GROUP 11F ENGINE OVERHAUL 4G69 - Out-Club
11F-1GROUP 11FENGINE OVERHAUL 4G69 CONTENTSGENERAL INFORMATION . . . . . . . .11F-2GENERAL SPECIFICATIONS . . . . . .11F-2SERVICE SPECIFICATIONS. . . . . . .11F-3REWORK DIMENSIONS . . . . . . . . . .11F-5TORQUE SPECIFICATIONS . . . . . . .11F-5SEALANTS . . . . . . . . . . . . . . . . . . . .11F-8SPECIAL TOOLS. . . . . . . . . . . . . . . .11F-9ALTERNATOR AND IGNITIONSYSTEM . . . . . . . . . . . . . . . . . . . . . . .REMOVAL AND INSTALLATION . . . . . . . .EXHAUST MANIFOLD. . . . . . . . . . . .REMOVAL AND INSTALLATION . . . . . . . .TIMING BELT. . . . . . . . . . . . . . . . . . .11F-1311F-1311F-1611F-1611F-18INLET MANIFOLD ANDWATER PUMP . . . . . . . . . . . . . . . . . . 11F-30REMOVAL AND INSTALLATION . . . . . . . .11F-30ROCKER ARMS AND CAMSHAFT . . 11F-34REMOVAL AND INSTALLATION . . . . . . . .11F-34INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .11F-36CYLINDER HEAD AND VALVES. . . . 11F-37REMOVAL AND INSTALLATION . . . . . . . .11F-37INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .11F-40OIL PAN AND OIL PUMP. . . . . . . . . . 11F-43REMOVAL AND INSTALLATION . . . . . . . .11F-43INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .11F-51PISTON AND CONNECTING ROD . . 11F-53REMOVAL AND INSTALLATION . . . . . . . .11F-53INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .11F-58CRANKSHAFT ANDCYLINDER BLOCK . . . . . . . . . . . . . . 11F-60REMOVAL AND INSTALLATION . . . . . . . .11F-18REMOVAL AND INSTALLATION . . . . . . . .11F-60INSPECTION . . . . . . . . . . . . . . . . . . . . . . .11F-26INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .11F-64FUEL AND EMISSION PARTS . . . . .REMOVAL AND INSTALLATION . . . . . . . .11F-2811F-28
11F-2ENGINE OVERHAUL 4G69 GENERAL INFORMATIONGENERAL INFORMATIONM1113000100534VEHICLE AND ENGINE MODELSVehicle nameVehiclemodelEngine modelDisplacement SpecificationmLOutlanderCU5W4G69-22,378Single overhead camshaft, 16-valveGENERAL n-line OHV, SOHCNumber of cylinders4Combustion chamberPent roof typeTotal displacement cm32,378Cylinder bore mm87Piston stroke mm100Compression ratio9.5Valve timingIntake valveOpens (BTDC)10 Low speed cam A 12 Low speed cam B 24 High speed cam Closes (ABDC)42 Low speed cam A 44 Low speed cam B 68 High speed cam Exhaust valveOpens (BBDC)58 Closes (ATDC)18 Lubrication systemPressure feed, full-flow filtrationOil pump typeInvolute gear type
11F-3ENGINE OVERHAUL 4G69 SERVICE SPECIFICATIONSSERVICE SPECIFICATIONSM1113000300806ItemStandard valueLimitAuto tensioner rod length mm3.8 4.5 Auto-tensioner rod projection length mm12 Timing beltAuto-tensioner rod pushed-in amount [When pushed with a 1.0 or lessforce of 98 196 N] mm Valve clearance mmIntake0.11 Exhaust0.20 Low speedcam A33.84Minimum 33.34Low speedcam B37.35Minimum 36.85High speed 37.21camMinimum 36.7137.86Minimum 37.3645 Cylinder head flatness of gasket surface mmLess than 0.030.2Cylinder head grinding limit of gasket surface mm (Totalresurfacing depth of cylinder head and cylinder block) 0.2Cylinder head overall height mm120 Cylinder head bolt shank length mm 99.4Valve thickness of valve head(margin) mmIntake1.0Minimum 0.5Exhaust1.2Minimum 0.7Valve overall height mmIntake111.33Minimum 110.83Exhaust113.54Minimum 113.046.0 Intake0.02 0.040.10Exhaust0.04 0.060.1543.5 44 Intake54.8Minimum 53.8Exhaust56.1Minimum 55.1Valve spring load/installed height N/mm267/44.2 Valve spring out-of-squareness2 or less4 Valve seat valve contact width mm0.9 1.3 Valve guide inside diameter mm6.0 Valve guide projection from cylinder head upper surfacemm14.0 Rocker arms and camshaftCamshaft cam height mmIntakeExhaustCamshaft journal outside diameter mmCylinder head and valvesValve stem outside diameter mmValve thickness to valve guideclearance mmValve face angle mmValve spring free length mm
11F-4ENGINE OVERHAUL 4G69 SERVICE SPECIFICATIONSItemStandard valueLimitIntake48.3348.83Exhaust48.3448.84Drive gear0.08 0.14 Driven gear0.06 0.12 Dimension (Normaltemperature)34.5 (1.358) By-pass hole closingtemperature 97 to103 C40.0 (1.575) 78 or more 87 No. 10.03 0.070.1No. 20.02 0.060.1No. 10.15 0.300.8No. 20.28 0.430.8Oil ring side rail0.10 0.401.0Piston pin outside diameter mm22.0 Piston pin press-in load N (Room temperature)7,350 17,200 Crankshaft pin oil clearance mm0.02 0.050.1Connecting rod big end side clearance mm0.10 0.250.4Crankshaft end play mm0.05 0.250.40Crankshaft journal outside diameter mm57.0 Crankshaft pin outside diameter mm45.0 Oil clearance at crankshaftjournals mmNo. 1,2,4,5 journal0.02 0.030.1No. 3 journal0.03 0.040.1Bearing cap bolt shank length mm 71.1Piston to cylinder clearance mm0.02 0.04 Cylinder block flatness of gasket surface mm0.050.1Valve stem projection mmOil pan and oil pumpOil pump side clearance mmOil cooler by-pass valve mmOil pressure at curb idle speed kPa[oil temperature is 75 to 90 ]Piston and connecting rodPiston outside diameter mmPiston ring side clearance mmPiston ring end gap mmCrankshaft and cylinder blockCylinder block grinding limit of gasket surface mm (Total resurfacing depth of both cylinder head and cylinder block)0.2Cylinder block overall height mm284 Cylinder block inside diameter mm87.0 Cylindricity mm0.01
11F-5ENGINE OVERHAUL 4G69 REWORK DIMENSIONSREWORK DIMENSIONSM1113024300413ItemStandard valueCylinder head And valvesDiameter of oversize valve seat ring hole in cylinder headmmIntakeExhaustDiameter of oversize valve guide hole in cylinder head mm0.3 oversize35.30 35.330.6 oversize35.60 35.630.3 oversize33.30 33.330.6 oversize33.60 33.630.05 oversize11.05 11.070.25 oversize11.25 11.270.50 oversize11.50 11.52TORQUE SPECIFICATIONSM1113023401971ItemN mAlternator and ignition systemAuto-tensioner bracket bolt M1044 10Auto-tensioner bracket bolt M822 4Camshaft position sensing cylinder bolt22 4Camshaft position sensor bolt11 1Camshaft position sensor support bolt14 1Connector bracket bolt11 1Crankshaft pulley bolt25 4Alternator bolt49 9Alternator pivot nut44 10Idler pulley bolt79 5Ignition coil bolt10 2Oil level gauge guide bolt13 1Spark plugs25 5Water pump pulley bolt8.8 1.0Exhaust manifoldOxygen sensor44 5Engine hanger bolt24 3Exhaust manifold cover bolt14 1Exhaust manifold bracket B bolt59 10Exhaust manifold nut49 5Exhaust manifold bracket A bolt35 6Timing beltAuto-tensioner bolt23 3Camshaft sprocket bolt89 9
11F-6ENGINE OVERHAUL 4G69 TORQUE SPECIFICATIONSItemN mCounterbalance shaft sprocket bolt45 3Crankshaft bolt167Crankshaft angle sensor bolt8.5 0.5Engine support bracket bolt49 5Generator bracket bolt49 9Idler pulley bolt35 6Oil pump sprocket nut54 4Tensioner "B" bolt19 3Tensioner arm bolt21 4Tensioner pulley bolt48 5Timing belt cover bolt M6 (Bolt, washer assembly)9.0 1.0Timing belt cover bolt M6 (Flange bolt and nut)11 1Timing belt cover bolt M814 1Fuel and emission partsEGR valve bolt24 3Injectors and delivery pipe bolt11 1Solenoid valve bracket bolt11 1Solenoid valve nut9.0 1.0Throttle body bolt19 3Vacuum pipe and hose bolt11 1Inlet manifold and water pumpDetonation sensor23 2Engine coolant temperature gauge unit11 1Engine coolant temperature sensor30 9Engine hanger bolt24 3Harness bracket bolt11 1Inlet manifold bolt24 3Inlet manifold nut20 2Inlet manifold stay bolt31 3Manifold differential pressure sensor bolt5.0 1.0Oil pressure switch19 3Thermostat housing bolt24 4Water inlet fitting bolt13 2Water inlet pipe bolt13 2Water outlet fitting bolt13 2Water pump bolt14 1Rocker arms and camshaftAccumulator body bolt44 5Oil feeder control valve bolt11 1Rocker arms and rocker arm shaft bolt exhaust side 13 1
11F-7ENGINE OVERHAUL 4G69 TORQUE SPECIFICATIONSItemN mRocker arms and rocker arm shaft bolt intake side 31 3Nut9.0 1.0Rocker cover bolt3.5 0.5Taper plug47 7Cylinder head and valvesCylinder head bolt78 2 0 20 2 90 90 Oil pan and oil pumpDrain plug39 5Flange bolt36 3Front case bolt23 3Oil cooler by-pass valve54 5Oil filter bracket bolt19 3Oil pan bolt9.0 3.0Oil pump cover bolt17 1Oil pump cover screw10 2Oil screen bolt19 3Plug23 3Relief plug44 5Transmission stay bolt22 4Piston and connecting rodConnecting rod cap nut20 2 90 to 94 Crankshaft and cylinder blockBearing cap bolt25 2 90 Bell housing cover bolt9.0 1.0Drive plate bolt132 5Flywheel bolt132 5Oil seal case bolt11 1Rear plate bolt11 1
11F-8ENGINE OVERHAUL 4G69 SEALANTSSEALANTSM1113000500725ItemSpecified sealantCamshaft position sensor support*Mitsubishi Genuine Part No. MD970389 or equivalentEngine support bracket seal boltMitsubishi Genuine Part No. MD970389 or equivalentEngine coolant temperature sensor3M ATD No.8660 or equivalentEngine coolant temperature e gauge unit3M Nut Locking Part No.4171 or equivalentWater outlet fitting*Mitsubishi Genuine Part No. MD970389 or equivalentThermostat housing*Thermostat housing seal bolt3M AAD Part No. 8672 or equivalentOil pressure switch3M ATD No.8660 or equivalentOil pan*Mitsubishi Genuine Part No. MD970389 or equivalentRear oil seal case*NOTE: *: Part to be sealed with a form-in-place gasket (FIPG)FORM-IN-PLACE GASKET (FIPG)This engine has several areas where theform-in-place gasket (FIPG) is used for sealing. Toensure that the FIPG fully serves its purpose, it isnecessary to observe some precautions when applying it.Bead size, continuity and location are of paramountimportance. Too thin a bead could cause leaks. Toothick a bead, on the other hand, could be squeezedout of location, causing blocking or narrowing of fluidpassages. To prevent leaks or blocking of passages,therefore, it is absolutely necessary to apply theFIPG evenly without a break, while observing thecorrect bead size.FIPG hardens as it reacts with the moisture in theatmospheric air, and it is usually used for sealingmetallic flange areas.REMOVAL OF FIPG SEALED PARTSParts sealed with a FIPG can be easily removedwithout need for the use of a special method. Insome cases, however, the FIPG in joints may have tobe broken by tapping parts with a mallet or similartool. You can also tap a flat, thin gasket scraper intothe joint to break the FIPG, taking extreme care notto damage the mating surfaces. The oil pan remover(MD998727) is available as a special tool for removing the oil pan. The tool, however, must not be usedwith an aluminum oil pan as it could damage the mating surfaces.CLEANING FIPG APPLICATIONSURFACEThoroughly remove all substances deposited on theFIPG application surface, using a gasket scraper orwire brush. Make sure that the FIPG application surface is flat and smooth. Also make sure that the surface is free from oils, greases and foreignsubstances. Do not fail to remove old FIPG that mayremain in the fastener fitting holes.APPLICATION OF FIPGApplied FIPG bead should be of the specified sizeand free of any break. FIPG can be wiped awayunless it has completely hardened. Install the matingparts in position while the FIPG is still wet (in lessthan 15 minutes after application). Do not allow FIPGto spread beyond the sealing areas during installation. Avoid operating the engine or letting oils orwater come in contact with the sealed area before atime sufficient for FIPG to harden (approximately onehour) has passed. FIPG application method mayvary from location to location. Follow the instructionfor each particular case described later in this manual.
11F-9ENGINE OVERHAUL 4G69 SPECIAL TOOLSSPECIAL el stopperSupporting drive plateMB991883Flywheel stopperSupporting flywheelMB991398Spark plug wrenchRemoval and installation ofspark plugMD998770Oxygen sensor wrenchRemoval and installation ofoxygen sensorMD998778Crankshaft sprocketpullerRemoval of crankshaft sprocketMD998785Sprocket stopperSupporting counterbalanceshaft sprocketMB990767End yoke holderHolding camshaft sprocketwhen loosening or torquing boltMD998719PinsD998781MB991883B990767D998719
11F-10ENGINE OVERHAUL 4G69 SPECIAL TOOLSToolNumberNameUseMD998738Adjusting screw Holding the auto-tensioner Timing belt tensionadjustmentMD998767Tension pulley wrenchAdjustment of timing belttensionMD998012Oil pressure switchsocket wrenchRemoval and installation of oilpressure switch to cylinderblock MD998713Camshaft oil sealinstallerInstallation of camshaft oil sealMB991654Cylinder head boltwrench (12)Removal and installation ofcylinder head boltMD998735Valve spring compressor Compression of valve springMB991999Valve steam stallation of valve steam seal
11F-11ENGINE OVERHAUL 4G69 SPECIAL TOOLSToolNumberNameUseMD998162Plug wrenchRemoval and installation offront case cap plugMD998783Plug wrench retainerMD998371Silent shaft bearingpullerRemoval of counterbalanceshaft front bearingMD998372Silent shaft bearingpullerRemoval of counterbalanceshaft rear bearingMB991603Bearing installer stopper Removal and installation of rearbearingMD998705Silent shaft bearinginstallerInstallation of counterbalanceshaft bearingMD998285Crankshaft front oil sealguideInstallation of crankshaft frontoil sealMD998375Crankshaft front oil sealinstallerD998285
11F-12ENGINE OVERHAUL 4G69 SPECIAL TOOLSToolD998776NumberNameUseMD998780Piston pin setting toolRemoval and installation ofpiston pinMB992010Bolt guideRemoval and installation ofpiston and connecting rodassemblyMB990938HandleInstallation of crankshaft rear oilsealMD998776Crankshaft rear oil sealinstaller
11F-13ENGINE OVERHAUL 4G69 ALTERNATOR AND IGNITION SYSTEMALTERNATOR AND IGNITION SYSTEMREMOVAL AND INSTALLATIONM111300100139511 1 N·m10 2 N·m11011 1 N·m1325 5 N·m1411151613 1 N·m1211 1 N·m14 1 N·m222 4 N·m384644 10 N·m8.8 1.0 N·m22 4 N·m25 4 N·m779 5 N·m49 9 N·m9544 10 N·mAK301540AD1.2.3.4.5.6.7.8.Removal stepsOil level gaugeOil level gauge guideO-ringAuto tensionerCrankshaft pulleyWater pump pulleyIdler pulleyConnector bracket9.10. A C 11.12.13.14. B 15. B A 16.Removal steps (Continued)AlternatorIgnition coilSpark plugConnector bracketCamshaft position sensorO-ringCamshaft position sensor supportCamshaft position sensing cylinder
11F-14ENGINE OVERHAUL 4G69 ALTERNATOR AND IGNITION SYSTEMREMOVAL SERVICE POINT A SPARK PLUG REMOVALINSTALLATION SERVICE POINT A CAMSHAFT POSITION SENSINGCYLINDER INSTALLATION A/T MB991398AK300130 ADUsing special tool Spark plug wrench (MB991398),removal the spark plug. B CAMSHAFT POSITION SENSINGCYLINDER REMOVALMD998781AK300135 AG M/T MB991883 A/T AK600660ABMD998781AK300135 AG M/T MB991883AK600659AB1. Using special tool Flywheel stopper (MD998781),hold the drive plate. Flywheel stopper (MB991883) Flywheel stopper (MD998781)2. Removal the camshaft position sensing cylinder.1. Using special tool Flywheel stopper (MD998781),hold the drive plate. Flywheel stopper (MB991883) Flywheel stopper (MD998781)2. Tighten the camshaft position sensing cylinder tothe specified torque.Tightening torque: 22 4 N m
11F-15ENGINE OVERHAUL 4G69 ALTERNATOR AND IGNITION SYSTEM B CAMSHAFT POSITION SENSORSUPPORT INSTALLATION C SPARK PLUG INSTALLATION3 mmMB991398AK300130 ADAK300004AE1. Remove completely the FIPG remaining on thecamshaft position sensor support and cylinderhead.2. Apply a 3 1 mm diameter bead of FIPG to theindicated surface of the camshaft position sensorsupport.Specified sealant:Mitsubishi Genuine Part No.MD970389 orequivalentUsing special tool Spark plug wrench (MB991398),tighten the spark plug to the specified torque.Tightening torque: 25 5 N m
11F-16ENGINE OVERHAUL 4G69 EXHAUST MANIFOLDEXHAUST MANIFOLDREMOVAL AND INSTALLATIONM111300490074714 1 N·m14 1 N·m4749 5 N·m612344 5 N·m24 3 N·m544 5 N·m835 6 N·m59 10 N·mAK303751AD A B A B B 1.2.3.4.Removal stepsEngine hangerOxygen sensorOxygen sensorExhaust manifold cover A 5.6.7.8.Removal steps (Continued)Exhaust manifold bracket BExhaust manifoldExhaust manifold gasketExhaust manifold bracket A
11F-17ENGINE OVERHAUL 4G69 EXHAUST MANIFOLDREMOVAL SERVICE POINT A OXYGEN SENSOR REMOVE B EXHAUST MANIFOLD COVER /OXYGEN SENSOR INSTALLATION1. Install the exhaust manifold cover to the exhaustmanifold.2. Temporarily tighten the exhaust manifold coverbolt.MD998770AK300132ADMD998770Using special tool Oxygen sensor wrench(MD998770), removal the oxygen sensor.INSTALLATION SERVICE POINT A EXHAUST MANIFOLD BRACKET"B" INSTALLATIONAK300131Check to ensure that the exhaust manifold bracket"B" is in close contact with the exhaust manifold andthe cylinder block before tightening the respectivemounting bolts to the specified torque.AK300132AD3. Using special tool Oxygen sensor wrench(MD998770), install both of the oxygen sensors tothe exhaust manifold.NOTE: Do not remove the special tool after theoxygen sensor is installed.4. Tighten the exhaust manifold cover bolt to thespecified torque of 14 1N m.5. Remove the special tool.
11F-18ENGINE OVERHAUL 4G69 TIMING BELTTIMING BELTREMOVAL AND INSTALLATIONM11130019015252114 1 N·m6548 5 N·m23 3 N·m711 1 N·m21 4 N·m14 1 N·m14131222167 N·m11 1 N·m39.0 1.0 N·m231918445 3 N·m2649 9 N·m89 9 N·m25212049 5 N·m81511 B H C G G 1049 9 N·m8.5 0.5 N·m1719 3 N·m54 4 N·m I 91635 6 N·m A K J 24Removal steps1. Connector bracket2. Timing belt front upper cover3. Timing belt front lower cover4. Timing belt5. Tensioner pulley6. Tensioner arm7. Auto-tensioner8. Idler pulley9. Bracket10. Crankshaft angle sensor11. Oil pump sprocket12. Crankshaft bolt13. Crankshaft pulley washerAK301538 ACRemoval steps (Continued) D G 14. Crankshaft sprocket G 15. Crankshaft sensing blade16. Tensioner "B" E F 17. Timing belt "B" F E 18. Counterbalance shaft sprocket D 19. Spacer G C 20. Crankshaft sprocket "B"21. Crankshaft key22. Generator bracket B 23. Engine support bracket24. Timing belt rear cover H A 25. Camshaft sprocket bolt26. Camshaft sprocket
11F-19ENGINE OVERHAUL 4G69 TIMING BELTREMOVAL SERVICE POINTS A TIMING BELT REMOVAL C CRANKSHAFT BOLT LOOSENING M/T MB991883AK600659ABAK300133 A/T CAUTIONWater or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, andtensioner must be washed or immersed in solvent. Replace parts if contaminated.If there is oilor water on any part, check the front case oilseals, camshaft oil seal, and water pump forleaks.1. Mark the belt running direction for reinstallation.2. Loosen the tensioner pulley bolt, and then removethe timing belt. B OIL PUMP SPROCKET REMOVAL1. Remove the plug on the left side of the cylinderblock.MD998781AK300135 AG1. Install Flywheel stopper (MD998781) to hold thedrive plate or the flywheel. Flywheel stopper (MB991883) Flywheel stopper (MD998781)2. Loosen and remove the crankshaft bolt andwasher. D CRANKSHAFT SPROCKETREMOVALAK3001342. Insert a Phillips screwdriver (shank diameter 8mm) through the plug hole to block the leftcounterbalance shaft.3. Loosen the nut, and then remove the oil pumpsprocket.MD998778AK300136 AD1. Set special tool Crankshaft sprocket puller(MD998778) as shown in the illustration.2. Screw in the center bolt of the special tool toremove the crankshaft sprocket.
11F-20ENGINE OVERHAUL 4G69 TIMING BELT E TIMING BELT "B" REMOVAL G CRANKSHAFT SPROCKET "B"REMOVALAK300137CAUTIONWater or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, andtensioner must be free from oil and water. Theseparts should not be washed or immersed in solvent. Replace parts if contaminated.If there is oilor water on each part, check the front case oilseals, camshaft oil seal and water pump forleaks.MD9987781. Set special tool Crankshaft sprocket puller(MD998778) as shown in the illustration.2. Screw in the center bolt
SERVICE SPECIFICATIONS 11F-4 ENGINE OVERHAUL 4G69 Valve stem projection mm Intake 48.33 48.83 Exhaust 48.34 48.84 Oil pan and oil pump Oil pump side clearance mm Drive gear 0.08 0.14
1.Engine Oil SABA 13 1.Engine Oil 8000 14 1.Engine Oil 6000 15 1.Engine Oil 3000 16 1.Engine Oil Alvand 17 1.Engine Oil Motor Cycle Engine Oil M-150 18 1.Engine Oil M-100 19 1.Engine Oil Gas Engine Oil CNG-BUS 20 1.Engine Oil G.I.C.X.LA 21 1.Engine Oil G.I.C.X. 22 1.Engine Oil Diesel Engine Oil Power 23 1.Engine Oil Top Engine 24
Engine components must be inspected to meet manufacturer’s specifications and tolerances during overhaul. Proper dimensions and tolerances must be met to obtain proper performance and maximum engine life. Micrometers, depth gauges and dial indicator are used for checking tolerances during engine overhaul. Magnaflux, Magnaglo, dye-
and provide longer engine life. Expanded engine overhaul kits include the contents of the genuine John Deere overhaul kit plus rod bolts and bushings, piston pins, and camshaft bushings and are available for many John Deere engines. All John Deere overhaul kits come with a 1-year/1,500 hour warranty. John Deere camshafts — Smoother for a reason
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