2001-2005 Mitsubishi Airtrek 2.0L Turbo Service & Repair Manual

11B-1 GROUP 11B ENGINE OVERHAUL CONTENTS GENERAL INFORMATION . . . . . . . . 11B-2 GENERAL SPECIFICATIONS . . . . . . 11B-2 SERVICE SPECIFICATIONS . . . . . . . 11B-3 REWORK DIMENSIONS . . . . . . . . . . 11B-5 TORQUE SPECIFICATIONS . . . . . . . 11B-5 SEALANTS . . . . . . . . . . . . . . . . . . . . 11B-8 SPECIAL TOOLS . . . . . . . . . . . . . . . . 11B-10 ALTERNATOR AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 11B-14 REMOVAL AND INSTALLATION . . . . . . . . 11B-14 SOLENOID AND VACUUM HOSE . . 11B-16 REMOVAL AND INSTALLATION . . . . . . . . 11B-16 TIMING BELT . . . . . . . . . . . . . . . . . . . 11B-17 REMOVAL AND INSTALLATION . . . . . . . . 11B-17 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 11B-27 FUEL AND EMISSION PARTS . . . . . 11B-29 REMOVAL AND INSTALLATION . . . . . . . . 11B-29 INLET MANIFOLD . . . . . . . . . . . . . . . 11B-31 REMOVAL AND INSTALLATION . . . . . . . . 11B-31 EXHAUST MANIFOLD . . . . . . . . . . . . 11B-32 REMOVAL AND INSTALLATION . . . . . . . . 11B-32 WATER PUMP AND WATER HOSE . 11B-34 REMOVAL AND INSTALLATION . . . . . . . . 11B-34 ROCKER ARMS AND CAMSHAFT . . 11B-36 REMOVAL AND INSTALLATION . . . . . . . . 11B-36 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-39 CYLINDER HEAD AND VALVES . . . . 11B-42 REMOVAL AND INSTALLATION . . . . . . . . 11B-42 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-46 OIL PAN AND OIL PUMP . . . . . . . . . . 11B-49 REMOVAL AND INSTALLATION . . . . . . . . 11B-49 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-56 PISTON AND CONNECTING ROD . . 11B-57 REMOVAL AND INSTALLATION . . . . . . . . 11B-57 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-62 CRANKSHAFT AND CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 11B-64 REMOVAL AND INSTALLATION . . . . . . . . 11B-64 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-67

GENERAL INFORMATION ENGINE OVERHAUL 11B-2 GENERAL INFORMATION M1113000100329 VEHICLE AND ENGINE MODELS GENERAL SPECIFICATIONS M1113000200597 Vehicle name Vehicle model Engine model Displacement mL Specification LANCER EVOLUTION CT9A 4G63-7 1,997 Double overhead camshaft, 16-valve Item Specification Bore × stroke mm 85 × 88 Displacement mL 1,997 Combustion chamber Pentroof type Number of cylinders 4 Valve mechanism Type Double overhead camshaft Number of intake valves 2 Number of exhaust valves 2 Lash adjusters Hydraulic Rocker arms Roller cam followers Compression ratio 8.8 Fuel injection system Electronically controlled multi-point injection (MPI) system Ignition system Electronically controlled two-coil system Generator Alternator (with built-in IC regulator) Starter motor Gear reduction drive type

SERVICE SPECIFICATIONS ENGINE OVERHAUL 11B-3 SERVICE SPECIFICATIONS M1113000301199 Item Standard value Limit TIMING BELT Auto-tensioner rod extension length (with timing belt installed) mm 3.8 − 4.5 − Auto-tensioner rod extension length (when free) mm 12.0 − Auto-tensioner rod retraction length (when pressed with force of 98 to 196 N) mm Less than 1 − ROCKER ARMS AND CAMSHAFTS Cam height mm Intake 35.96 35.46 Exhaust 35.49 34.99 CYLINDER HEAD AND VALVES Cylinder head gasket surface warp mm Less than 0.05 0.2 Cylinder head gasket surface grinding limit (including cylinder block grinding amount) mm − 0.2 Cylinder head overall height mm 131.9 − 132.1 − Cylinder head bolt nominal length mm − 99.4 Valve margin mm Intake valves 1.0 0.5 Exhaust valves 1.5 1.0 Valve stem diameter mm 6.6 − Valve face angle 43.5° − 44° − Valve stem-to-guide clearance mm Intake valves 0.02 − 0.05 0.10 Exhaust valves 0.05 − 0.09 0.15 Valve height mm Intake valves 109.5 109.0 Exhaust valves 109.7 109.2 Valve stem projection mm Intake valves 49.2 49.7 Exhaust valves 48.4 48.9 Valve spring free height mm 50.4 49.4 Valve spring load/height N/mm 279/40 − Valve spring squareness 1.5° or smaller 4° Valve face-to-seat contact width mm 0.9 − 1.3 − Valve guide inside diameter mm 6.6 − Valve guide press-in height mm 19.2 − 19.8 −

SERVICE SPECIFICATIONS ENGINE OVERHAUL 11B-4 OIL PAN AND OIL PUMP Oil pump gear side clearance mm Drive gear 0.08 − 0.14 − Driven gear 0.06 − 0.12 − Oil cooler by-pass valve mm Dimension (Normal temperature) 34.5 − By-pass hole closing temperature 97 to 103°C 40.0 − Oil pressure at curb idle speed kPa [oil temperature is 75 to 90°] 78 or more − PISTONS AND CONNECTING RODS Piston outside diameter mm 85.0 − Piston ring side clearance in ring groove mm No. 1 0.03 − 0.07 0.1 No. 2 0.02 − 0.06 0.1 Piston ring end gap mm No. 1 0.20 − 0.30 0.8 No. 2 0.30 − 0.50 0.8 Oil ring 0.10 − 0.40 1.0 Piston pin outside diameter mm 22.0 − Piston pin press-in load (at ambient temperature) N 7,350 − 17,100 − Oil clearance at crankshaft pins mm 0.02 − 0.04 0.1 Connecting rod big end thrust clearance mm 0.10 − 0.25 0.4 CRANKSHAFT AND CYLINDER BLOCK Crankshaft end play mm 0.05 − 0.25 0.4 Crankshaft journal diameter mm 57.0 − Crankshaft pin diameter mm 45.0 − Oil clearance at crankshaft journals mm 0.03 − 0.04 0.1 Cylinder block gasket surface warp mm 0.05 0.1 Cylinder block gasket surface grinding limit (including cylinder head grinding amount) mm − 0.2 Cylinder block overall height mm 284 − Cylinder bore diameter mm 85 − Taper of cylinder mm 0.01 or less − Cylinder-to-piston clearance mm 0.02 − 0.04 − Crankshaft bearing cap bolt nominal length mm − 71.1 Item Standard value Limit

REWORK DIMENSIONS ENGINE OVERHAUL 11B-5 REWORK DIMENSIONS M1113024300264 TORQUE SPECIFICATIONS M1113023401421 Item Standard value CYLINDER HEAD AND VALVES Diameter of oversize valve seat ring hole in cylinder head mm Intake 0.3 oversize 35.30 − 35.33 0.6 oversize 35.60 − 35.63 Exhaust 0.3 oversize 33.30 − 33.33 0.6 oversize 33.60 − 33.63 Diameter of oversize valve guide hole in cylinder head mm 0.05 oversize 12.05 − 12.07 0.25 oversize 12.25 − 12.27 0.50 oversize 12.50 − 12.52 Item N⋅m ALTERNATOR AND IGNITION COIL Oil level gauge guide bolt 13 ± 1 Auto-tensioner assembly bolt (M8) 22 ± 4 Auto-tensioner assembly bolt (M10) 44 ± 10 Water pump pulley bolts 8.8 ± 1.0 Alternator bracket bolt (flange bolt) 24 ± 4 Alternator bracket bolts (M8 × 22 washer assembled bolt) 22 ± 4 Alternator bracket bolts (M8 × 32 washer assembled bolt) 20 ± 2 Alternator nuts 44 ± 10 Crankshaft pulley bolts 25 ± 4 Centre cover bolts 3.0 ± 0.5 Ignition coil bolts 10 ± 2 Spark plugs 25 ± 5 SOLENOID AND VACUUM HOSE Vacuum pipe and hose assembly bolts 11 ± 1 Solenoid valve assembly bolts 9.0 ± 1.0 TIMING BELT Timing belt cover bolts (flange bolt) 11 ± 1 Timing belt cover bolt (washer-assembled bolt) 9.0 ± 1.0 Plug cap 32 ± 2 Power steering pump bracket bolts 49 ± 9 Tensioner pulley bolt 48 ± 5 Tensioner arm bolt 21 ± 4 Auto-tensioner bolts 23 ± 3 Idler pulley bolt 35 ± 6 Crankshaft angle sensor bolts 8.8 ± 1.0

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2001-2005 Mitsubishi Airtrek 2.0L Turbo Service & Repair Manual

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