nm 7 10 11 9 8 16 24 ± 3 Nm 17 15 Removal steps 1. Injector harness 2. Vacuum hose (6G75) 3. Fuel hose (6G75) 4. Injector and delivery pipe 5. Insulator "BA 6. Fuel pressure regulator 7. O-ring 8. Insulator 9. Injector 10. O-ring E Mitsubishi Motors Corporation Apr. 2003 11. 12. 13. 14. 15.
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11B-8-3 6G7 ENGINE – Fuel System REMOVAL AND INSTALLATION 19 ± 3 Nm 1 7 6 5 4 3 12 ± 1 Nm 2 24 ± 2 Nm 5→17 Nm 8 9 11 10 23 ± 2 Nm 26 16 22 23 24 13 15 27 14 17 25 18 21 12 20 19 ± 3 Nm 19 "HA "HA "HA "HA "HA "GA "GA "GA "FA "FA "FA Removal steps 1. Injector harness 2. Fuel feed pipe 3. Backup ring 4. O-ring 5. Backup ring 6. Fuel pump 7. O-ring 8. Flange 9. Fuel pressure sensor 10. O-ring 11. Backup ring 12. Fuel center pipe 13. Backup ring 14.
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11B-8-4 6G7 ENGINE – Fuel System INSTALLATION SERVICE POINTS "AA INTAKE MANIFOLD INSTALLATION 1. Tighten the nuts on the right bank to 7 ± 1 Nm. 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 bank again in that order.
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6G7 ENGINE – Fuel System 11B-8-5 4. Align the alignment mark on each injector with that on the delivery pipe. 5. Install the injector and delivery pipe into the cylinder head. 6. Tighten the bolt at the center of each delivery pipe to the specified torque. Then tighten bolts on both ends to the specified torque. Backup ring (no special orientation) Cut surface Backup ring (thicker one) 7EN1484 "FA BACKUP RING / O-RING / FUEL CENTER PIPE INSTALLATION 1.
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11B-8-6 6G7 ENGINE – Fuel System "HA FUEL PUMP / BACKUP RING / O-RING / FUEL FEED PIPE INSTALLATION 1. Apply engine oil to the roller of the fuel pump and O-ring. 1EN0651 2. Insert the fuel pump into the mounting hole in the cylinder head and lightly tighten the four bolts (slightly tighter than finger-tight). 7EN1488 Backup ring (no special orientation) Backup ring (thicker one) Cut surface 3. Fit the backup rings and O-ring to both ends of the fuel feed pipe.
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11B-9-1 6G7 ENGINE – Exhaust Manifold 9. EXHAUST MANIFOLD REMOVAL AND INSTALLATION <12-VALVE> 19 ± 3 Nm 5 14 ± 1 Nm 1 6 7 4 2 19 ± 3 Nm 14 ± 1 Nm 3 11 15 19 ± 3 Nm 24 ± 3 Nm 8 12 10 13 18 ± 2 Nm 14 12 ± 1 Nm Removal steps 1. Oil level gauge 2. OIl level gauge guide 3. O-ring 4. Heat protector, right 5. Engine hanger 6. Exhaust manifold, right "AA 7. Exhaust manifold gasket 8. Heat protector, left E Mitsubishi Motors Corporation Nov. 1995 Aug. 2001 9 9. 10. "AA 11. 12. 13. 14. 15.
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11B-9-2 6G7 ENGINE – Exhaust Manifold REMOVAL AND INSTALLATION <24-VALVE (6G72 and 6G74)> 4 14 ± 1 Nm 1 6 5 3 14 ± 1 Nm 2 44 ± 5 Nm 10 11 9 8 7 24 ± 3 Nm 44 ± 5 Nm 14 ± 1 Nm Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Heat protector, right 5. Exhaust manifold, right 6. Exhaust manifold gasket E Mitsubishi Motors Corporation Apr. 2003 7. 8. 9. 10. 11.
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11B-9-3 6G7 ENGINE – Exhaust Manifold REMOVAL AND INSTALLATION <24-VALVE (6G75), GDI> 14 ± 1 Nm 4 1 6 14 ± 1 Nm 2 5 3 14 ± 1 Nm 49 ± 5 Nm 44 ± 5 Nm <24-valve (6G75)> 10 7 11 9 8 49 ± 5 Nm 44 ± 5 Nm <24-valve (6G75)> 24 ± 3 Nm Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Heat protector, right 5. Exhaust manifold, right 6. Exhaust manifold gasket E Mitsubishi Motors Corporation Apr. 2003 7. 8. 9. 10. 11.
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11B-9-4 6G7 ENGINE – Exhaust Manifold INSTALLATION SERVICE POINTS For right bank Front 1 "AA EXHAUST MANIFOLD GASKET INSTALLATION Install gaskets with number 1, 3 and 5 embossed on their top side to the right bank and install those with number 2, 4 and 6 to the left bank. Cylinder No. 3 5 71N0010 Front For left bank Cylinder No. 7EN0593 E Mitsubishi Motors Corporation Nov. 1995 Aug.
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11B-10-1 6G7 ENGINE – Rocker Arms and Camshaft 10. ROCKER ARMS AND CAMSHAFT REMOVAL AND INSTALLATION <12-VALVE> 9 ± 1 Nm 20 ± 1 Nm 1 9 9 2 9 12 11 10 10 10 10 10 13 16 8 9 9 10 9 14 7 15 3 17 14 ± 1 Nm Apply engine oil to all moving parts before installation. 6 4 5 Removal steps "IA 1. Rocker cover 2. Rocker cover gasket "HA 3. Circular packing "GA 4. Oil seal 5. Distributor adaptor 6. O-ring "EA 7. Rocker arms, rocker arm shaft 8. Bearing cap No. 4 9.
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11B-10-2 6G7 ENGINE – Rocker Arms and Camshaft REMOVAL AND INSTALLATION <24-VALVE> 1 3.5 ± 0.5 Nm 31 ± 3 Nm 6 2 10 9 8 3 9 5 8 8 9 13 7 7 11 12 7 13 ± 2 Nm 12 12 14 15 16 17 Apply engine oil to all moving parts before installation. 4 7EN0879 Removal steps 1. Rocker cover 2. Gasket 3. Oil seal "GA 4. Oil seal 5. Rocker arms, Rocker arm shaft 6. Rocker arms, Rocker arm shaft "FA 7. Rocker shaft spring 8. Rocker arm “A” 9. Rocker arm “B” "CA 10.
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6G7 ENGINE – Rocker Arms and Camshaft 11B-10-3 REMOVAL SERVICE POINTS AA" LASH ADJUSTER REMOVAL Before removing the rocker arms and rocker arm shafts, install the Special Tools to prevent the lash adjusters from falling off. MD998443 Caution If the lash adjuster is re-used, clean the lash adjuster. (Refer to LASH ADJUSTER INSPECTION) 6AE0160 INSTALLATION SERVICE POINTS "AA CAMSHAFT INSTALLATION 1. Before attaching the camshafts, apply engine oil to the journals and cams.
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11B-10-4 6G7 ENGINE – Rocker Arms and Camshaft Rocker arm shaft “B” Notch on shaft Rocker arm shaft “A” "DA ROCKER ARM SHAFTS 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 bearing cap and shafts. 2. Install 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”. Rocker arm shaft “A” Cap No.
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6G7 ENGINE – Rocker Arms and Camshaft 11B-10-5 3. Tighten the bearing cap bolts to the specified torque. 4. Remove the special tools from all rocker arms. 7EN0128 "FA ROCKER SHAFT SPRING INSTALLATION Insert the rocker shaft spring at a slant with respect to the spark plug guide and install it normal to the guide. Rocker shaft spring 7EN0723 "GA CAMSHAFT OIL SEAL INSTALLATION Using the special tool, install the oil seal.
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11B-10-6 6G7 ENGINE – Rocker Arms and Camshaft Caution The packing is overdriven if no spacer is fitted to the special tool. 0.5 mm Spacer Circular packing MD998714 7EN0134 "IA ROCKER COVER INSTALLATION Apply specified sealant on the area specified in the figure. Specified sealant: 3M ATD Part No.8660 or equivalent 10 mm 10 mm 10 mm INSPECTION 1. CAMSHAFT Measure the cam height. Item Intake Exhaust 9EN0058 *1: *2: *3: *4: Standard value mm Limit mm 12-valve 41.25 40.75 24-valve 37.
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6G7 ENGINE – Rocker Arms and Camshaft 11B-10-6a 3. ROCKER ARM SHAFT (1) Check rocker arm mounting portions of rocker arm shaft for wear or damage. Replace as necessary. (2) Check to ensure that oil holes are clear. E Mitsubishi Motors Corporation Nov. 2002 1995 Apr.
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11B-10-6b 6G7 ENGINE – Rocker Arms and Camshaft Intentionally blank E Mitsubishi Motors Corporation Nov. 2002 1995 Apr.
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6G7 ENGINE – Rocker Arms and Camshaft 11B-10-7 4. LASH ADJUSTERS Caution (1) The lash adjusters are precision-engineered mechanisms. Do not allow them to become contaminated by dirt or other foreign substances. (2) Do not attempt to disassemble the lash adjusters. (3) Use only fresh diesel fuel to clean the lash adjusters. To clean outside A To clean inside B To fill diesel fuel (1) Prepare three containers and approximately five liters of diesel fuel.
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11B-10-8 6G7 ENGINE – Rocker Arms and Camshaft (4) Remove the lash adjuster from the container. Then, push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber. Wire or MD998442 Diesel fuel (5) Place the lash adjuster in container B. Then, gently push down the internal steel ball using special tool MD998442 and move the plunger through 5 to 10 strokes until it slides smoothly. This operation will clean the lash adjuster’s pressure chamber.
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6G7 ENGINE – Rocker Arms and Camshaft 11B-10-9 (9) Remove the lash adjuster from the container, then stand the lash adjuster with its plunger at the top. Push the plunger firmly and check that it does not move. Also, check that the lash adjuster’s height matches that of a new lash adjuster. NOTE If lash adjuster contracts, perform the operations (7) through (9) again to fill it with diesel fuel completely. Replace the lash adjuster if it still contracts after performing these steps.
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11B-11-1 6G7 ENGINE – Rocker Arms and Camshaft 11. ROCKER ARMS AND CAMSHAFT REMOVAL AND INSTALLATION 3.5 ± 0.5 Nm 3 4 3.5 ± 0.5 Nm 1 5 2 24 ± 2 Nm M8 bolt 11 ± 1 Nm M6 bolt 24 ± 2 Nm M8 bolt 7 11 ± 1 Nm M6 bolt 9 8 10 6 12 7 11 13 14 6 15 14 15 Apply engine oil to all moving parts before installation. 7EN1522 Removal steps 1. Rocker cover, right 2. Rocker cover gasket 3. Oil filler cap 4. Rocker cover, left 5. Rocker cover gasket "DA 6. Oil seal "CA 7.
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11B-11-2 6G7 ENGINE – Rocker Arms and Camshaft REMOVAL SERVICE POINT AA" LASH ADJUSTER REMOVAL Caution If the lash adjuster is re-used, clean the lash adjuster. (Refer to LASH ADJUSTER INSPECTION) INSTALLATION SERVICE POINTS "AA LASH ADJUSTER INSTALLATION Caution If the lash adjuster is re-used, clean the lash adjuster. (Refer to LASH ADJUSTER INSPECTION) Fit the lash adjuster onto the rocker arm without allowing diesel fuel to spill out.
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6G7 ENGINE – Rocker Arms and Camshaft 11B-11-3 "CA CIRCULA PACKING INSTALLATION Using the special tool, install the oil seal. MD998762 7EN1130 "DA OIL SEAL INSTALLATION Using the special tool, install the oil seal. MD998761 7EN1131 INSPECTION 1. CAMSHAFT Measure the cam height. Item Intake 9EN0058 Exhaust Standard value mm Limit mm Europe 35.20 34.70 Hong Kong 34.85 34.35 34.91 34.41 2. LASH ADJUSTER Caution (1) The lash adjusters are precision-engineered mechanisms.
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11B-11-4 6G7 ENGINE – Rocker Arms and Camshaft (2) Place the lash adjuster in container A and clean its outside surface. NOTE Use a nylon brush if deposits are hard to remove. Diesel fuel 6EN1699 (3) While gently pushing down the internal steel ball using special tool MD998442, move the plunger through 5 to 10 strokes until it slides smoothly. In addition to eliminating stiffness in the plunger, this operation will remove dirty oil.
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6G7 ENGINE – Rocker Arms and Camshaft 11B-11-5 (6) Remove the lash adjuster from the container. Then, push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber. Caution Make sure the oil hole in the side of the body is pointing toward container A. Do not point the oil hole at yourself or other people. MD998442 Diesel fuel 6EN1708 (7) Place the lash adjuster in container C. Then, gently push down the internal steel ball using special tool MD998442.
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11B-12-1 6G7 ENGINE – Cylinder Head and Valves 12. CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION <12-VALVE> 108 ± 5 Nm 1 Apply engine oil to all moving parts before installation. Back off 2 108 ± 5 Nm 5 6 13 7 14 17 16 15 9 18 3 12 19 20 21 11 10 22 8 4 Removal steps AA" "DA 1. Cylinder head bolt 2. Washer 3. Cylinder head assembly 4. Cylinder head gasket AB" "CA 5. Retainer lock 6. Valve spring retainer "BA 7. Valve spring 8. Intake valve AB" "CA 9. Retainer lock 10.
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11B-12-2 6G7 ENGINE – Cylinder Head and Valves REMOVAL AND INSTALLATION <24-VALVE> 108 ± 5 Nm 1 Apply engine oil to all moving parts before installation. 2 108 ± 5 Nm 5 6 Back off 7 13 14 11 16 17 3 9 22 15 10 18 21 12 19 20 8 4 7EN0915 AA" "DA AB" "CA "BA AB" "CA "BA Removal steps 1. Cylinder head bolt 2. Washer 3. Cylinder head assembly 4. Cylinder head gasket 5. Retainer lock 6. Valve spring retainer 7. Valve spring 8. Intake valve 9. Retainer lock 10. Valve spring retainer 11.
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11B-12-3 6G7 ENGINE – Cylinder Head and Valves REMOVAL AND INSTALLATION 108 ± 5 Nm 1 Back off 5 2 6 13 108 ± 5 Nm 7 14 3 17 21 19 12 20 11 18 8 16 10 15 9 4 Apply engine oil to all moving parts before installation. 7EN1132 AA" "DA AB" "CA "BA AB" "CA "BA Removal steps 1. Cylinder head bolt 2. Washer 3. Cylinder head assembly 4. Cylinder head gasket 5. Retainer lock 6. Valve spring retainer 7. Valve spring 8. Intake valve 9. Retainer lock 10. Valve spring retainer 11.
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11B-12-4 6G7 ENGINE – Cylinder Head and Valves REMOVAL SERVICE POINTS <12-VALVE> AA" CYLINDER HEAD BOLT REMOVAL Using the special tool, loosen the cylinder head bolts. Loosen evenly, little by little. 7EN0303 <24-VALVE> MD998051 6AE0166 MD998051 7EN1133 MD998735 AB" RETAINER LOCK REMOVAL Attach a tag with the cylinder No. and mounting location to the detached valves, springs and other parts and store them for reassembly. 7EN0892 <12-VALVE> 7EN0507 E Mitsubishi Motors Corporation Nov.
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6G7 ENGINE – Cylinder Head and Valves <24-VALVE> 11B-12-5 MD998772 6AE0167 MD998772 7EN1134 AC" VALVE STEM SEAL REMOVAL <24-VALVE> Caution Remove the valve stem seals with pliers and discard them. Do not reuse the stem seal. 7EN0444 E Mitsubishi Motors Corporation Nov. Aug.
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11B-12-6 6G7 ENGINE – Cylinder Head and Valves INSTALLATION SERVICE POINTS "AA VALVE STEM SEAL INSTALLATION <12-VALVE> 1. Install the valve spring seat. MD998729 Valve spring seat 5EN0018 2. Using the special tool, install a new stem seal to the valve guide. Caution Do not reuse the valve stem seal. MD998729 7EN0081 I.D. Colour Gray green I.D. Colour Gray <24-VALVE, GDI> 1. Attach a valve spring seat. 2. Attach a new stem seal to the valve guide with the Special Tool.
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6G7 ENGINE – Cylinder Head and Valves Identification colour Spring retainer 11B-12-7 "BA VALVE SPRING INSTALLATION (1) Install the valve spring with the painted end on the rocker arm side. Stem seal Spring seal 6EN0544 MD998735 "CA VALVE RETAINER LOCK INSTALLATION Using Special Tool install the valve retainer lock. 7EN0892 <12-VALVE> 7EN0507 <24-VALVE> MD998772 6AE0167 MD998772 7EN1134 E Mitsubishi Motors Corporation Nov. Aug.
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11B-12-8 6G7 ENGINE – Cylinder Head and Valves Cylinder head bolt Round shoulder Washer "DA CYLINDER HEAD BOLT INSTALLATION 1. Fit washers to the cylinder head bolts and install the bolts in the bolt holes in the cylinder head. Make sure of the correct orientation of the washer when installed. Cylinder head 7EN1138 2. Tighten the cylinder head bolts to the specified torque in the order shown. 3. Loosen all bolts. 4. Tighten the cylinder head bolts to the specified torque in the order shown.
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11B-12-9 6G7 ENGINE – Cylinder Head and Valves INSPECTION 7EN0258 1. CYLINDER HEAD (1) Check the cylinder head for water leaks, gas leaks, damage or cracks before washing it. (2) Completely remove oil, fur, sealer, carbon and the like. After washing the oil passages, blow air through them to make sure they are not clogged. (3) To ensure flatness of the cylinder head bottom surface, measure the distortion of the surface using a straight edge and a thickness gauge.
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11B-12-10 6G7 ENGINE – Cylinder Head and Valves (3) Measure the total length of the valve. If the measured value is below the limit, change the valve. Item Standard value mm Limit mm Intake 102.97 102.47 Exhaust 102.67 102.17 24-valve (6G72, (6G72 6G74) Intake 112.30 111.80 Exhaust 114.11 113.61 24-valve (6G75) Intake 110.30 109.80 Exhaust 112.11 111.61 GDI Intake 102.28 101.78 Exhaust 101.40 100.90 12-valve 3. VALVE SPRING (1) Measure the free height of the valve spring.
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11B-12-11 6G7 ENGINE – Cylinder Head and Valves Stem outside diameter 4. VALVE GUIDE Measure the clearance between the valve guide and the valve stem. When the clearance exceeds the specified limit, change the valve guide or the valve or both. Item 12-valve Guide inside diameter 1EN0279 24-valve GDI Valve stem end Valve protrusion Spring seat surface Standard value mm Limit mm Intake 0.03–0.06 0.10 Exhaust 0.05–0.09 0.15 Intake 0.02–0.05 0.10 Exhaust 0.04–0.06 0.15 Intake 0.02–0.
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11B-12-12 6G7 ENGINE – Cylinder Head and Valves <24-VALVE> 65° 65° 25° 15° 43.5 – 44° 43.5 – 44° 7EN0273 7. VALVE SEAT REPLACEMENT PROCEDURE (1) Cut off the inside of the valve seat to reduce its thickness before pulling out the valve seat. (2) Adjust the valve cylinder hole in the cylinder head to the diameter of the oversize valve seat to be press fitted. 0.5 – 1 mm Cut off 0.5 – 1 mm Item 12-valve Standard value mm Intake 0.30 O.S. 44.30–44.33 0.60 O.S. 44.60–44.63 0.30 O.S. 38.30–38.
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6G7 ENGINE – Cylinder Head and Valves Removal Installation Press Press MD998115 push rod MD998115 Valve guide Valve guide 6EN0543 11B-12-13 8. VALVE GUIDE REPLACEMENT PROCEDURE <12-VALVE> (1) Remove the snap ring from the exhaust valve guide. (2) Using the special tool and a press, remove the valve guide toward cylinder head gasket surface. (3) Rebore valve guide hole to the new oversize valve guide outside diameter. Valve guide hole diameter 0.05 O.S.: 13.05 – 13.07 mm 0.25 O.S.: 13.25 – 13.
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11B-13-1 6G7 ENGINE – Oil Pan and Oil Pump 13. OIL PAN AND OIL PUMP REMOVAL AND INSTALLATION <12-VALVE> 3 25 ± 2 Nm 4 54 ± 5 Nm 5 2 10 ± 2 Nm 16 1 17 18 19 10 ± 2 Nm 14 ± 1 Nm 14 ± 1 Nm 10 9 15 19 ± 3 Nm 13 12 14 11 39 ± 5 Nm 44 ± 5 Nm 6 9 ± 3 Nm Apply engine oil to all moving parts before installation. "IA "HA "GA AA" "DA Removal steps 1. Oil pressure switch 2. Oil cooler by-pass valve 3. Oil filter 4. Oil filter bracket 5. Oil filter bracket gasket 6. Drain plug 7.
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11B-13-2 6G7 ENGINE – Oil Pan and Oil Pump REMOVAL AND INSTALLATION <24-VALVE FOR L200, CHALLENGER> Apply engine oil to all moving parts before installation. 10 ± 2 Nm 20 17 21 12 14 ± 1 Nm 11 14 ± 1 Nm 19 16 19 ± 3 Nm 18 9 ± 1 Nm 15 23 ± 3 Nm 9 11 ± 1 Nm10 14 41 ± 8 Nm 13 4 44 ± 5 Nm 8 3 7 1 23 ± 3 Nm 10 ± 2 Nm 5 6 9 ± 3 Nm 39 ± 5 Nm 2 9 ± 3 Nm Removal steps "IA 1. Oil pressure switch "HA 2. Oil filter 3. Oil filter bracket 4. Oil filter bracket gasket 5. Drain plug "GA 6.
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11B-13-3 6G7 ENGINE – Oil Pan and Oil Pump REMOVAL AND INSTALLATION <24-VALVE FOR PAJERO (V33V)> Apply engine oil to all moving parts before installation. 21 19 23 22 10 ± 2 Nm 14 ± 1 Nm 13 19 ± 3 Nm 14 12 18 14 ± 1 Nm 20 24 ± 4 Nm 17 16 15 41 ± 8 Nm 11 ± 1 Nm 9 44 ± 5 Nm 5 1 4 11 8 10 ± 2 Nm 2 54 ± 5 Nm 39 ± 5 Nm 24 ± 4 Nm 9 ± 3 Nm 7 9 ± 3 Nm 11 ± 1 Nm 6 11 ± 1 Nm 3 9 ± 3 Nm 11 ± 1 Nm 10 "IA "HA "GA AB" "EA AC" "DA Removal steps 1. Oil pressure switch 2.
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11B-13-4 6G7 ENGINE – Oil Pan and Oil Pump REMOVAL AND INSTALLATION <24-VALVE FOR PAJERO (V63W, V65W, V73W, V75W), GDI> 10 ± 2 Nm 1 54 ± 5 Nm 19 4 3 5 5 ± 1 Nm 20 12 21 23 ± 3 Nm 22 11 ± 1 Nm 13 2 11 19 ± 3 Nm 10 ± 2 Nm 10 16 15 17 14 ± 1 Nm 14 18 8 9 ± 1 Nm 9 44 ± 5 Nm 11 ± 1 Nm Apply engine oil to all moving parts before installation. 6 7 39 ± 5 Nm 9 ± 3 Nm 9 ± 3 Nm 7EN1573 "IA "HA "GA AC" "FA Removal steps 1. Oil pressure switch 2. Oil filter 3.
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11B-13-4a 6G7 ENGINE – Oil Pan and Oil Pump REMOVAL AND INSTALLATION <24-VALVE FOR PAJERO (V67W, V77W)> 10 ± 2 Nm 1 19 54 ± 5 Nm 4 20 13 3 21 5 22 9 ± 2 Nm 23 ± 2 Nm 10 ± 2 Nm 12 5 ± 1 Nm 19 ± 3 Nm 2 14 ± 1 Nm 16 18 15 17 14 11 10 8 9 ± 1 Nm 44 ± 5 Nm 9 11 ± 1 Nm 6 Apply engine oil to all moving parts before installation. 39 ± 5 Nm Removal steps "IA 1. Oil pressure switch "HA 2. Oil filter 3. Oil cooler by-pass valve 4. Oil filter bracket 5.
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6G7 ENGINE – Oil Pan and Oil Pump MD998727 11B-13-5 REMOVAL SERVICE POINTS MD998727 AA" OIL PAN REMOVAL 1. Remove the oil pan mounting bolts. 2. Knock the special tool between the oil pan and cylinder block as shown in the illustration. 3. Tapping the side of the special tool, slide the tool along the oil pan/cylinder block seal and thus remove the oil pan. AB" OIL PAN LOWER REMOVAL Apply wood to the oil pan side and remove the oil pan lower with a plastic hammer. AC" OIL PAN UPPER REMOVAL 1.
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11B-13-6 6G7 ENGINE – Oil Pan and Oil Pump INSTALLATION SERVICE POINTS Alignment marks "AA OIL PUMP INNER AND OUTER ROTORS INSTALLATION Install the oil pump outer rotor in the proper direction using the setting mark drawn on it before disassembly. Apply engine oil over the entire rotor surface. 7EN0509 "BA OIL PUMP CASE INSTALLATION 1. Remove the old liquid gasket from the cylinder block (oil pump mounting surface) and from the oil pump. 2.
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6G7 ENGINE – Oil Pan and Oil Pump 11B-13-7 "DA OIL PAN UPPER INSTALLATION 1. Clean the gasket coating surfaces of the cylinder block and the oil pan upper. 2. Squeeze out a 4 mm bead of liquid gasket and coat the coating surface with it. A Top view Flange bolt tightening sequence 18 17 14 8 4 1 13 7 3 2 Liquid gasket: MITSUBISHI GENUINE Part No.
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11B-13-8 6G7 ENGINE – Oil Pan and Oil Pump "FA OIL PAN 1. Clean the gasket coating surfaces of the cylinder block and the oil pan upper. 2. Squeeze out a 4 mm bead of liquid gasket and coat the coating surface with it. A Liquid gasket: MITSUBISHI GENUINE Part No. MD970389 or equivalent Top view Flange bolt tightening sequence 11 9 17 16 13 8 4 12 7 3 1 NOTE During attachment of the oil pan upper, the sealer must not be expelled from the flange portion of the oil pan for distance A as shown.
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6G7 ENGINE – Oil Pan and Oil Pump 11B-13-9 INSPECTION 1. OIL PUMP (1) Check for tip clearance. Standard value: 0.03 – 0.08 mm 7EN0510 (2) Check for side clearance. Standard value: 0.04 – 0.10 mm 7EN0511 (3) Check for body clearance. Standard value: 0.10 – 0.18 mm Limit: 0.35 mm 7EN0512 2. OIL COOLER BY-PASS VALVE (1) Make sure that the valve moves smoothly. (2) Ensure that the dimension L measures the standard value under normal temperature and humidity. L Dimension L: 34.
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11B-13-10 6G7 ENGINE – Oil Pan and Oil Pump 3. OIL LEVEL SENSOR Put the oil level sensor in the oil, then move the float up and down with the oil at a temperature either lower than 40°C or higher than 80°C, and check for continuity. 40°C Float position Switch ON/OFF Condition when down ON (continuity) Condition when up ON (continuity) 7EN0379 80°C Float position Condition when down Condition when up E Mitsubishi Motors Corporation Nov. Aug.
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11B-14-1 6G7 ENGINE – Piston and Connecting Rod 14. PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION <12-VALVE, 6G72–24-VALVE> 6 7 10 4 8 9 11 12 5 Apply engine oil to all moving parts before installation. 3 2 1 51 ± 1 Nm Removal steps 1. Connecting rod cap nut AA" "GA 2. Connecting rod cap 3. Connecting rod bearing, lower "FA 4. Piston, connecting rod assembly 5. Connecting rod bearing, upper "DA 6. Piston ring No.1 E Mitsubishi Motors Corporation Nov. Aug. 1995 2001 "DA 7. Piston ring No.
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11B-14-2 6G7 ENGINE – Piston and Connecting Rod REMOVAL AND INSTALLATION <6G74–24-VALVE, 6G75> 6 7 12 4 8 10 11 9 13 14 5 Apply engine oil to all moving parts before installation. 3 2 1 "HA AA" "GA "EA "FA "EA "DA "DA 34 ± 2 Nm +90° Removal steps 1. Connecting rod cap nut 2. Connecting rod cap 3. Connecting rod bearing, lower 4. Piston, connecting rod assembly 5. Connecting rod bearing, upper 6. Piston ring No.1 7. Piston ring No.2 E Mitsubishi Motors Corporation Apr. 2003 "CA 8. 9.
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6G7 ENGINE – Piston and Connecting Rod 11B-14-3 REMOVAL AND INSTALLATION 7 6 12 4 8 10 9 11 13 14 5 Apply engine oil to all moving parts before installation. 3 2 1 "HA AA" "GA "EA "FA "EA "DA "DA 34 ± 2 Nm +90° Removal steps 1. Connecting rod cap nut 2. Connecting rod cap 3. Connecting rod bearing, lower 4. Piston, connecting rod assembly 5. Connecting rod bearing, upper 6. Piston ring No.1 7. Piston ring No.2 E Mitsubishi Motors Corporation Nov. Aug. 1995 2001 "CA 8. 9. AC" "BA 10.
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11B-14-4 6G7 ENGINE – Piston and Connecting Rod REMOVAL SERVICE POINTS Cylinder No. AA" CONNECTING ROD CAP REMOVAL Enter the cylinder No. on the side of the large end of the connecting rod to facilitate reassembly. 7EN0448 Push rod Guide B Guide A: 17.9 mm AB" PISTON PIN REMOVAL <6G72> The special piston pin setting tool (MD998780) consists of the parts shown at left. Guide A: 18.9 mm Guide C Guide A: 20.9 mm Base Guide A: 21.9 mm 7EN0431 <12-VALVE> Left bank Right bank 1.
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6G7 ENGINE – Piston and Connecting Rod 2. Set the piston and connecting rod assembly to the special tool piston pin setting base such that the front mark on the piston faces upward. 3. Pull out the piston pin with a press. Push rod Front mark 11B-14-5 Front mark NOTE After pulling out the piston pin, place the piston, the piston pin, and the connecting rod in order for each cylinder number. Guide C Base 7EN0390 70°C AC" PISTON PIN REMOVAL <6G74, 6G75> 1. Remove the snap rings. 2.
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11B-14-6 6G7 ENGINE – Piston and Connecting Rod INSTALLATION SERVICE POINTS Timing belt side Left bank Right bank No. 2 No. 4 No. 6 Check degit No. 5 No. 3 No. 1 Crankshaft bore size mark "AA PISTON PIN INSTALLATION <6G72> 1. When replacing the piston, read off the cylinder bore size mark on the cylinder block as illustrated, and select a piston according to the following table.
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6G7 ENGINE – Piston and Connecting Rod 8. Screw guide B into guide A until they are distance L (obtained per Step 3. above) plus 3 mm apart as shown. 3 mm + L Guide B 11B-14-7 Guide A 7EN0433 Push rod Piston pin Front mark Front mark 9. Use special tools to set the piston pin to a special tool piston setting base with the front mark of the piston facing up. 10. Press fit the piston pin with a press.
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11B-14-8 6G7 ENGINE – Piston and Connecting Rod Timing belt side Left bank Right bank No. 2 No. 4 No. 6 Check degit No. 5 No. 3 No. 1 Crankshaft bore size mark "BA PISTON PIN INSTALLATION <6G74, 6G75> 1. When replacing the piston, read off the cylinder bore size mark on the cylinder block as illustrated, and select a piston according to the following table. Cylinder bore size mark Piston size mark I A II None III C NOTE The piston size mark shows on the top of the piston.
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6G7 ENGINE – Piston and Connecting Rod 11B-14-9 Front mark Front mark Left bank Right bank Front mark Identification mark "CA OIL RING INSTALLATION 1. Fit the oil ring spacer into the piston ring groove. Upper side rail end gaps Lower side rail end gaps NOTE (1) Ensure that the end gaps of the side rails and spacer are located as shown. (2) The spacer and side rails (new) are color-coded as detailed below according to their sizes.
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11B-14-10 6G7 ENGINE – Piston and Connecting Rod 3. Mount the lower side rail. 4. A three-piece oil ring, if installed correctly, should turn smoothly in either direction. Check this. "DA PISTON RING NO.2 / PISTON RING NO.1 INSTALLATION Using a piston ring expander, fit the piston rings into position with the ring ID mark facing up. 7EN1155 ID mark: 1T or T ID mark: 2T or T2 Size mark NOTE Each piston ring is stamped with the following size mark as appropriately.
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11B-14-11 6G7 ENGINE – Piston and Connecting Rod "EA CONNECTING ROD BEARING INSTALLATION NOTE The replacement connecting rod bearings for the 6G72 and 6G73 engines are supplied in the unit of a package containing all necessary number of bearings for the engine. When replacing the bearing, select the proper bearing according to the crankshaft identification color and the connecting rod identification mark and install it.
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11B-14-12 6G7 ENGINE – Piston and Connecting Rod Upper side rail "FA 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 figure. 3. Rotate crankshaft so that crank pin is on center of cylinder bore. No. 1 Piston pin No. 2 ring gap and spacer gap Lower side rail 4.
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6G7 ENGINE – Piston and Connecting Rod 11B-14-13 2. Check if the thrust clearance in the connecting rod big end is correct. Standard value: 0.10 – 0.25 mm Limit: 0.4 mm "HA CONNECTING ROD CAP NUT INSTALLATION 1. Since the plastic region tightening method has been employed for the connecting rod bolts and nuts, be sure to check the bolts for elongation before reuse. Bolts can be checked for elongation by finger-screwing the nut to the end of the bolt threads.
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11B-14-14 6G7 ENGINE – Piston and Connecting Rod INSPECTION 1. PISTON RING (1) Check the clearance between the piston ring and the ring groove. If it exceeds the specified limit, change the ring or the piston and piston ring. Standard values: No. 1 0.03 – 0.07 mm No. 2 0.02 – 0.06 mm Limit: 0.1 mm 7EN0475 (2) Place the piston ring in the cylinder bore, push it in by applying the piston head side, and make sure it is square. Then measure the clearance at the ring ends with a thickness gauge.
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11B-15-1 6G7 ENGINE – Crankshaft, Flywheel and Drive Plate 15. CRANKSHAFT, FLYWHEEL AND DRIVE PLATE REMOVAL AND INSTALLATION <6G72–12-VALVE> 11 ± 1 Nm 3 1 8 74 ± 2 Nm 10 74 ± 2 Nm 2 20 1 11 ± 1 Nm 7 11 ± 1 Nm 9 4 17 5 18 19 6 16 13 15 Apply engine oil to all moving parts before installation. 14 12 93 ± 4 Nm 11 Removal steps 1. Flywheel bolt 2. Flywheel 3. Ball bearing 4. Adaptor plate 5. Drive plate 6. Crankshaft adaptor 7. Rear plate 8. Ball bearing cover "EA 9.
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11B-15-2 6G7 ENGINE – Crankshaft, Flywheel and Drive Plate REMOVAL AND INSTALLATION <6G72–24-VALVE> 7 23 ± 2 Nm 1 28 ± 2 Nm 20 74 ± 2 Nm 10 21 22 3 9 2 11 ± 1 Nm 11 ± 1 Nm 1 11 ± 1 Nm 74 ± 2 Nm 4 18 17 19 16 6 14 8 5 13 12 15 93 ± 4 Nm Apply engine oil to all moving parts before installation. 11 "EA "DA "CA "CA Removal steps 1. Flywheel bolt 2. Flywheel 3. Ball bearing 4. Adaptor plate 5. Drive plate 6. Crankshaft adaptor 7. Rear plate (M/T) 8. Rear plate (A/T) 9. Oil seal case 10.
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11B-15-3 6G7 ENGINE – Crankshaft, Flywheel and Drive Plate REMOVAL AND INSTALLATION <6G74, 6G75> 74 ± 2 Nm 1 7 23 ± 2 Nm 3 17 28 ± 2 Nm 10 9 18 2 11 ± 1 Nm 19 74 ± 2 Nm 11 ± 1 Nm 1 11 ± 1 Nm 4 15 16 14 6 5 8 13 12 11 74 ± 4 Nm Removal steps 1. Flywheel bolt 2. Flywheel 3. Ball bearing 4. Adaptor plate 5. Drive plate 6. Crankshaft adaptor 7. Rear plate (M/T) 8. Rear plate (A/T) "EA 9. Oil seal case "DA 10. Oil seal E Mitsubishi Motors Corporation Apr.
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11B-15-4 6G7 ENGINE – Crankshaft, Flywheel and Drive Plate INSTALLATION SERVICE POINTS "AA DETONATION SENSOR BRACKET INSTALLATION Check that the bracket is in proper contact with the cylinder block boses and tighten to the specified torque in the order shown. Timing belt side 4 2 1 3 Identification color position No.2 journal No.4 journal No.3 journal No.
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6G7 ENGINE – Crankshaft, Flywheel and Drive Plate 11B-15-5 <6G72–12-VALVE> Combination of crankshaft journal diameter and cylinder block bearing bore diameter O.D. mm Cylinder block bearing bore diameter identification id tifi ti mark k Bearing identification color or identification id tifi ti mark ((for or service part) 59.994 – 60.
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11B-15-6 6G7 ENGINE – Crankshaft, Flywheel and Drive Plate <6G74, 6G75> Combination of crankshaft journal diameter and cylinder block bearing bore diameter Crankshaft journal Classification Identification color Production part Service part None Yellow 1 2 None 3 None None White Identification mark (SOHC) Identification color Oil groove 7EN0600 Groove Bearing identification color ((for service i part) t) O.D. mm Cylinder block bearing bore diameter identification id tifi ti mark k 63.
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6G7 ENGINE – Crankshaft, Flywheel and Drive Plate 11B-15-7 "CA BEARING CAP / BEARING BOLT INSTALLATION 1. Attach the bearing cap on the cylinder block as shown in the figure. 2. Tighten the bearing cap bolts to the specified torque in the sequence shown in the figure. 3. Check that the crankshaft rotates smoothly. Crankshaft Front mark Bearing cap Bearing cap bolt Cylinder block 7EN0524 4. Check the end play. If it exceeds the limit value, replace the thrust bearing. Standard value : 0.05 – 0.
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11B-15-8 6G7 ENGINE – Crankshaft, Flywheel and Drive Plate "EA OIL SEAL CASE INSTALLATION Squeeze out a 3 mm bead of liquid gasket (FIPG) and apply it to the coating surface. Liquid gasket: MITSUBISHI genuine Part No. MD970389 7EN0467 INSPECTION 1. CRANKSHAFT If the oil clearance exceeds the limit, replace the bearing, and crankshaft if necessary. Measure the outside diameter of journal and inside diameter of crankshaft bearing.
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6G7 ENGINE – Crankshaft, Flywheel and Drive Plate 11B-15-9 (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 – 0.04 mm Limit: 0.1 mm 7EN0141 3. CYLINDER BLOCK (1) Visually check for scratches, rust and corrosion.
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11B-15-10 6G7 ENGINE – Crankshaft, Flywheel and Drive Plate 4. BORING CYLINDER (1) Oversize pistons to be used should be determined on the basis of the largest bore cylinder. Piston size identification <6G72, 6G74> Thrust direction Piston O.D. Size Identification mark 0.50 mm O.S. 0.50 1.00 mm O.S. 1.00 6EN0554 <6G75> Size Identification mark 0.25 mm O.S. 0.25 0.50 mm O.S. 0.50 NOTE Size mark is stamped on the piston top. (2) Measure outside diameter of piston to be used.
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Service Bulletins Click on the applicable bookmark to select the Service Bulletin.
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SERVICE PUBLICATION & TRAINING INTERNATIONAL AFTER-SALES DEPARTMENT. MITSUBISHI MOTORS CORPORATION SERVICE BULLETIN NO. : MSB–03E11–001 DATE : 2003–01–20 DISUSE OF INJECTOR BACKUP RINGS IN GDI ENGINES SUBJECT : GROUP : DRAFTNO. : ENGINE INFORMATION 02EN516 INTERNATIONAL AFTERĆSALES DEPARTMENT T.
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Attachment Applicable Manuals: Pub. No.
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GLOBAL AFTER SALES OFFICE, MITSUBISHI MOTORS CORPORATION SERVICE BULLETIN NO. : MSB–04E11–001 DATE : CHANGE TO CRANKSHAFT BEARING SELECTION INSTRUCTIONS FOR 6G7 ENGINES SUBJECT : GROUP : INFORMATION 1. 2. DRAFTNO. : ENGINE SERVICE INFORMATION MANAGEMENT DEPARTMENT (EUR)PAJERO/ MONTERO (V60 V70) (V60, 04 03EN509 M.
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4.
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See next page.
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MSB–04E11–001 4