2003-2008 Mitsubishi Outlander OEM 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

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2003-2008 Mitsubishi Outlander OEM Service & Repair Manual

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