Instruction/ maintenance manual of the product 4G9 Mitsubishi
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GENERAL INFORMA TION 1 1A-0-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. SPECIFICA TIONS 1 1A-1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE SPECIFICA TIONS 1 1A-1-1 .
1 1A-0-2 PWEE9502 E May 1995 Mitsubishi Motors Corporation NOTES.
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 .
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.
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.
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.
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.
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.
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.
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.
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 .
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 brack.
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.
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 o.
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.
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.
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.
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.
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 remo.
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 pi.
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.
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.
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.
4G9 ENGINE (E - W) - Alternator and Ignition System 1 1A-3-2b Intentionally blank PWEE9502-E E Dec. 1998 Mitsubishi Motors Corporation Added.
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.
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.
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.
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 N.
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.
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.
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.
4G9 ENGINE (E - W) - Timing Belt 1 1A-4-1b Intentionally blank PWEE9502-G E May 2000 Mitsubishi Motors Corporation Added.
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.
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.
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.
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.
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.
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.
4G9 ENGINE (E - W) - Timing Belt 1 1A-4-2f Intentionally blank PWEE9502-G E May 2000 Mitsubishi Motors Corporation Added.
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.
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.
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.
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.
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 .
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.
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.
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.
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> .
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.
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.
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.
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.
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.
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.
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.
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.
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.
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–CARBURE.
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 4G.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
4G9 ENGINE (E - W) - Exhaust Manifold (GDI) 1 1A-6b-1b Intentionally blank PWEE9502-G E May 2000 Mitsubishi Motors Corporation Added.
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.
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.
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 A.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
4G9 ENGINE (E - W) - Rocker Arms and Camshafts 1 1A-8-2 2b PWEE9502-C E July 1997 Mitsubishi Motors Corporation Added Intentionally blank.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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 .
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.
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.
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 .
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.
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.
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.
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.
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 A.
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 .
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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.
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.
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 .
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.
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 .
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.
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.
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.
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.
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.
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.
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.
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.
NOTES.
Service Bulletins Click on the applicable bookmark to select the Service Bulletin..
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.
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.
SER VICE PUBLICA TION & TRAINING INTERNA TIONAL AFTER-SALES DEP ARTMENT . MITSUBISHI MOT ORS CORPORA TION 1 MSB–03E11–001 SER VICE BULLETIN NO .
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.
An important point after buying a device Mitsubishi 4G9 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Mitsubishi 4G9 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Mitsubishi 4G9 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Mitsubishi 4G9 you will learn all the available features of the product, as well as information on its operation. The information that you get Mitsubishi 4G9 will certainly help you make a decision on the purchase.
If you already are a holder of Mitsubishi 4G9, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Mitsubishi 4G9.
However, one of the most important roles played by the user manual is to help in solving problems with Mitsubishi 4G9. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Mitsubishi 4G9 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
