. 11D-1 GROUP 11D ENGINE OVERHAUL CONTENTS HOW TO USE THIS MANUAL.11D-2 INLET MANIFOLD.11D-30 REMOVAL AND INSTALLATION. 11D-2 ENGINE OVERHAUL HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL M296 HOW TO USE THIS MANUAL Scope of Service Explanations This manual describes service procedures performed after removal of the engine from the vehicle. For removal of the engine from the vehicle, installation of the engine in the vehicle, and on-vehicle inspection and service of the engine, please use the separate Workshop Manuals prepared for the vehicle. 11D-3 ENGINE OVERHAUL HOW TO USE THIS MANUAL Page number Group title Section title ENGINE OVERHAUL 11-54 CRANKSHAFT AND CYLINDER BLOCK CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION Denotes non-reusable part. Apply engine oil to all moving 11 ± 1 Nm parts before installation.

• Mitsubishi 4g63 Wiring Diagram

11D-4 ENGINE OVERHAUL GENERAL INFORMATION GENERAL INFORMATION M523 VEHICLE AND ENGINE MODELS Vehicle name Vehicle Engine model Displacement Specification model OUTLANDER CU2W 4G63-7 1,997 Double overhead camshaft, 16-valve GENERAL SPECIFICATIONS M779 Item Specification Bore × stroke mm 85 × 88. 11D-5 ENGINE OVERHAUL SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS M776 Item Standard value Limit TIMING BELT 3.8 − 4.5 Auto-tensioner rod extension length − (with timing belt installed) mm Auto-tensioner rod extension length (when free) mm 12.0 − Auto-tensioner rod retraction length Less than 1 −. 11D-6 ENGINE OVERHAUL REWOK DIMENSIONS Item Standard value Limit Oil pressure at curb idle speed kPa 78 or more − oil temperature is 75 to 90° PISTONS AND CONNECTING RODS Piston outside diameter mm 85.0 − 0.03 − 0.07 Piston ring side clearance in ring No. 11D-7 ENGINE OVERHAUL TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS M989 Item N⋅m ALTERNATOR AND IGNITION COIL 13 ± 1 Oil level gauge guide bolt 79 ± 5 Idler pulley bolt 24 ± 4 Auto-tensioner assembly bolt (M8) 44 ± 10 Auto-tensioner assembly bolt (M10) 8.8 ±.

11D-8 ENGINE OVERHAUL TORQUE SPECIFICATIONS Item N⋅m FUEL SYSTEM 19 ± 3 Throttle body bolts 9.0 ± 2.0 Fuel pressure regulator bolts 11 ± 1 Delivery pipe and injector assembly bolts INLET MANIFOLD 31 ± 3 Inlet manifold stay bolts 20 ±. 11D-9 ENGINE OVERHAUL TORQUE SPECIFICATIONS Item N⋅m CYLINDER HEAD AND VALVES 78 ± 2 → 0 → 20 ± 2 → + 90° + 90° Cylinder head bolts OIL PUMP CASE AND OIL PAN 39 ± 5 Drain plug Oil filter 14 ±.

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.

11D-11 ENGINE OVERHAUL SPECIAL TOOLS SPECIAL TOOLS M788 Tool Number Name MD998781 Flywheel stopper Retention of flywheel D998781 MD998778 Crankshaft sprocket Removal of crankshaft sprocket puller and crankshaft sprocket B MD998785 Sprocket stopper Retention of counterbalancer shaft sprocket MD998767. 11D-12 ENGINE OVERHAUL SPECIAL TOOLS Tool Number Name MB991654 Cylinder head bolt Removal and installation of wrench cylinder head bolts B991654 MD998772 Valve spring Compression of valve spring compressor MD998735 Valve spring Compression of valve spring compressor MD998737 Valve stem seal. 11D-13 ENGINE OVERHAUL SPECIAL TOOLS Tool Number Name MB991603 Silent shaft bearing Guide and stopper for removal installer stopper and press-fitting of counterbalancer shaft rear bearing MD998705 Silent shaft bearing Press-fitting of counterbalancer installer shaft front and rear bearings. 11D-14 ENGINE OVERHAUL ALTERNATOR AND IGNITION SYSTEM ALTERNATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION M701 3.0 ± 0.5 Nm 10 ± 2 Nm 13 ± 1 Nm 25 ± 5 Nm 44 ± 10 Nm 22 ± 4 Nm 44 ±. 11D-15 ENGINE OVERHAUL SOLENOID AND VACUUM HOSE SOLENOID AND VACUUM HOSE REMOVAL AND INSTALLATION M074 20 ± 2 Nm 19 ± 3 Nm 23 ± 4 Nm 9.0 ± 1.0 Nm 36 ± 6 Nm 11 ± 1 Nm 11 ±.

11D-16 ENGINE OVERHAUL TIMING BELT TIMING BELT REMOVAL AND INSTALLATION M867 3.5 ± 0.5 Nm 11 ± 1 Nm 48 ± 5 Nm 21 ± 4 Nm 11 ± 1 Nm 23 ± 3 Nm 11 ± 1 Nm 11 ±. 11D-17 ENGINE OVERHAUL TIMING BELT Removal steps (Continued) CAUTION 23. PCV valve gasket Never remove the timing belt with any piston at 24.

Oil filler cap the top dead center (TDC). If a piston is at TDC, DD TIMING BELT CRANKSHAFT SPROCKET COUNTERBALANCER SHAFT REMOVAL SPROCKET REMOVAL MD998778 MD998785 AK304176 AK300138 Use the special tool Crankshaft sprocket puller 1.

Use the special tool Sprocket stopper (MD998778) if the sprocket is stuck and hard to (MD998785) to prevent the counterbalancer shaft remove. Specified sealant: 3M ATD No.8660 or equivalent AK202743AB 1. Remove thoroughly the old sealant remaining on the indicated bolt and in its hole. Coat the bolt with sealant, then install and tighten Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent. NOTE: Degreasing is necessary to prevent lack of Specified sealant: frictional coefficient between the mating surfaces.

Mitsubishi Genuine Part No.MD970389 or equivalent F TIMING BELT G TIMING BELT IJ TIMING BELT NOTE: If the timing marks were aligned, the exhaust camshaft would be turned counterclockwise by one sprocket tooth and stay there by the force of the valve springs. Timing marks AK300154 2. Install the auto-tensioner in position. Leave the wire installed until the auto-tensioner is completely installed. 11D-24 ENGINE OVERHAUL TIMING BELT (2) Insert a crosspoint screwdriver with a shank 6.

Turn the intake camshaft sprocket diameter of 8 mm through the plug hole. If it counterclockwise to bring the timing mark on it can be inserted 60 mm or more, the sprocket one sprocket tooth away from the mating timing is in the correct phase.

11D-25 ENGINE OVERHAUL TIMING BELT NOTE: Turning slightly the intake camshaft sprocket counterclockwise will facilitate installa- tion of the belt on the tensioner pulley. MD998738 Crankshaft sprocket AK202774 14.Install the special tool Set screw (MD998738) and turn down the tool until the wire (inserted in the. 11D-26 ENGINE OVERHAUL TIMING BELT Cracks Cracks Extension Peeling of canvas amount Cracks in sides Cracks in tooth roots AK202829 AK202793 20.Check that the wire (inserted in the auto-tensioner 2. Cracks in back rubber surface. When it was installed) can be moved freely. 11D-27 ENGINE OVERHAUL TIMING BELT AUTO-TENSIONER 3.

Measure the extension length of the rod. If it is not within the standard value range, replace the auto-tensioner. Standard value: 12 mm 12 mm 98 to 196 N Movement AK301307AD 1. Check the auto-tensioner for leaks from the sealed sections.

11D-28 ENGINE OVERHAUL FUEL AND EMISSION PARTS FUEL AND EMISSION PARTS REMOVAL AND INSTALLATION M708 9.0 ± 2.0 Nm 11 ± 1 Nm 19 ± 3 Nm AK400297 AB Removal steps (Continued) Removal steps 7. Throttle body A FUEL AND EMISSION PARTS INSTALLATION SERVICE POINTS 3. Check that the fuel pressure regulator turns smoothly.

If it does not, the O-ring may be A INLET MANIFOLD INLET MANIFOLD REMOVAL AND INSTALLATION M062 36 ± 6 Nm 36 ± 6 Nm 20 ± 2 Nm 23 ± 2 Nm 31 ± 3 Nm AK400302 INSTALLATION SERVICE POINTS Removal steps AA EXHAUST MANIFOLD EXHAUST MANIFOLD REMOVAL AND INSTALLATION M725 19 ± 3 Nm 23 ± 3 Nm 59 ± 5 Nm 17 ± 2 Nm 33 ± 6 Nm 17 ± 2 Nm 11 ± 1 Nm 19 ±. 11D-32 ENGINE OVERHAUL EXHAUST MANIFOLD INSTALLATION SERVICE POINT BA WATER PUMP AND WATER HOSE WATER PUMP AND WATER HOSE REMOVAL AND INSTALLATION M372 13 ± 2 Nm 13 ± 2 Nm 13 ± 2 Nm 23 ± 4 Nm 10.8 ± 1.0 Nm 29 ± 10 Nm 14 ±. NOTE: A new engine coolant temperature gauge Specified sealant: unit is coated with sealant. It does not require Mitsubishi Genuine Part No.MD970389 or coating with sealant before installation. Equivalent 2. Apply sealant to the indicated threads of the engine coolant temperature gauge unit.

Body Electrical. These car requirements could differ from those available inside additional nations. Please be aware of these potential variations before utilizing the information contained inside. Workshop manual holden nova. Electrical Wiring Diagrams.This workshop guide is yielded for the Australian marketplace. Information about Repair plus Service Manuals Note which repair manuals are usually yielded for models available inside a certain nation.

11D-35 ENGINE OVERHAUL ROCKER ARMS AND CAMSHAFT ROCKER ARMS AND CAMSHAFT REMOVAL AND INSTALLATION M853 10 ± 2 Nm 20 ± 1 Nm 14 ± 1 Nm 22 ± 4 Nm 10.8 ± 1.0 Nm 11 ± 1 Nm. 11D-36 ENGINE OVERHAUL ROCKER ARMS AND CAMSHAFT INSTALLATION SERVICE POINTS 2. The bearing caps No. 2 to 5 are identical in shape for both intake and exhaust camshafts. Check the AF ROCKER ARMS AND CAMSHAFT CAUTION The hole in the side of the lash adjuster must be directed toward the inside of container A.

Never direct it against any person. Take the lash adjuster out of the container, then. 11D-39 ENGINE OVERHAUL ROCKER ARMS AND CAMSHAFT 8. Place the lash adjuster upright with the plunger at the top. Push the plunger firmly until it makes a full stroke, then return the plunger slowly and release the hold of the steel ball to allow the pressure chamber to be filled with diesel fuel.

11D-40 ENGINE OVERHAUL CYLINDER HEAD AND VALVES CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION M787 78 ± 2 Nm → 0 Nm → 20 ± 2 Nm → +90˚ → +90˚ Apply engine oil to all moving parts before installation. 11D-41 ENGINE OVERHAUL CYLINDER HEAD AND VALVES NOTE: Store removed valves, springs and other Removal steps (Continued) A CYLINDER HEAD AND VALVES Compress the valve spring using the special tool Intake valve stem seal Exhaust valve stem seal Valve spring compressor (MD998735 or MD998772), Colour: Gray Colour: Grayish green then install the retainer lock. 11D-43 ENGINE OVERHAUL CYLINDER HEAD AND VALVES CAUTION The thickness of the metal that can be removed by grinding from both the cylinder head and the mating cylinder block is limited to 0.2 mm in 90˚ total. Check the cylinder head gasket surface for warp using a straightedge and thickness gauge. 11D-44 ENGINE OVERHAUL CYLINDER HEAD AND VALVES VALVE GUIDE Valve guide Total length AK202876 Stem diameter Guide inside diameter AK300168 3. Measure the total length of the valve. Measure the valve guide inside diameter and valve Replace the valve if the length is less than the stem diameter to calculate the clearance between limit.

11D-45 ENGINE OVERHAUL CYLINDER HEAD AND VALVES VALVE SEAT RECONDITIONING Intake valve seat hole diameters: 0.3 oversize: 35.30 − 35.33 mm 1. Before reconditioning the valve seat, check the 0.6 oversize: 35.60 − 35.63 mm clearance between the valve guide and valve stem and, if necessary, replace the valve guide. 11D-46 ENGINE OVERHAUL OIL PAN AND OIL PUMP OIL PAN AND OIL PUMP REMOVAL AND INSTALLATION M657 19 ± 3 Nm Apply engine oil to all moving parts before installation.

23 ± 3 Nm 10 ± 2 Nm 54 ± 5 Nm 23 ±. 11D-47 ENGINE OVERHAUL OIL PAN AND OIL PUMP REMOVAL SERVICE POINTS FLANGE BOLT REMOVAL OIL PAN LOWER REMOVAL Remove the oil pan by tapping it through a piece of wood applied to a side with a plastic hammer. 11D-48 ENGINE OVERHAUL OIL PAN AND OIL PUMP COUNTERBALANCER SHAFT REAR BEARING REMOVAL MB991603 MD998705 Rear bearing AK300619AG 1. Install special tool Silent shaft bearing installer MD998372 AK300175AD stopper (MB991603) to the cylinder block. Apply engine oil to the rear bearing outer surface 1.

11D-49 ENGINE OVERHAUL OIL PAN AND OIL PUMP MD998705 MD998705(Guide pin) MD998705(Guide pin) AK300179 AK300178 2. Install the guide pin of the Silent shaft bearing installer (MD998705) in the threaded hole of the MD998705 cylinder block as shown. Ratchet ball. 11D-50 ENGINE OVERHAUL OIL PAN AND OIL PUMP G OIL PAN AND OIL PUMP IK OIL PAN AND OIL PUMP M OIL PAN AND OIL PUMP OIL COOLER BY-PASS VALVE 2. Ensure that the dimension L measures the standard value under normal temperature and humidity. Standard value: 34.5 mm 3. The dimension must be the standard value when measured after the valve has been dipped in 97 to 103°C oil.

11D-55 ENGINE OVERHAUL PISTON AND CONNECTING ROD PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION M863 Apply engine oil to all moving parts before installation. 20 ± 2 Nm + 90º to 94º AK306012AC Removal steps (Continued) Removal steps C PISTON AND CONNECTING ROD REMOVAL SERVICE POINTS CONNECTING ROD CAP REMOVAL Push rod Cylinder Front mark number Front mark Guide C AK300189 Base Mark the cylinder number on the side of the connecting rod big end as a guide for reassembly. 11D-57 ENGINE OVERHAUL PISTON AND CONNECTING ROD 7. Insert the assembly of piston pin, Push rod, and Cylinder bore size mark Piston size mark Guide A (put together in step 4.) into the piston holes from the front mark side. 11D-58 ENGINE OVERHAUL PISTON AND CONNECTING ROD BC PISTON AND CONNECTING ROD D PISTON AND CONNECTING ROD F PISTON AND CONNECTING ROD CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE METHOD) Push in by piston 1. Wipe off oil from the crankshaft pin and connecting rod bearing. Cut a piece of plastic gauge whose length is equivalent to the width of the bearing and place it on the crankshaft pin in parallel with its axis.

11D-62 ENGINE OVERHAUL CRANKSHAFT AND CYLINDER BLOCK CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION M875 11 ± 1 Nm 132 ± 5 Nm 9.0 ± 1.0 Nm 11 ± 1 Nm Apply engine oil to all moving parts before installation. 11D-63 ENGINE OVERHAUL CRANKSHAFT AND CYLINDER BLOCK REMOVAL SERVICE POINTS NOTE: Applying engine oil to the bearings will help facilitate holding them in position.

OIL JET REMOVAL C CRANKSHAFT AND CYLINDER BLOCK D CRANKSHAFT AND CYLINDER BLOCK E CRANKSHAFT AND CYLINDER BLOCK INSPECTION CYLINDER BLOCK M645 1. Visually check the cylinder block for scratches, CRANKSHAFT OIL CLEARANCE rust, and any other corrosion.

Also check it for (PLASTIC GAUGE METHOD) cracks using a flaw detecting penetrant. 11D-67 ENGINE OVERHAUL CRANKSHAFT AND CYLINDER BLOCK BORING CYLINDERS 3. Based on the piston diameter measurement, calculate the boring finish dimension. Select an oversize of the pistons to be used.

Mitsubishi 4g63 Wiring Diagram

Boring finish dimension = Piston diameter + based on the largest of the cylinder bores.