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SECTION GI GI
CONTENTS
HOW TO USE THIS MANUAL ..............................GI-2 Precautions for Assembly and Installation .......GI-5
Description .......................................................GI-2 Parts Requiring Angle Tightening ....................GI-6
Definition of Terms ...........................................GI-2 Caution for Use of Power Tools .......................GI-6
Definition of Units .............................................GI-2 Precautions for Liquid Gasket Application .......GI-6
Description .......................................................GI-2 TIGHTENING TORQUE .......................................GI-7
PRECAUTIONS FOR SAFETY AND QUALITY ...GI-3 Standard Bolt Tightening Torque .....................GI-7
Reduction of Risk Operation ............................GI-3 Engine Part Tightening Torque ........................GI-8
Correct Operation ............................................GI-4 SPECIAL SERVICE TOOLS ...............................GI-10
Precautions for Radio Equipment Installation ..GI-4 ENGINE OUTSIDE DRAWINGS ........................GI-11
PRECAUTIONS ....................................................GI-5 MAIN SPECIFICATIONS ....................................GI-12
Precautions in Draining Engine Coolant ..........GI-5 STANDARD AND REPAIR LIMIT .......................GI-15
Precautions for Disconnecting Fuel Piping ......GI-5 STAMPED LOCATION OF ENGINE NO. ...........GI-19
Precautions for Removing and Disassembling GI-5 TROUBLE DIAGNOSIS ......................................GI-20
Precautions for Inspection, Correction, and Engine Adjustment .........................................GI-21
Replacement ....................................................GI-5 Engine LPG Fuel System ..............................GI-26
7
HOW TO USE THIS MANUAL
Definition of Terms
WARNING: Instructions and precautions that could lead to fatal
hazards and/or serious injuries if not observed properly.
CAUTION: Instructions and precautions that require special
attention and may lead to problems and/or accidents as
well as damages to the vehicle and/or components.
NOTE: Provides additional information that facilitates
operation.
Standard: Indicates tolerances for inspection and adjustment.
Repair limit: Indicates maximum or minimum values allowed for
inspection and adjustment.
Definition of Units
The units and numerical values in this Standard are SI units, and
those given in ( ) in this Standard are based on the conventional unit
system and are appended for informative reference.
Example: Tightening torque 59 - 78 Nm (6.0 - 8.0 kgf-m)
SI (Metric system)
Description
Caution: At the beginning of each section, the precautions
exclusive to the section are described.
Preparation: At the beginning of each section and during the trouble
diagnosis items, the Service Tools (STs), gauges, and
other tools to be prepared before operation are
described. Some commercial service tools, assumed to
be available in any workshop, are omitted.
Description: To perform correct operations, operational procedures,
notes, STs, and other service information are
described.
CAUTION: Descriptions of visual inspections and cleaning of
removed parts are generally omitted. Please remember
that actual operations require these processes.
GI-2 9
PRECAUTIONS FOR SAFETY AND QUALITY
PRECAUTIONS FOR SAFETY AND QUALITY The serviceman or mechanic may be unfamiliar with many of
the systems on this engine. This makes it important to use
caution when performing service work. Knowledge of the
system and/or components is important before the removal or
disassembly of any component. The following precautions must
be carefully observed for safe and appropriate service work.
Only the qualified and designated personnel must perform
inspections, repairs and adjustments.
GIM0060
10 GI-3
PRECAUTIONS FOR SAFETY AND QUALITY
Correct Operation
Make sure that you understand the symptoms before starting
trouble diagnosis.
Check correct installation status prior to removal or
disassembly. Make sure that they do not interfere with the
function of the parts they are applied to if matching marks are
required.
Once they are removed, always replace parts indicated as do
not reuse with new ones. This includes: oil seals, gaskets,
packings, O-rings, lock washers, cotter pins, and self-locking
nuts.
Replace inner and outer races of tapered or needle roller
bearings as a set.
Arrange disassembled parts in order and prevent them from
being mixed-up.
Clean or flush disassembled parts prior to inspection or
assembly.
Use Genuine MITSUBISHI parts for replacement.
Use authorized grease and sealer.
Release the pressure before disconnecting pressurized piping
or hoses.
Be sure to check for leakage after repairing fuel, oil, coolant,
exhaust, or vacuum systems.
GI-4 11
PRECAUTIONS
12 GI-5
PRECAUTIONS
CAUTION:
Be careful not to damage the mating surfaces.
In positions where a seal cutter is difficult to use, lightly tap with
a plastic hammer, and remove.
CAUTION:
Be careful not to scratch the mating surfaces when using a
GIM0061
screwdriver.
CAUTION:
Follow any directions specified in the text on the following pages.
GI-6 13
TIGHTENING TORQUE
CAUTION:
Except special nuts and bolts.
The bolts applicable to this table have one of the following
marks embossed on their heads.
4T......4
7T......7
9T......9
14 GI-7
TIGHTENING TORQUE
Nm 221 240
Crankshaft pulley bolt (lubricated)
(kgf-m) 22.5 24.5
Nm 132 142
Flywheel bolt (lubricated)
(kgf-m) 13.47 14.49
Nm 31.4 37.3
Connecting rod nut (lubricated)
(kgf-m) 3.2 3.81
Nm 44.1 58.8
Rear plate bolt
(kgf-m) 4.5 6.0
Nm 39.2 49
Camshaft sprocket bolt
(kgf-m) 4.0 5.0
Nm 29.4 39.2
Oil lter stud
(kgf-m) 3.0 4.0
Nm 14.7 20.6
Oil lter element
(kgf-m) 1.5 2.1
Nm 19.6 29.4
Spark plug
(kgf-m) 2.0 3.0
Nm 22.6 25.5
Engine slinger bolt
(kgf-m) 2.31 2.6
Nm 13.7 15.7
Rocker cover nut
(kgf-m) 1.4 1.6
Nm 15.7 19.6
Water temperature gauge
(kgf-m) 1.6 2.0
Nm 15.7 21.6
Oil pressure switch
(kgf-m) 1.6 2.2
Nm 41.2 48.1
Exhaust manifold nut
(kgf-m) 4.2 4.91
Nm 44.1 53.9
Straight screw plug (For head top face)
(kgf-m) 4.5 5.5
Nm 29.4 39.2
Oil pan drain plug
(kgf-m) 3.0 4.0
GI-8 15
TIGHTENING TORQUE
CYLINDER HEAD
Tightening torque for general service is 68.6 Nm (7.0 kgf-m) in the
place of the tightening torque (5) as shown in the figure.
MAM0142
GIM0064
16 GI-9
SPECIAL SERVICE TOOLS
GIM0066
GIM0067
GIM0068
GIM0069
GIM0071
GIM0072
GI-10 17
ENGINE OUTSIDE DRAWINGS
GIM0075
18 GI-11
MAIN SPECIFICATIONS
FUEL SYSTEM AND ENGINE SPEED CONTROL SYSTEM
Engine type K21
Engine control system Electronically controlled specications
Fuel specication Gasoline LPG Combined
Total displacement (cc) 2,065
Shape of combustion chamber Bathtub
Valve mechanism OHV
Bore x stroke (mm) 89 x 83
Compression ratio 8.7 9.3 8.7
Compression pressure [MPa (kg/cm )/rpm]2 1.45 (14.8)/250 1.57 (16.0)/250 1.45 (14.8)/250
Engine speed control system Engine Control System, electronically controlled throttle
Fuel in use (Note 1) Unleaded regular gasoline At 20P See the left column
Maximum output [kW (PS)/rpm] 42 (57)/2,700
Maximum torque [Nm (kgf-m)/rpm] 160 (16.3)/2,000
Valve opening/closing Intake open (BTDC) 14
timing (degree) Intake close (ABDC) 30
Exhaust open 32
(BBDC)
Exhaust close 12
(ATDC)
Valve clearance (mm) Intake (when engine 0.38
is hot)
Exhaust (when 0.38
engine is hot)
Firing order 1-3-4-2
Ignition timing (idling) (BTDC deg.) 0
On board idle speed ATM 700
(rpm) MTM 700
On board high-idle ATM 2,700
speed (rpm) MTM 2,700
Allowable maximum Instantaneous, no 2,700
engine speed (rpm) load
Continuous load 2,700
PTO system Silent chain-driven/side PTO
Engine oil (originally Specication 10W-30 (Class SJ)
tted) Amount (L) 3.8 (including lter)
Engine dimensions (length x width x height) 732.7 x 562.9 x 743
(Note 2) (mm)
Engine weight (w/o coolant, w/ oil) (Note 2) 150
(kg)
Note 1: Fuel
Gasoline: Use unleaded regular gasoline with an octane
rating of 91 or more.
LPG: Use a fuel of 30P or more in cold seasons. In ambient
temperature of -5C or less, use a 100P fuel.
Note 2: The engine dimensions and weight differs with the
customer specifications. The above data should be
deemed as reference.
GI-12 19
MAIN SPECIFICATIONS
EXHAUST GAS CLEANUP DEVICE LIST
Engine type K25
Engine control system Electronically controlled specications
Fuel specication Gasoline LPG Combined
Total displacement (cc) 2,488
Shape of combustion chamber Bathtub
Valve mechanism OHV
Bore x stroke (mm) 89 x 100
Compression ratio 8.7 9.2 8.7
Compression pressure [MPa (kg/cm )/rpm]2 1.51 (15.4)/250 1.57 (16.0)/250 1.51 (15.4)/250
Engine speed control system Engine Control System, electronically controlled throttle
Fuel in use (Note 1) Unleaded regular gasoline At 20P See the left column
Maximum output [kW (PS)/rpm] 47 (64)/2,700
Maximum torque [Nm (kgf-m)/rpm] 192 (19.6)/1,600
Valve opening/closing Intake open (BTDC) 14
timing (degree) Intake close (ABDC) 30
Exhaust open 32
(BBDC)
Exhaust close 12
(ATDC)
Valve clearance (mm) Intake (when engine 0.38
is hot)
Exhaust (when 0.38
engine is hot)
Firing order 1-3-4-2
Ignition timing (idling) (BTDC deg.) 0
On board idle speed ATM 700
(rpm) MTM 700
On board high-idle ATM 2,700
speed (rpm) MTM 2,700
Allowable maximum Instantaneous, no 2,700
engine speed (rpm) load
Continuous load 2,700
PTO system Silent chain-driven/side PTO
Engine oil (originally Specication 10W-30 (Class SJ)
tted) Amount (L) 3.8 (including lter)
Engine dimensions (length x width x height) 732.7 x 562.9 x 743
(Note 2) (mm)
Engine weight (w/o coolant, w/ oil) (Note 2) 150
(kg)
Note 1: Fuel
Gasoline: Use unleaded regular gasoline with an octane
rating of 91 or more.
LPG: Use a fuel of 30P or more in cold seasons. In ambient
temperature of -5C or less, use a 100P fuel.
Note 2: The engine dimensions and weight differs with the
customer specifications. The above data should be
deemed as reference.
20 GI-13
MAIN SPECIFICATIONS
MAIN SPECIFICATIONS OF IGNITION SYSTEM
Engine type K21 K25
Engine control system Electronically controls
Fuel specication Gasoline LPG Combined
Ignition device Non-contact type (Engine Control System)
Ignition coil (with power transistor) Hanshin Electric type AIC-4002G
Crankshaft position Hitachi Unisia
A29-640
Crankshaft position sensor (POS) Automotive
sensor Camshaft position Hitachi Unisia
A29-660
sensor (PHASE) Automotive
NGK type FR2A-D
Spark plug
Gap (mm) 0.9
GI-14 21
STANDARD AND REPAIR LIMIT
CYLINDER HEAD
Cylinder head (mm)
Material Aluminum alloy
Distortion limit 0.1
CYLINDER BLOCK
Block upper surface (mm)
Distortion limit 0.1
Bore diameter dimension (mm)
Standard 89.00 - 89.05
Bore diameter wear (mm)
Repair limit 0.2
Bore diameter out-of-round (mm)
Standard 0.02 or less
Bore diameter taper (mm)
Standard 0.02 or less
Bore diameter out-of-round and taper (mm)
Repair limit 0.1
22 GI-15
STANDARD AND REPAIR LIMIT
PISTON
Piston (mm)
Type Thermal flow type
Material Aluminum alloy
Outer diameter Standard 88.965 - 89.015
Clearance between piston and cylinder (mm)
Standard 0.025 - 0.045 (Selective fit service parts)
Piston pin outer diameter (mm)
Standard 19.993 - 19.998
Piston pin fitting quality
Standard To a degree allowing movement by hand
Piston ring end clearance (mm)
Standard Top 0.28 - 0.43
Second 0.45 - 0.60
Oil 0.20 - 0.60
Various limit values 1.00
Clearance between piston ring and ring groove (mm)
Standard Top 0.045 - 0.080
Second 0.030 - 0.070
Oil
Repair limit Top 0.10
Second 0.10
Oil
CONNECTING ROD
Distance between both end hole centers (mm)
Standard 143.970 - 144.030 (K25)
152.470 - 152.530 (K21)
Large end hole diameter (mm)
Standard 48.0 - 48.013
Small end hole diameter (mm)
Standard 19.965 - 19.978
Bend (per 100 mm) (mm)
Repair limit 0.05
Torsion (per 100 mm) (mm)
Repair limit 0.05
Large end thrust clearance
Standard 0.2 - 0.3
Repair limit 0.40
Large end oil clearance (mm)
Standard 0.030 - 0.066
Repair limit 0.10
Difference of weight (Piston combination) (g)
Standard 4 or less
CRANKSHAFT
Bend (mm)
Repair limit 0.05
End play (mm)
Standard 0.05 - 0.18
Repair limit 0.20
Journal dimension (mm)
Standard 62.942 - 62.955
Pin standard dimension (mm)
Standard 44.961 - 44.974
Journal oil clearance (mm)
Standard 0.020 - 0.073
Repair limit 0.10
GI-16 23
STANDARD AND REPAIR LIMIT
Pin oil clearance (mm)
Standard 0.032 - 0.066
FLYWHEEL
Flywheel surface swing (mm)
Repair limit 0.10
Ring gear surface swing (mm)
Repair limit 0.50
Flatness (mm)
Repair limit 0.30
CAMSHAFT
Bend (mm)
Repair limit 0.05
Camshaft height (mm)
Standard 36.750 - 36.800 (For both intake and exhaust)
Size reduction limit 36.5
Journal dimension (mm)
Standard Front 45.434 - 45.447
Center 43.897 - 43.910
Rear 41.218 - 41.231
End play (mm)
Standard 0.025 - 0.255
Repair limit 0.40
Journal oil clearance (mm)
Standard Front 0.025 - 0.051
Center 0.038 - 0.064
Rear 0.025 - 0.051
Repair limit Front 0.10
Center 0.15
Rear 0.10
VALVE
Head outer diameter (mm)
Standard Intake 38.0 - 38.3
Exhaust 32.0 - 32.3
Valve total length (mm)
Standard Intake 98.85 - 99.45
Exhaust 98.95 - 99.55
Valve stem outer diameter (mm)
Standard Intake 6.97 - 6.985
Exhaust 6.945 - 6.960
Valve guide inner diameter (mm)
Standard Intake 7.0 - 7.018
Exhaust 7.0 - 7.018
Clearance between valve stem and valve guide (mm)
Standard Intake 0.020 - 0.053
Exhaust 0.040 - 0.073
Repair limit Intake 0.10
Exhaust 0.10
Valve face angle
Standard Intake 45 30
Exhaust 45 30
24 GI-17
STANDARD AND REPAIR LIMIT
VALVE SPRING
Free length (mm)
Standard Intake 45.9
Exhaust 45.9
At valve full-open mm/N (mm/kgf, in/lb)
Standard Intake and Exhaust 25.0/347.0 - 391.2
(25.0/35.4 - 39.9, 0.984/78.1 - 88.0)
At valve closed mm/N (mm/kgf, in/lb)
Standard Intake and Exhaust 33.8/177.9 - 200.7
(33.8/18.1 - 20.5, 1.331/40.0 - 45.1)
Perpendicularity (mm)
Limit Intake 1.5
Exhaust 1.5
Clearance between valve lifter and lifter guide (mm)
Standard 0.016 - 0.052
Clearance between crankshaft and flywheel (mm)
Standard 0 - 0.038
Clearance between rocker shaft and rocker arm (mm)
Standard 0.020 - 0.054
GI-18 25
STAMPED LOCATION OF ENGINE NO.
GIM0076
26 GI-19
TROUBLE DIAGNOSIS
Application
Condition Possible causes Action Common Electronic Carburetor
controlled specications
specications
GI-20 27
TROUBLE DIAGNOSIS
Engine Adjustment
Condition Cause Action
1. Engine noise
Slapping noise of bearing and crankshaft Bearing looseness Replace.
Bearing seizure Replace.
Crankshaft bend Repair or replace.
Uneven wear of journal Correct.
Excessive end play Replace center bearing.
Slapping noise of piston, connecting rod Bearing looseness Replace.
Bearing seizure Replace.
Piston looseness Replace piston pin(s) or bushing(s).
Piston looseness relative to cylinder Reselect.
Piston ring damage Replace.
Poor rod alignment Realign.
Slapping noise of camshaft Bearing looseness Replace.
Excessive axial looseness Replace bearing thrust plate(s).
Rough gear tooth face(s) Correct.
Gear damage Replace.
Timing chain noise Inappropriate tension Adjust.
Damaged or sagged chain Replace.
Worn sprocket Replace.
Damaged or loose tensioner Replace.
Excessive camshaft-to-bearing clearance Replace.
Slapping noise of valve gear Inappropriate valve clearance Adjust.
Loose Adjust. screw(s) Replace.
Worn rocker face(s) Replace.
Worn valve guide(s) Replace guide(s).
Loose valve spring(s) Replace.
Valve seizure Repair or replace.
Slapping noise of water pump Inappropriate end play Replace.
Damaged impeller Replace.
2. Other mechanical damage
Stuck valve Inappropriate clearance Adjust.
Valve stem - insufcient guide-to-guide Clean stem(s), ream guide(s).
clearance
Loose or damaged spring Replace.
Seized or damaged valve stem(s) Replace or clean.
Poor fuel quality Use good fuel.
Burnt valve seat(s) Inappropriate valve clearance Adjust.
Deteriorated valve spring(s) Replace.
Edged valve end(s) Replace bulb.
Too narrow valve seat width Correct valve seat(s).
Engine over temperature (Overheat) Repair or replace.
Overrun Operate in optimum speed range.
Stuck valve guide(s) Correct.
28 GI-21
TROUBLE DIAGNOSIS
GI-22 29
TROUBLE DIAGNOSIS
30 GI-23
TROUBLE DIAGNOSIS
GI-24 31
TROUBLE DIAGNOSIS
32 GI-25
TROUBLE DIAGNOSIS
GI-26 33