Great Wall 4G64S4M Service Manual Download

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11-2

Specifications

4G64 S4 MPI

Type

In-line OHV, SOHC

Number of Cylinders

Combustion Chamber

Single Pitch Roof

Total Displacement

2,351

Cylinder Bore

86.5

Stroke

100.0

Compression Ratio

9.5

Intake valve

before top dead center

Valve Timing

Off

after bottom dead center

Exhaust valve

before bottom dead center

Off

after top dead center

Lubrication system

Compression supply, full flow filtering

Type of oil pump

Gear type

Cooling system

Water cooling forced circulation

Type of water pump

Centrifugal impeller

ENGINE

SPECIFICATION

General

Items

Summary of Contents for 4G64S4M

Page 1: ......

Page 2: ...ng to an assembly assemblies are further divided into several parts Brief introductions specifications main points of adjustments mounting and dismounting assembling and disassembling of the assembly components are covered in this manual On the top of the first page of all assemblies are the content through which the needed information can be easily found All explanations and specifications in thi...

Page 3: ...00 1 page Guide on Using the Manual 00 3 Engine 00 5 Tightening Torque 00 6 Sealant FIPG 00 7 General Contents 00 ...

Page 4: ...of parts to the number in the figure of composing parts to show the disassembly steps Mounting Steps Mounting steps should be indicated when the mounting may not in the reverse order with dismantling steps Otherwise the mounting steps can be omitted Assembly Steps Mounting steps should be indicated when the mounting may not in the reverse order with dismantling steps Otherwise the mounting steps c...

Page 5: ...00 5 VEHICLE MODEL ENGINE MODEL DISPLACEMENT TYPE HOVER CUV 4G64 D Y7 2 351 ML FOUR CYLINDERS IN LINE SOHC ENGINE MODEL OVERVIEW ENGINE ...

Page 6: ... alloy Cast iron steel NPTF 1 16 0 5 0 8 0 8 1 2 PT 1 8 0 8 1 2 1 5 2 2 PT 1 4 2 0 3 0 3 5 4 5 NPTF 1 4 2 0 3 0 3 5 4 5 PT 3 8 4 0 5 5 5 5 7 5 PT 1 2 7 0 10 0 12 0 16 0 Tightening torque of taper thread Torque Kg M Bolt with spring washer Valve bolt Head mark 4 Head mark 7 Head mark 10 Head mark 4 Head mark 7 M6 1 0 0 9 1 3 1 1 M8 1 25 1 1 1 8 3 0 1 4 2 4 M10 1 25 2 0 3 4 6 0 3 0 5 0 M12 1 25 3 6 ...

Page 7: ...sing a special method However in some cases it is necessary to lightly hit the components with a mallet or similar tools so as to break sealant on the coupling face or use a smooth thin sealant knife to hit into the joint face gently without damaging the coupling face When dismounting the engine oil pan use special tool for dismounting oil pan MD998727 Cleaning of Sealing Surfaces Remove rubbish o...

Page 8: ...stem 11 11 Timing Toothed belt 11 14 Fuel System 11 23 Intake Manifold 11 25 Exhaust Manifold and Water Pump 11 26 Rocker Arm and Camshaft 11 28 Cylinder Head and Valve 11 34 Front Cover and Oil Pump 11 40 Piston and Connecting Rod 11 49 Crankshaft Cylinder Block and Flywheel 11 55 AC Generator 11 62 Starter 11 66 Throttle Body 11 70 Engine Contents 11 ...

Page 9: ...ession Ratio 9 5 Intake valve On 18 before top dead center Valve Timing Off 53 after bottom dead center Exhaust valve On 50 before bottom dead center Off 18 after top dead center Lubrication system Compression supply full flow filtering Type of oil pump Gear type Cooling system Water cooling forced circulation Type of water pump Centrifugal impeller ENGINE SPECIFICATION General Items ...

Page 10: ...114 11 113 61 Free Height 51 0 50 0 Valve Spring Working pre tightening force Working depth Kg mm 27 2 44 2 Verticality 2 4 Contact width 0 9 1 3 Minor diameter 6 0 Valve Guide Major diameter 11 0 Indentation depth 14 0 Convex value of valve stem 49 3 49 8 Oil Pump Lateral clearance Driving gear 0 08 0 14 Driven gear 0 06 0 12 Piston Piston clearance 0 02 0 04 Lateral clearance Ring No 1 0 02 0 06...

Page 11: ...otor coil 3 5 0 05 O S 11 05 11 07 0 25 O S 11 25 11 27 0 50 O S 11 50 11 52 Cylinder Head 0 30 O S 34 435 34 455 0 60 O S 34 735 34 755 0 30 O S 31 935 31 955 0 60 O S 32 235 32 255 Top surface lapping limit Total lapping of cylinder block and head Secondary processing dimension of the enlargingofmountingholeofvalveguides intake valve and exhaust valve Secondary processing dimension of the enlarg...

Page 12: ... 9 Toothed belt wheel of balancing shaft 4 6 Camshaft toothed belt wheel bolt 9 0 Toothed belt wheel of balancing shaft 4 6 Fuel System Throttle 1 9 Fuel distributing pipe assembly 1 2 Intake manifold Eye bolt of engine 1 9 Cooling water temperature sensor plug of engine 3 0 Water outlet port coupling bolt 2 0 Intake manifold bolt 2 0 Water temperature sensor 3 0 Exhaust manifold Exhaust manifold ...

Page 13: ...orque Kg M Front cover and oil pump Oil drain plug 4 5 Oil pan 0 7 Oil suction filter bolt and nut 1 9 Oil pressure switch 1 0 Pressure relief plug 4 5 Oil suction filter bracket bolt 1 9 Front cover bolt 2 4 Plug 2 4 Flange bolt 3 7 Oil pump cover bolt 1 6 Oil pump cover screw 1 0 Piston and connecting rod assembly Connecting rod nut 2 0 90 100 Crankshaft cylinder block flywheel and drive board F...

Page 14: ... MD998719 for Fastening camshaft toothed belt wheel Use MD998767 for timing toothed belt tensioning Disassembly and mounting of front cover plug SCREW PLUG WRENCH CRANKSHAFT FRONT OIL SEAL GUIDE Use MD998375 for mounting of crankshaft front oil seal CRANKSHAFT FRONT OIL SEAL ASSEMBLER Mounting of crankshaft front oil seal CAMSHAFT OIL SEAL ASSEMBLER Use MB990767 for the fastening of camshaft tooth...

Page 15: ...front bearing BALANCING SHAFT BEARING PULLER Disassembly of reverse bal ancing shaft rear bearing Disassembly and mounting of valve and related spare parts VALVE OIL SEAL ASSEMBLER CRANKSHAFT REAR OIL SEAL ASSEMBLER Use MB990938 for mounting of crankshaft rear oil seal CRANKSHAFT TOOTHED BELT WHEEL PULLER Disassembly of crankshaft toothed belt wheel PISTON INSTALLATION TOOL Fastening flywheel and ...

Page 16: ... Air exhausting of hydraulic lifter HYDRAULIC LIFTER RETAINER HYDRAULIC LIFTER WIRE HYDRAULIC LIFTER RE TAINER Hydraulic lifter retainer while removing and mounting rocker shaft assembly BALANCING SHAFT BEARING INSTALLER BALANCING SHAFT BEARING PULLER CYLINDER HEAD BOLT WRENCH Disassembly and mounting of cylinder head bolt Mounting of reverse balancing shaft front rear bearing TIMING TOOTHED BELT ...

Page 17: ...ing pump pulley 4 AC generator support 5 AC generator 6 crankshaft pulley 7 spark plug cable 8 spark plug 9 ignition coll 10 front top cover of timing toothed belt 11 ignition coil bracket A D E ENGINE AC GENERATOR AND IGNITIONSYSTEM 7 8 25N m 23N m 4 5 10 11N m 9 25N m 6 11 3 9 11N m 23N m Disassembly Procedure ...

Page 18: ...en flywheel with special tools 2 Mount crankshaft bolt ADJUST DRIVING BELT TENSION TO STANDARD VALUE WITH DEFLECTION INDICATOR OR TENSION GAUGE STANDARD VALUE NEW BELT 5 5 7 5mm OLD BELT 7 5 8 5mm STANDARD VALUE NEW BELT 50 70KG OLD BELT 35 45KG D E MD998781 9EN0268 MD998781 9EN0268 100N water pumo pulley crankshaf AC generator pulley 6EN0595 6EN0596 ENGINE TIMING TOOTHED BELT A ...

Page 19: ... TOOTHED BELT DISASSEMBLY AND MOUNTING 11 crakshaft bolt 12 crankshaft toothed belt wheel 13 flange 14 tensioner B 15 timing toothed belt B 16 balancing shaft toothed belt wheel 17 spacer 18 crankshaft toothed belt wheel B 19 camshaft toothed belt bolt 20 camshaft toothed belt wheel E D F B D C A G E H F C B G H A 11N m 17 16 15 45N 19N 14 13 18 8 88N 19 20 2 9 8 8N m 10 54N 7 6 35N 4 22N 12 162N ...

Page 20: ...meter to fasten the balancing shaft on the left side 3 Disassemble oil pump toothed belt wheel nut 4 Disassemble oil pump toothed belt wheel DISASSEMBLY OF CRANKSHAFT BOLT 1 Fasten the flywheel with special tools 2 NOTES FOR DISASSEMBLY DISASSEMBLY OF TIMING TOOTHED BELT DISASSEMBLY OF CRANKSHAFT TOOTHED BELT WHEEL 1 In case difficult to disassemble due to adhesion use special tools DISASSEMBLY OF...

Page 21: ... 2 Disassemble the balancing shaft toothed belt wheel DISASSEMBLY OF CRANKSHAFT TOOTHED BELT WHEEL B 1 In case difficult to disassemble due to adhesion use special tools DISASSEMBLY OF CAMSHAFT TOOTHED BELT WHEEL BOLT 1 Fasten camshaft timing toothed belt wheel with special tools 2 Disassemble camshaft toothed belt wheel bolt F G H CHECK TIMING TOOTHED BELT WHEEL Carefully check each part of the t...

Page 22: ...de face is as level as being cut with a sharp knife 7 Abnormal abrasion on the tooth surface 8 Teeth broken off AUTOMATIC TENSIONER 1 Check automatic tensioner to see if there is leakage and replace with a new one if necessary 2 Check if there is abrasion or damages on the rod end and replace with a new one if necessary cracks canvas peel off side cracks crack at bottom of tooth 1EN0249 belt margi...

Page 23: ...tandard value 1mm 6 Clamp automatic tensioner with a soft jaw plier Notes Because there is screw plug outshot at the bottom of automatic tensioner a flat bearing plate should be inserted between the plier and the screw plug to avoid them from direct contacting 7 Rotate handle of plier to thrust in the rod of automatic tensioner Replace automatic tensioner if it can be easily thrusted in Certain re...

Page 24: ... figure 4 While applying force to the tensioner side of timing toothed belt with your finger move tensioner B in the direction of the arrow At this moment screw up the bolt to fixup tensioner B Don t let the shaft rotate together with toothed belt wheel thus while screwing up the bolt otherwise the toothed belt will be too tight 5 Confirm to align the mark on the toothed belt with the mark on the ...

Page 25: ... 1 If the rod of automatic tensioner is extruded the following procedures should be taken to retract it 2 Clamp automatic tensioner with a soft jaw plier Notes Because there is screw plug outshot at the bottom of auto matic tensioner a flat bearing plate should be inserted between the plier and the screw plug to avoid them from direct contacting 3 Use a plier to push it in slowly until hole on the...

Page 26: ...rdant mark 5 Disassemble plug from cylinder block then insert cross point screwdriver diameter 8mm into the hole Going over 60mm inwards means the timing mark is aligned incase of failure to go more than 20 25 inwards you should turn the oil pump toothed belt wheel 180 6 Connect timing toothed belt to crankshaft pulley central pulley camshaft toothed belt wheel and tensioner pulley in turn 7 Uplif...

Page 27: ...used 12 Use the torque wrench to screw down to a torque of 0 26 0 27 kg m 13 While holding the tensioner pulley with special tools and torque wrench screw down the central bolt till the standard value is reached 14 Place the crankshaft for about 15 minutes after turning it 2 circles clock wise Then check if the fixing steel wire of auto matic tensioner can glide freely Notes In case the steel wire...

Page 28: ...tion Assembly Before mounting fuel distribution assembly carefully lubricate the matching face of the manifold or the O ring with mineral lubricating oil align the center lines of the injector and the mounting hole then insert the intake manifold Finally screw down the bolt accord ing to the specified tightening torque 1 Mineral lubricating oil ISO 10 10 cSt at 40 2 Prevent lubricant from entering...

Page 29: ... No 4171 or the equivalent APPLICATION OF SEALANT FOR WATER OUTLET Sealant Specification Genuine MITSUBISHI brand parts No MD970389 or the equivalent 19N m 19N m 20N m 1 20N m 3 4 13N m 13N m 30N m 2 A B sealant diameter 3mm 6 N 1 engine Link Ring 2 engine Water Temperature Sensor 3 water Outlet 4 intake Manifold Bracket 5 intake manifold 6 intake Manifold Gasket Disassembly Procedure A B ...

Page 30: ...ensor 7 exhaust manifold 8 exhaust manifold gasket 9 water inlet 10 thermostat 11 water temperature sensing plug 12 bypass water pipe fitting 13 water pipe assembly 14 water pipe O ring 15 thermostat casing 16 water inlet 17 o ring 18 water pump 19 water pump gasket B A A A A 6 45N m 4 14N m 29N m 8 5 49N m 1 13N m 2 24N m 7 3 16 16 9 10 24N m 15 13N m 24N m 14N m 18 19 13 14 11 12 11N m N N N N N...

Page 31: ...tes There shouldn t be any oil or lubricating grease on the surface of O ring seal M O U N T I N G O F B Y P A S S W A T E R P I P E CONNECTOR Sealant Specification Genuine MITSUBISHI brand parts No MD970389 or the equivalent Notes 1 Swiftly mount bypass water pipe connector while sealant is still wet within 15 minutes 2 May not add oil on the sealing part within 1 hour or so after mounting A B ...

Page 32: ...er shaft 11 rocker shaft spring 12 A rocker arm A 13 B rocker arm B 14 rocker shaft air intake side 15 hydraulic lifter 16 rocker arm C 17 rocker shaft air exhaust side 18 hydraulic lifter 19 oil seal 20 thrust cover 21 o ring 22 camshaft 1 5 3 4 6 7 8 3 9N m 31N m 17 16 16 16 16 18 11 11 11 11 15 12 13 12 13 12 13 12 13 14 9 22 21 20 18N m 19 N N N Smear engine oil on all moving parts while mount...

Page 33: ...lockades the rocker arm should be replaced 2 Check if the roller can rotate smoothly If not or slacked the rocker arm should be replaced 3 Check the inside diameter In case of damages or blockages the rocker arm should be replaced HYDRAULIC LIFTER NOTES 1 Hydraulic lifter is a precise part There shouldn t be any dust and foreign body etc 2 Do not disassemble the hydraulic lifter 3 Clean the hydrau...

Page 34: ...can t move smoothly or mechanical devices seem abnormal replace the hydraulic lifter 5 Take the hydraulic lifter out of the vessel then lightly expel the steel ball and move the plunger remove diesel oil away from pressure chamber 6 Mount the special tool MD998441 onto the hydraulic lifter 7 Put the hydraulic lifter into vessel B then use the special tool MD998442 to lightly expel the steel ball i...

Page 35: ...12 and fully fill the hydraulic lifter with diesel oil If it still becomes shorter after repetition of these steps replace the hydraulic lifter 13 Mount the hydraulic lifter onto the special tool 14 After the plunger sink down 0 2 0 5mm measure the time taken for the plunger to sink down another 1mm Standard value 3 20 sec 1mm use the diesel oil with a temperature of 15 20 Notes If the measured va...

Page 36: ...ES FOR MOUNTING MOUNTING OF OIL SEAL MOUNTING OF HYDRAULIC LIFTER 1 Insert the hydraulic lifter into the rocker arm be careful not let diesel oil overflow then use the special tool to prevent it from falling NOTES If the hydraulic lifter is used repeatedly it must be cleaned 6EN1704 9EN0060 MD998713 6AE0161 MD998443 hydraulic lifter A B MOUNTING OF ROCKER SHAFT SPRING ROCKER ARM AND ROCKER SHAFT 1...

Page 37: ... N N N N B 1 cylinder head bolts 2 cylinder head cluster 3 head gasket 4 valve lock clamp 5 upper site of valve spring 6 valve spring 7 inlet valve 8 valve lock clamp 9 upper site of valve spring 10 valve spring 11 exhaust valve 11 valve oil seal 12 valve spring seat 13 valve spring 14 valve spring seat 15 inlet valve guide 16 exhaust valve guide 17 inlet valve seat 18 exhaust valve seat 19 cylind...

Page 38: ...en and gradual Dism Dismantle of Valve Lock Clamp 1 The dismantled parts such as the valve and spring should be marked with the cylinder number and signboard of mounting position and kept well so as to prepare the later reuse in assembly Dismantle of Valve Oil Seal 1 The valve oil seal must not be reused Mount of Valve Oil Seal 1 Mount the lower site of valve spring 2 Mount the valve oil on the va...

Page 39: ... Max 2 Coat the engine oil on the threaded part of the bolts and on the gasket 3 Tighten the bolts in the tightening order to the specified torque with SST MB991654 Tightening Moment 78N m 4 Loosen all parts thoroughly 5 Tighten the bolts with the torque of 20N m in the tightening order upper site of spring valve oil seal lower site of spring identifi cation 6EN0437 MD998772 9EN0062 bolt length 6E...

Page 40: ...pect the Planeness of the surface of cylinder head with ruler and feeler Standard value 0 03mm Limit value 0 2mm 2 The deformation should be corrected by grinding in case it exceeds the limit value Grinding limit value 0 2mm Total grinding amount of the cylinder head with the cylinder block together Height of cylinder head standard value for the new 119 9 120 1mm Valve 1 Check whether work faces o...

Page 41: ... stern and valve spring seat In case the measured value exceeds the specified limit change the valve seat Standard value Intake value 49 30mm Exhaust valve 49 30mm Limit value Intake value 49 80mm Exhaust value 49 80m Main Points on Trimming of Valve Seat 1 Before trimming the valve seat check the clearance between the valve guide and the valve rod conduct the trimming where necessary 2 Trim the w...

Page 42: ...t valve guide is different from that of the exhaust valve guide inlet valve 45 5 exhaust valve 50 5 4 Inset the new valve after mounting the valve guide and inspect whether it can move smoothly 0 5 1mm 1EN0274 0 5 1mm cut out height of valve seat ring enlarged lnside diameter 1EN0275 protrusion 1EN0106 3 Before assembling the valve seat ring heat the cylinder head to 250 or so or cool the valve se...

Page 43: ... filter 7 plug 8 o ring 9 flange bolt 10 oil pressure switch 11 relieve pug 12 gasket 13 pressure relief spring 14 pressure relief plunger 15 oil filter bracket 16 washer of oil filter bracket 17 lubricating pump cover 18 driven gear of lubricating pump 19 driving gear of lubricating pump 20 front oil seal of crankshaft 21 oil seal of lubricating pump 22 oil seal of balancing shaft 23 front cover ...

Page 44: ...come loose Disassembly of Flange Bolt 1 Tear down the plug from the side of cylinder block 2 Insert the screwdriver with pole diameter of 8mm in the plug hole to fasten the balancing shaft A B C MD998727 6EN0698 MD998162 6EN0909 6EN1026 screwdrive plug ENGINE CYLINDER HEAD AND VALVE 6EN0565 3EN0207 front bearing MD998372 D 3 Loosen the flange bolts Disassembly of Front bearing of Right Balancing s...

Page 45: ... left balanc ing shaft Main Points in Assembly Mount of Rear Bearing of Right Balancing Shaft 1 Coat the engine oil at the outside of the bearing 2 Mount the right rear bearing with SST The oil hole of the bearing should be confirmed in alignment with that on the cylinder block Mount of Rear Bearing of Left Balancing Shaft 1 Mount the SST guide plate on the cylinder block 2 Coat the engine oil at ...

Page 46: ...ont end of the crankshaft and coat the engine oil on the face of outer circumference of the SST then mount on the front cover MD998285 socket wrench front cover oil seal E 2 Mount on the front cover assembly with a new front gasket and tighten the flange bolts temporarily excluding the bolts of oil filter that must be tightened Mount of Oil Seal of Balancing Shaft 1 Press the oil seal into the fro...

Page 47: ...ing Gear of Oil Pump 1 Coat the engine oil on the surface of the gear and align the matching marks F G H 9EN0094 6EN0564 I J Coat Sealant on Oil Pressure Switch 1 Coat the sealant on the threaded part of the oil pressure switch and mount the switch with SST Specified Sealant 3M ATD Par No 8660 or corresponding substitute Notice Keep the end of the threaded part clean and do not coat it with sealan...

Page 48: ...rain plug washer L M Mount of Oil Sump 1 Clean the matching face of the oil sump and the cylinder block thoroughly 2 Coat the sealant of 4 mm in diameter on the full circumference of the oil sump flange Specified Sealant Genuine Mitsubishi brand Sealant MD970389 or the equivalents Remark 1 The oil sump must be mounted at the moment the sealant is still humid 15 min or so 2 The sealing part should ...

Page 49: ... oil hole is blocked 2 Inspect whether the journal has sintering or damage or whether it interferences with the bearing Change the balanc ing shaft bearing or the front cover assembly in case any defect is found Lubricating Oil Pump 1 Mount the gear of oil pump on the front cover and then rotate the gear to check whether it can runs smoothly and fixedly 2 Ensure the contact face of the front cover...

Page 50: ...d nut 2 connecting rod cap 3 connecting rod bearing 4 piston and connecting rod cluster 5 connecting rod bearing 6 first air ring 7 second air ring 8 oil ring 9 piston pin 10 piston 11 connecting rod 12 connecting rod bolt All inside parts must be coated with engine oil 6EN0526 G F A E D E C C B A B ...

Page 51: ...on top then mount the guide block C at the end of compression bar 2 Keep the mark for forward face of the piston to face upwardly and mount the piston and connecting rod cluster on the base seat SST of the assembler of piston pin 3 Press the piston pin out with the pressure Notice Put aside the dismantled piston piston pin and connecting rod as per the cylinder No marked on A B cylinder No DEN0050...

Page 52: ...piston pin 6 Encase the piston pin connecting rod and conduit cluster assembled as Step 3 in the piston pin hole at the side with mark for forward face with conduit A 7 Screw the guide block B in the conduit A and ensure the clearance between the guide block B and the guide block A is the value of the sum of L calculated in Step 2 plus 3 mm 8 Maintain the state that the mark for forward face of pi...

Page 53: ...procedure of Step 2 4 The scraper blade should be confirmed whether can rotate freely to left and right after the mount Mount of First and Second Air Ring 1 The first air ring should be mounted after the second air ring is mounted with the ring pliers Remark 1 There is identification mark at the ring end Identification mark First ring 1R Second ring 2R 2 Mount the piston ring and be sure the ident...

Page 54: ...ter of the crank pin and determine which group it belongs as per the following form the crank shaft to be maintained should be marked at the position shown in the figure with color paint to identify its dimension 2 The identification mark of the connecting rod is printed at the position shown in the figure Inside diameter of connecting rod 48 000 48 015mm 3 Select the bearing from the group determ...

Page 55: ...rewed down to the bottom it can be judged the threaded part of the bolt may be protracted change the bolt on such condition 2 Coat the oil on the threaded part and the seat face of the nut before tightening the nut 3 Tighten the nut on the bolt by hand and then screw the nuts down in turns so as to assemble the connecting rod cap correctly 4 Tighten the nut with the torque of 20N M 5 Coat the pain...

Page 56: ...ue First and second ring 0 8mm Oil ring 1 0mm Play of Crank Pin clearance gauge of plastic cord 1 Clear away the oil on the journal and bearing of the connecting rod thoroughly 2 Cut the clearance gauge of plastic cord in the length that is the same with the bearing width and then put them on the crank handle and parallel them with the axial center line 3 Mount on the connecting rod cap carefully ...

Page 57: ...9 8 7 25N m 90 100 12 Smear the engine oil on all moving parts N Disassembly Procedure 1 flywheel bolt 2 flywheel 3 rear cover plate 4 bell jar 5 rear oil seal cap 6 oil seal 7 main bearing cap bolt 8 main bearing cap 9 low bearing of crankshaft 10 crankshaft 11 bearing on crankshaft 12 thrust bearing of crankshaft 13 cylinder block E D C C B B A ...

Page 58: ...ase the cylinder block has obvious deflect repair or change it 2 Check the plane on cylinder block for warp with ruler and feeler and be sure there should be no washer scraps or other alien materials on the surface Standard value 0 05mm Limit value 0 1mm 3 In case the cylinder block has over large warp change or correct it within the permitted range Grinding limit 0 2 mm The max sum of thicknesses...

Page 59: ...to the dimension of reparation Notice When honing the cylinder in order to prevent the error caused by the increased temperature conduct the reparation as the order below No 2 No 4 No 1 No 3 5 Hone the cylinder to its final diameter piston diameter clearance between the piston and cylinder 6 Check the clearance between the piston and the cylinder Standard value 0 02 0 04mm Remark When repairing th...

Page 60: ...and 5 with identification mark 2 and identification color yellow or the No 3 bearing with identification mark 1 and identification color green In case there is no identification paint on the crankshaft measure the main journal and select the corresponding bearing as per the measured value 2 Mount the bearing with groove at the side of cylinder block 3 Mount the bearing without groove at the side o...

Page 61: ...ew down the paint mark at the position of the main bearing cap by 90 100 forward from the paint mark on bolt 7 Tighten each bolt by 90 100 in the above specified se quence until the paint marks on the bolts are in alignment with that on the main bearing cap Notice If the screwing angle is less than 90 the tightening property specified is cannot be guaranteed Therefore attention should be paid to t...

Page 62: ... Oil Seal Cover Specified sealant Brand Genuine Mitsubishi brand sealant MD970389 or the equivalents Notice 1 The rear oil seal cover should be mounted quickly on the condition the sealant is not dry 15 min 2 Keep the sealing area free from the lubricant and coolant for 1 hours or so after the mount D E ...

Page 63: ...DISASSEMBLY AND ASSEMBLY Disassembly Procedure 1 generator pulley 2 rotor assembly 3 rear bearing 4 bearing block 5 front bearing 6 front cap 7 stator assembly 8 retaining plate 9 adjustor and brush stand 10 brush 11 ring 12 rectifier assembly 13 rear cap A A A B 9EN0187 ...

Page 64: ...LY ADJUSTOR AND BRUSH STAND 1 Knock down the stator with an electric iron 180 250W such operation should be finished within 4 seconds lest heat is con ducted to the diode 2 While disassembling rectifier from adjustor burn off the part welded to the rectifier with the electric iron Ensure not to conduct the heat generated by the electric iron to the diode for a long time Do not let the diode pin ov...

Page 65: ...ive rectifier and the wiring terminals of stator windings with a multimeter If conduction exists in two direction the diode is breakdown the rectifier assembly should be replaced 2 Check the positive rectifier Check whether conduction exists between the negative rectifier and the wiring terminals of stator windings If conduction exists in two direction the diode is breakdown the rectifier assembly...

Page 66: ...wing steps 2 The brush may be taken off by burning off the soldering joint of the brush lead wire 3 While mounting new brush you should burn on the brush lead wire with the brush being pressed into the brush holder NOTES FOR ASSEMBLY MOUNTING OF ROTOR 1 Before mounting the rotor onto the rear cap insert a steel wire into the small hole on the rear cap to lift the mounted rotor and then pull out th...

Page 67: ...ar bearing 9 rotor 10 yoke assembly 11 washer A 12 washer B 13 plate 14 ball 15 planetary gear 16 rod 17 snap spring 18 checking ring 19 free engine clutch 20 inner gear 21 planetary gear carrier 22 front carrier STARTER DISASS0 EMBLY AND ASSEMBLY 1 17 16 13 12 21 2 11 14 15 4 5 3 9 10 7 6 22 18 19 6EN1412 A C A C A B B ...

Page 68: ...p spring 2 Dismantle the snap spring with a snap spring clamp first then disassemble the checking ring and free engine clutch CLEANING OF STARTER COMPONENTS 1 Don t clean the components in detergent Immerging the yoke and exciting coil assembly or rotor into detergent may damage their insulation property 2 When these components are contaminated use a piece of cloth to clean them 3 The driving part...

Page 69: ...REE ENGINE CLUTCH 1 Confirm that the pinion is resisted when rotating to the left while smoothly rotated when turning right 2 Check the wearing and damages of the pinion BRUSH 1 Check the roughness of the contact surface of brush and commu tator and the length of brush Limit value Wear limit mark 2 While rectifying the contact surface or changing new brush you may wrap a piece of sand paper around...

Page 70: ...or and observe the tagger If it is not magnetized and doesn t viberate the rotor is normal NOTES CONDUCTING DETECTION AFTER COMPLETELY CLEANING THE SURFACE OF ROTOR 3 Check the insulation between commutator separators and the iron core of rotor If conduction fails it s normal DETECT OPEN CIRCUIT OF WROTOR INDING 1 Check whether conduction exists between all commutator segment if yes its normal NOT...

Page 71: ...ol body assembly If these components are immerged into detergent their insulation property will be damaged Only cloth may be used to clean them Remarks 1 SAS has been adjusted before leaving factory so no adjustment is needed 2 In case the fixed SAS is dismantled by chance the speed adjusting screw of throttle should be fixed up again 3 In case the throttle speed adjusting screw is dismantled by c...

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