Dadi. Engine 4G64 S4M. Instruction - part 3

 

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Dadi. Engine 4G64 S4M. Instruction - part 3

 

 

11-27

ENGINE

ROCKER ARM AND CAMSHAFT

MD998442

MD998441

diesel oil

6EN1700

MD998441

MD998442

diesel oil

6EN1701

MD998441

MD998442

6EN1700

MD998441

6EN1701

diesel oil

(3)

Mount the special tool MD998441 onto the hydraulic lifter.

(4)

Use the special tool MD998442 to lightly expel the steel ball

inside the lifter and make it move 5-10 strokes until it can move

smoothly. Additionally, it can also eliminate resistance of the

plunger. Such operation can remove dirty oil.

NOTES:

Since the steel ball spring is extremely soft, so do not overexert

while impelling steel ball with air leak wire  lest the hydraulic

lifter is damaged.

If the plunger 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 inside the lifter and

make it move 5-10 strokes until it can move smoothly. Such

operation can clean the pressure chamber of hydraulic lifter.

NOTES:

Since the steel ball spring is extremely soft, so do not overexert

while impelling steel ball with air leak wire  lest the hydraulic

lifter is damaged.

(8)

Take the hydraulic lifter out of the vessel, then lightly expel the

steel ball and move the plunger, remove oil away from pressure

chamber.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

11-28

ENGINE

ROCKER ARM AND CAMSHAFT

(9)

Put the hydraulic lifter into vessel C, then use the special tool

MD998442 to lightly expel the steel ball inside the lifter.

NOTES:

Don

t clean the hydraulic lifter in vessel C. Otherwise foreign

body may enter the pressure chamber which is full of oil.

(10) Stick the hydraulic lifter up straight with its plunger  at the top,

stably move the plunger downwards to its maximum stroke, then

pull it back slowly, and then release the steel ball to make the

pressure chamber full of diesel oil.

(11) Remove the special tool MD998441.

(12) Take the hydraulic lifter out of the vessel, stick it up straight with

its plunger at the top, stably impel the plunger until it can

t

move any more. Check and compare the height difference

between the plunger and the new hydraulic lifter.

NOTES:

If the hydraulic lifter becomes shorter, repeat step (9) to (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 value doesn't conform to the standard, replace the

hydraulic lifter.

(15) Mount the special tool MD998441 onto the hydraulic lifter.

(16) Put the hydraulic lifter into vessel C again, then lightly impel the

steel ball inside the lifter downwards with special tool MD998442.

(17) Stick the hydraulic lifter up straight with its plunger  at the top,

stably move the plunger downwards to its maximum stroke, then

pull it back slowly, and then release the steel ball to make the

pressure chamber full of diesel oil.

(18) Remove the special tool MD998441.

MD998442

6EN1702

MD998441

MD998442

MD998441

6EN1703

6EN1704

6EN1705

MD998440

scale=1mm

MD998442

MD998441

6EN1706

hydraulic

tappet

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11-29

ENGINE

ROCKER ARM AND CAMSHAFT

(19) Take the hydraulic lifter out of the vessel, stick it up straight

with its plunger at the top, stably impel the plunger until it can



t move any more. Check and compare the height difference

between the plunger and the new hydraulic lifter.

NOTES:

If the hydraulic lifter becomes shorter, repeat step (15) to (19)

and fully fill the hydraulic lifter with diesel oil. If it still becomes

shorter after repetition of these steps, replace the hydraulic lifter.

(20) Keep the hydraulic lifter vertical lest the diesel oil overflows.

Prevent the hydraulic lifter from being contaminated by dirt or

foreign body and mount the hydraulic lifter onto the engine as

quickly as possible.

NOTES 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)

Temporarily screw down the intake rocker shaft with bolt until

the rocker arm doesn

t push and press the valve.

(2)

Mount the rocker arm spring from the top and make it perpen-

dicular to the spark plug guide.

NOTES:You should mount rocker shaft spring first, and then the

exhaust rocker arm and rocker shaft.

(3)

Remove the special tool which is mounted for the purpose of

holding the hydraulic lifter.

(4)

Confirm that the cutting edge on the rocker shaft is in the

location as shown in the figure.

6AE016

6AE016

C

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11-30

ENGINE

CYLINDER HEAD AND VALVE

CYLINDER HEAD AND VALVE

DISASSEMBLY AND ASSEMBLY

78N.m

thorough

looseness

20N.m 90

+90

1

2

8

9

10

14

17

15

20

5

4

6

13

16

18

7

19

11

3

12

All parts inside should be
coated with enging oil in
assembly

6EN1386

N

N

N

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. cylinder head

B

C

B

B

C

C

A

C

A

A

D

Disassembly Procedure

-------------------------------------------------------------------------------------------------------------------------------------------------------------

11-31

ENGINE

CYLINDER HEAD AND VALVE

MB991654

MD998772

9EN0062

9EN0063

MD998774

Notices after Disassembly

The disassembled parts should be sorted as per the cylinder number

and the intake/exhaust parts.

Dismantle of Cylinder head Bolts

(1)

Loosen the bolts of each cylinder heads with SST. The looseness

should be even 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 valve guide with SST tools. Incorrect

mount will lead to leakage.

Notice:

The valve oil seal must not be reused.

A

A

C

B

-------------------------------------------------------------------------------------------------------------------------------------------------------------

11-32

ENGINE

CYLINDER HEAD AND VALVE

Mount of Valve Lock Clamp

(1)

In case the valve spring is over compressed, it will contact the

bottom of the valve spring and thus damage the valve oil seal.

Mount of Cylinder head Bolts

(1)

When assembling the bolts of cylinder head, the bolt length

should be identified to meet the limit value, otherwise, change the

bolts.

Limit Value (A): 99.4 mm (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

6EN0782

6EN0695

C

D

Mount of Valve Spring

(1)

The valve spring shall be mounted in such way that the spring end

with identification color faces the upper site of the valve spring.

B

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11-33

ENGINE

CYLINDER HEAD AND VALVE

paint marks

6AE0297

90



90



9EN0064

contatc position
(the center of slope)

edge thickness

6EN0542

(6)

Mark a straight line with paint on the heads of cylinder head bolts

and the cylinder head.

(7)

Tighten the cylinder head bolts by 90

in tightening order.

(8)

Tighten the bolts by another 90

, ensuring the paint marks on

the heads of cylinder head bolts and the cylinder head should be

in alignment.

Notice:

If the screwing angle of the bolt is less than 90, correct

tightening moment cannot be expected. Therefore, sufficient

importance should be attached to whether the screwing

angle is correct when tightening the bolts.

In case the bolts are over tightened, they should be

loosened thoroughly and then re-tighten them from Step (1).

Inspection on Cylinder head

(1)

Inspect 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 of valve contact correctly. If not,

polish the valve applied and regrinding it. The contact face of

valve seat should be in consistency with the center of work face

of the valve.

(2)

In case the edge thickness exceeds the limit value, change the valve.

Standard edge thickness value:

Intake value ........................... 1.0 mm

Exhaust value ........................ 1.2 mm

Application limit value:

Intake value ........................... 0.5 mm

Exhaust value ........................ 0.7 mm

(3)

Measure the total valve height, in case it is less than the limit

value, change the valve.

Standard value:

Intake value ........................... 112.30mm

Exhaust Value ........................ 114.11mm

Limit Value:

Intake value ........................... 111.80mm

Exhaust Value ........................ 113.61mm

-------------------------------------------------------------------------------------------------------------------------------------------------------------

11-34

ENGINE

CYLINDER HEAD AND VALVE

Valve Spring

(1)

Measure the free spring height, in case it is less than the limit

value, change the spring.

Standard value: 51.0 mm

Limit value: 50.0 mm

(2)

Measure the perpendicularity of the center line with the surface

of the spring, if the gradient exceeds the limit, change the spring.

Standard value: 

2

Limit value: 4



Valve Guide

(1)

Measure the clearance between the valve guide and the valve

stern, if the clearance exceeds the limit value, Change the valve

guide or valve or both of them.

Standard value:

Intake value ........................... 0.02

0.05mm

Exhaust value ........................ 0.03

0.07mm

Limit value:

Intake value ........................... 0.10mm

Exhaust value ........................ 0.15mm

Valve Seat

1) Assemble the valve and measure the protruding height of the

valve stern between the end of valve 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 width and angle of the valve seat to the specified value

with the Muller.

(3)

Grind the valve seat with the corresponding valve with grinding

paste after trimming the valve seat. Then check the protruding

height of the valve stern (refer to inspection items of valve seat).

angle belwee cerrter line of spring and plun bine
of subface

free spring height

1EN0264

valve
guide

inside diamter of
valve guide

outside diameter
of valve guide

1EN0279

endof valve stern

protruding height
of valve stern

seat face of valve
spring

DEN0212

0.9

1.3mm

43.5

 44

6EN0491

-------------------------------------------------------------------------------------------------------------------------------------------------------------

11-35

ENGINE

CYLINDER HEAD AND VALVE

Main Points in Change of Valve Seat

(1)

Cut out part of the valve seat to be changed so as to thin and

remove it.

(2)

Trim the valve seat holes on the cylinder head as per the outside

diameter of the enlarged valve seat.

Diameter of valve seat ring:

Enlarged dimension: 0.30

34.435-34.455

Enlarged dimension: 0.60

34.735-34.755

Enlarged dimension: 0.30

31.935-31.955

Enlarged dimension: 0.60

32.235-32.255

Diameter of valve guide hole on cylinder head:

Dimension plus 0.05:

11.05-11.068

Dimension plus 0.25:

1.25-11.268

Dimension plus 0.50:

1.50-11.518

(3)

Press the valve guide as shown in the figure until its protrusion

meets the specification.

Standard value: 14mm

0.3

Notice:

Press down the valve guide from the superface of the cylinder

head.

The length of the inlet 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 seat ring in the liquid nitrogen so as

to prevent it from being seizing in the cylinder head.

(4)

Trim the valve seat to the specified width and angle with the

milling cutter of valve seat (refer to the Main Points for Trimming

of Valve Seat)

Main Points for Change of Valve Guide

(1)

Press the valve guide out toward the cylinder block with the

presser.

(2)

Process the valve guide hole of the cylinder head to make it reach

the dimension of the enlarged valve guide to be mounted.

Notice:

Do not apply the new valve guide with same dimension with the

dismantled one.

Inlet valve seat

Exhaust valve seat

-------------------------------------------------------------------------------------------------------------------------------------------------------------

11-36

ENGINE

CYLINDER HEAD AND VALVE

10N.m

1.0Kgft

27

29

24

26

23

18

19

17

24N.m

2.4Kgifm

22

16

15

14

13

12

11

44N.m
4.5Kgfm

7

8

2

3

6

25

23N.m
2.4Kgfm

36N.m
3.7Kgfm

5

9

39N.m
4.0Kgfm

7N.m
0.7Kgfm

4

19N.m
1.9Kgfm

20

16N.m
1.7Kgfm

10N.m
1.0Kgfm

28

10

N

N

N

N

N

N

21

N

N

N

N

N

N

All inside parts should be
coated with the engine oil

19N.m

1.9Kgifm

Disassembly Process

1. lubricating oil filter

2. drain plug

3. drain plug washer

4. oil sump

5. oil collector and filter

6. washer of oil collector and 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

24. front cover washer

25. left balancing shaft

26. right balancing shaft

27. front bearing of right balancing shaft

28. left balancing shaft bearing

29. rear bearing of right balancing shaft

N

M

L

A

K

B

I

G

H

H

F

D

E

J

C

C

D

B

E

A

E

FRONT COVER, OIL PUMP, BALANCE SHAFT ,OIL PAN

DISMANTLE AND ASSEMBLY

-------------------------------------------------------------------------------------------------------------------------------------------------------------

11-37

Main Points of Disassembly

Disassembly of Oil Sump

(1) 

Disassemble all of the bolts of oil sump.

(2) 

Tap the SST into the clearance between the cylinder block and

the oil sump.

Notice:

Do not replace the SST with screwdriver or chisel, otherwise the oil

sump will deform and leak oil.

Disassembly of Plug

(1)

In case the plug is over tight, tap it lightly with hand hammer

for two or three times, and it will become 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

shaft

(1)

Dismantle the front bearing of the right balancing shaft from

the cylinder block with the SST.

Remark: The front bearing must be dismantled first, otherwise, the

puller for rear bearing cannot be applied.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

11-38

ENGINE

CYLINDER HEAD AND VALVE

MB991603

MB998372

6EN0207

MD998705

6EN1034

A

MB991603

MD998705

MB991603

MD998705

rear bearing

6EN0557

B

Disassembly of Rear Bearing of Balancing Shaft

(1)

Tear down the rear bearing of the left balancing shaft from the

cylinder block with SST.

Remark:The SST (MB991603) should be mounted in front of the

cylinder block when dismantling the rear bearing of the 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 the outer circumference of rear bearing

and the inside of the bearing hole of the cylinder block.

(3)

Mount the rear bearing with SST.

Remark:

There is no engine oil in the left rear bearing hole.

E

-------------------------------------------------------------------------------------------------------------------------------------------------------------

11-39

ENGINE

CYLINDER HEAD AND VALVE

MD998705

MD998705

cylinderblock

bearing

6EN1035

MD998285

6EN0746

C

D

Mount of Front Bearing of Balancing Shaft

(1)

Mount the front bearing with SST.

Mount of Front Cover

(1)

Mount the SST on the front 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 front cover with the socket wrench.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

11-40

socket wrench

front cover

oil seal

ENGINE

CYLINDER HEAD AND VALVE

socket

front cover

oil seal

Matching

marks

6LU0015

Mount of Oil Seal of Lubricating Pump

(1)

Press the oil seal into the front cover with the socket wrench.

Mount of Front Oil Seal of Crankshaft

(1)

Mount the front oil seal of crankshaft on the front cover with

SST.

Mount of Driven/Driving 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 sealant.

Do not over tighten the bolts.

Mount of Flange Bolt

(1)

Insert the cross screwdriver in the hole at left side of cylinder

block to lock the balancing shaft.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

11-41

ENGINE

CYLINDER HEAD AND VALVE

6EN0565

6EN0909

MD998783

MD998162

K

(2)

Tighten the flange bolt with specified torque and ensure the

driven gear of oil pump is fastened on the left balancing shaft.

Mount of Plug

(1)

Mount the new O-ring in the grooves at the front cover.

(2)

Mount the plug with SST and tighten it to the specified torque.

bolt hole

groove

6EN0213

crankshaft pulley side

8mm-long bolts

bottom view of oil sump

6EN0449

7EN0307

oil sump side

oil drain 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 not be stained by the humid oil within

1 hour after the mount.

(3)

Confirm the length and mounting place of the bolt.

Mount of Oil Drain Plug

(1)

Mount the oil drain plug in the direction shown in the figure.

Notice:

The mount in wrong direction will cause oil leakage.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

11-42

ENGINE

CYLINDER HEAD AND VALVE

bracket side

6EN0591

DEN0711

6LU0013

Inspection

Front Cover

(1)

Check whether the oil hole is blocked, and clean it where

necessary.

(2)

Inspect whether there is abrasion, damage or sintering at the

front bearing of left balancing shaft, if any, change the front

cover.

(3)

Check whether the front cover has crack or other damages, if

it has, change the front cover assembly.

Oil Seal

(1)

Check whether the lip of oil seal has abrasion or damage.

Change the oil seal if necessary.

(2)

Check whether the lip of oil seal has deterioration. Change the

oil seal where necessary.

Balancing Shaft

(1)

Check whether the 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 and the gear flanks

of oil pump cover has no lophodont abrasion.

(3)

Check the side clearance.

Standard value:

Driving gear: 0.08-0.14mm

Driven gear: 0.06-0.12mm

Piston and Connecting Rod

Mount of Oil Filter

(1)

Clean the mounting face of the oil filter bracket.

(2)

Coat the engine oil on the O-ring of oil filter.

(3)

Screw in the oil filter, when the O-ring contacts the mounting

face, screw another 3/4 round (tightening moment: 1.4 kg.m)

N

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