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Mitsubishi Outlander GS45X. Manual - part 1232

REWORK DIMENSIONS

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-3

REWORK DIMENSIONS

M1113024300930

Clearance between valve guide
and valve stem mm (in)

Intake

0.020

− 0.047

(0.0008

− 0.0019)

0.10 (0.0039)

Exhaust

0.030

− 0.054

(0.0012

− 0.0021)

0.11 (0.0043)

Valve seat contact width mm (in) Intake

1.16

− 1.46 (0.046 − 0.058) −

Exhaust

1.35

− 1.65 (0.053 − 0.065) −

Valve guide press-in height mm (in)

14.6

− 15.2 (0.57 − 0.60)

−

Piston and connecting rod
Piston pin press-fit load N (lbf)

7,500

− 17,500

(1.686

− 3.934)

−

Clearance between piston ring
and ring groove mm (in)

Number 1

0.03

− 0.07 (0.001 − 0.003) 0.1 (0.004)

Number 2

0.03

− 0.07 (0.001 − 0.003) 0.1 (0.004)

Piston ring end gap mm (in)

Number 1

0.15

− 0.25 (0.006 − 0.011)

0.8 (0.03)

Number 2

0.25

− 0.40 (0.010 − 0.016) 0.8 (0.03)

Oil

0.10

− 0.35 (0.004 − 0.014) 1.0 (0.04)

Clearance of connecting rod big end thrust mm (in)

0.10

− 0.25 (0.004 − 0.010) 0.4 (0.016)

Difference of outside diameter of connecting rod bolt
mm (in)

−

0.1 (0.04)

Connecting rod bearing oil clearance mm (in)

0.018

− 0.045

(0.0007

− 0.0018)

0.1 (0.04)

Crankshaft and cylinder block
Underhead length of crankshaft bearing cap bolt mm
(in)

75.5

− 76.5 (2.972 − 3.012) −

Crankshaft end play mm (in)

0.05

− 0.25 (0.002 − 0.010) 0.4 (0.016)

Crankshaft journal oil clearance mm (in)

0.012

− 0.030

(0.0005

− 0.0012)

0.08 (0.0031)

Distortion of cylinder block top surface mm (in)

−

0.05 (0.0020)

Grinding limit of cylinder block top surface mm (in)

−

0.2 (0.008)

Cylinder block cylinder bore mm (in)

88 (3.46)

−

Cylindricity of cylinder block mm (in)

0.0076 (0.0003)

−

Item

Standard value

Limit

Item

Standard value

Cylinder head and valve
Cylinder head oversize valve seat bore diameter mm (in) Intake

0.30 Over
size

36.22

− 36.24

(1.426

− 1.427)

Exhaust

0.30 Over
size

30.22

− 30.24

(1.190

− 1.191)

Cylinder head oversize valve guide bore diameter mm (in)

0.25 Over
size

11.23

− 11.25

(0.442

− 0.443)

TORQUE SPECIFICATIONS

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-4

TORQUE SPECIFICATIONS

M1113023405144

Item

Specification

Generator and ignition system
Idler pulley bolt

± 7 N⋅m (36 ± 4 ft-lb)

Auto tensioner bolt

± 4 N⋅m (17 ± 2 ft-lb)

Crankshaft pulley center bolt

210 N

⋅m (155 ft-lb)

Generator nut

± 10 N⋅m (32 ± 7 ft-lb)

Generator bolt

± 10 N⋅m (32 ± 7 ft-lb)

Ignition coil bolt

± 2 N⋅m (89 ± 17 in-lb)

Spark plug

± 5 N⋅m (18 ± 3 ft-lb)

Power steering pump bracket bolt (M8)

± 3 N⋅m (19 ± 2 ft-lb)

Power steering pump bracket bolt (M10)

± 8 N⋅m (33 ± 5 ft-lb)

Throttle body and EGR system
Vacuum pipe and hose bolt (M6)

± 1 N⋅m (98 ± 8 in-lb)

Vacuum pipe and hose bolt (M8)

± 3 N⋅m (18 ± 1 ft-lb)

Throttle body bolt

9.5

± 2.5 N⋅m (84 ± 22 in-lb)

Throttle body stay bolt

± 2 N⋅m (15 ± 1 ft-lb)

EGR valve support bolt

± 2 N⋅m (15 ± 1 ft-lb)

EGR pipe bolt

± 2 N⋅m (15 ± 1 ft-lb)

EGR support stay A bolt

± 2 N⋅m (15 ± 1 ft-lb)

EGR support stay B bolt

± 2 N⋅m (15 ± 1 ft-lb)

EGR valve bolt

± 3 N⋅m (18 ± 1 ft-lb)

Manifold absolute pressure (MAP) sensor screw

4.0

± 1.0 N⋅m (36 ± 8 in-lb)

Solenoid valve screw

4.0

± 1.0 N⋅m (36 ± 8 in-lb)

Intake manifold and fuel system
Oil dipstick guide bolt

± 2 N⋅m (89 ± 17 in-lb)

Injector protector rear bolt

3.5

± 1.5 N⋅m (31 ± 13 in-lb) → 20 ± 2 N⋅m

(15

± 1 ft-lb)

Fuel rail bolt

3.5

± 1.5 N⋅m (31 ± 13 in-lb) → 20 ± 2 N⋅m

(15

± 1 ft-lb)

Intake manifold bolt and nut

3.5

± 1.5 N⋅m (31 ± 13 in-lb) → 20 ± 2 N⋅m

(15

± 1 ft-lb)

Intake manifold stay bolt

± 2 N⋅m (15 ± 1 ft-lb)

Injector protector front bolt

3.5

± 1.5 N⋅m (31 ± 13 in-lb) → 20 ± 2 N⋅m

(15

± 1 ft-lb)

Generator bracket bolt

± 8 N⋅m (33 ± 5 ft-lb)

Detonation sensor bolt

± 2 N⋅m (15 ± 1 ft-lb)

Engine oil pressure switch

± 2 N⋅m (89 ± 17 in-lb)

TORQUE SPECIFICATIONS

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-5

Exhaust manifold
Exhaust manifold upper cover bolt <Except vehicles for
California>

± 1 N⋅m (124 ± 8 in-lb)

Exhaust manifold upper cover bolt <Vehicles for California>

8.0

± 2.0 N⋅m (71 ± 17 in-lb)

Exhaust manifold lower cover bolt <Except vehicles for
California>

± 1 N⋅m (124 ± 8 in-lb)

Exhaust manifold lower cover bolt <Vehicles for California>

8.0

± 2.0 N⋅m (71 ± 17 in-lb)

Exhaust manifold nut

± 5 N⋅m (36 ± 3 ft-lb)

Exhaust manifold bracket bolt (M8) <Except vehicles for
California>

± 5 N⋅m (15 ± 3 ft-lb)

Exhaust manifold bracket bolt (M10) <Except vehicles for
California>

± 10 N⋅m (30 ± 7 ft-lb)

Exhaust manifold bracket bolt <Vehicles for California>

± 10 N⋅m (30 ± 7 ft-lb)

Crankshaft position sensor bolt

± 1 N⋅m (98 ± 8 in-lb)

Crankshaft position sensor cover bolt (M6)

± 1 N⋅m (98 ± 8 in-lb)

Crankshaft position sensor cover bolt (M10)

± 6 N⋅m (36 ± 4 ft-lb)

Water hose and pipe
Water inlet fitting bolt

± 3 N⋅m (18 ± 1 ft-lb)

Water outlet fitting bolt

± 3 N⋅m (18 ± 1 ft-lb)

Thermostat housing bolt

± 3 N⋅m (18 ± 1 ft-lb)

Engine hanger bolt

± 8 N⋅m (21 ± 5 ft-lb)

Engine coolant temperature sensor

± 9 N⋅m (22 ± 6 ft-lb)

Water pump bolt

± 3 N⋅m (18 ± 1 ft-lb)

Water pipe nut

± 3 N⋅m (18 ± 1 ft-lb)

Camshaft position sensor bolt

± 1 N⋅m (98 ± 8 in-lb)

Oil pan and timing chain case
Cylinder head cover bolt

3.0

± 1.0 N⋅m (27 ± 8 in-lb) → 5.5 ± 0.5 N⋅m

(49

± 4 in-lb)

Timing chain case bolt (M6)

± 2 N⋅m (89 ± 17 in-lb)

Timing chain case bolt (M8

× 10)

± 1 N⋅m (115 ± 8 in-lb)

Timing chain case bolt (M8

× 28)

± 4 N⋅m (18 ± 2 ft-lb)

Oil pan bolt (M6)

± 2 N⋅m (89 ± 17 in-lb)

Oil pan bolt (M8)

± 2 N⋅m (21 ± 1 ft-lb)

Air compressor bracket bolt

± 6 N⋅m (17 ± 4 ft-lb)

Oil drain plug

± 5 N⋅m (29 ± 3 ft-lb)

Oil filter

± 2 N⋅m (124 ± 17 in-lb)

Positive crankcase ventilation valve

2.5

± 0.4 N⋅m (22 ± 3 in-lb)

Engine support bracket bolt

± 6 N⋅m (35 ± 4 ft-lb)

Item

Specification

TORQUE SPECIFICATIONS

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-6

NEW TIGHTENING METHOD BY USING
PLASTIC REGION TIGHTENING BOLT

Plastic region tightening bolts are used in some parts
of the engine. Install these bolts according to the
method described in the body of the manual because
the tightening method of these bolts are different
from the conventional method. The service limit is
determined for these bolts. Be sure to strictly follow
the service limit described in the body of the manual.

• Parts to be used

1. Cylinder head bolt
2. Bearing cap bolt
3. Connecting rod cap bolt

• Tightening method

After tightening to the specified tightening torque,
further tighten 90

° and 90°, or 180° (90° + 90°).

Follow the tightening method described in the
body of the manual because the tightening
method differs from part to part.

Timing chain
V.V.T. intake sprocket bolt

± 5 N⋅m (44 ± 3 ft-lb)

V.V.T. exhaust sprocket bolt

± 5 N⋅m (44 ± 3 ft-lb)

Timing chain tensioner bolt

± 2 N⋅m (89 ± 17 in-lb)

Tensioner lever bolt

± 2 N⋅m (89 ± 17 in-lb)

Timing chain guide bolt

± 2 N⋅m (89 ± 17 in-lb)

Camshaft
Engine oil control valve (OCV) bolt

± 2 N⋅m (89 ± 17 in-lb)

Camshaft bearing cap bolt (M6)

± 1 N⋅m (107 ± 8 in-lb)

Front camshaft bearing cap bolt (M8)

± 3 N⋅m (14 ± 2 ft-lb) → 30 ± 2 N⋅m

(22

± 1 ft-lb)

Cylinder head and valves
Cylinder head bolt

± 2 N⋅m (26 ± 1 ft-lb) → +90°+90°

Balancer chain
Drive plate bolt

40 N

⋅m (30 ft-lb) → 130 N⋅m (96 ft-lb)

Balancer shaft module bolt

20 N

⋅m (15 ft-lb) → 44 N⋅m (32 ft-lb) → 0

⋅m (0 ft-lb) → 20 N⋅m (15 ft-lb) → +135°

Balancer shaft chain tensioner bolt

± 2 N⋅m (89 ± 17 in-lb)

Lever tensioner bolt

± 2 N⋅m (89 ± 17 in-lb)

Balancer shaft chain guide bolt

± 2 N⋅m (89 ± 17 in-lb)

Ladder frame bolt

± 2 N⋅m (21 ± 1 ft-lb)

Piston and connecting rod
Connecting rod cap bolt

5.0 N

⋅m (44 in-lb) → 20 N⋅m (15 ft-lb) →

+90

Crankshaft and cylinder block
Crankshaft sensing ring bolt

± 1 N⋅m (98 ± 8 in-lb)

Bearing cap bolt

26.5

± 2.0 N⋅m (20 ± 1 ft-lb) → +45°

Item

Specification

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