3G63 Turbo

ENGINE 4G61, 4663, 4664
<1992>
CONTENTS
BRACKET . . . . . . . . . . . . . . . . . . . . .,. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 CAMSHAFTS AND ROCKER ARMS - DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 CRANKSHAFT, FLYWHEEL AND DRIVE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 CYLINDER HEAD AND VALVES - SOHC . . . . . . . . 74 CYLINDER HEAD AND VALVES - DOHC . . . . . . . . EXHAUST MANIFOLD AND WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT CASE, SILENT SHAFT AND OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 59 85 GENERATOR AND IGNITION SYSTEM - SOHC ................................................ GENERATOR AND IGNITION SYSTEM - DOHC ................................................ INTAKE MANIFOLD ............................................ PISTON AND CONNECTING ROD .................... ROCKER ARMS AND CAMSHAFT- SOHC .... SPECIAL TOOLS .................................................... SEALANT ................................................................ SERVICE SPECIFICATIONS ................................ THROTTLE BODY ................................................ TIMING BELT - SOHC ........................................ TIMING BELT - DOHC . ....................................... TORQUE SPECIFICATIONS ................................ TURBOCHARGER ................................................
26 56 95 66 20 19 10 50 28 36 16 63
FUEL AND EMISSION CONTROL PARTS . . . . 46 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL SPECIFICATIONS
IIC-2
466 ENGINE <1992> - General Information
GENERAL INFQRMATION
ENGINE SECTIONAL VIEW - SOHC
6EN0313
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.I
4G6 ENGINE <1992> - General Information
6EN0314
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IIC-4
,NGlNE SECTIONAL VIEW - DOHC
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6EN0244
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IIC-6
ENGINE LUBRICATION SYSTEM - SOHC

Rocker shaft \
Camshaft Oil pressure switch \
rankshaft
6LUOO39
ENGINE LUBRICATION SYSTEM - DOHC
Camshaft
Oil cooler Oil cooler by-pass valve Silent shaft&I)
lressure switch
Crankshaft
Oil puml
I1 t- A/
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Silent shaft
6LUOO55
I -
4G6 ENGINE <1992> - General Information ENGINE LUBRICATION SYSTEM DOHC-TURBO
- To turbocharger Camshaft
ee Silent shaft From thermostat case n Oil filter K Oil cooler / \
EIe
+ I! IJ
,
To water inlet pipe i I 41
Key=
Oil pressure sw&h
Oil pump /
-7 (k,/ Silent shaft Crankshaft

6LUOW6
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IIC-8
4G63 SOHC Type
-4G6 ENGINE <1992> - General Specifications
GENERAL SPECIFICATIONS
In-line OHV, SOHC 4 Compact type 1,997 (121.9) 85 (3.35) 88 (3.46) 8.5
Number of cylinders Combustion chamber Total displacement cm3 (cu. in.) Cylinder bore mm (in.) Piston stroke mm (in.) Compression ratio Valve timing ( ): camshaft identification mark Intake valve Open BTDC ABDC Close Exhaust valve Open BBDC Close ATDC Lubrication system Oil pump type Cooling system Water pump type EGR system Injector type and number Injector identification mark Throttle position sensor Closed throttle position switch
(AR)
19" 57 57 1 19 Pressure feed, full-flow filtration Involute gear type Water-cooled forced circulation Centrifugal impeller type Single type Electromagnetic 4 N210H Variable resistor type Contact type, incorporated in idle speed control motor
4664 SOHC Type

Number of cylinders Combustion chamber Total displacement cm3 (cu. in .I mm (in.) Cylinder bore mm (in.) Piston stroke Compression ratio Valve timing ( ): camshaft identification mark Intake valve Open BTDC Close ABDC Exhaust valve BBDC Open ATDC Close Lubrication system Oil pump type Cooling system Water pump type EGR system Injector type and number Injector identification mark Throttle position sensor Closed throttle position switch 1 In-line OHV, SOHC
14
Compact type 2,350 (143.4) 86.5 (3.35) 100 (3.46) 8.5
0)
20 64
(AR)
19 57
64 57 19 20 Pressure feed, full-flow filtration Involute gear type Water-cooled forced circulation Centrifugal impeller type Single type Electromagnetic 4 N275H Variable resistor type Contact switch type, incorporated in idle speed control motor-TRUCK Movable contact type, incorporated in throttle position sensor - EXPO
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4G6 ENGINE <1992> - General Specifications

4661 DOHC Type
Number of cylinders Combustion chamber cm3 (cu. in.) Total displacement Cylinder bore mm (in.) Piston stroke mm (in,) Compression ratio Valve timing ( ): camshaft identification mark Intake valve Open BTDC Close ABDC Exhaust valve Open BBDC Close ATDC Lubrjcatlon system Oil pump type Cooling system Water pump type EGR system Injector type and number Injector identification mark Throttle position sensor Closed throttle position switch In-line OHV, DOHC 4 Pentroof type 1,595 (97.3) 82.3 (3.24) 75 (2.95) ,3.2
I33
TG9
..
(F)
26 38
16
1$8 L13
53 17 7 fressure feed, full-flow filtration I nvolute gear type 1Water-cooled forced circulation (Ientrifugal impeller type :;ingle type Eilectromagnetic 4 E3275H Lrariable resistor type CIontact type
4663 DOHC
Type
Number of cylinders Combustion chamber Total displacement cm3 (cu. in.) Cylinder bore mm (in.) Piston stroke mm (in.) Compression ratio valve timing ( ): camshaft identification mark Intake valve Open BTDC Close ABDC Exhaust valve BBDC Open ATDC Close Lubrication system 3il pump type Cooling system JVater pump type EG R system njector type and number njector identification mark Non-turbo Turbo for GALANT/ECLIPSE M/T Turbo for ECLIPSE A/T Throttle position sensor Closed throttle position switch piiEzGi
In-line OHV, DOHC 4 Pentroof type 1,997(121.9) 85 (3.35) 88 (3.46) 7.8 or 9.0 (Specs. varies according to engine model)
IA)
26 46
(B.C)
21 43
(D.C)
21 51 57 15
(EA
16 48 55 9
57 55 15 3 Pressure feed, full-flow filtration Involute gear type dater-cooled forced circulation Centrifugal impeller type Single type !lectromagnetic 4 J240H 345OL 33901. dariable resistor type Contact type
IIC-10
4G6 ENGINE <1992> - Service Specifications
SERVICE SPECIFICATIONS
mm (in.) Standard Cylinder head - SOHC Flatness of gasket surface Grinding limit of gasket surface * Total resurfacing depth of both cylinder head and cylinder block. Overall height Oversize rework dimensions of valve guide hole (both intake and exhaust) 0.05 (.002) 0.25 (.OlO) 0.50 (.020) Oversize rework dimensions of intake valve seat ring hole 0.30 f.012) 4G63 4G64 0.60 (024) 4663 4664 Oversize rework dimensions of exhaust valve seat ring hole 0.30 l.012) 4663 4664 0.60 (.012) 4G63 4G64 Cylinder head - DOHC Flatness of gasket surface Grinding limit of gasket surface * Total resurfacing depth of both cylinder head and cylinder block. Overall height, Oversize rework dimensions of valve guide hole (both intake and exhaust) 0.05 (.002) 0.25 (.OlO) 0.50 (020) Oversize rework dimensions of intake valve seat ring hole 0.30 i.012) 0.60 (024) Oversize rework dimensions of exhaust valve seat ring hole 0.30 l.012) 0.60 (.024) 0.05 (.0020) Limit 0.2 (008) *0.2 (008) _I 89.9 - 90.1 (3.539 - 3.547) I. I13.05- 13.07 (.5138- .5146) 13.25-13.27(.5217-.5224) 13.50 - 13.52 (5315 - .5323) i
44.30 - 44.33 (1.7441 - 1.7453) 47.30 -47.33 (3.8622 - 1.8634) 44.60 - 44.63 (1.7559 - 1.7571) 47.60 -47.63 (1.8740 - 1.8752) 4 38.30 40.30 38.60 40.60 38.33 (1.5079 - 1.5091) 40.33 (1.5866 - 1.5878) 38.63 (1.5197 - 1.5209) 40.63 (1.5984 - 1.5996) J ~ 0.2 (008) 0.2 (008)
0.05 (0020)
131.9-132.1 (5.193-5.201)
12.05-12.07(.4744-.4752) 12.25 - 12.27 (4823 - .4831) 12.50 - 12.52 i.4921 - .4929)
) ;
35.30 - 35.33 (1.3898 - 1.3909) 35.60 - 35.63 (1.4016 - 1.4028)
c -<
33.30 - 33.33 (1.3110 - 1.3122) 33.60 - 33.63 (1.3228 - 1.3240)
..
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466 ENGINE <1992> - Service Specification3
IWwl
mm (in.)
Standard Camshaft - SOHC Identification mark: D Cam height Identification mark: AR Cam height
Limit ., ;J _.
Intake Exhaust Intake Exhaust
42.40 (1.6693) 42.40 (1.6693) 44.53 (1.7531) 44.53 (1.7531)
41.90 (1.6496) 41.90 (1.6496) 44.03 (1.7335) 44.03 (1.7335)
NOTE: The camshaft identification mark is stamped on the rear end of the camshaft. Fuel pump driving cam diameter Journal diameter Oil clearance Camshaft - DOHC Intake Identification mark: A,D Cam height dentification mark: B,C,E,F Cam height Exhaust dentification mark: A Cam height dentification mark: C Cam height dentification mark E,F Cam height \lOTE: The camshaft identification mark is stamped In the rear end of the camshaft. lournal diameter Xl clearance locker arm - SOHC .D. sacker arm-to-shaft clearance -ash adjuster .eak down test Remarks: Diesel fuel at 15 - 20C (59 - 68F) locker shaft - SOHC I.D. Iverall length
38 (1.50) 33.94 - 33.95 (1.3362 - 1.3366) 0.05 - 0.09 (.0020 - .0035)
35.49 (1.3972) 35.20 (1.3858)
34.99 (1.3776) 34.70 (1.3661)
35.20 (1.3858) 35.49 (1.3972) 35.91 (1.3744)
34.70 (1.3661) 34.99 (1.3776) 34.41 (1.3547)
25.95 - 25.97 (1.0217 - 1.0224) 0.05 - 0.09 i.0020 - .0035) 18.91 - 18.93 (.7445- .7453) 0.01 - 0.04 LOO04 - .0016) 4 - 20 seconds/l mm (.04 in.)
011 (.004)
Intake Exhaust
18.89 - 18.90 (.7437 - .7441) 385.5(15.177) 372.5 (14.665)
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IIC-12
466 ENGINE c1992> - Service Specifications

mm (in.) Standard Limit
Valve - SOHC Overall length
Intake Exhaust
4663 4664 4G63 4664
Stem diameter Face angle Thickness of valve head (margin) Stem-to guide clearance Valve - DOHC Overall length Stem diameter Face angle Thickness of valve head (margin) Stem-to guide clearance Valve spring - SOHC Free height ~w$nstalled N/mm (Ibs./in.) Out-of-squareness Valve spring - DOHC Free height k;;hnstalled N/mm (IbsAn.) Out-of-squareness Valve guide- SOHC Overall length I.D. 3.D. Service size Press-in temperature
Intake Exhaust
109.8(4.321) 106.6 (4.197) 108.7 (4.280) 105.2 (4.142) 7.96-7.98(.3134-.3142) 7.93-7.95 (.3122-.3130) 45- 4530 1.2 (047) 2.0 (.079) 0.02 - 0.06 (.OOO%- .0024) 0.05 - 0.09 (0020 - .0035)
0.7 (02%) 1.5 (.059) 0.10 (004) 0.15 (006)
109.5 (4.311) 109.7 (4.319) 6.57 - 6.58 (.2587 - .2591) 6.53 - 6.55 (2571 - .2579) 45 - 4530 1 .o (039) 1.5 (.059) 0.02 - 0.05 (.OOO%- .0020) 0.05 - 0.09 (0020 - .0035) 49.8 (1.961) 329/40.4 (73/I ,591) 2 or less
_I /
0.7 (02%) 1 .o l.039) 0.10 (004) 0.15 (006) 48.8 (1.921) I Max. 4
48.3 (1.902) 300/40 (66/l .57) 1.5 or less Intake Exhaust -; 47 (1.85) 52 (2.05) 8.00 - 8.02 (3150 - .3157) 13.06- 13.07 (.5142- .5146) 0.05(.002),0.25(.010),0.50(.020)oversize Room temperature
47.4 (1.866)
Max. 4
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4G6 ENGINE <1992> - Service Snebifications

mm (in.) Standard Valve guide - DOHC Overall length I.D. O.D. Service size Press-in temperature Va Ive seat Seat angle Valve contact width Sinkage Service size Silent shaft Journal diameter 45.5 (1.791) 50.5 (1.988) 6.60 - 6.62 (.2598 - .2606) 12.06 - 12.07 (.4748 - .4752) 0.05 (.002), 0.25 (.OlO), 0.50 (.020) over size Room temperature 4330 - 44 0.9 - 1.3 (.035 - .051) 0.2 (.OO%) 0.3 (.012), 0.6 (.024) over size Limit
3il clearance
41.96 - 41.98 (1.6520 - 1.6528) 40.95 - 40.97 (1.6122 - 1.6130) 18.47 - 18.48 (.7272 - 0.7276) 40.95 - 40.97 (1.6122 - 1.6130) 0.03 - 0.06 LOO1 2 - .0024) 0.05-0.09 (.0020-.0036) 0.02 - 0.05 (.OOO% - .0020) 0.05 - 0.09 (.0020- .0036) 84.97 - 85.00 (3.3453 - 3.3465) 86.47 - 86.50 (3.404 - 3.4055) 0.02-0.04(.0008-.0016) 0.25 LOlO), 0.50 (.020), 0.75 (.030), 1 .OO f.039) over size 82.27 - 82.30 (3.2390 - 3.2401) 84.97 - 85.00 (3.3453 - 3.3465) 84.96 - 84.99 (3.3449 - 3.3461) 0.02 - 0.04 (.OOO% - .0016) 0.03 -0.05 (.0012 - .0020) 0.25 (.OlO), 0.50 (.020), 0.75 (.030). 1 .OO (.039) over size
iston - SOHC I.D.
4663 4G64 Won to cylinder clearance service size Won - DOHC I.D.
4G61 4663 - Non-turbo 4G63 -Turbo iston to cylinder clearance Non-turbo Turbo ;ervice size
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466 ENGINE <1992>
- Service Specifications
mm (in.)
Standard Piston ring - SOHC End gap No. 1 ring No. 2 ring 4663 4664 Oil ring No. 1 ring No. 2 ring 0.25 - 0.40 LOO98 - .0157) 0.20 - 0.35 LOO79 - .0138) 0.20 - 0.40 LOO79 - .0157) 0.20 - 0.70 LOO79 - .0276) 0.03 - 0.07 LOOI 2 - .0028) 0.02 - 0.06 (.OOO% - .0024) 0.25 (.OlO), 0.50 (.020), 0.75 (.030), 1 .OO (.039) over size 0.25 - 0.40 LOO98 - .0157) 0.35 - 0.50 (013% - .0197) 0.45 - 0.60 f.0177 - .0236) 0.20 - 0.70 LOO79 - .0276) 0.03 - 0.07 (.0012 - .0028) 0.03 - 0.07 LOO1 2 - .0028) 0.25 LOlO), 0.50 (.020), 0.75 (.030), 1 .OO (.039) over size 21 .OO - 21 .Ol (826% - .8272) 7,500 - 17,500 (1,653 - 3,858) Room temperature 149.9 - 150.0 (5.902 - 5.906) 0.05 (002) 0.1 (004) O.lO-0.25(.0039-.0098) :! 0.05-0.18 (.0020- .0071) 56.98 - 57.00 (2.2433 - 2.2441) 44.98 - 45.00 (1.7709 - 1.7717) Max. 0.01 (.0004) Max. 0.02 (.OOO%) 0 . 0 2 - (.OOO% - .0020) 0.05 0.02 0.05 - (.OOO% - .0020)
Limit
0.8 (031) 0.8 (.031) 0.8 (.031) 1 .o (.039) 0.1 (.004) 0.1 (004)
Ring-to-ring groove clearance Service size Piston ring - DOHC End gap
No. 1 ring No. 2 ring 4G61 4663 Oil ring No. 1 ring No. 2 ring
0.8 (031) 0.8 (.031) 0.8 (031) 1 .o f.039) 0.1 (004) 0.1 (004)
Ring-to-ring groove clearance Service size Piston pin 3.D. Press-in load N (Ibs.) press-in temperature
Connecting rod 3ig end center-to-small end center length 3end rwist 3ig end side clearance Crankshaft fnd play Journal O.D. in O.D. ht-of-roundness and taper of journal and pin kcentricity of journal Iii clearance of journal II clearance of pin
0.4 (016) 0.25 (.0098)
0.1 (004) 0.1 (004)
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466 ENGINE t1992> - Service Sbecifications

_
. mm (ir Limit
Standard Cylinder block Cylinder I.D. 4G61 4663 4664 82.30 - 82.33 (3.2402 - 3.2413) 85.00 - 85.03 (3.3465 - 3.3476) 86.50 - 86.53 (3.4055 - 3.4067) 0.05 (0020)
Flatness of gasket surface Grinding limit * Total resurfacing depth of both cylinder head and cylinder block. Overall height 4G61 4663 4G64 Oil pump Side clearance Drive gear Driven gear 3rive belt Ieflection V-ribbed type belt V type belt -ension V-ribbed type belt
0.1 (004) *0.2 (.008)
274.9 - 275.1 (10.823 - 10.831) 283.9-284.1 (11.177-11.185) 289.9-290.1 (11.413-11.421)
0.08 - 0.14 (0031 - .0055) 0.06 - 0.12 (0024 - .0047)
New belt Used belt
7.5 - 9.0 (.30 - .35) 8.0 (32) 7.0 - 10.0 (28 - .39) N (Ibs.) N (Ibs.) 500 - 700 (11 O- 154) 400 (88) 34.5 (1.358) - normal temperature 40 (1.57) or more
New belt Used belt
Xl cooler by-pass valve Iimension (L) ly-pass hole closing temperature 37 - 103C (207 - 217F) or more) ejector Ioil resistance Non -turbo Q Turbo R Jle speed control motor :oil resistance CR Ale air control motor :oil resistance Cn Ale speed control motor position sensor SOHC engine for GALANTITRUCK lesistance klR NOTE 0.D.; OuteL piameter I.D.: Inner Diameter U.S.: Undersize Diameter
13 - 16 at 20C (68F) 2 - 3 at 20C (68F) 5 - 35 at 20C (68F)
28 - 33 at 20C (68F)
4-6
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IIC-16
4G6 ENGINE <1992> - Torque Specifications
TORQUE SPECIFICATIONS
Nm Generator and ignition system - SOHC Cooling fan bolt Water pump pulley bolt - Engine without cooling fan Water pump pulley bolt - Engine with cooling fan Generator brace bolt Generator mounting bolt Generator pivot nut Crankshaft pulley bolt Spark plug Distributor nut Ignition coil bolt Ignition power transistor nut Generator and ignition system - DOHC Water pulley bolt pump Generator brace bolt Generator mounting bolt Generator pivot nut Crankshaft pulley bolt Center cover bolt Spark plug Ignition coil bolt Ignition power transistor bolt Crankshaft position sensor nut Timing belt - SOHC Tensioner bolt Tensioner spacer Oil pump sprocket nut Crankshaft sprocket bolt Tensioner B bolt Silent shaft sprocket bolt, right Engine supports bracket bolt, left Camshaft sprocket bolt riming belt- D O H C Tensioner pulley bolt Tensioner arm bolt Idler pulley bolt 3il pump sprocket nut Crankshaft sprocket bolt Tensioner B bolt Silent shaft sprocket bolt, right qocker cover bolt 3amshaft sprocket bolt Engine support bracket, left 11 9 11 14 24 23 25 25 11 14 18 .; f ft.1b.s. 8 7 8 10 17 17 18 18 8 IO 13
9 14 24 23 25 3 25 24 11 1 49 49 55 120 19 46 36 90 49 22 38 55 120 19 46 3 90 36
.i 9 :
7 IO 17 17 18 2 18 17 8 14
: :
35 35 40 87 14 33 26 65 35 16 27 40 87 14 33 22 65 26
j .
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4G6 ENGINE <1992> - Toraue SDecifications
IIC-17
ftlbs. 14 14 9 14 7 9
Nm Fuel and emission parts EGR valve bolt Throttle body stay nut - DOHC Throttle body bolt - SOHC Throttle body bolt - DOHC Fuel pressure regulator bolt Fuel rail bolt Throttle body Throttle position sensor bolt Idle speed control motor bolt Idle air control motor bolt Intake manifold Intake manifold bolt and nut Intake manifold nut - DOHC Intake manifold stay bolt - SOHC Intake manifold stay bolt - DOHC Intake manifold plenum bolt and nut Intake manifold plenum stay bolt Water outlet fitting bolt Engine coolant temperature gauge unit Engine coolant temperature sensor Thermostat case nut Exhaust manifold and water pump Oil level guide bolt gauge Heat protector bolt GALANT AND EXPO TRUCK Exhaust manifold nut - SOHC Exhaust manifold nut - DOHC Engine hanger bolt - DOHC Air outlet fitting bolt Turbocharger bolt and nut Exhaust fitting bolt Water inlet pipe bolt Water pump bolt Water pipe A and B eye bolt Water pipe A bolt Water pipe B flare nut Water pipe bolt M8 M6 Oil return pipe bolt Oil pipe Cylinder head side Turbocharger side 19 19 12 19 9 12
2 3.5 3.5
1.4 2.5 2.5
18 36 22 28 18 18 19 11 30 18 60 14 30 18 28 14 19 60 60 14 24 43 11 45 14 11 9 17 31
13 26 16 20 13 13 14 8 22 13 43 10 22 13 20 10 14 43 43 10 17 31 8 33 10 8 7 12 22
1 TSB Revision
IIC-18
466 ENGINE <1992> - Torque Specifications
Nm Turbocharger Turbocharger waste gate actuator bolt Rocker arms and camshaft- SOHC Rocker cover bolt Bearing cap bolt M8x25 M8x65 Camshafts and rocker arms - DOHC Bearing cap bolt Oil delivery body bolt Cylinder head and valves - SOHC Cylinder head bolt Cylinder head and valves- DOHC Cylinder head bolt Front case, silent shaft and oil pan Oil cooler bolt Drain plug Oil pan bolt Oil screen bolt and nut Oil pump sprocket bolt Plug Silent shaft, left flange bolt Oil filter bracket bolt Front case bolt M8 Ml0 Oil cooler by-pass valve Oil pressure switch Oil pressure gauge unit Relief plug Oil pump cover bolt Check valve Piston and connecting rod Connecting rod cap nut Crankshaft, flywheel and drive plate +wheel bolt Irive plate bolt 3il seal case bolt 3earing cap bolt - SOHC 3earing cap bolt - DOHC 135 135 11 53 68 r 12 6 24 20
ftlbs. 9 4 17 14
!.
20 11 95
? ( ;
14 8 69
110
:/ ;(
80
43 40 7 19 55 24 37 19 24 31 55 10 55 45 17 33
: : : - ; t ! -.~
31 29 5 14 40 17 27 14 17 22 40 7 40 33 12 24
:: !
52
.?&
38 98 98 8 38 49
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4G6 ENGINE <1992> - Torque Specifications / Sealant
1 IC-19
ft.lbs. 33 47 87 43 26
Nm Bracket Left and right engine support bracket bolt Roll stopper bracket bolt, front Roll stopper bracket bolt, rear Engine support bracket bolt, front Exhaust pipe support bracket bolt 45 65 120 60 36
SEALANT
Specified sealant Rocker cover Semi-circular packing Oil pan gasket Engine coolant temperature gauge unit Engine coolant temperature sensor Oil pressure switch Oil pressure gauge unit 3M ATD Part No. 8660 or equivalent 3M ATD Part No. 8660 or equivalent MITSUBISHI GENUINE PART MD970389 or equivalent 3M ATD Part No. 8660 or equivalent 3M Nut Locking Part No. 4171 or equivalent 3M ATD Part No. 8660 or equivalent 3M ATD Part No. 8660 or equivalent Quantity As required As required As required As required As required As required As required
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11 c-20 SPECIAL TOOLS

Tool
466 ENGINE <1992> - Special Tools
Number and tool name MB990767 End yoke holder Use with MD9987 19
Supersession M 8990767-01 Use with MIT308239
Application Holding camshaft spr&ket when loosening or torquing bolt. For SOHC engine only
MD998051-01 MD998051 Cylinder head bolt wrench
Loosening or torquing of cylinder head bolt
M D998162 Plug wrench
MD9981 62-01
Removal and installation of front case cap plug
M D998285 Crankshaft front oil seal guide
M D998285-0 1
Installation of crankshaft front oil seal
MD998371 Silent shaft bearing puller
MD998371-01 Use with MIT304204
Removal of silent shaft rear
M D998372 Silent shaft bearing puller
M D998372-01 Use with MIT304204
Removal of silent shaft rear
MD998374 Bearing installer stopper QQ c MD998375 Crankshaft front oil seal installer
M D998374-0 1
Removal and installation of rear bearing
MD998375-01
nstallation of crankshaft front oil seal
MD998376 Crankshaft rear oil seal installer
MD998376-01 Use with MB990938-01
nstallation of crankshaft rear oil seal
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4G6 ENGINE <1992> - Special Tools
MD998713 Camshaft oil seal installer
MD998713-01
MD99871 9 Pulley holding pins (2)
M IT308239
Holding camshaft sprocket when loosening or torquing bolt For SOHC engine only
MD998727 Oil pan remover
Removal of oil pan
MD998729 Valve stem seal installer
MD998729-01
Installation of valve stem seal For SOHC engine only
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IIC-22
4G6 ENGINE <1992> - Special Tools
M D998779 Sprocket stopper
Holding silent shaft sprocket
MD998780 Piston pin setting tool
M IT2 16941
Removal and installation of piston pin
MD998781 Flywheel stopper
Holding flywheel
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466 ENGINE <1992> - Generator and Ignition System - SOHC
1 IC-23
GENERATOR AND IGNITION SYSTEM - SOHC

REMOVAL AND INSTALLATION
25 Nm
14 Nm lOft.lbs.
-1
0Q I 23 Nm
17 ft.lbs. I 14 Nm 10 ftlbs. I 24 Nm 17 ftlbs. 4
!!!?a R W D
5 I
9 Nm** 7 ftlbs. 11 Nm*** 8 ft.lbs.
Removal steps
*B4 1. Drive belt 2. Cooling fan*** 3. Fan clutch*** 4. Water pump pulley 5. Water pump pulley 6. Generator brace 7. Generator 8. Crankshaft pulley 9. Spark plug cable 10. Spark plug 11. High tension cable *A4 12. Distributor
13. Ignition coil
NOTE * : Engine with power steering ** : Engine with cooling fan ***: Engine without cooling fan TSB Revision
14. Ignition power transistor

6EN0631
1 IC-24
466 E N G I N E <1992> - Generator and Ignition System - SOHC INSTALLATION SERVICE ,POINTS r)A4 DISTRIBUTOR INSTALLATION
(1) Align the marks put at the time of disassembly, and install the gear to the distributor shaft.
(2) When aligning the driven gears mating mark and the housings mating marks, make the combination so that notch A at the shaft end is at the position shown in the figure, and then align the spring pin holes and drive in a new spring pin. Caution Drive in the spring pin so that the slit is at a right angle relative to the shaft.
1ELOOlf
*64 DRIVE BELT TENSION ADJUSTMENT ADJUSTER TYPE (1) Adjust the belt deflection to the standard value. Turn the adjusting bolt clockwise to increase the belt tension and turn the adjusting bolt counterclockwise to decrease the belt tension. Standard value: V-ribbed type belt New belt 7.5 - 9.0 mm (30 - .35 in.) Used belt 8.0 mm (32 in.) V-type belt 7.0 - 10.0 mm (28 - .39 in.)
When using a tension gauge for V-ribbed belt only. Standard value: New belt 500 - 700 N (110 - 154 Ibs.) Used belt 400 N (88 Ibs.) (2) Tighten the lock bolt to the specified torque. (3) Tighten the nut for the pivot bolt to the specified torque.
TSB Revision
4G6 ENGINE <1992> - Generator and Ignition Svstem - SOHC

Water pulley
1 ICE-25
Crankshaft pulley
BRACE BOLT TYPE (1) Move the generator to adjust the belt deflection to the standard value. Standard value: V-ribbed type belt New belt 7.5 - 9.0 mm (.30 - .35 in.) Used belt 8.0 mm (.32 in.) V-type belt 7.0 - 10.0 mm (.28 - .39 in.) When using a tension gauge for V-ribbed belt only. Standard value: New belt 500 - 700 N (110 - 154 Ibs.) Used belt 400 N (88 Ibs.) (2) Tighten the brace bolt to the specified torque. (3) Tighten the nut for the pivot bolt to the specified torque.
6EN0593
/, Water pump pulley
Altern pulley
6EN059E
TSB Revision
11 C-26
4G6 ENGINE <1992>
- Generator and Ignition System - DOHC
GENERATOR AND IGNITION SYSTEM - DOHC

18 ft.lbs. 19 Nm 14 ftlbs. 5 I 23 Nm
14 Nm 10 ft.lbs.
24 Nm 17 ftlbs.
I 11
11 Nm 8 ft.lbs. 24 Nm 17 ftlbs. Removal steps eB4 1. Drive belt 2. Water pump pulley 3. Water pump pulley (For driving power steering pump) 4. Generator brace 5. Generator 6. Crankshaft pulley 7. Center cover 8.-Spark plug cable 9. Spark plug 10. Ignition coil 11. Ignition power transistor #A4 12. Crankshaft position sensor 13. O-ring TSB Revision
466 ENGINE <1992> - Generator and Ignition System - DOHC INSTALLATION SERVICE POINTS
IIC-27
CRANKSHAFT POSITION INSTALLATION (1) Turn the crankshaft so that the No. 1 cylinder is at top dead center. (2) Align the punch mark on the crankshaft position sensor housing with the notch in the plate. (3) Install the crankshaft position sensor on the cylinder head.
#A4
eB4 DRIVE BELT TENSION ADJUSTMENT

Refer to I)B4 DRIVE BELT TENSION ADJUSTMENT on page 11 C-24.
1 TSB Revision
I
II
11 C-28
4G6 ENGINE <1992> - Timing Belt - SOHC
TIMING BELT - SOHC

18
EE
i F 87 ---ft.lbs. --~~~
1 . . . . .
Nm
40 ft.lbs.
Removal steps 1. Timing belt front upper cover 2. Timing belt front lower cover (IAI) eH4 3. Timing belt #Gg 4. Tensioner spring *Gg 5. Tensioner QBg eF4 6. Oil pump sprocket 81: $E4 7. Crankshaft bolt 8. Crankshaft sprocket 9. Flange 10. Tensioner B c$ErJ eD4 11. Timing belt B (IFI) #C4 12. Silent shaft sprocket, right #B4 13. Spacer 14. Crankshaft sprocket B ($0 15. Engine support bracket, left (IHI) *A4 16. Camshaft sprocket bolt 17. Camshaft sprocket 18. Timing belt rear cover
6EN0633
TSB Revision
4G6 ENGINE <1992> - Timing Belt - S O H C
IIC-29
REMOVAL SERVICE POINTS
QAo
TIMING BELT REMOVAL
(1) Mark the belt running direction for reference in reinstallation. NOTE (1) Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and water. These parts should not be washed. Replace parts if seriously contaminated. (2) If there is oil or water on each part, check the front case oil seals, camshaft oil seal and water pump for leaks.
QBQ OIL PUMP SPROCKET REMOVAL

(1) Remove the plug on the left side of the cylinder block. (2) Insert a Phillips screwdriver [shank diameter 8 mm (31 in.)] to block the left silent shaft. (3) Remove the nut. (4) Remove the oil pump sprocket.
6EN0563
6EN056~
@@ CRANKSHAFT BOLT REMOVAL (1) Using the special tool, hold the drive plate or flywheel. (2) Remove the crankshaft bolt.
@I) CRANKSHAFT SPROCKET REMOVAL
QEo
TIMING BELT B REMOVAL (1) Make a mark on the back of the timing belt indicating the direction of rotation so that it may be reassembled in the same direction if it is to be reused. NOTE (1) Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and water. These parts should not be washed. Replace parts if seriously contaminated. (2) If there is oil or water on each part, check the front case oil seals, camshaft oil seal and water pump for leaks.
TSB Revision
4G6 ENGINE <1992> - Timing Belt - SOHC (IF0

SILENT SHAFT SPROCKET REMOVAL
QGt)
CRANKSHAFT SPROCKET B REMOVAL
aHo
CAMSHAFT SPROCKET BOLT REMOVAL
INSPECTION
TIMING BELT Replace belt if any of the following conditions exist. (1) Hardening of back rubber - the back side is glossy without resilience and leaves no indent when pressed with fingernail.
\ 00 B 000 &
8EN006Z
(2) (3) (4) (5)

Peeling Cracks
Cracks Cracks Cracks Cracks
on rubber back. or peeling of canvas. on rib root. on belt sides.
Cracks
1 EN0249
1 TSB Revision
1 IC-31
(6) Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife.
Roundededge
Abnormal wear (Fluffy strand)

8EN006;
(7) Abnormal wear on teeth. (8) Missing tooth.

Rubber exposed Tooth missing and canvas fiber
8EN006t
INSTALLATION SERVICE POINTS I)A4 CAMSHAFT SPROCKET BOLT INSTALLATION
I)B4 SPACER INSTALLATION

Spacer
7/
I A%&
/y/7/, f
\
Chamfer
53
Silkt shaft b
Oil seal
(1) Install the spacer with the chamfered end toward the oil seal.
6EN061 E
I)c4 SILENT SHAFT SPROCKET INSTALLATION
1 TSB Revision
11 C-32
466 ENGINE <1992> - Timing Belt - S O H C
+D4
TIMING BELT B INSTALLATION (1) Align timing marks on the crankshaft sprocket B and silent shaft sprocket with the marks on the front case respectively. (2) Install the timing belt B on the crankshaft sprocket B and silent shaft sprocket. There should be no slack on the tension side.
(3) Make sure that the relationship between the tensioner pulley center and the bolt center is as shown in the illustration.
Center of yx \ tensioner m P,...*-- -L L-Or. k

W /
6EN057
(4) Move the tensioner B in the direction of arrow while lifting with a finger to give a sufficient tension to the tension side of timing belt. In this condition, tighten the bolt to secure tensioner B. When the bolt is tightened, use care to prevent shaft from turning together. If the shaft is turned together, the belt will be over-tensioned.
(5) Check to ensure that the timing marks on the sprockets and front case are in alignment. (6) Press with index finger the center of span on the tension side of timing belt B. The belt must deflect 5 - 7 mm (.20 - .28 in.).
+E4
CRANKSHAFT BOLT INSTALLATION (1) Using the special tool, hold the drive plate or flywheel. (2) Install the crankshaft bolt.
TSB Revision
4G6 ENGINE <1992> - Timing Belt - SOHC I)F4 OIL PUMP SPROCKET INSTALLATION
1 IC-33
(1) Insert a Phillips screwdriver [shank diameter 8 mm (31 in.)] through the plug hole on the left side of the cylinder block to block the left silent shaft. (2) Install the oil pump sprocket. (3) Apply an appropriate amount of engine oil to the bearing surface of the nut. (4) Tighten the nut to the specified torque.
Screwdriver
6EN0564
I)G4
TENSIONER INSTALLATION (1) Hook the tensioner spring ends to the water pump body projection and tensioner bracket. (2) Move the tensioner fully toward the water pump and tighten the bolt and tensioner spacer.
Tensloner
6EN0555
I)H4 TIMING BELT INSTALLATION

(1) Align the timing marks on camshaft sprocket and crankshaft sprocket with their mating marks. (2) Align the timing mark on the oil pump sprocket with its mating mark.
Timing mark Timing mark for on-vehicle service only
ilange
Cal nshaft sprocket
I/
-/
Timing mark
Crankshaft
6EN0475
1 TSB Revision
IIC-34

(3) Remove the plug on the cylinder block and insert a Phillips screwdriver [shank diameter 8 mm (.31 in.) ] through the hole (Engine with silent shafts). If it can be inserted as deep as 60 mm (2.4 in.) or more, the timing marks are correctly aligned. If the inserted depth is only 20 - 25 mm (.8 - 1.0 in.), turn the oil pump sprocket one turn and realign the timing marks. Then check to ensure that the screwdriver can be inserted 60 mm (2.4 in.) or more. Keep the screwdriver inserted until installation of the timing belt is finished. (4) Install the timing belt on the crankshaft sprocket, oil pump sprocket and camshaft sprocket in that order. There should be no slack on the tension side.
6EN0563
6EN0564
(5) Loosen the tensioner mounting bolt and tensioner spacer.

Tensioner spacer
Timing mark
(6) Turn the crankshaft clockwise by two teeth of camshaft sprocket (or crankshaft sprocket).
(7) Apply force to the tensioner in the direction shown by arrow @I to make the belt engage completely with each sprocket.
1 TSB Revision
4G6 ENGINE <1992> - Timinn Belt - SOHC
tc-35
(8) Tighten the tensioner attaching bolt, then tighten the tensioner spacer. Caution If the tensioner spacer is tightened first, the tensioner turns as the tensioner spacer is tightened, resulting in an excessive belt tension.
i -
(9) Hold the center of the tension side span of the timing belt (between the camshaft and oil pump sprockets) between your thumb and index finger as shown. Then, make sure that the clearance between the belt back surface and cover is standard value. Standard value: 14 mm (.55 in.)
TSB Revision
WC-36
4G6 ENGINE <1992> - Timing Belt - DOHC
TIMING BELT - DOHC

3Nm 2.2 ft.lbs. -fl
*?
24
'25
87ft.lbs.
NO TE * : Engine without silent shafts ** Engine with silent shafts
Removal steps 1. Timing belt front upper cover 2. Timing belt front lower cover (IAIJ eK4 3. Timing belt eJ4 4. Tensioner pulley 5. Tensioner arm #I4 6. Auto tensioner 7. Idler pulley (~Brj +H4 8. Oil pump sprocket $I$ eG4 9. Crankshaft sprocket bolt 10. Crankshaft sprocket 11. Flange 12. Spacer* 13. Tensioner B** OEo eF4 14. Timing belt B (IFO eE4 15. Silent shaft sprocket** +D4 16. Spacer** 17. Crankshaft sprocket B** 4GO I)C4 18. Rocker cover #B4 19. Semi-circular packing (IHO *A4 20. Camshaft sprocket bolt 21. Camshaft sprocket 22. Engine support bracket 23. Timing belt rear right cover 24. Timing belt rear left upper cover 25. Timing belt rear left lower cover
TSB Revision
466 ENGINE <1992> - Timing ,Felt - DOHC REMOVAL SERVICE POINTS OAi) TIMING BELT REMOVAL
IIC-37
(1) Make a mark on the back of the timing belt indicating the direction of rotation so that it may be reassembled in the same direction if it is to be reused. NOTE (1) Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and water. These parts should not be washed. Replace parts if seriously contaminated. (2) If there is oil or water on each part, check the front case oil seals, camshaft oil seal and water pump for leaks.
OBo OIL PUMP SPROCKET REMOVAL (ENGINE WITH

SILENT SHAFTS) Refer to @o OIL PUMP SPROCKET REMOVAL on page 11 c-29.
of@ CRANKSHAFT BOLT REMOVAL (1) Using the special tool, hold the drive plate or flywheel. (2) Remove the crankshaft bolt.
ODo CRANKSHAFT SPROCKET REMOVAL
~EI)
&hdd~l~ELT B REMOVAL (ENGINE WITH SILENT Refer to OEO TIMING BELT B REMOVAL on page 11 c-29.
TSB Revision
1 IC-38
OF0
SILENT SHAFT SPROCKET REMOVAL
QGo
CRANKSHAFT SPROCKET B REMOVAL
(IHO
CAMSHAFT SPROCKET REMOVAL (1) Using a wrench, hold the camshaft at its hexagon (between the No. 2 and No. 3 journals) and remove the camshaft sprocket bolt. Caution Locking the camshaft sprocket with a tool damages the sprocket. (2) Remove the camshaft sprockets.
INSPECTION
TIMING BELTS Refer to INSPECTION on page 1 IC-29.
TSB Revision
4G6 ENGINE <1992> - Timina Belt - D O H C AUTO TENSIONER
IX-39
(1) Check the auto tensioner for possible leaks and replace as necessary. (2) Check the rod end for wear or damage and replace as necessary.
12mm ( 47 in.)
(3) Measure the rod protrusion. If it is out of specification, replace the auto tensioner. Standard value: 12 mm (.47 in.)
0
0
0
il;
6EN0161
I
(4) Clamp the auto tensioner in a vise with soft jaws. Caution The plug protrudes at the bottom of the auto tensioner. Insert a plain washer as illustrated to prevent the plug from being in direct contact with the vise. (5) Turning the vise handle, push in the auto tensioner rod. If the rod can be easily retracted, replace the auto tensioner. You should feel a fair amount of resistance when pushing the rod in.
Brass or aluminum laws
aluminum jaws
'6EN0404
INSTALLATION SERVICE POINTS
#A4
CAMSHAFT SPROCKET INSTALLATION (1) Using a wrench, hold the camshaft at its hexagon (between the No. 2 and No. 3 journals) and tighten the bolt to the specification. Caution Locking the camshaft sprocket with a tool damages the sprocket.
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11 c-40
I)B4
Apply sealant
SEALANT APPLICATION ON SEMI-CIRCULAR PACKING Specified sealant: 3M ATD Part No. 8660 or equivalent
: ::.:.. . . -.-.*...a. . . . . . . . . . . . . . . . ....::::::::.:.:.:.:.:.:.. ..*.-.-.*,*.d
DEN0052
3EN0044
ec4 SEALANT APPLICATION ON ROCKER COVER Apply sealant to the areas indicated in the illustration. Specified sealant: 3M ATD Part No. 8660 or equivalent
Apply sealant
IOmm f.39 in.)
Apply sealant
BEN0396
1 TSB Revision
4G6 ENGINE <1992> - Timing Belt - D O H C
x-47
I)04 SPACER INSTALLATION (ENGINE WITH SILENT SHAFTS) Refer to eB4 SPACER INSTALLATION on page 11 C-31.
r)E$
SILENT SHAFT SPROCKET INSTALLATION
I)F+
TIMING BELT B INSTALLATION (ENGINE WITH SILENT SHAFTS) Refer to Page 11 C-32. Note that the timing mark locations differ from those on the single camshaft engine.
I)G+
CRANKSHAFT BOLT INSTALLATION (1) Using the special tool, hold the drive plate or flywheel. (2) Install the crankshaft bolt.
#H4 OIL PUMP SPROCKET INSTALLATION (ENGINE

WITH SILENT SHAFTS) Refer to I)F4 OIL PUMP SPROCKET INSTALLATION on page 11 C-33.
1 TSB Revision
11 C-42
466 ENGINE <1992> - Timing Belt - DOHC

1)14 AUTO TENSIONER INSTALLATION (1) If the auto tensioner rod is in its fully extended position, reset it as follows. (2) Clamp the auto-tensioner in the vise with soft jaws. Caution The plug protrudes at the bottom of the auto tensioner. Insert a plain washer as illustrated to prevent the plug from being in direct contact with the vise.
(3) Push in the rod little by little with the vise until the set hole @ in the rod is aligned with the hole @I in the cylinder.
6EN015,
4
(4) Insert a wire [I .4 mm (055 in.) in diameter] into the set holes. (5) Unclamp the auto tensioner from the vise.
Wir>e
y-A
\
J040E
(6) Install the auto tensioner to front case and tighten to the specified torque. Caution Leave the wire installed in the auto tensioner.
I)J4 TENSIONER PULLEY INSTALLATION

(1) Install the tensioner pulley in such direction that its two small holes are arranged vertically.
1 TSB Revision
466 ENGINE <1992> - Timina Belt - D O H C

Camshaft sprocket
1 IC-43
r)K4
TIMING BELT INSTALLATION
(I) Turn the two sprockets so that their dowel pins are located on top. Then, align the timing marks facing each other with the top surface of the cylinder head. When you let go of the exhaust camshaft sprocket, it will rotate one tooth in the counterclockwise direction. This should be taken into account when installing the timing belt on the sprockets.
Timing marks
6EN0284
NOTE The same camshaft sprocket which is provided with two timing marks is used for the intake and exhaust camshafts. When the sprocket is mounted on the exhaust camshaft, use the timing mark on the right with the dowel pin hole on top. For the intake camshaft sprocket, use the one on the left with the dowel pin hole on top.
6ENOll E
(2) Align the crankshaft sprocket timing marks. (3) Align the oil pump sprocket timing marks (Engine with silent shafts).
Engine with silent shafts
Screwdriver
6EN0564
(4) Insert a Phillips screwdriver [shank diameter 8 mm (.31 in.)] through the plug hole (Engine with silent shafts). If it can be inserted as deep as 60 mm (2.4 in.) or more, the timing marks are correctly aligned. If the inserted depth is only 20 - 25 mm (.8 - 1 .O in.), turn the oil pump sprocket one turn and realign timing marks. Then check to ensure that the screwdriver can be inserted 60 mm (2.4 in.) or more. Keep the screwdriver inserted until the installation of the timing belt is finished. NOTE Step (4) is performed to ensure that the oil pump sprocket is correctly positioned with reference to the silent shafts.
TSB Revision
4G6 ENGINE <1992> - Timing Belt - DOHC.

(5) Thread the timing belt over the intake side camshaft sprocket and fix it at indicated position by a clip.
(6) Thread the timing belt over the exhaust side sprocket, while aligning the timing marks with the cylinder head top surface using two wrenches.
(7) Fix the belt at indicated position by a clip.
(8) Thread the timing belt over the idler pulley, the oil pump sprocket, the crankshaft sprocket and the tensioner pulley in the order shown. (9) Remove the two clips.
(1O)Lift up the tensioner pulley in the direction of arrow and tighten the center bolt. (IlKheck to see that all timing marks are lined up. (12)Remove the screwdriver inserted in step (4) and fit the plug. (Engine with silent shafts) (13)Give the crankshaft a quarter counter-clockwise turn. Then, turn it clockwise until the timing marks are lined up again.
TSB Revision
IIC-45
(14)lnstall the special tools, Socket Wrench and Torque Wrench, on the tensioner pulley, and loosen the tensioner pulley center bolt. NOTE If the special tool is not available, use a commercially available torque wrench that is capable of measuring 0 - 3 Nm (0 - 2.2 ftlbs.). (15)Torque to 2.6 - 2.8 Nm (1.88 - 2.03 ft.lbs.) with the torque wrench. (16)Holding the tensioner pulley with the special tool and torque wrench, tighten the center bolt to the specification. (17)After giving two clockwise turns to the crankshaft, let it alone for approx. 15 minutes. Then, make sure that the auto tensioner setting wire moves freely. NOTE If the wire does not move freely, repeat step (13) above until it moves freely. (18)Remove the auto tensioner setting wire.
(19)Measure the distance A (between the tensioner arm and auto tensioner body). Standard value: 3.8 - 4.5 mm (.15 - .18 in.)
6EN0285
TSB Revision
11 C-46
4G6 ENGINE <1992> - Fuel and Emission Control Parts
FUEL AND EMISSION CONTROL PARTS

REMOVAL AND INSTALLATION - SOHC for GALANT/EXPO
P-
12 Nm 9 ft.lbs
9Nm 7 ft.lbs.
7 12 Nm 9 ftlbs.
P
6 19 Nm 14 klbs.
Removal steps I. Throttle body 2. Throttle body gasket 3. EGR valve 4. EGR valve gasket 5. Injectors and fuel rail 6. Insulator 7. Fuel pressure regulator #B4 8. O-ring 9. Insulator #A4 IO. Injectors 11. O-ring 12. Grommet 13. Fuel rail
6EN0518
TSB Revision
466 ENGINE <1992> - Fuel and Emission Control Parts REMOVAL AND INSTALLATION - SOHC for TRUCK
12 Nm 9 ft.lbs.
IIC-47
I - - - -
12 Nm 9 ft.lbs.
9Nm 7 ft.lbs.
19Nm 14 ft.lbs.
Removal steps 1. Throttle body 2. Throttle body gasket 3. EGR valve 4. EGR valve gasket 5. Injectors and fuel rail 6. Insulator 7. Fuel pressure regulator )B4 8. O-ring 9. Insulator *AC 10. injectors 11. O-ring 12. Grommet 13. Fuel rail
6EN0534
11 C-48
4G6 ENGINE <1992> - Fuel and Emission Control Parts
IEMOVAL AND INSTALLATION - DOHC
12 Nm 9 ft.lbs.
19 Nm 14 ftlbs.
19Nm 14 ft.lbs.
Removal steps 1. Throttle body stay 2. Throttle body 3. Throttle body gasket 4. EGR valve 5. EGR valve gasket 6. Injectors and fuel rail 7. Insulator 8. Fuel pressure regulator $B4 9. O-ring 10. Insulator )A4 II. Injectors 12. O-ring 13. Grommet 14. Fuel rail TSB Revision
6EN0519
466 ENGINE <1992> - Fuel and Emission Control Parts INSPECTION
IX-49
6EMO3RL
EGR VALVE (1) Check EGR valve for sticking or carbon deposits. If such conditions exist, clean or replace EGR valve. (2) Connect a hand vacuum pump to the nipple of EGR valve and plug other nipple. (3) Apply a vacuum of 500 mmHg (19.7 in. Hg) to make sure that a vacuum is maintained. If there is a leak, replace the EGR valve. In addition, check the valve for its opening and closing by applying and removing a vacuum. I INJECTORS (1) Using an ohmmeter (circuit tester), test for continuity between terminals of injector; the circuit should be closed. If failure is detected, replace the injector. Standard value: N o n - t u r b o 1 3 - 16 IR [at 20C (68F)l 2 - 3 R [at 20C (68F)] Turbo
6FU1920
SOHC
INSTALLATION SERVICE POINTS I)A4 INJECTOR INSTALLATION

(1) Before installing an injector the rubber O-ring must be lubricated with a drop of clean engine oil to aid in installation.
6EN0520
DOHC
(2) Install the injectors from the top end into the fuel rail. Be careful not to damage the O-ring during installat.ion.
6EN0521
I)B4 FUEL PRESSURE REGULATOR INSTALLATION

(1) Before installing the pressure regulator the O-ring must be lubricated with a drop of clean engine oil to aid in installation.
1 TSB Revision
11 c-50 THROTTLE BODY
4G6 ENGINE <1992> - Throttle Body
DISASSEMBLY AND REASSEMBLY

SOHC for EXPO
Disassembly steps 1. Accelerator wire bracket @8 *A4 2. Throttle position sensor 3. Idle air control motor 4. Throttle valve set screw 5. Throttle body OBO
1.4 ft.lbs.
6FU1657
SOHC for GALANT/TRUCK
3.5 Nm 2.5 ft.lbs.
2Nm 1.4 ft.lbs.
Disassembly steps $@ *A4 1. Throttle position sensor 2. Idle speed control motor 3. Throttle valve set screw 4. Throttle body (30
6FU1292
TSB Revision
4G6 ENGINE <1992> - Throttle Body

DOHC
IIC-51
2Nm 1.4ft.lbs.
5 Disassembly steps (IAI) *AC I. Throttle position sensor 2. Idle air control motor (stepper motor) OAO 3. Closed throttle position switch 4. Adjusting nut 5. Throttle body (PO
6FU1427
1 TSB Revision
11 C-52
4G6 ENGINE <1992> - Throttle Bodv DISASSEMBLY SERVICE POINTS

THROTTLE POSITION SENSOR AND IDLE AIR/ SPEED CONTROL MOTOR REMOVAL (1) Do not disassemble the sensor and motor. (2) Do not immerse the sensor and motor in cleaning solvent. Clean them with shop towel.
QAo
~BI) THROTTLE BODY REMOVAL

(1) Do not remove the throttle valve. (2) Check if the vacuum port or passage is clogged. Use compressed air to clean the vacuum passage.
Red cl Blue MD998463

7FUO29(1
MD998463
7FUO29C
Operational Check (1) Connect Test Harness to the idle air control motor connector. (2) Connect the positive 0 terminal of 6 volt battery to white clip and green clip of Test Harness.
MD998463
7F11007F
TSB Revision
4G6 ENGINE <1992> - Throttle Bodv
IlC-53
7FUO295
(3) Holding the idle air control motor as shown in the illustration, connect the negative 0 terminal of the power supply to each clip as described in the following steps, and check whether or not a vibrating feeling (a feeling of very slight vibration of the stepper motor) is generated as a result of the activation of the stepper motor. @ Connect the negative 0 terminal of the power supply to the red and black clip. @ Connect the negative 0 termi.nal of the power supply to the blue and black clip. @ Connect the negative 0 terminal of the power supply to the blue and yellow clip. @ Connect the negative 0 terminal of the power supply to the red and yellow clip. @ Connect the negative 0 terminal of the power supply to the red and black clip. @ Repeat the tests in sequence from @ to 0. (4) If, as a result of these tests, vibration is detected, the stepper motor can be considered to be normal.
position sensor connector Idle speed control
6FU125i
IDLE SPEED CONTROL MOTOR POSITION SENSOR SOHC for GALANT and TRUCK (1) Measure the resistance between terminals @ and @ Standard value: 4 - 6 kQ (2) Disconnect the idle speed control motor connector. (3) Connect DC 6V between terminals @ and @ of the idle speed control motor connector, and then measure the resistance between terminals @ and @ of the idle speed control motor position sensor connector when the idle speed control motor is activated (caused to extend and retract). Standard value: It should decrease smoothly as the idle speed control motor plunger retracts. Caution Apply only a 6V DC or lower voltage. Application of higher voltage could cause locking of the motor gears. (4) If there is a deviation from the standard value, or if the change is not smooth, replace the idle speed control motor assembly.
6FU125:
TSB
Revision
1 IC-54
466 ENGINE <1992> - Throttle Body REASSEMBLY SERVICE POINTS I)A4 THROTTLE POSITION SENSOR INSTALLATlON SOHC FOR EXPO (1) Install the throttle position sensor to the throttle body as shown in the illustration.
(2) Turn the throttle position sensor 90 counterclockwise to set it in position and tighten the screws.
Throttle position sensor output Ground
(3) Connect a circuit tester between @ (ground) and @ (output), or between @(output) and @ (power). Then make sure that the resistance changes smoothly when the throttle valve is slowly moved to the fully open position. (4) Check for continuity between terminals @ (closed throttle position switch) and @ (ground) with the throttle valve both fully closed and fully open.
Closed throkle position switch
\ Throttle position sensor power

7FUO535
I Throttle valve position

I Fully closed
Fully oDen
I I I
Continuity
Conductive Non-conductive
1
I I
If there is no continuity with the throttle valve fully closed, turn the throttle position sensor clockwise, and then check again. (5) If the above specifications are not met, replace the throttle
position sensor.
#B4 THROTTLE POSlTlON SENSOR INSTALLATION GALANT, ECLIPSE, MIRAGE, TRUCK (1) Install the throttle position sensor to the throttle body as shown in the illustration.
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466 ENGINE <1992> - Throttle Bodv
IlC-55
(2) Turn the throttle position sensor 90 clockwise to set it and tighten the screws.
Throttle position sensor power
round
(3) Connect a circuit tester between @ (ground) and @ (output), or between @ (output) and @ (power). Then, make sure that the resistance changes smoothly when the throttle valve is slowly moved to the fully open position.
Throttle position sensor output

7FUO535
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11 C-56
466 ENGINE <1992> - Intake Manifold
INTAKE MANIFOLD
REMOVAL AND INSTALLATION - SOHC
(RWD)
18 Nm 13 ftlbs.
(FWD)
9
18 Nm 14ttlbs.
.- ._...
\ \ w-4 \ T34 18 Nrn 13 ftlbs. Ilklm 8 ftlbs.
30 Nm 22 ft.lbs.
13 ftlbs. 11 2iNm 16 ft.lbs.
u wrn
18 Nm 13 ftlbs.
Removal steps 1. Water hose 2. Water hose efl4 3. Engine coolant temperature gauge unit *Cg 4. Engine coolant temperature sensor 5. Water outlet fitting eB4 6. Gasket 7. Thermostat
8. Intake manifold plenum stay 9. Intake manifold plenum 10. Intake manifold plenum gasket 11. Intake manifold stay 12. Engine hanger
13. Intake manifold
14. Intake manifold gasket

6lN0109
TSB Revision
4G6 ENGINE <1992> - Intake Manifold {EMOVAL AND INSTALLATION - DOHC
IIC-57
(TO turbocharger) ;Xzr, ,, Nm
- 8 ft.lbs. Li
eg
(To oil cooler) Q
Removal steps 1. Water hose 2. Water hose 3. Water hose (turbo) 4. Water hose (turbo) *DC 5. Engine coolant temperature gauge unit #Q 6. Engine coolant temperature sensor 7. Water outlet fitting +fl4 8. Gasket 9. Thermostat 10. Thermostat case 11. Gasket
12. Intake manifold stay
20 ftlbs.
+A4 13. Intake manifold 14. Intake manifold gasket

6ENO460
TSB Revision
11 C-58
4G6 ENGINE <1992> - Intake Manifold INSTALLATION SERVICE POINTS *A4 INTAKE MANIFOLD INSTALLATION - DOHC
(1) Tighten the intake manifold bolts. Note that the bolts installed at the locations indicated in the illustration are tightened to a different torque.
6lNOO49
eB4
WATER OUTLET FITTING GASKET INSTALLATION (FOR RUBBER COATED METAL GASKET ONLY) (1) Install the water outlet fitting gasket with its UP mark facing up (toward the water outlet fitting side).
Sealant
ec4 SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE SENSOR Specified sealant: 3M Nut Locking Part No. 4171 or equivalent
eD4 SEALANT APPLICATION TO ENGINE COOLANT

Sealant
TEMPERATURE GAUGE UNIT Specified sealant: 3M ATD Part No. 8660 or equivalent
SEN0092
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4G6 ENGINE <1992> - Exhaust Manifold and Water Pumn
EXHAUST MANIFOLD AND WATER PUMP

REMOVAL AND INSTALLATION - SOHC
14 Nm* 10 ftlbs. 18 Nm 13 ft.lbs.
14 Nm 10 ft.lbs.
17 ft.lbs. Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Heat protector 5. Engine hanger 6. Exhaust manifold 7. Exhaust manifold gasket #A4 8. Water inlet pipe +A4 9. O-ring 10. Water pump 11. Water pump gasket NOTE * : GALANT and EXPO **: TRUCK
6EN0647
24Nm
1 TSB Revision
11 C-60
466 ENGINE <1992> - Exhaust Manifold and Water Pump
IEMOVAL AND INSTALLATION - DOHC FOR NON-TURBO
28 Nm 20 ftlbs. I
14 Nm 10 ft.lbs.
10 ft.lbs. 4 60 Nm 43 ftlbs. 14 Nm 10 ft.lbs. 4
24 Nm 17 ft.lbs. Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Heat protector A 5. Heat protector B 6. Engine hanger 7. Exhaust manifold 8. Exhaust manifold gasket +A4 9. Water inlet pipe )A4 10. O-ring 11. Water pump 12. Gasket
6EN0646
TSB Revision
4G6 ENGINE <1992> - Exhaust Manifold and Water Pump
1 X-61
IEMOVAL AND INSTALLATION - DOHC TURBO

43Nm 31 ft.lbs.
14 Nm
60 43
- 11 Nm 8 ftlbs.
14 Nm 10 ft.lbs.
16
43Nm
6
24 Nm
17 ft.lbs.
9Nm 7 ft.lbs. Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Heat protector A 5. Heat protector B 6. Exhaust fitting 7. Gasket 8. Air outlet fitting 9. Gasket I 0. Water pipe B 11. Oil return pipe 12. Gasket 13. Turbocharger assembly 14. Gasket TSB Revision
15. Ring 16. Oil pipe 17. Water pipe A 18. Turbocharger 19. Engine hanger 20. Exhaust manifold 21. Exhaust manifold gasket 22. Water pipe 23. Water hose 24. Water hose #A4 25. Water inlet pipe *A4 26. O-ring 27. Water pump 28. Gasket
6EN0649
11 C-62
O-ring
4G6 ENGINE <1992> - Exhaust Manifold and Water Pump INSTALLATION SERVICE POINT I)A4 WATER PIPE/O-RING INSTALLATION
(1) Wet the O-ring (with water) to facilitate assembly Caution Keep the O-ring free of oil or grease.
_jlr
6EN059
TSB
Revision
4G6 ENGINE <1992> - Turbocharger
K-63
TURBOCHARGER
DISASSEMBLY AND REASSEMBLY
Disassembly steps inspection of turbocharger waste gate W4 actuator operation 1. Snap pin 2. Turbocharger waste gate actuator +E4 3. Coupling *DC 4. Turbine housing *C4 5. Snap ring eB4 6. Turbine wheel assembly 7. Compressor cover +A4 8. O-ring
6lNOO52
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11 C-64
4G6 ENGINE <1992> - Turbocharger INSPECTION

TURBINE HOUSING (1) Check the housing for traces of contact with the turbine wheel, cracks due to overheating, pitching, deformation and other damage. Replace with a new turbine housing if cracked. (2) Operate the waste gate valve lever manually to check that the gate can be opened and closed smoothly. COMPRESSOR COVER (1) Check the compressor cover for traces of contact with the compressor wheel and other damage. TURBINE WHEEL ASSEMBLY (1) Check the turbine and compressor wheel blades for bend, burr, damage, corrosion and traces of contact on the back side and replace if defective. (2) Check the oil passage of the turbine wheel assembly for deposit and clogging. (3) In the case of water cooled type, check also the water passage for deposit and clogging. (4) Check the turbine wheel and compressor wheel for light and smooth turning.
6lN0055
Comr, whekl
3EN020E
REASSEMBLY SERVICE POINTS #A4 O-RING INSTALLATION

(1) Apply a light coat of engine oil to a new O-ring and fit the O-ring in the groove of the turbine wheel assembly.
*Bg
TURBINE WHEEL ASSEMBLY INSTALLATION (1) Install the turbine wheel assembly to the compressor cover while aligning the dowel pin with the dowel pin hole. Caution Use care not to damage the blades of turbine wheel and compressor wheel.
Chamfered 1
+c4 SNAP RING INSTALLATION (1) Fit the snap ring with its chamfered side facing up.
assembly
6lN0070
1 TSB Revision
4G6 ENGINE <1992> - Turbocharger eD4 TURBINE HOUSING INSTALLATION
11 C-65
(1) Install the turbine housing on the compressor cover while aligning the dowel pin with the dowel pin hole. Caution Use care not to damage the blades of the turbine wheel.
I)E4 COUPLING INSTALLATION

(1) Install the coupling and tighten it to the specified torque.
Coupling
eF4
WASTE GATE ACTUATOR OPERATION CHECK (1) Using a tester, apply a pressure of approx. 72 kPa (10.3 psi) to the actuator and make sure that the rod moves. Caution Do not apply a pressure of more than 85 kPa (12.4 psi) to the actuator. Otherwise, the diaphragm may be damaged. Never attempt to adjust the waste gate valve.
6lN005!
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llC=66
4G6 ENGINE <1992>
- Rocker Arms and Camshaft - SOHC
ROCKER ARMS AND CAMSHAFT - SOHC

Q-----7
nemoval steps 1. Breather hose 2. P.C.V. hose 3. Packing 4. Oil seal 5. Rocker cover 6. Gasket eG4 7. Semi-circular packing 8. Rocker arms and rocker shafts 9. Rear bearing cap eC4 10. Rocker arm D 11. Spring EC 12. Rocker arm D v*Dir 13. Bearing-cap No. 4 34 14. Rocker arm C C4 15. arm C _^ Rocker ^ rq I/. Beanng cap No. 3 I;4 18. arm D .- Rocker 20. Rocker arm D 21. Bearing cap No. 2 22. Rocker arm C 23. Rocker arm C 24. Spring +B4 25. Wave washer #A4 26. Right rocker shafts *A4 27. Left rocker shafts 28. Front bearing cap (IAO +E4 29. Lash adjuster +F4 30. Oil seal 31. Camshaft C4 +04 +C4 eC4
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- - - F&l~lluC /1663\ _ Rack r Arms

MD998443-01 I
and Camshaft - SOW
I K-67
REMOVAL SERVICE POINT (IAO ROCKER ARM AND CAMSHAFT REMOVAL

(1) Before removing rocker arms and shafts assembly, install the special tool as illustrated to prevent adjuster from dropping.
6EN056E
INSPECTION
CAMSHAFT (1) Measure the cam height
1 Identification mark (Standard value D: Intake Exhaust 42.40 42.40 44.53 44.53 (1.6692) (1.6692) (1.7531) (1.7531) 1 Limit 41.90 41.90 44.03 44.03 (1.6496) (1.6496) (1.7335) (I .7335) I
AR: Intake
Exhaust
NOTE The camshaft identification mark is stamped on the opposite end of the camshaft sprocket side.
ROCKER ARM (1) Check the roller surface. If any dent, damage or seizure is evident, replace the rocker arm. (2) Check rotation of the roller. If it does not rotate smoothly or if looseness is evident, replace the rocker arm.
(3) Check the inside diameter. If damage or seizure is evident,
replace the rocker arm.
7EN006L.
LASH ADJUSTER LEAK DOWN TEST

Caution 1. The lash adjuster is a precision part. Keep it free from dust and other foreign matters. 2. Do not disassemble the lash adjusters. 3. When cleaning the lash adjusters, use clean diesel fuel only.
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1
IIC-68
4G6 ENGINE <1992> - Rocker Arms and Camshaft - SOHC

(1) Immerse the lash adjuster in clean diesel fuel. (2) While lightly pushing down the inner steel ball using a small wire, move the plunger up and down four or five times to bleed air. Use of the retainer facilitates the air bleeding of a rocker arm mounted type lash adjuster. (3) Remove the small wire and press the plunger. If the plunger is hard to be pushed in, the lash adjuster is normal. If the plunger can be pushed in all the way readily, bleed the lash adjuster again and test again. If the plunger is still loose, replace the lash adjuster. Caution Upon completion of air bleeding, hold the lash adjuster upright to prevent inside diesel fuel from spilling.
6EN057t
Division = 1 mm LO4 in.)
(4) After air bleeding, set the lash adjuster on the special tool (Leak down tester MD998440). (5) After the plunger has gone down somewhat (.2 - .5 mm), measure time taken for it to go down 1 mm. Replace if the measured time is out of the specification. Standard value: 4 - 20 seconds / 1 mm (.04 in.) [Diesel fuel at 15 - 20C (59 - 68F)]
7EN0438

CAMSHAFT IDENTIFICATION Identification: E X P O / GALANT A R TRUCK D
Notch
+A4
ROCKER SHAFT INSTALLATION (1) Insert the rocker arm shaft into the front bearing cap with the notch on the shaft facing up, and insert the installation bolt without tightening it.
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4G6 ENGINE <1992> - Rocker Arms and Camshaft - SOHC

Wave washer
11 C-69
I)B+
WAVE WASHER INSTALLATION
(1) Install the wave washer in the correct direction as shown.
side rocker arm
6EN057Z
identification b Timing belt side No. 1 No. 2 No. 3 No. 4
I)c4 ROCKER ARM IDENTIFICATION

Identification mark: 1 - 3 for No. 1 and 3 cylinders
2-4
for No. 2 and 4 cylinders
No. 1
No. 2
N o . 3 No. 4
6EN055e
Rocker cover mounting bolt hole
FroAt mark Identification mark No. 2 No. 3
No. 4
6EN0024
I)D4 CAMSHAFT BEARING CAP IDENTIFICATION (1) No. 3 bearing cap looks very similar to No. 2 and No. 4 bearing caps. Use the identification marks shown at left for identification. NOTE No. 2 bearing cap is the same as No. 4 bearing cap. (2) Install the bearing caps with their front marks pointing to camshaft sprocket side.
I)Eg
LASH ADJUSTER INSTALLATION (1) Immerse the lash adjuster in clean diesel fuel. (2) Using a small wire, move the plunger up and down 4 or 5 times while pushing down lightly on the check ball in order to bleed out the air.
6EN0421
(3) Insert the lash adjuster to rocker arm, being careful not to spill the diesel fuel. Use the special tool to prevent adjuster from falling while installing it.
Lash adjuiter
7EN0174
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4G6 ENGINE <1992> - Rocker Arms and Camshaft - SOHC I)F4 CAMSHAFT OIL SEAL INSTALLATION
I)G4
Apply sealant
SEMI-CIRCULAR PACKING INSTALLATION Specified sealant: 3M ATD Part No. 8660 or equivalent
DEN0052
IOmm
Semi-circular packing
Gasket r$ of cvlinder head
6EN042
TSB Revision
4G6 ENGINE <1992>
- Camshafts and Rocker Arms - DOHC
1 IC-71
CAMSHAFTS AND ROCKER ARMS - DOHC

20 Nm 14 t=t.lbs.-
11 Nm 8 ftlbs.
Removal steps fiC4 1. Bearing cap rear #Q 2. Bearing cap front +04 3. Camshaft oil seal #C4 4. Bearing cap No. 5 eC4 5. Bearing cap No. 2 eC4 6. Bearing cap No. 4 eC4 7. Bearing cap No. 3 eB4 8. Camshaft 9. Rocker arm *A4 10. Lash adjuster 11. Oil delivery body
6EN0524
TSB Revision
11 C-72
4G6 ENGINE <1992>
- Camshafts and Rocker Arms - DOHC
INSPECTION
CAMSHAFT (1) Measure the cam height.
Identification mark Intake AD I3.CF.F Exhaust 2 35.49 (1.3972) 35.20 (1.3858) 35.49 35.20 (1.3972) (1.3858) 35.91 (1.3744) 34.99 (1.3776) 34.70 (I .3661) 34.99 34.70 (1.3776) (1.3661) 34.41 (1.3547) Standard value Limit
E.F
Roller
Tip I
6EN018!
Scale = 1 mm (.039 in.) M[
The camshaft identification mark is stamped on the rear end of camshaft. ROCKER ARM (1) Check the roller surface. If any dent, damage or seizure is evident, replace the rocker arm. (2) Check rotation of the roller. If it does not rotate smoothly or if looseness is evident, replace the rocker arm. (3) Check the inside diameter. If damage or seizure is evident, replace the rocker arm. LASH ADJUSTER LEAK DOWN TEST Refer to LASH ADJUSTER LEAK DOWN TEST on pages 1 lC-67 and 11 C-68 . Also note the following. When the lash adjuster is set on a tester, remove the adjusting screw of the tester and adjust it to the height of the lash adjuster as shown in the illustration.
6EN035
Nut
6EN035
INSTALLATION SERVICE POINTS *A4 LASH ADJUSTER INSTALLATION

(1) Immerse the lash adjuster in clean diesel fuel. (2) Using a small wire, move the plunger up an down 4 to 5 times while pushing down lightly on the check ball in order to bleed out the air.
6EN042
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4G6 ENGINE <1992> - Camshafts and Rocker Arms - DOHC

Camshaft sprocket side
1 IC-73
I)64 INSTALLATION OF CAMSHAFT (1) Apply engine oil to journals and cams of the camshafts. (2) Install the camshafts on the cylinder head. Use care not to confuse the intake camshaft with the exhaust one. The intake camshaft has a slit on its rear end for driving the crankshaft position sensor.
Intake side camshaft
6EN0289
Dowel pin
(3) Install the crankshaft sprocket B or spacer and flange to an end of the crankshaft, and turn the crankshaft until the timing marks are lined up, setting No. 1 cylinder to the TDC. (4) Set the camshafts so that their dowel pins are positioned at top.
I)c4 BEARING CAP INSTALLATION (1) According to the identification mark stamped on top of each bearing cap, install the caps to the cylinder head. Only L or R is stamped on No. 1 bearing cap. Cap No. is stamped on No. 2 to No. 5 bearing caps. No. 6 bearing cap has no stamping. I: For intake camshaft side E: For exhaust camshaft side
Cap number Symbol identifying intake or exhaust
6EN046r
- Camshaft sprocket side
(2) Tighten the bearing caps in the order shown by torquing progressively in two to three stages. Tighten to the specification in the final sequence. (3) Check to ensure that the rocker arm is held in position on the lash adjuster and valve stem end.
6EN019i
I)D4 CAMSHAFT OIL SEAL INSTALLATION
),\
\c
6EN0651
levision
11 c-74
4G6 ENGINE <1992>
- Cylinder Head and Valves - SOHC
CYLINDER HEAD AND VALVES - SOHC

95 Nm 69 fklbs. --1
0 1
e--2
III184
RI7 v
Removal steps (IA~J I)E4 ;. C&i;;;; head bolt 3: Cylinder head assembly $04 4. Gasket @I$ I)C4 5. Retainer lock 6. Valve spring retainer $64 7. Valve spring 8. Intake valve QBr) SC4 9. Retainer lock 10. Valve spring retainer I)B+ 11. Valve spring 12. Exhaust valve (A@ #A4 13. Valve stem seal 14. Valve spring seat (10) +A4 15. Valve stem seal 16. Valve spring seat 17. Intake valve guide 18. Exhaust valve guide 19. Intake valve seat 20. Exhaust valve seat 21. Cylinder head
6EN0309
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4G6 ENGINE <1992>
- Cvlinder Head and Valves - SOHC
IIC-75
REMOVAL SERVICE POINTS

PRECAUTION FOR REMOVED PARTS (1) Keep removed parts in order according to the cylinder number and intake/exhaust.
OAo CYLINDER HEAD BOLT REMOVAL

(1) Using the special tool, loosen the cylinder head bolts. Loosen evenly, little by little.
tJB0 RETAINER LOCK REMOVAL

(1) Using the special tool, compress the spring. (2) Remove the retainer locks. Keep removed parts in order according to the cylinder number and intake/exhaust.
a@ VALVE STEM SEAL REMOVAL (1) Do not reuse valve stem seal.
1 TSB Revision
1 IC-76
466 ENGINE <1992> - Cvlinder Head and Valves - SOHC INSPECTION

CYLINDER HEAD (1) Check the cylinder head gasket surface for flatness by using a straightedge in the directions of A through G shown in the illustration. Standard value: 0.05 mm (JO20 in.) Limit: 0.2 mm (008 in.) (2) If the service limit is exceeded, correct to meet the specification. Grinding limit: 0.2 mm (008 in.) Caution * Total resurfacing depth of both cylinder head and cylinder block. Cylinder head height (Specification when new): 89.9 - 90.1 mm (3.539 - 3.547 in.)
1 6EN0542
I
Gu:de I.D. Guide O.D.
Free height
1 EN0264
VALVE (1) Check the valve face for correct contact. If incorrect, reface using a valve refacer. The valve seat contact should be maintained uniform at the center of the valve face. (2) If the margin exceeds the service limit, replace the valve. Standard value: 1.2 mm LO47 in.) Intake Exhaust 2.0 mm (079 in.) Limit: 0.7 mm (.028 in.) Intake 1.5 mm (059 in.) Exhaust VALVE SPRING (1) Measure the free height of spring and, if it is smaller than the limit, replace. Identification color: White Standard value: 49.8 mm (1.961 in.) Limit: 48.8 mm (1.922 in.) (2) Measure the squareness of the spring and, if the limit is exceeded, replace. Standard value: 2 or less Limit: Max. 4 VALVE GUIDE (1) Measure the clearance between the valve guide and valve stem. If the limit is exceeded, replace the valve guide or valve, or both. Standard value: 0.02 - 0.06 mm (0008 - .0024 in.) Intake 0.05 - 0.09 mm (0020 - .0035 in.) Exhaust Limit: 0.10 mm (.004 in.) Intake Exhaust 0.15 mm (006 in.)
1 EN0279
1 TSB Revision
4G6 ENGINE <1992> - Cylinder Head and Valves - SOHC
IIC-77
VALVE SEAT RECONDITIONING PROCEDURE

(1) Before correcting the valve seat, check for clearance between the valve guide and valve and, if necessary, replace the valve guide. (2) Using the special tool or seat grinder, correct to obtain the specified seat width and angle. (3) After correction, valve and valve seat should be lapped with a lapping compound.
6EN049
0.5 - 1 mm (.020- ,039 in.)
VALVE SEAT REPLACEMENT PROCEDURE

(1) Cut the valve seat to be replaced from the inside to thin the wall thickness. Then, remove the valve seat.
0.5-I mm (.020-,039 in.)
1 EN027~
1 EN02
(2) Rebore the valve seat hole in the cylinder head to a selected oversize valve seat diameter. Seat ring hole diameter: See Service Specifications on page IIC-10. (3) Before fitting ttie valve seat, either heat the cylinder head up to approximately 250C (482F) or cool the valve seat in liquid nitrogen, to prevent the cylinder head bore from galling. (4) Using a valve seat cutter, correct the valve seat to the specified width and angle. See VALVE SEAT RECONDITIONING PROCEDURE.
Removal
Press a
Installation
Press a MD9981 15-01 Push rod Valve guide 6]
MD998115
VALVE GUIDE REPLACEMENT PROCEDURE

(1) Using the special tool and a press, remove the valve guide toward cylinder head gasket surface. (2) Rebore valve guide hole to the new oversize valve guide outside diameter. Valve guide hole diameter: See Service Specifications on page IIC-10.
-01 Valve guide

6EN054
NOTE Do not install a valve guide of the same size again. (3) Using the special tool, press-fit the valve guide, working from the cylinder head top surface. (4) After installing valve guides, insert new valves in them to check for sliding condition. (5) When valve guides have been replaced, check for valve contact and correct valve seats as necessary.
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1 IC-78
466 ENGINE <1992> - Cylinder Head and Valves - SOHC INSTALLATION SERVICE POINTS I)A4 VALVE STEM SEAL INSTALLATION
MD998729-01
(1) Install the valve spring seat.

4-l
5ENOOl E
(2) Using the special tool, install a new stem seal to the valve guide. Caution Do not reuse the valve stem seal.
61 ;
Identification color
I)& VALVE SPRING INSTALlATlON (I) Direct the valve spring end with identification color end toward the spring retainer.
Stem seal ) LSpring seal

I 6EN043i I A
I)c4 RETAINER LOCK INSTALLATION (1) Using the special tool, compress the valve spring and insert the retainer lock into position.
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4G6 ENGINE <1992> - Cylinder Head and Valves - SOHC

Identification mark
IIC-79
I)D4 CYLINDER HEAD GASKET IDENTIFICATION

Identification mark: 4663 . . . . . 63 4664 . . . . . 64 Caution Do not apply sealant to cylinder head gasket.
6EN054 5
I)E4 CYLINDER HEAD BOLT INSTALLATION
(=I
Camshaft sprocket side
(1) Tighten the cylinder head bolts in the sequence shown. Each bolt should be tightened in two to three steps, torquing progressively. Tighten to the specified torque in the final sequence.
6EN05413
MD998051-01 OPTIONAL\ -
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11 C-80
466 ENGINE <1992> - Cylinder Head and Valves - DOHC
CYLINDER HEAD AND VALVES - DOHC

Removal steps OArJ )E4 1. Cylinder head bolt 2. Washer 3. Cylinder head assembly )D4 4. Gasket (IBM *Cc 5. Retainer lock 6. Valve spring retainer 7. Valve spring 8. Intake valve 9. Retainer lock 10. Valve spring retainer II. Valve spring 12. Exhaust valve 13. Valve stem seal 14. Valve spring seat 15. Valve stem seal 6. Valve spring seat 17. Intake valve guide 18. Exhaust valve guide 19. Intake valve seat 20. Exhaust valve seat 21. Cylinder head
6EN0196
1 TSB Revision
4G6 ENGINE <1992> - Cylinder Head and Valves - DOHC REMOVAL SERVICE POINTS OAo CYLINDER HEAD BOLT REMOVAL
1 W-81
(1) Using the special tool, loosen the cylinder head bolts. Loosen evenly, little by little.
OBo RETAINER LOCK REMOVAL

MD998735-01
(1) Using the special tool, compress the spring. (2) Remove the retainer locks. Keep removed parts in order according to the cylinder number and intake/exhaust.
($0 VALVE STEM SEAL REMOVAL (1) Do not reuse the stem seals.
INSPECTION
(1) Only features differing from the single camshaft engine are described in the following. (Refer to Pages 1 lC-76.)
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11 C-82
4G6 ENGINE <1992> - Cylinder Head and Valves - DOHC CYLINDER HEAD
Cylinder head height (when new): 131.9 - 132.1 mm (5.193 - 5.201 in.)
VALVE Margin: Intake 1.0 mm (.039 in.) Exhaust I.5 mm (.059 in.) Limit: Intake 0.7 mm (.028 in.) Exhaust 1.0 mm (.039 in.)
VALVE SPRING Free height: 48.3 mm (1.902 in.) Limit: 47.4 mm (I.866 in.) Squareness: 1.5 or less Limit: Max. 4
VALVE GUIDE Valve guide to valve stem clearance: Intake 0.02 - 0.05 mm (.OOOS - .0020 in.) Exhaust 0.05 - 0.09 mm (.0020 - .0035 in.) Limit:
Intake 0.10 mm (.004 in.)
Exhaust 0.15 mm (.006 in.)
VALVE SEAT RECONDITIONING PROCEDURE

(1) Refer to Page 11 C-77, noting that the only difference is in the special tool (Cutter).
6EN0491
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4G6 ENGINE <1992> - Cylinder Head and Valves - DOHC
1 IC-83
VALVE SEAT REPLACEMENT PROCEDURE

(1) Refer to Page 1 IC-77 noting that the only difference is in the reboring size. Intake valve seat hole diameter 0.3 mm (.012 in.) O.S. . . . . . . . . . . . . . . . . . . . . 35.30- 35.33 mm (1.3898 - I .3909 in.) 0.6 mm (.024 in.) O.S. . . . . . . . . . . . . . . . . . . . . 35.60 - 35.63 mm (1.4016- 1.4028 in.) Exhaust valve seat hole diameter 0.3 mm (.012 in.) O.S. . . . . . . . . . . . . . . . . . . . . 33.30- 33.33 mm (1.3110- 1.3122 in.) 33.60- 33.63 mm . . . . . . . . . . . . . . . . . . . . 0.6 mm (024 in.) O.S. (1.3228- 1.3240 in.)
VALVE GUIDE REPLACEMENT PROCEDURE

(1) Refer to Page 11 C-77, noting that there are differences in the diameter of the valve guide hole as well as in the guides installed height. Valve Guide Hole Diameter 0.05 mm (.002 in.) O.S. . . . . . . . . . . . . . . . . 12.05 - 12.07 mm (.4744 - .4752 in.) 12.2512.27 mm . . . . . . . . . . . . . . . . 0.25 mm (.OIO in.) O.S. (.4823 - 4831 in.) 0.50 mm (.002 in.) O.S. . . . . . . . . . . . . . . . . 12.50- 12.52 mm (.4921- .4929 in.)
INSTALLATION SERVICE POINTS +A4 VALVE STEM SEAL INSTALLATION

Valve seat
6EN020!
(1) Install the valve spring seat. (2) Using the special tool, install a new stem seal to the valve guide. Caution Do not reuse the valve stem seal.
I)B4 VALVE SPRING INSTALLATION

Identificationcolor
(1) Install the valve spring so that its end with identification color is positioned on the rocker arm end.
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11 C-84
4G6 ENGINE <1992> - Cylinder Head and Valves - DOHC

I)& RETAINER LOCK INSTALLATION (1) Using the special tool, compress the valve spring and insert the retainer lock into position.
I)D4 CYLINDER HEAD GASKET IDENTIFICATION Identification mark: I6 4661 2 0 4663
6EN0209
#Eg CYLINDER HEAD BOLT INSTALLATION

a Camshaft sprocket side i 6 6 b 6 6
(1) Tighten the cylinder head bolts in the sequence shown. Each bolt should be tightened in two to three steps, torquing progressively. Tighten to the specified torque in the final sequence.
6EN0211
TSB Revision
4G6
ENGINE <1992> - Front Case, Silent Shaft and Oil Pan
X-85
FRONT CASE, SILENT SHAFT AND OIL PAN

22 **
24 Nm ****
40 ftlbs. Removal steps 1. Oil filter 2. Oil cooler bolt*** 3. Oil cooler*** 4. Drain plug 5. Drain plug gasket (IAO+N~ 6. Oil pan 7. Oil screen 8. Oil screen gasket OBrJ )EC 9. Flange nut 10. Oil pump sprocket** @IQ )MCl 1. Plug 12. O-ring @IQ )L~I 13. Flange bolt 14. Oil filter bracket 15. Oil filter bracket gasket *KC 16. Front case 17. Front case gasket 18. Silent shaft, left** 19. Silent shaft, right** (IEIJ +,I4 20. Silent shaft, front bearing** (IFO +I4 21, Silent shaft, rear bearing. left** (IGO *H4 22. Silent shaft, rear bearing, right** 1 TSB Revision
NOTE * : DOHC ** : Engine with silent shafts xxx : Engine with turbocharger **** : Engine without silent shafts *****: Engine with air-cooling type oil cooler
6EN0533
IIC-86
466 ENGINE <1992> - Front Case, Silent Shaft and Oil Pan
19=-Q& 2ow 33 Nm -189 24 ft.lbs.
1
\
m5? ? 45 Nm 33 ft.lbs.
: ***** 55 Nm 40 ft.lbs. :55 Nm 40 ft.lbs.
1. Oil cooler by-pass valve***** +G4 2. Oil pressure switch eF4 3. Oil pressure gauge unit ;. pm 6: Relief spring 7. Relief plunger 8. Oil filter bracket 9. Oil pump cover 10. Oil pump shaft**** 11. Oil pump driven gear 12. Oil pump drive gear 13. Crankshaft,front oil seal 14. Oil p,u,m,p,o~l seal
$04 I)D4 eC4 *Bg NOTE * : DOHC ** : Engine with silent shafts *** : Engine with turbocharger **** : Engine without silent shafts *****: Engine with air-cooling type oil cooler
I)A~ ig. .%%t shaft oil seal** 17: Front case 18. Check valve 19. Oil jet 20. Gasket
6EN0525
1 TSB Revision
4G6 ENGINE <1992> - Front Case, Silent Shaft and Oil Pan
Service tool :
1 IC-87
REMOVAL SERVICE POINTS aA OIL PAN REMOVAL

(1) Remove the all oil pan bolts. (2) Drive in the service tool between the cylinder block and oil pan. NOTE Never use a screwdriver or chisel, instead of the service tool, as a deformed oil pan flange will result in oil leakage.
OlLO583
OlLO584
(IBI) FLANGE NUT REMOVAL

(ENGINE WITH SILENT SHAFTS) (1) Remove the plug on the side of the cylinder block. (2) Insert a Phillips screwdriver [shank diameter 8 mm (.32 in.)] into the plug hole to lock the silent shaft. (3) Loosen the oil pump sprocket flange nut.
6EN0563 1
6EN05641
@) PLUG REMOVAL (1) If the plug is too tight, hit the plug head with a hammer two to three times, and the plug will be easily loosened.
Engine with sile
~DI) FLANGE BOLT REMOVAL

(ENGINE WITH SILENT SHAFTS) (1) Referring to ~BIJ (2). lock the silent shaft. (2) Loosen the flange bolt.
Engine without silent shafts
ODo FLANGE NUT REMOVAL

(ENGINE WITHOUT SILENT SHAFTS) (1) Clamp the oil pump shaft end in a vise.
6EN0339
1 TSB Revision
(2) Remove the oil pump sprocket nut.
OEo
SILENT SHAFT FRONT BEARING REMOVAL (ENGINE WITH SILENT SHAFTS) Using the special tool, remove the silent shaft front bearing from the cylinder block. NOTE Be sure to remove the front bearing first. If it has not been removed, the Rear Bearing Puller cannot be used.
OFr)
LEFT SILENT SHAFT REAR BEARING REMOVAL (ENGINE WITH SILENT SHAFTS) Using the special tool, remove the left silent shaft rear bearing from the cylinder block.
QGo
REAR BEARING REMOVAL (ENGINE WITH SILENT SHAFTS) Using the special tool, remove the right silent shaft rear bearing from the cylinder block.
INSPECTION
FRONT CASE (1) Check oil holes for clogging and clean if necessary. (2) Check left silent shaft front bearing section for wear, damage and seizure. If there is anything wrong with the section, replace the front case. (3) Check the front case for cracks and other damage. Replace cracked or damaged front case. OIL SEAL (1) Check the oil seal lip for wear and damage. Replace the oil seal if necessary. (2) Check the oil seal lip for deterioration. Replace the oil seal if necessary. TSB Revision
IIC-89
DEN0711
SILENT SHAFT (ENGINE WITH SILENT SHAFTS) (1) Check oil holes for clogging. (2) Check journal for seizure, damage and contact with bearing. If there is anything wrong with the journal, replace silent shaft, bearing or front case assembly. (3) Check the silent shaft oil clearance. If the clearance is excessively due to wear, replace the silent shaft bearing, silent shaft or front case assembly. Standard value: Front Right 0.03 - 0.06 mm (.0012 - .0024 in.) 0.02 - 0.05 mm (.OOOS - .0020 in.) Left Rear Right 0.05 - 0.09 mm (.0020 - .0036 in.) Left 0.05 - 0.09 mm (.0020 - .0036 in.)
OIL PUMP (1) Assemble the oil pump gears in the front case and rotate them to ensure smooth rotation with no looseness. (2) Ensure that there is no ridge wear on the gear contact surface of the front case and the oil pump cover. (3) Check the side clearance Standard value: 0.08 - 0.14 mm (.0031 - .0055 in.) Drive gear 0.06 - 0.12 mm (.0024 - .0047 in.) Driven gear
I
6LUOO13
OIL COOLER BYPASS VALVE (ENGINE WITH AIR COOLING TYPE OIL COOLER) (1) Make sure that the valve moves smoothly. (2) Ensure that the dimension (L) measures the standard value under normal temperature and humidity. Standard value (L): 34.5 (.358 in.) (3) The dimension must be the standard value when measured after the valve has been dipped in 100C (212F) oil. Standard value (L): 40 mm (1.57 in.) or more
6EN0589
Engine with silent shafts a

Socket wrench Front case
INSTALLATION SERVICE POINTS I)A4 SILENT SHAFT OIL SEAL INSTALLATION

(ENGINE WITH SILENT SHAFTS)
N05EX
TSR Revision
IIC-90
I)64 OIL PUMP OIL SEAL INSTALLATION
6EN0494I 6EN0494
CRANKSHAFT FRONT OIL SEAL INSTALLATION I)c4 (1) Using the special tool, install the crankshaft front oil seal into the front case.
I)D4
OIL PUMP DRIVEN GEAR / OIL PUMP DRIVE GEAR INSTALLATION
(I) Apply engine oil amply to the gears and line up the alignment marks.
IEngine without silent shafts ml
+E4
FLANGE NUT INSTALLATION (ENGINE WITHOUT SILENT SHAFTS) Caution Before installing the flange nut, apply an appropriate amount of oil to the seating surface. (I) Clamp the oil pump shaft end in a vise.
6EN033Y
Engine without silent shafts \ \
(2) Tighten the oil pump sprocket nut to the specified torque.
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4G6 ENGINE <1992>
- Front Case, Silent Shaft and Oil Pan
IIC-91
I)F~I
SEALANT APPLICATION TO OIL PRESSURE GAUGE UNIT
APP~
(1) Coat the threads of the oil pressure gauge unit with sealant and install the unit using the special tool. Specified sealant: 3M ATD Part No. 8660 or equivalent Caution 1. Keep the end of threaded portion clear of sealant. 2. Avoid an overtightening.
3EN0221
I)G4 SEALANT APPLICATION TO OIL PRESSURE

SWITCH (1) Coat the threads of the oil pressure switch with sealant and install the switch using the special tool. Specified sealant: 3M ATD Part No.8660 or equivalent Caution 1. Keep the end of threaded portion clear of sealant. 2. Avoid an overtightening.
9ENOOSL
I)H4
RIGHT SILENT SHAFT REAR BEARING INSTALLATION (ENGINE WITH SILENT SHAFTS) (1) Apply engine oil to the outer surface of the bearing. (2) Using special tools, install the right rear bearing. Make sure that the oil hole of the bearing is aligned with the oil hole of the cylinder block.
MD998373-01
6EN05t
6EN058
1)14
LEFT SILENT SHAFT REAR BEARING INSTALLATION (ENGINE WITH SILENT SHAFTS) (1) Install the special tool (Guide Plate) to the cylinder block. (2) Apply engine oil to the rear bearing outer circumference and bearing hole in the cylinder block.
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IIC-92
4G6 ENGINE <1992> - Front Case. Silent Shaft and Oil Pan
(3) Using the special tool, install the rear bearing. NOTE The left rear bearing has no oil holes.
6EN0578
+Jg
SILENT SHAFT FRONT BEARING INSTALLATION (ENGINE WITH SILENT SHAFTS) (1) Using the special tools, install the front bearing.
MD998$73-01
6EN0581
Cylinder block
\ --N /
6EN058E
I)K4 FRONT CASE INSTALLATION

(1) Set the special tool on the front end of the crankshaft and apply a thin coat of engine oil to the outer circumference of the special tool to install the front case.
(2) Install the front case assembly through a new front case gasket and temporarily tighten the flange bolts (other than those for tightening the filter bracket).
6EN02621
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r
IIC-93
(3) Mount the oil filter bracket with oil filter bracket gasket. Then, install the four bolts with washers. (4) Tighten the bolts to the specification. NOTE (1) The bolt marked with *I in the illustration differs in tightening torque. (2) The bolt marked with 2 in the illustration is for engine without silent shafts only.
= Bolt length Imm (in.)] 6EN031:
tIngine with silent shafts
I)14 FLANGE BOLT INSTALLATION (ENGINE WITH SILENT SHAFTS) (1) Insert a Phillips screwdriver into the hole on the left side of the cylinder block to lock the silent shaft.
6EN0564
Ingi
(2) Secure the oil pump driven gear on the left silent shaft by tightening the flange bolt to the specified torque.
eM4 PLUG INSTALLATION (1) Install a new O-ring in the groove of the front case. (2) Using the special tool, install the plug and tighten to the specified torque.
I)E4 FLANGE NUT INSTALLATION

(ENGINE WITH SILENT SHAFTS) (1) Referring to #J4 (I), lock the silent shaft. (2) Tighten the flange nut to the specified torque.
6EN049E
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IIC-94
I)N4 OIL PAN INSTALLATION

(1) Clean both mating surface of the oil pan and the cylinder block. (2) Apply a 4 mm (.I6 in.) wide bead of sealant to the entire circumference of the oil pan flange. Specified sealant: MITSUBISHI GENUINE PART No. MD970389 or equivalent (3) The oil pan should be installed in 15 minutes after the application of sealant.
6FNn71R
1 Crank pulley side
(4) Note that the bolts at the location shown are different in length from the others.
Oil pan viewed from bottom
6EN044E
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4G6 ENGINE <1992> - Piston and Connecting Rod
1 IC-95
PISTON AND CONNECTING ROD

6 7 8
?4
9 ll-
Removal steps 1. Nut (IAO )E4 2. Connecting rod cap 3. Connecting rod bearing eD4 4. Piston and connecting rod assembly 5. Connecting rod bearing eC4 6. Piston ring No. 1 +C4 7. Piston ring No. 2 #B4 8. Oil ring QBo *AC 9. Piston pin IO. Piston ; ;: Ch;7tecting rod
6EN0526
11 C-96
466 ENGINE <1992> - Piston and Connecting Rod REMOVAL SERVICE POINTS aA0 CONNECTING ROD CAP REMOVAL
number
(1) Mark the cylinder number on the side of the connecting rod big end for correct reassembly. (2) Keep the removed connecting rods, caps, and bearings in order according to the cylinder number.
iston pin setting 001 MIT216941
cJB0 PISTON PIN REMOVAL

Item No. Part No. 1 z 4 i i 9
8 Description
::
MIT310134 MIT310136 MIT310137 MIT310138 MIT310139 MIT310140 MIT310141 MIT310142 MIT48143 2 16943 10396
Base Piston Support Connecting Rod Connecting Rod Connecting Rod Piston Support Connecting Rod Piston Support Press Pin Stop Screw Nut
Guide Pin Guide Pin Guide Pin Guide Pin
11
(1) Remove the stop screw from the base. (2) Select the correct piston support for your application (See above). Fit the piston support onto the base. Place the base on press support blocks.
7EN042E
Press pin
.q.:::::::::::: .: .:.:.y,:, --is Piston pin
(3) Insert the press pin through the piston pin hole. Select the correct connecting rod guide pin (See above). Thread the guide pin onto the threaded portion of the press pin. (4) Position the piston assembly on the piston support in the press. With the press pin up as shown in the illustration,
insert the guide pin through the hole in the piston and
through the hole in the piston support.

Front mark
(5) Press the piston pin out of the assembly.
Connecting w /guide pin
rod
IMPORTANT: To avoid piston damage, 1. The piston support must seat squarely against the piston. 2. Verify that the piston pin will slide through the hole in the piston support. (6) Remove the piston pin from the press pin.
7EN042fI
vision
4G6 ENGINE <1992> - Piston and Connectina Rod INSPECTION
lW97
PISTON (1) Replace the piston if scratches or seizure is evident on its surfaces (especially the thrust surface). Replace the piston if it is cracked. PISTON PIN (1) Insert the piston pin into the piston pin hole with a thumb. You should feel a slight resistance. Replace the piston pin if it can be easily inserted or there is an excessive play. (2) The piston and piston pin must be replaced as an assembly. PISTON RING (1) Check the piston ring for damage, excessive wear, and breakage and replace if defects are evident. If the piston has been replaced with a new one, the piston rings must also be replaced with new ones. (2) Check for the clearance between the piston ring and ring groove. If the limit is exceeded, replace the ring or piston, or both. Standard value: 0.03 - 0.07 mm (.0012 - .0028 in.) No.1 0.02 - 0.06 mm (.OOOS - .0024 in.) No.2 SOHC 0.03 - 0.07 mm (.0012 - .0028 in.) No. 2 DOHC Limit: 0.1 mm (.004 in.) (3) Install the piston ring into the cylinder bore. Force it down with a piston, its crown being in contact with the ring, to correctly position it at right angles to the cylinder wall. Then, measure the end gap with a feeler gauge. If the ring gap is excessive, replace the piston ring. Standard value: 0.25 - 0.40 mm (.0098 - -0157 in.) No. 1 0.35 - 0.50 mm No. 2 4661 (.0138 - .0197 in.) 0.20 - 0.35 mm 4663 - SOHC LOO79 - .0138 in.) 0.45 - 0.60 mm 4663 - DOHC (.0177 - .0236 in.) 0.20 - 0.40 mm 4664 (.0079 - .0157 in.)
Oil 0 . 2 0 - 0.70 m m LOO79 - .0276 in.)
5EN0066
f?StOn ring End gap
6EN05413
Limit: 0.8 mm (.031 in.) No. 1, No. 2 1.0 mm 1.039 in.) Oil
CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE METHOD) (1) Remove oil from crankshaft pin and connecting rod bearing. (2) Cut the plastic gauge to the same length as the width of bearing and place it on crankshaft pin in parallel with its axis.
11 C-98

(3) Install the connecting rod cap carefully and tighten the bolts to the specified torque. (4) Carefully remove the connecting rod cap. (5) Measure the width of the plastic gauge at its widest part by using a scale printed on the plastic gauge package. Standard value: 0.02 - 0.05 mm (0008 - .0020 in.) Limit: 0.1 mm (.004 in.)
1 EN0271

PISTON PIN INSTALLATION (1) Thread the stop screw and lock nut assembly into the base. Fit the correct piston support on the top of the base. Insert the press pin, threaded end up, into the hole in the piston support until the press pin touches the stop screw. (2) Using the graduations on the press pin, adjust the* stop screw to the de.pth shown below. Depth: 56 mm (2.20 in.) SOHC and 4G61 DOHC 4663 DOHC 55 mm (2.17 in.)
I)A4
7EN0428
:.y.;,):,: Press pin 4 , .:.:A
, \/ Connecting rod -----guide pin -
(3) Place the base on press support blocks. (4) Slide the piston pin over the threaded end of the press pin, and thread the correct guide pin up against it. (5) Coat the piston pin with oil, and with the connecting rod held in position, slide the guide pin through the piston and connecting rod. (6) Press the piston pin through the connecting rod until the guide pin contacts the stop screw. (7) Remove the piston assembly from the base. Remove the guide pin and press pin from the assembly. IMPORTANT: Due to production tolerance variations, it is necessary to visually inspect the piston pin depth after installation to verify that the piston pin is centered. Adjust if necessary.
- \ Locknut
TSB Revision

(8) Check that the piston moves smoothly.
m-99
6EN0298
I)B4 OIL RING INSTALLATION

(1) Fit the oil ring spacer into the piston ring groove. NOTE The side rails and spacer may be installed in either direction.
6EN058E
Side rail gap d-,
1 EN026
(2) Install the upper side rail. To install the side rail, first fit one end of the rail into the piston groove, then press the remaining portion into position by finger. See illustration. Caution Do not use piston ring expander when installing side rail. (3) Install the lower side rail in the same procedure as described in step (2). (4) Make sure that the side rails move smoothly in either direction. I)c4 PISTON RING NO. 2 / PISTON RING NO. 1 INSTALLATION (1) Using a piston ring expander, fit No. 2 and then No. 1 piston ring into position. NOTE
(1) Note the difference in shape between No. 1 and No. 2
t
7EN045i
piston rings. (2) Install piston rings No. 1 and No. 2 with their side having marks facing up (on the piston crown side).
SOHC
6EN052
TSB
Revision
IIC-100
DOHC
Non-turbo
Turbo
6EN0497
I)D4
No. 1 a /
pulley side
PISTON AND CONNECTING ROD INSTALLATION (1) Liberally coat engine oil on the circumference of the piston, piston ring, and oil ring. (2) Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in the figure.
No. 2 ring gap and spacer gap
Lower rail
6EN0549
Timing belt side,
-*ront;r
Notches
(3) Rotate the crankshaft so that the crank pin is on the center of the cylinder bore. (4) Use suitable thread protectors on the connecting rod bolts before inserting the piston and connecting rod assembly into the cylinder block. Care must be taken not to nick the crank pin. (5) Using a suitable piston ring compressor tool, install the piston and connecting rod assembly into the cylinder block.
1 EN024 7
I)E4
Cylinder No
CONNECTING ROD CAP INSTALLATION (1) Verifying the mark made during disassembly, install the bearing cap to the connecting rod. If the connecting rod is new with no index mark, make sure that the bearing locking notches come on the same side as shown.
DEN0051
(2) Make sure that the connecting rod big end side clearance meets the specification. Standard value: 0.10 - 0.25 mm (.0039 - .0098 in.) Limit: 0.4 mm (.016 in.)
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.I
1 IC-101
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IIC-102
4G6 ENGINE <1992> - Crankshaft, Flywheel and Drive Plate
CRANKSHAFT, FLYWHEEL AND DRIVE PLATE 135 Nm

11 Nm 8 ft.lbs. 2 98ftJbs. I I
18 27 ml19
98 ft.lbs. 17 6 1 ** I **5*3 II
135 Nm 98 ftlbs.
Removal steps I, Flywheel bolt 2. Flywheel 3. Ball bearing* 4. Drive plate bolt** 5. Adapter plate** 6. Drive plate** 7. Crankshaft bushing** 8. Drive plate bolt 9. Adapter plate 10. Drive plate
11. Crankshaft bushing
12. Drive plate bolt* 13. Adapter plate*
14. Drive plate* 15. Crankshaft adapter* 16. Rear plate 17. Bell housing cover 18. Oil seal case 19. Gasket $04 20. Oil separator *C4 21. Oil seal 22. Bearing cap bolt +B4 23. Bearing cap &A4 24. Crankshaft bearing (lower) 25. Crankshaft +A4 26. Crankshaft bearing (upper) 27. Cylinder block TSB Revision
NOTE * : Rear wheel drive ** : Front wheel drive *** : SOHC **** : DOHC *****: DOHC Turbo for ECLIPSE
6EN0428
4G6 ENGINE <1992> - Crankshaft, Flywheel and Drive Plate INSPECTION
1 x-103
CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE METHOD) (1) Remove oil from the crankshaft journals and crankshaft bearings. (2) Install the crankshaft. (3) Cut the plastic gauge to the same length as the width of the bearing and place it on the journal in parallel with its axis.
6EN055C
(4) Install the crankshaft bearing cap carefully and tighten the bolts to the specified torque. (5) Carefully remove the crankshaft bearing cap. (6) Measure the width of the plastic gauge at its widest part by using a scale printed on the plastic gauge package. Standard value: 0.02 - 0.05 mm (0008 - .0020 in.) Limit: 0.1 mm (004 in.)
1 EN027
CYLINDER BLOCK (1) Visually check for scratches, rust, and corrosion. Use also a flaw detecting agent for the check. If defects are evident, correct, or replace. (2) Using a straightedge and feeler gauge, check the block top surface for warpage. Make sure that the surface is free from gasket chips and other foreign matter. Standard value: 0.05 mm (0020 in.) Limit: 0.1 mm (004 in.) (3) If the distortion is excessive, correct within the allowable limit or replace. Grinding limit: 0.2 mm (008 in.) The total resurfacing depth of both cylinder block and mating cylinder head is 0.2 mm (008 in.) at maximum. Cylinder block height (when new): 4G61 274.9 - 275.1 mm (10.823 - 10.831 in.) 283.9 - 284.1 mm 4663 (11.177 - 11.185 in.) 289.9 - 290.1 mm 4664 (11.413 - 11.421 in.)
I-,
3EN0184
TSB Revision
IIC-104
4G6 ENGINE <1992> - Crankshaft. Flvwheel and Drive Plate

(4) Check cylinder walls for scratches and seizure. If defects are evident, correct (rebore to an oversize) or replace. (5) Using a cylinder gauge, measure the cylinder bore and cylindricity. If worn badly, correct the cylinder to an oversize and replace the piston and piston rings. Measure at the points shown in illustration. Standard value: Cylinder I.D. 4661 82.30 - 82.33 mm (3.2402 - 3.2413 in.) 4663 85.00 - 85.03 mm (3.3465 - 3.3476 in.) 4G64 86.50 - 86.53 mm (3.4055 - 3.4067 in.) 0.01 mm (0004 in.) Cylindricity
BORING CYLINDER
(1) Oversize pistons to be used should be determined on the basis of the largest bore cylinder. Piston size identification Size
0.25 mm (.Ol in.) O.S. 0.50 mm (.02 in.) O.S. 0.75 mm (.03 in.) O.S. 1 .OO mm (.04 in.) OS.
Identification mark I
0.25 0.50 0.75
I .
I I
1.00
Piston O.D.
) Thrust direction
6EN0554
NOTE Size mark is stamped on the piston top. (2) Measure outside diameter of piston to be used. Measure it in thrust direction as shown. (3) Based on the measured piston O.D. calculate the boring finish dimension. Boring finish dimension = Piston O.D. + (clearance between piston 0-D. and cylinder) 0.02 mm (0008 in.) (honing margin) (4) Bore all cylinders to the calculated boring finish dimension. Caution To prevent distortion that may result from temperature rise during honing, bore cylinders, working from No. 2 to No. 4 to No. 1 to No. 3. (5) Hone to final finish dimension (piston O.D. + clearance between piston O.D. and cylinder). (6) Check the clearance between piston and cylinder. Clearance between piston and cylinder: 4663 SOHC 0.01 - 0.03 mm (.0004 - .0012 in.) 4663 DOHC T/C 0.03 - 0.05 mm (.0012 - .0020 in.) 4661, 4063 DOHC, 4664 0.02 - 0.04 mm (0008 - .0016 in.) NOTE When boring cylinders, finish all of four cylinders to the same oversize. Do not bore only one cylinder to an oversize.
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Grooveless Upper bearing (for No. 1,2.4,5) Lower bearing (for No. 1.2.4.5)
IIC-105
INSTALLATION SERVICE POINTS I)A4 CRANKSHAFT BEARING IDENTIFICATION

(1) The upper bearings (on the cylinder block side) for Nos. 1,2, 4 and 5 journals are provided with oil groove. (2) The lower bearings (on the cap side) for Nos. 1, 2, 4 and 5 journals are not provided with oil groove. (3) No.3 bearings are flanged and provided with no groove. Common bearings are used on the cap side and cylinder block side.
Upper and lower bearings (for No. 3)
1 EN0272
SOHC rl
Crankshaft pulley side
I)64 BEARING CAP INSTALLATION (1) Check the bearing cap for the identification mark before it is installed.
6EN055
IIOHC
Crankshaft pulley side
(2) After installing the bearing caps, make sure that the crankshaft turns smoothly and the end play is correct. If the end play exceeds the limit, replace crankshaft bearings.
Standard value: 0.05 - 0.18 mm (.0020 - .0071 in.) Limit: 0.25 m m (.0098 in.)
6EN0231
TSB Revision
IIC-106
I

I)c4 OIL SEAL INSTALLATION
1
MD998376-01
DEN0052
I)D4 OIL SEPARATOR INSTALLATION

Oil seal case
0 0
Oil separator \-
(1) Force the oil separator into the oil seal case so that the oil hole in the separator is directed downward (arrow in illustration).
? 0 nil &a2 -= hole

t
6EN055i
TSB Revision
4G6 ENGINE <1992> - Bracket
1 I-C-I 07
BRACKET
Rear wheel drive and four wheel drive
33 ft.lbs.
I, 2.
Engine support bracket, right Engine support bracket, left
45 Nm 33 ft.lbs.
6EN350
Front wheel drive and all wheel drive
I. 2. 3. 4.
Roll stopper bracket, front Engine support bracket, front Exhaust pipe support bracket Roll stopper bracket, rear
I
120 N, 87 ftlbs.
6EN0722
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NOTES

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ENGINE 4G61, 4663, 4664

FUEL AND EMISSION CONTROL PARTS . . . . 46 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL SPECIFICATIONS

466 ENGINE <1992> - General Information

4G6 ENGINE <1992> - General Information

466 ENGINE <1992> - General Information

,NGlNE SECTIONAL VIEW - DOHC

466 ENGINE <1992> - General Information

ENGINE LUBRICATION SYSTEM - SOHC

Camshaft Oil pressure switch \

ENGINE LUBRICATION SYSTEM - DOHC

Oil cooler Oil cooler by-pass valve Silent shaft&I)

4G6 ENGINE <1992> - General Information ENGINE LUBRICATION SYSTEM DOHC-TURBO

ee Silent shaft From thermostat case n Oil filter K Oil cooler / \

To water inlet pipe i I 41

Oil pressure sw&h

-7 (k,/ Silent shaft Crankshaft

-4G6 ENGINE <1992> - General Specifications

4664 SOHC Type

Compact type 2,350 (143.4) 86.5 (3.35) 100 (3.46) 8.5

4G6 ENGINE <1992> - General Specifications

4G6 ENGINE <1992> - Service Specifications

12.05-12.07(.4744-.4752) 12.25 - 12.27 (4823 - .4831) 12.50 - 12.52 i.4921 - .4929)

35.30 - 35.33 (1.3898 - 1.3909) 35.60 - 35.63 (1.4016 - 1.4028)

33.30 - 33.33 (1.3110 - 1.3122) 33.60 - 33.63 (1.3228 - 1.3240)

466 ENGINE <1992> - Service Specification3

Intake Exhaust Intake Exhaust

42.40 (1.6693) 42.40 (1.6693) 44.53 (1.7531) 44.53 (1.7531)

41.90 (1.6496) 41.90 (1.6496) 44.03 (1.7335) 44.03 (1.7335)

38 (1.50) 33.94 - 33.95 (1.3362 - 1.3366) 0.05 - 0.09 (.0020 - .0035)

35.49 (1.3972) 35.20 (1.3858)

34.99 (1.3776) 34.70 (1.3661)

35.20 (1.3858) 35.49 (1.3972) 35.91 (1.3744)

34.70 (1.3661) 34.99 (1.3776) 34.41 (1.3547)

18.89 - 18.90 (.7437 - .7441) 385.5(15.177) 372.5 (14.665)

466 ENGINE c1992> - Service Specifications

Valve - SOHC Overall length

4663 4664 4G63 4664

Intake Exhaust Intake Exhaust

0.7 (02%) 1.5 (.059) 0.10 (004) 0.15 (006)

Intake Exhaust Intake Exhaust

Intake Exhaust Intake Exhaust

4G6 ENGINE <1992> - Service Snebifications

iston - SOHC I.D.

466 ENGINE <1992>

0.4 (016) 0.25 (.0098)

0.1 (004) 0.1 (004)

466 ENGINE t1992> - Service Sbecifications

0.1 (004) *0.2 (.008)

274.9 - 275.1 (10.823 - 10.831) 283.9-284.1 (11.177-11.185) 289.9-290.1 (11.413-11.421)

0.08 - 0.14 (0031 - .0055) 0.06 - 0.12 (0024 - .0047)

New belt Used belt

New belt Used belt

13 - 16 at 20C (68F) 2 - 3 at 20C (68F) 5 - 35 at 20C (68F)

4G6 ENGINE <1992> - Torque Specifications

4G6 ENGINE <1992> - Toraue SDecifications

1.4 2.5 2.5

466 ENGINE <1992> - Torque Specifications

4G6 ENGINE <1992> - Torque Specifications / Sealant

11 c-20 SPECIAL TOOLS

466 ENGINE <1992> - Special Tools

9 Nm 7 ftlbs. 11 Nm* 8 ft.lbs.