| 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 | | 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 | | MAIN BEARING BOLT TORQUE CAUTION ON MITSUBISHI 4/6 G ENGINES | Main Bolt Tightening Caution For
1992-1999 Mitsubishi 4G & 6G Series Engines
The AERA Technical Committee offers the following information for main bolt tightening caution on 1992-1995 Mitsubishi 4G & 6G series engines. Information previously published in the OEM service manuals was incorrect and the following specifications should be used. The information in TB 2039 has abeen updated and it should be destroyed, as it is no longer valid information.
To install non-elastic main bearing bolts, the following procedure is applicable to all vehicles/engine listed below.
Tighten the bolts on each main bearing cap equally until the specified torque is achieved. Use the bolt-tightening sequence shown in Figure 1 if applicable.
Years Models Engine Torque
1992-95 Mirage 4G1/1.5L 38 ft/lbs (53 Nm)
1992-94 Eclipse 4G3/1.8L 38 ft/lbs (53 Nm)
1992 Galant, Expo & Truck 4G6/2.0&2.4L 38 ft/lbs (53 Nm) SOHC
1992 Eclipse, Galant 4G6/2.0L 49 ft/lbs (68 Nm) DOHC
1992-95 Truck,Montero,Galant,
Diamante 6G7/3.0L 57 ft/lbs (79 Nm) SOHC
1993-95 Diamante Wagon 6G7/3.0L 57 ft/lbs (79 Nm) SOHC
1992-95 Diamante & 3000 GT 6G7/3.0L 67 ft/lbs (93 Nm) DOHC Non/Turbo
1992 3000 GT 6G7/3.0L 67 ft/lbs (93 Nm) DOHC Turbo
1993-95 3000 GT 6G7/3.0L 54 ft/lbs (74 Nm) DOHC Turbo
1994-95 Montero 6G7/3.5L 54 ft/lbs (74 Nm) DOHC Turbo
Elastic main bolt tightening (plastic-angle tightening method). Before reusing main bolts measure the shank lengths of ALL the main bearing bolts. If the measurement of 2.799 (71.100 MM) is 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 3.
To tighten elastic main bearing bolts using the plastic/angle tightening method; the following procedure is applicable to all the engines listed below.
1. Torque bolts (in sequence see figure 2) to specification 18 ft/lbs.
2. Using a breaker bar (not a torque wrench), tighten each bolt 90°.
3. Using a breaker bar (not a torque wrench), turn each bolt an additional 90°.
The following vehicles/engines use elastic main bearing bolts:
1993-95 Mirage 4G9/1.8L 18 ft/lbs (25 Nm) Plus 90°, +90°
1992-95 Expo LRV 4G9/1.8L 18 ft/lbs (25 Nm) Plus 90°, +90°
1993-95 Eclipse 4G6/2.0L 18 ft/lbs (25 Nm) Plus 90°, +90°
1993 Galant 4G6/2.0L 18 ft/lbs (25 Nm) Plus 90°, +90°
1993-95 Expo, Expo LRV,
Truck 4G6/2.4L 18 ft/lbs (25 Nm) Plus 90°, +90°
1994-95 Galant 4G6/2.4L 18 ft/lbs (25 Nm) Plus 90°, +90°
The AERA Technical Committee | | CONNECTING ROD NUT TORQUE CAUTION | Connecting Rod Nut Tightening Caution On
1992-1995 Mitsubishi 4G Series & 6G7 Engines
The AERA Technical Committee offers the following information for connecting rod nut tightening caution on 1992-1995 Mitsubishi 4G Series & 6G7 engines. Information previously published in service manuals was incorrect and the following specifications should be used.
Years Models Engine Torque
1992-95 Mirage 4G1 14 FT/LBS (20 Nm) plus 90°
1992-94 Eclipse 4G3 25 FT/LBS (34 Nm)
1992 Eclipse, Galant, Mirage 4G6 38 FT/LBS (52 Nm)
Expo & Truck
1993-95 Eclipse, Galant, Mirage 4G6 14 FT/LBS (20 Nm) plus 90°
Expo LRV and Truck
1993-95 Mirage 4G9 14 FT/LBS (20 Nm) plus 90°
1992-95 Expo LRV
1992-96 Truck, Diamante (wagon) 6G72 38 FT/LBS
3000 GT, Montero & Galant
1992-95 Truck, Diamante (wagon) 6G74 25 FT/LBS (34 Nm) plus 90°
3000 GT, Montero & Galant
Note: If the above listed specifications are not used, engine failure may occur.
The AERA Technical Committee | | INTERFERENCE ENGINES | Interference Engines
The AERA Technical Committee would like to offer the following information on engines that present the possibility of interference between pistons and valves. The interference or contact may bend valve(s) when the timing between the camshaft and crankshaft is interrupted. This is generally the result of a timing belt or chain breaking or slipping.
The following list are engines that AERA is currently aware of that have exhibited interference. There may be other engines that are not listed below that have the possibility of piston to valve contact. If the engine you are working on is not listed, do not assume that it is a freewheeling design. It is suggested to add to this listing as additional information is obtained.
ACURA
1986-89 1.6L Integra
1991-95 1.7L Integra
1990-95 1.8L Integra
1986-89 2.5L Legend
1992-94 2.5L Vigor
1986-89 2.7L Legend
1990 2.7L Legend
1991-95 3.0L NSX
1991-95 3.2L Legend
AUDI
1970-93 All Except 1970-77
1.9L & 1970-73 1.8L
BMW
1987-95 2.5L 325I 525I
1994-95 4.0L 740I
CHRYSLER
1993-95 1.5L Colt
1987-88 1.5L Colt
1992-95 1.5L Eagle Summit
1987-88 1.6L Colt
1989-92 1.6L Eagle Summit
1994-98 2.0L Neon Stratus
1990-95 2.0L Eagle Talon
DAIHATSU
1988-92 1.0L Charade
1988-92 1.3L Charade
1990-92 1.6L Rocky
FIAT
1974-79 1.3L 128 Series
1979-82 1.5L Stranda
1974-78 1.6L 124 Series
1974-78 1.8L 124 Series
1974-78 1.8L 131 Series, Brava
1979-82 2.0L Brava, Spider
FORD
1981-85 1.6L Escort, EXP
1981-83 1.6L LN7, Lynx
1984-85 2.0L Escort, Tempo
1993-95 2.0L Probe
1986-88 2.0L Ranger
1984-87 2.0L Lynx, Topaz Diesel
1985 2.2L Ranger
1989-92 2.2L Probe
1986-88 2.3L Ranger
1986-87 2.3L Diesel Ranger
1991-98 4.6L Crown Victoria
GM
1986-95 1.0L Geo Metro
1989-91 1.0L Firefly (CANADA)
1985-88 1.5L Sunburst (CANADA)
1985-89 1.5L Spectrum
1990-93 1.6L Prizm, Storm
1981-84 1.8L Diesel (CANADA)
1982-86 1.8L Buick Skyhawk
1990-98 1.9L Saturn
1987-88 2.0L Buick Skyhawk
1988-95 2.3L Quad Four
1985-87 3.0L Buick
1979-95 3.8L Buick
HONDA
1986-87 1.0L Prelude
1973-78 1.2L All
1973-78 1.3L All
1980-84 1.3L All
1973-78 1.5L All
1985-89 1.5L Civic
1988-95 1.5L Civic, CRX
1993-95 1.5L Civic Del Sol
1979-84 1.5L All
1985-87 1.5L CRX
1993-95 1.6L Civic Del Sol
1973-78 1.6L All
1980-82 1.6L All
1988-95 1.6L Civic, CRX
1984-87 1.8L Prelude, Accord
1979-83 1.8L All
1986-91 2.0L Prelude
1990-91 2.1L Prelude
1990-95 2.2L Prelude, Accord
1992-95 2.2L Prelude
1995 2.7L Accord
HYUNDAI
1984-95 1.5L Excel Scoupe
1995-98 1.5L Accent
1992-95 1.6L Elantra
1993-95 1.8L Elantra
1992-95 2.0L Sonata
1989-91 2.4L Sonata
1990-95 3.0L Sonata
INFINITI
1990-92 3.0L M30
ISUZU
1987-89 1.5L I-Mark
1990-93 1.6L Stylus Impulse
1987-89 2.0L Impulse
1981-87 2.2L Diesel Truck
1986-95 2.3L Truck Trooper
1988-95 2.6L Truck Rodeo Amigo
1991-96 3.2L Trooper Rodeo Amigo
KIA
1995 2.0L Sportage
MAZDA
1984-85 2.0L 626
1988-92 2.2L 626 MX6
1989-93 2.2L Pickup
1988-95 3.0L 929 MPV
MITSUBISHI
1985-95 1.5L Mirage Precise
1990-92 1.6L Mirage
1989-95 2.0L Galant Eclipse
1983-86 2.3L Diesel Pickup
1994-95 2.4L Galant
NISSAN
1982 1.5L Centra
1983-88 1.6L Sentra Pulsar
1987-89 1.8L Pulsar
1982-89 2.0L Stanza 300ZX
1984-95 3.0L Maxima 300ZX Pathfinder
PORSCHE
1976-83 2.0L 924
1976-89 2.5L 944 Series
1989 2.7L 944 Series
1989-91 3.0L 944 Series
1976-83 4.5L 928
1984 4.7L 928
1985-91 5.0L 928
1992-95 5.4L 928
SUZUKI
1985-94 1.3L Samurai Sidekick
1989-94 1.3L Swift
TOYOTA
1986-95 1.5L Tercel
1981-83 2.2L Pickup
1984-87 2.4L Pickup
1982-88 2.8L Celica Cressida
1987-94 3.0L 4-Runner
VOLKSWAGEN
1976-91 All Except 1.9 2.1L Engine
1990-92 1.6L Golf (CANADA) Jetta
1990-95 2.0L GTI Jetta GLI Passat
VOLVO
1991 2.3L Coupe 940
1986-94 2.3L 240 740 940
The AERA Technical Committee |
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