Mitsubishi 4g64 Engine 2 4l Service Manual

Full download: http://manualplace.com/download/mitsubishi-4g64-engine-2-4l-service-manual/

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b ENGINE <2.4L> ”
I
CONTENTS

CAMSHAFT AND CAMSHAFT OIL Compression Pressure Check . . . . . . . . . . . ;. . .I1

SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Curb Idle Speed Check . . . . . . . . . ::. ......... 10
Drive Belt Tension Check and
CRANKSHAFT FRONT OIL SEAL . . . . . . . . . . 26 Adjustment . !. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Idle Mixture Check . . . . . . . . . . . . . . . . . . . . . . . 19
CRANKSHAFT PULLEY . . . . . . . . . . . . . . . . . . . 20 Ignition Timing Check . . . . . . . . . . . . . . . . . . . . . . 6
Lash Adjuster Check . . . . . . . . . . . . . . . . . . . . . 13
CRANKSHAFT REAR OIL SEAL . . . . . . . . . . . 27
Manifold Vacuum Check . . . . . . . . . . . . . . . . . . 12
_ :I, . . (
CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . 29
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . ..i .. 3
” (,I, d ; 2.: .....
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 15 SERVICE SPEClFiCATlOid ...... . . . .: ..... .’ i
::
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OIL PAN AND OIL SCREEN . . . . . . . . . . . . . . . 24
TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 7
TIMING BELT B . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Basic Idle Speed Adjustment
. . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 13A TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 6

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 ENGINE <2.4L> - General Information
I
GENERAL INFORMATION
Specifications

Type In-line OHV, SOHC

Number of cylinders 4
,.
Bore mm(in.) 86.5(3.41)

I Stroke mm(in.) 1 OO(3.94)

I Piston displacement cm3(cu.in.) 2,351(143.4) 1

Compression ratio 9.5

Firing order l-3-4-2

1 Counterbalance shaft Equipped

Valve timing Intake valve Opens 18” BTDC
Closes 58” ABDC

Exhaust valve Opens 58” BBDC

Closes 18” ATDC

Lubrication system Pressure feed-full flow filtration

., ‘, ‘ I
LUBRICATION SYSTEM

f Rocker arm shah

Oil filter eii’i A

Oil I 17
pressure I , Camshaft Piston

ZSEN0734

screen

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 $q$&~
ENGINE <2.4L> - Service Sp6cificationsBealants ,.‘“,, . ,% ,a

SERVICE SPECIFICATIONS
Items Standard ualue Limit
Drive belt Tension N (Ibs.) When checked 245-490(5$.1-110.2) ;- ,
(For genera- When a new belt is installed 490 - 686 (110.2 - 154.3) “*
tor) When a used belt is installed 392 (88.2) ; ’ ” f-’
Deflection Whenchecked 9.0-11.5(.35-.45) y ..s ,’ “”
r, /
mm (in.) When a new belt is installed 7.5 - 9.0 (-30 - .35)
<Reference When a used belt is installed 10.0 (.39)
value>
Drive belt Tension N (Ibs.) When checked 245 - 490 (55.1 - 110.2) -
(For power When a new belt is installed 490-686 (110.2- 1 5 4 .3) ;
steering When a used belt is installed 343 - 441 (77.2 - 99.2) ”
pump)
Deflection Whenchecked 5.5 - 8.0 (.22 - .32) -
mm (in.) When a new belt is installed 4.5 - 3.5 (J-8--, .22)
When a used belt is installed 6.0 - 7.0 (.24 - .28)
Drive belt Tension N (Ibs.) When checked 255 - 333 (57.3 - 75.0) -
:For A/C When a new belt is installed 382 - 441 (86.0 - 99.2)
zompressor) When a used belt is installed 255 - 333 (57.3 y 75.0) : ’
Deflection Whenchecked 6.5 - 7.5 (.26 - .30) -
mm (in.) When a new belt is installed 5.5 - 6.0 (.2? L .24)
When a used belt is installed 6.5 - 7.5 (.26 - .30)
3asic ignition timing at idle 5”BTDC f 3” - Jh, -
3ctual ignition timing at idle Approx. 10” BTDC -
Xrrb idle speed r/min 750+100 ’
20 contents % 0.5 or less
iC contents ppm 100 or less -
Compression pressure (at 250 - 400 r/min) kPa (psi) 1,350 (192) min: ti ,020 (145)
Compression pressure difference of all cylinder kPa (psi) ma& 100 (14)
ntake manifold vacuum kPa (in. Hg) min. 60 (18)
;ylinder head bolt length mm (in.) 99.4 (3.91)
iuto tensioner push rod movement mm (in.) Within 1 (04)
Iming belt tension torque Nm (ftlbs) 3.5 (2.6) -
u.rto tensioner rod protrusion mm (in.) 3 . 8 - 4 . 5 (.150-.177) -
Iming belt B tension mm (in.) 5 - 7 C-20 - .28)

S E A L A N T S ~‘jmoo50195

Items Specified sealant ‘:

Oil pan, cylinder block and thermostat case assembly MITSUBISHI GENUINE PART MD970389 or equivalent

Flywheel bolt or drive plate bolt 3M Stud locking 4170 or eqhivalent

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WE-4 ENGINE <2.4L> - Special Tools a, , , /”

SPECIAL TOOLS
Tool Tool number and name Supersession Application
MB991 562 MB991 502 Idle speed insbection
<
.,Scan tool
(MUT-II)

ROM pack

\
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8991325

MD998443 MD998443-01 Supporting of the lash adjuster

Lash adjuster holder to prevent it from falling when
rocker shaft assembly is re- *
moved or installed
I.

MD99871 3 MD99871 3-01 Camshaft oil seal installation

Canshaft oil seal in-

Oil pan gasket cutter

Crankshaft pulley are removed or reinstalled.

Use together with MB990767
Camshaft pulley supporting

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 EhiGIN*E <2.4L> - Snecial Tools

Appl~ati&n’s; 1 ‘, ,1 G I
Tool Tool number and name Supersession
MD998776 MD998776-01 Crankshaft rear oil seal .installa:
Crankshaft rear oil tion
( ‘9 seal installer .,

MB990938 MB990938-01
Handle

*j i

GENERAL SERVICE MZ203827-01 Suppcqting engine assembly

TOOL when removing and installing
MZ203827 transaxle
Engine lifter

MD998767 M D998752-01 Auto tensioner installation

\ Tensioner pulley
/ wrench
QI

QI
MD998778 General service tool Crankshaft sprocket removal .:rr-
: i
Crankshaft sprocket
-$ Qh4

@I ‘.% c?Y puller

MB991 654 - Removal and installation of

Cylinder head bolt cylinder head bolt 5
wrench (12)

8991654

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llE-6 ENGINE ‘<2.4L> - Troubleshooting . _ “_ 8. *s_ LIwdI

TROUBLESHOOTING
Symptom Probable cause Remedy

Compression too low Cylinder head gasket blown Replace gasket

Piston ring worn or damaged Replace rings

Piston or cylinder worn Repair or replace piston and/or cylinder

block iii.. .: c ,
/I,
Valve seat worn or damaged Repair or replace valve and/or seat ring

Oil pressure drop Engine oil level too low Check engine oil level

Oil pressure switch faulty ‘Replace oif, pressure switch

.’ ”
Oil filter clogged Install new filter ,~,

Oil pump gears or cover worn Replace gears and/or cover

Thin or diluted engine oil Change engine oil to correct viscosity

Oil relief valve stuck (open) Repair relief valve

> ‘.
Excessive bearing clearance Replace bearings

Oil pressure too high Oil relief valve stuck (closed) Repair relief valve ”

Noisy valves Incorrect lash adjuster Bleed air or replace lash adjuster

Thin or diluted engine oil (low oil pressure) Change engine oil >’
Valve stem or valve guide worn or damaged Replace valve and/or guide

Connecting rod noise/ Insufficient oil supply Check engine oil level
main bearing noise
Low oil pressure Refer to “Oil pressure drop”
, -:i
Thin or diluted engine oil Change engine oil

Excessive bearing clearance Replace bearings -^’

Timing belt noise Incorrect belt tension Adjust belt tension and/or replace tim-
ing belt

Zxcessive engine rol- Loose engine roll stopper (Front, Rear) Retighten
ing and vibration
Loose transaxle mount bracket Retighten

Loose engine mount bracket Retighten

Loose center member Retighten

Broken transaxle mount insulator Replace

Broken engine mount insulator Replace

Broken roll stopper insulator Replace

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 ENGINE c2.4Ls - On-vehicle Service IlE-7

ON-VEHICLE SERVICE 11laoom34

DRIVE BELT TENSION CHECK AND

A D J U S T M E N T
GENERATOR DRIVE BELT TENSION CHECK ‘,
Use the belt tension gauge to check belt tension at the shown
point or check deflection by applying 68 N (22 Ibs.) to the
shown point. .,’ ,
,:f
6ENO596 Standard value:
Tension: 245 - 490 N (55.1 - 110.2 Ibs.)
Deflection <Reference, value>:
9.0 - 11.5 mm (.35 - .45 In.)
98 N (22 Ibs.) Water
pump
pulley
a,. i’
I ‘, _.(

‘,..T

Generator
pulley Cranksha3Jlg!J ..

Dullev 01A0184

GENERATOR DRIVE BELT TENSION ADJUSTMENT

1. Loosen the nut of the generator pivot bolt.
2. Loosen the lock bolt.
3. Turn the adjusting bolt to adjust the belt tension or deflec-
tion to the standard value.
Standard value:
Adjus
bolt 1 Items Ta;new belt is ( yv’Iv’:used belt is 1

I Tension
N (Ibs.)
Deflection
490-686
(110.2-154.3)
7.5-9.0
392
(88.2)
10.0
mm (in) (.30-.35) (-39)
<Reference
value>

4 Tighten the nut of the generator pivot bolt.

Tightening torque: 23 Nm (17 ft.lbs.)
5. Tighten the lock bolt.
Tightening torque: 23 Nm (17 ft.lbs.)
6. Tighten the adjusting bolt.
Tightening torque: 10 Nm (7 ft.lbs.)

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IIE-8 ENGINE <2.4L> - O n - v e h i c l e S e r v i c e I

POWER STEERING PUMP DRIVE BELT TENSION

CHECK S’ 111001101aa

Use the belt tension gauge to check belt tension at the shown
point or check deflection by applying 98 N (22 Ibs.) to the
shown point.
Standard value:
Tension: 245 - 490 N (55.1 - 110.2 Ibs.)
Deflection: 5.5 - 8.0 mm (.22 - .32 in.)”
pump pulley
AOlC0028

POWER STEERING PUMP DRIVE BELT TENSION

ADJUSTMENT / /
1. Loosen power steering pump fixing bolt (A, 8, C, D).
2. Move power steering pump, tension belt moderately and
adjust tension.
Standard value:

Items When a new belt is When a used belt is

installed instatted,,
Tension 490-686 343-441.
N (Ibs.) (110.2-154.3) (77.24f9.2)
Deflection 4:5-5.5 6.0-7:0
mm (in.) (.18-.22) (.24-.28)

3. Tighten fixing bolt (A).

Tightening torque: 28 Nm (21 ft.lbs.) ” ”
4. Tighten the remaining fixing bolts (6, C and D)..
Tightening torque:
Bolt B and D 28 Nm (21 ft.lbs.)
Bolt C 22 Nm (16 ft.lbs.)
5. Check the belt deflection amount and readjust if neces-
sary.
Caution
This check should be carried out after turning the
crankshaft one full rotation or more in the forward
direction (to the right).

A/C COMPRESSOR DRIVE BELT TENSION CHECK

111001ooooa

Use the belt tension gauge to check belt tension at the shown
point (a) or (b), or check deflection by applying 98 N (22
Ibs.) to the shown point.
Cranksh Standard value:
pulley
Tension: 255 - 333 N (57.3 - 75.0 Ibs.)
Deflection: 6.5 - 7.5 mm (-26 - -30 In.)

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ENGI’NE <2,4L> - On-vehicle Service i $1 l-e&g

A/C COMPRESSOR DRIVE BELT TENSION ADJUSTMENT

1. Loosen tension pulley fixing nut A.

2. Adjust belt tension with adjusting bolt B.
Standard value:
Items When a new belt is When a used belt is
installed installed
Tension 382-411 255-333
N (Ibs.) (88.0-99.2) (57.3-75.0)
Deflection 5.5-8.0 8.5-7.5
mm (in.) (.22-.24) (.26-.30)

3. Tighten fixing nut A.

Tightening torque: 23-26 Nm (17-20 ft.lbs.)
4. Check the belt deflection amount and readjust if neces-
sary.
Caution
This check should be carried out after turning the
crankshaft one full rotation or more In the forward
direction (to the right).
IGNITION TIMING CHECK 11100170108

1. Before inspection and adjustment set vehicle in the follow-

ing condition.
l Engine coolant temperature: 80-95°C (178-203°F)
l Lights, electric cooling fan and all accessories: OFF
o Transaxle: Neutral (P range on vehicles with A/T)
2. Turn the ignition switch to OFF and connect the scan
tool to the data link connector.
3. Set up a timing light.
4. Start the engine and run at idle.
5. Select No. 22 of the SCAN TOOL DATA LIST.
6. Check that engine idle speed is within the standard value.
Standard value: 750 + 100 r/min
7. Select No. 17 of the SCAN TOOL ACTUATOR TEST.

Check that basic ignition timing is within the standard

value.
Standard value: 5” BTDC f 3”
If the basic ignition timing is outside the standard value,
inspect the MFI components by referring to GROUP 13A
- Troubleshooting.

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Mitsubishi 4g64 Engine 2 4l Service Manual
Full download: http://manualplace.com/download/mitsubishi-4g64-engine-2-4l-service-manual/
llE-IO ENGINE <2.4L> - On-vehicle Seryice, , .m ,.

10. Press the scan tool clear key (select a forced driving
cancel mode) to release the ACTUATOR TEST
NOTE
If the test is not cancelled, a forced driving will continue
for 27 minutes. Driving under this condition may damage
the engine.
11. Check that the actual ignition timing is at the standard
value.
Standard value: Approx. 10” BTDC
NOTE
1. Ignition timing is variable within about &7”, even under
normal operating.
2. And it is automatically further advanced by about
5” from IO” BTDC at higher altitudes.
CURB IDLE SPEED CHECK 11199199992

1. Before inspection and adjustment, set vehicles in the

following condition.
l Engine coolant temperature: 80-95°C (176-203°F)
l Lights, electric cooling fan and all accessories: OFF
l Transaxle: Neutral (P range on vehicles with A/T)
2. Turn the ignition switch to OFF and connect the scan
tool to the data link connector.
3. Select No. 17 of the SCAN TOOL ACTUATOR TEST
4. Check the basic ignition timing.
Standard value: 5” BTDC f 3”
5. Run the engine at idle for 2 minutes.
6. Select No. 22 of the SCAN TOOL DATA LIST.
7. Check the curb idle speed.
Standard value: 750 f 100 r/min
NOTE
The idle speed is controlled automatically by the idle air
control system.
8. If the idle speed is outside the standard value, check
the MFI components by referring to GROUP 13A - Trou-
bleshooting.
IDLE MIXTURE CHECK 11199210292

1. Before inspection, set vehicles in the following condition:

l Engine coolant temperature: 80-95°C (176-203°F)
l Lights, electric cooling fan and all accessories: OFF
l Transaxle: Neutral (P range on vehicles with m
2. Turn the ignition switch to OFF and connect the scan
tool to the data link connector.
3. Select No. 17 of the SCAN TOOL ACTUATOR TEST.
4. Check that the basic ignition timing is within the standard, :
value. .
Standard value: 5”BTDC f 3”

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