Mitsubishi 4G1 series General Information Manual Download

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GENERAL INFORMATION

11A-0-3

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1. SPECIFICATIONS

11A-1-1

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SERVICE SPECIFICATIONS

11A-1-1

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REWORK DIMENSIONS

11A-1-3

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TORQUE SPECIFICATIONS

11A-1-4

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NEW TIGHTENING METHOD-BY USE OF BOLTS TO BE

TIGHTENED IN PLASTIC AREA

11A-1-6

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SEALANT

11A-1-6

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FORM-IN-PLACE GASKET

11A-1-7

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2. SPECIAL TOOLS

11A-2-1

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3. ALTERNATOR AND IGNITION SYSTEM

11A-3-1

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4. TIMING BELT

11A-4-1

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5. FUEL AND EMISSION CONTROL SYSTEMS

11A-5-1

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5a. INTAKE MANIFOLD AND THROTTLE BODY (GDI)

11A-5a-1

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5b. EXHAUST MANIFOLD (GDI)

11A-5b-1

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6. WATER PUMP AND WATER HOSE

11A-6-1

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7. INTAKE AND EXHAUST MANIFOLDS

11A-7-1

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7a. FUEL SYSTEM (GDI)

11A-7a-1

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8. ROCKER ARMS AND CAMSHAFTS

11A-8-1

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8a. ROCKER ARMS AND CAMSHAFTS (GDI)

11A-8a-1

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9. CYLINDER HEAD AND VALVES

11A-9-1

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10. OIL PUMP AND OIL PAN

11A-10-1

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11. PISTONS AND CONNECTING RODS

11A-11-1

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12. CRANKSHAFT AND CYLINDER BLOCK

11A-12-1

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11A-0-1

PWEE9520

Nov. 1995

Mitsubishi Motors Corporation

ENGINE

4G1 SERIES

CONTENTS

PWEE9520-D

Aug. 2000

Mitsubishi Motors Corporation

Revised

Summary of Contents for 4G1 series

Page 1: ...OL SYSTEMS 11A 5 1 5a INTAKE MANIFOLD AND THROTTLE BODY GDI 11A 5a 1 5b EXHAUST MANIFOLD GDI 11A 5b 1 6 WATER PUMP AND WATER HOSE 11A 6 1 7 INTAKE AND EXHAUST MANIFOLDS 11A 7 1 7a FUEL SYSTEM GDI 11A 7a 1 8 ROCKER ARMS AND CAMSHAFTS 11A 8 1 8a ROCKER ARMS AND CAMSHAFTS GDI 11A 8a 1 9 CYLINDER HEAD AND VALVES 11A 9 1 10 OIL PUMP AND OIL PAN 11A 10 1 11 PISTONS AND CONNECTING RODS 11A 11 1 12 CRANKS...

Page 2: ...11A 0 2 PWEE9520 E Nov 1995 Mitsubishi Motors Corporation NOTES ...

Page 3: ...4G1 ENGINE E W General Information 11A 0 3 PWEE9520 E Nov 1995 Mitsubishi Motors Corporation GENERAL INFORMATION ...

Page 4: ...4G1 ENGINE E W General Information 11A 0 4 PWEE9520 E Nov 1995 Mitsubishi Motors Corporation ...

Page 5: ... 0 Compression ratio 9 5 9 5 Number of Intake 8 8 valves Exhaust 4 4 Valve timing Intake opens BTDC 14_ BTDC 19_ Intake closes ABDC 48_ ABDC 43_ Exhaust opens BBDC 55_ BBDC 60_ Exhaust closes ATDC 13_ ATDC 8_ Lubrication system Pressure feed full flow filtration Pressure feed full flow filtration Oil pump type Trochoid type Trochoid type Cooling system Water cooled forced circulation Water cooled ...

Page 6: ... 9 5 10 9 5 1 Number of valves Intake 8 8 valves Exhaust 8 8 Valve timing Intake opens BTDC 12_ BTDC 17_ Intake closes ABDC 48_ ABDC 39_ Exhaust opens BBDC 48_ BBDC 49_ Exhaust closes ATDC 12_ ATDC 7_ Lubrication system Pressure feed full flow filtration Pressure feed full flow filtration Oil pump type Trochoid type Trochoid type Cooling system Water cooled forced circulation Water cooled forced c...

Page 7: ... 14_ BTDC 13_ 1 BTDC 16_ BTDC 12_ Intake closes ABDC 48_ ABDC 48_ ABDC 47_ 1 ABDC 40_ ABDC 44_ Exhaust opens BBDC 55_ BBDC 55_ BBDC 56_ 1 BBDC 45_ BBDC 48_ Exhaust closes ATDC 13_ ATDC 13_ ATDC 8_ 1 ATDC 15_ ATDC 12_ Lubrication system Pressure feed full flow filtration Pressure feed full flow filtration Pressure feed full flow filtration Pressure feed full flow filtration Oil pump type Trochoid t...

Page 8: ...st 8 8 Valve timing Intake opens BTDC 12_ BTDC 17_ BTDC 9_ 1 BTDC 17_ 2 Intake closes ABDC 48_ ABDC 39_ ABDC 51_ 1 ABDC 43_ 2 Exhaust opens BBDC 48_ BBDC 49_ BBDC 49_ 1 BBDC 53_ 2 Exhaust closes ATDC 12_ ATDC 7_ ATDC 15_ 1 ATDC 7_ 2 Lubrication system Pressure feed full flow filtration Pressure feed full flow filtration Oil pump type Trochoid type Trochoid type Cooling system Water cooled forced c...

Page 9: ...SOHC 45 93 45 94 SOHC 16 VALVE 7 44 93 44 94 DOHC 25 95 25 97 Cylinder head and valves Flatness of cylinder head gasket surface mm 0 05 or less Cylinder head gasket surface grinding limit including grinding of cylinder block gasket surface mm 0 2 Cylinder head overall height mm SOHC 12 VALVE 106 9 107 1 SOHC 16 VALVE 119 9 120 1 DOHC 131 9 132 1 Cylinder head bolt nominal length mm 103 2 Valve mar...

Page 10: ... Exhaust 101 05 105 55 SOHC 16 VALVE Intake 111 56 111 06 Exhaust 114 71 114 21 DOHC Intake 106 35 105 85 Exhaust 106 85 106 35 Valve spring free SOHC 12 VALVE Intake 46 1 45 6 height mm Exhaust 46 8 46 3 SOHC 16 VALVE 50 9 50 4 DOHC 49 1 48 6 Valve spring load SOHC 12 VALVE Intake 226 40 0 installed height N mm Exhaust 284 39 6 mm SOHC 16 VALVE 216 44 2 DOHC 177 40 0 Valve spring squareness 2 4 V...

Page 11: ... 700 Crankshaft pin oil clearance mm 0 02 0 04 0 1 Connecting rod big end side clearance mm 0 10 0 25 0 4 Crankshaft and cylinder block Crankshaft end play mm 0 05 0 18 0 25 Crankshaft journal diameter mm 48 0 Crankshaft pin diameter mm 42 0 Crankshaft journal oil clearance mm 0 02 0 04 0 1 Cylinder block gasket surface flatness mm 0 05 or less Cylinder block gasket surface grinding limit includin...

Page 12: ...E W Specifications 11A 1 2b PWEE9520 E Nov 1995 Mitsubishi Motors Corporation Intentionally blank PWEE9520 A E Dec 1998 Mitsubishi Motors Corporation Added PWEE9520 A E Dec 1998 Mitsubishi Motors Corporation Added ...

Page 13: ...50 O S 11 060 11 070 Oversize valve seat ring hole diameter SOHC 12 VALVE Intake primary 0 3 O S 27 300 27 325 ring hole diameter mm 12 VALVE 0 6 O S 27 600 27 625 mm Intake secondary 0 3 O S 32 300 32 325 0 6 O S 32 600 32 625 Exhaust 0 3 O S 35 300 35 325 0 6 O S 35 600 35 625 SOHC 16 VALVE Intake 0 3 O S 28 300 28 321 16 VALVE 4G13 0 6 O S 28 600 28 621 4G13 Exhaust 0 3 O S 26 300 26 321 0 6 O ...

Page 14: ...r bolt 9 Camshaft position sensor support bolt 13 Camshaft position sensing cylinder bolt 21 Timing belt Timing belt cover bolt 11 Timing belt tensioner bolt 23 Crankshaft angle sensor bolt 9 Bracket bolt 21 Engine support bracket bolt M8 21 Engine support bracket bolt nut M10 35 Idler pulley bolt 35 Camshaft sprocket bolt 88 Fuel and emission control system Vacuum pipe hose bolt 9 Delivery pipe b...

Page 15: ...4G1 ENGINE E W Specifications 11A 1 4a PWEE9520 E Nov 1995 Mitsubishi Motors Corporation Item Nm Cover bolt M8 16 18 EGR valve bolt 21 PWEE9520 G E Apr 2003 Mitsubishi Motors Corporation Revised ...

Page 16: ...4G1 ENGINE E W Specifications 11A 1 4b PWEE9520 E Nov 1995 Mitsubishi Motors Corporation Intentionally blank PWEE9520 F E Aug 2001 Mitsubishi Motors Corporation Added ...

Page 17: ...29 Power plant stay left bolt 35 Water pump and water hose Water inlet fitting bolt 22 Water inlet pipe bolt M8 12 Water inlet pipe bolt M10 25 Fitting bolt 23 Water outlet fitting bolt Front wheel drive 23 Water outlet fitting bolt Rear wheel drive 18 Thermostat case bolt 23 Thermo valve 27 Engine coolant temperature gauge unit 11 Engine coolant temperature sensor 29 Water pump bolt 13 Exhaust ma...

Page 18: ...ery pipe and injector bolt 12 Rocker arms and camshaft Fuel pump cover bolt 12 Rocker cover bolt SOHC 3 5 Rocker cover bolt DOHC 4 Rocker shaft assembly bolt 31 Adjusting screw 15 Bearing cap bolt M6 11 Bearing cap bolt M8 24 Rocker arms and camshaft GDI Engine hanger bolt 19 Rocker cover bolt 3 5 Beam camshaft cap bolt M6 11 Beam camshaft cap bolt M8 25 Cylinder head and valves Cylinder head bolt...

Page 19: ...rods Connecting rod nut 17 90_ to 100_ Crankshaft and cylinder block Flywheel bolt 132 Drive plate bolt Except GDI 132 Drive plate bolt GDI 98 Rear plate bolt 10 Bell housing cover bolt 10 Rear oil seal case bolt 11 Bearing cap bolt 34 30_ to 34_ Oil pressure switch 19 Knock sensor 23 PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Revised ...

Page 20: ...equivalent As required Water pump Mitsubishi Genuine Part No MD970389 or equivalent As required Thermo valve Mitsubishi Genuine Part No MD970389 or equivalent As required Thermostat housing Mitsubishi Genuine Part No MD970389 or equivalent As required Water outlet fitting Mitsubishi Genuine Part No MD970389 or equivalent As required Engine coolant temperature sensor 3M Nut Locking Part No 4171 or ...

Page 21: ...raper 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 applicatio...

Page 22: ...NOTES ...

Page 23: ...ad bolts MB991659 Guide D Guide for removal and press fitting of piston pins MB991671 Valve stem installer Press fitting of valve stem seals SOHC 16 VALVE DOHC MD998011 Crankshaft rear oil seal installer Installation of crankshaft rear oil seal MD998054 Oil pressure switch wrench Removal and installation of oil pressure switch MD998304 Crankshaft front oil seal installer Installation of crankshaft...

Page 24: ...osening or tightening bolt used with MB990767 MD998727 Oil pan remover Removal of oil pan MD998735 Valve spring com pressor Compression of valve springs MD998760 Valve stem seal installer Installation of valve stem seals SOHC 12 VALVE MD998762 Circular packing installer Installing of circular packing MD998772 Valve spring com pressor Compression of valve springs MD998780 Piston pin setting tool Re...

Page 25: ... Number MD998781 Flywheel stopper Locking flywheel in fixed position MD998306 Crankshaft front oil seal installer Installation of crankshaft front oil seal MB991962 Crankshaft front oil seal guide Guide for installation of crankshaft oil seal PWEE9520 G E Apr 2003 Mitsubishi Motors Corporation Revised ...

Page 26: ... 3 2 23 Nm 1 11 25 Nm 10 13 12 12 Nm 9 Nm 5 Removal steps 1 Oil level gauge 2 Oil level gauge guide 3 O ring 4 Drive belt 5 Water pump pulley 6 Alternator brace 7 Alternator AA BA 8 Crankshaft bolt BA 9 Crankshaft pulley 10 Spark plug cable 11 Spark plug AA 12 Distributor 13 O ring NOTE For details of adjustment refer to the relevant model s chassis workshop manual PWEE9520 G E Apr 2003 Mitsubishi...

Page 27: ... 10 13 12 12 Nm 9 Nm 5 M12 125 Nm M14 181 Nm Removal steps 1 Oil level gauge 2 Oil level gauge guide 3 O ring 4 Drive belt 5 Water pump pulley 6 Alternator brace 7 Alternator AA BA 8 Crankshaft bolt BA 9 Crankshaft pulley 10 Spark plug cable 11 Spark plug AA 12 Distributor 13 O ring NOTE For details of adjustment refer to the relevant model s chassis workshop manual PWEE9520 G E Apr 2003 Mitsubish...

Page 28: ...m Removal steps 1 Oil level gauge 2 Oil level gauge guide 3 O ring 4 Drive belt 5 Water pump pulley 6 Alternator brace 7 Alternator AA BA 8 Crankshaft bolt BA 9 Crankshaft pulley 10 Spark plug cable 11 Ignition coil 12 Spark plug 13 Ignition failure sensor only vehicles for Europe 14 Cam position sensor CA 15 Cam position sensor support 16 Cam position sensing cylinder NOTE For details of adjustme...

Page 29: ...Removal steps 1 Oil level gauge 2 Oil level gauge guide 3 O ring 4 Drive belt 5 Water pump pulley 6 Alternator brace 7 Alternator AA BA 8 Crankshaft bolt BA 9 Crankshaft pulley 10 Spark plug cable 11 Ignition coil 12 Spark plug 13 Cam position sensor CA 14 Cam position sensor support 15 Cam position sensing cylinder NOTE For details of adjustment refer to the relevant model s chassis workshop manu...

Page 30: ...1 Nm 9 Nm 5 11 Removal steps 1 Oil level gauge 2 Oil level gauge guide 3 O ring 4 Drive belt 5 Water pump pulley 6 Alternator brace 7 Alternator AA BA 8 Crankshaft bolt BA 9 Crankshaft pulley 10 Spark plug cable 11 Spark plug AA 12 Distributor 13 O ring NOTE For details of adjustment refer to the relevant model s chassis workshop manual PWEE9520 E E Feb 2001 Mitsubishi Motors Corporation Revised ...

Page 31: ...m 21 Nm 3 14 11 13 9 Nm 8 Removal steps 1 Oil level gauge 2 Engine hanger 3 Oil level gauge guide 4 O ring 5 Drive belt 6 Water pump pulley 7 Alternator brace 8 Alternator assembly AA BA 9 Crankshaft bolt BA 10 Crankshaft pulley 11 Ignition coil 12 Spark plug 13 Cam position sensor CA 14 Cam position sensor support 15 Cam position sensing cylinder PWEE9520 E E Feb 2001 Mitsubishi Motors Corporatio...

Page 32: ...unting flange BA CRANKSHAFT PULLEY BOLT INSTALLATION 1 Hold the flywheel or drive plate using the special tool 2 Clean the bolt hole in crankshaft crankshaft bolt and crankshaft pulley s seating surface 3 Degrease the cleaned seating surface of the crankshaft pulley 4 Install the crankshaft pulley 5 Apply oil to the threads of crankshaft bolt and the outer surface of washer 6 Tighten the crankshaf...

Page 33: ...lt upper cover 2 Timing belt lower cover AA DA 3 Timing belt CA 4 Tensioner spring CA 5 Timing belt tensioner 6 Crankshaft angle sensor Without Distributor BA 7 Crankshaft sprocket BA 8 Spacer Without Distributor BA 9 Sensing blade Without Distributor BA 10 Flange With Distributor AB AA 11 Camshaft sprocket bolt 12 Camshaft sprocket 13 Engine support bracket 14 Timing belt rear cover PWEE9520 E E ...

Page 34: ...Removal steps 1 Timing belt upper cover 2 Timing belt lower cover AA DA 3 Timing belt CA 4 Tensioner spring CA 5 Timing belt tensioner 6 Crankshaft angle sensor Without Distributor BA 7 Crankshaft sprocket BA 8 Spacer Without Distributor BA 9 Sensing blade Without Distributor AB AA 10 Camshaft sprocket bolt 11 Camshaft sprocket 12 Bracket 13 Engine support bracket PWEE9520 E E Feb 2001 Mitsubishi ...

Page 35: ... Timing belt upper cover 2 Timing belt lower cover AA EA 3 Timing belt AA CA 4 Tensioner spring AA CA 5 Timing belt tensioner 6 Idler pulley BA 7 Crankshaft sprocket BA 8 Flange AB AA 9 Camshaft sprocket bolt 10 Camshaft sprocket 11 Engine support bracket 12 Timing belt rear cover lower 13 Timing belt rear cover right 14 Timing belt rear cover left PWEE9520 E E Feb 2001 Mitsubishi Motors Corporati...

Page 36: ... steps 1 Timing belt front upper cover 2 Timing belt front lower cover AC GA 3 Timing belt 4 Tensioner spring FA 5 Timing belt tensioner 6 Idler pulley 7 Crank angle sensor BA 8 Crankshaft sprocket BA 9 Spacer BA 10 Sensing blade 11 Bracket 12 Right engine support bracket AB AA 13 Camshaft sprocket bolt 14 Camshaft sprocket 15 Timing belt rear upper cover PWEE9520 E E Feb 2001 Mitsubishi Motors Co...

Page 37: ...AL 1 Using the special tools shown in the illustration lock the camshaft sprocket in position 2 Loosen the camshaft sprocket bolt AC TIMING BELT REMOVAL 1 If the timing belt is to be refused it is necessary to install it in the same direction as it was before Mark an arrow that shows the direction of rotation on the back surface of the timing belt with chalk etc 2 Using pliers and the like hold th...

Page 38: ...the side of the belt 6 Abnormal wear on the belt s sides NOTE The sides of the belt are normal if they are sharp as if cut by a knife 7 Abnormal wear on teeth Initial stage Canvas worn fluffy canvas fibers rubbery texture gone white discoloration canvas texture indistinct Final stage Canvas worn exposing rubber tooth width reduced 8 Missing teeth 2 TENSIONER PULLEY AND IDLER PULLEY 1 Check that th...

Page 39: ...he mating surfaces due to presence of oil Type without crank angle sensor 1 Clean the hole in the crankshaft sprocket 2 Clean and degrease the crankshaft sprocket flange and sprocket fitting surface of the crankshaft NOTE Degreasing is necessary to prevent decrease in friction between the mating surfaces due to presence of oil CA TIMING BELT TENSIONER TENSIONER SPRING INSTALLATION 1 Lock the timin...

Page 40: ...he tension side of the timing belt tight fit the timing belt onto the crankshaft sprocket camshaft sprocket and tensioner pulley in that order 4 Loosen the tensioner pulley mounting bolts by 1 4 to 1 2 of a turn and allow the tensioner spring to apply tension to the timing belt 5 Turn the crankshaft twice in the normal rotating direction clockwise and check that the timing marks are correctly alig...

Page 41: ...th from jumping 5 Fit the timing belt onto the idler pulley crankshaft sprocket and tensioner pulley in that order NOTE When fitting the belt keep the camshaft sprocket timing marks correctly aligned and keep the tension side of the belt tight 6 Loosen the tensioner pulley mounting bolts by 1 4 to 1 2 of a turn and allow the tensioner spring to apply tension to the timing belt 7 Remove the bulldog...

Page 42: ...e to the crankshaft sprocket GATIMING BELT INSTALLATION 1 Align the timing marks on each camshaft sprocket NOTE After the timing marks on the sprockets are aligned the sprockets can turn by about one tooth in the direction shown and remain stable in this position 2 Align the crankshaft sprocket timing marks 3 While paying attention to the direction of rotation marked on the timing belt if the timi...

Page 43: ... sprocket are in alignment 7 Loosen the timing belt tensioner securing bolt which has temporarily been tightened a quarter to half turn Utilizing tensioner spring tension give tension to the timing belt 8 Remove the paper clips etc 9 Make two turns of the crankshaft sprocket in clockwise direction to ensure that the timing marks on each camshaft sprocket are in alignment Caution Operation under it...

Page 44: ...OHC 12 VALVE CARBURETOR 17 Nm 12 Nm 31 Nm 21 Nm 11 12 10 9 8 7 3 2 4 5 6 1 10 Nm 13 12 Nm 14 Removal steps 1 Breather tube 2 Fuel hose 3 Hose clamp 4 Fuel pump 5 Gasket 6 Insulator 7 Gasket 8 Carburetor 9 Upper gasket 10 Spacer 11 Lower gasket 12 EGR valve engine with EGR 13 Cover engine without EGR 14 Gasket PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Revised ...

Page 45: ...STALLATION SOHC 16 VALVE CARBURETOR 17 Nm 19 Nm 31 Nm 11 12 10 9 8 7 3 2 4 5 6 1 10 Nm 13 12 Nm Removal steps 1 Breather tube 2 Fuel hose 3 Hose clamp 4 Fuel pump 5 Gasket 6 Insulator 7 Gasket 8 Carburetor 9 Upper gasket 10 Spacer 11 Lower gasket 12 Cover 13 Gasket PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Added ...

Page 46: ...4G1 ENGINE E W Fuel and Emission Control Systems 11A 5 1b PWEE9520 E Nov 1995 Mitsubishi Motors Corporation Intentionally blank PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Added ...

Page 47: ...M8 16 12 Nm 15 4 18 Nm 17 11 12 9 Nm Removal steps 1 Vacuum pipe and hose assembly 2 Vacuum hose assembly 3 Throttle body assembly 4 Gasket 5 Fuel return pipe BA 6 Fuel pressure regulator 7 O ring 8 Insulator 9 Insulator AA 10 Injector 11 O ring 12 Grommet 13 Delivery pipe 14 EGR valve With EGR valve 15 Cover Without EGR valve 16 Gasket 17 Air temperature sensor Up to 2000 model 18 Gasket Up to 20...

Page 48: ...RIVE FROM 2001 model FOR EUROPE 11 Nm 18 Nm 21 Nm 9 Nm 1 3 11 6 4 5 9 10 8 7 13 12 9 Nm 2 Removal steps 1 Vacuum pipe and hose 2 Throttle body assembly 3 Gasket BA 4 Fuel pressure regulator 5 O ring 6 Insulator 7 Insulator AA 8 Injector 9 O ring 10 Grommet 11 Delivery pipe 12 EGR valve 13 Gasket PWEE9520 G E Apr 2003 Mitsubishi Motors Corporation Revised ...

Page 49: ...PI REAR WHEEL DRIVE 12 11 Nm 18 Nm 21 Nm 9 Nm 1 2 3 11 6 4 5 9 10 8 7 13 9 Nm Removal steps 1 Throttle body assembly 2 Gasket 3 Fuel return pipe BA 4 Fuel pressure regulator 5 O ring 6 Insulator 7 Insulator AA 8 Injector 9 O ring 10 Grommet 11 Delivery pipe 12 EGR valve 13 Gasket PWEE9520 G E Apr 2003 Mitsubishi Motors Corporation Revised ...

Page 50: ...EMOVAL AND INSTALLATION DOHC 11 Nm 11 6 2 1 18 Nm 9 Nm 3 5 4 9 10 8 7 Removal steps 1 Throttle body assembly 2 Gasket 3 Fuel return pipe BA 4 Fuel pressure regulator 5 O ring 6 Insulator 7 Insulator AA 8 Injector 9 O ring 10 Grommet 11 Delivery pipe PWEE9520 G E Apr 2003 Mitsubishi Motors Corporation Revised ...

Page 51: ...otate smoothly its O ring may be binding If this occurs remove the injector from the delivery pipe check the O ring and re insert the injector BA FUEL PRESSURE REGULATOR INSTALLATION 1 Apply a little new engine oil to the O ring then insert the fuel pressure regulator into the delivery pipe taking care not to damage the O ring Caution Ensure that no engine oil enters the delivery pipe 2 Check that...

Page 52: ...15 30 Nm 6 10 Nm 13 24 Nm 14 2 19 Nm 11 9 17 16 19 Nm 14 18 Removal steps 1 Accelerator cable 2 Water hose 3 Throttle body 4 Gasket 5 Air intake plenum resonator 6 O ring 7 Power plant stay right BA 8 Intake manifold stay 9 Water hose 10 Water hose 11 EGR valve 12 Gasket 13 EGR valve support 14 Gasket 15 P C V hose AA AA 16 Intake manifold 17 Gasket 18 Insulator PWEE9520 D E Aug 2000 Mitsubishi Mo...

Page 53: ...ctors INSTALLATION SERVICE POINTS AA INTAKE MANIFOLD INSTALLATION After installing the intake manifold connect the fuel pressure sensor connectors BA INTAKE MANIFOLD STAY INSTALLATION Ensure that the intake manifold stay is in close contact with the intake manifold and the cylinder block boss After that tighten the bolts to the specified torque PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation A...

Page 54: ...I REMOVAL AND INSTALLATION 30 Nm 3 18 Nm 7 4 2 6 29 Nm 5 35 Nm 35 Nm 1 44 Nm Removal steps 1 Oxygen sensor 2 Exhaust manifold cover 3 Exhaust manifold bracket B 4 Exhaust manifold 5 Exhaust manifold gasket 6 Exhaust manifold bracket A 7 Power plant stay left PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Added ...

Page 55: ...7 8 9 10 11 12 13 14 27 Nm 27 Nm 22 Nm 23 Nm 12 Nm 13 Nm Removal steps 1 Water hose 2 Water hose 3 Water hose FA 4 Thermo valve engines with EGR FA 5 Thermo valve DA 6 Engine coolant temperature gauge unit 7 Water inlet fitting CA 8 Thermostat 9 Thermostat case 10 Gasket BA 11 Water inlet pipe BA 12 O ring BA 13 O ring AA 14 Water pump PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Revised ...

Page 56: ...22 Nm 12 Nm 13 Nm 23 Nm 12 Nm Removal steps 1 Water hose 2 Water hose 3 Water hose FA 4 Thermo valve DA 5 Engine coolant temperature gauge unit 6 Water inlet fitting CA 7 Thermostat 8 Thermostat case 9 Gasket BA 10 Water inlet pipe BA 11 O ring BA 12 O ring AA 13 Water pump PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Added ...

Page 57: ...4G1 ENGINE E W Water Pump and Water Hose 11A 6 1b Intencionalmenteen blanco PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Added ...

Page 58: ...6 22 Nm 5 23 Nm 1 Removal steps 1 Water hose 2 Water hose EA 3 Engine coolant temperature sensor DA 4 Engine coolant temperature gauge unit 5 Water inlet fitting CA 6 Thermostat 7 Thermostat case 8 Gasket BA 9 Water inlet pipe BA 10 O ring BA 11 O ring AA 12 Water pump PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Revised ...

Page 59: ...2 10 9 11 12 Nm 11 Nm 4 29 Nm 3 8 7 6 22 Nm 5 23 Nm 1 12 Nm Removal steps 1 Water hose 2 Water hose EA 3 Engine coolant temperature sensor DA 4 Engine coolant temperature gauge unit 5 Water inlet fitting CA 6 Thermostat 7 Thermostat case 8 Gasket BA 9 Water inlet pipe BA 10 O ring BA 11 O ring AA 12 Water pump PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Revised ...

Page 60: ... 12 11 10 12 Nm 11 Nm 4 1 25 Nm 9 8 23 Nm 18 Nm 5 7 6 29 Nm 3 12 Nm Removal steps 1 Water hose 2 Water hose EA 3 Engine coolant temperature sensor DA 4 Engine coolant temperature gauge unit 5 Water outlet fitting 6 Gasket CA 7 Thermostat 8 Fitting 9 Gasket BA 10 Water inlet pipe BA 11 O ring AA 12 Water pump PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Revised ...

Page 61: ...UROPE 2 13 Nm 12 10 9 11 12 Nm 11 Nm 4 23 Nm 3 8 7 6 22 Nm 5 29 Nm 1 12 Nm Removal steps 1 Water hose 2 Water hose EA 3 Engine coolant temperature sensor DA 4 Engine coolant temperature gauge unit 5 Water inlet fitting CA 6 Thermostat 7 Thermostat case 8 Gasket BA 9 Water inlet pipe BA 10 O ring BA 11 O ring AA 12 Water pump PWEE9520 G E Apr 2003 Mitsubishi Motors Corporation Added ...

Page 62: ...4G1 ENGINE E W Water Pump and Water Hose 11A 6 2d PWEE9520 E Nov 1995 Mitsubishi Motors Corporation Intentionally blank PWEE9520 G E Apr 2003 Mitsubishi Motors Corporation Added ...

Page 63: ...4 29 Nm 3 8 7 6 22 Nm 5 23 Nm 1 12 Nm 11 Nm Removal steps 1 Water hose 2 Water hose EA 3 Engine coolant temperature sensor DA 4 Engine coolant temperature gauge unit 5 Water inlet fitting CA 6 Thermostat 7 Thermostat case 8 Gasket BA 9 Water inlet pipe BA 10 O ring BA 11 O ring AA 12 Water pump PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Revised ...

Page 64: ... 3 8 9 22 Nm 12 Nm 13 Nm 29 Nm 12 Nm 22 Nm 23 Nm 11 Nm Removal steps HA 1 Water outlet fitting 2 Water inlet fitting CA 3 Thermostat DA 4 Engine coolant temperature gauge unit EA 5 Engine coolant temperature sensor GA 6 Thermostat housing BA 7 Water inlet pipe BA 8 O ring AA 9 Water pump PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Revised ...

Page 65: ... not apply engine oil or any other oily substance to the O rings 2 Secure the water pipe after the thermostat case has been installed CA THERMOSTAT INSTALLATION 1 Fit the thermostat such that its jiggle valve is at the top DA ENGINE COOLANT TEMPERATURE GAUGE UNIT INSTALLATION 1 If the engine coolant temperature gauge unit is to be reused apply the specified sealant to its thread Specified sealant ...

Page 66: ...thickness of 3 mm Specified sealant Mitsubishi Genuine Part No MD970389 or equivalent Caution Squeeze the liquid gasket uniformly so that there is no break in the gasket nor is there too much gasket HA WATER OUTLET FITTING INSTALLATION 1 Remove the old liquid gasket from the thermostat housing water outlet fitting mounting surface and the water outlet fitting 2 Apply liquid gasket to the water out...

Page 67: ...S REMOVAL AND INSTALLATION SOHC 12 VALVE CARBURETOR 17 Nm 1 2 3 4 5 6 7 8 30 Nm 17 Nm 29 Nm Removal steps 1 Engine hanger 2 Intake manifold stay 3 Intake manifold 4 Intake manifold gasket 5 Exhaust manifold cover 6 Engine hanger 7 Exhaust manifold 8 Exhaust manifold gasket PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Revised ...

Page 68: ...TION SOHC 16 VALVE CARBURETOR 17 Nm 1 2 3 4 5 6 7 8 30 Nm 17 Nm 29 Nm 29 Nm 19 Nm Removal steps 1 Engine hanger 2 Intake manifold stay 3 Intake manifold 4 Intake manifold gasket 5 Exhaust manifold cover 6 Engine hanger 7 Exhaust manifold 8 Exhaust manifold gasket PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Revised ...

Page 69: ...1 10 9 54 Nm 8 30 Nm 17 Nm 11 Nm 29 Nm 6 7 1 13 Nm 83 Nm 8 3 12 Removal steps 1 Engine hanger 2 Intake manifold stay 3 Intake manifold 4 Intake manifold gasket 5 Air hose 6 Exhaust manifold cover AA 7 Air pipe AA 8 Reed valve and bracket 9 Reed valve 10 Reed valve bracket A 11 Reed valve bracket B 12 Exhaust manifold PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Revised ...

Page 70: ...MPI 1 3 4 44 Nm 5 9 8 7 29 Nm 6 17 Nm 2 31 Nm 17 Nm 17 Nm Removal steps 1 Engine hanger 2 Intake manifold stay 3 Intake manifold 4 Intake manifold gasket 5 Oxygen sensor vehicles for Hong Kong only 6 Engine hanger 7 Exhaust manifold cover 8 Exhaust manifold 9 Exhaust manifold gasket PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Revised ...

Page 71: ...Nm 7 4 17 Nm 15 16 35 Nm Removal steps 1 Boost sensor 2 Engine hanger 3 Power plant stay right From 2004 model 4 Intake manifold stay 5 Intake manifold 6 Intake manifold gasket 7 Solenoid valve assembly 8 Solenoid valve assembly 9 Oxygen sensor 10 Engine hanger 11 Exhaust manifold cover 12 Exhaust monifold bracket B 13 Exhaust manifold 14 Exhaust manifold gasket 15 Exhaust manifold bracket A Up to...

Page 72: ...7 Nm 17 Nm 29 Nm 6 7 1 5 Nm 9 Nm 19 Nm Removal steps 1 Boost sensor 2 Engine hanger 3 Intake manifold stay 4 Intake manifold 5 Intake manifold gasket 6 Solenoid valve assembly Without catalytic converter 7 Solenoid valve assembly With catalytic converter 8 Engine hanger 9 Exhaust manifold cover 10 Exhaust manifold 11 Exhaust manifold gasket PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Revis...

Page 73: ... 31 Nm 5 Nm 17 Nm 9 Nm 49 Nm 17 Nm 11 10 17 Nm 9 29 Nm 19 Nm 8 35 Nm 29 Nm 12 Removal steps 1 Boost sensor 2 Engine hanger 3 Power plant stay right CVT 4 Intake manifold stay 5 Solenoid valve assembly 6 Intake manifold 7 Intake manifold gasket 8 Engine hanger 9 Exhaust manifold cover 10 Exhaust manifold 11 Exhaust manifold gasket 12 Power plant stay left CVT PWEE9520 D E Aug 2000 Mitsubishi Motors...

Page 74: ...oration REMOVAL AND INSTALLATION DOHC 1 3 4 9 8 7 29 Nm 6 17 Nm 2 21 Nm 17 Nm 17 Nm 5 44 Nm 29 Nm Removal steps 1 Engine hanger 2 Intake manifold stay 3 Intake manifold 4 Intake manifold gasket 5 Oxygen sensor 6 Exhaust manifold cover 7 Engine hanger 8 Exhaust manifold 9 Exhaust manifold gasket ...

Page 75: ...assembly to the reed valve bracket B and tighten the mounting bolts temporarily 4 Tighten the nuts on both ends of the air pipe to the specified torque Caution The tightening torque of the reed valve side nut and that of the exhaust manifold side nut are different from each other Be sure to tighten each nut correctly to the specified torque 5 Tighten the reed valve and bracket mounting bolts to th...

Page 76: ... 1 Injector harness EA 2 Fuel pipe EA 3 Backup ring EA 4 O ring EA 5 Backup ring EA 6 Fuel pump 7 O ring 8 Flange DA 9 Fuel pressure sensor DA 10 O ring DA 11 Backup ring 12 Harness bracket 13 Washer 14 Injector holder CA 15 Delivery pipe and injector 16 Insulator 17 Injector gasket BA 18 Corrugate washer AA 19 Backup ring AA 20 O ring AA 21 Backup ring 22 Injector 23 Delivery pipe PWEE9520 D E Au...

Page 77: ... spindle oil or gasoline to injector O rings 2 Insert the injector straight in the injector mounting hole on the delivery pipe 3 Try to the turn the injector If the injector dose not turn smoothly remove the injector and check the O rings for damage If damage is evident replace the O rings and reinstall the injector 4 Align the matchmark on the injector with that on the delivery pipe 5 Install the...

Page 78: ...n the illustration 4 Apply spindle oil or gasoline to the O rings on both ends of the pipe 5 Insert the fuel pipe straight in the mounting hole on the fuel pump When the fuel pipe is inserted use care not to twist it and insert as far as it goes 6 Tighten the bolts on both ends of the pipe to the specified torque 7 Using the torque wrench minimum scale 0 5 Nm tighten the fuel pump mounting bolts b...

Page 79: ...stallation Removal steps 1 Breather hose 2 P C V hose 3 P C V valve 4 P C V valve gasket 5 Oil filler cap 6 Rocker cover 7 Rocker cover gasket FA 8 Camshaft oil seal EA 9 Rocker arm and shaft assembly EA 10 Rocker arm and shaft assembly 11 Rocker arm A 12 Rocker arm spring 13 Rocker arm B 14 Rocker arm shaft 15 Rocker arm C 16 Wave washer 17 Spacer 18 Rocker arm D 19 Rocker arm shaft CA 20 Adjusti...

Page 80: ...tion 9 8 7 Removal steps 1 Breather hose 2 P C V hose 3 Oil filler cap 4 P C V valve 5 P C V valve gasket 6 Rocker cover 7 Rocker cover gasket 8 Oil seal FA 9 Oil seal EA 10 Rocker arms and rocker arm shaft intake EA 11 Rocker arms and rocker arm shaft exhaust 12 Rocker arm A 13 Rocker arm B DA 14 Rocker arm shaft CA 15 Adjusting screw 16 Nut 17 Rocker arm C DA 18 Rocker arm shaft CA 19 Adjusting ...

Page 81: ...9 18 17 Removal steps 1 Breather hose 2 P C V hose 3 Oil filler cap 4 P C V valve 5 P C V valve gasket 6 Rocker cover 7 Rocker cover gasket 8 Oil seal FA 9 Oil seal AA EA 10 Rocker arms and rocker arm shaft intake AA EA 11 Rocker arms and rocker arm shaft exhaust 12 Rocker arm A 13 Rocker arm B DA 14 Rocker arm shaft IA 15 Lash adjuster 16 Rocker arm C DA 17 Rocker arm shaft IA 18 Lash adjuster 19...

Page 82: ... moving parts before installation 4 Nm Removal steps 1 Breather hose 2 P C V hose 3 P C V valve 4 P C V valve gasket 5 Oil filler cap HA 6 Rocker cover 7 Rocker cover gasket A 8 Rocker cover gasket B GA 9 Semi circular packing FA 10 Camshaft oil seal BA 11 Bearing cap AA 12 Camshaft AA 13 Camshaft 14 Roller rocker arm AB JA 15 Lash adjuster PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Revis...

Page 83: ...S REMOVAL Caution If the lash adjuster is re used clean the lash adjuster Refer to 11A 8 3 Set special tool MD998443 to prevent the lash adjuster from coming free and falling to the floor AB LASH ADJUSTER REMOVAL Caution If the lash adjuster is re used clean the lash adjuster Refer to 11A 8 6 PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Added MD998443 ...

Page 84: ...4G1 ENGINE E W Rocker Arms and Camshafts 11A 8 2b PWEE9520 E Nov 1995 Mitsubishi Motors Corporation Intentionallyblank PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Added ...

Page 85: ...hout low pollution system 3 Except 2001 model front wheel drive vehicles 4 2001 model front wheel drive vehicles for Europe 5 2001 model front wheel drive vehicles for General Export 6 2002 model front wheel drive vehicles for Europe 2 LASH ADJUSTERS SOHC Caution 1 The lash adjusters are precision engineered mechanisms Do not allow them to become contaminated by dirt or other foreign substances 2 ...

Page 86: ...TE 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 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...

Page 87: ...he plunger slowly then release the steel ball and allow the pressure chamber to fill with 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 thr...

Page 88: ...uel 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 2 Place the lash adjuster in container A and clean its outside surface NOTE Use a nylon brush if deposits are hard to remove PWEE95...

Page 89: ...ure 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 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 spr...

Page 90: ... 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 stillcontracts after performing these steps 10 Stand the lash adjuster upright to prevent diesel fuel from sp...

Page 91: ...hen for the outer caps and soon Tighten the bolts a little at a time such that each bolt is tightened to the specified torque in the final sequence Specified sealant 3M ATD Part No 8660 or equivalent 4 Check that the rocker arms are installed correctly CA ADJUSTING SCREW INSTALLATION 1 Install provisionally the screw to the rocker arm Insert it so that the end of the screw is flush with the edge o...

Page 92: ...ion marks Then mount the assembly on the cylinder head FA CAMSHAFT OIL SEAL INSTALLATION GASEMI CIRCULAR PACKING INSTALLATION 1 Apply the specified sealant to the area shown Specified sealant 3M ATD Part No 8660 or equivalent PWEE9520 A E Dec 1998 Mitsubishi Motors Corporation Added Timing belt side SOHC 12 VALVE Identification mark Timing belt side SOHC 16 VALVE Identification mark MD998713 SOHC ...

Page 93: ...ER INSTALLATION Caution If the lash adjuster is re used clean the lash adjuster Refer to 11A 8 6 Fit the lash adjuster onto the rocker arm without allowing diesel fuel to spill out VALVE CLEARANCE ADJUSTMENT SOHC 12 VALVE 1 Position the No 1 cylinder at top dead center on the compression stroke 2 Adjust the valve clearance at the points shown in the illustration 3 Loosen the adjusting screw locknu...

Page 94: ... and adjust if necessary Standard value on hot engine Intake 0 20 mm Exhaust 0 25 mm SOHC 16 VALVE 1 Position the No 1 cylinder at top dead center on the compression stroke 2 Adjust the valve clearance at the points shown in the illustration 3 Loosen the adjusting screw locknut 4 Using a feeler gauge adjust the valve clearance by turning the adjusting screw Standard value on cold engine Intake 0 0...

Page 95: ...e clearance at points as shown in the illustration 8 Repeat steps 3 to 5 to adjust the valve clearance of remaining valves 9 With the engine mounted on vehicle warm up the engine Then check for valve clearance on hot engine and adjust if necessary Standard value on hot engine Intake 0 20 mm Exhaust 0 25 mm Timing belt side PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Added ...

Page 96: ...Apply engine oil to all moving parts before installation Removal steps 1 Engine hanger 2 Breather hose FA 3 P C V valve 4 Gasket 5 Oil filler cap 6 Inlet rocker cover 7 Gasket 8 Exhaust rocker cover 9 Gasket EA 10 Oil seal DA 11 Semi circular packing CA 12 Beam camshaft cap 13 Gasket BA 14 Intake camshaft BA 15 Exhaust camshaft 16 Roller rocker arm AA AA 17 Lash adjuster PWEE9520 D E Aug 2000 Mits...

Page 97: ...center 2 Place dowel pins of the camshafts in the positions shown in the illustration CA BEAM CAMSHAFT CAP INSTALLATION 1 Remove deposits from the liquid gasket coating surfaces of the beam camshaft cap and the cylinder head 2 Apply liquid gasket to the five grooves on the bottom surface of the beam camshaft cap by squeezing it to a thickness of 3 mm Specified sealant Mitsubishi Genuine Part No MD...

Page 98: ...y wipe out the liquid gasket that has overflowed the intake part before the gasket is hardened within 15 minutes after application of liquid gasket DA SEMI CIRCULAR PACKING INSTALLATION Using the special tool install the semi circular packing EA OIL SEAL INSTALLATION Using the special tool install the oil seal FA P C V VALVE INSTALLATION Install the P C V valve with its nipple directed as shown PW...

Page 99: ...ster when it is standing upright Then perform the following steps with each lash adjuster 2 Place the lash adjuster in container A and clean its outside surface NOTE Use a nylon brush if deposits are hard to remove 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...

Page 100: ...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 7 Place the lash adjuster in container C Then gently push down the internal steel ball using special tool MD998442...

Page 101: ... 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...

Page 102: ...r head assembly 3 Cylinder head gasket AB CA 4 Retainer lock 5 Valve spring retainer BA 6 Valve spring 7 Intake valve primary 8 Intake valve secondary AB CA 9 Retainer lock 10 Valve spring retainer BA 11 Valve spring 12 Exhaust valve AC AA 13 Valve stem seal 14 Valve spring seat AC AA 15 Valve stem seal 16 Valve spring seat 17 Intake valve guide 18 Exhaust valve guide 19 Intake valve seat primary ...

Page 103: ...er head bolt 2 Cylinder head assembly 3 Cylinder head gasket AB CA 4 Retainer lock 5 Valve spring retainer BA 6 Valve spring 7 Exhaust valve AB CA 8 Retainer lock 9 Valve spring retainer BA 10 Valve spring 11 Intake valve AC AA 12 Valve stem seal 13 Valve spring seat AC AA 14 Valve stem seal 15 Valve spring seat 16 Exhaust valve guide 17 Intake valve guide 18 Exhaust valve seat 19 Intake valve sea...

Page 104: ...A 1 Cylinder head bolt 2 Cylinder head assembly 3 Cylinder head gasket AB CA 4 Retainer lock 5 Valve spring retainer BA 6 Valve spring 7 Intake valve AB CA 8 Retainer lock 9 Valve spring retainer BA 10 Valve spring 11 Exhaust valve AC AA 12 Valve stem seal 13 Valve spring seat AC AA 14 Valve stem seal 15 Valve spring seat 16 Intake valve guide 17 Exhaust valve guide 18 Intake valve seat 19 Exhaust...

Page 105: ...eps AA DA 1 Cylinder head bolt 2 Cylinder head assembly 3 Gasket AB CA 4 Retainer lock 5 Valve spring retainer BA 6 Valve spring 7 Intake valve AB CA 8 Retainer lock 9 Valve spring retainer BA 10 Valve spring 11 Exhaust valve AC EA 12 Valve stem seal 13 Valve spring seat AC EA 14 Valve stem seal 15 Valve spring seat 16 Intake valve guide 17 Exhaust valve guide 18 Intake valve seat 19 Exhaust valve...

Page 106: ...ion REMOVAL SERVICE POINTS AA CYLINDER HEAD BOLT REMOVAL AB RETAINER LOCK REMOVAL 1 Tag removed valves springs and other components noting their cylinder numbers and locations to facilitate reassembly Store these components safely MB991653 SOHC MB991653 DOHC SOHC MD998772 DOHC MD998772 MD998735 ...

Page 107: ... grind the gasket surface to specification Gasket surface distortion Standard value 0 05 mm or less Limit 0 2 mm Grinding limit 0 2 mm Cylinder head height specification when new SOHC 12 VALVE 106 9 107 1 mm SOHC 16 VALVE 119 9 120 1 mm DOHC 131 9 132 1 mm Caution No more than 0 2 mm of stock may be removed from the cylinder head and cylinder block mating surfaces in total 2 VALVES 1 Check the val...

Page 108: ... 101 05 100 55 SOHC 16 VALVE 114 71 114 21 DOHC 106 85 106 35 3 VALVE SPRINGS 1 Measure the valve spring s free height If the measurement is less than specified replace the spring Standard mm Limit mm SOHC Intake 46 1 45 6 12 VALVE Exhaust 46 8 46 3 SOHC 16 VALVE 50 9 50 4 DOHC 49 1 48 6 2 Measure the squareness of the spring If the measurement exceeds the specified limit replace the spring Standa...

Page 109: ...0 050 0 15 SOHC 16 VALVE 0 030 0 057 0 15 DOHC 0 030 0 062 0 15 5 VALVE SEATS 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 mm Limit mm SOHC Intake 43 70 44 20 12 VALVE Exhaust 43 30 43 80 SOHC Intake 53 21 53 71 16 VALVE Exhaust 54 10 54 60 ...

Page 110: ...nce between the valve guide and valve and if necessary replace the valve guide 2 Correct to obtain the specified seat width and angle 3 After correction the valve and valve seat should be lapped with a lapping compound PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Revised 0 9 1 3 mm 65 15 46 46 5 except GDI GDI Intake side 0 9 1 3 mm 65 44 20 GDI Exhaust side 0 9 1 3 mm 65 44 15 ...

Page 111: ... O S 35 600 35 625 SOHC Intake 0 30 O S 28 300 28 321 16 VALVE 0 60 O S 28 600 28 621 4G13 Exhaust 0 30 O S 26 300 26 321 0 60 O S 26 600 26 621 SOHC Intake 0 30 O S 30 300 30 321 16 VALVE 0 60 O S 30 600 30 621 4G18 Exhaust 0 30 O S 28 300 28 321 0 60 O S 28 600 28 621 DOHC Intake 0 30 O S 31 300 31 325 0 60 O S 31 600 31 625 Exhaust 0 30 O S 27 800 27 825 0 60 O S 28 100 28 125 3 Prevent galling...

Page 112: ...m 0 50 O S 11 06 11 07 mm 3 Press fit the valve guide until it projects by the specified amount Standard value SOHC 12 VALVE 17 mm SOHC 16 VALVE DOHC 23 mm Caution 1 The valve guide must be installed from the upper side of the cylinder head 2 The valve guides differ in length on the intake and exhaust sides 48 mm for intake valve 55 mm for exhaust valve 3 After press fitting the valve guide insert...

Page 113: ...pring such that its painted end is on the rocker arm side CA RETAINER LOCK INSTALLATION 1 The valve spring if excessively compressed causes the bottom end of retainer to be in contact with the stem seal and damage it SOHC 16 VALVE DOHC MB991671 PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Revised Painted end Spring retainer Stem seal Spring seat MD998772 SOHC DOHC MD998772 MD998735 ...

Page 114: ...f the bolts are tightened by an angle of less than 90_ they may not hold the cylinder head with sufficient strength If the bolts are tightened by an angle exceeding 90_ completely remove them and carry out the installation procedure again EA VALVE STEM SEAL INSTALLATION 1 Install the valve spring seat 2 Install the valve 3 Apply a small amount of engine oil to the valve stem seal 4 Using the valve...

Page 115: ...ngine oil to all moving parts before installation 24 Nm 23 Nm 17 19 Nm Removal steps EA 1 Oil filter 2 Drain plug DA 3 Gasket 4 Transmission stay cast metal 5 Transmission stay sheet metal AA CA 6 Oil pan 7 Oil screen 8 Gasket 9 Relief valve 10 Relief valve spring 11 Relief plunger BA 12 Front oil seal AA 13 Front case 14 O ring 15 Oil pump cover 16 Oil pump outer rotor 17 Oil pump inner rotor PWE...

Page 116: ...m 23 Nm 24 Nm Apply engine oil to all moving parts before installation 19 Nm Removal steps EA 1 Oil filter 2 Drain plug DA 3 Gasket 4 Transmission stay AA CA 5 Oil pan 6 Oil screen 7 Gasket 8 Relief valve 9 Relief valve spring 10 Relief plunger BA 11 Front oil seal AA 12 Front case 13 O ring 14 Oil pump cover 15 Oil pump outer rotor 16 Oil pump inner rotor PWEE9520 D E Aug 2000 Mitsubishi Motors C...

Page 117: ... Nm 19 Nm 7 Nm 4 39 Nm Apply engine oil to all moving parts before installation Removal steps FA 1 Oil filter 2 Drain plug DA 3 Gasket AA CA 4 Oil pan 5 Oil screen 6 Gasket 7 Relief valve 8 Relief valve spring 9 Relief plunger BA 10 Oil seal AA 11 Front case 12 O ring 13 Oil pump cover 14 Outer rotor 15 Inner rotor PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Added ...

Page 118: ...ecial tool slide the tool along the oil pan cylinder block seal and thus remove the oil pan INSPECTION 1 OIL PUMP 1 Fit the rotor into the front case 2 Check the tip clearance using a thickness gauge Standard value 0 06 0 18 mm 3 Check the side clearance using a straight edge and thickness gauge Standard value 0 04 0 10 mm 4 Check the body clearance using a thickness gauge Standard value 0 10 0 18...

Page 119: ... apply engine oil to the its outer circumference 2 Apply engine oil to the oil seal lip then push the oil seal along the guide by hand until it touches the front case Tap the oil seal into place using the special tool CA OIL PAN INSTALLATION 1 Clean the mating surfaces of the cylinder block and oil pan 2 Apply a 4 mm bead of form in place gasket to the outer circumference of the oil pan flange Spe...

Page 120: ...wrench If the filter is tightened by hand only it will be insufficiently torqued resulting in oil leaks FA OIL FILTER INSTALLATION 1 Clean the filter mounting surface on the front case 2 Apply engine oil to the O ring of the oil filter 3 Screw the oil filter in and tighten the oil filter approximately 3 4 of a turn approx 16 4 Nm from where the O ring has come into contact with the oil filter moun...

Page 121: ...N 6 7 8 10 12 4 9 11 5 1 2 3 Apply engine oil to all moving parts before installation Removal steps GA 1 Connecting rod nut AA FA 2 Connecting rod cap EA 3 Connecting rod bearing DA 4 Piston and connecting rod assem bly 5 Connecting rod bearing CA 6 Piston ring No 1 CA 7 Piston ring No 2 BA 8 Oil ring AB AA 9 Piston pin 10 Piston 11 Connecting rod 12 Bolt ...

Page 122: ...om different cylinders to become mixed up INSPECTION 1 PISTON RINGS 1 Check the piston ring side clearance If the clearance exceeds the specified limit replace the ring or piston or both Standard values No 1 ring 0 03 0 07 mm No 2 ring 0 02 0 06 mm Limits No 1 ring 0 1 mm No 2 ring 0 1 mm 2 Insert the piston ring into the cylinder bore and push it down with a piston Ensure that the piston s crown ...

Page 123: ...the piston read off the cylinder bore size mark on the cylinder block as illustrated and select a piston according to the flowing table CYLINDER BORE SIZE MARK PISTON SIZE MARK A A B None C C NOTE The piston size mark shows on the top of the piston 2 Measure the following lengths as shown A Piston boss to piston boss outside dimension B Piston boss to piston boss inside dimension C Piston pin leng...

Page 124: ...ng groove Then fit the upper and lower side rails NOTE 1 The spacer and side rails may be fitted in either direction No distinction is made between top and bottom 2 Spacer and side rail sizes are color coded as follows Size Color STD None ALL 0 25 mm O S White 4G18 0 50 mm O S Blue ALL 1 00 mm O S Yellow 4G13 4G15 2 To install a side rail fit one end of the rail into the groove then press the rest...

Page 125: ...8 0 50 mm O S 50 ALL 1 00 mm O S 100 4G13 4G15 DA PISTON AND CONNECTING ROD ASSEMBLY INSTALLATION 1 Apply oil to the piston piston rings and oil ring 2 Align the gaps of the piston rings and oil ring side rails and spacer as shown 3 With the piston crown s front arrow mark pointing toward the timing belt side press the piston and connecting rod assembly into the cylinder from the top of the cylind...

Page 126: ...No 4 No 1 No 3 No 2 No 2 No 1 A B No 3 No 4 P P 1 Select bearings according to crankshaft and connecting rod identification marks or color codes referring to the following table Crankshaft identification mark Connecting rod identification color Bearing identification mark I Yellow White 1 None 1 Yellow 2 II None White 1 None 2 Yellow 3 III White White 2 None 3 Yellow 3 PWEE9520 A E Dec 1998 Mitsub...

Page 127: ... bolts must therefore be checked for stretching before reuse To check a bolt for stretching screw the nut down the entire length of the thread by hand Unless the nut turns smoothly all the way the bolt s threaded section is stretched and the bolt must be replaced 2 Before fitting the nuts apply engine oil to their threads and seating surfaces 3 Fit the nuts onto the bolts and turn them until they ...

Page 128: ...tors Corporation Caution 1 If the nuts are turned by less than 90_ the cap may not be held on with sufficient strength 2 If the nuts are turned by more than 100_ loosen them completely and carry out the tightening procedure again PWEE9520 A E Dec 1998 Mitsubishi Motors Corporation Added ...

Page 129: ...NKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION EXCEPT GDI 19 Nm 11 11 Nm 10 Nm 132 Nm 16 12 34 Nm 30_ to 34_ 132 Nm 10 Nm 14 22 24 1 2 3 4 5 6 7 8 9 10 17 18 19 20 21 132 Nm 13 15 23 Nm 23 A Apply engine oil to all moving parts before installation PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Revised ...

Page 130: ...ring cap bolt CA 18 Bearing cap BA 19 Crankshaft bearing lower 20 Crankshaft BA 21 Crankshaft bearing upper AA AA 22 Oil pressure switch 23 Knock sensor 4G13 SOHC 16 VALVE for Europe 4G18 for GCC and 4G18 for Europe From 2004 model 24 Cylinder block Caution On the flexible flywheel equipped engines do not remove any of the bolts A of the flywheel shown in the illustration The balance of the flexib...

Page 131: ... Nm 5 9 1 Removal steps FA 1 Drive plate bolt 2 Adapter plate 3 Drive plate 4 Crankshaft bushing 5 Rear plate 6 Bell housing cover EA 7 Rear oil seal case DA 8 Rear oil seal 9 Bearing cap bolt CA 10 Bearing cap CA 11 Bearing cap No 4 CA 12 Bearing cap center BA 13 Crankshaft bearing lower 14 Crankshaft BA 15 Crankshaft bearing upper BA 16 Crankshaft bearing center AA AA 17 Oil pressure switch 18 K...

Page 132: ...4G1 ENGINE E W Crankshaft and Cylinder Block 11A 12 2b PWEE9520 E Nov 1995 Mitsubishi Motors Corporation Intentionallyblank PWEE9520 D E Aug 2000 Mitsubishi Motors Corporation Added ...

Page 133: ...g cap and tighten the bolts to the specified torque 5 Remove the bolts and gently remove the crankshaft bearing cap 6 Using the scale printed on the plastic gauge bag measure the plastic gauge s crushed section at its widest point Standard value 0 02 0 04 mm Limit 0 1 mm NOTE The crankshaft pins and journals are fillet rolled and must not be machined to undersize dimensions 2 CYLINDER BLOCK 1 Visu...

Page 134: ... the points shown 3 Calculate the boring finish dimension based on the piston diameter dimension D Boring finish dimension piston O D piston to cylinder clearance 0 02 0 04 mm honing margin 0 02 mm 4 Bore each cylinder to the calculated boring finish dimension Caution To prevent distortion caused by heat increases during boring bore the cylinders in the following order No 2 No 4 No 1 No 3 5 Hone t...

Page 135: ...No 1 Identification mark positions No 4 No 3 No 5 No 2 No 1 4G18 No 4 No 3 No 5 No 2 No 1 No 4 No 3 No 5 No 2 No 1 No 4 No 3 No 5 No 2 No 1 No 4 No 3 No 1 1 Select bearings according to the crankshaft identification marks or color codes referring to the following table If they are not identifiable measure the crankshaft journals and choose bearings to match the measurements PWEE9520 A E Dec 1998 M...

Page 136: ... on the identification markings verified in steps 1 and 2 select bearings from table above See the following example 1 If the measured crankshaft journal diameter is 48 000 mm this corresponds to classification 1 in the above table 2 If the identification mark on the cylinder block bearing hole is 1 select a bearing with an identification mark of 2 4 Except for the center bearing all the upper bea...

Page 137: ...ortion and bearing surface of the bolt Tighten the bolts to 34 Nm 3 Using the special tool tighten the bolts to a further 30 to 34 degrees 4 After fitting the bearing caps measure the end play in the crankshaft If the measurement exceeds the specified limit replace the crankshaft bearings Standard value 0 05 0 18 mm Limit 0 25 mm DA REAR OIL SEAL INSTALLATION Press fit the rear oil seal using the ...

Page 138: ...to the entire periphery of the oil seal lip and install the oil seal on the cylinder block FA FLYWHEEL BOLT DRIVE PLATE BOLT INSTALLATION 1 Clean off sealant oil and deposits from the threaded portion of the drive plate adapter plate tightening bolts and from the threaded holes on the crankshaft 2 Apply engine oil to the bolt flange and to the threaded holes on the crankshaft 3 Apply sealant to th...

Page 139: ...Service Bulletins Click on the applicable bookmark to select the Service Bulletin ...

Page 140: ...5 10 95 10 95 10 CORRECTION INTERNATIONAL CAR ADMINISTRATION OFFICE T Inoue Manager SERVICE PUBLICATION 1 Description In the 4G1 engine Workshop Manuals shown below omission of descriptions from the identification marks for the connecting rod bearing and the crankshaft bearing has been rectified 2 Applicable Manuals Manual Pub No Language Page s ENGINE 4G1 E W PWEE9520 English 11A 11 6 Workshop Ma...

Page 141: ...o 3 No 2 No 4 No 1 No 3 No 2 P P Color code positions Identification mark positions 1EN0619 Identification color Crankshaft identification mark Connecting rod identification color Bearing identification mark or color White 1 or Yellow None 1 or Yellow I Yellow Yellow 2 or None White 1 or Yellow None 2 or None II None Yellow 3 or Blue White 2 or None None 3 or Blue III White Yellow 3 or Blue or Inc...

Page 142: ...3 1EN0920 To replace the one on previous page Correct Identification mark Identification color ...

Page 143: ...ified in steps 1 and 2 select bearings from table above See the following example 1 If the measured crankshaft journal diameter 48 000 mm this corresponds to classification 1 in the above table 2 If the identification mark on the cylinder block bearing hole is 1 select a bearing with an identification mark of 2 1EN0317 4 Except for the center bearing all the upper bearings are grooved The center b...

Page 144: ...ger SERVICE PUBLICATION TRAINING 1 Description This Service Bulletin informs you of the change that has been made to the tightening torque for the 4G1 engine s M12 crankshaft bolt The tightening procedure for the upsized M14 crankshaft bolt is also contained here in addition to the new tightening torque and procedure for the existing M12 crankshaft bolt 2 Applicable Manuals Manual Pub No Page ENGI...

Page 145: ... 125 N m 132 N m 3 132 N m 35 to 55 Caution Stop tightening and never tighten the bolt any more if a torque of 206 N m is reached during additional tightening to an angle within the specified range 4 Applicable vehicle models Vehicle model code Type Remarks LANCER CJ1A CJ2A 3 Crankshaft with casting pulley 4 Crankshaft with steel plate pulley LANCER CS1A CS2A CS3A 4 Crankshaft with steel plate pul...

Page 146: ...haft bolt flange 6 Clean the washer 7 Install the washer with the shear droop side toward the bolt head 8 Tighten the crankshaft bolt in the following proce dure Crankshaft with steel plate pulley 1 Tighten the crankshaft bolt to 132 N m Caution Never exceed a torque of 206 N m during additional tightening to an angle within the specified range 2 Using the special tool Angle gauge MB991614 turn th...

Page 147: ...t pulley NOTE Degreasing is necessary to prevent lack of frictional coefficient on the mating surfaces due to presence of oil or grease 4 Install the crankshaft pulley 5 Apply necessary minimum amount of engine oil to the threads and bearing surface of the crankshaft bolt flange 6 Clean the washer 7 Install the washer with the grooved side toward the bolt head 8 Tighten the crankshaft bolt to 181 ...

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