MITSUBISHI 6G7 Series Engine Full Service & Repair Manual 2002-Onwards
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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 E Nov. 1995 Mitsubishi Motors Corporation
ENGINE
6G7 SERIES
<From 2002>
CONTENTS
PWEE9061-I E Aug. 2001 Mitsubishi Motors Corporation Added
11B-0-2
PWEE9520 E Nov. 1995 Mitsubishi Motors Corporation
NOTES
PWEE9061-I E Aug. 2001 Mitsubishi Motors Corporation Added
6G7 ENGINE – General Information 11B-0-3
PWEE9520 E Nov. 1995 Mitsubishi Motors Corporation
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 dm
3
2,972 2,972
Cylinder bore mm 91.1 91.1
Piston stroke mm 76.0 76.0
Compression ratio 8.9 9.0
Valve timing Intake
valve
Opens
(BTDC)
19_ 19_*
1
, 11_*
2
Closes
(ABDC)
59_ 45_*
1
, 49_*
2
Exhaust
valve
Opens
(BBDC)
59_ 49_
Closes
(ATDC)
19_ 15_
Lubrication system Pressure feed, full-flow filtration Pressure feed, full-flow filtration
Oil pump type Trochoid type Trochoid type
Cooling system Water-cooled forced circulation Water-cooled forced circulation
Water pump type Centrifugal impeller type Centrifugal impeller type
*
1
: Except for Hong Kong
*
2
: For Hong Kong
PWEE9061-L E Feb. 2004 Mitsubishi Motors Corporation Revised
6G7 ENGINE – General Information 11B-0-4
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 dm
3
3,497 3,497
Cylinder bore mm 93.0 93.0
Piston stroke mm 85.8 85.8
Compression ratio 9.0 10.4
Valve timing Intake
valve
Opens
(BTDC)
13_*
1
, 5_*
2
8_*
3
, 12_*
4
Closes
(ABDC)
55_ 52_*
3
, 48_*
4
Exhaust
valve
Opens
(BBDC)
51_ 52_*
3
, 48_*
4
Closes
(ATDC)
17_ 8_*
3
, 12_*
4
Lubrication system Pressure feed, full-flow filtration Pressure feed, full-flow filtration
Oil pump type Trochoid type Trochoid type
Cooling system Water-cooled forced circulation Water-cooled forced circulation
Water pump type Centrifugal impeller type Centrifugal impeller type
*
1
: Up to 2002 model
*
2
: From 2003 model
*
3
: For Europe
*
4
: For Hong Kong
PWEE9061-L E Feb. 2004 Mitsubishi Motors Corporation Revised
6G7 ENGINE – General Information 11B-0-5
PWEE9520 E Nov. 1995 Mitsubishi Motors Corporation
6G75
Descriptions 6G75 24-valve
Type 60_ OHV, SOHC
Number of cylinders 6
Combustion chamber Pentroof type
Total displacement dm
3
3,828
Cylinder bore mm 95.0
Piston stroke mm 90.0
Compression ratio 9.5*
1
, 10.0*
2
Valve timing Intake
valve
Opens
(BTDC)
5_
Closes
(ABDC)
55_
Exhaust
valve
Opens
(BBDC)
51_
Closes
(ATDC)
17_
Lubrication system Pressure feed, full-flow filtration
Oil pump type Trochoid type
Cooling system Water-cooled forced circulation
Water pump type Centrifugal impeller type
*
1
: Except for Taiwan
*
2
: For Taiwan
PWEE9061-K E Apr. 2003 Mitsubishi Motors Corporation Added
6G7 ENGINE – Specifications 11B-1-1
1. SPECIFICATIONS
SERVICE SPECIFICATIONS
Item Standard Limit
Timing belt
Auto-tensioner rod length mm 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 –
Rocker arms and camshaft
Camshaft cam height mm 12-valve 41.25 40.75
24-valve Intake 37.58*
1
, 37.39*
2
37.08*
1
, 36.89*
2
Exhaust 37.14*
3
, 36.95*
4
36.64*
3
, 36.45*
4
GDI Intake 35.20*
5
, 34.85*
6
34.70*
5
, 34.35*
6
Exhaust 34.91 34.41
Camshaft journal outside
di t
12-valve 34.5 –
diameter mm
24-valve 45 –
GDI 26 –
Cylinder head and valves
Cylinder head Flatness of gasket
f
12-valve Less than 0.05 0.2
surface mm
24-valve, GDI Less than 0.03 0.2
Cylinder head grinding limit of gasket surface
(including grinding of cylinder block gasket surface) mm
– 0.2
Cylinder head overall height mm 12-valve 84 –
24-valve 120 –
GDI 132 –
Valve thickness of valve head
( i)
12-valve Intake 1.2 0.7
(margin) mm
Exhaust 2.0 1.5
24-valve Intake 1.0 0.5
Exhaust 1.2 0.7
GDI Intake 1.0 0.5
Exhaust 1.5 1.0
Valve overall height mm 12-valve Intake 102.97 102.47
Exhaust 102.67 102.17
24-valve Intake 112.30*
7
, 110.30*
8
111.80*
7
, 109.80*
8
Exhaust 114.11*
7
, 112.11*
8
113.61*
7
, 111.61*
8
GDI Intake 102.28 101.78
Exhaust 101.40 100.90
Valve stem outside diameter mm 12-valve, GDI 6.6 –
24-valve 6.0 –
*
1
: 6G72 (Except for Hong Kong) *
3
: For 6G74 and 6G75 *
5
: Except for Hong Kong *
7
: For 6G72 and 6G74
*
2
: 6G72 (For Hong Kong) and 6G74, 6G75 *
4
: For 6G72 *
6
: For Hong Kong *
8
: For 6G75
PWEE9061-K E Apr. 2003 Mitsubishi Motors Corporation Revised
6G7 ENGINE – Specifications 11B-1-2
Item Standard Limit
Valve stem to guide clearance
mm
12-valve Intake 0.03–0.06 0.10
mm
Exhaust 0.05–0.09 0.15
24-valve Intake 0.02–0.05 0.10
Exhaust 0.04–0.06 0.15
GDI Intake 0.02–0.05 0.10
Exhaust 0.04–0.07 0.15
Valve face angle 43.5_–44_ –
Valve spring free height mm 12-valve 49.8 48.8
24-valve 51.0 50.0
GDI 47.2 46.2
Valve spring load/installed height
N/mm
12-valve 323/40.4 –
N/mm
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 –
Valve guide internal diameter
mm
12-valve, GDI 6.6 –
mm
24-valve 6.0 –
Valve guide projection mm 14.0 –
Valve stem projection mm 12-valve 41.65 42.15
24-valve 49.30 49.80
GDI Intake 47.10 47.60
Exhaust 46.60 47.10
Oil pump and oil pan
Oil pump tip clearance mm 0.03–0.08 –
Oil pump side clearance mm 0.04–0.10 –
Oil pump body clearance mm 0.10–0.18 0.35
Pistons and connecting rods
Piston outside diameter mm 6G72 91.1 –
6G74 93.0 –
6G75 95.0 –
Piston ring side clearance mm No.1 ring 0.03–0.07 –
No. 2 ring 0.02–0.06 –
PWEE9061-K E Apr. 2003 Mitsubishi Motors Corporation Revised
6G7 ENGINE – Specifications 11B-1-3
Item Limit Standard
Piston ring out gap clearance mm No.1 ring 6G72 0.25–0.35*
1
0.8
0.30–0.45*
2
0.8
6G74 0.25–0.40*
3
0.8
0.30–0.45*
4
0.8
6G75 0.25–0.40 0.8
No. 2 ring 6G72 0.35–0.50*
1
0.8
0.45–0.60*
2
0.8
6G74 0.35–0.50*
3
0.8
0.45–0.60*
4
0.8
6G75 0.35–0.50 0.8
Oil ring 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 0.1
Connecting rod big end side clearance mm 0.10–0.25 0.4
Crankshaft, flywheel and drive plate
Crankshaft end play mm 0.05–0.25 0.4
Crankshaft journal outside
diameter mm
6G72 60.0 –
diameter mm
6G74, 6G75 64.0 –
Crankshaft pin outside
diameter mm
6G72 50.0 –
diameter mm
6G74, 6G75 55.0 –
Crankshaft journal oil clearance mm 0.02–0.05 0.1
Piston to cylinder clearance mm 6G72, 6G75 0.02–0.04 0.1
6G74 0.03–0.05 0.1
Cylinder block flatness of gasket surface mm 0.05 0.1
Cylinder block grinding limit of gasket surface mm
(Total resurfacing depth of both cylinder head and cylinder block)
– 0.2
Cylinder block overall height mm 6G72 210 –
6G74, 6G75 228 –
Cylinder bore inside diameter
mm
6G72 91.1 –
mm
6G74 93.0 –
6G75 95.0 –
Cylinder block cylindricality mm 0.01 –
*
1
: For Hong Kong *
3
: From 2003 model GDI
*
2
: Except for Hong Kong *
4
: SOHC, 2002 model GDI
PWEE9061-K E Apr. 2003 Mitsubishi Motors Corporation Revised
6G7 ENGINE – Specifications 11B-1-4
REWORK DIMENSIONS
Item Standard Limit
Cylinder head and valves
Cylinder head oversize valve
guide hole diameter mm
12-valve 0.05 O.S. 13.05–13.07 –
guide hole diameter mm
0.25 O.S. 13.25–13.27 –
0.50 O.S. 13.50–13.52 –
24-valve 0.05 O.S. 11.05–11.07 –
0.25 O.S. 11.25–11.27 –
0.50 O.S. 11.50–11.52 –
GDI 0.05 O.S. 12.05–12.07 –
0.25 O.S. 12.25–12.27 –
0.50 O.S. 12.50–12.52 –
Oversize valve seat ring hole
diameter mm
12-valve Intake 0.3 O.S. 44.30–44.33 –
diameter mm
0.6 O.S. 44.60–44.63 –
Exhaust 0.3 O.S. 38.30–38.33 –
0.6 O.S. 38.60–38.63 –
24-valve
(6G72
Intake 0.3 O.S. 34.30–34.33 –
(6G72,
6G74)
0.6 O.S. 34.60–34.63 –
6G74)
Exhaust 0.3 O.S. 31.80–31.83 –
0.6 O.S. 32.10–32.13 –
24-valve
(6G75)
Intake 0.3 O.S. 37.80–37.83 –
(6G75)
0.6 O.S. 38.10–38.13 –
Exhaust 0.3 O.S. 34.80–34.83 –
0.6 O.S. 35.10–35.13 –
GDI Intake 0.3 O.S. 36.30–36.33 –
0.6 O.S. 36.60–36.63 –
Exhaust 0.3 O.S. 33.30–33.33 –
0.6 O.S. 33.60–33.63 –
PWEE9061-K E Apr. 2003 Mitsubishi Motors Corporation Revised
6G7 ENGINE – Specifications 11B-1-5
TORQUE SPECIFICATIONS
Item Nm
Alternator
Accessory mount bolt (M10 x 1.25) 44"10
Accessory mount bolt (M10 x 1.5) 41"8
Accessory mount bolt (M12) 74"9
Accessory mount stay bolt (M8) 24"4
Accessory mount stay bolt (M10) 49"9
Alternator bolt <12-valve> 14"1
Alternator bolt <24-valve> (M8) 23"3
Alternator bolt <24-valve> (M10) 49"5
Alternator nut 23"2
Alternator cover bolt (M6) 10"2
Alternator cover bolt (M8) 13"2
Auto tensioner bolt (Flange) 24"4
Auto tensioner bolt (Washer) 44"10
Cooling fan bolt 11"1
Cooling fan bracket bolt <12-valve> (M8) 42"8
Cooling fan bracket bolt <12-valve> (M10) 75"10
Cooling fan bracket bolt <24-valve> 41"8
Cooling fan pulley bolt 11"1
Crankshaft bolt 185"5
Drive belt tensioner pulley nut 49"10
Engine hanger bolt 17"2
Fan clutch bolt 11"1
Idler pulley bolt 44"10
Tensioner pulley bolt 44"10
Tensioner bracket bolt (Flange) 24"3
Tensioner bracket bolt (M8 washer) 19"3
Tensioner bracket bolt (M10 washer) 42"8
Tensioner bracket stay bolt 24"3
Timing indicator bolt 11"1
Oil filler bolt <12-valve> 9"1
Oil filler bolt <24-valve> 22"4
Power steering pump bracket bolt 44"10
Control and EGR system
EGR valve bolt <12-valve> 22"4
EGR valve bolt <24-valve (Except 6G75 for Taiwan)> 21"4
EGR valve bolt <6G75 for Taiwan> 24"3
EGR pipe bolt 18"2
PWEE9061-K E Apr. 2003 Mitsubishi Motors Corporation Revised
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