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

TORQUE SPECIFICATIONS ENGINE OVERHAUL 11B-6 Oil pump sprocket nut 54 ± 5 Crankshaft bolt 167 Tensioner "B" bolt 19 ± 3 Counterbalance shaft sprocket bolt 45 ± 3 Rocker cover bolts 3.5 ± 0.5 Engine support bracket bolts 49 ± 5 V.V.T. sprocket bolt 65 ± 5 Camshaft sprocket bolt 88 ± 10 FUEL AND EMISSION SYSTEM Throttle body bolts 19 ± 3 EGR valve bolts 20 ± 2 Fuel pressure regulator bolts 8.8 ± 2.0 Delivery pipe and injector assembly bolts 12 ± 1 INLET MANIFOLD Engine hanger bolt 19 ± 3 Inlet manifold stay bolts 31 ± 3 Inlet manifold bolts (M8) 20 ± 2 Inlet manifold bolts and nuts (M10) 36 ± 6 EXHAUST MANIFOLD Engine hanger bolt 19 ± 3 Turbocharger heat protector bolts 23 ± 3 Oxygen sensor 44 ± 5 Exhaust fitting bracket bolts 35 ± 6 Exhaust fitting bolts 59 ± 5 Air outlet fitting bolts 19 ± 1 Oil return pipe bolts (oil pan side) 14 ± 1 Oil return pipe bolts (turbocharger side) 9.0 ± 1.0 Exhaust manifold heat protector bolts 23 ± 3 Turbocharger assembly and pipe assembly bolts, nuts 64 ± 5 Oil pipe bolt (flange bolt) 11 ± 1 Oil pipe bolt (eye bolt M10) 17 ± 2 Oil pipe bolt (eye bolt M12) 31 ± 2 Water pipe bolt (eye bolt M12) 42 ± 7 Water pipe bolt (flange bolt) 10 ± 1 Exhaust manifold nuts (M8) 33 ± 6 Exhaust manifold nuts (M10) 55 ± 5 Item N⋅m

TORQUE SPECIFICATIONS ENGINE OVERHAUL 11B-7 WATER PUMP AND WATER HOSE Engine coolant temperature sensor 29 ± 10 Engine coolant temperature gauge unit 11 ± 1 Water outlet fitting bolts 10 ± 1 Thermostat housing bolts 23 ± 4 Water inlet pipe bolt (M6) 10 ± 1 Water inlet pipe bolt (M8) 13 ± 2 Water pump bolts 14 ± 1 Detonation sensor 23 ± 2 ROCKER ARMS AND CAMSHAFT Camshaft position sensor bolt 11 ± 1 Cover bolts 10 ± 2 Camshaft position sensing cylinder bolt 22 ± 4 Camshaft position sensor support bolts 14 ± 1 Bearing cap bolts 20 ± 1 Oil delivery body bolts 11 ± 1 Oil feeder control valve bolt 11 ± 1 Check valve 30 ± 3 Eye bolt 42 ± 2 Oil pipe bolt 11 ± 1 Oil pipe joint 30 ± 3 CYLINDER HEAD AND VALVES Cylinder head bolts 78 ± 2 → 0 → 20 ± 2 → +90° → +90° OIL PAN AND OIL PUMP Drain plug 39 ± 5 Oil level sensor bolts 9.0 ± 1.0 Oil filter 14 ± 2 Oil pan bolts 9.0 ± 3.0 Oil screen bolts 19 ± 3 Baffle plate bolts 22 ± 4 Oil pressure switch 19 ± 3 Oil cooler by-pass valve 54 ± 5 Relief plug 44 ± 5 Oil filter bracket bolts 19 ± 3 Plug cap 23 ± 3 Flange bolt 36 ± 3 Oil pump case bolts 23 ± 3 Oil pump cover bolts 17 ± 1 Oil pump cover screw 10 ± 2 Item N⋅m

SEALANTS ENGINE OVERHAUL 11B-8 SEALANTS M1113000501007 NOTE: *: Part to be sealed with a form-in-place gasket (FIPG) PISTON AND CONNECTING ROD Connecting rod cap nuts 20 ± 2 → +90° to 94° CRANKSHAFT AND CYLINDER BLOCK Flywheel bolts 132 ± 5 Rear plate bolt 11 ± 1 Bell housing cover bolts 9.0 ± 1.0 Rear oil seal case bolts 11 ± 1 Beam bearing cap bolts 25 ± 2 → +90° Check valve 32 ± 2 Item N⋅m Item Specified sealant Engine support bracket bolts Mitsubishi Genuine Part No.MD970389 or equivalent Semicircular packing 3M ATD No.8660 or equivalent Rocker cover Mitsubishi Genuine Part No. MD970389 or equivalent Engine coolant temperature e gauge unit 3M Nut Locking Part No.4171 or equivalent Engine coolant temperature sensor 3M ATD No.8660 or equivalent Cylinder head (camshaft bearing cap fitting section) 3M ATD No.8660 or equivalent Camshaft position sensor support* Mitsubishi Genuine Part No. MD970389 or equivalent Oil pressure switch 3M ATD No.8660 or equivalent Oil pan* Mitsubishi Genuine Part No. MD970389 or equivalent Rear oil seal case*

SEALANTS ENGINE OVERHAUL 11B-9 FORM-IN-PLACE GASKET (FIPG) This engine has several areas where the form-in-place gasket (FIPG) is used for sealing. To ensure that the FIPG fully serves its purpose, it is necessary to observe some precautions when apply- ing it. 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 fluid passages. To prevent leaks or blocking of passages, therefore, it is absolutely necessary to apply the FIPG evenly without a break, while observing the correct bead size. FIPG hardens as it reacts with the moisture in the atmospheric air, and it is usually used for sealing metallic flange areas. REMOVAL OF FIPG SEALED PARTS Parts sealed with a FIPG can be easily removed without need for the use of a special method. In some cases, however, the FIPG in joints may have to be broken by tapping parts with a mallet or similar tool. You can also tap a flat, thin gasket scraper into the joint to break the FIPG, taking extreme care not to damage the mating surfaces. The oil pan cutter (MD998727) is available as a special tool for remov- ing the oil pan. The tool, however, must not be. CLEANING FIPG APPLICATION SURFACE Thoroughly remove all substances deposited on the FIPG application surface, using a gasket scraper or wire brush. Make sure that the FIPG application surface is flat and smooth. Also make sure that the surface is free from oils, greases and foreign substances. Do not fail to remove old FIPG that may remain in the fastener fitting holes. APPLICATION OF FIPG Applied FIPG bead should be of the specified size and free of any break. FIPG can be wiped away unless it has completely hardened. Install the mating parts in position while the FIPG is still wet (in less than 15 minutes after application). Do not allow FIPG to spread beyond the sealing areas during installation. Avoid operating the engine or letting oils or water come in contact with the sealed area before a time sufficient for FIPG to harden (approximately one hour) has passed. FIPG application method may vary from location to location. Follow the instruction for each particular case described later in this manual.

SPECIAL TOOLS ENGINE OVERHAUL 11B-10 SPECIAL TOOLS M1113000601394 Tool Number Name Use MD998781 Flywheel stopper Retention of flywheel MD998778 Crankshaft sprocket puller Removal of crankshaft sprocket and crankshaft sprocket B MD998785 Sprocket stopper Retention of counterbalancer shaft sprocket MD998767 Tension pulley socket wrench Manipulation of tensioner pulley during adjustment of timing belt tension MD998738 Set screw Retention of tensioner arm and auto-tensioner during timing belt installation MD998713 Camshaft oil seal installer Installation of camshaft oil seal MD998442 Air bleed wire Air bleeding of lash adjuster MB991654 Cylinder head bolt wrench Removal and installation of cylinder head bolts D998781 D998767 D998738 D998713 B991654

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

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