2003-2006 Mitsubishi Outlander 2.0L 4G63 Service & Repair Manual

2008 ENGINE Engine Overhaul (2.4L) - Outlander GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS Item Specifications Engine model 4B12 Type In-line OHV, DOHC Number of cylinders 4 Combustion chamber Pentroof type Total displacement cm 3 (cu in) 2,359 (144.0) Cylinder bore mm 88 Piston stroke mm 97 Compression ratio 10.5 Valve timing Intake valve Open 0-40° Close 64-24° Exhaust valve Open 44-24° Close 0-20° Auto lash adjuster Non-equipped Item Standard value Limit Timing chain Valve clearance mm (in) Intake 0.20 ± 0.03 (0.008 ± 0.001) - Exhaust 0.30 ± 0.03 (0.012 ± 0.001) - Camshaft Cam height of camshaft mm (in) Intake 44.1 (1.736) 43.6 (1.717) Exhaust 45.0 (1.772) 44.5 (1.752) Cylinder head and valves Distortion of cylinder head bottom mm (in) Within 0.05 (0.002) 0.02 (0.0008) Grinding limit of cylinder head bottom mm (in) - 0.2 (0.008) Overall height of cylinder head mm (in) 128.5 (5.06) - Overall length of valve mm (in) Intake 113.18 (4.456) 112.68 (4.436) Exhaust 105.89 (4.169) 105.39 (4.149) Valve margin mm (in) Intake 1.022 (0.0402) 0.522 (0.0206) 2008 Mitsubishi Outlander XLS 2008 ENGINE Engine Overhaul (2.4L) - Outlander 2008 Mitsubishi Outlander XLS 2008 ENGINE Engine Overhaul (2.4L) - Outlander

REWORK DIMENSIONS REWORK DIMENSIONS Exhaust 1.094 (0.0431) 0.594 (0.0234) Free height of valve spring mm (in) 47.44 (1.867) - Squareness of valve spring 2° or less 4° Clearance between valve guide and valve stem mm (in) Intake 0.020-0.047 (0.0008- 0.0019) 0.10 (0.0039) Exhaust 0.030-0.054 (0.0012- 0.0021) 0.11 (0.0043) Valve seat contact width mm (in) Intake 1.16-1.46 (0.046-0.058) - Exhaust 1.35-1.65 (0.053-0.065) - Press fit the valve guide mm (in) 14.6-15.2 (0.57-0.60) - Piston and connecting rod Piston pin press-fit load N (lbf) 7,500-17,500 (1.686- 3.934) - Clearance between piston ring and ring groove mm (in) Number 1 0.03-0.07 (0.001-0.003) 0.1 (0.004) Number 2 0.03-0.07 (0.001-0.003) 0.1 (0.004) Piston ring end gap mm (in) Number 1 0.15-0.25 (0.006-0.011) 0.8 (0.03) Number 2 0.25-0.40 (0.010-0.016) 0.8 (0.03) Oil 0.10-0.35 (0.004-0.014) 1.0 (0.04) Clearance of connecting rod big end thrust mm (in) 0.10-0.25 (0.004-0.010) 0.4 (0.016) Difference of outside diameter of connecting rod bolt mm (in) - 0.1 (0.04) Connecting rod bearing oil clearance mm (in) 0.018-0.045 (0.0007- 0.0018) 0.1 (0.04) Crankshaft and cylinder block Underhead length of crankshaft bearing cap bolt mm (in) 75.5-76.5 (2.972-3.012) - Crankshaft end play mm (in) 0.05-0.25 (0.002-0.010) 0.4 (0.016) Crankshaft journal oil clearance mm (in) 0.012-0.030 (0.0005- 0.0012) 0.08 (0.0031) Distortion of cylinder block top surface mm (in) - 0.05 (0.0020) Grinding limit of cylinder block top surface mm (in) - 0.2 (0.008) Cylinder block cylinder bore mm (in) 88 (3.46) - Cylindricity of cylinder block mm (in) 0.0076 (0.0003) - Item Standard value Cylinder head and valve Cylinder head oversize valve seat bore diameter mm Intake 0.30 Over size 36.22-36.24 (1.426- 1.427) 2008 Mitsubishi Outlander XLS 2008 ENGINE Engine Overhaul (2.4L) - Outlander

TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS (in) Exhaust 0.30 Over size 30.22-30.24 (1.190- 1.191) Cylinder head oversize valve guide bore diameter mm (in) 0.25 Over size 11.23-11.25 (0.442- 0.443) Item Specification Generator and ignition system Idler pulley bolt 48 ± 7 N.m (36 ± 4 ft-lb) Auto tensioner bolt 22 ± 4 N.m (17 ± 2 ft-lb) Crankshaft pulley center bolt 210 N.m (155 ft-lb) Generator nut 44 ± 10 N.m (32 ± 7 ft-lb) Generator bolt 44 ± 10 N.m (32 ± 7 ft-lb) Ignition coil bolt 10 ± 2 N.m (89 ± 17 in-lb) Spark plug 25 ± 5 N.m (19 ± 3 ft-lb) Power steering pump bracket bolt (M8) 23 ± 2 N.m (17 ± 1 ft-lb) Power steering pump bracket bolt (M10) 44 ± 8 N.m (33 ± 5 ft-lb) Throttle body and EGR system Vacuum pipe and hose bolt (M6) 11 ± 1 N.m (98 ± 8 in-lb) Vacuum pipe and hose bolt (M8) 24 ± 3 N.m (18 ± 1 ft-lb) Water pipe bolt 10 ± 2 N.m (89 ± 17 in-lb) Throttle body bolt 9.5 ± 2.5 N.m (84 ± 22 in-lb) Throttle body stay bolt 20 ± 2 N.m (15 ± 1 ft-lb) EGR valve support bolt 20 ± 2 N.m (15 ± 1 ft-lb) EGR pipe bolt 20 ± 2 N.m (15 ± 1 ft-lb) EGR support stay A bolt 20 ± 2 N.m (15 ± 1 ft-lb) EGR support stay B bolt 20 ± 2 N.m (15 ± 1 ft-lb) EGR valve bolt 24 ± 3 N.m (18 ± 1 ft-lb) Manifold absolute pressure (MAP) sensor screw 4.0 ± 1.0 N.m (36 ± 8 in-lb) Solenoid valve screw 4.0 ± 1.0 N.m (36 ± 8 in-lb) Intake manifold and fuel system Oil dipstick guide bolt 10 ± 2 N.m (89 ± 17 in-lb) Injector protector rear bolt 20 ± 2 N.m (15 ± 1 ft-lb) Fuel rail bolt 20 ± 2 N.m (15 ± 1 ft-lb) Intake manifold bolt and nut 3.5 ± 1.5 N.m (31 ± 13 in-lb) --> 20 ± 2 N.m (15 ± 1 ft-lb) Intake manifold stay bolt 20 ± 2 N.m (15 ± 1 ft-lb) Injector protector front bolt 20 ± 2 N.m (15 ± 1 ft-lb) Generator bracket bolt 44 ± 8 N.m (33 ± 5 ft-lb) 2008 Mitsubishi Outlander XLS 2008 ENGINE Engine Overhaul (2.4L) - Outlander

Detonation sensor bolt 20 ± 2 N.m (15 ± 1 ft-lb) Engine oil pressure switch 10 ± 2 N.m (89 ± 17 in-lb) Exhaust manifold Exhaust manifold upper cover bolt 14 ± 1 N.m (124 ± 8 in-lb) Exhaust manifold lower cover bolt 14 ± 1 N.m (124 ± 8 in-lb) Exhaust manifold nut 49 ± 5 N.m (36 ± 3 ft-lb) Exhaust manifold bracket C bolt (M8) 20 ± 5 N.m (15 ± 3 ft-lb) Exhaust manifold bracket A bolt (M10) 41 ± 10 N.m (30 ± 7 ft-lb) Crankshaft position sensor bolt 11 ± 1 N.m (98 ± 8 in-lb) Crankshaft position sensor cover bolt (M6) 11 ± 1 N.m (98 ± 8 in-lb) Crankshaft position sensor cover bolt (M10) 49 ± 6 N.m (36 ± 4 ft-lb) Water hose and pipe Water inlet fitting bolt 24 ± 3 N.m (18 ± 1 ft-lb) Water outlet fitting bolt 24 ± 3 N.m (18 ± 1 ft-lb) Thermostat housing bolt 24 ± 3 N.m (18 ± 1 ft-lb) Engine hanger bolt 24 ± 3 N.m (18 ± 1 ft-lb) Engine coolant temperature sensor 30 ± 9 N.m (22 ± 6 ft-lb) Water pump bolt 24 ± 3 N.m (18 ± 1 ft-lb) Water pipe nut 24 ± 3 N.m (18 ± 1 ft-lb) Camshaft position sensor bolt 11 ± 1 N.m (98 ± 8 in-lb) Oil pan and timing chain case Cylinder head cover bolt 3.0 ± 1.0 N.m (27 ± 8 in-lb) --> 5.5 ± 0.5 N.m (49 ± 8 in-lb) Timing chain case bolt (M6) 10 ± 2 N.m (89 ± 17 in-lb) Timing chain case bolt (M8 x 10) 13 ± 1 N.m (115 ± 8 in-lb) Timing chain case bolt (M8 x 28) 24 ± 4 N.m (18 ± 1 ft-lb) Oil pan bolt (M6) 10 ± 2 N.m (89 ± 17 in-lb) Oil pan bolt (M8) 29 ± 2 N.m (21 ± 1 ft-lb) Air compressor bracket bolt 23 ± 6 N.m (17 ± 4 ft-lb) Oil drain plug 39 ± 5 N.m (29 ± 3 ft-lb) Oil filter 14 ± 2 N.m (124 ± 17 in-lb) Positive Crankcase Ventilation Valve 2.5 ± 0.4 N.m (22 ± 3 in-lb) Engine support bracket bolt 45 ± 5 N.m (33 ± 3 ft-lb) Timing chain Chain upper guide bolt 10 ± 2 N.m (89 ± 17 in-lb) Oil jet bolt 10 ± 2 N.m (89 ± 17 in-lb) V.V.T. intake sprocket bolt 59 ± 5 N.m (44 ± 3 ft-lb) V.V.T. exhaust sprocket bolt 59 ± 5 N.m (44 ± 3 ft-lb) Timing chain tensioner bolt 10 ± 2 N.m (89 ± 17 in-lb) Tensioner lever bolt 10 ± 2 N.m (89 ± 17 in-lb) Timing chain guide bolt 10 ± 2 N.m (89 ± 17 in-lb) 2008 Mitsubishi Outlander XLS 2008 ENGINE Engine Overhaul (2.4L) - Outlander

NEW TIGHTENING METHOD BY USING PLASTIC REGION TIGHTENING BOLT Plastic region tightening bolts are used in some parts of the engine. Install these bolts according to the method described in the body of the manual because the tightening method of these bolts are different from the conventional method. The service limit is determined for these bolts. Be sure to strictly follow the service limit described in the body of the manual.  Parts to be used 1. Cylinder head bolt 2. Bearing cap bolt 3. Connecting rod cap bolt  Tightening method After tightening to the specified tightening torque, further tighten 90° and 90°, or 180° (90° + 90°). Follow the tightening method described in the body of the manual because the tightening method differs from part to part. SEALANTS SEALANTS REFERENCE Camshaft Engine oil control valve (OCV) bolt 10 ± 2 N.m (89 ± 17 in-lb) Camshaft bearing cap bolt (M6) 12 ± 1 N.m (107 ± 8 in-lb) Front camshaft bearing cap bolt (M8) 17 ± 3 N.m (14 ± 2 ft-lb) --> 30 ± 2 N.m (22 ± 1 ft- lb) Cylinder head and valves Cylinder head bolt 35 ± 2 N.m (26 ± 1 ft-lb) --> +180° Balancer chain Drive plate bolt 40 N.m (30 ft-lb) --> 130 N.m (95 ft-lb) Balancer shaft module bolt 20 (15 ft-lb) --> 44 (32 ft-lb) --> 0 --> 20 (15 ft-lb) - -> +135° Balancer shaft chain tensioner bolt 10 ± 2 N.m (89 ± 17 in-lb) Lever tensioner bolt 10 ± 2 N.m (89 ± 17 in-lb) Balancer shaft chain guide bolt 10 ± 2 N.m (89 ± 17 in-lb) Ladder frame bolt 26 ± 1 N.m (19 ± 1 ft-lb) Piston and connecting rod Connecting rod cap bolt 5.0 N.m (44 in-lb) --> 20 N.m (15 ft-lb) --> +90° Crankshaft and cylinder block Crankshaft sensing ring bolt 11 N.m (98 in-lb) Bearing cap bolt 26.5 ± 2.0 N.m (20 ± 1 ft-lb) --> +45° Points of application Specified sealant/adhesive 2008 Mitsubishi Outlander XLS 2008 ENGINE Engine Overhaul (2.4L) - Outlander

LIQUID GASKET (FIPG) FIPG is used for some parts in the engine. It is necessary to pay attention to an application amount, application procedure and applied surface condition for this gasket to fully achieve its purpose. Too small amount causes leakage while too much amount squeezes out to block or narrow water and oil passages. Therefore, it is absolutely essential to apply a correct amount of liquid sealant continuously without break to eliminate leakage from joints. FIPG used for engine parts hardens reacting with moisture in the air, and is usually used for metal flanges. DISASSEMBLY Parts assembled with FIPG can be easily disassembled without using a special method. In some cases, however, it is necessary to lightly tap parts with a wooden hammer or similar tool to break sealant between mating surfaces. Or lightly driving a smooth and thin gasket scraper in mating surfaces is useful, but full care must be exercised not to damage mating surfaces. As special tool oil pan FIPG cutter (MD998727) is set, use this tool. CLEANING OF GASKET SURFACE Completely remove all deposits from the gasket surface with a gasket scraper or wire brush. Make sure that the surface to which FIPG is applied is smooth. The gasket surface must be free from grease and foreign substances. Be sure to remove old FIPG that has entered mounting holes and screw holes. Drive plate bolt Three bond 1324 or exact equivalent Ladder frame Three bond 1227D, Three bond 1217G (Mitsubishi Genuine Tool number and name 1000A923), Three bond 1207F (Mitsubishi Genuine Tool number and name MD970389), LOCTITE 5971, LOCTITE 5970, LOCTITE 5900 Oil pan Cylinder head cover (matching area of the cylinder head and the timing chain case assembly) Three bond 1227D, Three bond 1217G (Mitsubishi Genuine Tool number and name 1000A923), Cylinder head gasket (matching area of the cylinder block and the cylinder head) Three bond 1217G (Mitsubishi Genuine Tool number and name 1000A923), Timing chain case Engine coolant temperature sensor Three bond 1324N, LOCTITE 262 or exact equivalent Engine oil pressure switch Three bond 1212D, Three bond 1215 or exact equivalent NOTE: The number in square brackets shows the genuine part number. 2008 Mitsubishi Outlander XLS 2008 ENGINE Engine Overhaul (2.4L) - Outlander

APPLICATION PROCEDURE Apply FIPG in a determined diameter and continuously without break. Completely enclose the periphery of mounting holes. FIPG can be wiped off if it is not hardened. Install parts in place while FIPG is still wet. Take care not to allow FIPG to adhere to other locations than necessary locations during installation. Do not pour oil or water on applied locations or do not start the engine until sufficient time (approximately one hour) passes. The application procedure of FIPG may differ depending on areas. Follow the procedure in the body of the manual to apply FIPG. SPECIAL TOOLS SPECIAL TOOLS DESCRIPTION Tool Tool number and name Supersession Application MB991883 Flywheel stopper - Securing of drive plate MB991398 Spark plug wrench - Removal and installation of spark plug MB992106 O-ring installer - Installation of O-ring on injector injection nozzle side MB991396 Oil filter wrench - Removal and installation of oil filter MD998727 Oil pan FIPG cutter MD998727-01 Removal of oil pan MB991448 Bushing remover and installer base MB991448-01 Press fit of front oil seal 2008 Mitsubishi Outlander XLS 2008 ENGINE Engine Overhaul (2.4L) - Outlander

MD998735 Valve spring compressor MD998735-01 Compression of valve spring MB992089 Retainer holder C MB992089-01 MB992085 Valve stem seal pliers - Extraction of valve stem seal MD998737 Valve stem seal installer MD998737-01 Installation of valve stem seal MD998780 Piston pin setting tool MIT216941 Extraction and press fit of piston pin MB991659 Guide D - MB991614 General service tool Installation of crankshaft 2008 Mitsubishi Outlander XLS 2008 ENGINE Engine Overhaul (2.4L) - Outlander

GENERATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION Angle gauge bearing cap bolt and installation of balancer shaft module bolt MD998718 Rear oil seal installer MD998718-01 Press fit of rear oil seal 2008 Mitsubishi Outlander XLS 2008 ENGINE Engine Overhaul (2.4L) - Outlander

Fig. 1: Identifying Generator And Ignition System With Torque Specifications Courtesy of MITSUBISHI MOTOR SALES OF AMERICA. Required Special Tool:  MB991883: Flywheel Stopper  MB991398: Spark plug wrench 2008 Mitsubishi Outlander XLS 2008 ENGINE Engine Overhaul (2.4L) - Outlander

2003-2006 Mitsubishi Outlander 2.0L 4G63 Service & Repair Manual

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