11A-0-1
ENGINE
4G9 SERIES
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-0-3
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1
REWORK DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-4
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-5
NEW TIGHTENING METHOD–BY USE OF BOLTS TO BE
TIGHTENED IN PLASTIC AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-7
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-7
FORM-IN-PLACE GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-8
2. SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-2-1
3. ALTERNATOR AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 11A-3-1
4. TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-4-1
5. FUEL AND EMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . 11A-5-1
5a. THROTTLE BODY AND EGR SYSTEM (GDI) . . . . . . . . . . . . . . . . . 11A-5a-1
6. INTAKE AND EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-6-1
6a. INTAKE MANIFOLD (GDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-6a-1
6b.EXHAUST MANIFOLD (GDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-6b-1
6c. INJECTOR AND FUEL PUMP ASSEMBLY (GDI) . . . . . . . . . . . . . 11A-6c-1
6d.INTAKE AND EXHAUST MANIFOLD
<4G94–GDI for PAJERO io> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-6d-1
7. WATER PUMP AND WATER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-7-1
8. ROCKER ARMS AND CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-8-1
8a. ROCKER COVER AND CAMSHAFTS (MIVEC) . . . . . . . . . . . . . . . 11A-8a-1
8b.ROCKER ARMS AND ROCKER SHAFT CAPS (MIVEC) . . . . . 11A-8b-1
9. CYLINDER HEAD AND VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-9-1
10. FRONT CASE AND OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-10-1
11. PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-11-1
12. CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE
PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-12-1
Mitsubishi Motors Corporation
Mar. 2001
PWEE9502-I
Revised
E
4G9 ENGINE (E-W) - General Information
11A-0-3
GENERAL INFORMATION
4G92
Descriptions
4G92-SOHC
4G92-DOHC-MIVEC
Type
In-line OHV, SOHC
In-line OHV, DOHC
Number of cylinders
Combustion chamber
Total displacement dm3
Cylinder bore mm
Piston stroke mm
Compression ratio
4
4
Pentroof type
1,597
81.0
Pentroof type
1,597
81.0
77.5
77.5
10.0
11.0
Valve timing
Intake
valve
Opens
(BTDC)
20_, 14_*
17_ (Low-speed cam)
47.5_ (High-speed cam)
Closes
42_, 58_*
54_, 52_*
2_, 16_*
31_ (Low-speed cam)
(ABDC)
72.5_ (High-speed cam)
Exhaust
valve
Opens
(BBDC)
41_ (Low-speed cam)
70_ (High-speed cam)
Closes
(ATDC)
11_ (Low-speed cam)
35_ (High-speed cam)
Lubrication system
Oil pump type
Pressure feed, full-flow filtration
Trochoid type
Pressure feed, full-flow filtration
Trochoid type
Cooling system
Water pump type
Water-cooled forced circulation
Centrifugal impeller type
Water-cooled forced circulation
Centrifugal impeller type
*: LANCER for general export and CARISMA for 6B model
Mitsubishi Motors Corporation
July 1997
PWEE9502-C
Revised
E
11A-0-4
4G9 ENGINE (E-W) - General Information
4G93
Descriptions
4G93-SOHC
4G93-DOHC
4G93-DOHC-GDI
Type
In-line OHV, SOHC
In-line OHV, DOHC
In-line OHV, DOHC
Number of cylinders
Combustion chamber
Total displacement dm
Cylinder bore mm
Piston stroke mm
Compression ratio
4
4
4
Pentroof type
1,834
81.0
Pentroof type
1,834
81.0
Pentroof type
1,834
3
81.0
89.0
89.0
89.0
1
2
10.0, 9.5
14_
10.5
11.7* , 12.0*
Valve timing
Intake
valve
Opens
20_
15_
56_
55_
15_
(BTDC)
Closes
(ABDC)
50_
58_
10_
60_
61_
15_
Exhaust
valve
Opens
(BBDC)
Closes
(ATDC)
Lubrication system
Pressure feed, full- Pressure feed, full- Pressure feed, full-
flow filtration
flow filtration
flow filtration
Oil pump type
Trochoid type
Trochoid type
Trochoid type
Cooling system
Water-cooled forced Water-cooled forced Water-cooled forced
circulation
circulation
circulation
Water pump type
Centrifugal
type
impeller Centrifugal
type
impeller Centrifugal
type
impeller
1
2
* : Up to 1999 model
* : From 2000 model
Mitsubishi Motors Corporation
May 2000
PWEE9502-G
Revised
E
11A-0-5
4G9 ENGINE (E–W) – General Information
4G94
Descriptions
4G94–SOHC
4G94–DOHC–GDI
Type
In-line OHV, SOHC
In-line OHV, DOHC
Number of cylinders
Combustion chamber
Total displacement dm
Cylinder bore mm
Piston stroke mm
Compression ratio
4
4
Pentroof type
Pentroof type
1,999
81.5
3
1,999
81.5
95.8
9.5
95.8
10.6
Valve timing
Intake
valve
Opens
(BTDC)
2_
15_
Closes
(ABDC)
58_
58_
10_
51_
55_
15_
Exhaust
valve
Opens
(BBDC)
Closes
(ATDC)
Lubrication system
Oil pump type
Pressure feed, full-flow filtration
Trochoid type
Pressure feed, full-flow filtration
Trochoid type
Cooling system
Water pump type
Water-cooled forced circulation
Centrifugal impeller type
Water-cooled forced circulation
Centrifugal impeller type
Mar. 2001
PWEE9502-I
Revised
E Mitsubishi Motors Corporation
E
11A-1-1
4G9 ENGINE (E–W) – Specifications
1. SPECIFICATIONS
SERVICE SPECIFICATIONS
Items
Standard value
Limit
–
Timing belt
Auto-tensioner rod protrusion amount (When removed from engine) 11
mm
Auto-tensioner rod stroke mm
Within 1
–
–
Auto-tensioner rod protrusion amount (When checking with installed 3.8 – 4.5
on engine) mm
Rocker arms and camshaft
1
2
3
4
5
Camshaft cam
height mm
Intake
37.34
36.79
37.78
37.83
36.92
36.70
37.53
37.64
37.11
37.15
37.91
37.70
35.31
35.20
35.49
34.73
35.49
34.91
0.09
36.84
36.29
37.28
37.33
36.42
36.65
37.03
37.14
36.61
36.65
37.41
37.20
34.81
34.70
34.99
34.23
34.99
34.41
–
4G92–SOHC*
4G92–SOHC*
4G92–SOHC*
4G93–SOHC*
4G93–SOHC*
4G94–SOHC
4G93–DOHC
Exhaust
Intake
Exhaust
Intake
Exhaust
Intake
Exhaust
Intake
Exhaust
Intake
Exhaust
Intake
Exhaust
Intake
4G93–DOHC–GDI
4G94–DOHC–GDI
Exhaust
Intake
Exhaust
Intake
Valve clearance mm
Exhaust
SOHC
DOHC
0.20
–
Camshaft journal O.D. mm
26.0
–
45.0
–
Rocker cover and camshaft (MIVEC)
Camshaft height mm
Intake A
Intake B
Exhaust A
Exhaust B
Intake
36.41
33.58
35.83
34.24
0.1
36.91
33.08
35.33
33.74
–
Valve clearance (cold engine) mm
Exhaust
0.2
–
1
2
* : LANCER for Europe and CARISMA for Europe
* : LANCER for general export and CARISMA for 6B model
3
4
5
* : LANCER for Europe (from 2001 model) and CARISMA for Europe (from 2001 model)
* : Except for Europe
* : For Europe
Mitsubishi Motors Corporation
Jun. 2002
PWEE9502-K
Revised
E
11A-1-2
4G9 ENGINE (E–W) – Specifications
Items
Standard value
Limit
Cylinder head and valve
Cylinder head gasket surface flatness mm
Less than 0.03
–
0.2
Grinding limit of cylinder head gasket surface mm
0.2*
*Total resurfacing depth of both cylinder head and cylinder block
Cylinder head overall height mm
SOHC
119.9 – 120.1
131.9 – 132.1
119.8 – 120.0
131.9 – 132.1
1.0
–
DOHC
–
DOHC–MIVEC
DOHC–GDI
Intake
–
–
Thickness of valve SOHC
head (margin) mm
0.5
Exhaust
Intake
1.3
0.8
DOHC
1.0
0.5
Exhaust
Intake
1.2
0.7
Valve overall height SOHC
mm
110.15
109.65
113.20
103.69
103.37
115.13
115.13
103.69
103.37
49.9
Exhaust
Intake
113.70
DOHC
104.19
Exhaust
Intake
103.87
DOHC–MIVEC
115.63
Exhaust
Intake
115.63
DOHC–GDI
104.19
Exhaust
103.87
Valve spring free length mm
SOHC (with lash ad- 50.9
juster)
SOHC (with adjust- 49.5
ing screw)
48.5
DOHC
45.0
44.0
50.5
43.8
4_
DOHC–MIVEC
DOHC–GDI
51.5
44.8
Valve spring out-of-squareness
Max. 2_
0.02 – 0.05
0.05 – 0.09
0.02 – 0.05
0.04– 0.06
0.9 – 1.3
14.0
Valve stem to valve Except DOHC–GDI
guide clearance mm for PAJERO io
Intake
0.10
0.15
0.10
0.15
–
Exhaust
Intake
DOHC–GDI
for PAJERO io
Exhaust
Valve seat valve contact width mm
Valve guide projection from cylinder head SOHC
–
upper surface mm
DOHC
19.0
–
Mitsubishi Motors Corporation
Jun. 2002
PWEE9502-K
Revised
E
11A-1-3
4G9 ENGINE (E–W) – Specifications
Items
Standard value
Limit
Valve stem projec- SOHC
tion mm
Intake
49.30
49.80
49.85
47.20
47.15
58.63
58.35
47.20
47.15
96.4
–
Exhaust
Intake
49.35
DOHC
46.70
Exhaust
Intake
46.65
DOHC–MIVEC
58.13
Exhaust
Intake
57.85
DOHC–GDI
46.70
Exhaust
46.65
Cylinder head bolt shank length mm
Valve stem O.D. mm
–
6.0
Valve face angle
45_ – 45.5_
216/44.2
255/44.5
255/44.5
196/37.5
6.0
–
Valve spring load/installed height N/mm
SOHC
–
DOHC
–
DOHC–MIVEC
DOHC–GDI
–
–
Valve guide I.D. mm
–
Font case, oil pump and oil pan
Oil pump tip clearance mm
Oil pump side clearance mm
Oil pump body clearance mm
Piston and connecting rod
0.06 – 0.18
0.04 – 0.10
0.10 – 0.18
–
–
0.35
Piston ring to piston ring groove clearance No. 1
0.03 – 0.07
0.02 – 0.06
0.25 – 0.40
0.15 – 0.30
0.40 – 0.55
0.1
0.1
0.8
0.8
0.8
1.0
1.0
mm
No. 2
Piston ring end gap No. 1
mm
4G92, 4G93
4G94
No. 2
Oil ring
SOHC (4G92, 4G93) 0.20 – 0.60
SOHC (4G94),
DOHC
0.10 – 0.35
Crankshaft pin oil clearance mm
Piston pin press-in load N [Room temperature]
Connecting rod big end side clearance mm
Piston pin O.D. mm
0.02 – 0.05
4,500 – 14,700
0.10 – 0.25
19.0
0.1
–
0.4
–
Piston O.D. mm
4G92, 4G93
4G94
81.0
–
81.5
–
Crankshaft, cylinder block, flywheel and drive plate
Crankshaft journal oil clearance mm
0.02 – 0.04
0.1
0.1
0.2*
Cylinder block gasket surface flatness mm
0.05
–
Grinding limit of cylinder block gasket surface mm
*Total resurfacing depth of both cylinder head and cylinder block
Mitsubishi Motors Corporation
Mar. 2001
PWEE9502-I
Revised
E
11A-1-4
4G9 ENGINE (E–W) – Specifications
Items
Standard value
Limit
Cylinder block overall height mm
4G92
243.5
263.5
286.7
81.0
–
4G93
–
4G94
–
Cylinder block I.D. mm
4G92, 4G93
4G94
–
81.5
–
Piston to cylinder clearance mm
Bearing cap bolt shank length mm
Crankshaft end play mm
0.02 – 0.04
–
–
71.1
0.4
–
0.05 – 0.25
50
Crankshaft journal O.D. mm
Crankshaft pin O.D. mm
45
–
REWORK DIMENSIONS
Items
Standard value
Cylinder head and valve
Oversize rework dimensions of valve guide hole (both intake and 0.05 O.S.
11.05 – 11.07
11.25 – 11.27
11.50 – 11.52
31.80 – 31.83
32.10 – 32.13
34.30 – 34.32
34.60 – 34.62
29.30 – 29.32
29.60 – 29.62
30.80 – 30.82
31.10 – 31.13
exhaust) mm
0.25 O.S.
0.50 O.S.
Oversize rework dimensions of intake valve SOHC
seat hole mm
0.30 O.S.
0.60 O.S.
0.30 O.S.
0.60 O.S.
0.30 O.S.
0.60 O.S.
0.30 O.S.
0.60 O.S.
DOHC
Oversize rework dimensions of exhaust valve SOHC
seat hole mm
DOHC
Crankshaft, flywheel and drive plate
Crankshaft out of roundness and taper of journal and pin mm
0.005
NOTE
O.D.: Outer diameter
I.D.: Inner diameter
O.S.: Oversize diameter
Mitsubishi Motors Corporation
Mar. 2001
PWEE9502-I
Revised
E
11A-1-5
4G9 ENGINE (E–W) – Specifications
TORQUE SPECIFICATIONS
Items
Nm
Alternator and ignition system
Oil level gauge
13
12
10
25
182 ± 4
23
49
23
5
Distributor
Ignition coil
Spark plug
Crankshaft bolt
Alternator brace (M8)
Alternator brace (M10)
Lock bolt
Adjusting bolt
Power steering pump pulley
Power steering pump bracket stay
Power steering pump bracket (M8)
Power steering pump bracket (M10)
Alternator pivot bolt
Center cover
25
49
21
44
44
3
Ignition failure sensor (M6)
Ignition failure sensor (M8)
Ignition failure sensor bracket
Cam position sensor
Cam position sensor support
Cam position sensing cylinder
Engine cover
5
23
10
9
13
21
2.9
Timing belt
Camshaft sprocket bolt
Cam position sensor
Crank angle sensor
Timing belt rear cover
Timing belt rear upper cover
Timing belt tensioner
Engine support bracket, right
Accessory mount
88
9.8
9.8
11
11
24
49
49
11
49
44
13
36
Timing belt cover
Tensioner pulley bolt
Tensioner arm bolt
Auto-tensioner bolt
Idler pulley bolt
Mitsubishi Motors Corporation
Jun. 2002
PWEE9502-K
Revised
E
11A-1-6
4G9 ENGINE (E–W) – Specifications
Items
Nm
Fuel system and emission system
Breather tube
21
18
17
21
12
9
Fuel pump
Carburetor
EGR valve
Cover <Without EGR valve>
Fuel return pipe
Delivery pipe
12
9
Fuel pressure regulator
Throttle body stay <MIVEC>
Throttle body stay <4G94>
Throttle body
23
24
19
19
24
11
Throttle cable bracket
Stay
Harness bracket
Vacuum hose and pipe assembly <Engine with solenoid valve> (Flange bolt) 11
Vacuum hose and pipe assembly <Engine with solenoid valve> (Bolt and
washer assembly)
9
Vacuum hose and pipe assembly <Engine without solenoid valve>
Solenoid valve assembly
Throttle body and EGR system (GDI)
Air intake resonator
10
9
9
Intake manifold stay (M8)
Intake manifold stay (M10)
Water hose clamp
20
30
13
11
18
24
Water pipe
Throttle body
Throttle body stay
<CARISMA from 2001 model, SPACE STAR from 2001 model, GALANT>
Throttle body stay <For PAJERO io – 4G94>
EGR valve (Bolt and washer assembly)
EGR valve (Flange bolt)
18
18
24
18
18
23
9
Engine hanger
EGR valve support bolt
EGR valve support nut
Air by-pass valve
Mitsubishi Motors Corporation
Jun.2002
PWEE9502-K
Revised
E
11A-1-6a
4G9 ENGINE (E–W) – Specifications
Items
Nm
Intake manifold and exhaust manifold
Exhaust manifold (M8)
18
29
19
35
98
12
19
14
5
Exhaust manifold (M10)
Exhaust manifold bracket (M8)
Exhaust manifold bracket (M10 Bolt and washer assembly)
Exhaust manifold bracket (M10 Flange bolt)
Engine hanger (Bolt with head mark “4”)
Engine hanger (Bolt with head mark “7”)
Oil level gauge guide
Boost sensor
Intake air temperature sensor
Heat protector
13
13
20
31
44
Intake manifold
Intake manifold stay
Oxygen sensor
Intake manifold (GDI)
Vacuum pipe and hose <Except for PAJERO io>
Vacuum pipe and hose <For PAJERO io>
Solenoid valve
11
9
9
Fuel pump protector
23
11
11
9
Connector bracket
Branch tube (M6 x 14)
Branch tube (M6 x 18)
Intake manifold stay
30
9
Accelerator cable bracket
Vacuum pipe
11
19
Intake manifold
Exhaust manifold (GDI)
Oil level gauge guide
13
13
24
18
29
18
35
19
35
98
Exhaust manifold cover
Engine hanger bolt
Engine hanger nut (M8)
Engine hanger nut (M10)
Exhaust manifold bracket (M8 × 20)
Exhaust manifold bracket (M8 × 22)
Exhaust manifold bracket (M8 × 25)
Exhaust manifold bracket (M10)
Exhaust manifold bracket <For PAJERO io>
Mitsubishi Motors Corporation
Jun. 2002
PWEE9502-K
Revised
E
11A-1-6b
4G9 ENGINE (E–W) – Specifications
Items
Nm
17
Exhaust manifold (M8)
Exhaust manifold (M10)
29
Injector and fuel pump assembly (GDI)
Fuel low pressure pipe (M6)
Fuel low pressure pipe (M8)
Fuel nipple
18
9
9
Clamp
9
Fuel feed pipe
11
17
11
11
11
9
Fuel pump
Harness bracket
Fuel pipe
Fuel return pipe
Fuel return pipe clamp
Fuel high pressure regulator
Fuel pressure sensor <Except for PAJERO io>
Fuel pressure sensor <For PAJERO io>
Spacer
18
23
18
18
23
22
11
Pump camshaft case
Injector holder
Delivery pipe and injector
Intake and exhaust manifold <4G94–GDI for PAJERO io>
Vacuum pipe and hose
Solenoid valve
9
9
Fuel pump protector
Connector bracket
23
11
29
31
9
Intake manifold stay nut
Intake manifold stay bolt
Low pressure fuel pipe
Intake manifold
20
13
18
98
17
29
Exhaust manifold cover
Engine hanger
Exhaust manifold bracket
Exhaust manifold (M8)
Exhaust manifold (M10)
Water pump and water hose
Water pump
24
14
24
Water inlet pipe
Thermostat case
Mitsubishi Motors Corporation
Jun. 2002
PWEE9502-K
Revised
E
11A-1-6c
4G9 ENGINE (E–W) – Specifications
Items
Nm
Water inlet fitting <Except PAJERO io>
Water inlet fitting <PAJERO io>
Water by-pass fitting
19
24
24
14
19
24
10
29
24
Water pipe
Water outlet fitting <Except PAJERO io>
Water outlet fitting <PAJERO io>
Engine coolant temperature gauge unit
Engine coolant temperature sensor
Water fitting
Rocker arms and camshaft
Lock nut
9
Rocker arm shaft
31
10
3.5
11
24
11
21
Harness bracket
Rocker cover
Bearing cap bolt (M6)
Bearing cap bolt (M8)
Beam camshaft cap (M6)
Beam camshaft cap (M8)
Rocker cover and camshafts (MIVEC)
Rocker cover
4
Oil pump
11
11
11
23
9
Arm spring holder
Camshaft bearing cap (M6)
Camshaft bearing cap (M8)
Oil control valve
Rocker arms and rocker shaft caps (MIVEC)
Rocker shaft cap
11
Cylinder head and valves
CylInder head bolt
74 Nm and then completely loosen,
finally tighten 20 Nm + 90_ + 90_
Oil pressure switch
Front case and oil pump
Oil pump cover
Oil pump case
Relief plug
10
10
14
44
19
9
Oil screen
Oil pan
Upper oil pan (M6)
9
Mitsubishi Motors Corporation
Jun. 2002
PWEE9502-K
Revised
E
11A-1-6d
4G9 ENGINE (E–W) – Specifications
Items
Nm
Upper oil pan (M8)
Lower oil pan
24
11
7
Cover
Baffle plate <DOHC–MPI>
7
Baffle plate <Except DOHC–MPI>
Drain plug
11
39
10
23
Oil pressure switch
Transmission stay
Piston and connecting rod
Connecting rod cap nut
Crankshaft, cylinder block, flywheel and drive plate
Bearing cap bolt
20 + 90_ to 100_
25 + 90_ to 100_
11
10
9
Oil seal case
Bell housing cover (Flange bolt)
Bell housing cover (Bolt and washer assembly)
Rear plate <SPACE STAR>
Rear plate <Except SPACE STAR>
Drive plate bolt
10
11
98
98
9
Flywheel bolt
Baffle plate
Knock sensor
23
Mitsubishi Motors Corporation
Jun. 2002
PWEE9502-K
Revised
E
11A-1-7
4G9 ENGINE (E-W) - Specifications
NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC
AREA
A new type of bolts, to be tightened in plastic area, is currently used for some parts of the engine.
The tightening method for bolts of this type is different from the conventional one. Be sure to observe
the method described in the text when tightening the bolts.
Service limits are provided for the bolts. Make sure that the service limits described in the text are strictly
observed.
D
Areas where the bolts are in use:
(1) Cylinder head bolts
(2) Main bearing cap bolts
(3) Connecting rod cap bolts
D
Tightening method
After tightening the bolts to the specified torque, tighten them another 90_ or 180_ (twice 90_). The
tightening method varies on different areas. Observe the tightening method described in the text.
SEALANT
Items
Specified sealant
Quantity
Water pump
Mitsubishi Genuine Part No.MD970389 or equivalent As required
Mitsubishi Genuine Part No.MD970389 or equivalent As required
Mitsubishi Genuine Part No.MD970389 or equivalent As required
Mitsubishi Genuine Part No.MD970389 or equivalent As required
Thermostat case
Water by-pass fitting
Water fitting
Engine coolant temperature sensor
3M Nut Locking Part No.4171 or equivalent
As required
As required
As required
As required
As required
Engine coolant temperature gauge unit 3M ATD Part No.8660 or equivalent
Camshaft bearing cap
Semi-circular packing
Rocker cover
3M ATD Part No.8660 or equivalent
3M ATD Part No.8660 or equivalent
3M ATD Part No.8660 or equivalent
Beam camshaft cap
Cover
Mitsubishi Genuine Part No.MD970389 or equivalent As required
3M ATD Part No.8660 or equivalent As required
Mitsubishi Genuine Part No.MD970389 or equivalent As required
3M ATD Part No.8660 or equivalent As required
Cylinder head
Oil pressure switch
Water outlet fitting
Oil pump case
Mitsubishi Genuine Part No.MD970389 or equivalent As required
Mitsubishi Genuine Part No.MD970389 or equivalent As required
Mitsubishi Genuine Part No.MD970389 or equivalent As required
Mitsubishi Genuine Part No.MD970389 or equivalent As required
Oil pan/Upper oil pan/Lower oil pan
Oil seal case
Drive plate bolt
3M Nut Locking Part No.4171 or equivalent
3M Nut Locking Part No.4171 or equivalent
As required
As required
Flywheel bolt
Cam position sensor support
Oil control valve
Mitsubishi Genuine Part No.MD970389 or equivalent As required
3M ATD Part No.8660 or equivalent
3M ATD Part No.8660 or equivalent
As required
As required
Camshaft holder
Mitsubishi Motors Corporation
July 2000
PWEE9502-H
Revised
E
11A-1-8
4G9 ENGINE (E-W) - Specifications
FORM-IN-PLACE GASKET
The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket
fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead
size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick
a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the
fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to
apply the gasket evenly without a break, while observing the correct bead size.
The FIPG used in the engine is a room temperature vulcanization (RTV) type and is supplied in a 100-gram
tube (Part No. MD970389 or MD997110). Since the RTV hardens as it reacts with the moisture in the
atomospheric air, it is normally used in the metallic flange areas. The FIPG, Part No. MD970389, can
be used for sealing both engine oil and coolant, while Part No. 997110 can only be used for engine
oil sealing.
Disassembly
The parts assembled with the FIPG can be easily disassembled without use of a special method. In
some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking
with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the
joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.
For removal of the oil pan, the special tool “Oil Pan Remover” (MD998727) is available. Be sure to use
the special tool to remove the oil pan. <Except aluminium die-cast oil pans>
Surface Preparation
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure
that there are no oils, greases and foreign substances deposited on the application surfaces. Do not
forget to remove the old sealant remained in the bolt holes.
Form-In-Place Gasket Application
When assembling parts with the FIPG, you must observe some precautions, but the procedures is very
simple as in the case of a conventional precut gasket.
Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the
bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is
hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When
the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do
not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time
(about one hour) has passed after installation is completed.
The FIPG application procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.
Mitsubishi Motors Corporation
May 1995
PWEE9502
E
11A-2-1
4G9 ENGINE (E-W) - Special Tools
2. SPECIAL TOOLS
Tool
Number
Name
Use
MB990938
MB990767
MD998440
MD998442
MD998713
MD998716
MD998717
MB991653
MB991659
Handle
Use with MD998776
Crankshaft pulley Holding camshaft sprocket when loosening
holder
and tightening of bolt.
Use with MD998719
Leak-down tester
Leak-down test of lash adjuster
Air bleeding of lash adjuster
Air bleed wire
Camshaft oil seal Installation of camshaft oil seal
installer
Crankshaft wrench Rotation of crankshaft when installing piston
and timing belt.
Crankshaft front oil Installation of crankshaft front oil seal
seal installer
Cylinder head bolt Tightening and loosening of cylinder head bolt
wrench
Guide D
Removal of piston pin (Use with MD998780)
Mitsubishi Motors Corporation
Nov. 1995
PWEE9502-A
Revised
E
11A-2-2
4G9 ENGINE (E-W) - Special Tools
Tool
Number
Name
Use
MD998719
Pulley holder pin Use with MB990767
(2)
MD998727
MD998754
MD998767
MD998772
MD998774
MD998775
MD998776
Oil pan remover
Removal of the oil pan
Pin
Use with MB990767
Tensioner pulley
socket wrench
Adjustment of timing belt tension
Valve spring
compressor
Removal and installation of valve and related
parts
Valve stem seal Installation of valve stem seal
installer
Valve stem seal Installation of valve stem seal
installer
Crankshaft rear oil Installation of crankshaft rear oil seal
seal installer
Use with MB990938
Revised
Mitsubishi Motors Corporation
Nov. 1995
PWEE9502-A
E
11A-2-3
4G9 ENGINE (E-W) - Special Tools
Tool
Number
Name
Use
MD998780
SETTING TOOL
Piston pin
Removal and installation of piston pin
MD998735
MD998781
MB991477
MB991478
MB991479
MD998784
Valve spring
compressor
Compression of valve spring
Flywheel stopper
Holding flywheel and drive plate
Valve adjusting
wrench
Adjustment of valve clearance (MIVEC)
Adjustment of valve clearance (MIVEC)
Adjustment of valve clearance (MIVEC)
Valve adjusting
wrench feeler
gauge set
Rocker arm
piston checker
Valve spring
compressor
adapter
Compression of valve spring (MIVEC)
(Use with MD998772)
Mitsubishi Motors Corporation
Nov. 1995
PWEE9502-A
Revised
E
11A-3-1
4G9 ENGINE (E–W) – Alternator and Ignition System
3. ALTERNATOR AND IGNITION SYSTEM
REMOVAL AND INSTALLATION <SOHC> (Engines with distributor)
7
12 Nm
25 Nm
8
9
5 Nm
23 Nm
2
3
10
44 Nm
23 Nm
49 Nm
21 Nm
13
12
1
44 Nm
49 Nm
6
11
44 Nm
4
5
25 Nm
182 ± 4 Nm
Removal steps
1. Drive belt*
2. Alternator
3. Alternator brace
8. Spark plug
9. O-ring
10. Distributor
AA" "BA 4. Crankshaft bolt
"BA 5. Crankshaft pulley
"BA 6. Front flange
7. Spark plug cable
11. Power steering pump pulley
12. Power steering pump bracket stay
13. Power steering pump bracket
NOTE:
*: For details of adjustment, refer to the relevant model’s
chassis workshop manual.
Mitsubishi Motors Corporation
Apr. 2002
PWEE9502-J
Revised
E
11A-3-2
4G9 ENGINE (E–W) – Alternator and Ignition System
REMOVAL AND INSTALLATION <SOHC for other than PAJERO io>
(Engines without distributor)
7
10 Nm
11
12
9 Nm
13 Nm
8
9
25 Nm
10
5 Nm
2
13
21 Nm
5 Nm
23 Nm
3
44 Nm
23 Nm
21 Nm
49 Nm
16
15
1
49 Nm
6
44 Nm
4
5
44 Nm
25 Nm
14
182 ± 4 Nm
Removal steps
1. Drive belt*
11. Cam position sensor
2. Alternator
"AA 12. Cam position sensor support
13. Cam position sensing cylinder
14. Power steering pump pulley
3. Alternator brace
AA" "BA 4. Crankshaft bolt
"BA 5. Crankshaft pulley
"BA 6. Front flange
7. Spark plug cable
15. Power steering pump bracket stay
16. Power steering pump bracket
NOTE:
8. Ignition coil
9. Spark plug
10. Ignition failure sensor (From 2001
model vehicles for Europe)
*: For details of adjustment, refer to the relevant model’s
chassis workshop manual.
Mitsubishi Motors Corporation
Apr. 2002
PWEE9502-J
Revised
E
11A-3-2a
4G9 ENGINE (E–W) – Alternator and Ignition System
REMOVAL AND INSTALLATION <SOHC for PAJERO io>
(Engines without distributor)
5 Nm
10 Nm
10
11
Removal steps
1. Drive belt*
10. Ignition failure sensor (For Europe)
11. Ignition failure sensor bracket
(For Europe)
2. Alternator
3. Alternator brace
AA" "BA 4. Crankshaft bolt
"BA 5. Crankshaft pulley
"BA 6. Front flange
7. Spark plug cable
12. Cam position sensor
"AA 13. Cam position sensor support
14. Cam position sensing cylinder
15. Power steering pump pulley
16. Power steering pump bracket stay
17. Power steering pump bracket
8. Ignition coil
9. Spark plug
NOTE
*: For details of adjustment, refer to the relevant model’s
chassis workshop manual.
Mitsubishi Motors Corporation
Jun. 2002
PWEE9502-K
Revised
E
11A-3-2b
4G9 ENGINE (E-W) - Alternator and Ignition System
Intentionally blank
Mitsubishi Motors Corporation
Dec. 1998
PWEE9502-E
Added
E
11A-3-3
4G9 ENGINE (E–W) – Alternator and Ignition System
REMOVAL AND INSTALLATION <DOHC>
7
3 Nm
10 Nm
9
8
25 Nm
10
11
5 Nm
23 Nm
23 Nm
2
3
44 Nm
21 Nm
23 Nm
6
29 Nm
5
14
13
182 ± 4 Nm
1
4
44 Nm
49 Nm
44 Nm
25 Nm
12
Removal steps
1. Drive belt*
2. Alternator
3. Alternator brace
9. Spark plug cable
10. Spark plug
11. Ignition failure sensor
AA" "BA 4. Crankshaft bolt
"BA 5. Crankshaft pulley
"BA 6. Front flange
7. Center cover
12. Power steering pump pulley
13. Power steering pump bracket stay
14. Power steering pump bracket
NOTE:
8. Ignition coil
*: For details of adjustment, refer to the relevant model’s
chassis workshop manual.
E Mitsubishi Motors Corporation
E
Apr. 2002
PWEE9502-J
Revised
11A-3-4
4G9 ENGINE (E–W) – Alternator and Ignition System
REMOVAL AND INSTALLATION <DOHC–MIVEC>
7
3 Nm
10 Nm
9 Nm
8
11
13 Nm
9
25 Nm
10
5 Nm
12
2
23 Nm
21 Nm
3
13
44 Nm
21 Nm
23 Nm
6
49 Nm
5
182 ± 4 Nm
16
15
1
4
44 Nm
49 Nm
44 Nm
25 Nm
14
Removal steps
1. Drive belt*
10. Spark plug
11. Cam position sensor
"AA 12. Cam position sensor support
13. Cam position sensing cylinder
14. Power steering pump pulley
2. Alternator
3. Alternator brace
AA" "BA 4. Crankshaft bolt
"BA 5. Crankshaft pulley
"BA 6. Front flange
7. Center cover
15. Power steering pump bracket stay
16. Power steering pump bracket
8. Spark plug cable
9. Ignition coil
NOTE:
*: For details of adjustment, refer to the relevant model’s
chassis workshop manual.
E Mitsubishi Motors Corporation
E
Apr. 2002
PWEE9502-J
Revised
11A-3-5
4G9 ENGINE (E–W) – Alternator and Ignition System
REMOVAL AND INSTALLATION
<DOHC–GDI for CARISMA, SPACE STAR, SPACE RUNNER, GALANT>
2.9 Nm
7
14
11
5 Nm
9 Nm
10 Nm
9
8
25 Nm
10
12
13
2
13 Nm
21 Nm
5 Nm
23 Nm
3
44 Nm
21 Nm
23 Nm
6
5
49 Nm
17
16
1
44 Nm
49 Nm
4
44 Nm
15
182 ± 4 Nm
25 Nm
Removal steps
1. Drive belt*
2. Alternator
11. Cam position sensor
"AA 12. Cam position sensor support
13. Cam position sensing cylinder
14. Ignition failure sensor (From 2001
model for CARISMA, From 2001
model for SPACE STAR)
3. Alternator brace
AA" "BA 4. Crankshaft bolt
"BA 5. Crankshaft pulley
"BA 6. Front flange
7. Engine cover
15. Power steering pump pulley
16. Power steering pump bracket stay
17. Power steering pump bracket
8. Earth strap (From 2001 model for
CARISMA, From 2001 model for
SPACE STAR)
9. Ignition coil
10. Spark plug
NOTE:
*: For details of adjustment, refer to the relevant model’s
chassis workshop manual.
E Mitsubishi Motors Corporation
E
Apr. 2002
PWEE9502-J
Revised
11A-3-6
4G9 ENGINE (E–W) – Alternator and Ignition System
REMOVAL AND INSTALLATION <DOHC–GDI for PAJERO io>
10 Nm
13
9 Nm
25 Nm
14
13 Nm
17
16
21 Nm
5 Nm
23 Nm
5
1
6
13 Nm
3
2
3
44 Nm
23 Nm
44 Nm
9
8
182 ± 4 Nm
21 Nm
4
11
7
12
49 Nm
44 Nm
44 Nm
10
25 Nm
Removal steps
1. Oil level gauge
10. Power steering pump pulley
11. Power steering pump bracket stay
12. Power steering pump bracket
13. Ignition coil
2. Oil level gauge guide
3. O-ring
4. Drive belt*
5. Alternator
14. Spark plug
6. Alternator brace
15. Cam position sensor
AA" "BA 7. Crankshaft bolt
"BA 8. Crankshaft pulley
"BA 9. Front flange
"AA 16. Cam position sensor support
17. Cam position sensing cylinder
NOTE:
*: For details of adjustment, refer to the relevant model’s
chassis workshop manual.
E Mitsubishi Motors Corporation
E
Mar. 2001
PWEE9502-I
Revised
11A-3-7
4G9 ENGINE (E–W) – Alternator and Ignition System
REMOVAL SERVICE POINT
AA" CRANKSHAFT BOLT REMOVAL
M
(1) Use the special tool to hold the flywheel or the drive
plate, and then loosen the crankshaft mounting bolts.
INSTALLATION SERVICE POINTS
"AA CAM POSITION SENSOR SUPPORT
INSTALLATION
(1) Apply a 3 mm bead of form-in-place gasket (FIPG) to
the area shown.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or
equivalent.
"BA FRONT FLANGE / CRANKSHAFT PULLEY /
CRANKSHAFT BOLT INSTALLATION
M
(1) Use the special tool to hold the flywheel or the drive
plate.
(2) Clean and then degrease the front flange contacting
surface of the crankshaft pulley.
NOTE
Degreasing is necessary to prevent decrease in the friction
between contacting surfaces.
(3) Clean the bolt hole in the crankshaft, the crankshaft
contacting surface and washer contacting surface of the
crankshaft pulley, and the washer.
(4) Apply an appropriately small amount of oil to the threads
and seating surface of the crankshaft bolt.
(5) Tighten the crankshaft bolt to the specified torque of 182
± 4 Nm.
Washer
Bigchamferedside
E Mitsubishi Motors Corporation
E
Jun. 2002
PWEE9502-K
Revised
11A-4-1
4G9 ENGINE (E–W) – Timing Belt
4. TIMING BELT
REMOVAL AND INSTALLATION <SOHC for CARISMA (Up to 1999 model),
LANCER (Except from 2001 model for Europe), GALANT>
Removal steps
1. Timing belt front upper cover
2. Timing belt front lower cover
3. Engine support bracket, right
8. Crankshaft angle sensor
(Engines without distributor)
"GA 9. Crankshaft sprocket
AA" "DA 4. Timing belt
"GA 10. Crankshaft spacer
"CA 5. Tensioner spring
"BA 6. Timing belt tensioner
7. Timing belt rear cover
(Engines without distributor)
"GA 11. Crankshaft sensing blade
(Engines without distributor)
12. Crankshaft key
AB" "AA 13. Camshaft sprocket bolt
14. Camshaft sprocket
Mitsubishi Motors Corporation
Mar. 2001
PWEE9502-I
Revised
E
11A-4-1a
4G9 ENGINE (E–W) – Timing Belt
REMOVAL AND INSTALLATION
<SOHC for CARISMA (From 2000 model), LANCER (From 2001 model for
Europe), SPACE STAR>
Removal steps
1. Timing belt front upper cover
2. Timing belt front lower cover
3. Engine support bracket, right
"GA 9. Crankshaft sprocket
"GA 10. Crankshaft spacer
(Engines without distributor)
AA" "DA 4. Timing belt
"CA 5. Tensioner spring
"BA 6. Timing belt tensioner
7. Timing belt rear cover
"GA 11. Crankshaft sensing blade
(Engines without distributor)
12. Crankshaft key
AB" "AA 13. Camshaft sprocket bolt
8. Crankshaft angle sensor
(Engines without distributor)
14. Camshaft sprocket
Mitsubishi Motors Corporation
Apr. 2002
PWEE9502-J
Revised
E
11A-4-1b
4G9 ENGINE (E-W) - Timing Belt
Intentionallyblank
Mitsubishi Motors Corporation
May 2000
PWEE9502-G
Added
E
11A-4-2
4G9 ENGINE (E–W) – Timing Belt
REMOVAL AND INSTALLATION <SOHC for PAJERO io>
88 Nm
14
13
11 Nm
1
11 Nm
23 Nm
7
6
5
8
3
10
9.8 Nm
12
11
9
4
49 Nm
2
Removal steps
1. Timing belt front upper cover
2. Timing belt front lower cover
3. Accessory mount
8. Crankshaft angle sensor
"GA 9. Crankshaft sprocket
"GA 10. Crankshaft spacer
"GA 11. Crankshaft sensing blade
12. Crankshaft key
AA" "DA 4. Timing belt
"CA 5. Tensioner spring
"BA 6. Timing belt tensioner
7. Timing belt rear cover
AB" "AA 13. Camshaft sprocket bolt
14. Camshaft sprocket
Mitsubishi Motors Corporation
Mar. 2001
PWEE9502-I
Revised
E
11A-4-2a
4G9 ENGINE (E–W) – Timing Belt
REMOVAL AND INSTALLATION <DOHC>
Removal steps
1. Timing belt upper cover
2. Timing belt lower cover
3. Engine support bracket
11. Cam position sensor
12. Crankshaft angle sensor
"GA 13. Crankshaft sprocket
"GA 14. Crankshaft spacer
"GA 15. Crankshaft sensing blade
16. Crankshaft sprocket key
AA" "FA 4. Timing belt
5. Tensioner pulley
6. Tensioner arm
7. Shaft
AB" "AA 17. Camshaft sprocket bolt
"EA 8. Auto-tensioner
9. Timing belt rear cover
10. Idler pulley
18. Camshaft sprocket
19. Timing belt rear cover
20. Timing belt rear cover
Mitsubishi Motors Corporation
Mar. 2001
PWEE9502-I
Revised
E
11A-4-2b
4G9 ENGINE (E–W) – Timing Belt
REMOVAL AND INSTALLATION <DOHC–MIVEC>
Removal steps
1. Timing belt front upper cover
2. Timing belt front lower cover
3. Engine support bracket, right
11. Crankshaft angle sensor
"GA 12. Crankshaft sprocket
"GA 13. Crankshaft spacer
"GA 14. Crankshaft sensing blade
15. Crankshaft key
AA" "FA 4. Timing belt
5. Tensioner pulley
6. Tensioner arm
7. Shaft
AB" "AA 16. Camshaft sprocket bolt
17. Camshaft sprocket
"EA 8. Auto tensioner
18. Timing belt rear cover
9. Timing belt rear cover
19. Timing belt rear cover
10. Idler pulley
Mitsubishi Motors Corporation
Mar. 2001
PWEE9502-I
Revised
E
11A-4-2c
4G9 ENGINE (E–W) – Timing Belt
REMOVAL AND INSTALLATION
<DOHC–GDI for CARISMA, SPACE STAR, SPACE RUNNER>
21
11 Nm
11 Nm
19
4
88 Nm
18
10
17
11 Nm
1
7
5
6
48 Nm
11 Nm
35 Nm
14
16
15
48 Nm
13
12
9
20
8
3
11 Nm
11
13 Nm
12
9.8 Nm
49 Nm
2
9.8 Nm
Removal steps
1. Timing belt front upper cover
2. Timing belt front lower cover
3. Engine support bracket, right
"GA 13. Crankshaft sprocket
"GA 14. Crankshaft spacer
"GA 15. Crankshaft sensing blade
AA" "FA 4. Timing belt
16. Crankshaft key
5. Tensioner pulley
6. Tensioner arm
AB" "AA 17. Camshaft sprocket bolt
18. Camshaft sprocket
7. Shaft
19. Timing belt rear cover
(Up to 2000 model)
"EA 8. Auto tensioner
9. Timing belt rear cover
10. Idler pulley
20. Timing belt rear cover
(Up to 2000 model)
11. Crankshaft angle sensor
(Up to 1999 model)
12. Crankshaft angle sensor
(From 2000 model)
21. Timing belt rear upper cover
(From 2001 model)
Mitsubishi Motors Corporation
Mar. 2001
PWEE9502-I
Revised
E
11A-4-2d
4G9 ENGINE (E–W) – Timing Belt
REMOVAL AND INSTALLATION <DOHC–GDI for GALANT>
18
11 Nm
4
88 Nm
17
16
11 Nm
7
1
5
10
6
48 Nm
35 Nm
13
15
14
48 Nm
12
9
3
8
11 Nm
11
49 Nm
13 Nm
9.8 Nm
2
Removal steps
1. Timing belt front upper cover
2. Timing belt front lower cover
3. Engine support bracket, right
10. Idler pulley
11. Crankshaft angle sensor
"GA 12. Crankshaft sprocket
"GA 13. Crankshaft spacer
"GA 14. Crankshaft sensing blade
15. Crankshaft key
AA" "FA 4. Timing belt
5. Tensioner pulley
6. Tensioner arm
7. Shaft
AB" "AA 16. Camshaft sprocket bolt
"EA 8. Auto tensioner
9. Timing belt rear cover
17. Camshaft sprocket
18. Timing belt rear upper cover
Mitsubishi Motors Corporation
Mar. 2001
PWEE9502-I
Revised
E
11A-4-2e
4G9 ENGINE (E–W) – Timing Belt
REMOVAL AND INSTALLATION <DOHC–GDI for PAJERO io>
21
11 Nm
Removal steps
1. Timing belt front upper cover
2. Timing belt front lower cover
3. Accesory mount
11. Bracket
12. Crankshaft angle sensor
"GA 13. Crankshaft sprocket
"GA 14. Crankshaft spacer
"GA 15. Crankshaft sensing blade
16. Crankshaft key
AA" "FA 4. Timing belt
5. Tensioner pulley
6. Tensioner arm
7. Shaft
AB" "AA 17. Camshaft sprocket bolt
"EA 8. Auto tensioner
18. Camshaft sprocket
9. Timing belt rear cover
19. Timing belt rear cover <4G93>
20. Timing belt rear cover <4G93>
21. Timing belt rear upper cover
<4G94>
10. Idler pulley
Mitsubishi Motors Corporation
Mar. 2001
PWEE9502-I
Revised
E
11A-4-2f
4G9 ENGINE (E-W) - Timing Belt
Intentionallyblank
Mitsubishi Motors Corporation
May 2000
PWEE9502-G
Added
E
11A-4-3
4G9 ENGINE (E-W) - Timing Belt
REMOVAL SERVICE POINTS
AA" TIMING BELT REMOVAL
(1) Mark belt running direction for reinstallation.
AB" CAMSHAFT SPROCKET BOLT REMOVAL
MB990767
MD998719
or
MD998754
<With rocker cover removed> (Except SOHC)
(1) Use a wrench to hold the hexagonal part of the camshaft,
and then remove the camshaft sprocket mounting bolt.
INSTALLATION SERVICE POINTS
MB990767
"AA CAMSHAFT SPROCKET BOLT INSTALLATION
MD998719
or
MD998754
Mitsubishi Motors Corporation
Nov. 1995
PWEE9502-A
Revised
E
11A-4-4
4G9 ENGINE (E-W) - Timing belt
"BA TIMING BELT TENSIONER INSTALLATION
(1) Let the pulley of the timing belt tensioner comr closest
to the exhaust side. Temporarily tighten the tensioner
pulley fixing bolt.
Exhaust
side
Tensioner
pulley fixing
bolt
"CA TENSIONER SPRING INSTALLATION
Tensioner
“B”
(1) Insert the tip A (shorter one) of the tensioner spring into
the oil pump case.
(2) Use pliers or similar tool to pinch the tip B (longer one),
and then hook it to the tensioner bracket arm.
“A”
Pliers
"DA TIMING BELT INSTALLATION
(1) Turn the crankshaft sprocket by three teeth from the timing
mark.
Caution
Aligning the timing marks positions the piston to the
top dead centre. Then, if the camshaft turns, the valves
may hit and damage the pistons.
(2) Check that the timing belt tensioner and tensioner spring
are installed correctly. (Refer to the service points B and
C.)
(3) Align the timing marks on the camshaft sprocket to that
on the cylinder head.
Timing mark
(4) Align the timing mark on the crankshaft sprocket to that
on the oil pump case.
Timing marks
(5) Place the timing belt over the sprocket according in the
following order.
1. Crankshaft sprocket
2. Water pump sprocket
3. Camshaft sprocket
4. Tension pulley
Mitsubishi Motors Corporation
May 1995
PWEE9502
E
11A-4-5
4G9 ENGINE (E-W) - Timing Belt
(6) Slightly loosen the tensioner pulley fixing bolt which is
tightened temporarily to tighten the belt by a force of
the tensioner spring.
(7) Turn the crankshaft clockwise by two turns.
(8) Check that the timing marks are aligned.
(9) Tighten the fixing bolt of the tensioner pulley.
MD998716
"EA AUTO-TENSIONER INSTALLATION
Set hole (A)
(1) If the auto-tensioner rod is fully extended, set it in the
retracted position with the following procedure.
1) Hold the auto-tensioner in a vice, being careful not
to tilt it.
Set hole (B)
2) Slowly close the vice to force the rod in to align hole
(A) of the rod with the set hole (B).
3) Insert a 2.0-mm-Allen key in diameter or similar into
the set holes.
4) Remove the auto-tensioner from the vice.
(2) Install the auto-tensioner
Leave the align key until installation of the timing belt
is completed.
Mitsubishi Motors Corporation
Nov. 1995
PWEE9502-A
Revised
E
11A-4-6
4G9 ENGINE (E-W) - Timing Belt
"FA TIMING BELT INSTALLATION
Timing marks
(1) Make sure that the auto-tensioner is installed properly.
(Refer to service point F.)
(2) Align the timing mark on each sprocket with the
corresponding mark on the timing belt.
(3) Turn the crankshaft sprocket one half the tooth width
counterclockwise.
Timing mark
(4) Fit the timing belt to the intake camshaft sprocket and
secure with a paper clip at the illustrated position.
Paper clip
(5) Use two wrenches to fit the timing belt to the exhaust
sprocket while aligning the timing marks.
Timing mark
Timing mark
Mitsubishi Motors Corporation
Nov. 1995
PWEE9502-A
Revised
E
11A-4-7
4G9 ENGINE (E-W) - Timing Belt
(6) Secure the timing belt with a paper clip at the illustrated
position.
(7) Fit the belt to the idler pulley water pump sprocket,
crankshaft sprocket and tensioner pulley in that order.
Idler pulley
Water
pump
sprocket
Tensioner
pulley
Crankshaft sprocket
(8) Raise the tensioner pulley in the direction of an arrow
and tighten the tensioner pulley bolt.
(9) Remove the two paper clips.
(10)Make sure that all timing marks are in alignment.
(11)Give a 1/4 counterclockwise turn to the crankshaft. Then
turn the crankshaft clockwise to align the timing marks
again.
Mitsubishi Motors Corporation
May 1995
PWEE9502
E
11A-4-8
4G9 ENGINE (E–W) – Timing Belt
(12)Install the special tool and a torque wrench to the tensioner
pulley.
(13)Using torque wrench, torque to 2.6 Nm.
(14)While holding the tensioner pulley to prevent it from
turning, tighten the center bolt to the specified torque.
(15)Give two clockwise turns to the crankshaft and leave
as it is for approx. 15 minutes.
MD998767
(16)Check if the Allen wrench inserted during installation of
the auto-tensioner can be pulled out lightly. If it can be
pulled out lightly, the belt is properly tensioned. Therefore,
pull out the wrench. The belt is also properly tensioned
if the auto-tensioner projection is of standard value.
Standard value: 3.8 – 4.5 mm
(17)If the wrench cannot be pulled out lightly, repeat the steps
(12) through (15) to obtain appropriate belt tension.
NOTE
Check the tightening torque of the crankshaft bolt always
after rotating the crankshaft counterclockwise using the
crankshaft bolt. Retighten the bolt if the tightening torque
is not up to specification.
"GACRANKSHAFT SENSING BLADE / CRANKSHAFT
SPACER / CRANKSHAFT SPROCKET
INSTALLATION
Crankshaft
sprocket
Crankshaft sensing blade
(1) Clean and then degrease the following surfaces and parts:
front surface of oil pump case, sprocket mounting surface
of crankshaft, crankshaft spacer, crankshaft sensing
blade, and crankshaft sprocket.
Crankshaft
Crankshaft spacer
NOTE
Degreasing is necessary to prevent decrease in the friction
between contacting surfaces.
Degrease
(2) Clean the crankshaft contacting surface of the crankshaft
sprocket.
Clean
Oil pump case
INSPECTION
11300200077
TIMING BELT
Replace belt if any of the following conditions exist.
(1) Hardening of back rubber.
Back side is glossy without resilience and leaves no indent
when pressed with fingernail.
(2) Cracks on rubber back.
(3) Cracks or peeling of canvas.
(4) Cracks on tooth bottom.
(5) Cracks on belt sides.
Mitsubishi Motors Corporation
E
Mar. 2001
PWEE9502-I
Revised
11A-4-9
4G9 ENGINE (E-W) - Timing Belt
(6) Abnormal wear of belt sides. The sides are normal if
they are sharp as if cut by a knife.
Rounded edge
Abnormal wear
(Fluffy strand)
(7) Abnormal wear on teeth.
(8) Missing tooth.
Rubber exposed
Tooth missing
and canvas
fiber exposed
TENSIONER PULLER, IDLER PULLEY
(1) Check the pulley for smooth rotation, excessive play,
abnormal noise. Replace it if necessary.
AUTO-TENSIONER
(1) Check the tensioner for oil leaks. Replace it if necessary.
(2) Check the rod end for wear or damage. Replace the
tensioner if necessary.
(3) Measure the rod projection length. If not within the
standard value, replace the tensioner.
Standard value: 11 mm
11 mm
(4) Press the rod by a force of 98 to 196 N and measure
the rod stroke. If not within the standard value, replace
the tensioner.
98 to 196 N
Stroke
Standard value: 1 mm or less
Mitsubishi Motors Corporation
May 1995
PWEE9502
E
11A-5-1
4G9 ENGINE (E-W) - Fuel and Emission Control System
5. FUEL AND EMISSION CONTROL SYSTEM
REMOVAL AND INSTALLATION <SOHC-CARBURETOR>
18 Nm
17 Nm
21 Nm
8
10
3
4
9
11
5
6
2
7
1
21 Nm
Removal steps
1. Breather tube
2. Fuel hose
3. Fuel hose
4. Fuel pump
5. Gasket
6. Insulator
7. Gasket
8. Carburetor
9. Gasket
10. EGR valve
11. Gasket
Revised
Mitsubishi Motors Corporation
Nov. 1996
PWEE9502-B
E
11A-5-2
4G9 ENGINE (E–W) – Fuel and Emission Control System
REMOVAL AND INSTALLATION <SOHC–MPI for other than PAJERO io>
12 Nm
9 Nm
10
19 Nm
16
17
2
15
13
Engine with solenoid valve Flange 11 Nm
Engine with solenoid valve Washer 9 Nm
12
14
Engine without solenoid valve
10Nm
3
19
21
1
21 Nm
11
7
24 Nm
4
20
6
12 Nm
9
5
8
18
9 Nm
9 Nm
Removal steps
1. Vacuum hose and pipe assembly
2. Throttle body
"AA 13. Injector
14. O-ring
"CA 3. Gasket
15. Grommet
4. Engine hanger (4G94)
16. Delivery pipe
5. Throttle body stay (4G94)
17. Fuel return pipe
6. Vacuum hose
18. Solenoid valve assembly
(Engine with solenoid valve)
19. EGR valve
7. Fuel hose
"BA 8. Fuel pressure regulator
9. O-ring
(Engine with EGR valve)
20. Cover
(Engine without EGR valve)
21. Gasket
10. Delivery pipe and injector
11. Insulator
12. Insulator
Mitsubishi Motors Corporation
Mar. 2001
PWEE9502-I
Revised
E
E
11A-5-3
4G9 ENGINE (E–W) – Fuel and Emission Control System
REMOVAL AND INSTALLATION <SOHC–MPI for PAJERO io>
9 Nm
12 Nm
8
18
24 Nm
19 Nm
17
1
11
6
3
5
11 Nm
14
13
15
2
12
4
22 Nm
9 Nm
20
21
7
19
9
9 Nm
10
9 Nm
Removal steps
1. Stay (From 2002 model)
2. Harness bracket
3. Throttle cable bracket
4. Vacuum hose and pipe assembly
5. Throttle body
12. Insulator
13. Insulator
"AA 14. Injector
15. O-ring
16. Grommet
"CA 6. Gasket
17. Delivery pipe
7. Vacuum hose
8. Fuel hose
18. Fuel return pipe
19. Solenoid valve assembly
20. EGR valve
"BA 9. Fuel pressure regulator
10. O-ring
21. Gasket
11. Delivery pipe and injector
Revised
E Mitsubishi Motors Corporation
E
Jun. 2002
PWEE9502-K
11A-5-4
4G9 ENGINE (E–W) – Fuel and Emission Control System
REMOVAL AND INSTALLATION <DOHC>
9 Nm
Removal steps
1. Vacuum pipe assembly
2. Throttle body assembly
"CA 3. Gasket
10. Insulator
11. Insulator
"AA 12. Injector
4. Throttle body stay (MIVEC)
5. Vacuum hose
13. O-ring
14. Grommet
15. Delivery pipe
16. Fuel return pipe
17. Solenoid valve
6. Fuel hose
"BA 7. Fuel pressure regulator
8. O-ring
9. Delivery pipe and injector
E Mitsubishi Motors Corporation
E
Jun. 2002
PWEE9502-K
Revised
11A-5-5
4G9 ENGINE (E-W) - Fuel and Emission Control System
INSTALLATION SERVICE POINTS
"AA INJECTORS INSTALLATION
(1) Apply a small amount of new engine oil to the O-ring.
Caution
Be sure not to let engine oil get into the delivery
pipe.
(2) While turning the injector to the left and right, install it
to the delivery pipe.
(3) Check that the injector turns smoothly. If it does not turn
smoothly, the O-ring may be trapped. Remove the injector
and check the O-ring for damage, and then re-insert it
into the delivery pipe and check once again.
(4) Check that the clearance between the injector connector
and the delivery pipe is uniform (A = B).
Injector connector
A
B
Delivery pipe
"BA FUEL PRESSURE REGULATOR INSTALLATION
(1) Apply a small amount of new engine oil to the O-ring.
Insert the fuel pressure regulator into the delivery pipe
being careful not to damage the O-ring.
Caution
Be sure not to let engine oil get into the delivery
pipe.
(2) Check that the fuel pressure regulator turns smoothly.
If it does not turn smoothly, the O-ring may be trapped.
Remove the fuel pressure regulator and check the O-ring
for damage, and then re-insert it into the delivery pipe
and check once again.
<SOHC-MPI for other
than PAJERO io>
Projection
"CA GASKET INSTALLATION
(1) Position the projection as shown in the illustration.
Mitsubishi Motors Corporation
Dec. 1998
PWEE9502-E
Added
E
11A-5-6
4G9 ENGINE (E-W) - Fuel and Emission Control System
<SOHC-MPI
for PAJERO io>
Projection
Mitsubishi Motors Corporation
Dec. 1998
PWEE9502-E
Added
E
11A-5a-1
4G9 ENGINE (E-W) - Throttle Body and EGR System (GDI)
5a. THROTTLE BODY AND EGR SYSTEM (GDI)
REMOVAL AND INSTALLATION <Up to 2000 model for CARISMA, 1999 model for
SPACE STAR, SPACE RUNNER>
18 Nm
6
7
4
17
15
12
16
18 Nm
18 Nm
3
2
9 Nm
14
13
9 Nm
14
24 Nm
18 Nm
8
11
30 Nm
1
10
5
18 Nm
9
Removal steps
1. Air intake plenum resonator
2. O-ring
12. Engine hanger
13. EGR valve support
14. Gasket
"BA 3. Intake manifold stay
4. Water hose
15. Water hose (Up to 1998 model for
CARISMA, SPACE RUNNER)
16. Air by-pass valve
5. Water hose (Up to 1998 model for
CARISMA, SPACE RUNNER)
6. Throttle body
(Up to 1998 model for CARISMA,
SPACE RUNNER)
17. Air by-pass valve gasket
(Up to 1998 model for CARISMA,
SPACE RUNNER)
"AA 7. Throttle body gasket
8. Ignition harness
9. Water hose
10. EGR valve
11. EGR valve gasket
Mitsubishi Motors Corporation
May 2000
PWEE9502-G
Revised
E
11A-5a-2
4G9 ENGINE (E–W) – Throttle Body and EGR System (GDI)
REMOVAL AND INSTALLATION
<From 2001 model for CARISMA, SPACE STAR and GALANT>
24 Nm
Removal steps
"BA 1. Intake manifold stay (For GALANT)
"AA 7. Throttle body gasket
8. Ignition harness
9. Water hose
2. Water hose
3. Water hose
4. Water hose
5. Throttle body stay
6. Throttle body
10. EGR valve
11. EGR valve support
12. Gasket
Mitsubishi Motors Corporation
Apr. 2003
PWEE9502-L
Revised
E
11A-5a-3
4G9 ENGINE (E-W) - Throttle Body and EGR System (GDI)
REMOVAL AND INSTALLATION <For PAJERO io - 4G93>
1
18 Nm
14
9
18 Nm
13
23 Nm
7
11 Nm
14
11
12
10
13 Nm
3
5
16
15
18 Nm
6
18 Nm
2
8
11 Nm
4
Removal steps
1. Water hose
2. Water hose
3. Water hose
4. Water hose
5. Water hose
9. Throttle body
"AA 10. Throttle body gasket
11. EGR valve
12. EGR valve gasket
13. EGR valve support
14. Gasket
6. Water hose clamp
7. Water pipe
15. Engine hanger
8. Water pipe
Mitsubishi Motors Corporation
July 2000
PWEE9502-H
Revised
E
11A-5a-4
4G9 ENGINE (E-W) - Throttle Body and EGR System (GDI)
REMOVAL AND INSTALLATION <For PAJERO io - 4G94>
1
18 Nm
15
18 Nm
14
23 Nm
18 Nm
11 Nm
14
7
13
9
12
3
10
11
13 Nm
6
16
18 Nm
5
18 Nm
2
8
11 Nm
4
Removal steps
1. Water hose
2. Water hose
3. Water hose
4. Water hose
5. Water hose
6. Water hose clamp
7. Water pipe
8. Water pipe
9. Throttle body stay
10. Throttle body
"AA 11. Throttle body gasket
12. EGR valve
13. EGR valve gasket
14. EGR valve support
15. Gasket
16. Engine hanger
Mitsubishi Motors Corporation
July 2000
PWEE9502-H
Revised
E
11A-5a-5
4G9 ENGINE (E-W) - Throttle Body and EGR System (GDI)
<Up to 2000 model for
INSTALLATION SERVICE POINTS
"AA THROTTLE BODY GASKET
Tab
CARISMA,1999model
for SPACE STAR,
SPACE RUNNER>
<From 2001 model for CARISMA,
From 2001 model for SPACE STAR,
GALANT>
<PAJERO io>
"BA INTAKE MANIFOLD STAY INSTALLATION
<Up to 2000 model>
(1) Tighten the four bolts at the top and bottom of the stay
handtight.
Intake manifold
(2) Check that the stay seating surface is in close contact
with the bosses on the intake manifold and the cylinder
block.
Bolt
(3) Tighten the four bolts to the specified torque.
Intake
manifold
stay
Bolt
Cylinder block
<From 2001 model>
Intakemanifold
Cylinder
block
Bolt
Intake manifold
stay
Bolt
Mitsubishi Motors Corporation
July 2000
PWEE9502-H
Added
E
11A-6-1
4G9 ENGINE (E–W) – Intake and Exhaust Manifold
6. INTAKE AND EXHAUST MANIFOLD
REMOVAL AND INSTALLATION <SOHC–CARBURETOR>
20 Nm
Bolt with head mark “4” 12 Nm
Bolt with head mark “7” 19 Nm
Bolt with head mark “4” 12 Nm
Bolt with head mark “7” 19 Nm
Removal steps
1. Engine hanger
"BA 2. Intake manifold stay
3. Intake manifold
7. O-ring
8. Exhaust manifold cover
9. Engine hanger
4. Intake manifold gasket
5. Oil level gauge
"AA 10. Exhaust manifold bracket A
"AA 11. Exhaust manifold bracket B
12. Exhaust manifold
6. Oil level gauge guide
13. Exhaust manifold gasket
Revised
E Mitsubishi Motors Corporation
E
Mar. 2001
PWEE9502-I
11A-6-2
4G9 ENGINE (E–W) – Intake and Exhaust Manifold
REMOVAL AND INSTALLATION <SOHC–MPI–FRONT WHEEL DRIVE (4G92 and
4G93–Except from 2001 model for Europe)>
Bolt with head mark “4” 12 Nm
Bolt with head mark “7” 19 Nm
20
Bolt with head mark “4” 12 Nm
Bolt with head mark “7” 19 Nm
Removal steps
1. Engine hanger
2. Intake manifold stay
3. Intake manifold
4. Intake manifold gasket
5. Oil level gauge
6. Oil level gauge guide
7. O-ring
8. Exhaust manifold cover
9. Engine hanger
"AA 10. Exhaust manifold bracket A
"AA 11. Exhaust manifold bracket B
12. Exhaust manifold
13. Exhaust manifold gasket
Mar. 2001
PWEE9502-I
Mitsubishi Motors Corporation
Revised
E
E
11A-6-2a
4G9 ENGINE (E–W) – Intake and Exhaust Manifold
REMOVAL AND INSTALLATION <SOHC–MPI–FRONT WHEEL DRIVE (4G92 and
4G93–From 2001 model for Europe)>
3
20 Nm
20 Nm
5
19 Nm
1
6
4
7
14 Nm
8
13
2
44 Nm
30 Nm
18 Nm
13 Nm
31 Nm
12
10
14
19 Nm
19 Nm
9
13 Nm
11
35 Nm
Removal steps
1. Engine hanger
8. Oxygen sensor
9. Engine hanger
2. Intake manifold stay
3. Intake manifold
4. Intake manifold gasket
5. Oil level gauge
6. Oil level gauge guide
7. O-ring
10. Exhaust manifold cover
11. Exhaust manifold bracket B
12. Exhaust manifold
13. Exhaust manifold gasket
14. Exhaust manifold bracket A
Revised
E Mitsubishi Motors Corporation
E
Mar. 2001
PWEE9502-I
11A-6-2b
4G9 ENGINE (E–W) – Intake and Exhaust Manifold
REMOVAL AND INSTALLATION <SOHC–MPI–FRONT WHEEL DRIVE (4G94)>
20 Nm
2
3
20 Nm
4
5
6
14 Nm
12
1
11
29 Nm
18 Nm
31 Nm
10
9
7
8
13 Nm
19 Nm
19 Nm
Removal steps
1. Intake manifold stay
2. Intake manifold
3. Intake manifold gasket
4. Oil level gauge
5. Oil level gauge guide
6. O-ring
7. Exhaust manifold cover
8. Engine hanger
"AA 9. Exhaust manifold bracket A
"AA 10. Exhaust manifold bracket B
11. Exhaust manifold
12. Exhaust manifold gasket
Mar. 2001
PWEE9502-I
Mitsubishi Motors Corporation
Revised
E
E
11A-6-2c
4G9 ENGINE (E–W) – Intake and Exhaust Manifold
REMOVAL AND INSTALLATION
<SOHC–MPI – REAR WHEEL DRIVE (4G93 – Except from 2002 model for
Europe)>
8
20 Nm
13 Nm
7
6
13 Nm
12
4
11
5
9
19 Nm
18 Nm
1
10
31 Nm
35 Nm
29 Nm
2
14 Nm
3
Removal steps
1. Oil level gauge
2. Oil level gauge guide
3. O-ring
4. Engine hanger
5. Intake manifold stay
6. Intake manifold
7. Intake manifold gasket
8. Exhaust manifold cover
9. Engine hanger
"AA 10. Exhaust manifold bracket
11. Exhaust manifold
12. Exhaust manifold gasket
Revised
E Mitsubishi Motors Corporation
E
Jun. 2002
PWEE9502-K
11A-6-2d
4G9 ENGINE (E–W) – Intake and Exhaust Manifold
REMOVAL AND INSTALLATION
<SOHC–MPI – REAR WHEEL DRIVE (4G93 – from 2002 model for Europe)>
1
Removal steps
1. Oil level gauge
2. Oil level gauge guide
3. O-ring
4. Engine hanger
5. Intake manifold stay
6. Intake manifold
7. Intake manifold gasket
8. Exhaust manifold cover
9. Engine hanger
"AA 10. Exhaust manifold bracket
11. Exhaust manifold
12. Exhaust manifold gasket
E Mitsubishi Motors Corporation
E
Jun. 2002
PWEE9502-K
Revised
11A-6-2e
4G9 ENGINE (E–W) – Intake and Exhaust Manifold
REMOVAL AND INSTALLATION <SOHC–MPI – REAR WHEEL DRIVE (4G94)>
98 Nm
Removal steps
1. Oil level gauge
2. Oil level gauge guide
3. O-ring
4. Engine hanger
5. Intake manifold stay
6. Intake manifold
7. Intake manifold gasket
8. Exhaust manifold cover
9. Engine hanger
"AA 10. Exhaust manifold bracket
11. Exhaust manifold
12. Exhaust manifold gasket
Added
E Mitsubishi Motors Corporation
E
Jun. 2002
PWEE9502-K
11A-6-2f
4G9 ENGINE (E–W) – Intake and Exhaust Manifold
Intentionally blank
E Mitsubishi Motors Corporation
E
Jun. 2002
PWEE9502-K
Added
11A-6-3
4G9 ENGINE (E–W) – Intake and Exhaust Manifold
REMOVAL AND INSTALLATION <DOHC>
12Nm
19Nm
Boltwith head mark “4”
Boltwithheadmark“7”
Removal steps
1. Engine hanger
2. Intake manifold stay
3. Intake manifold
4. Intake manifold gasket
5. Oil level gauge
6. Oil level gauge guide
7. O-ring
8. Engine hanger
"AA 9. Exhaust manifold bracket A
"AA 10. Exhaust manifold bracket B
11. Exhaust manifold
12. Exhaust manifold gasket
Mitsubishi Motors Corporation
E
E
Mar. 2001
PWEE9502-I
Revised
11A-6-4
4G9 ENGINE (E–W) – Intake and Exhaust Manifold
INSTALLATION SERVICE POINT
Bracket A
Bracket B
"AA EXHAUST MANIFOLD BRACKET INSTALLATION
<FRONT WHEEL DRIVE>
(1) Install temporarily the exhaust manifold brackets A and
B as shown in the illustration.
(2) Check that both brackets are in close contact with the
bosses, and then tighten fully the bracket mounting bolts.
Exhaust
manifold
<REAR WHEEL DRIVE>
(1) Temporarily install the exhaust manifold bracket as shown
in the illustration.
(2) Verify that the bracket is brought into close contact with
the boss on the exhaust manifold, then tighten the bolts
to the specified torque.
Exhaust
manifold
"BA INTAKE MANIFOLD STAY INSTALLATION
<FRONT WHEEL DRIVE>
Intake
manifold
(1) Check to ensure that the intake manifold stay is in close
contact with the intake manifold and the cylider block
before tightening the respective mounting bolts to the
specified torque.
Intake
manifold
stay
Cylinder block
<REAR WHEEL DRIVE>
(1) Install the intake manifold stay with its “UP” mark directed
toward the intake manifold.
“UP” mark
Revised
E Mitsubishi Motors Corporation
E
Mar. 2001
PWEE9502-I
11A-6a-1
4G9 ENGINE (E-W) - Intake Manifold (GDI)
6a. INTAKE MANIFOLD (GDI)
REMOVAL AND INSTALLATION <Up to 2000 model for CARISMA, 1999 model for
SPACE STAR, SPACE RUNNER>
1
11 Nm
9 Nm
6
9 Nm
8
11 Nm
4
11 Nm
3
2
5
19 Nm
7
9
10
19 Nm
Removal steps
1. Air by-pass hose
5. Connector bracket
(Up to 1998 model for CARISMA,
SPACE RUNNER)
6. Accelerator cable bracket
7. Vacuum hose
2. Vacuum pipe and hose
3. Bracket
4. Solenoid valve
8. Vacuum pipe
9. Intake manifold
10. Intake manifold gasket
Revised
Mitsubishi Motors Corporation
May 2000
PWEE9502-G
E
11A-6a-1a
4G9 ENGINE (E–W) – Intake Manifold (GDI)
REMOVAL AND INSTALLATION
<From 2001 model for CARISMA, SPACE STAR and GALANT>
Removal steps
1. Vacuum pipe and hose
2. Purge hose
3. Solenoid valve
4. Vacuum pipe
5. Intake manifold
E Mitsubishi Motors Corporation
E
Apr. 2003
PWEE9502-L
Revised
11A-6a-1b
4G9 ENGINE (E-W) - Intake Manifold (GDI)
Intentionallyblank
Added
Mitsubishi Motors Corporation
May 2000
PWEE9502-G
E
11A-6a-2
4G9 ENGINE (E-W) - Intake Manifold (GDI)
REMOVAL AND INSTALLATION <For SPACE RUNNER>
1
11 Nm
9 Nm
6
9 Nm
4
3
2
11 Nm
8
11 Nm
5
19 Nm
7
9
10
19 Nm
Removal steps
1. Air by-pass hose
6. Accelerator cable bracket
7. Vacuum hose
2. Vacuum pipe and hose
3. Bracket
8. Vacuum pipe
4. Solenoid valve
5. Connector bracket
9. Intake manifold
10. Intake manifold gasket
Mitsubishi Motors Corporation
Jun. 1998
PWEE9502-D
Added
E
11A-6a-3
4G9 ENGINE (E-W) - Intake Manifold (GDI)
REMOVAL AND INSTALLATION <For PAJERO io>
9 Nm
6
1
4
11 Nm
7
9
9 Nm
9 Nm
3
23 Nm
19 Nm
9 Nm
2
10
11 Nm
5
8
30 Nm
Removal steps
1. P.C.V. hose
6. Branch tube
7. Gasket
2. Vacuum pipe and hose
3. Solenoid valve
"AA 8. Intake manifold stay
4. Fuel pump protector
5. Connector bracket
9. Intake manifold
10. Intake manifold gasket
Mitsubishi Motors Corporation
Dec. 1998
PWEE9502-E
Added
E
11A-6a-4
4G9 ENGINE (E-W) - Intake Manifold (GDI)
INSTALLATION SERVICE POINT
"AA INTAKE MANIFOLD STAY INSTALLATION
Intake
manifold
(1) Check to ensure that the intake manifold stay is in close
contact with the intake manifold and the cylinder block
before tightening the respective mounting bolts to the
specified torque.
Intake
manifold
stay
Cylinder block
Mitsubishi Motors Corporation
Dec. 1998
PWEE9502-E
Added
E
11A-6b-1
4G9 ENGINE (E-W) - Exhaust Manifold (GDI)
6b. EXHAUST MANIFOLD (GDI)
REMOVAL AND INSTALLATION <For CARISMA, SPACE STAR, SPACE RUNNER>
9
8
17 Nm
6
13 Nm
35 Nm
4
29 Nm
18 Nm
5
7
24 Nm
35 Nm
1
18 Nm
13 Nm
2
13 Nm
3
Removal steps
1. Oil level gauge
2. Oil level gauge guide
3. O-ring
4. Exhaust manifold cover
5. Engine hanger
"AA 6. Exhaust manifold bracket A
"AA 7. Exhaust manifold bracket B
8. Exhaust manifold
9. Exhaust manifold gasket
Mitsubishi Motors Corporation
May 2000
PWEE9502-G
Revised
E
11A-6b-1a
REMOVAL AND INSTALLATION <For GALANT>
10
4
9
17 Nm
44 Nm
6
13 Nm
8
29 Nm
5
19 Nm
24 Nm
1
7
13 Nm
11
2
35 Nm
35 Nm
13 Nm
3
Removal steps
1. Oil level gauge
2. Oil level gauge guide
3. O-ring
4. Oxygen sensor
5. Engine hanger
6. Exhaust manifold cover
7. Exhaust manifold bracket B
8. Heat protector
9. Exhaust manifold
10. Exhaust manifold gasket
11. Exhaust manifold bracket A
Mitsubishi Motors Corporation
May 2000
PWEE9502-G
Added
E
11A-6b-1b
4G9 ENGINE (E-W) - Exhaust Manifold (GDI)
Intentionallyblank
Mitsubishi Motors Corporation
May 2000
PWEE9502-G
Added
E
11A-6b-2
4G9 ENGINE (E-W) - Exhaust Manifold (GDI)
REMOVAL AND INSTALLATION <For PAJERO io>
1
13 Nm
5
4
2
18 Nm
29 Nm
3
17 Nm
98 Nm
29 Nm
Removal steps
1. Exhaust manifold cover
2. Engine hanger
"BA 3. Exhaust manifold bracket
4. Exhaust manifold
5. Exhaust manifold gasket
Mitsubishi Motors Corporation
Dec. 1998
PWEE9502-E
Revised
E
11A-6b-3
4G9 ENGINE (E-W) - Exhaust Manifold (GDI)
INSTALLATION SERVICE POINTS
"AA EXHAUST MANIFOLD BRACKET INSTALLATION
(1) Slide the washers over the bolts with the chamfered side
toward the bolt.
(2) Install temporarily the exhaust manifold brackets A and
B as shown in the illustration.
(3) Check that both brackets are in close contact with the
bosses, and then tighten fully the bracket mounting bolts.
Bracket A
Bracket B
Exhaust
manifold
"BA EXHAUST MANIFOLD BRACKET INSTALLATION
(1) The washers must be installed with the shear-drooped
side toward the bolts.
Shear-droop
(2) Temporarily install the exhaust manifold bracket as shown
in the illustration.
(3) Verify that the bracket is brought into close contact with
the boss on the exhaust manifold, then tighten the bolts
to the specified torque.
Exhaust
manifold
Bracket
Mitsubishi Motors Corporation
Dec. 1998
PWEE9502-E
Added
E
11A-6c-1
4G9 ENGINE (E-W) - Injector and Fuel Pump Assembly (GDI)
6c. INJECTOR AND FUEL PUMP ASSEMBLY (GDI)
REMOVAL AND INSTALLATION <Up to 2000 model for CARISMA, 1999 model for
SPACE STAR, SPACE RUNNER>
18 Nm
9 Nm
6
11 Nm
9 Nm
2
13
27
14
11 Nm
3
17
16
1
15
7
9
10
18
21
22
8
11 Nm
17 ± 2 Nm
20
9 Nm
19
23 Nm
11 Nm
38
11
26
4
12
11 Nm
5
35
36
37
33
23
30
25
31
22 Nm
34
28
29
23 Nm
32
24
Removal steps
1. Fuel hose
"DA 20. Fuel pressure sensor
21. O-ring
2. Fuel low pressure pipe
3. O-ring
22. Backup ring
4. Fuel nipple
5. O-ring
"CA 23. Pump camshaft case
24. O-ring
6. Clamp
25. O-ring
"FA 7. Fuel feed pipe
26. Harness bracket
27. Injector harness
28. Washer
8. Backup ring
9. O-ring
10. Backup ring
"FA 11. Fuel pump
12. O-ring
29. Injector holder
"BA 30. Delivery pipe and injector
31. Insulator
13. Harness bracket
14. Fuel return pipe
15. Backup ring
16. O-ring
32. Injector gasket
33. Injector
"AA 34. Corrugated washer
"AA 35. Backup ring
"AA 36. O-ring
17. Backup ring
"EA 18. Fuel high pressure regulator
"AA 37. Backup ring
38. Delivery pipe
19. Flange
Mitsubishi Motors Corporation
May 2000
PWEE9502-G
Revised
E
11A-6c-1a
4G9 ENGINE (E–W) – Injector and Fuel Pump Assembly (GDI)
REMOVAL AND INSTALLATION
<From 2001 model for CARISMA, SPACE STAR and GALANT>
11 Nm
11 Nm
23 Nm
9
8
7
11 Nm
17 Nm
Removal steps
1. Injector harness
2. Flange
12. Washer
13. Injector holder
"BA 14. Delivery pipe and injector
15. Insulator
"IA 3. Fuel pressure sensor
"IA 4. Backup ring
"IA 5. O-ring
16. Injector gasket
"HA 6. Fuel pipe
"HA 7. Backup ring
"HA 8. O-ring
"AA 17. Corrugated washer
"AA 18. Backup ring
"AA 19. O-ring
"HA 9. Backup ring
"GA 10. Fuel pump
"GA 11. O-ring
"AA 20. Backup ring
21. Injector
22. Delivery pipe
Mitsubishi Motors Corporation
Apr. 2003
PWEE9502-L
Revised
E
11A-6c-1b
4G9 ENGINE (E-W) - Injector and Fuel Pump Assembly (GDI)
REMOVAL AND INSTALLATION <For PAJERO io - 4G94>
11 Nm
11 Nm
23 Nm
3
11
10
8
5
6
4
9
11 Nm
11
10
9
17 Nm
7
12
13
11 Nm
21
19
20
22
2
24
23
22 Nm
18
1
16
14
15
17
Removal steps
1. Fuel hose
2. Fuel hose
"JA 13. O-ring
14. Washer
15. Injector holder
3. Injector harness
4. Flange
"BA 16. Delivery pipe and injector
17. Insulator
"IA 5. Fuel pressure sensor
"IA 6. Backup ring
"IA 7. O-ring
"HA 8. Fuel pipe
"HA 9. Backup ring
"HA 10. O-ring
"HA 11. Backup ring
"JA 12. Fuel pump
18. Injector gasket
"AA 19. Corrugated washer
"AA 20. Backup ring
"AA 21. O-ring
"AA 22. Backup ring
23. Injector
24. Delivery pipe
Mitsubishi Motors Corporation
July 2000
PWEE9502-H
Revised
E
11A-6c-2
4G9 ENGINE (E-W) - Injector and Fuel Pump Assembly (GDI)
REMOVAL AND INSTALLATION <For PAJERO io - 4G93>
10
11 Nm
11
12
13
9 Nm
11 Nm
2
17 ± 2 Nm
3
14
15
16
17
18
19
5
4
21
18 Nm
18 Nm
7
9 Nm
22
6
11 Nm
18 Nm
23
35
31
20
9
8
33
1
34
24
32
9 Nm
29
30
22 Nm
27
25
28
26
Removal steps
1. Injector harness
2. Fuel hose
"EA 20. Fuel high pressure regulator
"DA 21. Fuel pressure sensor
22. Backup ring
3. Fuel hose
4. Fuel hose
23. O-ring
5. Fuel pipe
24. Spacer
6. Fuel nipple
7. O-ring
25. Washer
26. Injector holder
8. Fuel nipple
9. O-ring
"BA 27. Delivery pipe and injector
28. Insulator
"FA 10. Fuel feed pipe
11. Backup ring
12. O-ring
29. Injector gasket
"AA 30. Corrugated washer
"AA 31. Backup ring
"AA 32. O-ring
13. Backup ring
"FA 14. Fuel pump
15. O-ring
"AA 33. Backup ring
34. Injector
16. Fuel return pipe
17. Backup ring
18. O-ring
35. Delivery pipe
19. Backup ring
Mitsubishi Motors Corporation
July 2000
PWEE9502-H
Revised
E
11A-6c-3
4G9 ENGINE (E-W) - Injector and Fuel Pump Assembly (GDI)
INSTALLATION SERVICE POINTS
"AA BACKUP RING / O-RING / CORRUGATED
WASHER INSTALLATION
(1) Attach the backup rings and O-ring to the injector. The
thicker backup ring must be so installed that the inside
cut surface is directed as shown in the illustration.
Cut surface
Backup ring
(2) Coat the corrugated washer with white vaseline and install
it to the injector as shown.
Caution
Always replace the corrugated washer with new one.
Reused corrugated washer can cause fuel or gas
leaks.
Corrugated washer
"BA DELIVERY PIPE AND INJECTOR ASSEMBLY
<CARISMA>
INSTALLATION
(1) Lubricate O-ring in the injector with spindle oil or gasoline.
(2) Insert the injector straight into the injector mounting hole
in the delivery pipe.
Mating marks
(3) Turn the injector clockwise and counterclockwise. If it
dose not rotate smoothly, remove it to check for damaged
O-ring. Damaged O-ring must be replaced with a new
one. Reinstall the injector and check for smooth rotation
again.
(4) Align the mating mark on the injector with that on the
delivery pipe.
(5) Install the injector gaskets and insulators on the cylinder
head. The insulator can drop off easily. Apply vaseline
to it before installation so that it may be held in position.
(6) Install the delivery pipe and injector assembly onto the
cylinder head, then tighten the fasteners temporarily.
(7) Install the injector holders and the washers to the assembly
and tighten the fasteners to the specified torque.
<PAJERO io>
Mating marks
Caution
Strictly observe the specified torque.
Injector
gasket
Mitsubishi Motors Corporation
Dec. 1998
PWEE9502-E
Revised
E
11A-6c-4
4G9 ENGINE (E-W) - Injector and Fuel Pump Assembly (GDI)
(8) Tighten the fasteners of the delivery pipe and injector
assembly to the specified torque in the order given in
the illustration.
<CARISMA>
4
2
1
3
<PAJERO io>
3
1
2
4
"CA PUMP CAMSHAFT CASE INSTALLATION
(1) Apply small amount of engine oil to the O-ring (larger
one) on the case.
Coupling
key
Groove
O-ring
(2) Install the pump camshaft case onto the cylinder head
while aligning the coupling keys of the case with the
grooves in the rear end face of the camshaft.
NOTE
The coupling keys and the grooves at the camshaft rear
end are offset with respect to the camshaft center.
Camshaft
(3) Tighten the case mounting bolts to the specified torque.
"DA FUEL PRESSURE SENSOR INSTALLATION
(1) Install the backup ring to the fuel pressure sensor with
its inside cut surface in the illustrated direction.
(2) Install the fuel pressure sensor straight into the fuel
pressure regulator with labeled surface upward.
(3) Tighten the fuel pressure sensor mounting bolt to the
specified torque.
Cut surface
Backup ring
"EA FUEL HIGH PRESSURE REGULATOR
INSTALLATION
(1) Install the fuel high pressure regulator on the pump
camshaft case <for CARISMA> or onto the spacer <for
PAJERO io> and tighten the 3 bolts lightly (with somewhat
larger torque than fingertight). Tightening to the
specification is to be carried out in the step described
in "FA.
Cut surface
Backup ring
Mitsubishi Motors Corporation
Dec. 1998
PWEE9502-E
Revised
E
11A-6c-5
4G9 ENGINE (E-W) - Injector and Fuel Pump Assembly (GDI)
(2) Fit the backup rings and the O-ring on both ends of the
fuel return pipe. Note that the larger backup ring must
be installed with the inside cut surface in the direction
shown in the illustration.
(3) Lubricate the O-rings on both ends of the pipe with spindle
oil or gasoline.
(4) Insert the fuel return pipe ends straight in the respective
mounting holes of the pressure regulator and the delivery
pipe. Be sure to insert the pipe fully to the stop using
care not to twist it.
(5) Tighten the bolts at both ends of the pipe to the specified
torque.
"FA FUEL PUMP / FUEL FEED PIPE INSTALLATION
(1) Insert the fuel pump into the mounting hole in the pump
camshaft case <for CARISMA> or in the cylinder head
<for PAJERO io>, and secure it temporarily with 4 bolts
(tighten somewhat with a larger torque than fingertight).
(2) Fit the backup rings and the O-ring on both ends of the
feed pipe. Note that the larger backup ring must be
installed with the inside cut surface in the direction shown
in the illustration.
Cut surface
Backup ring
(3) Lubricate the O-rings on both ends of the pipe with spindle
oil or gasoline.
(4) Insert the fuel feed pipe ends straight in the respective
mounting holes of the fuel and the delivery pipe. Be sure
to insert the pipe fully to the stop using care not to twist
it.
(5) Tighten the bolts at ends of the pipe to the specified
torque.
(6) Tighten the mounting bolts of the fuel pressure regulator
to the specified torque.
(7) Using a torque wrench having the minimum scale of 0.5
Nm, tighten the fuel pump mounting bolts in the following
order.
<CARISMA>
1
1) Tighten the bolts to 5 Nm in the order given in the
illustration.
3
2) Tighten the bolts to 17 Nm in the order given in the
illustration. The torque variation among 4 bolts must
be within 2 Nm.
4
Caution
2
Strictly observe the specified tightening torque.
Deviation from the specification can cause problems
such as leakage or the like.
<PAJERO io>
3
1
2
4
Mitsubishi Motors Corporation
Dec. 1998
PWEE9502-E
Added
E
11A-6c-6
4G9 ENGINE (E-W) - Injector and Fuel Pump Assembly (GDI)
"GAO-RING / FUEL PUMP INSTALLATION
(1) Apply engine oil to the roller of the fuel pump and O-ring.
(2) Insert the fuel pump into the mounting hole in the cylinder
head and lightly tighten the four bolts.
(3) Using a torque wrench (minimum graduations of 0.5 Nm),
follow these steps to tighten the fuel pump mounting bolts.
1) Tighten the bolts to 4.9 Nm in the order shown.
2) Tighten the bolts to 17 ± 2 Nm in the order shown.
Variations in torque among the four bolts should be
within 2 Nm.
1
4
3
2
Caution
Strictly observe the tightening order. A leak and other
problem could result if the torque specifications and
torquing order are not met.
"HA O-RING / BACKUP RING / FUEL PIPE
Backup ring
(no special orientation)
INSTALLATION
(1) Fit the backup rings and O-ring to both ends of the fuel
pipe. Mount the backup ring (thicker one) so that its inner
cut surface faces in the direction shown.
(2) Coat the O-rings on both ends of the pipe with spindle
oil or gasoline.
(3) Insert the fuel pipe straight into the mounting hole in
the delivery pipe. Insert it all the way into the hole, ensuring
that it does not twist.
(4) Tighten the bolts on both ends of the fuel pipe to the
specified torque.
Cut surface
Backup ring
(thicker one)
Mitsubishi Motors Corporation
May 2000
PWEE9502-G
Added
E
11A-6c-7
4G9 ENGINE (E-W) - Injector and Fuel Pump Assembly (GDI)
"IA O-RING / BACKUP RING / FUEL PRESSURE
SENSOR INSTALLATION
(1) Fit the backup ring to the fuel pressure sensor so that
its inner cut surface faces in the direction shown.
Cut surface
Backup ring
(2) Being attentive to the shape of the connector and label
surface of the fuel pressure sensor, install the fuel pressure
sensor in the direction shown.
Fuel pressure sensor
Label
surface
Delivery pipe
"JA O-RING / FUEL PUMP INSTALLATION
(1) Apply engine oil to the O-ring.
(2) Insert the fuel pump into the mounting hole in the cylinder
head and lightly tighten the four bolts.
(3) Using a torque wrench (minimum graduations of 0.5 Nm),
follow these steps to tighten the fuel pump mounting bolts.
1) Tighten the bolts to 4.9 Nm in the order shown.
2) Tighten the bolts to 17 ± 2 Nm in the order shown.
Variations in torque among the four bolts should be
within 2 Nm.
1
3
2
Caution
4
Strictly observe the tightening order. A leak and other
problem could result if the torque specifications and
torquing order are not met.
Mitsubishi Motors Corporation
July 2000
PWEE9502-H
Revised
E
11A-6d-1
4G9 ENGINE (E-W) - Intake and Exhaust Manifold <4G94-GDI for PAJERO io>
6d. INTAKE AND EXHAUST MANIFOLD
<4G94-GDI for PAJERO io>
REMOVAL AND INSTALLATION
1
5
9 Nm
9 Nm
20 Nm
9
4
3
23 Nm
2
9 Nm
13 Nm
10
11
8
11 Nm
15
6
14
7
12
29 Nm
18 Nm
13
31 Nm
98 Nm
17 Nm
29 Nm
Removal steps
1. P.C.V. hose
2. Purge hose
9. Intake manifold
10. Intake manifold gasket
3. Vacuum pipe and hose
4. Solenoid valve
11. Exhaust manifold cover
12. Engine hanger
5. Fuel pump protector
6. Connector bracket
"AA 13. Exhaust manifold bracket
14. Exhaust manifold
"BA 7. Intake manifold stay
15. Exhaust manifold gasket
8. Low pressure fuel pipe
Mitsubishi Motors Corporation
July 2000
PWEE9502-H
Added
E
11A-6d-2
4G9 ENGINE (E-W) - Intake and Exhaust Manifold <4G94-GDI for PAJERO io>
INSTALLATION SERVICE POINTS
"AA EXHAUST MANIFOLD BRACKET INSTALLATION
(1) The washers must be installed with the shear-drooped
side toward the bolts.
Shear-droop
(2) Temporarily install the exhaust manifold bracket as shown
in the illustration.
(3) Verify that the bracket is brought into close contact with
the boss on the exhaust manifold, then tighten the bolts
to the specified torque.
Exhaust
manifold
Bracket
"BA INTAKE MANIFOLD STAY INSTALLATION
Intake
manifold
(1) Check to ensure that the intake manifold stay is in close
contact with the intake manifold and the cylinder block
before tightening the respective mounting bolts to the
specified torque.
Intake
manifold
stay
Cylinder block
Mitsubishi Motors Corporation
July 2000
PWEE9502-H
Added
E
11A-7-1
4G9 ENGINE (E–W) – Water Pump and Water Hose
7. WATER PUMP AND WATER HOSE
11301790016
REMOVAL AND INSTALLATION <SOHC – FRONT WHEEL DRIVE>
19 Nm
Removal steps
1. Water hose
(Except carburetor engines)
2. Water hose
6. Water inlet fitting
"DA 7. Thermostat
"CA 8. Thermostat case
"BA 9. O-ring
"GA 3. Engine coolant temperature sensor
"FA 4. Engine coolant temperature gauge
unit
"EA 5. Water outlet fitting
"BA 10. Water inlet pipe
"BA 11. O-ring
"AA 12. Water pump
Revised
E Mitsubishi Motors Corporation
E
Jun. 2002
PWEE9502-K
11A-7-2
4G9 ENGINE (E–W) – Water Pump and Water Hose
REMOVAL AND INSTALLATION <SOHC – REAR WHEEL DRIVE>
2
24 Nm
8
1
11
17
12
13
14 Nm
14
15
13
24 Nm
16
24 Nm
10
9
Removal steps
1. Water hose
2. Water hose
3. Water hose
4. Water pipe
9. Water inlet fitting
"DA 10. Thermostat
"HA 11. Water by-pass fitting
"BA 12. Water pipe
"BA 13. O-ring
"GA 5. Engine coolant temperature sensor
"FA 6. Engine coolant temperature gauge
unit
"CA 14. Thermostat case
"BA 15. Water pipe
"BA 16. O-ring
"IA 7. Water fitting
"EA 8. Water outlet fitting
"AA 17. Water pump
E Mitsubishi Motors Corporation
E
Jun. 2002
PWEE9502-K
Revised
11A-7-3
4G9 ENGINE (E–W) – Water Pump and Water Hose
REMOVAL AND INSTALLATION <DOHC – FRONT WHEEL DRIVE>
29 Nm
1
14 Nm
19 Nm
Removal steps
1. Water hose A (Except GDI engine)
2. Water hose B (Except GDI engine)
"DA 7. Thermostat
"CA 8. Thermostat case
"BA 9. O-ring
"GA 3. Engine coolant temperature sensor
"FA 4. Engine coolant temperature gauge
unit
"BA 10. Water inlet pipe
"BA 11. O-ring
"EA 5. Water outlet fitting
"AA 12. Water pump
6. Water inlet fitting
Revised
E Mitsubishi Motors Corporation
E
Jun. 2002
PWEE9502-K
11A-7-4
4G9 ENGINE (E–W) – Water Pump and Water Hose
REMOVAL AND INSTALLATION <DOHC – REAR WHEEL DRIVE>
10 Nm
2
24 Nm
29 Nm
1
4
3
24 Nm
24 Nm
7
13
9
24 Nm
8
9
10
14 Nm
11
9
5
12
24 Nm
12
24 Nm
6
Removal steps
"GA 1. Engine coolant temperature sensor
"FA 2. Engine coolant temperature gauge
unit
"HA 7. Water by-pass fitting
"BA 8. Water pipe
"BA 9. O-ring
"IA 3. Water fitting
"CA 10. Thermostat case
"BA 11. Water pipe
"BA 12. O-ring
"EA 4. Water outlet fitting
5. Water inlet fitting
"DA 6. Thermostat
"AA 13. Water pump
E Mitsubishi Motors Corporation
E
Jun. 2002
PWEE9502-K
Revised
11A-7-5
4G9 ENGINE (E–W) – Water Pump and Water Hose
INSTALLATION SERVICE POINTS
"AA WATER PUMP INSTALLATION
(1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG)
to the location shown in the illustration.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
"BA WATER INLET PIPE <FRONT WHEEL
DRIVE>/WATER PIPE <REAR WHEEL
DRIVE>/O-RING INSTALLATION
(1) Replace the O-ring of the water inlet pipe <FRONT WHEEL
DRIVE> or water pipe <REAR WHEEL DRIVE>, and then
apply water to the O-ring to make installation easy.
Caution
1. Never apply any oil or grease to the O-ring.
2. Secure the water pipe after the thermostat case
has been installed.
"CA THERMOSTAT CASE INSTALLATION
(1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG)
to the location shown in the illustration.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
"DA THERMOSTAT INSTALLATION
(1) Install the thermostat so that the jiggle valve is facing
straight up.
Jiggle valve
"EA WATER OUTLET FITTING INSTALLATION
<FRONT WHEEL DRIVE>
(1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG)
to the location shown in the illustration.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
Revised
E Mitsubishi Motors Corporation
E
Jun. 2002
PWEE9502-K
11A-7-6
4G9 ENGINE (E–W) – Water Pump and Water Hose
<REAR WHEEL DRIVE>
"FA ENGINE COOLANT TEMPERATURE GAUGE UNIT
INSTALLATION
(1) Apply the specified sealant to the threads.
Specified sealant:
3M ATD Part No.8660 or equivalent
"GAENGINE COOLANT TEMPERATURE SENSOR
INSTALLATION
(1) When reusing the sensor, apply the specified sealant
to the threads.
Specified sealant:
3M Nut Locking Part No.4171 or equivalent
"HA WATER BY-PASS FITTING INSTALLATION
(1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG)
to the location shown in the illustration.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent.
"IA WATER FITTING INSTALLATION
(1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG)
to the location shown in the illustration.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent.
E Mitsubishi Motors Corporation
E
Jun. 2002
PWEE9502-K
Added
11A-8-1
4G9 ENGINE (E–W) – Rocker Arms and Camshafts
8. ROCKER ARMS AND CAMSHAFTS
11300540070
REMOVAL AND INSTALLATION <SOHC (with Adjusting screw)>
Removal steps
1. Breather hose
2. P.C.V. hose
3. Oil filler cap
4. Rocker cover
5. Rocker cover gasket
6. Oil seal
11. Rocker arm B
12. Rocker arm A
"BA 13. Rocker arm shaft
"AA 14. Adjusting screw
15. Nut
16. Rocker arm C
"BA 17. Rocker arm shaft
"AA 18. Adjusting screw
19. Nut
"EA 7. Oil seal
"DA 8. Rocker arm spring
"CA 9. Rocker arms and rocker arm shaft
IN
20. Camshaft
10. Rocker arms and rocker arm shaft
EX
E Mitsubishi Motors Corporation
E
Mar. 2001
PWEE9502-I
Revised
11A-8-1a
4G9 ENGINE (E–W) – Rocker Arms and Camshafts
REMOVAL AND INSTALLATION <SOHC (with Lash adjuster)>
Apply engine oil to all
moving parts before
installation.
Removal steps
1. Breather hose
2. P.C.V. hose
3. Oil filler cap
4. Rocker cover
5. Rocker cover gasket
6. Oil seal
11. Rocker arm B
12. Rocker arm A
"BA 13. Rocker arm shaft
AA" "FA 14. Lash adjuster
15. Rocker arm C
"BA 16. Rocker arm shaft
AA" "FA 17. Lash adjuster
18. Camshaft
"EA 7. Oil seal
"DA 8. Rocker arm spring
"CA 9. Rocker arms and rocker arm shaft
IN
10. Rocker arms and rocker arm shaft
EX
E Mitsubishi Motors Corporation
E
Mar. 2001
PWEE9502-I
Revised
11A-8-1b
4G9 ENGINE (E-W) - Rocker Arms and Camshafts
Intentionallyblank
Mitsubishi Motors Corporation
May 2000
PWEE9502-G
Added
E
11A-8-2
4G9 ENGINE (E-W) - Rocker Arms and Camshafts
REMOVAL AND INSTALLATION <DOHC>
9
5
3
1
2
4
6
7
3.5 Nm
8
11 Nm
24 Nm
11
13
12
10
14
15
Apply engine oil to
all moving parts
before installation.
Removal steps
1. Breather hose
2. P.C.V. hose
10. Oil seal
"HA 11. Bearing cap
"GA 12. Intake camshaft
"GA 13. Exhaust camshaft
14. Rocker arm
3. P.C.V. valve
4. P.C.V. valve gasket
5. Oil filler cap
"KA 6. Rocker cover
7. Rocker cover gasket A
8. Rocker cover gasket B
"JA 9. Semi-circular packing
AA" "FA 15. Lash adjuster
Mitsubishi Motors Corporation
May 2000
PWEE9502-G
Revised
E
11A-8-1
2a
4G9 ENGINE (E-W) - Rocker Arms and Camshafts
REMOVAL AND INSTALLATION <DOHC-GDI>
11 Nm
23 Nm
23 Nm
1
3.5 Nm
9
5
3.5 Nm
3
4
11
6
12
10
7
2
8
13
14
Apply engine oil to all
moving parts before
installation.
Removal steps
1. Breather hose
2. P.C.V hose
"LA 8. Oil seal
"KA 9. Beam camshaft cap
10. Gasket
3. P.C.V valve
4. P.C.V valve gasket
5. Oil filler cap
6. Rocker cover
7. Rocker cover gasket
"JA 11. Intake camshaft
"JA 12. Exhaust camshaft
13. Rocker arm
14. Lash adjuster
Mitsubishi Motors Corporation
July 1997
PWEE9502-C
Added
E
11A-8-
2b
4G9 ENGINE (E-W) - Rocker Arms and Camshafts
Intentionally blank
Mitsubishi Motors Corporation
July 1997
PWEE9502-C
Added
E
11A-8-3
4G9 ENGINE (E-W) - Rocker Arms and Camshafts
REMOVAL AND INSTALLATION <DOHC-GDI for CARISMA (Up to 2000 model),
SPACE STAR (1999 model), SPACE RUNNER>
11 Nm
21 Nm
21 Nm
1
3.5 Nm
9
5
3.5 Nm
3
4
11
6
12
10
7
2
8
13
14
Apply engine oil to
all moving parts
before installation.
Removal steps
1. Breather hose
2. P.C.V. hose
8. Oil seal
"IA 9. Beam camshaft cap
10. Gasket
3. P.C.V. valve
4. P.C.V. valve gasket
5. Oil filler cap
6. Rocker cover
7. Rocker cover gasket
11. Intake camshaft
12. Exhaust camshaft
13. Rocker arm
AA" "FA 14. Lash adjuster
Mitsubishi Motors Corporation
May 2000
PWEE9502-G
Revised
E
11A-8-3a
4G9 ENGINE (E–W) – Rocker Arms and Camshafts
REMOVAL AND INSTALLATION <DOHC–GDI for CARISMA, SPACE STAR and
GALANT (From 2001 model)>
10 Nm
3.5 Nm
6
2
3
4
7
8
1
11 Nm
5
21 Nm
9
21 Nm
12
11
13
14
15
10
16
17
Removal steps
1. P.C.V. hose
10. Oil seal
11. Circular packing
"IA 12. Beam camshaft cap
13. Beam camshaft cap gasket
14. Intake camshaft
2. P.C.V. valve
3. P.C.V. valve gasket
4. Breather hose
5. Oil filler cap
6. Rocker cover, intake
7. Rocker cover gasket, intake
8. Rocker cover, exhaust
9. Rocker cover gasket, exhaust
15. Exhaust camshaft
16. Rocker arm
AA" "FA 17. Lash adjuster
E Mitsubishi Motors Corporation
E
Apr. 2003
PWEE9502-L
Revised
11A-8-3b
4G9 ENGINE (E-W) - Rocker Arms and Camshafts
REMOVAL AND INSTALLATION <DOHC-GDI for PAJERO io - 4G94>
3
10 Nm
21 Nm
11 Nm
21 Nm
3.5 Nm
1
2
5
12
6
9
7
8
10
4
13
15
14
11
16
17
Apply engine oil to all
moving parts before
installation.
Removal steps
1. P.C.V. valve
"LA 10. O-ring
"IA 11. Oil seal
"IA 12. Beam camshaft cap
2. P.C.V. valve gasket
3. Breather hose
4. Oil filler cap
"IA 13. Beam camshaft cap gasket
"IA 14. Intake camshaft
"IA 15. Exhaust camshaft
16. Rocker arm
5. Rocker cover, inlet
6. Rocker cover gasket, inlet
7. Rocker cover, exhaust
8. Rocker cover gasket, exhaust
17. Lash adjuster
"LA 9. Cover
Mitsubishi Motors Corporation
July 2000
PWEE9502-H
Revised
E
11A-8-4
4G9 ENGINE (E-W) - Rocker Arms and Camshafts
REMOVAL AND INSTALLATION <DOHC-GDI for PAJERO io - 4G93>
11 Nm
21 Nm
3.5 Nm
2
10
1
3
8
9
5
4
11
13
12
15
7
6
14
Apply engine oil to all
moving parts before
installation.
Removal steps
1. Breather hose
2. P.C.V. valve
9. O-ring
"IA 10. Beam camshaft cap
11. Gasket
3. P.C.V. valve gasket
4. Oil filler cap
12. Intake camshaft
13. Exhaust camshaft
14. Rocker arm
5. Rocker cover
6. Rocker cover gasket
7. Oil seal
AA" "FA 15. Lash adjuster
8. Thrust case
Mitsubishi Motors Corporation
July 2000
PWEE9502-H
Revised
E
11A-8-5
4G9 ENGINE (E-W) - Rocker Arms and Camshafts
REMOVAL SERVICE POINT
AA" LASH ADJUSTER REMOVAL
Caution
D
If the lash adjuster is re-used, clean the lash
adjuster. (Refer to 11A-8-10.)
INSTALLATION SERVICE POINTS
"AA ADJUSTING SCREW INSTALLATION
1 mm or less
(1) Install provisionally the screw to the rocker arm. Insert
it so that the end of the screw is flush with the edge
of the rocker arm or projects slightly (1 mm or less).
"BA ROCKER ARM SHAFT INSTALLATION
Timing belt side
Chamfered side
(1) Place the end with the larger chamfered side toward the
timing belt side.
NOTE
The rocker arm shaft for intake valves has eight oil holes.
(2) Install the shaft with the oil holes toward the cylinder
head.
Oil holes
"CA ROCKER ARMS AND ROCKER ARM SHAFT
INSTALLATION
(1) Move the rocker arms in the directions shown in the
illustration before tightening the rocker arm shaft bolts.
NOTE
Move the rocker arms until they touch the rocker arm
shaft mounting bosses on the cylinder head.
"DA ROCKER ARM SPRING INSTALLATION
(1) Insert the rocker arm spring at an angle to the spark
plug guide and then install it so that it is at a right angle
to the guide.
Mitsubishi Motors Corporation
Dec. 1998
PWEE9502-E
Revised
E
11A-8-6
4G9 ENGINE (E-W) - Rocker Arms and Camshafts
"EA OIL SEAL INSTALLATION
MD998713
"FA LASH ADJUSTER INSTALLATION
Caution
D
If the lash adjuster is re-used, clean the lash
adjuster. (Refer to 11A-8-10.)
(1) Fit the lash adjuster onto the cylinder head using care
not to allow diesel fuel to spill out.
"GACAMSHAFT INSTALLATION
(1) Apply engine oil to the camshaft journals and cam before
installing the camshaft. Use care not to confuse the intake
camshaft with the exhaust camshaft.
Slit
NOTE
The rear end of the intake camshaft is provided with
a 4 mm-wide slit.
Journal
"HA BEARING CAP INSTALLATION
(1) Locate the camshaft dowel pins as illustrated.
Dowel
pins
(2) Apply sealant to the locations shown in the illustration.
Specified sealant:
3M ATD Part No. 8660 or equivalent
Mitsubishi Motors Corporation
Dec. 1998
PWEE9502-E
Revised
E
11A-8-7
4G9 ENGINE (E-W) - Rocker Arms and Camshafts
(3) The bearing caps No. 2 through No. 5 are of the same
shape. Before they are installed, check the cap number
and the intake and exhaust identification marks.
Identification mark (stamped on front and No. 2
through No. 5 bearing caps)
L: Intake side
Cap No.
IN or EX side
identification
R: Exhaust side
(4) Make sure that the rocker arms are installed in the
specified locations.
<DOHC-GDI for CARISMA (Up to 2000 model),
SPACE STAR (1999 model), SPACE RUNNER>
"IA BEAM CAMSHAFT CAP INSTALLATION
(1) Locate the camshaft dowel pin as illustrated.
Dowel pin
<DOHC-GDI for CARISMA (From 2001 model),
SPACE STAR (From 2001 model), GALANT,
PAJERO io>
Dowel pin
Approx.
106_
Approx.
150_
<DOHC-GDI for CARISMA (Up to 2000 model),
SPACE STAR (1999 model), SPACE RUNNER>
(2) Turn the crankshaft anticlockwise a quarter turn (90_).
(3) Apply a 3 mm thick continuous bead of sealant to the
bottom surface of the beam camshaft cap along the
groove.
3 mm
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or
equivalent
Beam camshaft cap
<DOHC-GDI for CARISMA (From 2001 model), SPACE STAR
(From 2001 model), GALANT, PAJERO io>3 mm
Timing belt side
Beam camshaft cap
Mitsubishi Motors Corporation
May 2000
PWEE9502-G
Revised
E
11A-8-8
4G9 ENGINE (E-W) - Rocker Arms and Camshafts
<DOHC-GDI for CARISMA (Up to 2000 model),
SPACE STAR (1999 model), SPACE RUNNER>
(4) Apply sealant to the illustrated position of the cylinder
head upper surface.
Specified sealant:
Mitsubishi Genuine Part No. MD970389
or equivalent
<DOHC-GDI for CARISMA (From 2001 model),
SPACE STAR (From 2001 model), GALANT, PAJERO io>
Engine front side
<DOHC-GDI for CARISMA (Up to 2000 model),
SPACE STAR (1999 model), SPACE RUNNER>
(5) Install the beam camshaft cap before the sealant applied
becomes dry and hard.
(6) Tighten the bolts to the specified torque in the order shown
in the illustration.
M6 bolt 11Nm
M8 bolt 21Nm
Caution
The M8 bolts plated green cannot be reused. Always
replace such bolts with M8 bolts finished by glossy
plating which are available separately.
The M8 bolt finished by glossy plating is reusable;
if the caps have already been assembled with such
bolts, then reassemble the caps using them.
<DOHC-GDI for CARISMA (From 2001 model),
SPACE STAR (From 2001 model), GALANT, PAJERO io>
Engine front side
(7) Install the camshaft oil seal (use the special tool) and
the thrust case <DOHC-GDI for PAJERO io - 4G93>
before the sealant applied becomes dry and hard.
(8) Wipe off squeezed out excess sealant from the
circumference of the beam camshaft cap.
MD998713
Mitsubishi Motors Corporation
July 2000
PWEE9502-H
Revised
E
11A-8-9
4G9 ENGINE (E-W) - Rocker Arms and Camshafts
"JA SEALANT APPLICATION ON SEMI-CIRCULAR
PACKING
Specified sealant: 3M ATD Part No.8660 or equivalent
"KA SEALANT APPLICATION ON ROCKER COVER
(1) Apply sealant to the areas indicated in the illustration.
Specified sealant: 3M ATD Part No.8660 or equivalent
"LA O-RING / COVER INSTALLATION
O-ring
(1) Apply liquid gasket on the illustrated position of the cover.
Specified sealant: 3M ATD Part No.8660 or equivalent
(2) Lubricate the O-ring in the cover with engine oil. Install
the cover in place on the cylinder head and the beam
camshaft cap.
VALVE CLEARANCE ADJUSTMENT
Adjust the valve clearance by the following procedure.
Adjustment values (when engine is cold):
Intake valve: 0.09 mm
Timing mark
Exhaust valve: 0.20 mm
(1) Turn the crankshaft in the clockwise direction to align
the camshaft sprocket timing marks and to set the No.1
cylinder to the compression top dead centre position.
(2) The valve clearances at the places indicated by arrows
in the illustration can be adjusted.
When No.1 cylinder is at compression top
dead centre
(3) Use a thickness gauge to adjust the clearance between
the ends of the valve stems and the adjusting screws.
(4) Hold the adjusting screws with a screwdriver so that they
do not turn, and then tighten the lock nuts.
(5) Turn the crankshaft once in the clockwise direction to
set the No.4 cylinder to the compression top dead centre
position.
Mitsubishi Motors Corporation
July 2000
PWEE9502-H
Revised
E
11A-8-9a
4G9 ENGINE (E-W) - Rocker Arms and Camshafts
(6) Adjust the valve clearances indicated by arrows in the
illustration by the same procedure as in steps (3) and
(4) above.
When No.4 cylinder is at compression top
dead centre
Mitsubishi Motors Corporation
July 2000
PWEE9502-H
Added
E
11A-8-9b
4G9 ENGINE (E-W) - Rocker Arms and Camshafts
Intentionallyblank
Mitsubishi Motors Corporation
July 2000
PWEE9502-H
Added
E
11A-8-10
4G9 ENGINE (E–W) – Rocker Arms and Camshafts
INSPECTION
CAMSHAFT
(1) Measure the cam height.
Standard
value mm
Limit mm
36.84
1
2
3
4
5
Intake
side
4G92–SOHC*
4G92–SOHC*
4G92–SOHC*
4G93–SOHC*
4G93–SOHC*
4G94–SOHC
4G93–DOHC
37.34
37.78
36.92
37.53
37.11
37.91
35.49
35.49
35.49
37.83
37.83
36.70
37.64
37.15
37.70
35.20
34.73
34.91
37.28
36.42
37.03
36.61
37.41
34.99
34.99
34.99
37.33
37.33
36.65
37.14
36.65
37.20
34.70
34.23
34.41
4G93–DOHC–GDI
4G94–DOHC–GDI
1
Exhaust 4G92–SOHC*
side
2
3
4
5
4G92–SOHC*
4G92–SOHC*
4G93–SOHC*
4G93–SOHC*
4G94–SOHC
4G93–DOHC
4G93–DOHC–GDI
4G94–DOHC–GDI
1
* : LANCER for Europe and CARISMA for Europe
2
3
* : LANCER for general export and CARISMA for 6B model
* : LANCER for Europe (from 2001 model) and CARISMA for
Europe (from 2001 model)
* : Except for Europe
* : For Europe
4
5
LASH ADJUSTER
(SOHC)
Caution
1. The lash adjusters are precision-engineered
mechanisms. Do not allow them to become
contained by dirt or other foreign substances.
2. Do not attempt to disassemble the lash adjusters.
3. Use only fresh diesel fuel to clean the lash adjusters.
(1) Prepare three containers and approximately five liters
of diesel fuel. Into each container, pour enough diesel
fuel to completely cover a lash adjuster when it is standing
upright. Then, perform the following steps with each lash
adjuster.
Outside
cleaning
Inside
cleaning
Filling with
diesel fuel
E Mitsubishi Motors Corporation
E
Jun. 2002
PWEE9502-K
Revised
11A-8-11
4G9 ENGINE (E-W) - Rocker Arms and Camshafts
(2) Place the lash adjuster in container A and clean its outside
surface.
NOTE
Use a nylon brush if deposits are hard to remove.
Diesel fuel
(3) While gently pushing down the internal steel ball using
special tool MD998442, move the plunger through 5 to
10 strokes until it slides smoothly. In addition to eliminating
stiffness in the plunger, this operation will remove dirty
oil.
Caution
The steel ball spring is extremely weak, so the lash
adjuster’s functionality may be lost if the air bleed
wire is pushed in hard.
Diesel fuel
Wire or MD998442
NOTE
If the plunger remains stiff or the mechanism appears
otherwise abnormal, replace the lash adjuster.
(4) Remove the lash adjuster from the container. Then, push
down the steel ball gently and push the plunger to eliminate
diesel fuel from the pressure chamber.
Wire or MD998442
Diesel fuel
(5) Place the lash adjuster in container B. Then, gently push
down the internal steel ball using special tool MD998442
and move the plunger through 5 to 10 strokes until it
slides smoothly. This operation will clean the lash
adjuster’s pressure chamber.
Caution
The steel ball spring is extremely weak, so the lash
adjuster’s functionality may be lost if the air bleed
wire is pushed in hard.
Diesel fuel
Wire or MD998442
Mitsubishi Motors Corporation
May 2000
PWEE9502-G
Revised
E
11A-8-12
4G9 ENGINE (E-W) - Rocker Arms and Camshafts
(6) Remove the lash adjuster from the container. Then, push
down the steel ball gently and push the plunger to eliminate
diesel fuel from the pressure chamber.
Wire or MD998442
Diesel fuel
(7) Place the lash adjuster in container C. Then, gently push
down the internal steel ball using special tool MD998442.
Wire or MD998442
Caution
Do not use container C for cleaning. If cleaning is
performed in container C, foreign matter could enter
the pressure chamber when chamber is filled with
diesel fuel.
Diesel fuel
(8) Stand the lash adjuster with its plunger at the top, then
push the plunger downward firmly until it moves through
its greatest possible stroke. Return the plunger slowly,
then release the steel ball and allow the pressure chamber
to fill with diesel fuel.
Wire or MD998442
Diesel fuel
(9) Remove the lash adjuster from the container, then stand
the lash adjuster with its plunger at the top. Push the
plunger firmly and check that it does not move. Also,
check that the lash adjuster’s height matches that of a
new lash adjuster.
NOTE
If lash adjuster contracts, perform the operations (7)
through (9) again to fill it with diesel fuel completely.
Replace the lash adjuster if it still contracts after performing
these steps.
(10)Stand the lash adjuster upright to prevent diesel fuel from
spilling out. Do not allow the lash adjuster to become
contaminated by dirt or other foreign matter. Fit the lash
adjuster onto the engine as soon as possible.
Mitsubishi Motors Corporation
May 2000
PWEE9502-G
Revised
E
11A-8-13
4G9 ENGINE (E-W) - Rocker Arms and Camshafts
(DOHC)
Caution
1. The lash adjusters are precision-engineered
mechanisms. Do not allow them to become
contained by dirt or other foreign substances.
2. Do not attempt to disassemble the lash adjusters.
3. Use only fresh diesel fuel to clean the lash adjusters.
(1) Prepare three containers and approximately five liters
of diesel fuel. Into each container, pour enough diesel
fuel to completely cover a lash adjuster when it is standing
upright. Then, perform the following steps with each lash
adjuster.
Outside
cleaning
Inside
cleaning
Filling with
diesel fuel
A
B
C
(2) Place the lash adjuster in container A and clean its outside
surface.
NOTE
Use a nylon brush if deposits are hard to remove.
Diesel fuel
(3) While gently pushing down the internal steel ball using
special tool MD998442, move the plunger through 5 to
10 strokes until it slides smoothly. In addition to eliminating
stiffness in the plunger, this operation will remove dirty
oil.
Caution
The steel ball spring is extremely weak, so the lash
adjuster’s functionality may be lost if the air bleed
wire is pushed in hard.
Diesel fuel
MD998442
NOTE
If the plunger remains stiff or the mechanism appears
otherwise abnormal, replace the lash adjuster.
Mitsubishi Motors Corporation
May 2000
PWEE9502-G
Revised
E
11A-8-14
4G9 ENGINE (E-W) - Rocker Arms and Camshafts
(4) Remove the lash adjuster from the container. Then, push
down the steel ball gently and push the plunger to eliminate
diesel fuel from the pressure chamber.
Caution
Make sure the oil hole in the side of the body is pointing
toward container A. Do not point the oil hole at yourself
or other people.
MD998442
Diesel fuel
(5) Place the lash adjuster in container B. Then, gently push
down the internal steel ball using special tool MD998442
and move the plunger through 5 to 10 strokes until it
slides smoothly. This operation will clean the lash
adjuster’s pressure chamber.
Caution
The steel ball spring is extremely weak, so the lash
adjuster’s functionality may be lost if the air bleed
wire is pushed in hard.
Diesel fuel
MD998442
(6) Remove the lash adjuster from the container. Then, push
down the steel ball gently and push the plunger to eliminate
diesel fuel from the pressure chamber.
Caution
Make sure the oil hole in the side of the body is pointing
toward container B. Do not point the oil hole at yourself
or other people.
MD998442
Diesel fuel
(7) Place the lash adjuster in container C. Then, gently push
down the internal steel ball using special tool MD998442.
Caution
Do not use container C for cleaning. If cleaning is
performed in container C, foreign matter could enter
the pressure chamber when chamber is filled with
diesel fuel.
MD998442
Diesel fuel
(8) Stand the lash adjuster with its plunger at the top, then
push the plunger downward firmly until it moves through
its greatest possible stroke. Return the plunger slowly,
then release the steel ball and allow the pressure chamber
to fill with diesel fuel.
Diesel fuel
MD998442
Mitsubishi Motors Corporation
May 2000
PWEE9502-G
Added
E
11A-8-15
4G9 ENGINE (E-W) - Rocker Arms and Camshafts
(9) Remove the lash adjuster from the container, then stand
the lash adjuster with its plunger at the top. Push the
plunger firmly and check that it does not move. Also,
check that the lash adjuster’s height matches that of a
new lash adjuster.
NOTE
If lash adjuster contracts, perform the operations (7)
through (9) again to fill it with diesel fuel completely.
Replace the lash adjuster if it still contracts after performing
these steps.
(10)Stand the lash adjuster upright to prevent diesel fuel from
spilling out. Do not allow the lash adjuster to become
contaminated by dirt or other foreign matter. Fit the lash
adjuster onto the engine as soon as possible.
Mitsubishi Motors Corporation
May 2000
PWEE9502-G
Added
E
11A-8a-1
4G9 ENGINE (E-W) - Rocker Cover and Camshafts (MIVEC)
8a. ROCKER COVER AND CAMSHAFTS (MIVEC)
REMOVAL AND INSTALLATION
9 Nm
11 Nm
3.5 Nm
2
23 Nm
23 Nm
23 Nm
8
1
11 Nm
3
4
5
10
12
9
11
6
13
7
Apply engine oil to
all moving parts be-
fore installation.
14
Removal steps
1. Breather hose
2. PCV hose
9. Arm spring holder
"DA 10. Camshaft bearing cap
"DA 11. Arm spring
3. Oil filler cap
"GA 4. Rocker cover
"CA 12. Camshaft
"BA 13. Camshaft holder
"AA 14. Semi-circular packing
5. Rocker cover gasket
6. Oil seal
"FA 7. Oil seal
"EA 8. Oil control valve
Added
Mitsubishi Motors Corporation
Nov. 1995
PWEE9502-A
E
11A-8a-2
4G9 ENGINE (E-W) - Rocker Cover and Camshafts (MIVEC)
INSPECTION
1. OIL CONTROL VALVE
(1) Connect a 12VDC power supply between terminals (1)
and (2) of the oil control valve and check if the valve
operates smoothly.
12 V
Valve
2. CAMSHAFT
(1) Measure the cam heights. If the specified limit is
exceeded, replace the camshaft.
Unit: mm
A B
A B
A B
A B
Standard
value
Limit
4G92 DOHC-MIVEC
Intake A
36.41
33.58
35.83
34.24
35.91
33.08
35.33
33.74
Intake B
Exhaust A
Exhaust B
Mitsubishi Motors Corporation
Nov. 1995
PWEE9502-A
Added
E
11A-8a-3
4G9 ENGINE (E-W) - Rocker Cover and Camshafts (MIVEC)
INSTALLATION SERVICE POINTS
Sealant
"AA SEMI-CIRCULAR PACKING INSTALLATION
(1) Apply the specified sealant to the area shown.
Specified sealant:
3M ATD Part No. 8660 or equivalent.
Sealant
"BA CAMSHAFT HOLDER ASSEMBLY INSTALLATION
(1) Apply the specified sealant to the area shown.
Specified sealant:
3M ATD Part No. 8660 or equivalent
"CA CAMSHAFT INSTALLATION
(1) Ensure that the intake-side and exhaust-side camshafts
are not reversed. The exhaust-side camshaft is longer
and has a slot in its rear end.
(2) Set the No. 1 piston at the top dead center and install
the camshafts with their cams for No. 1 cylinder directed
upward so that the No. 1 cylinder becomes the top dead
center on the compression stroke.
"DA CAMSHAFT BEARING CAP / CAMSHAFT
HOLDER INSTALLATION
(1) Confirm the identification mark on each bearing cap to
install the cap in the correct position.
Identification mark
L1: Front bearing for exhaust camshaft
R1: Front bearing for intake camshaft
Added
Mitsubishi Motors Corporation
Nov. 1995
PWEE9502-A
E
11A-8a-4
4G9 ENGINE (E-W) - Rocker Cover and Camshafts (MIVEC)
(2) Apply the specified sealant to the front and rear camshaft
bearing caps at the positions shown. Position the
camshaft bearing caps and tighten their mounting bolts
not numbered in the illustration. Then tighten the
remaining (numbered) bolts in the order shown in the
illustration to install the bearing caps and camshaft holder
to the cylinder head.
Specified sealant:
3M ATD part No. 8660 or equivalent
Sealant
5
9
1
3
7 13
14
11
12
6
2
4
8
10
Sealant
Sealant
"EA OIL CONTROL VALVE INSTALLATION
(1) Apply the specified sealant to the area shown.
Specified sealant:
3M ATD Part No. 8660 or equivalent
Sealant
"FA OIL SEAL INSTALLATION
Mitsubishi Motors Corporation
Nov. 1995
PWEE9502-A
Added
E
11A-8a-5
4G9 ENGINE (E-W) - Rocker Cover and Camshafts (MIVEC)
"GAROCKER COVER INSTALLATION
Apply the specified sealant to the area shown.
Specified sealant:
3M ATD part No. 8660 or equivalent
VALVE CLEARANCE ADJUSTMENT
Adjustment must be performed with the cylinder at the top
dead center on the compression stroke.
(1) Inserting the special tool between one of two adjusting
screws and the valve and adjust the clearance.
MB991477
MB991478
(2) Then adjust the other adjusting screw in the same way.
MB991477
MB991478
ROCKER ARM PISTON INSPECTION
(1) Screw in the special tool to the rocker arm piston for
high speed side rocker arm and check that the piston
can be lifted up lightly by hand.
MB991479
Added
Mitsubishi Motors Corporation
Nov. 1995
PWEE9502-A
E
11A-8b-1
4G9 ENGINE (E-W) - Rocker Arms and Rocker Shaft Caps (MIVEC)
8b. ROCKER ARMS AND ROCKER SHAFT CAPS (MIVEC)
REMOVAL AND INSTALLATION
4
5
10
6
4
5
6
4
7
5
8
6
9
4
7
5
8
6
9
7
2
8
9
7
3
8
9
1
2
Apply engine oil to
all moving parts be-
fore installation.
11 Nm
Removal steps
1. Rocker shaft cap
2. Seal cap “A”
3. Seal cap “B”
4. Spring guide
5. Wave washer
"AA 6. Intake rocker arm assembly “A”
7. Spring guide
8. Wave washer
"AA 9. Exhaust rocker arm assembly “A”
10. Camshaft holder
Added
Mitsubishi Motors Corporation
Nov. 1995
PWEE9502-A
E
11A-8b-2
4G9 ENGINE (E-W) - Rocker Arms and Rocker Shaft Caps (MIVEC)
INSTALLATION SERVICE POINT
"AA ROCKER ARM ASSEMBLY INSTALLATION
Timing belt side
Identification mark
(1) Install the rocker arm assemblies while checking the
identification marks at the positions shown to ensure that
the intake and exhaust sides are not reversed.
Identification marks:
E: Intake
I: Exhaust
Mitsubishi Motors Corporation
Nov. 1995
PWEE9502-A
Added
E
11A-9-1
4G9 ENGINE (E-W) - Cylinder Head and Valves
9. CYLINDER HEAD AND VALVES
11300690072
REMOVAL AND INSTALLATION <SOHC>
8
9
1
10
14
15
4
5
6
2
17
12
13
16
20
19
11
18
7
3
Lubricate all internal
parts with engine oil
during reassembly.
Removal steps
AA" "DA 1. Cylinder head bolt
2. Cylinder head assembly
3. Cylinder head gasket
AB" "CA 4. Retainer lock
5. Valve spring retainer
11. Intake valve
AC" "AA 12. Valve stem seal
13. Valve spring seat
AC" "AA 14. Valve stem seal
15. Valve spring seat
"BA 6. Valve spring
16. Exhaust valve guide
17. Intake valve guide
18. Exhaust valve seat
19. Intake valve seat
7. Exhaust valve
AB" "CA 8. Retainer lock
9. Valve spring retainer
"BA 10. Valve spring
20. Cylinder head
Mitsubishi Motors Corporation
May 1995
PWEE9502
E
11A-9-2
4G9 ENGINE (E-W) - Cylinder Head and Valves
REMOVAL AND INSTALLATION <DOHC>
3
2
10 Nm
1
5
6
21
7
9
13
14
17
10
11
15
16
18
19
8
20
12
4
Lubricate all internal
parts with engine oil
during assembly.
Removal steps
"EA 1. Oil pressure switch
AA" "DA 2. Cylinder head bolt
3. Cylinder head assembly
4. Cylinder head gasket
12. Intake valve
AC" "AA 13. Valve stem seal
14. Valve spring seat
AC" "AA 15. Valve stem seal
16. Valve spring seat
AB" "CA 5. Retainer lock
6. Valve spring retainer
17. Exhaust valve guide
18. Intake valve guide
19. Exhaust valve seat
20. Intake valve seat
"BA 7. Valve spring
8. Exhaust valve
AB" "CA 9. Retainer lock
10. Valve spring retainer
"BA 11. Valve spring
21. Cylinder head
Mitsubishi Motors Corporation
May 1995
PWEE9502
E
11A-9-3
4G9 ENGINE (E-W) - Cylinder Head and Valves
REMOVAL AND INSTALLATION <DOHC-MIVEC>
3
10 Nm
1
2
9
10
11
15
16
18
21
5
6
7
13
14
17
20
12
19
8
4
Apply engine oil to all
moving parts before
installation.
Removal steps
"EA 1. Oil pressure switch
AA" "DA 2. Cylinder head bolt
3. Cylinder head assembly
4. Cylinder head gasket
AD"
12. Exhaust valve
AC" "AA 13. Valve stem seal
14. Valve spring seat
AC" "AA 15. Valve stem seal
16. Valve spring seat
AB" "CA 5. Retainer lock
6. Valve spring retainer
17. Intake valve guide
18. Exhaust valve guide
19. Intake valve seat
20. Exhaust valve seat
21. Cylinder head
"BA 7. Valve spring
AD"
8. Intake valve
AB" "CA 9. Retainer lock
10. Valve spring retainer
"BA 11. Valve spring
Revised
Mitsubishi Motors Corporation
Nov. 1995
PWEE9502-A
E
11A-9-
3a
4G9 ENGINE (E-W) - Cylinder Head and Valves
REMOVAL AND INSTALLATION <DOHC-GDI>
1
2
8
9
10
14
15
17
4
5
20
6
12
13
16
19
11
18
7
3
Apply engine oil to all
moving parts before
installation.
Removal steps
AA" "DA 1. Cylinder head bolt
2. Cylinder head assembly
3. Cylinder head gasket
AD"
11. Exhaust valve
AC" "AA 12. Valve stem seal
13. Valve spring seat
AB" "CA 4. Retainer lock
5. Valve spring retainer
AC" "AA 14. Valve stem seal
15. Valve spring seat
"BA 6. Valve spring
16. Intake valve guide
AD"
7. Intake valve
17. Exhaust valve guide
18. Intake valve seat
AB" "CA 8. Retainer lock
9. Valve spring retainer
"BA 10. Valve spring
19. Exhaust valve seat
20. Cylinder head
Mitsubishi Motors Corporation
July 1997
PWEE9502-C
Added
E
11A-9-5
3b
4G9 ENGINE (E-W) - Cylinder Head and Valves
Intentionally blank
Added
Mitsubishi Motors Corporation
July 1997
PWEE9502-C
E
11A-9-4
4G9 ENGINE (E-W) - Cylinder Head and Valves
REMOVAL SERVICE POINTS
SOHC
MB991653
AA" CYLINDER HEAD BOLT REMOVAL
(1) Loosen the cylinder head bolts using the special tool.
DOHC, MIVEC
Except MIVEC
MIVEC
MB991653
AB" RETAINER LOCK REMOVAL
(1) Store the removed valves, springs and other parts, tagged
to indicate their cylinder No. and location to aid
reassembly.
MD998772
MD998772
MD998735
MD998784
Mitsubishi Motors Corporation
Nov. 1995
PWEE9502-A
Revised
E
11A-9-5
4G9 ENGINE (E-W) - Cylinder Head and Valves
AC" VALVE STEM SEAL REMOVAL
AD" VALVE HANDLING PRECAUTIONS
(1) Sodium reacts violently with water or moisture generation
heat and liberating hydrogen. It must be handled with
utmost care because otherwise the following dangerous
conditions may result:
Loss of eyesight if sodium gets in eyes.
Burns if sodium contact skin.
Fire hazard.
(2) Handling of Sodium-filled Exhaust Valves
Sodium-filled exhaust valves are not dangerous and may
be handled in the same way as ordinary valves unless
they are broken.
Never try to break the valves and expose sodium to the
air. When worn exhaust valves are to be discarded,
have them disposed of by a salvage company equipped
with special disposal system, notifying them that the valves
contain sodium.
Should the exhaust valves be broken, neutralize sodium
using the method described below, and discard the valves
in the same way as ordinary valves.
(3) How to Neutralize Sodium
Place a container filled with more than 10 liters of water
in a well ventilated large space.
Wear rubber gloves and goggles, and carefully take out
broken valves from the cylinder head.
Put a broken valve in the water-filled container and quickly
get away from the container at least 2 or 3 m (6.6 or
10 ft.)
Revised
Mitsubishi Motors Corporation
Nov. 1995
PWEE9502-A
E
11A-9-6
4G9 ENGINE (E-W) - Cylinder Head and Valves
Caution
D
D
Valves must be neutralized one at a time.
Put a valve in the container only after sodium
in the preceding one has completely reacted with
water.
Keep fire away from the container during the
neutralization. The resulting hydrogen gas is highly
explosive.
When the reaction has finished (there is no more
generation of hydrogen gas), take the valves out of the
container with large tweezers or the like.
NOTE
The reaction occurs when water enters the cavity in the
valve. Hydrogen gas may be trapped inside the valve,
temporarily blocking the water passage. In such a case,
wait until hydrogen gas in released and remaining sodium
reacts with water.
After the neutralization of sodium, water in the container
contains sodium hydroxide and is highly alkaline. The
water solution should be disposed of according to local
regulations.
Caution
D
Do not let the solution contact the eyes or the
skin.
D
Should it get in the eyes, immediately flush them
with clean water thoroughly, and receive medical
attention. When it contacts the skin, wash with
ample amounts of clean water.
INSTALLATION SERVICE POINTS
SOHC
"AA VALVE STEM SEAL INSTALLATION
(1) Install the vale spring seat.
(2) Use the special tool to install the valve stem seal. Improper
installation could result oil leaking past the valve guide.
Caution
MD998774
Do not reuse removed valve stem seals.
DOHC
MD998775
Mitsubishi Motors Corporation
Nov. 1995
PWEE9502-A
Revised
E
11A-9-7
4G9 ENGINE (E-W) - Cylinder Head and Valves
"BA VALVE SPRING INSTALLATION
Spring
retainer
(1) Install the valve spring with the painted end on the rocker
arm side.
Painted
end
Stem seal
Spring seat
"CA RETAINER LOCK INSTALLATION
Except
MIVEC
(1) The valve spring, if excessively compressed, causes the
bottom end of retainer to be in contact with the stem
seal, and damage it.
MD998772
MIVEC
MD998772
MD998735
MD998784
"DA CYLINDER HEAD BOLT INSTALLATION
(1) When installing the cylinder head bolts, check that the
shank length of each bolt meets the limit. If the limit
is exceeded, replace the bolts.
Limit: Max. 96.4 mm
(2) Install the washers as illustrated.
(3) Apply engine oil to the bolt threads and washers.
Shank length
Revised
Mitsubishi Motors Corporation
Nov. 1995
PWEE9502-A
E
11A-9-8
4G9 ENGINE (E-W) - Cylinder Head and Valves
(4) According to the tightening sequence, tighten the bolts
Timing belt side
to the specified torque 74 Nm.
(5) Loosen all bolts fully.
(6) Retighten the loosened bolts to a torque of 20 Nm in
the specified tightening sequence.
8
6
4
1
2
3
5
9
(7) Make paint marks on the cylinder head bolt heads and
cylinder head.
(8) Give a 90_ turn to the cylinder head bolts in the specified
tightening sequence.
10
7
(9) Give another 90_ turn to the cylinder head bolts and
make sure that the paint mark on the head of each cylinder
head bolt and that on the cylinder head are on the same
straight line.
Caution
1. If the bolt is turned less than 90_, proper fastening
performance may not be expected. When tightening
the bolt, therefore, be careful to give a sufficient turn
to it.
90_
2. If the bolt is overtightened, loosen the bolt completely
and then retighten it by repeating the tightening
procedure from step (1).
90_
Pain mark
"EA SEALANT APPLICATION TO OIL PRESSURE
SWITCH
(1) Apply sealant to the threads of the switch.
Specified sealant:
3M ATD Part No. 8660 or equivalent
Caution
Use care not to allow the sealant to plug the oil
passage.
Oil passage
Mitsubishi Motors Corporation
Nov. 1995
PWEE9502-A
Revised
E
11A-9-9
4G9 ENGINE (E-W) - Cylinder Head and Valves
INSPECTION
CYLINDER HEAD
(1) Check the cylinder head gasket surface for flatness by
using a straightedge and thickness gauge.
Standard value: 0.03 mm
Limit: 0.2 mm
(2) If the service limit is exceeded, correct to meet the
specification.
Grinding limit:*0.2 mm
*Includes/combined with cylinder block grinding
Cylinder head height (Specification when new):
119.9 - 120.1 mm <SOHC>
131.9 - 132.1 mm <DOHC>
119.8 - 120.0 mm <DOHC-MIVEC>
131.9 - 132.1 mm <DOHC-GDI>
VALVE
(1) Check the valve face for correct contact. If incorrect,
reface using a valve refacer. Valve should make a uniform
contact with the seat at the centre of valve face.
(2) If the margin is smaller than the service limit, replace
the valve.
Valve seat contact
Margin
Standard value
mm
Limit mm
Intake
1.0
1.3
1.2
0.5
Exhaust
SOHC
DOHC
0.8
0.7
(3) Measure the overall height of the valve. If the specified
limit is exceeded, replace the valve.
Standard value
mm
Limit mm
Intake
SOHC
DOHC
110.15
104.19
109.65
103.69
115.13
103.69
113.20
103.37
115.13
103.37
DOHC-MIVEC 115.63
DOHC-GDI
SOHC
104.19
113.70
103.87
Exhaust
DOHC
DOHC-MIVEC 115.63
DOHC-GDI 103.87
Revised
Mitsubishi Motors Corporation
July 1997
PWEE9502-C
E
11A-9-10
4G9 ENGINE (E–W) – Cylinder Head and Valves
VALVE SPRING
(1) Measure the valve spring’s free height. If the measurement
is less than specified, replace the spring.
Standard value
mm
Limit mm
SOHC (with adjusting screw) 50.9
49.9
48.5
SOHC (with lash adjuster)
DOHC
49.5
45.0
51.5
44.8
44.0
50.5
43.8
DOHC–MIVEC
DOHC–GDI
(2) Measure the squareness of the spring. If the measurement
exceeds the specified limit, replace the spring.
Standard value: 2_ or less
Limit: 4_
VALVE SEAT
d
(1) Assemble the valve, then measure the valve stem
projection between the end of the valve stem and the
spring seating surface. If the measurement exceeds the
specified limit, replace the valve seat.
Standard value
mm
Limit mm
Intake
SOHC
DOHC
49.30
46.70
49.80
47.20
58.35
47.15
49.85
47.15
58.63
47.20
DOHC–MIVEC 57.85
DOHC–GDI
SOHC
46.65
49.35
46.65
Exhaust
DOHC
DOHC–MIVEC 58.13
DOHC–GDI 46.70
VALVE GUIDE
(1) Measure the clearnace between the valve guide and valve
stem. If the limit is exceeded, replace the valve guide
or valve, or both.
Standard value:
Intake: 0.02 – 0.05 mm
Exhaust: 0.05 – 0.09 mm
<SOHC, DOHC, DOHC–MIVEC, DOHC–GDI for
CARISMA, SPACE STAR, SPACE RUNNER,
GALANT>
0.04 – 0.06 mm <DOHC–GDI for PAJERO io>
Limit:
Intake: 0.10 mm
Exhaust: 0.15 mm
E Mitsubishi Motors Corporation
E
Jun. 2002
PWEE9502-K
Revised
11A-9-11
4G9 ENGINE (E-W) - Cylinder Head and Valves
VALVE SEAT RECONDITIONING PROCEDURE
0.9 - 1.3 mm
0.9 - 1.3 mm
(1) Before correcting the valve seat, check the clearance
between the valve guide and valve. If necessary, replace
the valve and/or valve guide.
65_
65_
(2) Using the appropriate special tool or seat grinder, correct
the valve seat to achieve the specified seat width and
angle.
(3) After correcting the valve seat, lap the valve and valve
seat using lapping compound. Then, check the valve
stem projection (refer to VALVE SEAT in INSPECTION).
15_
15_
44_
44_
VALVE SEAT REPLACEMENT PROCEDURE
0.5 - 1.0 mm
(1) Cut the valve seat to be replaced from the inside to thin
the wall thickness. Then, remove the valve seat.
(2) Rebore the valve seat hole in the cylinder head to a
selected oversize valve seat diameter.
Cut away
Intake valve seat hole diameter
0.3 O.S. <SOHC>: 31.80 - 31.83 mm
<DOHC>: 34.30 - 34.33 mm
0.5 - 1.0 mm
0.6 O.S. <SOHC>: 32.10 - 32.13 mm
<DOHC>: 34.60 - 34.63 mm
Exhaust valve seat hole diameter
0.3 O.S. <SOHC>: 29.30 - 29.32 mm
<DOHC>: 30.80 - 30.83 mm
0.6 O.S. <SOHC>: 29.60 - 29.62 mm
<DOHC>: 31.10 - 31.13 mm
Valve seat
height
Oversize valve seat
hole diameter
(3) Before fitting the valve seat, either heat the cylinder head
up to approximately 250_C or cool the valve seat in liquid
nitrogen, to prevent the cylinder head bore from galling.
(4) Correct the valve seat to the specified width and angle.
VALVE GUIDE REPLACEMENT
(1) Force the valve guide out toward the cylinder block using
a press.
(2) Machine the valve guide hole in the cylinder head to
the size of the oversize valve guide to be installed.
Caution
Do not use the valve guide of the same size as the
removed one.
Valve guide hole diameters in cylinder head
0.05 O.S.: 11.05 - 11.07 mm
0.25 O.S.: 11.25 - 11.27 mm
0.50 O.S.: 11.50 - 11.52 mm
Revised
Mitsubishi Motors Corporation
July 1997
PWEE9502-C
E
11A-9-12
4G9 ENGINE (E-W) - Cylinder Head and Valves
(3) Press-fit the valve guide until it protrude specified value
(SOHC: 14 mm, DOHC: 19 mm) as shown in the
illustration.
Caution
1. Press the valve guide from the cylinder head top
surface.
2. Valve guide for intake valve and that for exhaust
valve are different in length. (45.5 mm for intake
valve; 50.5 mm for exhaust valve)
Protrusion
(4) After the valve guide has been installed, insert a new
valve to check for smooth sliding motion.
Mitsubishi Motors Corporation
Nov. 1995
PWEE9502-A
Added
E
11A-10-1
4G9 ENGINE (E–W) – Front Case and Oil Pump
10. FRONT CASE AND OIL PUMP
REMOVAL AND INSTALLATION <SOHC (4G92, 4G93)>
13
7
11
23 Nm
Removal steps
"FA 1. Oil pressure switch
10. Relief spring
11. Relief plunger
"EA 2. Oil filter
3. Drain plug
4. Drain plug gasket
5. Transmission stay
"CA 12. Oil seal
"BA 13. Oil pump case
14. O-ring
AA" "DA 6. Oil pan
15. Oil pump case cover
7. Oil screen
AC" "AA 16. Outer rotor
8. Oil screen gasket
AC" "AA 17. Inner rotor
9. Relief plug
E Mitsubishi Motors Corporation
E
Jun. 2002
PWEE9502-K
Revised
11A-10-1a
4G9 ENGINE (E–W) – Front Case and Oil pump
REMOVAL AND INSTALLATION <SOHC (4G94 Except for PAJERO io)>
Removal steps
"FA 1. Oil pressure switch
11. Relief plug
"EA 2. Oil filter
12. Relief spring
3. Drain plug
13. Relief plunger
4. Drain plug gasket
5. Cover
"CA 14. Oil seal
"BA 15. Oil pump case
16. O-ring
6. Baffle plate
AB" "DA 7. Upper oil pan
"DA 8. Lower oil pan
9. Oil screen
17. Oil pump case cover
AC" "AA 18. Outer rotor
AC" "AA 19. Inner rotor
10. Oil screen gasket
E Mitsubishi Motors Corporation
E
Jun. 2002
PWEE9502-K
Revised
11A-10-1b
4G9 ENGINE (E–W) – Front Case and Oil pump
REMOVAL AND INSTALLATION <SOHC (4G94 for PAJERO io)>
14
10
9 Nm
Removal steps
"FA 1. Oil pressure switch
10. Relief plug
"EA 2. Oil filter
11. Relief spring
3. Drain plug
4. Drain plug gasket
5. Cover
12. Relief plunger
"CA 13. Oil seal
"BA 14. Oil pump case
15. O-ring
AB" "DA 6. Upper oil pan
"DA 7. Lower oil pan
8. Oil screen
16. Oil pump case cover
AC" "AA 17. Outer rotor
9. Oil screen gasket
AC" "AA 18. Inner rotor
E Mitsubishi Motors Corporation
E
Jun. 2002
PWEE9502-K
Revised
11A-10-2
4G9 ENGINE (E–W) – Front Case and Oil pump
REMOVAL AND INSTALLATION <DOHC (Except GDI for PAJERO io)>
10 Nm
10 Nm
15
17
18
16
19
1
7
10
9
19 Nm
MPI
7 Nm
GDI, MIVEC 11Nm
6
13
12
14
9 Nm
11
44 Nm
14 Nm
24 Nm
3
4
2
39 Nm
5
MPI
7 Nm
GDI, MIVEC 11Nm
8
7 Nm
Apply engine oil to all
moving parts before
installation.
Removal steps
"FA 1. Oil pressure switch
"EA 2. Oil filter
3. Drain plug
11. Relief plug
12. Relief spring
13. Relief plunger
4. Drain plug gasket
5. Cover (GDI, MIVEC)
6. Baffle plate
"CA 14. Oil seal
"BA 15. Oil pump case
16. O-ring
<Except SPACE RUNNER>
17. Oil pump case cover
AB" "DA 7. Upper oil pan
"DA 8. Lower oil pan
9. Oil screen
AC" "AA 18. Outer rotor
AC" "AA 19. Inner rotor
10. Oil screen gasket
E Mitsubishi Motors Corporation
E
Mar. 2001
PWEE9502-I
Revised
11A-10-3
4G9 ENGINE (E–W) – Front Case and Oil pump
REMOVAL AND INSTALLATION <DOHC–GDI for PAJERO io>
7
Removal steps
"FA 1. Oil pressure switch
10. Relief plug
"EA 2. Oil filter
11. Relief spring
3. Drain plug
4. Drain plug gasket
5. Cover
12. Relief plunger
"CA 13. Oil seal
"BA 14. Oil pump case
15. O-ring
AB" "DA 6. Upper oil pan
"DA 7. Lower oil pan
8. Oil screen
16. Oil pump case cover
AC" "AA 17. Outer rotor
9. Oil screen gasket
AC" "AA 18. Inner rotor
E Mitsubishi Motors Corporation
E
Jun. 2002
PWEE9502-K
Revised
11A-10-4
4G9 ENGINE (E-W) - Front Case and Oil Pump
MD998727
REMOVAL SERVICE POINTS
MD998727
AA" OIL PAN REMOVAL
(1) Knock in the special tool deeply between the oil pan
and the cylinder block.
(2) Hitting the side of the special tool, slide the special tool
along the oil pan to remove the oil pan.
AB" REMOVAL OF UPPER OIL PAN
(1) At first remove the bolt (Length: 121 mm <DOHC,
DOHC-GDI for CARISMA>, 116 mm <DOHC-GDI for
PAJERO io>) which is nearest to flywheel, and the remove
the other bolts.
Caution
Never use the special tool (oil pan remover), etc.
AC" OUTER ROTOR/INNER ROTOR REMOVAL
(1) Make alignment dots on the outer and inner rotors for
reference in reassembly.
Alignment dots
INSTALLATION SERVICE POINTS
"AA INNER ROTOR/OUTER ROTOR INSTALLATION
Alignment dots
(1) Apply engine oil to the rotors. Then, install the rotors
ensuring that the alignment dots made at disassembly
are properly aligned.
"BA SEALANT APPLICATION TO OIL PUMP CASE
3 mm diameter
bead sealant
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or
equivalent
Mitsubishi Motors Corporation
Dec. 1998
PWEE9502-E
Revised
E
11A-10-5
4G9 ENGINE (E–W) – Front Case and Oil Pump
"CA CRANKSHAFT FRONT OIL SEAL INSTALLATION
MD998717
Using the special tool, knock the oil seal into the oil pump
case.
Oil pump case
MD998717
Crankshaft
Guide
Oilseal
"DA OIL PAN/UPPER OIL PAN/LOWER OIL PAN
OILPAN, UPPEROILPAN
INSTALLATION
(1) Remove all the remaining gasket from the mating surfaces
using a scraper or a wire brush.
(2) Apply a 4 mm diameter bead of sealant to the oil pan
flange.
See “Form-In-Place Gasket” in “SPECIFICATIONS”.
Specified sealant:
Bolt hole
portion
Mitsubishi Genuine Part No. MD970389 or
equivalent
Groove
portion
(3) Install the oil pan within 15 minutes after applying the
sealant.
LOWER OIL PAN <Except for PAJERO io>
4 mm
diameter
bead
sealant
Bolt hole
portion
Groove portion
E Mitsubishi Motors Corporation
E
Jun. 2002
PWEE9502-K
Revised
11A-10-6
4G9 ENGINE (E–W) – Front Case and Oil Pump
(4) Tighten the lower oil pan mounting bolts in the sequence
<Except for PAJERO io>
shown in the illustration.
"EA OIL FILTER INSTALLATION
(1) Clean the filter installation surface of the cylinder block.
(2) Apply engine oil to the O-ring of the oil filter.
(3) Screw in the oil filter until its O-ring comes in contact
with the base. Then tighten one more turn.
"FA SEALANT APPLICATION TO OIL PRESSURE
SWITCH
(1) Apply sealant to the threads of the switch.
Specified sealant:
3M ATD Part No. 8660 or equivalent
Caution
Use care not to allow the sealant to plug the oil
passage.
INSPECTION
11300730026
OIL PUMP
(1) Check the tip clearance.
Standard value: 0.06 – 0.18 mm
Mitsubishi Motors Corporation
E
Jun. 2002
PWEE9502-K
Revised
11A-10-7
4G9 ENGINE (E-W) - Front Case and Oil Pump
(2) Check the side clearance.
Standard value: 0.04 - 0.10 mm
(3) Check the body clearance.
Standard value: 0.10 - 0.18 mm
Limit: 0.35 mm
Mitsubishi Motors Corporation
Dec. 1998
PWEE9502-E
Added
E
11A-11-1
4G9 ENGINE (E-W) - Piston and Connecting Rod
11. PISTON AND CONNECTING ROD
REMOVAL AND INSTALLATION
Lubricate all inter-
nal parts with en-
gine oil during re-
assembly.
6
7
8
9
4
10
12
11
5
3
2
1
Removal steps
"GA 1. Nut
"CA 7. Piston ring No. 2
AA" "FA 2. Connecting rod cap
"EA 3. Connecting rod bearing
"DA 4. Piston and connecting rod
"EA 5. Connecting rod bearing
"CA 6. Piston ring No. 1
"BA 8. Oil ring
AB" "AA 9. Piston pin
10. Piston
11. Connecting rod
12. Bolt
Mitsubishi Motors Corporation
May 1995
PWEE9502
E
11A-11-2
4G9 ENGINE (E-W) - Piston and Connecting Rod
REMOVAL SERVICE POINTS
AA" CONNECTING ROD CAP REMOVAL
(1) Mark the cylinder number on the side of the connecting
rod big end for correct reassembly.
Cylinder number
AB" PISTON PIN REMOVAL
Piston pin setting tool: MD998780
Piston pin setting tool (MD998780) consists of the parts shown
in the illustration at left.
To remove the piston pin, Guide D (MB991659) is also used
in combination with the Piston pin setting tool.
Guide A:
17.9 mm
Push rod
Guide B
Guide A:
18.9 mm
Guide C
Base
Guide A:
20.9 mm
Guide A:
21.9 mm
(1) Insert the Push Rod (special tool) into the piston from
the side on which the front mark is stamped in the piston
head, and attach the guide D to the push rod end.
(2) Place the piston and connecting rod assembly on the
Piston Pin Setting Base (special tool) with the front mark
facing upward.
Push rod
Front mark
(3) Using a press, remove the piston pin.
Front
mark
NOTE
Keep the disassembled pistons, piston pins and
connecting rods in order according to the cylinder number.
Guide D
Base
Mitsubishi Motors Corporation
Nov. 1995
PWEE9502-A
Revised
E
11A-11-3
4G9 ENGINE (E–W) – Piston and Connecting Rod
INSTALLATION SERVICE POINTS
"AA PISTON PIN INSTALLATION
Manufacturingdate
(1) When replacing a piston, read off the cylinder bore size
mark on the cylinder block as illustrated, and select a
piston of proper size according to the following table.
Check digit
No. 1
No. 2
No. 3
No. 4
Cylinder bore size
mark
Piston class
Piston size mark
Cylinder bore
size mark
A
B
C
A
B
C
A
None
C
NOTE
The piston size mark shows on the top of the piston.
(2) Measure the following dimensions of the piston, piston
pin and connecting rod.
A: Piston pin insertion hole length
B: Distance between piston bosses
C: Piston pin length
D: Connecting rod small end width
(3) Calculate the following formula by substituting the
measured value.
L = ((A – C) – (B – D))/2
(4) Insert the Push Rod (special tool) into the piston pin and
attach the guide A to the push rod end.
(5) Assemble the connecting rod in the piston with their front
marks facing the same direction.
(6) Apply engine oil to the entire periphery of the piston pin.
(7) Insert the piston pin, push rod and guide A assembly
having assembled in step (3) from the guide A side into
the piston pin hole on the front marked side.
(8) Screw the guide B into the guide A until the gap between
both guides amounts to the value L obtained in step
(3) plus 3 mm.
E Mitsubishi Motors Corporation
E
Apr. 2003
PWEE9502-L
Revised
11A-11-4
4G9 ENGINE (E–W) – Piston and Connecting Rod
(9) Place the piston and connecting rod assembly onto the
piston setting base with the front marks directed upward.
(10)Press-fit the piston pin using a press. If the press-fitting
force required is less than the standard value, replace
the piston and piston pin set or/and the connecting rod.
Standard value: 4,500 – 14,700 N
"BA OIL RING INSTALLATION
(1) Fit the oil ring spacer into the piston ring groove. Install
the upper side rail, and then install the lower side rail.
NOTE
1. The side rails and spacer may be installed in either
direction.
2. New spacer and side rail are painted with the following
identification colour according to the size.
Size
Identification colour
∗
∗
2
1
Standard size
0.50 mm O.S.
1.00 mm O.S.
None or red
Blue
Side rail end
Yellow
∗
1: Except PAJERO io 4G94–16-valve for General
Export, South Africa, Egypt
∗
2: PAJERO io 4G94–16-valve for General Export,
South Africa, Egypt
3. To install the side rail, first fit one end of the rail
into the piston groove, then press the remaining
portion into position by finger as shown in the
illustration.
Caution
Do not use piston ring expander when installing side
rail. Use of piston ring expander to expand the side
rail end gap can break the side rail, unlike other piston
rings.
(2) Make sure that the side rails move smoothly in either
direction.
E Mitsubishi Motors Corporation
E
Jun. 2002
PWEE9502-K
Revised
11A-11-5
4G9 ENGINE (E–W) – Piston and Connecting Rod
"CA PISTON RING NO.2/PISTON RING NO.1
INSTALLATION
(1) Using piston ring expander, install the piston rings with
their side having identification marks facing up.
Identification mark:
No.1 ring: T
No.2 ring: 2T or T2
NOTE
Identification mark “T”
I
The piston ring is stamped with the following size mark.
“
Size
Size mark
None
50
Standard size
0.50 mm O.S.
1.00 mm O.S.
100
"DA PISTON AND CONNECTING ROD INSTALLATION
(1) Liberally coat engine oil on the circumference of the piston,
piston ring and oil ring.
(2) Arrange the piston ring and oil ring gaps (side rail and
spacer) as shown in the illustration.
(3) Face the front mark (arrow) on the top of the piston toward
the camshaft sprocket.
(4) Using a suitable piston ring compressor tool, insert the
piston and connecting rod assembly into the cylinder block.
Caution
Do not strike the piston into the cylinder block because
the piston ring or crank pin will be damaged.
E Mitsubishi Motors Corporation
E
Apr. 2003
PWEE9502-L
Revised
11A-11-6
4G9 ENGINE (E–W) – Piston and Connecting Rod
"EA CONNECTING ROD BEARING INSTALLATION
(1) When the bearings are to be replaced, select correct
ones according to the identification marks stamped in
the crankshaft.
Crankshaft
Pin O.D.
Connecting rod bearing
Identification Identification colour (Line
identification mark (service
production part)
mark
part)
l
1
2
3
S1 or 1
S2 or 2
S3 or 3
Brown
Black
Green
P
P view
Check digit
No.4
No.3
No.2
No.1
Mitsubishi Motors Corporation
E
Jun. 2002
PWEE9502-K
Revised
11A-11-7
4G9 ENGINE (E–W) – Piston and Connecting Rod
"FA CONNECTING ROD CAP INSTALLATION
(1) Mate the correct bearing cap with the correct connecting
rod by checking with the alignment marks marked during
disassembly. If a new connecting rod has no alignment
mark, position the notches for locking the bearing on
the same side.
(2) Check if the thrust clearance in the connecting rod big
end is correct.
Standard value: 0.10 – 0.25 mm
Limit: 0.4 mm
"GACONNECTING ROD CAP NUT INSTALLATION
Caution
If the cylinder head has been installed before installing
the connecting rod cap nut, be sure to remove the spark
plugs.
(1) Since the connecting rod cap bolts and nuts are torqued
using the plastic area tightening method, the bolts should
be examined BEFORE reuse. If the bolt threads are
“necked down”, the bolt should be replaced.
Necking can be checked by running a nut with fingers
to the full length of the bolt threads. If the nut does not
run down smoothly, the bolt should be replaced.
(2) Before installation of each nut, apply engine oil to the
thread portion and bearing surface of the nut.
(3) Install each nut to the bolt and tighten it with fingers.
Then tighten the nuts alternately to install the cap properly.
(4) Tighten the nuts to a torque of 20 Nm.
Paint mark
Paint
mark
90_ – 100_
(5) Make a paint mark on the head of each nut.
(6) Make a paint mark on the bolt end at the position 90_
to 100_ from the paint mark made on the nut in the direction
of tightening the nut.
Bolt
Nut
(7) Give a 90_ to 100_ turn to the nut and make sure that
the paint mark on the nut and that on the bolt are in
alignment.
Caution
1. If the nut is turned less than 90_, proper fastening
performance may not be expected. When
tightening the nut, therefore, be careful to give
a sufficient turn to it.
2. If the nut is overtightened (exceeding 100_), loosen
the nut completely and then retighten it by
repeating the tightening procedure from step (1).
E Mitsubishi Motors Corporation
E
Jun. 2002
PWEE9502-K
Revised
11A-11-8
4G9 ENGINE (E–W) – Piston and Connecting Rod
INSPECTION
11300850074
PISTON RING
(1) Check the clearance between the piston ring and ring
groove. If the limit is exceeded, replace the ring or piston,
or both.
Standard value:
No.1: 0.03 – 0.07 mm
No.2: 0.02 – 0.06 mm
Limit:
No.1: 0.1 mm
No.2: 0.1 mm
Install the piston ring into the cylinder bore. Force the
ring down with a piston, the piston crown being in contact
with the ring, to correctly position it at right angles to
the cylinder wall. Then, measure the end gap with a
thickness gauge.
If the ring gap is excessive, replace the piston ring.
Standard value:
No.1: 0.25 – 0.40 mm (4G92, 4G93)
0.15 – 0.30 mm (4G94)
No.2: 0.40 – 0.55 mm
Oil:
SOHC (4G92, 4G93): 0.20 – 0.60 mm
SOHC (4G94), DOHC: 0.10 – 0.35 mm
Limit:
No.1, No.2: 0.8 mm
Oil: 1.0 mm
CRANKSHAFT PIN OIL CLEARANCE (PLASTIGAUGE
METHOD)
(1) Remove oil from crankshaft pin and connecting rod
bearing.
(2) Cut the Plastigauge to the same length as the width of
bearing and place it on crankshaft pin in parallel with
its axis.
(3) Install the connecting rod cap carefully and tighten the
bolts to specified torque.
(4) Carefully remove the connecting rod cap.
(5) Measure the width of the Plastigauge at its widest part
by using a scale printed on the Plastigauge package.
Standard value: 0.02 – 0.05 mm
Limit: 0.1 mm
E Mitsubishi Motors Corporation
E
Mar. 2001
PWEE9502-I
Revised
11A-12-1
4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate
12. CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE PLATE
REMOVAL AND INSTALLATION (MANUAL TRANSMISSION)
Flange 10 Nm
Washer 9 Nm
Apply engine oil to all
moving parts before
installation.
Removal steps
"FA 1. Flywheel bolt
"CA 13. Bearing cap bolt
"CA 14. Bearing cap
2. Flywheel
"FA 3. Flywheel bolt
4. Plate
"BA 15. Crankshaft bearing, lower
16. Crankshaft
5. Adapter plate
6. Flywheel
"BA 17. Thrust plate
"BA 18. Crankshaft bearing, upper
7. Adapter plate
8. Rear plate
19. Knock sensor
<Except GALANT–CARBURETOR,
LANCER for Australia>
9. Bell housing cover
<4G92–SOHC, 4G93–SOHC>
AA" "AA 20. Oil jet
"EA 10. Rear oil seal case
<DOHC–MIVEC>
21. Cylinder block
"DA 11. Oil seal
12. Baffle plate
<MIVEC engine manufactured from
Nov. 1995 to Dec. 1995>
Caution
On the flexible wheel equipped engines, do not remove any of the bolts “A” of the flywheel shown
in the illustration.
The balance of the flexible flywheel is adjusted in an assembled condition. Removing the bolt,
therefore, can cause the flexible flywheel to be out of balance, giving damage to the flywheel.
E Mitsubishi Motors Corporation
E
Apr. 2002
PWEE9502-J
Revised
11A-12-1a
4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate
REMOVAL AND INSTALLATION (AUTOMATIC TRANSMISSION)
SPACE STAR
10 Nm
<Drive plate with ring gear>
23 Nm
Except SPACE STAR 11 Nm
7
18
10
20
1
9
2
98 Nm
3
11 Nm
17
4
8
19
5
98 Nm
6
16
15
<Except drive plate with ring
gear>
14
Flange 10 Nm
Washer 9 Nm
13
12
Apply engine oil to all
moving parts before
installation.
11
9 Nm
Removal steps
"FA 1. Flywheel bolt
"CA 12. Bearing cap bolt
"CA 13. Bearing cap
2. Adapter plate
3. Drive plate
"BA 14. Crankshaft bearing, lower
15. Crankshaft
"FA 4. Drive plate bolt
5. Adapter plate
"BA 16. Thrust plate
6. Drive plate
"BA 17. Crankshaft bearing, upper
7. Rear plate
18. Knock sensor
8. Bell housing cover
<Except GALANT–CARBURETOR,
<4G92–SOHC, 4G93–SOHC>
LANCER for Australia>
AA" "AA 19. Oil jet <DOHC–MIVEC>
20. Cylinder block
"EA 9. Rear oil seal case
"DA 10. Oil seal
11. Baffle plate
<MIVEC engine manufactured from
Nov. 1995 to Dec. 1995>
Mitsubishi Motors Corporation
Apr. 2002
PWEE9502-J
Revised
E
11A-12-1b
4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate
REMOVAL AND INSTALLATION <PAJERO io>
Flange bolt
Bolt, washer assembly 9 Nm
10 Nm
Removal steps
"FA 1. Flywheel bolt <M/T>
13. Bell housing cover
<with transmission stay>
"EA 14. Rear oil seal case
"DA 15. Oil seal
2. Flywheel <M/T>
"FA 3. Flywheel bolt <M/T>
4. Plate <M/T>
5. Adapter plate <M/T>
6. Flywheel <M/T>
"CA 16. Bearing cap bolt
"CA 17. Bearing cap
"BA 18. Crankshaft bearing, lower
19. Crankshaft
7. Adapter plate <M/T>
"FA 8. Drive plate bolt <A/T>
9. Adapter plate <A/T>
10. Drive plate <A/T>
11. Crankshaft adaptor <A/T>
12. Rear plate
"BA 20. Thrust plate
"BA 21. Crankshaft bearing, upper
22. Knock sensor
23. Cylinder block
Caution
On the flexible wheel equipped engines, do not remove any of the bolts “A” of the flywheel shown
in the illustration.
The balance of the flexible flywheel is adjusted in an assembled condition. Removing the bolt,
therefore, can cause the flexible flywheel to be out of balance, giving damage to the flywheel.
Mitsubishi Motors Corporation
Jun. 2002
PWEE9502-K
Revised
E
11A-12-2
4G9 ENGINE (E-W) - Crankshaft, Cylinder Block, Flywheel and Drive Plate
REMOVAL SERVICE POINT
AA" OIL JET REMOVAL
(1) Knock out the oil jets using an appropriate metal rod.
Caution
1. Be careful not to scratch the cylinder wall.
2. Do not reuse the removed oil jets.
INSTALLATION SERVICE POINTS
"AA OIL JET INSTALLATION
(1) Using a 4.5 mm diameter pin punch, drive in the oil jet
to the crankshaft journal until it seats to the bottom.
"BA CRANKSHAFT BEARING INSTALLATION
(1) When the bearings are to be replaced, select correct
ones and install them in the correct positions according
to the identification marks stamped on the crankshaft
and the top surface of the cylinder block.
Check digit
Crank pin
O.D.identifi-
cation mark
Crankshaft
journal
Cylinder
block bearing
bore
Crankshaft bearing
No. 5
No. 4
No. 3
No. 2
No. 1
Journal
O.D.identifi-
cation mark
Identification Identification Identification
Identification
colour (Line
production parts)
mark
mark
mark (service
parts)
1
0
1
2
0
1
2
0
1
2
S1
S2
S3
S2
S3
S4
S3
S4
S5
Brown
Black
Green
Black
Green
Yellow
Green
Yellow
Pink*
2
3
*: Older bearings may be marked in red.
Mitsubishi Motors Corporation
May 2000
PWEE9502-G
Revised
E
11A-12-3
4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate
P
P view
No.5
No.4
No.3
No.2
No.1
Oil pan view
Cylinder head view (Reference)
Timing belt side
Timing belt side
No. 5
No. 4
No. 3
No. 3
No. 2
No. 1
No. 4
No. 2
No. 1
No. 5
(2) Install the bearings having an oil groove to the cylinder
block.
(3) Install the bearings having no oil groove on the bearing
caps.
Oil groove
(4) Install the thrust bearings at the No. 3 upper bearing
with the grooved side towards the crank web.
Grooves
Identification
mark
Identifica-
tion colour
Identification
colour
Identification
colour
E Mitsubishi Motors Corporation
E
Mar. 2001
PWEE9502-I
Revised
11A-12-4
4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate
"CA BEARING CAP/BEARING CAP BOLT INSTALLATION
(1) Install the bearing caps so that their arrows are positioned
on the time belt side.
(2) When installing the bearing cap bolts, check that the
shank length of each bolt meets the limit. If the limit is
exceeded, replace the bolt.
Limit: max. 71.1 mm
(3) Apply engine oil to the threaded portion and bearing
surface of the bolt.
Length of shank
(4) Tighten the bearing cap bolts to 25 Nm torque in the
tightening sequence.
(8)
(4)
(3)
(1)
(2)
(5)
(6)
(9)
(7)
(10)
Arrow
(5) Make a paint mark on the head of each bolt.
(6) Make a paint mark on the area around the bolt bearing
surface at location 90_ to 100_ in the direction of tightening
the bolt, as referenced from the paint mark on the bolt
head.
Paint
marks
Paint marks
(7) Give a 90_ to 100_ turn to the bolts in the tightening
sequence. Make sure that the paint mark on the bolt
and that on the area around the bolt bearing surface
are in alignment.
90_ – 100_
Caution
1. If the bolt is turned less than 90_, proper fastening
performance may not be expected.
When
tightening the bolt, therefore, be careful to give
a sufficient turn to it.
2. If the bolt is overtightened (exceeding 100_),
loosen the bolt completely and then retighten it
by repeating the tightening procedure from step
(1).
(8) After installing the bearing caps, make sure that the
crankshaft turns smoothly and the end play is correct.
If the end play exceeds the limit, replace crankshaft
bearings.
Standard value: 0.05 – 0.25 mm
Limit: 0.4 mm
E Mitsubishi Motors Corporation
E
Mar. 2001
PWEE9502-I
Revised
11A-12-5
4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate
"DA OIL SEAL INSTALLATION
"EA SEALANT APPLICATION TO OIL SEAL CASE
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or
equivalent
"FA DRIVE PLATE BOLT/FLYWHEEL BOLT
INSTALLATION
(1) Remove all the ramaining sealant from bolts and thread
holes of crankshaft.
(2) Apply engine oil to the flange of bolt.
(3) Apply engine oil into the thread holes of crankshaft.
(4) Apply specified sealant to the thread of bolts.
Specified sealant:
3M Nut Locking Part No. 4171 or equivalent
(5) Tighten the bolts to specified torque.
INSPECTION
CRANKSHAFT JOURNAL OIL CLEARANCE
(PLASTIGAUGE METHOD)
(1) Remove oil from the crankshaft journal and he crankshaft
bearing.
(2) Install the crankshaft.
(3) Cut the Plastigauge to the same length as the width of
bearing and place it on the journal in parallel with its
axis.
Plastigauge
(4) Install the crankshaft bearing cap carefully and tighten
the bolts to the specified torque.
(5) Carefully remove the crankshaft bearing cap.
(6) Measure the width of the Plastigauge at its widest part
by using a scale printed on the Plastigauge package.
Standard value: 0.02 – 0.04 mm
Limit: 0.1 mm
Plastigauge
E Mitsubishi Motors Corporation
E
Mar. 2001
PWEE9502-I
Revised
11A-12-6
4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate
CYLINDER BLOCK
(1) Using a straightedge and thickness gauge, check the
block top surface for warpage. Make sure that the surface
is free from gasket chips and other foreign matter.
Standard value: 0.05 mm or less
Limit: 0.1 mm
(2) If the distortion is excessive, correct within the allowable
limit or replace.
Grinding limit: 0.2 mm
The total thickness of the stock allowed to be
removed from cylinder block and mating cylinder
head 0.2 mm at maximum.
Cylinder block height (when new):
243.5 mm <4G92>
263.5 mm <4G93>
286.7 mm <4G94>
(3) Check the cylinder walls for scratches and seizure. If
defects are evident, correct (bored to oversize) or replace.
(4) Using a cylinder gauge, measure the cylinder bore and
cylindricity. If worn badly, correct the cylinder to an
oversize and replace the piston and piston rings. Measure
at the points shown in illustration.
A
B
Standard value:
12 mm
Cylinder inner diameter:
4G92, 4G93
4G94
81.00 – 81.03 mm
81.50 – 81.53 mm
Centre
Bottom
Out-of-roundness and taper of cylinder bore: 0.01
mm or less
BORING CYLINDER
(1) Oversize pistons to be used should be determined on
the basis of the largest bore cylinder.
Piston size identification
Size
Identification mark
0.50 mm O.S.
1.00 mm O.S.
0.50
1.00
NOTE
Size mark is stamped on the piston top.
(2) Measure outside diameter of piston to be used. Measure
it in thrust direction as shown.
(3) Based on the measured piston O.D., calculate the boring
finish dimension.
Boring finish dimension = Piston O.D. + (Clearance
between piston O.D. and cylinder) – 0.02 mm
(honing margin)
(4) Bore all cylinders to the calculated boring finish dimension.
E Mitsubishi Motors Corporation
E
Mar. 2001
PWEE9502-I
Revised
11A-12-7
4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate
Caution
To prevent distortion that may result from temperature
rise during honing, bore cylinders, in the order of
No. 2, No. 4, No.1 and No. 3.
(5) Hone to the final finish dimension (Piston O.D. + clearance
between piston O.D. and cylinder.)
(6) Check the clearance between piston and cylinder.
Clearance between piston and cylinder:
0.02 – 0.04 mm
NOTE
When boring cylinders, finish all of four cylinders to the
same oversize. Do not bore only one cylinder to an
oversize.
HYDRO-FLYWHEEL <DOHC–GDI for PAJERO io>
(1) Check the rear side of the flywheel for color of the hatched
area A in the illustration, and determine whether it is
serviceable or not in accordance with the criteria given
in the following table.
A
If judged unendurable for reuse, replace the flywheel
assembly.
Color
Purple
Dark blue Light blue
Not reusable
Gray
Judgment Reusable
4ME0272
(2) Measure the play in the circumferential direction using
the following procedure.
Flywheel
Distance moved
(3) Turn the flywheel clockwise and anticlockwise to measure
the distance over which the dowel pin moves freely.
Limit: 9 mm
Dowelpin
4ME0273
(4) Check the friction surface for runout in the following
manner.
(5) Apply a thrust force of approx. 98 N by hand on the
flywheel to move it in the axial direction, and measure
the runout at the dowel pin position. If the limit is exceeded,
replace the flywheel assembly.
Runout
Dowelpin
Flywheel
Limit: 0.75 mm
4ME0274
E Mitsubishi Motors Corporation
E
Mar. 2001
PWEE9502-I
Revised
NOTES
Service Bulletins
Click on the applicable bookmark to select the Service Bulletin.
SERVICE BULLETIN
QUALITY INFORMATION ANALYSIS
OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION
No.:
MSB-99E11-001
SERVICE BULLETIN
Date:
<Model>
<M/Y>
1999-12-15
(EC) COLT (CJ,CK)
(EC) LANCER (CJ,CK)
(EC) SPACE STAR
(DG1A, DG5A)
96-10
96-10
96-10
96-10
96-10
96-10
Subject:
Group:
CHANGE IN POSITIONS OF CRANKSHAFT
IDENTIFICATION MARKS
Draft No.:
ENGINE
99EN531509
(EC) CARISMA
(EC) SPACE RUNNER
(N60,N90)
(EC) PAJERO iO (H6,
H7)
INTERNATIONAL
CAR
ADMINISTRATION
OFFICE
INFORMATION
T.NITTA - PROJECT LEADER
AFTER SALES SERVICE & CS PROMOTION
1. Description:
This Service Bulletin informs you that the journal O.D. identification marks and the pin O.D.
identification marks have been changed in their positions.
2. Applicable Manuals:
Manual
Pub. No.
Language
Page(s)
’98 4G9 Series
(E-W) Engine Supplement
PWEE9502-E
PWES9503-E
PWEF9504-E
PWEG9505-E
PWED9506-E
PWEW9507-E
PWEE9101-E
PWES9102-E
PWEF9103-E
PWEG9104-E
PWED9105-E
PWEW9106-E
(English) 11A-12-2
(Spanish)
(French)
(German)
(Dutch)
(Swedish)
(English) 11A-18-6
(Spanish)
(French)
(German)
(Dutch)
(Swedish)
’96 4G9 Series
Engine Supplement
3. Effective Date:
From September 1997
Effective model: 4G93-G-10Z3K (HP9123)
• Crankshaft weight
Front
Journal O.D.
identification
mark
Journal O.D.
identification
mark
Pin O.D.
identification
mark
Pin O.D.
identification
mark
New
Old
2
SERVICEPUBLICATION & TRAINING
INTERNATIONALAFTER-SALESDEPARTMENT. MITSUBISHI MOTORSCORPORATION
NO. : MSB–03E11–001
SERVICE BULLETIN
DATE : 2003–01–20
<MODEL>
<M/Y>
(EUR)CARISMA(DX) 97–01
(EUR)SPACE
RUNNER(DZ)
(EUR)SPACE
WAGON(DZL)
SUBJECT : DISUSE OF INJECTOR BACKUP RINGS IN GDI
ENGINES
(EUR)GALANT(ST41)
(EUR)SPACE STAR
(MGX)
GROUP : ENGINE
DRAFTNO. : 02EN516
(EUR)PAJERO
PININ(KR)
(EUR)PAJERO/
MONTERO(CK)
INTERNATIONAL
AFTERĆSALES
DEPARTMENT
INFORMATION
T. Kobayashi – Manager SERVICE
PUBLICATION & TRAINING
1.
Description:
This service bulletin informs you of disuse of one of the backup rings that has been used in
each fuel injector on GDI engines.
2.
3.
Applicable Manuals:
See attachment.
Effective date:
From the engines produced in the middle of July 2002. This modification is also applicable
to the engines produced before that date, as modified injectors will be supplied as service parts
for these engines.
4.
Details:
The backup ring indicated by the arrow in the drawing below has been disused.
Backup ring
O-ring
Backup ring
Fuel injector
Disused
Insulator
MSB–03E11–001
1
Attachment
Applicable Manuals:
Manual
Pub. No.
Page
11A-5a-1,
11A-5a-2a
ENGINE 4G6 (E–W)
Workshop Manual
PWEE9616 (English)
PWES9617 (Spanish)
PWEF9618 (French)
PWEG9619 (German)
PWED9620 (Dutch)
PWEW9621 (Swedish)
PWEE9502 (English)
PWES9503 (Spanish)
PWEF9504 (French)
PWEG9505 (German)
PWED9506 (Dutch)
ENGINE 4G9 (E–W)
Workshop Manual
11A-6c-1,
11A-6c-1a,
11A-6c-1b,
11A-6c-2
PWEW9507 (Swedish)
PWEE9061 (English)
PWES9062 (Spanish)
PWEF9063 (French)
PWEG9064 (German)
PWED9065 (Dutch)
ENGINE 6G7 (E–W)
Workshop Manual
11A-6c-1,
11B-8-3
PWEW9066 (Swedish)
PWDE9502-C (English)
PWDS9503-C (Spanish)
PWDF9504-C (French)
PWDG9505-C (German)
PWDD9506-C (Dutch)
PWDW9507-C (Swedish)
PWDE9502-E (English)
PWDS9503-E (Spanish)
PWDF9504-E (French)
PWDG9505-E (German)
PWDD9506-E (Dutch)
PWDW9507-E (Swedish)
’98 CARISMA GDI
Workshop Manual chassis
13J-103, 104
13J-134, 135
2001 CARISMA
Workshop Manual chassis
MSB–03E11–001
2
|