Mitsubishi 6A1 series User manual

GENERAL INFORMATION 11A-0-3
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1.SPECIFICATIONS 11A-1-1
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SERVICE SPECIFICATIONS 11A-1-1
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REWORK DIMENSIONS 11A-1-3
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TORQUE SPECIFICATION 11A-1-4
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NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE
TIGHTENED IN PLASTIC AREA 11A-1-7
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SEALANTS 11A-1-7
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FORM-IN-PLACE GASKET (FIPG) 11A-1-8
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2.SPECIAL TOOLS 11A-2-1
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3.DRIVE BELT 11A-3-1
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4.TIMING BELT 11A-4-1
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5.FUEL AND EMISSION CONTROL PARTS 11A-5-1
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6.IGNITION SYSTEM 11A-6-1
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7.WATER PUMP AND WATER PIPE 11A-7-1
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8.INTAKE MANIFOLD AND EXHAUST MANIFOLD 11A-8-1
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9.ROCKER ARM AND CAMSHAFT <SOHC> 11A-9-1
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10.ROCKER COVER AND CAMSHAFT <MIVEC> 11A-10-1
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11. ROCKER ARM AND ROCKER SHAFT CAP <MIVEC> 11A-11-1
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12.CYLINDER HEAD AND VALVES 11A-12-1
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13.OIL PUMP CASE AND OIL PAN 11A-13-1
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14.PISTON AND CONNECTING ROD 11A-14-1
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15.CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL
AND DRIVE PLATE 11A-15-1
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11A-0-1
PWEE9622
EFeb. 1997Mitsubishi Motors Corporation
ENGINE
6A1 SERIES
CONTENTS

11A-0-2
PWEE9622
EFeb. 1997Mitsubishi Motors Corporation
NOTES

6A1 ENGINE (E-W) - General Information 11A-0-3
GENERAL INFORMATION
GENERAL SPECIFICATIONS
Descriptions 6A12 6A13
Type 60°V, OHV, DOHC (for each bank) 60°V, OHV, SOHC (for each bank)
Number of cylinders 6 6
Combustion chamber Pentroof type Pentroof type
Total displacement dm31,998 2,498
Cylinder bore mm 78.4 81.0
Piston stroke mm 69.0 80.8
Compression ratio 10.0 9.5*1or 9.0*2
Valve timing Intake
valve
Opens
(BTDC)
15°(Low-speed cam)
37.5°(High-speed cam)
15°
Closes
(ABDC)
41°(Low-speed cam)
82.5°(High-speed cam)
53°
Exhaust
valve
Opens
(BBDC)
41°(Low-speed cam)
75°(High-speed cam)
53°
Closes
(ATDC)
15°(Low-speed cam)
30°(High-speed cam)
15°
Lubrication system Pressure feed, full-flow filtration Pressure feed, full-flow filtration
Oil pump type Trochoid type Trochoid type
Cooling system Water-cooled forced circulation Water-cooled forced circulation
Water pump type Centrifugal impeller type Centrifugal impeller type
NOTE
*1: Europe and Hong Kong
*2: GCC and Export
PWEE9622
EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Specifications 11A-1-1
1. SPECIFICATIONS
SERVICE SPECIFICATIONS
Items Standard value Limit
Timing belt
Auto tensioner rod projection mm 12.0 -
Auto tensioner rod pushed-in amount (when pushed with a force
of 98 - 196 N) mm
1.0 or less -
Rocker arm and camshaft <SOHC>
Camshaft cam height mm Intake 35.20 34.70
Exhaust 34.70 34.20
Camshaft journal diameter mm 45 -
Rocker cover and camshaft <MIVEC>
Camshaft cam height mm Intake (Low-speed cam) 34.34 33.84
(High-speed cam) 36.46 35.96
Exhaust (Low-speed cam) 34.40 33.90
(High-speed cam) 35.86 35.36
Camshaft journal diameter mm 26 -
Valve clearance mm Intake 0.10 -
Exhaust 0.13 -
Cylinder head and valve
Flatness of cylinder head gasket surface mm - -
Cylinder head gasket surface grinding limit (including grinding of
cylinder block gasket surface) mm
Less than 0.03 -
Cylinder head overall height SOHC 119.9 - 120.1 -
mm
MIVEC 119.6 - 119.8 -
Cylinder head bolt nominal length mm - 96.4
Valve margin mm Intake 1.0 0.5
Exhaust 1.3 0.8
Valve stem diameter mm 6.0 -
Valve stem-to-guide clearance Intake 0.02 - 0.05 0.10
mm
Exhaust 0.04 - 0.07 0.15
Valve face angle 45°- 45.5°-
Valve stem projection mm SOHC 48.45 48.95
MIVEC 48.40 48.90
PWEE9622
EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Specifications
11A-1-2
Items LimitStandard value
Overall valve length mm Intake SOHC 113.02 112.52
MIVEC 112.37 111.87
Exhaust SOHC 115.32 114.82
MIVEC 110.74 110.74
Valve spring free height mm SOHC 49.9 48.9
MIVEC 51.5 50.5
Valve spring load/installed SOHC 265/43.4 -
height N/mm
MIVEC 255/44.5 -
Valve spring squareness 2°4°
Valve seat contact width mm 0.9 - 1.3 -
Valve guide internal diameter mm 6.6 -
Valve guide projection mm SOHC 14.0 -
MIVEC 19.0 -
Oil pump case and oil pan
Oil pump tip clearance mm 0.06 - 0.18 -
Oil pump side clearance mm 0.04 - 0.10 -
Oil pump body clearance mm 0.10 - 0.18 0.35
Piston and connecting rod
Piston outside diameter mm 6A12 78.4 -
6A13 81.0 -
Piston ring side clearance mm No.1 ring 0.02 - 0.06 -
No.2 ring 0.02 - 0.06 -
Piston ring end gap mm No.1 ring 0.20 - 0.35 0.8
No.2 ring 0.35 - 0.50 0.8
Oil ring 0.20 - 0.50 1.0
Piston pin outside diameter mm 19.0 -
Piston pin press-in load (at room temperature) N 4,900 - 14,700 -
Crankshaft pin oil clearance mm 0.02 - 0.05 0.1
Connecting rod big end side clearance mm 0.10 - 0.25 0.4
Crankshaft, cylinder block, flywheel and drive plate
Crankshaft end play mm 0.05 - 0.25 0.4
PWEE9622
EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Specifications 11A-1-3
Items LimitStandard value
Crankshaft journal diameter 6A12 53.0 -
mm
6A13 56.0 -
Crankshaft pin diameter mm 6A12 43.0 -
6A13 51.0 -
Crankshaft journal oil clearance mm 0.02 - 0.04 0.1
Cylinder block gasket surface flatness mm 0.05 -
Cylinder block gasket surface grinding limit (including grinding of
cylinder head gasket surface) mm
- 0.2
Cylinder block overall height 6A12 190.0 -
mm
6A13 209.0 -
Cylinder block cylindricity mm 0.01 or less -
Cylinder block internal diame- 6A12 78.4 -
ter mm
6A13 81.0 -
Bearing cap bolt nominal length mm - 71.1
Piston-to-cylinder clearance mm 0.02 - 0.04 -
REWORK DIMENSIONS
Item Standard
Cylinder head and valves
Cylinder head oversize valve guide hole diameter mm 0.05 O.S. 11.05 - 11.07
0.25 O.S. 11.25 - 11.27
0.50 O.S. 11.50 - 11.52
Oversize intake valve seat SOHC 0.3 O.S. 29.80 - 29.82
ring hole diameter mm
0.6 O.S. 30.10 - 30.12
MIVEC 0.3 O.S. 32.30 - 32.32
0.6 O.S. 32.60 - 32.62
Oversize exhaust valve SOHC 0.3 O.S. 27.80 - 27.82
seat ring diameter mm
0.6 O.S. 28.10 - 28.12
MIVEC 0.3 O.S. 29.80 - 29.82
0.6 O.S. 30.10 - 30.12
PWEE9622
EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Specifications
11A-1-4
TORQUE SPECIFICATION
Items Nm
Alternator and drive belt
Alternator pivot nut 44
Alternator bolt 21
Oil level gauge guide 23
Tensioner pulley 15
Engine hanger 23
Tensioner pulley bracket A 45
Crankshaft bolt 182
Engine cover 3
Timing belt
Timing belt front cover 11
Engine support bracket 49
Angle sensor 9
Angle sensor connector bracket 11
Tensioner pulley 48
Tensioner arm 24
Auto tensioner 21
Camshaft sprocket bolt 88
Idler pulley 35
Timing belt rear cover 11
Angle sensor connector bracket 11
Fuel and emission control parts
Air intake plenum stay 18
Connector bracket 11
EGR valve 22
Throttle body 12
Air intake plenum 18
Delivery pipe 12
Fuel pipe 9
Fuel pressure regulator 9
Alternator bracket 23
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EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Specifications 11A-1-5
Items Nm
Ignition system
Spark plug 25
Water cover (SOHC) 11
Distributor (SOHC) 13
Ignition failure sensor (MIVEC) 10
Condenser bracket assembly (MIVEC) 5
Ignition coil (MIVEC) 10
Water pump and water pipe
Engine hanger (MIVEC) 11
Engine coolant temperature gauge unit 11
Engine coolant temperature sensor 29
Heater pipe (SOHC) 23
Water inlet fitting 18
Water outlet fitting 18
Thermostat housing 23
Water pipe 13
Water pump 23
Intake manifold and exhaust manifold
Intake manifold 17
Heat protector 13
Exhaust manifold stay 44
Exhaust manifold 49
Rocker arm and camshaft <SOHC>
Rocker cover 4
Rocker arm and rocker shaft 31
Thrust case 24
Rocker arm and camshaft <MIVEC>
Rocker cover 4
Oil control valve holder 9
Cam cap 24
Bearing cap M6 11
Bearing cap M8 24
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EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Specifications
11A-1-6
Items Nm
Arm spring holder 11
Rocker arm and rocker shaft cap <MIVEC>
Rocker shaft cap 11
Cylinder head and valves
Cylinder head bolt 20 + 120°+ 120°
Oil pan and oil pump
Oil pressure switch 10
Oil filter cover 21
Water hose 30
Bolt 68
Drain plug 39
Oil level sensor 9
Oil pan 7
Oil screen 19
Baffle plate 9
Relief plug 44
Oil pump case 14
Oil pump case cover 12
Piston and connecting rod
Connecting rod 18 + 90°- 100°
Crankshaft, cylinder block, flywheel and drive plate
Detonation sensor 23
Idler pulley bracket 35
Flywheel bolt 98
Drive plate bolt 98
Rear plate 11
Bell housing cover 9
Oil seal case 11
Bearing cap bolt 25 + 90°- 100°
PWEE9622
EFeb. 1997Mitsubishi Motors Corporation

6A1 ENGINE (E-W) - Specifications 11A-1-7
NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED IN
PLASTIC AREA
A new type of bolts, to be tightened in plastic area, is currently used in some parts of the engine. The
tightening method for the bolts is different from the conventional one. Be sure to observe the method
described in the text when tightening the bolts.
Service limits are provided for the bolts. Make sure that the service limits described in the text are strictly
observed.
DAreas where the bolts are in use:
(1) Cylinder head bolts
(2) Main bearing cap bolts
(3) Connecting rod cap bolts
DTightening Method
After tightening the bolts to the specified torque, tighten them another 90°to 100°, or 240°(twice
120°). The tightening method varies on different areas. Observe the tightening method described
in the text.
SEALANTS
Item Specified sealant Quantity
Water pump* Mitsubishi Genuine Part No. MD970389 or equivalent As required
Water outlet fitting* Mitsubishi Genuine Part No. MD970389 or equivalent As required
Engine coolant temperature sensor 3M Nut Locking Part No. 4171 or equivalent As required
Engine coolant temperature gauge unit 3M ATD Part No. 8660 or equivalent As required
Camshaft bearing 3M ATD Part No. 8660 or equivalent As required
Cam cap 3M ATD Part No. 8660 or equivalent As required
Oil control valve 3M ATD Part No. 8660 or equivalent As required
Camshaft holder* Mitsubishi Genuine Part No. MD970389 or equivalent As required
Rocker cover 3M ATD Part No. 8660 or equivalent As required
Oil pump case* Mitsubishi Genuine Part No. MD970389 or equivalent As required
Oil pan* Mitsubishi Genuine Part No. MD970389 or equivalent As required
Oil pressure switch 3M ATD Part No. 8660 or equivalent As required
Oil seal case* Mitsubishi Genuine Part No. MD970389 or equivalent As required
Drive plate bolt 3M Nut Locking Part No. 4171 or equivalent As required
Flywheel bolt 3M Nut Locking Part No. 4171 or equivalent As required
*: parts sealed by foam-in-place gasket (FIPG)
PWEE9622
EFeb. 1997Mitsubishi Motors Corporation