ENGINE Workshop Manual 4M4 (W-E)up.picr.de/17114998ja.pdf · 3 21229 Caution • If the cylinder...
Transcript of ENGINE Workshop Manual 4M4 (W-E)up.picr.de/17114998ja.pdf · 3 21229 Caution • If the cylinder...
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NOTES
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NOTES
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NOTES
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NOTES
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NOTES
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NOTES
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NOTES
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NOTES
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NOTES
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NOTES
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NOTES
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NOTES
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Service Bulletins
Click on the applicable bookmark to select the Service Bulletin.
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SERVICE BULLETINQUALITY INFORMATION ANALYSIS
OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION
SERVICE BULLETIN No.: MSB-99E11-505
Date: 1999-11-15 <Model> <M/Y>Subject: ADDED DESCRIPTION OF TIMING CHAIN
CLEARANCE MEASUREMENT(EC,EXP) PAJERO(V10,V20,V30,V40)
99-10
Group: ENGINE Draft No.: 99EN531510
CORRECTION INTERNATIONALCARADMINISTRATIONOFFICE
T.NITTA - PROJECT LEADERAFTER SALES SERVICE & CS PROMOTION
1. Description:
Under TIMING CHAIN INSTALLATION, a description has been added of the timing chainclearance measurement.
2. Applicable Manuals:
Manual Pub. No. Language Page(s)Engine 4M4 Series PWEE9409 (English) 11A-19-9Workshop Manual PWES9410 (Spanish)
PWEF9411 (French)PWEG9412 (German)PWED9413 (Dutch)PWEW9414 (Swedish)
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2
!!!!G"""" TIMING CHAIN INSTALLATION
(1) Hold the cam sprocket 1 using the special tool.Component Parts of Special Tool MH062381-Cam Sprocket HolderKit.A: NutB: WasherC: SpacerD: Adjusting plateE: NutG: Bolt
(2) Check that the match mark “1” on the idler gear and sprocketassembly 36 is in alignment with that on the crankshaft gear *3.
(3) Align the match mark “o” on the idler gear and sprocket assembly36 with the mark link plate H of the timing chain 2.NOTEThe timing chain 2 has the match mark provided at two places: onebright white link plate H at one place and a pair of bright white linkplates J at the other.
(4) Place the timing chain 2 around the cam sprocket 1 while aligningthe timing mark “o” on the cam sprocket 1 with the mark link plate Jon the timing chain 2.
(5) Attach the idler washer 35 with the front mark “F” facing outward.
(6) With the stamped lines L on the adjusting plate D and nut E inalignment, set the cam sprocket 1 in the normal operating position.Push the tension lever 4 by hand to take up the slack of the timingchain 2.
(7) Measure the clearance K of the timing chain 2 stretched. If thereading deviates the specified standard limit, replace the timingchain.
<Added>Measurement should be carried out at a narrowinside area of the timing chain.
4M4 ENGINE – Timing Gear and Balance Shaft 11A-19-9
Standard value: 16.5 mmLimit: 9.0 mm
<Added>
03892
4ME0366
03891
04570
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SERVICE BULLETINQUALITY INFORMATION ANALYSIS
OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION
SERVICE BULLETIN No.: MSB-99E11-506
Date: 2000-08-15 <Model> <M/Y>Subject: ADDITION OF CAUTIONS ON BOLTS
TIGHTENED BY USING PLASTIC AREATIGHTENING METHOD
(EC)PAJERO(V10,20,30,40)
94-10
Group: ENGINE Draft No.: 99EN592316
CORRECTION INTERNATIONALCARADMINISTRATIONOFFICE
T.NITTA - PROJECT LEADERAFTER SALES SERVICE & CS PROMOTION
1. Description:
In explanation of the 4M4 engine given in the following manual, cautions have been added on thebolts tightened by using the plastic area tightening method.
2. Applicable Manuals:
Manual Pub. No. Language Page(s)ENGINE 4M4 Series PWEE9409 (English) 11A-13-4,Workshop Manual PWES9410 (Spanish) 11A-28-6Engine & Transmission PWEF9411 (French)
PWEG9412 (German)PWED9413 (Dutch)PWEW9414 (Swedish)
3. Details:
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When only the gasket is to be replaced, check the identification markstamped on the top of the crankcase assembly *5 and choose the onewith the same classification markNOTE:If no identification mark is stamped, select classification C.Caution• If a piston, connecting rod, etc. has been replaced, be sure to
measure the piston protrusion as the replacement may changethe piston protrusion.
!!!! B """" CYLINDER HEAD ASSEMBLY INSTALLATION
03769
(1) Choose a usable cylinder head gasket 14.(2) Apply an even coat of sealant to the upper part J of the mating
surfaces of the timing gear case assembly *4 and crankcaseassembly *5.
(3) Within three minutes after the application of sealant, install thecylinder head assembly 13, with the cylinder head gasket 14attached, to the crankcase assembly *5.Caution• Prior to applying sealant, make sure that the surfaces to
be coated are clean and free of slush and other foreignmatters.
• When installing the cylinder head assembly, be sure thatsealant J is in place.
• After the cylinder head assembly is installed, wait for atleast one hour before starting the engine.
(4) If the cylinder head bolts 11 were loosened or removed afterinstalling the cylinder head assembly, be sure to replace theexisting sealant with a fresh coat.
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(5) Tighten the cylinder head bolts 11, M12 bolts of Q through y andM8 bolts of u and i, in the sequence of the following steps:Tightening bolts Q-y(a) Fit the washer 12 on each cylinder head bolt 11, with its shear
droop side K facing in the direction shown in the illustration.(b) Apply a thin coat of engine oil evenly to the threaded part of
each of the cylinder head bolts 11 and tighten them to 100 Nm(10 kgm, 72 ft.lbs. in the direction shown in the illustration.
(c) Loosen the tightened cylinder head bolts 11 in the reversesequence, and retighten them to 50 Nm (5 kgm, 36 ft.lbs.) inthe sequence of the numbers shown.
(d) Then, tighten the cylinder head bolts 11 further by giving theman additional ¼ turn (90°) in the specified sequence.
(e) Finally, give the cylinder head bolts 11 another ¼ turn (90°).
Tightening bolts u and iAfter the tightening of bolts Q through y is finished, tightenthe u and i to the specified torque.
11A-13-4 4M4 ENGINE – Rocker Cover and Cylinder Head Assembly
A on the following page addedhere.
B on the followingpage added here.
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Caution• If the cylinder head bolt 11 is to be reused, make
sure that punch mark D is placed on the head of thecylinder head bolt every time the bolt is reused.The number of punch marks denotes how manytimes the bolt has been reused in the plastic
• If the bolt to be tightened has three punch marks onits heads, replace the bolt.
<Added> BCautionBecause cylinder head bolts 11 are fastened by theplastic zone fastening method, do not tighten furtherafter they have been tightened at the specified angle.
<Added> A
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END PLAY OF CRANKSHAFT(1) If the end play exceeds the specified service limit, replace the trust
plates 18 and 25 with oversize thrust plates.
Thrust plate installation:<Available oversizes>+0.15 mm (+0.0059 in.), +0.30 mm (+0.0118 in.), +0.45 mm(+0.0177 in.)
03742
!!!! F """" BOLT / MAIN CAP BOLT INSTALLATION(1) Apply a thin coat of engine oil to the main bearing cap bolts 15, and
tighten them to 20 Nm (2 kgm, 14 ft.lbs.) in the sequence ofnumbers t – S shown in the illustration.
(2) Then, tighten the bolts ¼ turn (90 deg.) in the sequence of numbersshown.
(3) Give them an additional ¼ turn (90 deg.) in the same way as above.(4) After the main bearing cap bolts 15 are all tightened, tighten the
bolts 14 to the specified torque in the sequence of numbers Q-rshown in the illustration.
!!!! G """" FRONT PLATE INSTALLATION
03740
(1) Apply an even bead of sealant A without break to the crankcaseassembly 13 where indicated in the illustration. [Bead diameter:2 ± 1 mm (0.08 ± 0.04 in.)]
(2) Install the front plate 2 to the crankcase assembly 13 within15 minutes after the application of sealant A.
Caution• Be sure that the surface to be coated with sealant A is clean
and free of slush and other foreign matters.• When installing the front plate, use care that the surroundings
are not smeared with sealant A.• After the front plate is installed, wait for at least one hour
before starting the engine.• The bolt 1 that holds the front plate 2 is also used to secure
the timing gear case. Attach the front plate 2 with a temporarybolt until the timing gear case is installed.
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Caution• If the main cap bolts 2 are to be reused, make sure that
punch mark A is placed on the head of each of the maincap volts every time the bolts are reused.The number of punch marks denotes how many times thebolts have been reused in the plastic area.
• If the bolt to be tightened has three punch marks on itshead, replace the bolt.
11A-28-6 4M4 ENGINE – Crankshaft and Crankcase
CautionBecause main cap bolts 2 are fastened by the plasticzone fastening method, do not tighten further after theyhave been once tightened.
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