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Manual Mitsubishi 4G9

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  • Mitsubishi 4G9 - page 1

    GENERAL INFORMA TION 1 1A-0-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. SPECIFICA TIONS 1 1A-1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE SPECIFICA TIONS 1 1A-1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REWOR ...

  • Mitsubishi 4G9 - page 2

    1 1A-0-2 PWEE9502 E May 1995 Mitsubishi Motors Corporation NOTES ...

  • Mitsubishi 4G9 - page 3

    4G9 ENGINE (E - W) - General Information 1 1A-0-3 PWEE9502-C E July 1997 Mitsubishi Motors Corporation Revised GENERAL INFORMA TION 4G92 Descriptions 4G92 - SOHC 4G92 - DOHC - MIVEC T ype In-line OHV , SOHC In-line OHV , DOHC Number of cylinders 4 4 Combustion chamber Pentroof type Pentroof type T otal displacement dm 3 1,597 1,597 Cylinder bore mm ...

  • Mitsubishi 4G9 - page 4

    4G9 ENGINE (E - W) - General Information 1 1A-0-4 4G93 Descriptions 4G93 - SOHC 4G93 - DOHC 4G93 - DOHC - GDI T ype In-line OHV , SOHC In-line OHV , DOHC In-line OHV , DOHC Number of cylinders 4 4 4 Combustion chamber Pentroof type Pentroof type Pentroof type T otal displacement dm 3 1,834 1,834 1,834 Cylinder bore mm 81.0 81.0 81.0 Piston stroke m ...

  • Mitsubishi 4G9 - page 5

    4G9 ENGINE (E–W) – General Information 1 1A-0-5 PWEE9502-C E July 1997 Mitsubishi Motors Corporation Revised 4G94 Descriptions 4G94–SOHC 4G94–DOHC–GDI T ype In-line OHV , SOHC In-line OHV , DOHC Number of cylinders 4 4 Combustion chamber Pentroof type Pentroof type T otal displacement dm 3 1,999 1,999 Cylinder bore mm 81.5 81.5 Piston str ...

  • Mitsubishi 4G9 - page 6

    4G9 ENGINE (E–W) – Specifications 1 1A-1-1 1. SPECIFICA TIONS SER VICE SPECIFICA TIONS Items Standard value Limit Timing belt Auto-tensioner rod protrusion amount (When removed from engine) mm 11 – Auto-tensioner rod stroke mm Within 1 – Auto-tensioner rod protrusion amount (When checking with installed on engine) mm 3.8 – 4.5 – Rocker ...

  • Mitsubishi 4G9 - page 7

    4G9 ENGINE (E –W) – Specifications 1 1A-1-2 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 *T otal resurfacing depth of both cylinder head and cylinder block – 0.2* Cylinder head overall height mm SOHC 1 19.9 – 120.1 – DOHC 13 ...

  • Mitsubishi 4G9 - page 8

    4G9 ENGINE (E –W) – Specifications 1 1A-1-3 Items Limit Standard value V alve stem projec- tion mm SOHC Intake 49.30 49.80 tion mm Exhaust 49.35 49.85 DOHC Intake 46.70 47.20 Exhaust 46.65 47.15 DOHC–MIVEC Intake 58.13 58.63 Exhaust 57.85 58.35 DOHC–GDI Intake 46.70 47.20 Exhaust 46.65 47.15 Cylinder head bolt shank length mm – 96.4 V alv ...

  • Mitsubishi 4G9 - page 9

    4G9 ENGINE (E –W) – Specifications 1 1A-1-4 Items Limit Standard value Cylinder block overall height mm 4G92 243.5 – 4G93 263.5 – 4G94 286.7 – Cylinder block I.D. mm 4G92, 4G93 81.0 – 4G94 81.5 – Piston to cylinder clearance mm 0.02 – 0.04 – Bearing cap bolt shank length mm – 71.1 Crankshaft end play mm 0.05 – 0.25 0.4 Cranksh ...

  • Mitsubishi 4G9 - page 10

    4G9 ENGINE (E–W) – Specifications 1 1A-1-5 T ORQUE SPECIFICA TIONS Items Nm Alternator and ignition system Oil level gauge 13 Distributor 12 Ignition coil 10 Spark plug 25 Crankshaft bolt 182 ± 4 Alternator brace (M8) 23 Alternator brace (M10) 49 Lock bolt 23 Adjusting bolt 5 Power steering pump pulley 25 Power steering pump bracket stay 49 Po ...

  • Mitsubishi 4G9 - page 11

    4G9 ENGINE (E –W) – Specifications 1 1A-1-6 Items Nm Fuel system and emission system Breather tube 21 Fuel pump 18 Carburetor 17 EGR valve 21 Cover <Without EGR valve> 12 Fuel return pipe 9 Delivery pipe 12 Fuel pressure regulator 9 Throttle body stay <MIVEC> 23 Throttle body stay <4G94> 24 Throttle body 19 Throttle cable brac ...

  • Mitsubishi 4G9 - page 12

    4G9 ENGINE (E–W) – Specifications 1 1A-1-6a Items Nm Intake manifold and exhaust manifold Exhaust manifold (M8) 18 Exhaust manifold (M10) 29 Exhaust manifold bracket (M8) 19 Exhaust manifold bracket (M10 Bolt and washer assembly) 35 Exhaust manifold bracket (M10 Flange bolt) 98 Engine hanger (Bolt with head mark “4”) 12 Engine hanger (Bolt ...

  • Mitsubishi 4G9 - page 13

    4G9 ENGINE (E –W) – Specifications 1 1A-1-6b Items Nm Exhaust manifold (M8) 17 Exhaust manifold (M10) 29 Injector and fuel pump assembly (GDI) Fuel low pressure pipe (M6) 18 Fuel low pressure pipe (M8) 9 Fuel nipple 9 Clamp 9 Fuel feed pipe 11 Fuel pump 17 Harness bracket 11 Fuel pipe 11 Fuel return pipe 11 Fuel return pipe clamp 9 Fuel high pr ...

  • Mitsubishi 4G9 - page 14

    4G9 ENGINE (E –W) – Specifications 1 1A-1-6c Items Nm W ater inlet fitting <Except P AJERO io> 19 W ater inlet fitting <P AJERO io> 24 W ater by-pass fitting 24 W ater pipe 14 W ater outlet fitting <Except P AJERO io> 19 W ater outlet fitting <P AJERO io> 24 Engine coolant temperature gauge unit 10 Engine coolant tempera ...

  • Mitsubishi 4G9 - page 15

    4G9 ENGINE (E –W) – Specifications 1 1A-1-6d Items Nm Upper oil pan (M8) 24 Lower oil pan 11 Cover 7 Baffle plate <DOHC –MPI> 7 Baffle plate <Except DOHC –MPI> 11 Drain plug 39 Oil pressure switch 10 T ransmission stay 23 Piston and connecting rod Connecting rod cap nut 20 + 90 _ to 100 _ Crankshaft, cylinder block, flywheel and ...

  • Mitsubishi 4G9 - page 16

    4G9 ENGINE (E - W) - Specifications 1 1A-1-7 NEW TIGHTENING METHOD - BY USE OF BOL TS 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 dif ferent from the conventional one. Be sure to observe the method described in t ...

  • Mitsubishi 4G9 - page 17

    4G9 ENGINE (E - W) - Specifications 1 1A-1-8 PWEE9502 E May 1995 Mitsubishi Motors Corporation FORM-IN-PLACE GASKET The engine has several areas where the form-in-place gasket (FIPG) is in use. T o ensure that the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size, continuity and locatio ...

  • Mitsubishi 4G9 - page 18

    4G9 ENGINE (E - W) - Special T ools 1 1A-2-1 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Revised 2. SPECIAL TOOLS T ool Number Name Use MB990938 Handle Use with MD998776 MB990767 Crankshaft pulley holder Holding camshaft sprocket when loosening and tightening of bolt. Use with MD998719 MD998440 Leak-down tester Leak-down test of lash adju ...

  • Mitsubishi 4G9 - page 19

    4G9 ENGINE (E - W) - Special T ools 1 1A-2-2 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Revised T ool U se Name Number MD998719 Pulley holder pin (2) Use with MB990767 MD998727 Oil pan remover Removal o f the oil pan MD998754 Pin Use with MB990767 MD998767 T ensioner pulley socket wrench Adjustment of timing belt tension MD998772 V alve ...

  • Mitsubishi 4G9 - page 20

    4G9 ENGINE (E - W) - Special T ools 1 1A-2-3 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Revised T ool U se Name Number MD998780 SETTING TOOL Piston pin Removal and installation of piston pin MD998735 V alve spring compressor Compression of valve spring MD998781 Flywheel stopper Holding flywheel and drive plate MB991477 V alve adjusting w ...

  • Mitsubishi 4G9 - page 21

    4G9 ENGINE (E–W) – Alternator and Ignition System 1 1A-3-1 3. AL TERNA TOR AND IGNITION SYSTEM REMOV AL AND INST ALLA TION <SOHC> (Engines with distributor) 5 Nm 23 Nm 25 Nm 12 Nm 23 Nm 49 Nm 44 Nm 182 ± 4 Nm 3 2 8 7 9 10 4 1 5 6 12 13 21 Nm 44 Nm 11 25 Nm 44 Nm 49 Nm Removal steps 1. Drive belt* 2. Alternator 3. Alternator brace A A &qu ...

  • Mitsubishi 4G9 - page 22

    4G9 ENGINE (E –W) – Alternator and Ignition System 1 1A-3-2 REMOV AL AND INST ALLA TION <SOHC for other than P AJERO io> (Engines without distributor) 5 Nm 23 Nm 25 Nm 13 Nm 23 Nm 49 Nm 44 Nm 3 2 8 7 9 Nm 11 4 1 5 6 10 Nm 21 Nm 9 13 12 5 Nm 10 182 ± 4 Nm 15 16 21 Nm 44 Nm 14 25 Nm 44 Nm 49 Nm Removal steps 1. Drive belt* 2. Alternator 3. ...

  • Mitsubishi 4G9 - page 23

    4G9 ENGINE (E–W) – Alternator and Ignition System 1 1A-3-2a REMOV AL AND INST ALLA TION <SOHC for P AJERO io> (Engines without distributor) 5 Nm 23 Nm 25 Nm 13 Nm 23 Nm 49 Nm 44 Nm 3 2 8 7 9 Nm 12 4 1 5 6 10 Nm 21 Nm 9 14 13 8 7 182 ± 4 Nm 16 17 21 Nm 44 Nm 15 25 Nm 44 Nm 49 Nm 10 11 10 Nm 5 Nm Removal steps 1. Drive belt* 2. Alternator ...

  • Mitsubishi 4G9 - page 24

    4G9 ENGINE (E - W) - Alternator and Ignition System 1 1A-3-2b Intentionally blank PWEE9502-E E Dec. 1998 Mitsubishi Motors Corporation Added ...

  • Mitsubishi 4G9 - page 25

    4G9 ENGINE (E–W) – Alternator and Ignition System 1 1A-3-3 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC> 10 Nm 25 Nm 23 Nm 29 Nm 182 ± 4 Nm 3 2 7 8 4 1 5 6 9 3 Nm 11 23 Nm 5 Nm 23 Nm 44 Nm 10 21 Nm 12 25 Nm 13 14 44 Nm 49 Nm 44 Nm Removal steps 1. Drive belt* 2. Alternator 3. Alternator brace A ...

  • Mitsubishi 4G9 - page 26

    4G9 ENGINE (E –W) – Alternator and Ignition System 1 1A-3-4 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Added REMOV AL AND INST ALLA TION <DOHC –MIVEC> 5 Nm 23 Nm 13 Nm 23 Nm 49 Nm 44 Nm 182 ± 4 Nm 3 2 8 7 9 10 4 1 5 6 3 Nm 10 Nm 25 Nm 21 Nm 11 9 Nm 13 12 21 Nm 16 44 Nm 14 25 Nm 44 Nm 49 Nm 15 Removal steps 1. Drive belt* 2. ...

  • Mitsubishi 4G9 - page 27

    4G9 ENGINE (E –W) – Alternator and Ignition System 1 1A-3-5 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC– GDI for CARISMA, SP ACE ST AR, SP ACE RUNNER, GALANT> 5 Nm 23 Nm 9 Nm 23 Nm 49 Nm 44 Nm 182 ± 4 Nm 3 2 9 7 11 4 1 5 6 2.9 Nm 10 Nm 25 Nm 21 Nm 12 13 13 Nm 10 14 5 Nm 8 21 Nm 17 44 Nm 15 25 ...

  • Mitsubishi 4G9 - page 28

    4G9 ENGINE (E –W) – Alternator and Ignition System 1 1A-3-6 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Added REMOV AL AND INST ALLA TION <DOHC – GDI for P AJERO io> 15 21 Nm 9 Nm 23 Nm 5 Nm 44 Nm 182 ± 4 Nm 3 2 8 7 10 4 1 5 6 10 Nm 25 Nm 21 Nm 11 12 13 Nm 9 44 Nm 49 Nm 44 Nm 44 Nm 23 Nm 13 Nm 14 25 Nm 17 16 3 13 Removal step ...

  • Mitsubishi 4G9 - page 29

    4G9 ENGINE (E–W) – Alternator and Ignition System 1 1A-3-7 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation REMOV AL SERVICE POINT A A " CRANKSHAFT BOL T REMOV AL (1) Use the special tool to hold the flywheel or the drive plate, and then loosen the crankshaft mounting bolts. INST ALLA TION SERVICE POINTS " A A CAM POSITION SENSOR ...

  • Mitsubishi 4G9 - page 30

    4G9 ENGINE (E–W) – Timing Belt 1 1A-4-1 4. TIMING BEL T REMOV AL AND INST ALLA TION <SOHC for CARISMA (Up to 1999 model), LANCER (Except from 2001 model for Europe), GALANT> 11 N m 88 Nm 11 N m 23 Nm 11 N m 49 Nm 11 10 1 4 5 3 2 6 7 8 9 12 9.8 Nm 14 13 Removal steps 1. T iming belt front upper cover 2. T iming belt front lower cover 3. En ...

  • Mitsubishi 4G9 - page 31

    4G9 ENGINE (E–W) – Timing Belt 1 1A-4-1a REMOV AL AND INST ALLA TION <SOHC for CARISMA (From 2000 model), LANCER (From 2001 model for Europe), SP ACE ST AR> 11 N m 88 Nm 11 N m 23 Nm 11 N m 49 Nm 11 10 1 4 5 3 2 6 7 9 12 14 13 8 9.8 Nm Removal steps 1. T iming belt front upper cover 2. T iming belt front lower cover 3. Engine support brac ...

  • Mitsubishi 4G9 - page 32

    4G9 ENGINE (E - W) - Timing Belt 1 1A-4-1b Intentionally blank PWEE9502-G E May 2000 Mitsubishi Motors Corporation Added ...

  • Mitsubishi 4G9 - page 33

    4G9 ENGINE (E–W) – Timing Belt 1 1A-4-2 REMOV AL AND INST ALLA TION <SOHC for P AJERO io> 11 N m 88 Nm 11 N m 23 Nm 49 Nm 11 10 1 4 5 3 2 6 7 8 9 12 9.8 Nm 14 13 Removal steps 1. T iming belt front upper cover 2. T iming belt front lower cover 3. Accessory mount A A "" D A 4. T iming belt " C A 5. T ensioner spring " B ...

  • Mitsubishi 4G9 - page 34

    4G9 ENGINE (E–W) – Timing Belt 1 1A-4-2a REMOV AL AND INST ALLA TION <DOHC> 88 Nm 11 N m 11 N m 36 Nm 44 Nm 11 N m 49 Nm 13 Nm 11 N m 9.8 Nm 20 12 9 8 3 2 1 5 17 18 4 19 6 10 7 13 15 14 16 11 24 Nm Removal steps 1. T iming belt upper cover 2. T iming belt lower cover 3. Engine support bracket A A "" F A 4. T iming belt 5. T ensi ...

  • Mitsubishi 4G9 - page 35

    4G9 ENGINE (E –W) – Timing Belt 1 1A-4-2b REMOV AL AND INST ALLA TION <DOHC –MIVEC> 11 N m 88 Nm 11 N m 35 Nm 11 N m 49 Nm 11 10 1 4 5 3 2 6 7 8 9 11 N m 18 17 16 48 Nm 12 14 13 15 48 Nm 13 Nm 19 9.8 Nm Removal steps 1. T iming belt front upper cover 2. T iming belt front lower cover 3. Engine support bracket, right A A "" F A ...

  • Mitsubishi 4G9 - page 36

    4G9 ENGINE (E –W) – Timing Belt 1 1A-4-2c REMOV AL AND INST ALLA TION <DOHC– GDI for CARISMA, SP ACE ST AR, SP ACE RUNNER> 21 11 N m 88 Nm 11 N m 35 Nm 11 N m 49 Nm 11 10 1 4 5 3 2 6 7 8 9 11 N m 19 18 48 Nm 13 15 14 16 48 Nm 13 Nm 20 9.8 Nm 17 11 N m 12 9.8 Nm 12 Removal steps 1. T iming belt front upper cover 2. T iming belt front low ...

  • Mitsubishi 4G9 - page 37

    4G9 ENGINE (E –W) – Timing Belt 1 1A-4-2d REMOV AL AND INST ALLA TION <DOHC – GDI for GALANT> 11 N m 88 Nm 11 N m 35 Nm 11 N m 49 Nm 11 10 1 4 5 3 2 6 7 8 9 18 17 48 Nm 12 14 13 15 48 Nm 13 Nm 9.8 Nm 16 Removal steps 1. T iming belt front upper cover 2. T iming belt front lower cover 3. Engine support bracket, right A A "" F A ...

  • Mitsubishi 4G9 - page 38

    4G9 ENGINE (E –W) – Timing Belt 1 1A-4-2e REMOV AL AND INST ALLA TION <DOHC – GDI for P AJERO io> 11 N m 88 Nm 11 N m 35 Nm 11 N m 49 Nm 11 10 1 4 5 3 2 6 7 8 9 11 N m 19 18 48 Nm 13 15 14 16 48 Nm 13 Nm 12 9.8 Nm 17 20 11 N m 21 11 N m Removal steps 1. T iming belt front upper cover 2. T iming belt front lower cover 3. Accesory mount A ...

  • Mitsubishi 4G9 - page 39

    4G9 ENGINE (E - W) - Timing Belt 1 1A-4-2f Intentionally blank PWEE9502-G E May 2000 Mitsubishi Motors Corporation Added ...

  • Mitsubishi 4G9 - page 40

    4G9 ENGINE (E - W) - Timing Belt 1 1A-4-3 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Revised REMOV AL SERVICE POINTS A A " TIMING BEL T REMOV AL (1) Mark belt running direction for reinstallation. A B " CAMSHAFT SPROCKET BOL T REMOV AL <With rocker cover removed> (Except SOHC) (1) Use a wrench to hold the hexagonal part o ...

  • Mitsubishi 4G9 - page 41

    4G9 ENGINE (E - W) - Timing belt 1 1A-4-4 PWEE9502 E May 1995 Mitsubishi Motors Corporation " B A TIMING BEL T TENSIONER INST ALLA TION (1) Let the pulley of th e timing belt tensioner comr closest to the exhaust side. T emporarily tighten the tensioner pulley fixing bolt. " C A TENSIONER SPRING INST ALLA TION (1) Insert t he tip A (short ...

  • Mitsubishi 4G9 - page 42

    4G9 ENGINE (E - W) - Timing Belt 1 1A-4-5 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Revised (6) Slightly loosen t he tensioner pulley fixing bolt which is tightened temporarily to tighten the belt by a force of the tensioner spring. (7) T urn th e crankshaft clockwise by two turns. (8) Check that the timing marks are aligned. (9) T ight ...

  • Mitsubishi 4G9 - page 43

    4G9 ENGINE (E - W) - Timing Belt 1 1A-4-6 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Revised " F A TIMING BEL T INST ALLA TION (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) T urn the crankshaft ...

  • Mitsubishi 4G9 - page 44

    4G9 ENGINE (E - W) - Timing Belt 1 1A-4-7 PWEE9502 E May 1995 Mitsubishi Motors Corporation (6) Secure the timing belt with a paper clip at the illustrated position. (7) Fit t he belt to the idler pulley water pump sprocket, crankshaft sprocket and tensioner pulley in that order . (8) Raise t he tensioner pulley in t he direction of an arrow and ti ...

  • Mitsubishi 4G9 - page 45

    4G9 ENGINE (E–W) – Timing Belt 1 1A-4-8 PWEE9502 E May 1995 Mitsubishi Motors Corporation (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 clock ...

  • Mitsubishi 4G9 - page 46

    4G9 ENGINE (E - W) - Timing Belt 1 1A-4-9 PWEE9502 E May 1995 Mitsubishi Motors Corporation (6) Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife. (7) Abnormal wear on teeth. (8) Missing tooth. TENSIONER PULLER, IDLER PULLEY (1) Check the pulley for smooth rotation, excessive play , abnormal noise. Replace it ...

  • Mitsubishi 4G9 - page 47

    4G9 ENGINE (E - W) - Fuel and Emission Control System 1 1A-5-1 PWEE9502-B E Nov . 1996 Mitsubishi Motors Corporation Revised 5. FUEL AND EMISSION CONTROL SYSTEM REMOV AL AND INST ALLA TION <SOHC - CARBURETOR> 17 Nm 21 Nm 18 Nm 8 11 10 1 9 5 6 7 3 2 21 Nm 4 Removal steps 1. Breather tube 2. Fuel hose 3. Fuel hose 4. Fuel pump 5. Gasket 6. Insu ...

  • Mitsubishi 4G9 - page 48

    4G9 ENGINE (E–W) – Fuel and Emission Control System 1 1A-5-2 PWEE9502-B E Nov . 1996 Mitsubishi Motors Corporation Revised REMOV AL AND INST ALLA TION <SOHC–MPI for other than P AJERO io> 12 Nm 19 Nm Engine with solenoid valve Flange Engine with solenoid valve Washer Engine without solenoid valve 9 Nm 9 Nm 16 15 13 12 14 1 11 7 8 9 3 17 ...

  • Mitsubishi 4G9 - page 49

    4G9 ENGINE (E–W) – Fuel and Emission Control System 1 1A-5-3 PWEE9502-B E Nov . 1996 Mitsubishi Motors Corporation Revised REMOV AL AND INST ALLA TION <SOHC–MPI for P AJERO io> 16 12 Nm 19 Nm 9 Nm 9 Nm 17 3 11 14 13 15 4 12 10 6 2 9 9 Nm 9 Nm 18 8 19 11 N m 5 1 24 Nm 7 20 21 22 Nm Removal steps 1. Stay (From 2002 model) 2. Harness brack ...

  • Mitsubishi 4G9 - page 50

    4G9 ENGINE (E –W) – Fuel and Emission Control System 1 1A-5-4 PWEE9502-B E Nov . 1996 Mitsubishi Motors Corporation Revised REMOV AL AND INST ALLA TION <DOHC> 11 N m 18 Nm 10 Nm 9 Nm 9 Nm 15 14 9 12 11 13 1 10 6 7 8 3 2 5 16 23 Nm 17 4 23 Nm 9 Nm Removal steps 1. V acuum pipe assembly 2. Throttle body assembly " C A 3. Gasket 4. Thro ...

  • Mitsubishi 4G9 - page 51

    4G9 ENGINE (E - W) - Fuel and Emission Control System 1 1A-5-5 INST ALLA TION SERVICE POINTS " A A INJECT ORS INST ALLA TION (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 an d right, install it to the delivery pipe. (3) Chec ...

  • Mitsubishi 4G9 - page 52

    4G9 ENGINE (E - W) - Fuel and Emission Control System 1 1A-5-6 PWEE9502-E E Dec. 1998 Mitsubishi Motors Corporation Added <SOHC - MPI for P AJERO io> Projection ...

  • Mitsubishi 4G9 - page 53

    4G9 ENGINE (E - W) - Throttle Body and EGR System (GDI) 1 1A-5a-1 5a. THROTTLE BODY AND EGR SYSTEM (GDI) REMOV AL AND INST ALLA TION <Up to 2000 model for CARISMA, 1999 model for SP ACE ST AR, SP ACE RUNNER> 18 Nm 30 Nm 24 Nm 9N m 14 13 8 11 10 12 1 9 5 6 7 32 15 4 16 17 18 Nm 18 Nm 18 Nm 18 Nm 9N m 14 Removal steps 1. Air intake plenum reson ...

  • Mitsubishi 4G9 - page 54

    4G9 ENGINE (E–W) – Throttle Body and EGR System (GDI) 1 1A-5a-2 REMOV AL AND INST ALLA TION <From 2001 model for CARISMA, SP ACE ST AR and GALANT> 18 Nm 30 Nm 24 Nm 4 11 8 12 10 9 6 7 1 2 24 Nm 18 Nm 12 5 3 20 Nm 24 Nm Removal steps " B A 1. Intake manifold stay (For GALANT) 2. W ater hose 3. W ater hose 4. W ater hose 5. Throttle bo ...

  • Mitsubishi 4G9 - page 55

    4G9 ENGINE (E - W) - Throttle Body and EGR System (GDI) 1 1A-5a-3 REMOV AL AND INST ALLA TION <For P AJERO io - 4G93> 13 Nm 23 Nm 18 Nm 14 6 10 1 9 2 8 4 7 13 3 16 11 N m 18 Nm 18 Nm 12 18 Nm 14 11 5 11 N m 15 Removal steps 1. W ater hose 2. W ater hose 3. W ater hose 4. W ater hose 5. W ater hose 6. W ater hose clamp 7. W ater pipe 8. W ater ...

  • Mitsubishi 4G9 - page 56

    4G9 ENGINE (E - W) - Throttle Body and EGR System (GDI) 1 1A-5a-4 REMOV AL AND INST ALLA TION <For P AJERO io - 4G94> 13 Nm 23 Nm 18 Nm 15 6 11 1 9 2 8 4 7 14 3 16 11 N m 18 Nm 18 Nm 13 18 Nm 14 12 5 11 N m 10 18 Nm Removal steps 1. W ater hose 2. W ater hose 3. W ater hose 4. W ater hose 5. W ater hose 6. W ater hose clamp 7. W ater pipe 8. ...

  • Mitsubishi 4G9 - page 57

    4G9 ENGINE (E - W) - Throttle Body and EGR System (GDI) 1 1A-5a-5 INST ALLA TION SERVICE POINTS " A A THROTTLE BODY GASKET " B A INT AKE MANIFOLD ST A Y INST ALLA TION (1) T ighten the four bolts at the top and bottom of the stay handtight. (2) Check that the stay seating surface is in close contact with the bosses on the intake manifold ...

  • Mitsubishi 4G9 - page 58

    4G9 ENGINE (E–W) – Intake and Exhaust Manifold 1 1A-6-1 PWEE9502-B E Nov . 1996 Mitsubishi Motors Corporation Revised 6. INT AKE AND EXHAUST MANIFOLD REMOV AL AND INST ALLA TION <SOHC–CARBURET OR> 20 Nm 20 Nm 31 Nm 29 Nm 18 Nm 19 Nm 14 Nm 7 6 5 8 9 10 11 13 4 1 3 2 13 Nm 13 Nm 12 Bolt with head mark “4” Bolt with head mark “7” 1 ...

  • Mitsubishi 4G9 - page 59

    4G9 ENGINE (E –W) – Intake and Exhaust Manifold 1 1A-6-2 PWEE9502-B E Nov . 1996 Mitsubishi Motors Corporation Revised REMOV AL AND INST ALLA TION <SOHC –MPI– FRONT WHEEL DRIVE (4G92 and 4G93– Except from 2001 model for Europe)> 20 Nm 20 Nm 31 Nm 29 Nm 18 Nm 13 Nm 19 Nm 14 Nm 7 6 5 8 9 10 11 13 4 1 3 2 12 Bolt with head mark “4” ...

  • Mitsubishi 4G9 - page 60

    4G9 ENGINE (E–W) – Intake and Exhaust Manifold 1 1A-6-2a PWEE9502-B E Nov . 1996 Mitsubishi Motors Corporation Revised REMOV AL AND INST ALLA TION <SOHC–MPI–FRONT WHEEL DRIVE (4G92 and 4G93–From 2001 model for Europe)> 20 Nm 20 Nm 19 Nm 31 Nm 30 Nm 18 Nm 13 Nm 19 Nm 14 Nm 7 6 5 10 9 14 11 13 4 1 3 2 12 8 44 Nm 35 Nm 19 Nm 13 Nm Remo ...

  • Mitsubishi 4G9 - page 61

    4G9 ENGINE (E –W) – Intake and Exhaust Manifold 1 1A-6-2b PWEE9502-B E Nov . 1996 Mitsubishi Motors Corporation Revised REMOV AL AND INST ALLA TION <SOHC –MPI– FRONT WHEEL DRIVE (4G94)> 20 Nm 20 Nm 31 Nm 29 Nm 18 Nm 13 Nm 19 Nm 14 Nm 5 3 4 6 7 8 10 12 2 1 9 11 19 Nm Removal steps 1. Intake manifold stay 2. Intake manifold 3. Intake ma ...

  • Mitsubishi 4G9 - page 62

    4G9 ENGINE (E–W) – Intake and Exhaust Manifold 1 1A-6-2c PWEE9502-B E Nov . 1996 Mitsubishi Motors Corporation Revised REMOV AL AND INST ALLA TION <SOHC–MPI – REAR WHEEL DRIVE (4G93 – Except from 2002 model for Europe)> 20 Nm 4 6 19 Nm 31 Nm 5 2 3 14 Nm 1 29 Nm 10 35 Nm 18 Nm 9 13 Nm 13 Nm 8 7 12 11 Removal steps 1. Oil level gauge ...

  • Mitsubishi 4G9 - page 63

    4G9 ENGINE (E –W) – Intake and Exhaust Manifold 1 1A-6-2d PWEE9502-B E Nov . 1996 Mitsubishi Motors Corporation Revised REMOV AL AND INST ALLA TION <SOHC–MPI – REAR WHEEL DRIVE (4G93 – from 2002 model for Europe)> 20 Nm 4 6 19 Nm 31 Nm 5 2 3 14 Nm 1 29 Nm 10 35 Nm 18 Nm 9 13 Nm 13 Nm 8 7 12 11 1 Removal steps 1. Oil level gauge 2. O ...

  • Mitsubishi 4G9 - page 64

    4G9 ENGINE (E –W) – Intake and Exhaust Manifold 1 1A-6-2e PWEE9502-B E Nov . 1996 Mitsubishi Motors Corporation Revised REMOV AL AND INST ALLA TION <SOHC –MPI – REAR WHEEL DRIVE (4G94)> 20 Nm 4 6 19 Nm 31 Nm 5 2 3 14 Nm 1 29 Nm 10 18 Nm 9 13 Nm 13 Nm 8 7 12 11 98 Nm Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4 ...

  • Mitsubishi 4G9 - page 65

    4G9 ENGINE (E –W) – Intake and Exhaust Manifold 1 1A-6-2f PWEE9502-B E Nov . 1996 Mitsubishi Motors Corporation Revised Intentionally blank PWEE9502-K E Jun. 2002 Mitsubishi Motors Corporation Added ...

  • Mitsubishi 4G9 - page 66

    4G9 ENGINE (E–W) – Intake and Exhaust Manifold 1 1A-6-3 PWEE9502-B E Nov . 1996 Mitsubishi Motors Corporation Revised REMOV AL AND INST ALLA TION <DOHC> 20 Nm 20 Nm Bolt with head mark “4” Bolt with head mark “7” 31 Nm 29 Nm 18 Nm 12 Nm 19 Nm 19 Nm 14 Nm 7 6 5 8 9 10 11 12 4 1 3 2 Bolt with head mark “4” Bolt with head mark ? ...

  • Mitsubishi 4G9 - page 67

    4G9 ENGINE (E –W) – Intake and Exhaust Manifold 1 1A-6-4 PWEE9502-B E Nov . 1996 Mitsubishi Motors Corporation Added INST ALLA TION SERVICE POINT " A A EXHAUST MANIFOLD BRACKET INST ALLA TION <FRONT WHEEL DRIVE> (1) Install temporarily the exhaust manifold brackets A and B as shown in the illustration. (2) Check that both brackets ar ...

  • Mitsubishi 4G9 - page 68

    4G9 ENGINE (E - W) - Intake Manifold (GDI) 1 1A-6a-1 PWEE9502-D E Jun. 1998 Mitsubishi Motors Corporation Revised 6a. INT AKE MANIFOLD (GDI) REMOV AL AND INST ALLA TION <Up to 2000 model for CARISMA, 1999 model for SP ACE ST AR, SP ACE RUNNER> 11 N m 19 Nm 9N m 8 10 1 9 5 6 7 3 2 4 11 N m 11 N m 9N m 19 Nm Removal steps 1. Air by-pass hose (U ...

  • Mitsubishi 4G9 - page 69

    4G9 ENGINE (E–W) – Intake Manifold (GDI) 1 1A-6a-1a PWEE9502-D E Jun. 1998 Mitsubishi Motors Corporation Added REMOV AL AND INST ALLA TION <From 2001 model for CARISMA, SP ACE ST AR and GALANT> 11 N m 19 Nm 4 5 1 3 11 N m 19 Nm 2 Removal steps 1. V acuum pipe and hose 2. Purge hose 3. Solenoid valve 4. V acuum pipe 5. Intake manifold PWEE ...

  • Mitsubishi 4G9 - page 70

    4G9 ENGINE (E - W) - Intake Manifold (GDI) 1 1A-6a-1b PWEE9502-D E Jun. 1998 Mitsubishi Motors Corporation Revised Intentionally blank PWEE9502-G E May 2000 Mitsubishi Motors Corporation Added ...

  • Mitsubishi 4G9 - page 71

    4G9 ENGINE (E - W) - Intake Manifold (GDI) 1 1A-6a-2 PWEE9502-D E Jun. 1998 Mitsubishi Motors Corporation Added REMOV AL AND INST ALLA TION <For SP ACE RUNNER> 11 N m 19 Nm 9N m 8 10 1 9 5 6 7 3 2 4 11 N m 11 N m 9N m 19 Nm Removal steps 1. Air by-pass hose 2. V acuum pipe and hose 3. Bracket 4. Solenoid valve 5. Connector bracket 6. Accelera ...

  • Mitsubishi 4G9 - page 72

    4G9 ENGINE (E - W) - Intake Manifold (GDI) 1 1A-6a-3 REMOV AL AND INST ALLA TION <For P AJERO io> 9N m 19 Nm 23 Nm 8 10 1 9 5 6 3 2 4 11 N m 11 N m 9N m 30 Nm 7 9N m 9N m Removal steps 1. P .C.V . hose 2. V acuum pipe and hose 3. Solenoid valve 4. Fuel pump protector 5. Connector bracket 6. Branch tube 7. Gasket " A A 8. Intake manifold ...

  • Mitsubishi 4G9 - page 73

    4G9 ENGINE (E - W) - Intake Manifold (GDI) 1 1A-6a-4 INST ALLA TION SERVICE POINT " A A INT AKE MANIFOLD ST A Y INST ALLA TION (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. PWEE9502-E E Dec. 1998 Mits ...

  • Mitsubishi 4G9 - page 74

    4G9 ENGINE (E - W) - Exhaust Manifold (GDI) 1 1A-6b-1 6b. EXHAUST MANIFOLD (GDI) REMOV AL AND INST ALLA TION <For CARISMA, SP ACE ST AR, SP ACE RUNNER> 17 Nm 35 Nm 18 Nm 13 Nm 8 1 9 5 6 7 3 2 4 29 Nm 13 Nm 13 Nm 35 Nm 18 Nm 24 Nm Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Exhaust manifold cover 5. Engine hanger &qu ...

  • Mitsubishi 4G9 - page 75

    1 1A-6b-1a REMOV AL AND INST ALLA TION <For GALANT> 17 Nm 19 Nm 35 Nm 13 Nm 9 1 10 5 4 7 3 2 6 29 Nm 13 Nm 13 Nm 44 Nm 24 Nm 35 Nm 11 8 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 ...

  • Mitsubishi 4G9 - page 76

    4G9 ENGINE (E - W) - Exhaust Manifold (GDI) 1 1A-6b-1b Intentionally blank PWEE9502-G E May 2000 Mitsubishi Motors Corporation Added ...

  • Mitsubishi 4G9 - page 77

    4G9 ENGINE (E - W) - Exhaust Manifold (GDI) 1 1A-6b-2 REMOV AL AND INST ALLA TION <For P AJERO io> 17 Nm 13 Nm 1 3 5 2 4 29 Nm 18 Nm 98 Nm 29 Nm Removal steps 1. Exhaust manifold cover 2. Engine hanger " B A 3. Exhaust manifold bracket 4. Exhaust manifold 5. Exhaust manifold gasket PWEE9502-E E Dec. 1998 Mitsubishi Motors Corporation Rev ...

  • Mitsubishi 4G9 - page 78

    4G9 ENGINE (E - W) - Exhaust Manifold (GDI) 1 1A-6b-3 INST ALLA TION SERVICE POINTS " A A EXHAUST MANIFOLD BRACKET INST ALLA TION (1) Slide th e washers over the bolts with the chamfered side toward th e bolt. (2) Install temporarily the exhaust manifold brackets A and B as shown in the illustration. (3) Check that both brackets are in close c ...

  • Mitsubishi 4G9 - page 79

    4G9 ENGINE (E - W) - Injector and Fuel Pump Assembly (GDI) 1 1A-6c-1 6c. INJECTOR AND FUEL PUMP ASSEMBL Y (GDI) REMOV AL AND INST ALLA TION <Up to 2000 model for CARISMA, 1999 model for SP ACE ST AR, SP ACE RUNNER> 18 Nm 17 ± 2N m 9N m 14 13 8 11 10 12 1 9 5 6 7 3 2 15 4 16 17 18 19 20 28 30 21 29 25 26 27 23 22 24 38 31 35 36 37 33 32 34 11 ...

  • Mitsubishi 4G9 - page 80

    4G9 ENGINE (E–W) – Injector and Fuel Pump Assembly (GDI) 1 1A-6c-1a REMOV AL AND INST ALLA TION <From 2001 model for CARISMA, SP ACE ST AR and GALANT> 14 13 8 10 12 1 9 5 6 3 2 15 4 16 17 21 22 11 N m 22 Nm 7 11 18 19 20 23 Nm 11 N m 7 8 9 11 N m 11 N m 17 Nm Removal steps 1. Injector harness 2. Flange " I A 3. Fuel pressure sensor & ...

  • Mitsubishi 4G9 - page 81

    4G9 ENGINE (E - W) - Injector and Fuel Pump Assembly (GDI) 1 1A-6c-1b REMOV AL AND INST ALLA TION <For P AJERO io - 4G94> 14 13 10 12 1 9 11 4 3 2 15 5 18 19 23 22 11 N m 22 Nm 7 24 21 20 23 Nm 11 N m 11 9 11 N m 11 N m 17 Nm 16 17 6 10 8 Removal steps 1. Fuel hose 2. Fuel hose 3. Injector harness 4. Flange " I A 5. Fuel pressure sensor ...

  • Mitsubishi 4G9 - page 82

    4G9 ENGINE (E - W) - Injector and Fuel Pump Assembly (GDI) 1 1A-6c-2 REMOV AL AND INST ALLA TION <For P AJERO io - 4G93> 28 18 Nm 17 ± 2N m 9N m 14 10 8 7 1 9 6 5 2 15 4 16 17 34 24 25 26 27 22 23 20 35 32 30 3 33 31 22 Nm 9N m 11 N m 18 Nm 11 N m 9N m 18 19 11 N m 18 Nm 21 11 12 13 29 Removal steps 1. Injector harness 2. Fuel hose 3. Fuel h ...

  • Mitsubishi 4G9 - page 83

    4G9 ENGINE (E - W) - Injector and Fuel Pump Assembly (GDI) 1 1A-6c-3 INST ALLA TION SERVICE POINTS " A A BACKUP RING / O-RING / CORRUGA TED W ASHER INST ALLA TION (1) Attach the backup rings a nd 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. (2) Coat ...

  • Mitsubishi 4G9 - page 84

    4G9 ENGINE (E - W) - Injector and Fuel Pump Assembly (GDI) 1 1A-6c-4 (8) T ighten the fasteners of the delivery pipe and injector assembly to the specified torque in the order given in the illustration. " C A PUMP CAMSHAFT CASE INST ALLA TION (1) Apply small amount of engine oil to the O-ring (larger one) on the case. (2) Install the pump cams ...

  • Mitsubishi 4G9 - page 85

    4G9 ENGINE (E - W) - Injector and Fuel Pump Assembly (GDI) 1 1A-6c-5 (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 th e inside cut surface in t he direction shown in the illustration. (3) Lubricate the O-rings on both ends of the pipe with spindle oil or gasolin ...

  • Mitsubishi 4G9 - page 86

    4G9 ENGINE (E - W) - Injector and Fuel Pump Assembly (GDI) 1 1A-6c-6 " G A O-RING / FUEL PUMP INST ALLA TION (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 t ...

  • Mitsubishi 4G9 - page 87

    4G9 ENGINE (E - W) - Injector and Fuel Pump Assembly (GDI) 1 1A-6c-7 " I A O-RING / BACKUP RING / FUEL PRESSURE SENSOR INST ALLA TION (1) Fit the backup ring to the fuel pressure sensor so that its inner cut surface faces in the direction shown. (2) Being attentive to the shape of the connector and label surface of the fuel pressure sensor , i ...

  • Mitsubishi 4G9 - page 88

    4G9 ENGINE (E - W) - Intake and Exhaust Manifold <4G94 - GDI for P AJERO io> 1 1A-6d-1 6d. INT AKE AND EXHAUST MANIFOLD <4G94 - GDI for P AJERO io> REMOV AL AND INST ALLA TION 20 Nm 31 Nm 23 Nm 9N m 14 13 8 11 10 12 1 9 5 6 7 3 2 4 15 11 N m 98 Nm 13 Nm 18 Nm 9N m 29 Nm 9N m 17 Nm 29 Nm Removal steps 1. P .C.V . hose 2. Purge hose 3. V ...

  • Mitsubishi 4G9 - page 89

    4G9 ENGINE (E - W) - Intake and Exhaust Manifold <4G94 - GDI for P AJERO io> 1 1A-6d-2 INST ALLA TION SERVICE POINTS " A A EXHAUST MANIFOLD BRACKET INST ALLA TION (1) The washers must be installed with the shear-drooped side toward the bolts. (2) T emporarily install the exhaust manifold bracket as shown in the illustration. (3) V erify ...

  • Mitsubishi 4G9 - page 90

    4G9 ENGINE (E–W) – W ater Pump and W ater Hose 1 1A-7-1 PWEE9502-B E Nov . 1996 Mitsubishi Motors Corporation Revised 7. W A TER PUMP AND W A TER HOSE 1 1301790016 REMOV AL AND INST ALLA TION <SOHC – FRONT WHEEL DRIVE> 29 Nm 10 Nm 24 Nm 14 Nm 24 Nm 14 Nm 19 Nm 12 11 10 9 2 4 3 1 8 7 6 5 19 Nm Removal steps 1. W ater hose (Except carbure ...

  • Mitsubishi 4G9 - page 91

    4G9 ENGINE (E –W) – W ater Pump and W ater Hose 1 1A-7-2 PWEE9502 E May 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC – REAR WHEEL DRIVE> 29 Nm 10 Nm 24 Nm 24 Nm 24 Nm 14 Nm 16 10 13 4 6 5 7 3 17 1 8 2 15 14 16 10 9 12 24 Nm 11 14 Nm 13 13 24 Nm 24 Nm Removal steps 1. W ater hose 2. W ater hose 3. W ater hose 4. W ...

  • Mitsubishi 4G9 - page 92

    4G9 ENGINE (E –W) – W ater Pump and W ater Hose 1 1A-7-3 PWEE9502-B E Nov . 1996 Mitsubishi Motors Corporation Revised REMOV AL AND INST ALLA TION <DOHC – FRONT WHEEL DRIVE> 24 Nm 19 Nm 24 Nm 10 Nm 10 2 4 6 8 7 3 11 12 5 14 Nm 9 29 Nm 1 14 Nm 19 Nm Removal steps 1. W ater hose A (Except GDI engine) 2. W ater hose B (Except GDI engine) & ...

  • Mitsubishi 4G9 - page 93

    4G9 ENGINE (E –W) – W ater Pump and W ater Hose 1 1A-7-4 PWEE9502 E May 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC – REAR WHEEL DRIVE> 29 Nm 10 Nm 24 Nm 14 Nm 24 Nm 12 11 10 9 2 4 3 1 8 7 6 5 24 Nm 24 Nm 9 9 24 Nm 12 24 Nm 13 Removal steps " G A 1. Engine coolant temperature sensor " F A 2. Engine coo ...

  • Mitsubishi 4G9 - page 94

    4G9 ENGINE (E –W) – W ater Pump and W ater Hose 1 1A-7-5 PWEE9502-B E Nov . 1996 Mitsubishi Motors Corporation Revised INST ALLA TION SERVICE POINTS " A A W A TER PUMP INST ALLA TION (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 eq ...

  • Mitsubishi 4G9 - page 95

    4G9 ENGINE (E –W) – W ater Pump and W ater Hose 1 1A-7-6 PWEE9502 E May 1995 Mitsubishi Motors Corporation " F A ENGINE COOLANT TEMPERA TURE GAUGE UNIT INST ALLA TION (1) Apply the specified sealant to the threads. Specified sealant: 3M A TD Part No.8660 or equivalent " G A ENGINE COOLANT TEMPERA TURE SENSOR INST ALLA TION (1) When re ...

  • Mitsubishi 4G9 - page 96

    4G9 ENGINE (E–W) – Rocker Arms and Camshafts 1 1A-8-1 PWEE9502 E May 1995 Mitsubishi Motors Corporation 8. ROCKER ARMS AND CAMSHAFTS 1 1300540070 REMOV AL AND INST ALLA TION <SOHC (with Adjusting screw)> 35 Nm 31 Nm 9 Nm 9 Nm Apply engine oil to all moving parts before installation. 2 3 1 4 5 9 13 10 17 19 18 8 11 12 15 14 6 7 16 20 Remov ...

  • Mitsubishi 4G9 - page 97

    4G9 ENGINE (E–W) – Rocker Arms and Camshafts 1 1A-8-1a PWEE9502 E May 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC (with Lash adjuster)> 35 Nm 31 Nm 2 3 1 4 59 13 10 17 8 11 12 6 7 15 18 16 14 Apply engine oil to all moving parts before installation. Removal steps 1. Breather hose 2. P .C.V . hose 3. Oil filler cap ...

  • Mitsubishi 4G9 - page 98

    4G9 ENGINE (E - W) - Rocker Arms and Camshafts 1 1A-8-1b PWEE9502 E May 1995 Mitsubishi Motors Corporation Intentionally blank PWEE9502-G E May 2000 Mitsubishi Motors Corporation Added ...

  • Mitsubishi 4G9 - page 99

    4G9 ENGINE (E - W) - Rocker Arms and Camshafts 1 1A-8-2 PWEE9502 E May 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC> 3 7 2 3.5 Nm 4 1 5 6 11 N m 24 Nm 9 10 11 8 12 13 Apply engine oil to all moving parts before installation. 14 15 Removal steps 1. Breather hose 2. P .C.V . hose 3. P .C.V . valve 4. P .C.V . valve gaske ...

  • Mitsubishi 4G9 - page 100

    4G9 ENGINE (E - W) - Rocker Arms and Camshafts 1 1A-8-1 2a PWEE9502-C E July 1997 Mitsubishi Motors Corporation Added REMOV AL AND INST ALLA TION <DOHC - GDI> 3.5 Nm 23 Nm 11 N m Apply engine oil to all moving parts before installation. 2 3 1 4 5 9 13 10 8 11 12 14 6 7 23 Nm 3.5 Nm Removal steps 1. Breather hose 2. P .C.V hose 3. P .C.V valve ...

  • Mitsubishi 4G9 - page 101

    4G9 ENGINE (E - W) - Rocker Arms and Camshafts 1 1A-8-2 2b PWEE9502-C E July 1997 Mitsubishi Motors Corporation Added Intentionally blank ...

  • Mitsubishi 4G9 - page 102

    4G9 ENGINE (E - W) - Rocker Arms and Camshafts 1 1A-8-3 PWEE9502 E May 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC - GDI for CARISMA (Up to 2000 model), SP ACE ST AR (1999 model), SP ACE RUNNER> 3.5 Nm 21 Nm 11 N m Apply engine oil to all moving parts before installation. 2 3 1 4 5 9 13 10 8 11 12 14 6 7 21 Nm 3.5 Nm ...

  • Mitsubishi 4G9 - page 103

    4G9 ENGINE (E–W) – Rocker Arms and Camshafts 1 1A-8-3a PWEE9502 E May 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC–GDI for CARISMA, SP ACE ST AR and GALANT (From 2001 model)> 21 Nm 21 Nm 11 N m 2 1 3 5 15 10 8 12 14 6 10 Nm 7 9 3.5 Nm 11 13 16 17 4 Removal steps 1. P .C.V . hose 2. P .C.V . valve 3. P .C.V . valv ...

  • Mitsubishi 4G9 - page 104

    4G9 ENGINE (E - W) - Rocker Arms and Camshafts 1 1A-8-3b PWEE9502 E May 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC - GDI for P AJERO io - 4G94> 11 N m 21 Nm 1 3 5 15 10 8 14 6 10 Nm 7 9 3.5 Nm 11 13 16 17 4 21 Nm 12 2 Apply engine oil to all moving parts before installation. Removal steps 1. P .C.V . valve 2. P .C.V ...

  • Mitsubishi 4G9 - page 105

    4G9 ENGINE (E - W) - Rocker Arms and Camshafts 1 1A-8-4 PWEE9502 E May 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC - GDI for P AJERO io - 4G93> 3.5 Nm 21 Nm 11 N m 2 3 1 4 5 8 13 10 9 11 12 14 6 7 15 Apply engine oil to all moving parts before installation. Removal steps 1. Breather hose 2. P .C.V . valve 3. P .C.V . ...

  • Mitsubishi 4G9 - page 106

    4G9 ENGINE (E - W) - Rocker Arms and Camshafts 1 1A-8-5 REMOV AL SERVICE POINT A A " LASH ADJUSTER REMOV AL Caution D If the lash adjuster is re-used, clean the lash adjuster . (Refer to 1 1A-8-10.) INST ALLA TION SERVICE POINTS " A A ADJUSTING SCREW INST ALLA TION (1) Install provisionally the screw to th e rocker arm. Insert it so that ...

  • Mitsubishi 4G9 - page 107

    4G9 ENGINE (E - W) - Rocker Arms and Camshafts 1 1A-8-6 " E A OIL SEAL INST ALLA TION " F A LASH ADJUSTER INST ALLA TION Caution D If the lash adjuster is re-used, clean the lash adjuster . (Refer to 1 1A-8-10.) (1) Fit the lash adjuster onto the cylinder head using care not to allow diesel fuel to spill out. " G A CAMSHAFT INST ALLA ...

  • Mitsubishi 4G9 - page 108

    4G9 ENGINE (E - W) - Rocker Arms and Camshafts 1 1A-8-7 PWEE9502 E May 1995 Mitsubishi Motors Corporation (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: Inta ...

  • Mitsubishi 4G9 - page 109

    4G9 ENGINE (E - W) - Rocker Arms and Camshafts 1 1A-8-8 PWEE9502 E May 1995 Mitsubishi Motors Corporation (4) Apply sealant to the illustrated position of the cylinder head upper surface. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent (5) Install the beam camshaft cap before the sealant applied becomes dry and hard. (6) T igh ...

  • Mitsubishi 4G9 - page 110

    4G9 ENGINE (E - W) - Rocker Arms and Camshafts 1 1A-8-9 PWEE9502 E May 1995 Mitsubishi Motors Corporation " J A SEALANT APPLICA TION ON SEMI-CIRCULAR P ACKING Specified sealant: 3M A TD Part No.8660 or equivalent " K A SEALANT APPLICA TION ON ROCKER COVER (1) Apply sealant to the areas indicated in the illustration. Specified sealant: 3M ...

  • Mitsubishi 4G9 - page 111

    4G9 ENGINE (E - W) - Rocker Arms and Camshafts 1 1A-8-9a PWEE9502 E May 1995 Mitsubishi Motors Corporation (6) Adjust the valve clearances indicated by arrows in the illustration by the same procedure as in steps (3) and (4) above. PWEE9502-H E July 2000 Mitsubishi Motors Corporation Added When No.4 cylinder is at compression top dead centre ...

  • Mitsubishi 4G9 - page 112

    4G9 ENGINE (E - W) - Rocker Arms and Camshafts 1 1A-8-9b PWEE9502 E May 1995 Mitsubishi Motors Corporation Intentionally blank PWEE9502-H E July 2000 Mitsubishi Motors Corporation Added ...

  • Mitsubishi 4G9 - page 113

    4G9 ENGINE (E–W) – Rocker Arms and Camshafts 1 1A-8-10 PWEE9502 E May 1995 Mitsubishi Motors Corporation INSPECTION CAMSHAFT (1) Measure the cam height. Standard value mm Limit mm Intake id 4G92–SOHC* 1 37.34 36.84 side 4G92–SOHC* 2 37.78 37.28 4G92–SOHC* 3 36.92 36.42 4G93–SOHC* 4 37.53 37.03 4G93–SOHC* 5 37.1 1 36.61 4G94–SOHC 37. ...

  • Mitsubishi 4G9 - page 114

    4G9 ENGINE (E - W) - Rocker Arms and Camshafts 1 1A-8-1 1 PWEE9502 E May 1995 Mitsubishi Motors Corporation (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 ...

  • Mitsubishi 4G9 - page 115

    4G9 ENGINE (E - W) - Rocker Arms and Camshafts 1 1A-8-12 PWEE9502 E May 1995 Mitsubishi Motors Corporation (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 . (7) Place the lash adjuster in container C. Then, gently push down the internal s ...

  • Mitsubishi 4G9 - page 116

    4G9 ENGINE (E - W) - Rocker Arms and Camshafts 1 1A-8-13 PWEE9502 E May 1995 Mitsubishi Motors Corporation (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 di esel fuel to cl ean ...

  • Mitsubishi 4G9 - page 117

    4G9 ENGINE (E - W) - Rocker Arms and Camshafts 1 1A-8-14 PWEE9502 E May 1995 Mitsubishi Motors Corporation (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 contain ...

  • Mitsubishi 4G9 - page 118

    4G9 ENGINE (E - W) - Rocker Arms and Camshafts 1 1A-8-15 PWEE9502 E May 1995 Mitsubishi Motors Corporation (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 adjus ...

  • Mitsubishi 4G9 - page 119

    4G9 ENGINE (E - W) - Rocker Cover an d Camshafts (MIVEC) 1 1A-8a-1 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Added 8a. ROCKER COVER AND CAMSHAFTS (MIVEC) REMOV AL AND INST ALLA TION 3.5 Nm 9N m Apply engine oil to all moving parts be- fore installation. 2 3 1 4 5 9 13 10 8 11 12 6 7 14 11 N m 23 Nm 23 Nm 23 Nm 11 N m Removal steps 1. Br ...

  • Mitsubishi 4G9 - page 120

    4G9 ENGINE (E - W) - Rocker Cover an d Camshafts (MIVEC) 1 1A-8a-2 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Added INSPECTION 1. OIL CONTROL V AL VE (1) Connect a 12VDC power supply between terminals (1) and (2) of th e oil control valve a nd check if the valve operates smoothly . 2. CAMSHAFT (1) Measure th e cam heights. If the specifi ...

  • Mitsubishi 4G9 - page 121

    4G9 ENGINE (E - W) - Rocker Cover an d Camshafts (MIVEC) 1 1A-8a-3 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Added INST ALLA TION SERVICE POINTS " A A SEMI-CIRCULAR P ACKING INST ALLA TION (1) Apply the specified sealant to th e area shown. Specified sealant: 3M A TD Part No. 8660 or equivalent. " B A CAMSHAFT HOLDER ASSEMBL Y ...

  • Mitsubishi 4G9 - page 122

    4G9 ENGINE (E - W) - Rocker Cover an d Camshafts (MIVEC) 1 1A-8a-4 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Added (2) Apply t he specified sealant to the front a nd rear camshaft bearing caps at the positions shown. Position the camshaft bearing caps an d tighten their mounting bolts not numbered in the illustration. Then tighten the r ...

  • Mitsubishi 4G9 - page 123

    4G9 ENGINE (E - W) - Rocker Cover an d Camshafts (MIVEC) 1 1A-8a-5 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Added " G A ROCKER COVER INST ALLA TION Apply th e specified sealant to the area shown. Specified sealant: 3M A TD part No. 8660 or equivalent V AL VE CLEARANCE ADJUSTMENT Adjustment must be performed with the cylinder at th ...

  • Mitsubishi 4G9 - page 124

    4G9 ENGINE (E - W) - Rocker Arms and Rocker Shaft Caps (MIVEC) 1 1A-8b-1 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Added 8b. ROCKER ARMS AND ROCKER SHAFT CAPS (MIVEC) REMOV AL AND INST ALLA TION 11 N m Apply engine oil to all moving parts be- fore installation. 2 3 1 2 10 9 8 7 9 8 7 9 8 7 9 8 7 4 5 6 4 5 6 4 5 6 4 5 6 Removal steps 1. ...

  • Mitsubishi 4G9 - page 125

    4G9 ENGINE (E - W) - Rocker Arms and Rocker Shaft Caps (MIVEC) 1 1A-8b-2 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Added INST ALLA TION SERVICE POINT " A A ROCKER ARM ASSEMBL Y INST ALLA TION (1) Install the rocker arm assemblies while checking the identification marks at the positions shown to ensure that the intake and exhaust si ...

  • Mitsubishi 4G9 - page 126

    4G9 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-9-1 PWEE9502 E May 1995 Mitsubishi Motors Corporation 9. CYLINDER HEAD AND V AL VES 1 1300690072 REMOV AL AND INST ALLA TION <SOHC> Lubricate all internal parts with engine oil during reassembly . 3 19 11 7 18 20 2 16 13 12 6 5 4 17 15 14 10 9 8 1 Removal steps A A "" D A 1. Cylin ...

  • Mitsubishi 4G9 - page 127

    4G9 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-9-2 PWEE9502 E May 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC> Lubricate all internal parts with engine oil during assembly . 4 19 7 15 20 12 16 18 13 6 10 9 17 11 14 5 2 8 3 1 10 Nm 21 Removal steps " E A 1. Oil pressure switch A A "" D A 2. Cylinde ...

  • Mitsubishi 4G9 - page 128

    4G9 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-9-3 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Revised REMOV AL AND INST ALLA TION <DOHC - MIVEC> Apply engine oil to all moving parts before installation. 4 19 7 15 20 12 16 18 13 6 10 9 17 11 14 5 2 8 3 1 10 Nm 21 Removal steps " E A 1. Oil pressure switch A A "" ...

  • Mitsubishi 4G9 - page 129

    4G9 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-9-4 3a PWEE9502-C E July 1997 Mitsubishi Motors Corporation Added REMOV AL AND INST ALLA TION <DOHC - GDI> Apply engine oil to all moving parts before installation. 4 19 7 15 20 12 16 18 13 6 10 9 17 11 14 5 2 8 3 1 Removal steps A A "" D A 1. Cylinder head bolt 2. Cylinder head a ...

  • Mitsubishi 4G9 - page 130

    4G9 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-9-5 3b PWEE9502-C E July 1997 Mitsubishi Motors Corporation Added Intentionally blank ...

  • Mitsubishi 4G9 - page 131

    4G9 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-9-4 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Revised REMOV AL SERVICE POINTS A A " CYLINDER HEAD BOL T REMOV AL (1) Loosen the cylinder head bolts using the special tool. A B " RET AINER LOCK REMOV AL (1) Store the removed valves, springs and other parts, tagged to indicate ...

  • Mitsubishi 4G9 - page 132

    4G9 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-9-5 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Revised A C " V AL VE STEM SEAL REMOV AL A D " V AL VE 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 fol ...

  • Mitsubishi 4G9 - page 133

    4G9 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-9-6 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Revised Caution D V alves must be neutralized one at a time. D 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 resulti ...

  • Mitsubishi 4G9 - page 134

    4G9 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-9-7 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Revised " B A V AL VE SPRING INST ALLA TION (1) Install the valve spring with the painted e nd on the rocker arm side. " C A RET AINER LOCK INST ALLA TION (1) The valve spring, if excessively compressed, causes th e bottom end of ...

  • Mitsubishi 4G9 - page 135

    4G9 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-9-8 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Revised (4) According to the tightening sequence, tighten the bolts 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. (7) Make paint mark ...

  • Mitsubishi 4G9 - page 136

    4G9 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-9-9 PWEE9502-C E July 1997 Mitsubishi Motors Corporation Revised 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 specificat ...

  • Mitsubishi 4G9 - page 137

    4G9 ENGINE (E–W) – Cylinder Head and V alves 1 1A-9-10 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Revised V AL VE 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 SOHC (with lash adjuster) 49.5 48.5 DOHC ...

  • Mitsubishi 4G9 - page 138

    4G9 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-9-1 1 PWEE9502-C E July 1997 Mitsubishi Motors Corporation Revised V AL VE SEA T RECONDITIONING PROCEDURE (1) Before correcting the valve seat, check the clearance between the valve guide a nd valve. If necessary , replace the valve and/or valve guide. (2) Using the appropriate special tool or se ...

  • Mitsubishi 4G9 - page 139

    4G9 ENGINE (E - W) - Cylinder Head a nd V alves 1 1A-9-12 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Added (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. V alve guide for intake valve and that ...

  • Mitsubishi 4G9 - page 140

    4G9 ENGINE (E–W) – Front Case and Oil Pump 1 1A-10-1 PWEE9502 E May 1995 Mitsubishi Motors Corporation 10. FRONT CASE AND OIL PUMP REMOV AL AND INST ALLA TION <SOHC (4G92, 4G93)> 10 Nm 10 Nm 19 Nm 44 Nm 14 Nm 39 Nm 9 Nm Apply engine oil to all moving parts before installation. 5 4 3 2 9 10 1 12 17 16 15 14 8 6 13 11 7 23 Nm Removal steps ...

  • Mitsubishi 4G9 - page 141

    4G9 ENGINE (E–W) – Front Case and Oil pump 1 1A-10-1a PWEE9502 E May 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC (4G94 Except for P AJERO io)> 10 Nm 19 Nm 14 Nm 44 Nm 39 Nm 11 N m 13 1 10 11 12 2 3 7 6 4 8 9 16 17 18 15 14 19 9 Nm 24 Nm 11 N m 10 Nm 5 7 Nm Apply engine oil to all moving parts before installation. ...

  • Mitsubishi 4G9 - page 142

    4G9 ENGINE (E –W) – Front Case and Oil pump 1 1A-10-1b PWEE9502 E May 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC (4G94 for P AJERO io)> 10 Nm 19 Nm 14 Nm 44 Nm 39 Nm 11 N m 13 1 11 12 2 3 7 6 4 8 9 17 18 15 16 9 Nm 24 Nm 10 Nm 5 7 Nm Apply engine oil to all moving parts before installation. 14 10 9 Nm Removal ste ...

  • Mitsubishi 4G9 - page 143

    4G9 ENGINE (E–W) – Front Case and Oil pump 1 1A-10-2 PWEE9502 E May 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC (Except GDI for P AJERO io)> 10 Nm 19 Nm 14 Nm 44 Nm 39 Nm MPI 7 Nm GDI, MIVEC 1 1Nm Apply engine oil to all moving parts before installation. 13 1 10 11 12 2 3 7 6 4 8 9 16 17 18 15 14 19 9 Nm 24 Nm 10 ...

  • Mitsubishi 4G9 - page 144

    4G9 ENGINE (E–W) – Front Case and Oil pump 1 1A-10-3 PWEE9502 E May 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC–GDI for P AJERO io> 10 Nm 19 Nm 14 Nm 44 Nm 39 Nm 11 N m Apply engine oil to all moving parts before installation. 12 1 9 10 11 2 3 6 5 4 8 15 16 17 14 13 18 9 Nm 24 Nm 7 Nm 10 Nm 9 Nm 7 Removal steps ...

  • Mitsubishi 4G9 - page 145

    4G9 ENGINE (E - W) - Front Case and Oil Pump 1 1A-10-4 REMOV AL SERVICE POINTS A A " OIL P AN REMOV AL (1) Knock in the special tool deeply between the oil pa n and t he cylinder block. (2) Hitting t he side of the special tool, slide th e special tool along the oil pan to remove the oil pan. A B " REMOV AL OF UPPER OIL P AN (1) At first ...

  • Mitsubishi 4G9 - page 146

    4G9 ENGINE (E–W) – Front Case and Oil Pump 1 1A-10-5 PWEE9502 E May 1995 Mitsubishi Motors Corporation " C A CRANKSHAFT FRONT OIL SEAL INST ALLA TION Using the special tool, knock the oil seal into the oil pump case. " D A OIL P AN/UPPER OIL P AN/LOWER OIL P AN INST ALLA TION (1) Remove all the remaining gasket from the mating surface ...

  • Mitsubishi 4G9 - page 147

    4G9 ENGINE (E –W) – Front Case and Oil Pump 1 1A-10-6 PWEE9502 E May 1995 Mitsubishi Motors Corporation (4) T ighten the lower oil pan mounting bolts in the sequence shown in the illustration. " E A OIL FIL TER INST ALLA TION (1) Clean the filter installation surface of the cylinder block. (2) Apply engine oil to the O-ring of the oil filt ...

  • Mitsubishi 4G9 - page 148

    4G9 ENGINE (E - W) - Front Case and Oil Pump 1 1A-10-7 (2) Check th e 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 PWEE9502-E E Dec. 1998 Mitsubishi Motors Corporation Added ...

  • Mitsubishi 4G9 - page 149

    4G9 ENGINE (E - W) - Piston and Connecting Rod 1 1A-1 1-1 PWEE9502 E May 1995 Mitsubishi Motors Corporation 1 1. PISTON A ND CONNECTING ROD REMOV AL AND INST ALLA TION Lubricate all inter- nal parts with en- gine oil during re- assembly . 6 7 8 10 12 9 11 4 5 3 2 1 Removal steps " G A 1. Nut A A "" F A 2. Connecting rod cap " E ...

  • Mitsubishi 4G9 - page 150

    4G9 ENGINE (E - W) - Piston and Connecting Rod 1 1A-1 1-2 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Revised REMOV AL SERVICE POINTS A A " CONNECTING ROD CAP REMOV AL (1) Mark the cylinder number on the side of th e connecting rod big en d for correct reassembly . A B " PISTON PIN REMOV AL Piston pin setting tool (MD998780) con ...

  • Mitsubishi 4G9 - page 151

    4G9 ENGINE (E–W) – Piston and Connecting Rod 1 1A-1 1-3 PWEE9502 E May 1995 Mitsubishi Motors Corporation INST ALLA TION SERVICE POINTS " A A PISTON PIN INST ALLA TION (1) When replacing a piston, read of f the cylinder bore size mark on the cylinder block as illustrated, and select a piston of proper size according to the following table. ...

  • Mitsubishi 4G9 - page 152

    4G9 ENGINE (E –W) – Piston and Connecting Rod 1 1A-1 1-4 PWEE9502 E May 1995 Mitsubishi Motors Corporation (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 t ...

  • Mitsubishi 4G9 - page 153

    4G9 ENGINE (E–W) – Piston and Connecting Rod 1 1A-1 1-5 PWEE9502 E May 1995 Mitsubishi Motors Corporation " C A PISTON RING NO.2/PISTON RING NO.1 INST ALLA TION (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 The pist ...

  • Mitsubishi 4G9 - page 154

    1 1A-1 1-6 PWEE9502 E May 1995 Mitsubishi Motors Corporation " E A CONNECTING ROD BEARING INST ALLA TION (1) When the bearings are to be replaced, select correct ones according to the identification marks stamped in the crankshaft. Crankshaft Connecting rod bearing Pin O.D. identification mark Identification mark (service part) Identification ...

  • Mitsubishi 4G9 - page 155

    4G9 ENGINE (E –W) – Piston and Connecting Rod 4G9 ENGINE (E –W) – Piston and Connecting Rod 1 1A-1 1-7 PWEE9502 E May 1995 Mitsubishi Motors Corporation " F A CONNECTING ROD CAP INST ALLA TION (1) Mate the correct bearing cap with the correct connecting rod by checking with the alignment marks marked during disassembly . If a new conne ...

  • Mitsubishi 4G9 - page 156

    4G9 ENGINE (E –W) – Piston and Connecting Rod 1 1A-1 1-8 PWEE9502 E May 1995 Mitsubishi Motors Corporation INSPECTION 1 1300850074 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: ...

  • Mitsubishi 4G9 - page 157

    4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate 1 1A-12-1 PWEE9502-C E July 1997 Mitsubishi Motors Corporation Revised 12. CRANKSHAFT , CYLINDER BLOCK, FL YWHEEL AND DRIVE PLA TE REMOV AL AND INST ALLA TION (MANUAL TRANSMISSION) SP ACE ST AR 10 Nm Except SP ACE ST AR 1 1 Nm 98 Nm 11 N m 13 14 15 16 17 18 21 8 3 4 5 6 7 9 ...

  • Mitsubishi 4G9 - page 158

    4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate 1 1A-12-1a REMOV AL AND INST ALLA TION (AUT OMA TIC TRANSMISSION) 11 N m 12 13 14 15 16 17 20 7 1 2 9 Nm 23 Nm 19 8 11 10 9 98 Nm <Drive plate with ring gear> Apply engine oil to all moving parts before installation. 18 3 4 5 6 98 Nm <Except drive plate with ring g ...

  • Mitsubishi 4G9 - page 159

    4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate 1 1A-12-1b REMOV AL AND INST ALLA TION <P AJERO io> 11 N m 98 Nm 11 N m Apply engine oil to all moving parts before installation. 22 23 17 15 16 3 9 5 6 12 14 23 Nm 19 21 20 13 98 Nm 1 2 8 98 Nm 10 18 7 4 A 11 <Engines with hydro flywheel> <Engines with flexi ...

  • Mitsubishi 4G9 - page 160

    4G9 ENGINE (E - W) - Crankshaft, Cylinder Block, Flywheel and Drive Plate 1 1A-12-2 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Revised REMOV AL SERVICE POINT A A " OIL JET REMOV AL (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. ...

  • Mitsubishi 4G9 - page 161

    4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate 1 1A-12-3 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Revised Oil pan view No. 5 No. 4 No. 3 No. 2 No. 1 No. 5 No. 4 No. 3 No. 2 No. 1 Timing belt side Cylinder head view (Reference) Timing belt side (2) Install the bearings having an oil groove to the cylinder bl ...

  • Mitsubishi 4G9 - page 162

    4G9 ENGINE (E – W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate 1 1A-12-4 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Revised " C A BEARING CAP/BEARING CAP BOL T INST ALLA TION (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 th ...

  • Mitsubishi 4G9 - page 163

    4G9 ENGINE (E – W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate 1 1A-12-5 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Revised " D A OIL SEAL INST ALLA TION " E A SEALANT APPLICA TION TO OIL SEAL CASE Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent " F A DRIVE PLA TE BOL T/FL YWHEEL BOL T ...

  • Mitsubishi 4G9 - page 164

    4G9 ENGINE (E – W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate 1 1A-12-6 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Revised 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. ...

  • Mitsubishi 4G9 - page 165

    4G9 ENGINE (E – W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate 1 1A-12-7 PWEE9502-A E Nov . 1995 Mitsubishi Motors Corporation Revised Caution T o 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. + ...

  • Mitsubishi 4G9 - page 166

    NOTES ...

  • Mitsubishi 4G9 - page 167

    Service Bulletins Click on the applicable bookmark to select the Service Bulletin. ...

  • Mitsubishi 4G9 - page 168

    SERVICE BULLETIN QUALITY INFORMA TION A NALYSIS OVERSEA S SERVICE DEPT. MITSU BISHI MOTOR S CORPORA TION SERVICE BULLETIN No.: MSB-9 9E11-001 Date : 1999-12-15 <Model> <M/Y> Subject: CHAN GE IN POSITIONS OF CRANKSHAF T IDENTIFICATION MARKS Group: ENGINE Draft No.: 99EN531509 INFORMATION INT ERNA TIONA L CA R ADM IN I S T R AT I ON OFFIC ...

  • Mitsubishi 4G9 - page 169

    2 • Crankshaf t weight Front Journal O. D. id enti fica tio n mar k J ournal O.D. id enti fica tio n mar k Pin O.D. id enti fica tio n mar k Pin O.D. id enti fica tio n mar k New Old ...

  • Mitsubishi 4G9 - page 170

    SER VICE PUBLICA TION & TRAINING INTERNA TIONAL AFTER-SALES DEP ARTMENT . MITSUBISHI MOT ORS CORPORA TION 1 MSB–03E11–001 SER VICE BULLETIN NO . : MSB–03E11–001 D A TE : 2003–01–20 <MODEL> (EUR)CARISMA(DX) ( EUR ) SP ACE <M/Y> 97–01 SUBJECT : DISUSE OF INJECT OR BACKUP RINGS IN GDI ENGINES (EUR)SP ACE RUNNER(DZ) (EUR)S ...

  • Mitsubishi 4G9 - page 171

    2 MSB – 03E11 – 001 Attachment Applicable Manuals: Manual Pub. No. Page ENGINE 4G6 (E – W) Wk h M l PWEE9616 (English) 1 1A-5a-1, 11 A 5 2 W orkshop Manual PWES9617 (Spanish) 1 1A-5a-2a PWEF9618 (French) PWEG9619 (German) PWED9620 (Dutch) PWEW9621 (Swedish) ENGINE 4G9 (E – W) Wk h M l PWEE9502 (English) 1 1A-6c-1, 11 A 6 1 W orkshop Manual ...

Manufacturer Mitsubishi Category Air Conditioner

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