| The following technical bulletins were published by AERA. |
| | REMANUFACTURED ENGINE CAUTION | Remanufactured Engine Caution For
1989-99 Mitsubishi 2.0L VIN E, F, R & U Engines
The AERA Technical Committee offers the following information regarding a remanufactured engine caution for 1989-99 Mitsubishi 2.0L VIN E, F, R & U engines. In some instances a technician may encounter an above-described engine that has been remanufactured by Mitsubishi. If so, correct head gasket selection and usage is critical during subsequent engine work.
Engines remanufactured for Mitsubishi dealerships have an additional thickness (.012"or .300 mm) head gasket installed to compensate for machining during rebuilding. Failure to re-install a similar gasket on a Mitsubishi remanufactured engine may result in an engine knock and eventual engine damage. All remanufactured engines for Mitsubishi are shipped with a yellow colored one-inch by two-inch sticker with identification numbers attached to the block. The head gasket is available under part number MD349347. Listed below are engines and identification numbers that require use of the thicker head gasket.
Short Block Number Car Model Engine
RMD136421 1989-92 Eclipse 2.0L DOHC Turbo, VIN U
RMD192471 1993-94 Eclipse 2.0L DOHC Turbo, VIN F
RMD314497 1995-97 Eclipse 2.0L DOHC Turbo, VIN F
RMD330756 1998-99 Eclipse 2.0L DOHC Turbo, VIN F
RMD136420 1989-92 Eclipse & Galant 2.0L DOHC, VIN R
RMD178413 1991-92 Galant 2.0L DOHC, VIN R
RMD192470 1993-94 Eclipse 2.0L DOHC, VIN E
RMD192474 1993 Galant 2.0L DOHC, VIN E
The AERA Technical Committee | | TIMING BELT INSTALLATION ON 1990 2.0L DOHC ENGINES | Timing Belt Installation On
1990 Chrysler 2.2L DOHC Engines
The 1990 Chrysler 2.2L DOHC (double overhead camshaft) engine is manufactured jointly by Chrysler and Mitsubishi for service in Chrysler Laser, Eagle Talon and Mitsubishi Eclipse automobiles. In this engine, both camshafts are driven by a single timing belt while one of the two balance (silent) shafts is driven by its own timed belt. The second balance shaft is driven indirectly by the
timing belt and oil pump.
It is necessary to install the belt that drives the balance shaft before installing the belt that drives the camshafts.
1) Rotate the crankshaft and balance shaft to align the timing marks and mount the belt (Figure 1).
2) Temporarily mount the tensioner pulley and rotate it toward the belt to remove any slack (Figure 2).
3) Tighten the tensioner pulley bolt in such a way that no additional tension is placed on the belt. The proper amount of tension permits a belt deflection of .200-.280 measured opposite the tensioner assembly (Figure 3). Repeat if proper tension is not achieved. Torque the bolt to 31-40 lbs.ft.
The following steps outline the recommended procedure for installing the actual timing belt. It should be noted that the timing belt tension once set during installation is maintained by engine oil pressure through an auto tensioner.
4) Inspect the auto tensioner for leaks and measure the protrusion of the tensioning rod. If leaks are noticed or the rod protrudes more than .470, replace the auto tensioner. Should the auto tensioner's rod be fully extended, but within specifications, it is necessary to push it back into the housing
before installation.
5) This can be accomplished by a soft jaw vice (Figure 4). If the plug at the bottom of the tensioner protrudes, protect it from direct contact with the vice by surrounding it with a thick plain washer.
6) Slowly push the rod back into the adjuster until the set hole (A in Figure 5) is aligned with the hole in the adjuster body (B). Insert a .055 wire into the set hole to fix the rod in position.
7) Mount the tensioner pulley onto the tensioner arm (Figure
6), locating the pin holes in the tensioner pulley shaft to the left of the center bolt. Do not remove the wire inserted in step 6.
8) This engine uses the same camshaft sprocket for either camshaft. Each sprocket is therefore fitted with two timing marks (Figure 7). When the sprocket is used to drive the exhaust valve camshaft, use the timing mark on the right with the dowel pin hole on top. For the intake valve camshaft use the timing mark on the left with the dowel pin hole on top. Turn both sprockets until the dowel pins are facing up and the timing marks are aligned with the cylinder head (Figure 8).
9) Align the crankshaft and oil pump sprocket timing marks (Figure 9). Since the oil pump sprocket also drives the second, lower balance shaft, be sure to verify the position of the balance shaft. This can be accomplished by removing a threaded plug on the side of the cylinder block and inserting a .310 shank Philips screwdriver into the hole (Figure 10). If the screwdriver can be inserted at least 2.400, the timing of the balance shaft is correct. Otherwise rotate the oil pump drive sprocket one revolution and retest. The screwdriver should remain in the block until the timing belt installation is complete.
10) Install the timing belt around all of the sprockets as indicated (Figure 11). Be sure to maintain the alignment of the timing marks. Gently raise the tensioner pulley so the belt does not sag and temporarily tighten the center bolt.
11) Remove the Philips screwdriver inserted into the block in step 9. Rotate the crankshaft 1/4 turn counter-clockwise. Then turn the crankshaft clockwise to bring #1 cylinder to top dead center (TDC). Insert special tool #MD998752, or equivalent, into a torque wrench capable of reading a range of 0 to 2.2 lbs.ft.
(Figure 12).
12) Holding the tensioner pulley with the special tool and torque wrench, tighten the center bolt to 14-20 lbs.ft. The torque wrench holding the tensioner pulley via the special tool should not exceed readings of 2.2 lbs.ft.
13) Remove a rubber plug from the right hand side of the timing cover and screw special tool #MD998738 into the left engine support bracket (Figure 13) until it makes contact with the tensioner arm. Screw the tool in further to apply pressure against the tensioner arm before removing the wire from the auto
tensioner. Remove the tool.
14) Rotate the crankshaft two complete revolutions in the clockwise direction and permit the engine to rest for approximately 15 minutes.
15) Measure the amount the tensioner rod is protruding, from of the auto tensioner body (Figure 14). The recommended protrusion is .150-180. If this is not achieved, repeat steps 11 through 15 and remeasure.
16) If it is not possible to measure the amount of tensioner rod protrusion directly, a substitute method is available. Reinstall the special tool #MD998738 until contact is made with the tensioner arm. It should take 2.5 to 3 additional turns of the special tool to fully push the tensioner rod back into the auto
tensioner. Again, if this specification is not met, repeat steps
11 through 15 and retest.
The AERA Technical Committee | | CYLINDER HEAD BOLT TORQUE FOR 4 & 6 G MITSUBISHI ENGINES | Cylinder Head Bolt Tightening Caution For
1992-1996 Mitsubishi 4G & 6G Series Engines
The AERA Technical Committee offers the following information regarding cylinder head bolt tightening caution on 1992-1996 Mitsubishi 4G & 6G series engines. Information previously published in the OEM service manuals was incorrect and the following specifications should be used.
Installing non-elastic head bolts use the following torque values for vehicles/engine.
For torque sequence see Figure 1 to tighten in three steps use the bolt tightening sequence, if applicable. Refer to sequence chart. Note: Designations such as Turbo, Non-Turbo, SOHC and DOHC are only used if these items cause variations to the torque information of the engine.
Years Models Engine Torque
1992-95 Mirage thru May 1995 4G1 / 1.5L 53 ft/lbs (73 Nm)
1992-94 Eclipse 4G3 / 1.8L 53 ft/lbs (73 Nm)
1992 Eclipse, Galant 4G6 / 2.0L 80 ft/lbs (108 Nm) DOHC
1992 Galant, Expo & Truck 4G6 / 2.4L 80 ft/lbs (108 Nm) SOHC
1995 Galant 4G6 / 2.5L 80 ft/lbs (108 Nm) SOHC
1992-95 Truck, Montero, Galant 6G7 / 3.0L 80 ft/lbs (108 Nm) SOHC
& Diamante
1993-95 Diamante Wagon 6G7 / 3.0L 80 ft/lbs (108 Nm) SOHC
1992-95 Diamante & 3000 GT 6G7 / 3.5L 80 ft/lbs (108 N m) DOHC non-Turbo
1992-95 3000 GT 6G7 / 3.0L 91 ft/lbs (123 N m) DOHC Turbo *
* Loosen all bolts and retighten to 91 ft/lbs.
1994-95 Montero 6G7 / 3.5L 80 ft/lbs (108 N m) DOHC Turbo
Figure 1. Cylinder Head bolt torque Sequence
Installing Elastic Head Bolts (plastic-angle tightening method).
Before reusing head bolts measure the shank lengths of ALL the head bearing bolts, if measurement of (see below) exceeded or the bolt has visual damage REPLACE THE BOLTS. Measure from the tip to the shoulder under the bolt head (not to the shoulder of the washer). See Figure 2
1995-96 Mirage after 5/95 4G9 / 1.5L ** 4.063" (103.200 MM) SOHC 16Valve
1993-96 Mirage 4G9 / 1.8L *** 3.795" (96.400 MM) SOHC 8Valve
1992-95 Expo LRV 4G9 / 1.8L 3.795" (96.400 MM) SOHC 8Valve
1993-96 Eclipse 4G6 / 2.0L 3.913" (99.400 MM) S & D 16 Valve 1993 Galant 4G6 / 2.0L 3.913" (99.400 MM) S & D 16 Valve
1993-95 Expo, Expo LRV & Truck 4G6 / 2.4L 4.740" (120.400 MM) SOHC 8 Valve
1994-96 Galant 4G6 / 2.4L 4.740" (120.400 MM) SOHC 8 Valve
Figure 2. Cylinder Head Bolt Shank Measurement
For torque sequence see Figure 3 to tighten elastic head bolts using the plastic/angle tightening method; the following procedure is applicable to all the engines listed below.
Step 1; Torque all bolts (in sequence) to specification 58 ft/lbs (78 Nm). ***
Step 2, Loosen all bolts fully.
Step 3, Tighten all bolts to 14 ft/lbs (20 Nm).
Step 4, Tighten using a breaker bar (not a torque wrench) 90° rotation.
Step 5, Repeat step four.
Note: ** For the 1995-96 Mirage after 5/95 initial torque is a lower value Step one Torque all bolts (in sequence) to specification 34 ft/lbs (49 Nm).
*** For the 1993-96 Mirage & 1992-95 Expo LRV initial torque is a lower value Step one Torque all bolts (in sequence) to specification 54 ft/lbs (74 Nm).
Figure 2. Cylinder Head Bolt Shank Measurement
Figure 3. Cylinder Head Bolt Torque Sequence.
The AERA Technical Committee | | CYLINDER HEAD BOLT TORQUE SPECIFICATIONS | Cylinder Head Bolt Torque Specifications On
Mitsubishi Engines
The AERA Technical Committee is announcing revised cylinder head torque values for various Mitsubishi engines. Previously there may have been some confusion since torques were listed in both hot or cold specifications.
Consider the cold torque specifications listed below when mounting cylinder heads on various Mitsubishi engines. Do not retorque the cylinder head bolts when the engine is hot.
53 lbs.ft. 80 lbs.ft. 87 lbs.ft.
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1.5L Mirage 1.6L 1985-92 2.3L Diesel 1983-85
1985-92 1.8L 1983-88
1.8L* Eclipse 2.0L 1983-92
1990-92 2.4L 1985-92
2.6L 1983-92
3.0L** 1988-2000
* 1992 1.8L Expo LRV = 14.5 lbs.ft., + 1/4 turn + 1/4 turn.
** 1991-92 3.0L 3000GT = 90 lbs.ft. loosen all bolts, retorque all bolts to 90 lbs.ft.
The AERA Technical Committee |
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