11A-0-1

ENGINE
4G9 SERIES
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-0-3
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1
REWORK DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE
TIGHTENED IN PLASTIC AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FORM-IN-PLACE GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11A-1-4
11A-1-4
11A-1-7
11A-1-7
11A-1-8

2. SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-2-1
3. ALTERNATOR AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 11A-3-1
4. TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-4-1
5. FUEL AND EMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . 11A-5-1
5a. THROTTLE BODY AND EGR SYSTEM (GDI) . . . . . . . . . . . . . . . . . 11A-5a-1
6. INTAKE AND EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-6-1
6a. INTAKE MANIFOLD (GDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-6a-1
6b.EXHAUST MANIFOLD (GDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-6b-1
6c. INJECTOR AND FUEL PUMP ASSEMBLY (GDI) . . . . . . . . . . . . . 11A-6c-1
7. WATER PUMP AND WATER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-7-1
8. ROCKER ARMS AND CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-8-1
8a. ROCKER COVER AND CAMSHAFTS (MIVEC) . . . . . . . . . . . . . . . 11A-8a-1
8b.ROCKER ARMS AND ROCKER SHAFT CAPS (MIVEC) . . . . . 11A-8b-1
9. CYLINDER HEAD AND VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-9-1
10. FRONT CASE AND OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-10-1
11. PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-11-1
12. CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE
PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-12-1

E Mitsubishi Motors Corporation

Dec. 1998

PWEE9502-E

Revised

11A-0-2
NOTES

E Mitsubishi Motors Corporation

May 1995

PWEE9502

4G9 ENGINE (E - W) - General Information

11A-0-3

GENERAL INFORMATION
4G92
Descriptions

4G92- SOHC

4G92- DOHC- MIVEC

Type

In-line OHV, SOHC

In-line OHV, DOHC

Number of cylinders

4

4

Combustion chamber

Pentroof type

Pentroof type

Total displacement dm3

1,597

1,597

Cylinder bore mm

81.0

81.0

Piston stroke mm

77.5

77.5

Compression ratio

10.0

11.0

Opens
(BTDC)

20_, 14_*

17_ (Low-speed cam)
47.5_ (High-speed cam)

Closes
(ABDC)

42_, 58_*

31_ (Low-speed cam)
72.5_ (High-speed cam)

Opens
(BBDC)

54_, 52_*

41_ (Low-speed cam)
70_ (High-speed cam)

Closes
(ATDC)

2_, 16_*

11_ (Low-speed cam)
35_ (High-speed cam)

Lubrication system

Pressure feed, full-flow filtration

Pressure feed, full-flow filtration

Oil pump type

Trochoid type

Trochoid type

Cooling system

Water-cooled forced circulation

Water-cooled forced circulation

Water pump type

Centrifugal impeller type

Centrifugal impeller type

Valve timing

Intake
valve

Exhaust
valve

*:

LANCER for general export and CARISMA for 6B model

E Mitsubishi Motors Corporation

July 1997

PWEE9502-C

Revised

DOHC In-line OHV.General Information 4G93 Descriptions 4G93.W) .0 81. fullflow filtration Pressure feed.5 10.834 Cylinder bore mm 81. SOHC In-line OHV.GDI Type In-line OHV.834 1.DOHC.5 11.0 Piston stroke mm 89.0. fullflow filtration Pressure feed.SOHC 4G93.7 Opens (BTDC) 14_ 20_ 15_ Closes (ABDC) 50_ 60_ 56_ Opens (BBDC) 58_ 61_ 55_ Closes (ATDC) 10_ 15_ 15_ Lubrication system Pressure feed.11A-0-4 4G9 ENGINE (E .DOHC 4G93. DOHC Number of cylinders 4 4 4 Combustion chamber Pentroof type Pentroof type Pentroof type Total displacement dm3 1. fullflow filtration Oil pump type Trochoid type Trochoid type Trochoid type Cooling system Water-cooled circulation Water pump type Centrifugal type Valve timing Intake valve Exhaust valve E Mitsubishi Motors Corporation July 1997 forced impeller PWEE9502-C Water-cooled circulation Centrifugal type forced impeller Water-cooled circulation Centrifugal type forced impeller Revised .834 1.0 89.0 89.0 81. 9.0 Compression ratio 10.

D.28 Exhaust 37.8 .2* Timing belt Rocker arms and camshaft Camshaft cam height mm 4G92-SOHC*1 4G92-SOHC*2 4G93-SOHC 4G93-DOHC 4G93-DOHC-GDI*3 4G93-DOHC-GDI*4 Valve clearance mm Camshaft journal O.Specifications 1. SPECIFICATIONS SERVICE SPECIFICATIONS Items Standard value Limit 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 3.83 35.70 Intake 35.33 Exhaust B 34.91 Intake B 33.41 36.20 - SOHC 26.5 - Intake 37.24 33.29 Intake 37. 1998 PWEE9502-E Revised .64 37.08 Exhaust A 35. mm Rocker cover and camshaft (MIVEC) Camshaft height mm Valve clearance (cold engine) mm Cylinder head and valve *1: *2: *3: *4: LANCER for Europe and CARISMA for Europe LANCER for general export and CARISMA for 6B model For CARISMA For PAJERO io E Mitsubishi Motors Corporation Dec.09 - Exhaust 0.83 37.78 37.34 36.03 0.4.2 - Cylinder head gasket surface flatness mm Less than 0.81 Exhaust 35.79 36.0 - Intake A 36.0 - DOHC 45.49 34.53 37.74 Intake 0.03 Exhaust 37.91 34.1 - Exhaust 0.99 Exhaust 34.W) .31 34.58 33.33 Intake 37.73 34.23 Intake 0.99 Exhaust 34.49 34.2 Grinding limit of cylinder head gasket surface mm *Total resurfacing depth of both cylinder head and cylinder block - 0.20 34.84 Exhaust 36.11A-1-1 4G9 ENGINE (E .14 Intake 35.41 Intake 35.

MIVEC 51.8 Max.05 0.0 DOHC.0.1 - DOHC 131.0.132.0.MIVEC DOHC.0 - DOHC.0 - DOHC 19.W) .11A-1-2 4G9 ENGINE (E .9 DOHC 45.65 Exhaust 113.GDI for PAJERO io Intake 0.10 Exhaust 0.20 Exhaust 46.69 Exhaust 103.37 SOHC 50.15 0.9 .1 - Intake 1.19 103.70 47.1.9 .4 SOHC DOHC DOHC.1 - DOHC.37 Intake 115.2 0.GDI Valve spring free length mm Standard value Limit SOHC 119.15 - 96.5 50.87 103.0 - Valve stem projection mm Intake 49.13 58.20 Intake 104.0.GDI 131.8 43.02 .120.15 109.MIVEC DOHC.06 0.69 Exhaust 103.70 47.132.02 .05 .85 58.04.9 49.65 47.8 .0 0.05 0.63 Exhaust 57.9 .8 Intake 1.13 Exhaust 115.15 Intake 58.80 Exhaust 49.0 0.GDI 44.3 - Valve seat valve contact width mm Valve guide projection from cylinder head upper surface mm SOHC 14.3 0.19 103.87 103.35 49.9 . 2_ 4_ Valve spring out-of-squareness Valve stem to valve guide clearance mm Except DOHC.63 115.GDI for PAJERO io Intake 0.70 113.15 DOHC.10 Exhaust 0.65 47.120.30 49.7 Intake 110.5 DOHC.5 Exhaust 1.09 0.13 Intake 104.63 115.85 Intake 46.0 44.MIVEC 119.GDI Cylinder head bolt shank length mm E Mitsubishi Motors Corporation Dec.35 Intake 46. 1998 PWEE9502-E Revised .Specifications Items Cylinder head overall height mm Thickness of valve head (margin) mm SOHC DOHC Valve overall height mm SOHC DOHC DOHC.20 Exhaust 46.5 Exhaust 1.

700 - Connecting rod big end side clearance mm 0.0 - Piston to cylinder clearance mm 0.0.1 Crankshaft end play mm 0.D.D.11A-1-3 4G9 ENGINE (E .04 - Bearing cap bolt shank length mm - 71.4 Piston pin O.0 - Valve face angle 45_ . mm 50 - Crankshaft pin O. mm 81. 1998 PWEE9502-E Revised .04 0.02 .05 .0. 2 0.4 Crankshaft journal O. cylinder block.18 0.0.5 - DOHC.06 0.20 .03 .10 - Oil pump body clearance mm 0. 1 0.0 DOHC 0.1 No. 2 0.MIVEC 255/44.500 .60 1.0 - Piston O.1 Piston pin press-in load N [Room temperature] 4.35 No.1 Grinding limit of cylinder block gasket surface mm *Total resurfacing depth of both cylinder head and cylinder block - 0.04 .8 No.10 .0.5_ - SOHC 216/44.0.W) .07 0.5 - Cylinder block I.5 - 6.14. mm 45 - Valve spring load/installed height N/mm Valve guide I.5 - DOHC. oil pump and oil pan Piston and connecting rod Piston ring to piston ring groove clearance mm Piston ring end gap mm Oil ring Crankshaft.25 0.45.0. mm Font case. mm 6.D.02 .GDI 196/37.5 - 4G93 263.35 1.05 0.55 0.25 .0.05 0. flywheel and drive plate Cylinder block overall height mm E Mitsubishi Motors Corporation Dec.10 .10 .1 No.0 - Crankshaft journal oil clearance mm 0.Specifications Items Standard value Limit Valve stem O.0.2 - DOHC 255/44.02 .2* 4G92 243. 1 0.02 .0.0 - Oil pump tip clearance mm 0. mm 19. mm 81.0 Crankshaft pin oil clearance mm 0.40 .D.0.40 0.06 .25 0.D.D.0.1 Cylinder block gasket surface flatness mm 0.18 - Oil pump side clearance mm 0.D.0.0.0.8 SOHC 0.

13 Crankshaft.S.005 NOTE O. 31.31.52 0. 32.11. 34.82 0.11A-1-4 4G9 ENGINE (E .: Inner diameter O.10 . 11.60 .11.D. 11.11.30 O.9 Power steering pump pulley 25 Power steering pump bracket stay 49 Power steering pump bracket (M8) 21 Power steering pump bracket (M10) 44 Alternator pivot bolt 44 Center cover 3 E Mitsubishi Motors Corporation Dec.S.31.S.S.: Outer diameter I. 11. flywheel and drive plate Crankshaft out of roundness and taper of journal and pin mm 0.30 .13 0.PAJERO io and DOHC.30.S. 1998 PWEE9502-E Revised .60 O.25 O.30 .30 O.60 O.25 .S.30 O.07 0.29.27 0.50 O.60 .05 .80 .S.34.W) .: Oversize diameter TORQUE SPECIFICATIONS Items Nm Alternator and ignition system Oil level gauge 13 Distributor 12 Ignition coil 10 Spark plug 25 Crankshaft bolt 181 Alternator brace (M10) 49 Alternator brace (M8) 23 Lock bolt 23 Adjusting bolt <Except SOHC for PAJERO io and DOHC.S.32.60 O.80 .S.05 O.32 0.GDI for PAJERO io> 10 Adjusting bolt <SOHC. 34. 29.30 O.S. 29.60 O.34.D.29.10 .83 0.S.50 .62 0.GDI for PAJERO io> 4.62 0. 30.S.32 0.Specifications REWORK DIMENSIONS Items Standard value Cylinder head and valve Oversize rework dimensions of valve guide hole (both intake and exhaust) mm Oversize rework dimensions of intake valve seat hole mm SOHC DOHC Oversize rework dimensions of exhaust valve seat hole mm SOHC DOHC 0. 31.

4G9 ENGINE (E .8 Crank angle sensor 9.9 11A-1-5 Timing belt Camshaft sprocket bolt 88 Cam position sensor <DOHC> 9.MPI for PAJERO io> 9 Throttle body and EGR system (GDI) Air intake resonator 9 Intake manifold stay 30 Water hose clamp 13 Water pipe 11 Throttle body 18 E Mitsubishi Motors Corporation Dec.MPI for other than PAJERO io> 10 Vacuum hose and pipe assembly <SOHC.8 Timing belt rear cover 11 Timing belt tensioner 24 Engine support bracket.W) .MPI for PAJERO io> 9 Solenoid valve assembly <SOHC. right 49 Accessory mount 49 Timing belt cover 11 Tensioner pulley bolt 49 Tensioner arm bolt 44 Auto-tensioner bolt 13 Idler pulley bolt 36 Fuel system and emission system Breather tube 21 Fuel pump 18 Carburetor 17 EGR valve 21 Fuel return pipe 9 Delivery pipe 12 Fuel pressure regulator 9 Throttle body stay 23 Throttle body 19 Vacuum hose and pipe assembly <SOHC. 1998 PWEE9502-E Revised .Specifications Items Nm Ignition failure sensor 23 Cam position sensor 9 Cam position sensor support 13 Cam position sensing cylinder 21 Engine cover 2.MPI for other than PAJERO io> 11 Solenoid valve assembly <SOHC.

1998 PWEE9502-E Revised .11A-1-6 4G9 ENGINE (E .W) .Specifications Items Nm EGR valve 18 Engine hanger 18 EGR valve support bolt 18 EGR valve support nut 23 Air by-pass valve 9 Intake manifold and exhaust manifold Exhaust manifold (M10) 29 Exhaust manifold (M8) 18 Exhaust manifold bracket 19 Engine hanger 12 Oil level gauge guide 14 Boost sensor 5 Intake air temperature sensor 13 Heat protector 13 Intake manifold 20 Intake manifold stay 30 Intake manifold (GDI) Vacuum pipe and hose <For CARISMA> 11 Vacuum pipe and hose <For PAJERO io> 9 Solenoid valve 9 Fuel pump protector 23 Connector bracket 11 Branch tube (M6 x 18) 9 Branch tube (M6 x 14) 11 Intake manifold stay 30 Accelerator cable bracket 9 Vacuum pipe 11 Intake manifold 19 Exhaust manifold (GDI) Oil level gauge guide 13 Exhaust manifold cover 13 Engine hanger bolt 18 Engine hanger nut (M8) 18 Engine hanger nut (M10) 29 Exhaust manifold bracket (M8 ´ 22) 35 Exhaust manifold bracket (M8 ´ 20) 18 Exhaust manifold bracket (M10) 98 Exhaust manifold (M10) 29 E Mitsubishi Motors Corporation Dec.

4G9 ENGINE (E .5 Bearing cap bolt (M6) 11 Bearing cap bolt (M8) 24 Beam camshaft cap (M8) 21 E Mitsubishi Motors Corporation Dec.GDI for PAJERO io> 19 Water inlet fitting <DOHC. 1998 PWEE9502-E Revised .Specifications Items Nm Exhaust manifold (M8) 17 11A-1-6a 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 return pipe 11 Fuel return pipe clamp 9 Fuel high pressure regulator 18 Fuel pressure sensor <For CARISMA> 23 Fuel pressure sensor <For PAJERO io> 18 Spacer 18 Pump camshaft case 23 Injector holder 22 Delivery pipe and injector 11 Water pump and water hose Water pump 24 Water inlet pipe 14 Thermostat case 24 Water inlet fitting <Except DOHC.GDI for PAJERO io> 23 Engine coolant temperature gauge unit 10 Engine coolant temperature sensor 29 Water fitting 23 Rocker arms and camshaft Lock nut 9 Rocker arm shaft 31 Rocker cover 3.W) .GDI for PAJERO io> 14 Water outlet fitting <DOHC.GDI for PAJERO io> 23 Water by-pass fitting 23 Water pipe 13 Water outlet fitting <Except DOHC.

W) .11A-1-6b 4G9 ENGINE (E . finally tighten 20 Nm + 90_ + 90_ Oil pressure switch 10 Front case and oil pump Oil pump cover 10 Oil pump case 14 Relief plug 44 Oil screen 19 Oil pan 7 Upper oil pan <Only M6 ´ 121> 7 Upper oil pan <Except M6 ´ 121> 11 Upper oil pan <M8> 24 Lower oil pan 7 Cover 7 Baffle plate <For CARISMA. SPACE STAR only> 7 Drain plug 39 Oil pressure switch 10 Baffle plate mounting bolt 7 Piston and connecting rod Connecting rod cap nut 20 + 90_ to 100_ Crankshaft.Specifications Items Nm Beam camshaft cap (M6) 11 Rocker cover and camshafts (MIVEC) Rocker cover 4 Oil pump 11 Arm spring holder 11 Camshaft bearing cap (M6) 11 Camshaft bearing cap (M8) 23 Oil control valve 9 Rocker arms and rocker shaft caps (MIVEC) Rocker shaft cap 11 Cylinder head and valves CylInder head bolt 74 Nm and then completely loosen. flywheel and drive plate Bearing cap bolt 25 + 90_ to 100_ Oil seal case 11 Bell housing cover 9 Rear plate 11 Drive plate bolt 98 Flywheel bolt 98 Baffle plate 9 Knock sensor 22 E Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised . cylinder block.

8660 or equivalent As required Water outlet fitting Mitsubishi Genuine Part No. Make sure that the service limits described in the text are strictly observed.MD970389 or equivalent As required Water by-pass fitting Mitsubishi Genuine Part No.8660 or equivalent As required Camshaft bearing cap 3M ATD Part No.4G9 ENGINE (E .MD970389 or equivalent As required Oil pan/Upper oil pan/Lower oil pan Mitsubishi Genuine Part No.MD970389 or equivalent As required Oil pump case Mitsubishi Genuine Part No. D D Areas where the bolts are in use: (1) Cylinder head bolts (2) Main bearing cap bolts (3) Connecting rod cap bolts Tightening method After tightening the bolts to the specified torque.MD970389 or equivalent As required Engine coolant temperature sensor 3M Nut Locking Part No. is currently used for some parts of the engine.W) . 1998 PWEE9502-E Revised . tighten them another 90_ or 180_ (twice 90_).4171 or equivalent As required Cam position sensor support Mitsubishi Genuine Part No.8660 or equivalent As required Beam camshaft cap Mitsubishi Genuine Part No. Service limits are provided for the bolts.MD970389 or equivalent As required Cylinder head Mitsubishi Genuine Part No.8660 or equivalent As required Rocker cover 3M ATD Part No. The tightening method varies on different areas.8660 or equivalent As required Semi-circular packing 3M ATD Part No.4171 or equivalent As required Flywheel bolt 3M Nut Locking Part No.BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA A new type of bolts. SEALANT Items Specified sealant Quantity Water pump Mitsubishi Genuine Part No.Specifications 11A-1-7 NEW TIGHTENING METHOD .8660 or equivalent As required Camshaft holder 3M ATD Part No.MD970389 or equivalent As required Oil seal case Mitsubishi Genuine Part No.MD970389 or equivalent As required Drive plate bolt 3M Nut Locking Part No. The tightening method for bolts of this type is different from the conventional one. Observe the tightening method described in the text.MD970389 or equivalent As required Thermostat case Mitsubishi Genuine Part No. Be sure to observe the method described in the text when tightening the bolts.MD970389 or equivalent As required Oil control valve 3M ATD Part No.8660 or equivalent As required E Mitsubishi Motors Corporation Dec. to be tightened in plastic area.4171 or equivalent As required Engine coolant temperature gauge unit 3M ATD Part No.MD970389 or equivalent As required Water fitting Mitsubishi Genuine Part No.MD970389 or equivalent As required Oil pressure switch 3M ATD Part No.

you must observe some precautions. however. could be squeezed out of location. 997110 can only be used for engine oil sealing. using a gasket scraper or wire brush. mount the parts in position. while Part No. Form-In-Place Gasket Application When assembling parts with the FIPG. care must be taken to prevent damage to the joined surfaces. continuity and location are of paramount importance. The FIPG. In this case. Bead size. In some cases. it is normally used in the metallic flange areas. Check to ensure that the surfaces to which the FIPG is to be applied is flat. The FIPG can be wiped away unless it is hardened. can be used for sealing both engine oil and coolant. A flat and thin gasket scraper may be lightly hammered in between the joined surfaces. Be sure to use the special tool to remove the oil pan. Too thick a bead. When the parts are mounted. Applied FIPG bead should be of the specified size and without breaks. The FIPG application procedure may vary on different areas. Also be sure to encircle the bolt hole circumference with a completely continuous bead. Part No. Observe the procedure described in the text when applying the FIPG. MD970389 or MD997110).Specifications FORM-IN-PLACE GASKET The engine has several areas where the form-in-place gasket (FIPG) is in use. Make sure that there are no oils.11A-1-8 4G9 ENGINE (E . the sealant between the joined surfaces may have to be broken by lightly striking with a mallet or similar tool. while observing the correct bead size.W) . therefore. Do not forget to remove the old sealant remained in the bolt holes. <Except aluminium die-cast oil pans> Surface Preparation Thoroughly remove all substances deposited on the gasket application surfaces. it is absolutely necessary to apply the gasket evenly without a break. however. Since the RTV hardens as it reacts with the moisture in the atomospheric air. In addition. To eliminate the possibility of leaks from a joint. but the procedures is very simple as in the case of a conventional precut gasket. do not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time (about one hour) has passed after installation is completed. greases and foreign substances deposited on the application surfaces. E Mitsubishi Motors Corporation May 1995 PWEE9502 . The FIPG used in the engine is a room temperature vulcanization (RTV) type and is supplied in a 100-gram tube (Part No. To ensure that the gasket fully serves its purpose. Too thin a bead could cause leaks. it is necessary to observe some precautions when applying the gasket. MD970389. While the FIPG is still moist (in less than 15 minutes). causing blocking or narrowing of the fluid feed line. make sure that the gasket is applied to the required area only. the special tool “Oil Pan Remover” (MD998727) is available. For removal of the oil pan. Disassembly The parts assembled with the FIPG can be easily disassembled without use of a special method. on the other hand.

1995 PWEE9502-A Revised .Special Tools 11A-2-1 2.4G9 ENGINE (E .W) . Use with MD998719 MD998440 Leak-down tester Leak-down test of lash adjuster MD998442 Air bleed wire Air bleeding of lash adjuster MD998713 Camshaft oil seal installer Installation of camshaft oil seal MD998716 Crankshaft wrench Rotation of crankshaft when installing piston and timing belt. SPECIAL TOOLS Tool E Mitsubishi Motors Corporation Number Name Use MB990938 Handle Use with MD998776 MB990767 Crankshaft pulley holder Holding camshaft sprocket when loosening and tightening of bolt. MD998717 Crankshaft front oil seal installer Installation of crankshaft front oil seal MB991653 Cylinder head bolt wrench Tightening and loosening of cylinder head bolt MB991659 Guide D Removal of piston pin (Use with MD998780) Nov.

Special Tools Number Name Use MD998719 Pulley holder pin (2) Use with MB990767 MD998727 Oil pan remover Removal of the oil pan MD998754 Pin Use with MB990767 MD998767 Tensioner pulley socket wrench Adjustment of timing belt tension MD998772 Valve spring compressor Removal and installation of valve and related parts MD998774 Valve stem seal installer Installation of valve stem seal MD998775 Valve stem seal installer Installation of valve stem seal MD998776 Crankshaft rear oil seal installer Installation of crankshaft rear oil seal Use with MB990938 Nov. 1995 PWEE9502-A Revised .11A-2-2 Tool E Mitsubishi Motors Corporation 4G9 ENGINE (E .W) .

W) . 1995 PWEE9502-A Revised .Special Tools Tool E Mitsubishi Motors Corporation 11A-2-3 Number Name Use MD998780 SETTING TOOL Piston pin Removal and installation of piston pin MD998735 Valve spring compressor Compression of valve spring MD998781 Flywheel stopper Holding flywheel and drive plate MB991477 Valve adjusting wrench Adjustment of valve clearance (MIVEC) MB991478 Valve adjusting wrench feeler gauge set Adjustment of valve clearance (MIVEC) MB991479 Rocker arm piston checker Adjustment of valve clearance (MIVEC) MD998784 Valve spring compressor adapter Compression of valve spring (MIVEC) (Use with MD998772) Nov.4G9 ENGINE (E .

PWEE9502-A Revised . 10. ALTERNATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION <SOHC> (Engines with distributor) 7 12 Nm 10 Nm 23 Nm 9 8 25 Nm 2 3 10 44 Nm 23 Nm 49 Nm 1 6 4 5 181 Nm Removal steps 1. Flange Spark plug cable Spark plug Distributor O-ring NOTE: *: For details of adjustment. Drive belt* 2. 1995 6. 7. 9. Alternator 3. refer to the relevant model’s chassis workshop manual.11A-3-1 4G9 ENGINE (E . Crankshaft bolt 5.Alternator and Ignition System 3. Crankshaft pulley E Mitsubishi Motors Corporation Nov. 8. Alternator brace AA" "BA 4.W) .

Crankshaft bolt 5. 12. Drive belt* 2. Front flange E Mitsubishi Motors Corporation Dec. refer to the relevant model’s chassis workshop manual. PWEE9502-E Revised . Alternator 3.W) . Crankshaft pulley 6. Alternator brace AA" "BA 4. 8. 10. 1998 7. Spark plug cable Ignition coil Spark plug Cam position sensor Cam position sensor support Cam position sensing cylinder NOTE: *: For details of adjustment.Alternator and Ignition System REMOVAL AND INSTALLATION <SOHC for other than PAJERO io> (Engines without distributor) 10 Nm 7 10 11 9 Nm 25 Nm 13 Nm 8 9 21 Nm 12 2 10 Nm 23 Nm 3 44 Nm 23 Nm 49 Nm 1 6 5 4 181 Nm Removal steps 1.11A-3-2 4G9 ENGINE (E . 9. "AA 11.

PWEE9502-E Added . Drive belt* 2. refer to the relevant model’s chassis workshop manual.4G9 ENGINE (E . Crankshaft pulley 6.Alternator and Ignition System 11A-3-2a REMOVAL AND INSTALLATION <SOHC for PAJERO io> (Engines without distributor) 10 Nm 8 7 9 Nm 7 10 8 21 Nm 9 25 Nm 11 12 44 Nm 4. Front flange E Mitsubishi Motors Corporation Dec. 9. Crankshaft bolt 5. 1998 7.9 Nm 13 Nm 23 Nm 3 23 Nm 2 49 Nm 6 5 4 1 181 Nm Removal steps 1. Spark plug cable Ignition coil Spark plug Cam position sensor Cam position sensor support Cam position sensing cylinder NOTE: *: For details of adjustment. Alternator 3. Alternator brace AA" "BA 4. 12. 8. 10.W) . "AA 11.

Alternator and Ignition System Intentionally blank E Mitsubishi Motors Corporation Dec.11A-3-2b 4G9 ENGINE (E . 1998 PWEE9502-E Added .W) .

9.W) . PWEE9502-A Revised . Crankshaft pulley 6. Center cover Ignition coil Spark plug cable Spark plug Ignition failure sensor NOTE: *: For details of adjustment. refer to the relevant model’s chassis workshop manual. Crankshaft bolt 5. Drive belt* 2. 8. 1995 7. 10. Flange E Mitsubishi Motors Corporation Nov. 11.11A-3-3 4G9 ENGINE (E .Alternator and Ignition System REMOVAL AND INSTALLATION <DOHC> 7 3 Nm 10 Nm 9 8 10 25 Nm 11 23 Nm 10 Nm 2 23 Nm 3 44 Nm 23 Nm 5 6 29 Nm 181 Nm 1 4 Removal steps 1. Alternator brace AA" "BA 4. Alternator 3.

11.Alternator and Ignition System REMOVAL AND INSTALLATION <DOHC . 9. Front flange 7. Alternator brace AA" "BA 4. Crankshaft bolt 5. Alternator 3. 8.11A-3-4 4G9 ENGINE (E . 13. E Mitsubishi Motors Corporation Nov.W) .MIVEC> 7 3 Nm 10 Nm 9 Nm 8 11 13 Nm 9 10 12 25 Nm 13 2 10 Nm 23 Nm 3 21 Nm 44 Nm 23 Nm 49 Nm 5 6 181 Nm 1 4 Removal steps 1. 1995 PWEE9502-A Added . Drive belt* 2. 10. Crankshaft pulley 6. "AA 12. Center cover Spark plug cable Ignition coil Spark plug Cam position sensor Cam position sensor support Cam position sensing cylinder NOTE: *: For details of adjustment. refer to the relevant model’s chassis workshop manual.

Front flange E Mitsubishi Motors Corporation Dec. PWEE9502-E Revised . 10.11A-3-5 4G9 ENGINE (E .GDI for CARISMA> 2. Alternator 3. Drive belt* 2. Crankshaft bolt 5. Engine cover Ignition coil Spark plug Cam position sensor Cam position sensor support Cam position sensing cylinder NOTE: *: For details of adjustment. 12. 9. 1998 7. 8. Alternator brace AA" "BA 4. "AA 11.Alternator and Ignition System REMOVAL AND INSTALLATION <DOHC . Crankshaft pulley 6. refer to the relevant model’s chassis workshop manual.W) .9 Nm 10 Nm 7 9 Nm 8 10 25 Nm 9 11 12 2 13 Nm 21 Nm 10 Nm 23 Nm 3 44 Nm 6 23 Nm 5 49 Nm 1 4 181 Nm Removal steps 1.

Crankshaft bolt 8.9 Nm 21 Nm 5 23 Nm 1 6 13 Nm 23 Nm 2 44 Nm 3 44 Nm 181 Nm 4 8 3 9 21 Nm 11 7 12 49 Nm 44 Nm 44 Nm 10 25 Nm Removal steps 1. refer to the relevant model’s chassis workshop manual.Alternator and Ignition System REMOVAL AND INSTALLATION <DOHC . Alternator brace AA" "BA 7. Oil level gauge 2. 1998 10. 17.GDI for PAJERO io> 10 Nm 13 9 Nm 25 Nm 15 14 13 Nm 17 16 4. 13. 15. Oil level gauge guide 3. Power steering pump pulley Power steering pump bracket stay Power steering pump bracket Ignition coil Spark plug Cam position sensor Cam position sensor support Cam position sensing cylinder NOTE: *: For details of adjustment. 12. Drive belt* 5.W) . 14. Alternator 6.11A-3-6 4G9 ENGINE (E . "AA 16. 11. PWEE9502-E Revised . Crankshaft pulley 9. Front flange E Mitsubishi Motors Corporation Dec. O-ring 4.

No. MD998781 INSTALLATION SERVICE POINTS "AA CAM POSITION SENSOR SUPPORT INSTALLATION (1) Apply a 3 mm bead of form-in-place gasket (FIPG) to the area shown. Specified sealant: Mitsubishi Genuine equivalent. MD970389 or "BA CRANKSHAFT BOLT INSTALLATION (1) Use the special tool to hold the flywheel or the drive plate.4G9 ENGINE (E . and then tighten the crankshaft mounting bolts.Alternator and Ignition System 11A-3-7 REMOVAL SERVICE POINT AA" CRANKSHAFT BOLT REMOVAL (1) Use the special tool to hold the flywheel or the drive plate. MD998781 E Mitsubishi Motors Corporation Part Dec. 1998 PWEE9502-E Added . and then loosen the crankshaft mounting bolts.W) .

Timing belt front lower cover 3. Crankshaft sensing plate (Engines without distributor) 12. Crankshaft angle sensor (Engines without distributor) 9. Crankshaft sprocket 10. Timing belt front upper cover 2. Timing belt rear cover E Mitsubishi Motors Corporation Dec. Tensioner spring "BA 6. Engine support bracket. Camshaft sprocket bolt 14. Timing belt tensioner 7.8 Nm 12 9 23 Nm 3 2 49 Nm Removal steps 1. Camshaft sprocket PWEE9502-E Revised . Crankshaft key AB" "AA 13. 1998 8. Timing belt "CA 5. right AA" "DA 4. TIMING BELT REMOVAL AND INSTALLATION <SOHC for other than PAJERO io> 14 88 Nm 13 11 Nm 1 7 4 5 6 8 11 Nm 11 Nm 11 10 9. Crankshaft spacer (Engines without distributor) 11.11A-4-1 4.

Timing Belt REMOVAL AND INSTALLATION <SOHC for PAJERO io> 88 Nm 14 13 1 11 Nm 11 Nm 23 Nm 7 6 5 8 3 10 11 12 9.11A-4-2 4G9 ENGINE (E . 12. 9. Tensioner spring "BA 6. Accessory mount AA" "DA 4.8 Nm 9 4 49 Nm 2 Removal steps 1. Timing belt front upper cover 2. 10. PWEE9502-E Crankshaft angle sensor Crankshaft sprocket Crankshaft spacer Crankshaft sensing plate Crankshaft key Camshaft sprocket bolt Camshaft sprocket Revised . 11. 14.W) . Timing belt "CA 5. Timing belt rear cover E Mitsubishi Motors Corporation Dec. AB" "AA 13. 1998 8. Timing belt tensioner 7. Timing belt front lower cover 3.

11A-4-2a

4G9 ENGINE (E - W) - Timing Belt
REMOVAL AND INSTALLATION <DOHC>

19
11 Nm

4

88 Nm

18
17
5
24 Nm
11 Nm

1
6
10

36 Nm

7

1516

11

14

44 Nm

11 Nm

13

20
9
11 Nm
9.8 Nm

8

12

13 Nm

3

2

49 Nm

Removal steps
1. Timing belt upper cover
2. Timing belt lower cover
3. Engine support bracket
AA" "FA 4. Timing belt
5. Tensioner pulley
6. Tensioner arm
7. Shaft
"EA 8. Auto-tensioner
9. Timing belt rear cover
10. Idler pulley

E Mitsubishi Motors Corporation

Dec. 1998

11.
12.
13.
14.
15.
16.
AB" "AA 17.
18.
19.
20.

PWEE9502-E

Cam position sensor
Crank angle sensor
Crankshaft sprocket
Sensing plate
Crankshaft spacer
Crankshaft sprocket key
Camshaft sprocket bolt
Camshaft sprocket
Timing belt rear cover
Timing belt rear cover

Revised

11A-4-2b

4G9 ENGINE (E - W) - Timing Belt

REMOVAL AND INSTALLATION <DOHC - MIVEC>

18
88 Nm

11 Nm

4

17

16
5
48 Nm

1
11 Nm

10

6

7
35 Nm
48 Nm

15
12 14 13

11 Nm

19
11 Nm

9
3

13 Nm

8

9.8 Nm

2

11

49 Nm

Removal steps
1. Timing belt front upper cover
2. Timing belt front lower cover
3. Engine support bracket, right
AA" "FA 4. Timing belt
5. Tensioner pulley
6. Tensioner arm
7. Shaft
"EA 8. Auto tensioner
9. Timing belt rear cover
10. Idler pulley

E Mitsubishi Motors Corporation

Dec. 1998

11.
12.
13.
14.
15.
AB" "AA 16.
17.
18.
19.

PWEE9502-E

Crankshaft angle sensor
Crankshaft sprocket
Crankshaft spacer
Crankshaft sensing plate
Crankshaft key
Camshaft sprocket bolt
Camshaft sprocket
Timing belt rear cover
Timing belt rear cover

Revised

11A-4-2c

4G9 ENGINE (E - W) - Timing Belt
REMOVAL AND INSTALLATION <DOHC - GDI for CARISMA>

11 Nm

18
4

88 Nm

17

16

11 Nm

1

7

5

6

10

48 Nm

35 Nm

13

11 Nm

15

14

48 Nm

12

19

9
3

8

49 Nm

11 Nm
9.8 Nm

13 Nm

11

2

Removal steps
1. Timing belt front upper cover
2. Timing belt front lower cover
3. Engine support bracket, right
AA" "FA 4. Timing belt
5. Tensioner pulley
6. Tensioner arm
7. Shaft
"EA 8. Auto tensioner
9. Timing belt rear cover
10. Idler pulley

E Mitsubishi Motors Corporation

Dec. 1998

11.
12.
13.
14.
15.
AB" "AA 16.
17.
18.
19.

PWEE9502-E

Crankshaft angle sensor
Crankshaft sprocket
Crankshaft spacer
Crankshaft sensing plate
Crankshaft key
Camshaft sprocket bolt
Camshaft sprocket
Timing belt rear cover
Timing belt rear cover

Added

20. 16.Timing Belt REMOVAL AND INSTALLATION <DOHC . 13. Shaft "EA 8. 12. Idler pulley E Mitsubishi Motors Corporation Dec. Timing belt 5. 19. 15. Auto tensioner 9. 18. PWEE9502-E Bracket Crankshaft angle sensor Crankshaft sprocket Crankshaft sensing plate Crankshaft spacer Crankshaft key Camshaft sprocket bolt Camshaft sprocket Timing belt rear cover Timing belt rear cover Added . Timing belt front lower cover 3.11A-4-2d 4G9 ENGINE (E . Timing belt rear cover 10.W) . 1998 11.GDI for PAJERO io> 19 11 Nm 4 18 88 Nm 17 5 1 11 Nm 6 10 7 14 48 Nm 20 15 35 Nm 16 12 48 Nm 13 11 Nm 9 11 Nm 11 11 Nm 9. Timing belt front upper cover 2. 14.8 Nm 8 49 Nm 13 Nm 3 2 Removal steps 1. AB" "AA 17. Tensioner pulley 6. Tensioner arm 7. Accesory mount AA" "FA 4.

4G9 ENGINE (E - W) - Timing Belt

11A-4-3

REMOVAL SERVICE POINTS
AA" TIMING BELT REMOVAL
(1) Mark belt running direction for reinstallation.

AB" CAMSHAFT SPROCKET BOLT REMOVAL
MB990767

MD998719
or
MD998754

<With rocker cover removed> (Except SOHC)
(1) Use a wrench to hold the hexagonal part of the camshaft,
and then remove the camshaft sprocket mounting bolt.

INSTALLATION SERVICE POINTS
MB990767

"AA CAMSHAFT SPROCKET BOLT INSTALLATION

MD998719
or
MD998754
E Mitsubishi Motors Corporation

Nov. 1995

PWEE9502-A

Revised

11A-4-4

4G9 ENGINE (E - W) - Timing belt
"BA TIMING BELT TENSIONER INSTALLATION
(1) Let the pulley of the timing belt tensioner comr closest
to the exhaust side. Temporarily tighten the tensioner
pulley fixing bolt.

Exhaust
side
Tensioner
pulley fixing
bolt

Tensioner
“B”

“A”

"CA TENSIONER SPRING INSTALLATION
(1) Insert the tip A (shorter one) of the tensioner spring into
the oil pump case.
(2) Use pliers or similar tool to pinch the tip B (longer one),
and then hook it to the tensioner bracket arm.

Pliers

"DA TIMING BELT INSTALLATION
(1) Turn the crankshaft sprocket by three teeth from the timing
mark.
Caution
Aligning the timing marks positions the piston to the
top dead centre. Then, if the camshaft turns, the valves
may hit and damage the pistons.

(2) Check that the timing belt tensioner and tensioner spring
are installed correctly. (Refer to the service points B and
C.)
(3) Align the timing marks on the camshaft sprocket to that
on the cylinder head.

Timing mark

(4) Align the timing mark on the crankshaft sprocket to that
on the oil pump case.
(5) Place the timing belt over the sprocket according in the
following order.
1. Crankshaft sprocket
2. Water pump sprocket
3. Camshaft sprocket
4. Tension pulley

Timing marks

E Mitsubishi Motors Corporation

May 1995

PWEE9502

4G9 ENGINE (E - W) - Timing Belt

11A-4-5

(6) Slightly loosen the tensioner pulley fixing bolt which is
tightened temporarily to tighten the belt by a force of
the tensioner spring.

(7) Turn the crankshaft clockwise by two turns.
(8) Check that the timing marks are aligned.
(9) Tighten the fixing bolt of the tensioner pulley.

MD998716

Set hole (A)
Set hole (B)

"EA AUTO-TENSIONER INSTALLATION
(1) If the auto-tensioner rod is fully extended, set it in the
retracted position with the following procedure.
1) Hold the auto-tensioner in a vice, being careful not
to tilt it.
2) Slowly close the vice to force the rod in to align hole
(A) of the rod with the set hole (B).
3) Insert a 2.0-mm-Allen key in diameter or similar into
the set holes.
4) Remove the auto-tensioner from the vice.
(2) Install the auto-tensioner
Leave the align key until installation of the timing belt
is completed.

E Mitsubishi Motors Corporation

Nov. 1995

PWEE9502-A

Revised

(Refer to service point F. Timing mark Timing mark E Mitsubishi Motors Corporation Nov. (3) Turn the crankshaft sprocket one half the tooth width counterclockwise.) (2) Align the timing mark on each sprocket with the corresponding mark on the timing belt. (5) Use two wrenches to fit the timing belt to the exhaust sprocket while aligning the timing marks.11A-4-6 4G9 ENGINE (E . Timing marks Timing mark Paper clip (4) Fit the timing belt to the intake camshaft sprocket and secure with a paper clip at the illustrated position. 1995 PWEE9502-A Revised .W) .Timing Belt "FA TIMING BELT INSTALLATION (1) Make sure that the auto-tensioner is installed properly.

crankshaft sprocket and tensioner pulley in that order. E Mitsubishi Motors Corporation May 1995 PWEE9502 .Timing Belt 11A-4-7 (6) Secure the timing belt with a paper clip at the illustrated position.4G9 ENGINE (E . (10)Make sure that all timing marks are in alignment. Water pump sprocket Tensioner pulley Crankshaft sprocket (8) Raise the tensioner pulley in the direction of an arrow and tighten the tensioner pulley bolt. (9) Remove the two paper clips. (11)Give a 1/4 counterclockwise turn to the crankshaft. Idler pulley (7) Fit the belt to the idler pulley water pump sprocket.W) . Then turn the crankshaft clockwise to align the timing marks again.

5 mm (17)If the wrench cannot be pulled out lightly.6 Nm.4. pull out the wrench. (16)Check if the Allen wrench inserted during installation of the auto-tensioner can be pulled out lightly. If it can be pulled out lightly. Cracks Peeling (2) (3) (4) (5) Cracks Cracks Cracks Cracks Cracks Cracks E Mitsubishi Motors Corporation May 1995 PWEE9502 on rubber back. (13)Using torque wrench. on tooth bottom.11A-4-8 4G9 ENGINE (E . The belt is also properly tensioned if the auto-tensioner projection is of standard value. or peeling of canvas. . Therefore. tighten the center bolt to the specified torque. (15)Give two clockwise turns to the crankshaft and leave as it is for approx. MD998767 Standard value: 3. torque to 2. (14)While holding the tensioner pulley to prevent it from turning. 15 minutes.Timing Belt (12)Install the special tool and a torque wrench to the tensioner pulley. on belt sides. the belt is properly tensioned.8 . INSPECTION 11300200077 TIMING BELT Replace belt if any of the following conditions exist. (1) Hardening of back rubber. repeat the steps (12) through (15) to obtain appropriate belt tension. Back side is glossy without resilience and leaves no indent when pressed with fingernail.W) .

Rubber exposed Tooth missing and canvas fiber exposed TENSIONER PULLER. Rounded edge Abnormal wear (Fluffy strand) (7) Abnormal wear on teeth. (3) Measure the rod projection length. The sides are normal if they are sharp as if cut by a knife. excessive play. Standard value: 1 mm or less PWEE9502 . IDLER PULLEY (1) Check the pulley for smooth rotation. If not within the standard value. Replace it if necessary.W) . abnormal noise. 11 mm 98 to 196 N Stroke E Mitsubishi Motors Corporation May 1995 Standard value: 11 mm (4) Press the rod by a force of 98 to 196 N and measure the rod stroke. replace the tensioner. (2) Check the rod end for wear or damage. If not within the standard value.4G9 ENGINE (E . Replace the tensioner if necessary. Replace it if necessary. AUTO-TENSIONER (1) Check the tensioner for oil leaks. replace the tensioner.Timing Belt 11A-4-9 (6) Abnormal wear of belt sides. (8) Missing tooth.

Fuel hose 3. EGR valve 11. Fuel hose 4. Insulator 7. Gasket 10.W) . Gasket 6.4G9 ENGINE (E .Fuel and Emission Control System 11A-5-1 5. Breather tube 2. Gasket E Mitsubishi Motors Corporation Nov. Gasket 8. 1996 PWEE9502-B Revised . Fuel pump 5. Carburetor 9.CARBURETOR> 18 Nm 17 Nm 21 Nm 8 3 10 4 9 11 5 6 2 7 1 21 Nm Removal steps 1. FUEL AND EMISSION CONTROL SYSTEM REMOVAL AND INSTALLATION <SOHC .

"AA 11. Delivery pipe and injector 9.MPI for other than PAJERO iO> 12 Nm 19 Nm 14 2 8 13 11 10 10 Nm 12 3 1 9 5 9 Nm 21 Nm 15 17 18 4 7 6 16 9 Nm 16 11 Nm Removal steps 1. PWEE9502-F Insulator Injector O-ring Grommet Delivery pipe Fuel return pipe Solenoid valve assembly EGR valve Gasket Revised . Vacuum hose and pipe assembly 2.W) . 13. Throttle body "CA 3. 18.Fuel and Emission Control System REMOVAL AND INSTALLATION <SOHC . 16. Vacuum hose 5. Gasket 4. Fuel pressure regulator 7. Insulator E Mitsubishi Motors Corporation July 1999 10. 15. 14. 17. 12. Fuel hose "BA 6. O-ring 8.11A-5-2 4G9 ENGINE (E .

Gasket 4. 16.MPI for PAJERO io> 12 Nm 9 Nm 14 19 Nm 15 5 13 11 12 8 10 9 1 2 9 Nm 3 4 16 6 7 9 Nm 9 Nm Removal steps 1. 13. 10. 14. Fuel hose "BA 6. 15. PWEE9502-E Insulator Insulator Injector O-ring Grommet Delivery pipe Fuel return pipe Solenoid valve assembly Revised .W) . Delivery pipe and injector E Mitsubishi Motors Corporation Dec. Fuel pressure regulator 7.Fuel and Emission Control System REMOVAL AND INSTALLATION <SOHC . Vacuum hose and pipe assembly 2. O-ring 8. Throttle body "CA 3. 12.11A-5-3 4G9 ENGINE (E . Vacuum hose 5. 1998 9. "AA 11.

Throttle body assembly "CA 3. 13.11A-5-4 4G9 ENGINE (E . 16. 1998 10. Delivery pipe and injector E Mitsubishi Motors Corporation Dec. Gasket 4. Vacuum pipe assembly 2. Fuel hose "BA 7. 14. 15. Throttle body stay (MIVEC) 5.W) . O-ring 9. "AA 12. Vacuum hose 6. PWEE9502-E Insulator Insulator Injector O-ring Grommet Delivery pipe Fuel return pipe Revised .Fuel and Emission Control System REMOVAL AND INSTALLATION <DOHC> 11 Nm 4 15 4 14 23 Nm 2 9 18 Nm 12 10 Nm 11 13 3 1 23 Nm 10 9 Nm 16 6 5 8 7 9 Nm Removal steps 1. 11. Fuel pressure regulator 8.

Fuel and Emission Control System 11A-5-5 INSTALLATION SERVICE POINTS "AA INJECTORS INSTALLATION (1) Apply a small amount of new engine oil to the O-ring. the O-ring may be trapped. the O-ring may be trapped. (4) Check that the clearance between the injector connector and the delivery pipe is uniform (A = B). Caution Be sure not to let engine oil get into the delivery pipe. If it does not turn smoothly. (2) Check that the fuel pressure regulator turns smoothly. and then re-insert it into the delivery pipe and check once again. Remove the injector and check the O-ring for damage. install it to the delivery pipe. (3) Check that the injector turns smoothly. Remove the fuel pressure regulator and check the O-ring for damage. 1998 PWEE9502-E Added .MPI for other than PAJERO io> Projection E Mitsubishi Motors Corporation Dec.4G9 ENGINE (E .W) . and then re-insert it into the delivery pipe and check once again. <SOHC . Insert the fuel pressure regulator into the delivery pipe being careful not to damage the O-ring. If it does not turn smoothly. Delivery pipe "BA FUEL PRESSURE REGULATOR INSTALLATION (1) Apply a small amount of new engine oil to the O-ring. "CA GASKET INSTALLATION (1) Position the projection as shown in the illustration. Injector connector A B (2) While turning the injector to the left and right. Caution Be sure not to let engine oil get into the delivery pipe.

W) .MPI for PAJERO io> Projection E Mitsubishi Motors Corporation Dec.Fuel and Emission Control System <SOHC .11A-5-6 4G9 ENGINE (E . 1998 PWEE9502-E Added .

Water hose E Mitsubishi Motors Corporation Dec. 1998 10.4G9 ENGINE (E . 13. 16. 11. O-ring "BA 3. PWEE9502-E EGR valve EGR valve gasket Engine hanger EGR valve support Gasket Water hose Air by-pass valve Air by-pass valve gasket Revised . 14. Throttle body gasket 8. 12. THROTTLE BODY AND EGR SYSTEM (GDI) REMOVAL AND INSTALLATION <For CARISMA> 18 Nm 6 7 4 17 12 15 16 18 Nm 3 2 18 Nm 9 Nm 14 9 Nm 13 14 24 Nm 18 Nm 8 11 30 Nm 1 10 5 18 Nm 9 Removal steps 1. 15. Throttle body "AA 7. Water hose 5. Intake manifold stay 4. 17. Water hose 6.W) .Throttle Body and EGR System (GDI) 11A-5a-1 5a. Air intake plenum resonator 2. Ignition harness 9.

Water hose clamp 7. Water hose 4. Water pipe 8. 13. Water pipe E Mitsubishi Motors Corporation Dec. 11. "AA 10. Water hose 6.11A-5a-2 4G9 ENGINE (E . 1998 9. Water hose 5. 15. Water hose 2. 12. PWEE9502-E Throttle body Throttle body gasket EGR valve EGR valve gasket EGR valve support Gasket Engine hanger Revised . Water hose 3.W) - Throttle Body and EGR System (GDI) REMOVAL AND INSTALLATION <For PAJERO io> 1 18 Nm 14 9 18 Nm 13 23 Nm 7 11 Nm 14 12 10 11 3 16 15 13 Nm 5 6 18 Nm 18 Nm 2 8 11 Nm 4 Removal steps 1. 14.

(3) Tighten the four bolts to the specified torque.Throttle Body and EGR System (GDI) <CARISMA> 11A-5a-3 INSTALLATION SERVICE POINTS Tab "AA THROTTLE BODY GASKET <PAJERO io> Intake manifold Bolt Intake manifold stay "BA INTAKE MANIFOLD STAY INSTALLATION (1) Tighten the four bolts at the top and bottom of the stay handtight.4G9 ENGINE (E . Bolt Cylinder block E Mitsubishi Motors Corporation Dec. (2) Check that the stay seating surface is in close contact with the bosses on the intake manifold and the cylinder block.W) . 1998 PWEE9502-E Added .

"AA 11. Intake manifold 4. Intake manifold gasket 5. INTAKE AND EXHAUST MANIFOLD REMOVAL AND INSTALLATION <SOHC .CARBURETOR> 20 Nm 3 5 4 9 6 7 20 Nm 14 Nm 12 Nm 13 12 2 29 Nm 18 Nm 13 Nm 8 30 Nm 12 Nm 1 11 10 13 Nm 19 Nm Removal steps 1. "AA 10. 12. Oil level gauge 6. Engine hanger "BA 2. Intake manifold stay 3. 1996 7. Oil level gauge guide E Mitsubishi Motors Corporation Nov. PWEE9502-B O-ring Exhaust manifold Engine hanger Exhaust manifold Exhaust manifold Exhaust manifold Exhaust manifold cover bracket A bracket B gasket Revised . 9. 13. 8.Intake and Exhaust Manifold 6.11A-6-1 4G9 ENGINE (E .W) .

Engine hanger 2.W) . Intake manifold 4.11A-6-2 4G9 ENGINE (E . "AA 10.Intake and Exhaust Manifold REMOVAL AND INSTALLATION <SOHC . "AA 11. Intake manifold gasket 5. Oil level gauge 6. 13. 8. 12. 1996 7. PWEE9502-B O-ring Exhaust manifold Engine hanger Exhaust manifold Exhaust manifold Exhaust manifold Exhaust manifold cover bracket A bracket B gasket Revised .MPI> 20 Nm 12 Nm 3 20 Nm 5 1 6 4 14 Nm 7 13 2 29 Nm 18 Nm 12 30 Nm 11 10 8 9 12 13 Nm 19 Nm Removal steps 1. 9. Oil level gauge guide E Mitsubishi Motors Corporation Nov. Intake manifold stay 3.

"AA 10. 11. 8. Intake manifold 4. Oil level gauge guide E Mitsubishi Motors Corporation Nov.W) . Intake manifold stay 3.11A-6-3 4G9 ENGINE (E . 12. Engine hanger 2.Intake and Exhaust Manifold REMOVAL AND INSTALLATION <DOHC> 20 Nm 12 Nm 3 1 20 Nm 4 12 11 2 29 Nm 18 Nm 30 Nm 8 12 Nm 5 10 6 9 19 Nm Removal steps 1. Intake manifold gasket 5. Oil level gauge 6. PWEE9502-B 7 14 Nm O-ring Engine hanger Exhaust manifold bracket A Exhaust manifold bracket B Exhaust manifold Exhaust manifold gasket Revised . "AA 9. 1996 7.

Intake and Exhaust Manifold INSTALLATION SERVICE POINT Bracket A Bracket B "AA EXHAUST MANIFOLD INSTALLATION (1) Install temporarily the exhaust manifold brackets A and B as shown in the illustration.11A-6-4 4G9 ENGINE (E . (2) Check that both brackets are in close contact with the bosses. Exhaust manifold "BA INTAKE MANIFOLD STAY INSTALLATION (1) Install the intake manifold stay with its “UP” mark directed toward the intake manifold.W) . “UP” mark E Mitsubishi Motors Corporation Nov. and then tighten fully the bracket mounting bolts. 1996 PWEE9502-B Added .

Solenoid valve 5. SPACE STAR> 1 11 Nm 9 Nm 6 8 11 Nm 4 11 Nm 5 9 Nm 3 2 19 Nm 7 9 10 19 Nm Removal steps 1. 1998 6. Bracket 4. Connector bracket E Mitsubishi Motors Corporation Jun. 10.Intake Manifold (GDI) 6a.W) . Vacuum pipe and hose 3. 7. 8. PWEE9502-D Accelerator cable bracket Vacuum hose Vacuum pipe Intake manifold Intake manifold gasket Revised . Air by-pass hose 2.11A-6a-1 4G9 ENGINE (E . INTAKE MANIFOLD (GDI) REMOVAL AND INSTALLATION <For CARISMA. 9.

Intake Manifold (GDI) REMOVAL AND INSTALLATION <For SPACE RUNNER> 1 11 Nm 9 Nm 6 4 8 2 11 Nm 9 Nm 3 11 Nm 5 19 Nm 7 9 10 19 Nm Removal steps 1. Solenoid valve 5. Connector bracket E Mitsubishi Motors Corporation Jun. PWEE9502-D Accelerator cable bracket Vacuum hose Vacuum pipe Intake manifold Intake manifold gasket Added . 8. 7.W) . Bracket 4. Air by-pass hose 2.11A-6a-2 4G9 ENGINE (E . Vacuum pipe and hose 3. 9. 10. 1998 6.

hose 2. Vacuum pipe and hose 3.W) .C. 1998 6. Fuel pump protector 5. 7. PWEE9502-E Branch tube Gasket Intake manifold stay Intake manifold Intake manifold gasket Added . 10.Intake Manifold (GDI) 11A-6a-3 REMOVAL AND INSTALLATION <For PAJERO io> 9 Nm 6 1 4 7 11 Nm 9 Nm 9 3 9 Nm 23 Nm 19 Nm 2 9 Nm 10 11 Nm 5 8 30 Nm Removal steps 1. 9. Connector bracket E Mitsubishi Motors Corporation Dec.V. "AA 8. P. Solenoid valve 4.4G9 ENGINE (E .

W) . Intake manifold Intake manifold stay Cylinder block E Mitsubishi Motors Corporation Dec.11A-6a-4 4G9 ENGINE (E .Intake Manifold (GDI) INSTALLATION SERVICE POINT "AA INTAKE MANIFOLD STAY INSTALLATION (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. 1998 PWEE9502-E Added .

O-ring 4.W) . Oil level gauge 2. Engine hanger "AA 6. EXHAUST MANIFOLD (GDI) REMOVAL AND INSTALLATION <For CARISMA> 9 8 17 Nm 6 13 Nm 35 Nm 4 29 Nm 18 Nm 5 18 Nm 7 35 Nm 1 18 Nm 13 Nm 2 13 Nm 3 Removal steps 1. Oil level gauge guide 3. Exhaust manifold bracket B 8.Exhaust Manifold (GDI) 6b. Exhaust manifold bracket A "AA 7. 1998 PWEE9502-E Revised . Exhaust manifold gasket E Mitsubishi Motors Corporation Dec. Exhaust manifold 9.11A-6b-1 4G9 ENGINE (E . Exhaust manifold cover 5.

11A-6b-2 4G9 ENGINE (E . Exhaust manifold cover 2. 1998 PWEE9502-E Revised . Exhaust manifold 5.Exhaust Manifold (GDI) REMOVAL AND INSTALLATION <For PAJERO io> 1 13 Nm 5 4 2 18 Nm 29 Nm 3 17 Nm 98 Nm 29 Nm Removal steps 1. Exhaust manifold bracket 4. Exhaust manifold gasket E Mitsubishi Motors Corporation Dec. Engine hanger "BA 3.W) .

then tighten the bolts to the specified torque.4G9 ENGINE (E .W) . Bracket A Bracket B (2) Install temporarily the exhaust manifold brackets A and B as shown in the illustration. and then tighten fully the bracket mounting bolts. Exhaust manifold Bracket E Mitsubishi Motors Corporation Dec. Shear-droop (2) Temporarily install the exhaust manifold bracket as shown in the illustration. (3) Check that both brackets are in close contact with the bosses.Exhaust Manifold (GDI) 11A-6b-3 INSTALLATION SERVICE POINTS "AA EXHAUST MANIFOLD BRACKET INSTALLATION (1) Slide the washers over the bolts with the chamfered side toward the bolt. 1998 PWEE9502-E Added . (3) Verify that the bracket is brought into close contact with the boss on the exhaust manifold. Exhaust manifold "BA EXHAUST MANIFOLD BRACKET INSTALLATION (1) The washers must be installed with the shear-drooped side toward the bolts.

31. "BA 30. Harness bracket 14. O-ring 13. 29. 25. Fuel high pressure regulator 19. "CA 23. "AA 37. Fuel feed pipe 8. Clamp "FA 7. 24. 1998 "DA 20. O-ring 17. 33. "AA 34. "AA 35. O-ring 10. 32. 27. 38. 28. Backup ring "FA 11. Fuel low pressure pipe 3. 26. O-ring 4. 22. O-ring 6. PWEE9502-E Fuel pressure sensor O-ring Backup ring Pump camshaft case O-ring O-ring Harness bracket Injector harness Washer Injector holder Delivery pipe and injector Insulator Injector gasket Injector Corrugated washer Backup ring O-ring Backup ring Delivery pipe Revised .4G9 ENGINE (E . Backup ring 16. Fuel hose 2. Backup ring 9. Fuel nipple 5. Backup ring "EA 18. 21. Fuel return pipe 15. Fuel pump 12. "AA 36. INJECTOR AND FUEL PUMP ASSEMBLY (GDI) REMOVAL AND INSTALLATION <For CARISMA> 9 Nm 6 18 Nm 11 Nm 13 27 9 Nm 2 14 11 Nm 7 11 Nm 16 15 10 9 18 8 3 1 17 17 ± 2 Nm 21 20 9 Nm 19 22 23 Nm 11 Nm 38 11 26 4 11 Nm 35 36 37 33 31 12 5 23 30 25 34 22 Nm 28 23 Nm 32 24 29 Removal steps 1.Injector and Fuel Pump Assembly (GDI) 11A-6c-1 6c.W) . Flange E Mitsubishi Motors Corporation Dec.

Fuel return pipe 17.11A-6c-2 4G9 ENGINE (E . O-ring 24. Spacer 25. Fuel pressure sensor 22. O-ring 16. Injector harness 2. Corrugated washer "AA 31. Fuel high pressure regulator "DA 21. Injector gasket "AA 30. O-ring 8. Injector holder "BA 27. Delivery pipe PWEE9502-E Revised . Backup ring 34. O-ring 19. O-ring 13. Fuel pump 15. Backup ring 12. O-ring "FA 10. Fuel hose 5. Backup ring "AA 32. Insulator 29. 1998 "EA 20. Delivery pipe and injector 28. Fuel hose 3. O-ring "AA 33. Fuel hose 4. Fuel nipple 7. Fuel feed pipe 11. Injector 35. washer 26. Fuel pipe 6.W) - Injector and Fuel Pump Assembly (GDI) REMOVAL AND INSTALLATION <For PAJERO io> 10 11 Nm 11 12 9 Nm 11 Nm 13 17 ± 2 Nm 2 3 14 16 5 18 Nm 17 18 19 22 4 15 21 18 Nm 7 9 Nm 18 Nm 6 11 Nm 23 35 31 33 34 20 9 8 24 32 9 Nm 30 22 Nm 1 29 27 25 28 26 Removal steps 1. Backup ring E Mitsubishi Motors Corporation Dec. Backup ring "FA 14. Fuel nipple 9. Backup ring 18. Backup ring 23.

1998 PWEE9502-E Revised . Caution Strictly observe the specified torque. Corrugated washer <CARISMA> Mating marks <PAJERO io> Mating marks "BA DELIVERY PIPE AND INJECTOR ASSEMBLY INSTALLATION (1) Lubricate O-ring in the injector with spindle oil or gasoline. (4) Align the mating mark on the injector with that on the delivery pipe.W) . (6) Install the delivery pipe and injector assembly onto the cylinder head. Cut surface Backup ring (2) Coat the corrugated washer with white vaseline and install it to the injector as shown. Injector gasket E Mitsubishi Motors Corporation Dec. Damaged O-ring must be replaced with a new one. Apply vaseline to it before installation so that it may be held in position. If it dose not rotate smoothly. Reused corrugated washer can cause fuel or gas leaks.Injector and Fuel Pump Assembly (GDI) 11A-6c-3 INSTALLATION SERVICE POINTS "AA BACKUP RING / O-RING / CORRUGATED WASHER INSTALLATION (1) Attach the backup rings and O-ring to the injector. Caution Always replace the corrugated washer with new one. The insulator can drop off easily. (5) Install the injector gaskets and insulators on the cylinder head. Reinstall the injector and check for smooth rotation again. The thicker backup ring must be so installed that the inside cut surface is directed as shown in the illustration. (3) Turn the injector clockwise and counterclockwise. remove it to check for damaged O-ring. then tighten the fasteners temporarily.4G9 ENGINE (E . (2) Insert the injector straight into the injector mounting hole in the delivery pipe. (7) Install the injector holders and the washers to the assembly and tighten the fasteners to the specified torque.

(3) Tighten the case mounting bolts to the specified torque. (3) Tighten the fuel pressure sensor mounting bolt to the specified torque. (2) Install the fuel pressure sensor straight into the fuel pressure regulator with labeled surface upward. NOTE The coupling keys and the grooves at the camshaft rear end are offset with respect to the camshaft center.11A-6c-4 4G9 ENGINE (E . PWEE9502-E Revised . Tightening to the specification is to be carried out in the step described in "FA. 1998 "EA FUEL HIGH PRESSURE REGULATOR INSTALLATION (1) Install the fuel high pressure regulator on the pump camshaft case <for CARISMA> or onto the spacer <for PAJERO io> and tighten the 3 bolts lightly (with somewhat larger torque than fingertight). <CARISMA> 4 2 1 3 Injector and Fuel Pump Assembly (GDI) <PAJERO io> 3 O-ring 1 2 4 Coupling key Groove Camshaft "CA PUMP CAMSHAFT CASE INSTALLATION (1) Apply small amount of engine oil to the O-ring (larger one) on the case. (2) Install the pump camshaft case onto the cylinder head while aligning the coupling keys of the case with the grooves in the rear end face of the camshaft. Backup ring Cut surface Backup ring E Mitsubishi Motors Corporation Dec.W) - (8) Tighten the fasteners of the delivery pipe and injector assembly to the specified torque in the order given in the illustration. Cut surface "DA FUEL PRESSURE SENSOR INSTALLATION (1) Install the backup ring to the fuel pressure sensor with its inside cut surface in the illustrated direction.

Deviation from the specification can cause problems such as leakage or the like.W) . 1998 PWEE9502-E Added . (3) Lubricate the O-rings on both ends of the pipe with spindle oil or gasoline. (5) Tighten the bolts at both ends of the pipe to the specified torque. 1) Tighten the bolts to 5 Nm in the order given in the illustration. <CARISMA> 1 3 4 Caution Strictly observe the specified tightening torque. and secure it temporarily with 4 bolts (tighten somewhat with a larger torque than fingertight). (6) Tighten the mounting bolts of the fuel pressure regulator to the specified torque. Note that the larger backup ring must be installed with the inside cut surface in the direction shown in the illustration.4G9 ENGINE (E . Note that the larger backup ring must be installed with the inside cut surface in the direction shown in the illustration. Be sure to insert the pipe fully to the stop using care not to twist it. Be sure to insert the pipe fully to the stop using care not to twist it. (7) Using a torque wrench having the minimum scale of 0. Cut surface Backup ring "FA FUEL PUMP / FUEL FEED PIPE INSTALLATION (1) Insert the fuel pump into the mounting hole in the pump camshaft case <for CARISMA> or in the cylinder head <for PAJERO io>.Injector and Fuel Pump Assembly (GDI) 11A-6c-5 (2) Fit the backup rings and the O-ring on both ends of the fuel return pipe. The torque variation among 4 bolts must be within 2 Nm. tighten the fuel pump mounting bolts in the following order. (5) Tighten the bolts at ends of the pipe to the specified torque. (3) Lubricate the O-rings on both ends of the pipe with spindle oil or gasoline. (4) Insert the fuel feed pipe ends straight in the respective mounting holes of the fuel and the delivery pipe. 2 <PAJERO io> 1 3 2 4 E Mitsubishi Motors Corporation Dec. (2) Fit the backup rings and the O-ring on both ends of the feed pipe. (4) Insert the fuel return pipe ends straight in the respective mounting holes of the pressure regulator and the delivery pipe. 2) Tighten the bolts to 17 Nm in the order given in the illustration.5 Nm.

Water outlet fitting 6.W) . Water hose "GA 3. Engine coolant temperature sensor "FA 4.11A-7-1 4G9 ENGINE (E . Engine coolant temperature gauge unit "EA 5. Thermostat Thermostat case O-ring Water inlet pipe O-ring Water pump Revised .Water Pump and Water Hose 7. Water hose (Except carburetor engines) 2. 10. WATER PUMP AND WATER HOSE 11301790016 REMOVAL AND INSTALLATION <SOHC> 10 Nm 29 Nm 1 3 4 24 Nm 8 2 7 6 14 Nm 9 14 Nm 5 24 Nm 14 Nm 10 14 Nm 11 12 Removal steps 1. 12. 8. 11. 9. Water inlet fitting E Mitsubishi Motors Corporation Nov. 1996 PWEE9502-B "DA "CA "BA "BA "BA "AA 7.

9. Water outlet fitting 6.11A-7-2 4G9 ENGINE (E . 10. Water hose A 2. 8.W) . Water hose B "GA 3. 11. 12. Water inlet fitting E Mitsubishi Motors Corporation May 1995 PWEE9502 "DA "CA "BA "BA "BA "AA 7. Engine coolant temperature gauge unit "EA 5. Engine coolant temperature sensor "FA 4. Thermostat Thermostat case O-ring Water inlet pipe O-ring Water pump .Water Pump and Water Hose REMOVAL AND INSTALLATION<DOHC> 10 Nm 29 Nm 1 3 4 24 Nm 8 2 7 6 14 Nm 9 24 Nm 14 Nm 5 14 Nm 10 14 Nm 11 12 Removal steps 1.

Engine coolant temperature gauge unit 3.Water Pump and Water Hose REMOVAL AND INSTALLATION <DOHC .W) . 10. 9. 8. 1998 PWEE9502-E "HA "BA "BA "CA "BA "BA "AA 5 7. Water outlet fitting 5. Water fitting 4. 11. Water inlet fitting 6.GDI for PAJERO io> 10 Nm 2 23 Nm 1 4 29 Nm 3 23 Nm 23 Nm 7 13 9 24 Nm 8 9 10 13 Nm 11 9 12 12 23 Nm 24 Nm 6 "GA "FA "IA "EA "DA Removal steps 1.11A-7-3 4G9 ENGINE (E . 13. 12. Engine coolant temperature sensor 2. Water by-pass fitting Water pipe O-ring Thermostat case Water pipe O-ring Water pump Revised . Thermostat E Mitsubishi Motors Corporation Dec.

Specified sealant: Mitsubishi Genuine Part No. Jiggle valve "EA WATER OUTLET FITTING INSTALLATION (1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG) to the location shown in the illustration. "CA THERMOSTAT CASE INSTALLATION (1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG) to the location shown in the illustration. 2. Secure the water pipe after the thermostat case has been installed. <SOHC. and then apply water to the O-ring to make installation easy.MD970389 or equivalent "BA WATER INLET PIPE <SOHC.W) . DOHC> / WATER PIPE <DOHC . Never apply any oil or grease to the O-ring. DOHC> or water pipe <DOHC . 1998 PWEE9502-E Part No.GDI for PAJERO io>.11A-7-4 4G9 ENGINE (E .GDI for PAJERO io> / O-RING INSTALLATION (1) Replace the O-ring of the water inlet pipe <SOHC.MD970389 or equivalent "DA THERMOSTAT INSTALLATION (1) Install the thermostat so that the jiggle valve is facing straight up. DOHC> Specified sealant: Mitsubishi Genuine equivalent E Mitsubishi Motors Corporation Dec.Water Pump and Water Hose INSTALLATION SERVICE POINTS "AA WATER PUMP INSTALLATION (1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG) to the location shown in the illustration. Caution 1.MD970389 or Revised . Specified sealant: Mitsubishi Genuine Part No.

1998 PWEE9502-E Part No. apply the specified sealant to the threads.W) .8660 or equivalent "GA ENGINE COOLANT TEMPERATURE SENSOR INSTALLATION (1) When reusing the sensor.MD970389 or "IA WATER FITTING INSTALLATION (1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG) to the location shown in the illustration. Specified sealant: Mitsubishi Genuine equivalent.GDI for PAJERO io> "FA ENGINE COOLANT TEMPERATURE GAUGE UNIT INSTALLATION (1) Apply the specified sealant to the threads. Specified sealant: 3M ATD Part No. Part No. Specified sealant: Mitsubishi Genuine equivalent.Water Pump and Water Hose <DOHC .MD970389 or Added . Specified sealant: 3M Nut Locking Part No.11A-7-5 4G9 ENGINE (E . E Mitsubishi Motors Corporation Dec.4171 or equivalent "HA WATER BY-PASS FITTING INSTALLATION (1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG) to the location shown in the illustration.

V. 13. 20. Rocker arms and rocker arm shaft EX E Mitsubishi Motors Corporation May 1995 PWEE9502 "BA "AA "BA "AA 11. 18. Breather hose 2. 16. Oil seal "DA 8. Oil filler cap 4. 12. 14. 7 Removal steps 1. hose 3. Oil seal "EA 7. 17.C. Rocker cover gasket 6.4G9 ENGINE (E . P. Rocker arms and rocker arm shaft IN 10. Rocker cover 5. Rocker arm B Rocker arm A Rocker arm shaft Adjusting screw Nut Rocker arm C Rocker arm shaft Adjusting screw Nut Camshaft . 19. 15. Rocker arm spring "CA 9.Rocker Arms and Camshafts 8.W) . ROCKER ARMS AND CAMSHAFTS 11A-8-1 11300540070 REMOVAL AND INSTALLATION <SOHC> 3 2 1 4 31 Nm 35 Nm 5 9 13 10 8 17 18 19 11 12 9 Nm 14 15 9 Nm 16 6 20 Apply engine oil to all moving parts before installation.

11A-8-2 4G9 ENGINE (E .W) . P. valve 4. 1998 10. Bearing cap "GA 12.V.Rocker Arms and Camshafts REMOVAL AND INSTALLATION <DOHC> 9 5 3 2 1 4 6 3. Exhaust camshaft 14. valve gasket 5. Rocker cover gasket A 8. Lash adjuster PWEE9502-E Revised . hose 3. Rocker cover 7. Rocker cover gasket B "JA 9.V. Oil filler cap "KA 6. Oil seal "HA 11.C. Rocker arm AA" "FA 15. P.C. P.C.V. Intake camshaft "GA 13. Breather hose 2.5 Nm 7 8 11 Nm 24 Nm 11 13 12 10 14 Apply engine oil to all moving parts before installation. Semi-circular packing E Mitsubishi Motors Corporation Dec. 15 Removal steps 1.

C.5 Nm 4 11 6 12 10 7 2 8 Apply engine oil to all moving parts before installation.V valve 4. P. 13 14 Removal steps 1. P. Rocker cover 7. P.V valve gasket 5.11A-8-1 2a 4G9 ENGINE (E . Gasket "JA 11. Oil seal "KA 9.C. Breather hose 2. Exhaust camshaft 13. Intake camshaft "JA 12.V hose 3. Rocker cover gasket E Mitsubishi Motors Corporation July 1997 "LA 8. Rocker arm 14.W) . Oil filler cap 6.5 Nm 9 5 3 3. Beam camshaft cap 10.Rocker Arms and Camshafts REMOVAL AND INSTALLATION <DOHC .GDI> 11 Nm 23 Nm 23 Nm 1 3.C. Lash adjuster PWEE9502-C Added .

11A-8-2 2b 4G9 ENGINE (E .W) .Rocker Arms and Camshafts Intentionally blank E Mitsubishi Motors Corporation July 1997 PWEE9502-C Added .

12.C. 1998 13 14 8.5 Nm 9 5 3 3.5 Nm 4 11 6 12 10 7 2 8 Apply engine oil to all moving parts before installation. Rocker cover 7.11A-8-3 4G9 ENGINE (E .V. "IA PWEE9502-E Oil seal Beam camshaft cap Gasket Intake camshaft Exhaust camshaft Rocker arm Lash adjuster Revised .W) .V.Rocker Arms and Camshafts REMOVAL AND INSTALLATION <DOHC . Removal steps 1. 13. 11. hose 3.C. 9. Oil filler cap 6.GDI for CARISMA> 11 Nm 21 Nm 21 Nm 1 3. P.C. 10. valve gasket 5. Breather hose 2. AA" "FA 14. Rocker cover gasket E Mitsubishi Motors Corporation Dec. P.V. valve 4. P.

AA" "FA 15. 14. Thrust case E Mitsubishi Motors Corporation Dec. Oil filler cap 5.GDI for PAJERO io> 11 Nm 21 Nm 3. 1998 15 9.C.11A-8-4 4G9 ENGINE (E . valve 3. PWEE9502-E O-ring Beam camshaft cap Gasket Intake camshaft Exhaust camshaft Rocker arm Lash adjuster Revised . Breather hose 2. "IA 10. P. Rocker cover 6. Oil seal 8. P. 11.V.5 Nm 2 1 10 3 8 9 5 4 11 13 12 6 7 14 Apply engine oil to all moving parts before installation. Removal steps 1. 13. valve gasket 4.V.Rocker Arms and Camshafts REMOVAL AND INSTALLATION <DOHC .W) . Rocker cover gasket 7.C. 12.

Timing belt side Chamfered side NOTE The rocker arm shaft for intake valves has eight oil holes. clean the lash adjuster. "DA ROCKER ARM SPRING INSTALLATION (1) Insert the rocker arm spring at an angle to the spark plug guide and then install it so that it is at a right angle to the guide. NOTE Move the rocker arms until they touch the rocker arm shaft mounting bosses on the cylinder head. 1998 PWEE9502-E Revised .) INSTALLATION SERVICE POINTS 1 mm or less "AA ADJUSTING SCREW INSTALLATION (1) Install provisionally the screw to the rocker arm.Rocker Arms and Camshafts 11A-8-5 REMOVAL SERVICE POINT AA" LASH ADJUSTER REMOVAL Caution D If the lash adjuster is re-used.4G9 ENGINE (E . (Refer to 11A-8-10. Oil holes "CA ROCKER ARMS AND ROCKER ARM SHAFT INSTALLATION (1) Move the rocker arms in the directions shown in the illustration before tightening the rocker arm shaft bolts. Insert it so that the end of the screw is flush with the edge of the rocker arm or projects slightly (1 mm or less). E Mitsubishi Motors Corporation Dec. (2) Install the shaft with the oil holes toward the cylinder head.W) . "BA ROCKER ARM SHAFT INSTALLATION (1) Place the end with the larger chamfered side toward the timing belt side.

Use care not to confuse the intake camshaft with the exhaust camshaft. Slit "GA CAMSHAFT INSTALLATION (1) Apply engine oil to the camshaft journals and cam before installing the camshaft. 8660 or equivalent E Mitsubishi Motors Corporation Dec.11A-8-6 4G9 ENGINE (E .) (1) Fit the lash adjuster onto the cylinder head using care not to allow diesel fuel to spill out. (Refer to 11A-8-10. Dowel pins (2) Apply sealant to the locations shown in the illustration. 1998 PWEE9502-E Revised . clean the lash adjuster. NOTE The rear end of the intake camshaft is provided with a 4 mm-wide slit.Rocker Arms and Camshafts "EA OIL SEAL INSTALLATION MD998713 "FA LASH ADJUSTER INSTALLATION Caution D If the lash adjuster is re-used. Journal "HA BEARING CAP INSTALLATION (1) Locate the camshaft dowel pins as illustrated.W) . Specified sealant: 3M ATD Part No.

2 through No.GDI for PAJERO io> Dowel pin Approx. <DOHC . 5 are of the same shape. <DOHC .GDI for CARISMA> Dowel pin <DOHC . 106_ Approx.GDI for PAJERO io> 3 mm Timing belt side Beam camshaft cap E Mitsubishi Motors Corporation Dec. MD970389 or Beam camshaft cap <DOHC .11A-8-7 4G9 ENGINE (E . IN or EX side identification (4) Make sure that the rocker arms are installed in the specified locations. 1998 PWEE9502-E Revised .W) .Rocker Arms and Camshafts (3) The bearing caps No. 150_ (2) Turn the crankshaft anticlockwise a quarter turn (90_).GDI for CARISMA only> (3) Apply a 3 mm thick continuous bead of sealant to the bottom surface of the beam camshaft cap along the groove. Identification mark (stamped on front and No.GDI for CARISMA> 3 mm Specified sealant: Mitsubishi Genuine equivalent Part No. 2 through No. <DOHC . check the cap number and the intake and exhaust identification marks. "IA BEAM CAMSHAFT CAP INSTALLATION (1) Locate the camshaft dowel pin as illustrated. Before they are installed. 5 bearing caps) L: Intake side R: Exhaust side Cap No.

M6 bolt 11Nm M8 bolt 21Nm <DOHC .GDI for PAJERO io> before the sealant applied becomes dry and hard. (7) Install the camshaft oil seal (use the special tool) and the thrust case <DOHC . The M8 bolt finished by glossy plating is reusable. MD970389 or equivalent <DOHC .GDI for PAJERO io> Engine front side (5) Install the beam camshaft cap before the sealant applied becomes dry and hard.GDI for PAJERO io> Engine front side MD998713 E Mitsubishi Motors Corporation Dec. PWEE9502-E Revised . Always replace such bolts with M8 bolts finished by glossy plating which are available separately.GDI for CARISMA> <DOHC . 1998 Caution The M8 bolts plated green cannot be reused.11A-8-8 4G9 ENGINE (E .Rocker Arms and Camshafts (4) Apply sealant to the illustrated position of the cylinder head upper surface. (8) Wipe off squeezed out excess sealant from the circumference of the beam camshaft cap. if the caps have already been assembled with such bolts. then reassemble the caps using them. (6) Tighten the bolts to the specified torque in the order shown in the illustration. <DOHC .W) .GDI for CARISMA> Specified sealant: Mitsubishi Genuine Part No.

and then tighten the lock nuts.09 mm Exhaust valve: 0.Rocker Arms and Camshafts 11A-8-9 "JA SEALANT APPLICATION ON SEMI-CIRCULAR PACKING Specified sealant: 3M ATD Part No. 1998 (2) The valve clearances at the places indicated by arrows in the illustration can be adjusted. PWEE9502-E Added .20 mm (1) Turn the crankshaft in the clockwise direction to align the camshaft sprocket timing marks and to set the No.4 cylinder to the compression top dead centre position. (4) Hold the adjusting screws with a screwdriver so that they do not turn.8660 or equivalent Timing mark VALVE CLEARANCE ADJUSTMENT Adjust the valve clearance by the following procedure. When No. Specified sealant: 3M ATD Part No. (6) Adjust the valve clearances indicated by arrows in the illustration by the same procedure as in steps (3) and (4) above.4 cylinder is at compression top dead centre E Mitsubishi Motors Corporation Dec.W) .1 cylinder is at compression top dead centre When No.1 cylinder to the compression top dead centre position. Adjustment values (when engine is cold): Intake valve: 0. (3) Use a thickness gauge to adjust the clearance between the ends of the valve stems and the adjusting screws. (5) Turn the crankshaft once in the clockwise direction to set the No.4G9 ENGINE (E .8660 or equivalent "KA SEALANT APPLICATION ON ROCKER COVER (1) Apply sealant to the areas indicated in the illustration.

(1) Prepare three containers and approximately five liters of diesel fuel.73 34.84 4G92.20 34.29 4G93. Diesel fuel E Mitsubishi Motors Corporation Dec. Then. NOTE Use a nylon brush if deposits are hard to remove. pour enough diesel fuel to completely cover a lash adjuster when it is standing upright.99 4G93.W) . Do not attempt to disassemble the lash adjusters.79 36.33 4G92.41 4G93.53 37.GDI*4 35.83 37. 1998 PWEE9502-E Added .DOHC.SOHC*1 37. perform the following steps with each lash adjuster.GDI*4 34. (2) Place the lash adjuster in container A and clean its outside surface.99 4G92. 2.49 34.DOHC.91 34. Into each container. 3.SOHC 37.SOHC*2 37.23 LANCER for Europe and CARISMA for Europe LANCER for general export and CARISMA for 6B model For CARISMA For PAJERO io LASH ADJUSTER Caution 1.33 4G93.GDI*3 36. Do not allow them to become contained by dirt or other foreign substances.Rocker Arms and Camshafts INSPECTION CAMSHAFT (1) Measure the cam height.DOHC 35.DOHC 35.03 4G93.DOHC.SOHC 37.34 36.78 37.SOHC*1 37.SOHC*2 37.DOHC.14 4G93.70 4G93.11A-8-10 4G9 ENGINE (E . The lash adjusters are precision-engineered mechanisms. Use only fresh diesel fuel to clean the lash adjusters.64 37. Standard value mm Intake side Exhaust side *1: *2: *3: *4: Outside cleaning A Inside cleaning B Filling with diesel fuel C Limit mm 4G92.83 37.GDI*3 34.28 4G93.49 34.

Rocker Arms and Camshafts MD998442 Diesel fuel 11A-8-11 (3) While gently pushing down the internal steel ball using special tool. Caution Do not use container C for cleaning. Caution The steel ball spring is extremely weak. gently push down the internal steel ball using special tool and move the plunger through five to ten strokes until it slides smoothly. Diesel fuel (7) Place the lash adjuster in container C. MD998442 Caution Make sure the oil hole in the side of the body is pointing toward container A. Diesel fuel (5) Place the lash adjuster in container B. push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber. move the plunger through five to ten strokes until it slides smoothly. so the lash adjuster’s functionality may be lost if the air bleed wire is pushed in hard. Then. push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber. Do not point the oil hole at yourself or other people. Then. If cleaning is performed in container C. 1998 PWEE9502-E Added . gently push down the internal steel ball using special tool.4G9 ENGINE (E . so the lash adjuster’s functionality may be lost if the air bleed wire is pushed in hard. MD998442 Diesel fuel Caution The steel ball spring is extremely weak. Do not point the oil hole at yourself or other people. NOTE If the plunger remains stiff or the mechanism appears otherwise abnormal. this operation will remove dirty oil. In addition to eliminating stiffness in the plunger. replace the lash adjuster.W) . MD998442 Diesel fuel E Mitsubishi Motors Corporation Dec. This operation will clean the lash adjuster’s pressure chamber. (6) Remove the lash adjuster from the container. MD998442 Caution Make sure the oil hole in the side of the body is pointing toward container A. Then. Then. (4) Removal the lash adjuster from the container. foreign matter could enter the pressure chamber when chamber is filled with diesel fuel.

(13)Place the lash adjuster in container C again. MD998440 Division = 1 mm (10)Set the lash adjuster on the special tool. then push the plunger downward firmly until it moves through its greatest possible stroke. Return the plunger slowly. perform the operation (7) through (9) again to fill it with diesel fuel completely. NOTE If lash adjuster contracts. then adjust the height as illustrated. check that the lash adjuster’s height matches that of a new lash adjuster. MD998442 E Mitsubishi Motors Corporation Diesel fuel Dec. (14)Stand the lash adjuster with its plunger at the top. Return the plunger slowly. Also. (12)After the plunger has moved downward slightly (0. then gently push down the internal steel ball using special tool.2 to 0. then push the plunger downward firmly until it moves through its greatest possible stroke.20 second/1 mm (with diesel fuel at 15 to 20_C) NOTE Replace the lash adjuster if the time measurement is out of specification. 1998 PWEE9502-E Added .Rocker Arms and Camshafts (8) Stand the lash adjuster with its plunger at the top. measure the time taken for it to move downward by a further 1 mm. Standard value: 3 .5 mm). then release the steel ball and allow the pressure chamber to fill with diesel fuel.11A-8-12 4G9 ENGINE (E . MD998442 Diesel fuel (9) Remove the lash adjuster from the container. Push the plunger firmly and check that it does not move. then release the steel ball and allow the pressure chamber to fill with diesel fuel.W) . Lash adjuster Lash adjuster Nut (11)Remove the bolt from the tester. then stand the lash adjuster with its plunger at the top. Replace the lash adjuster if it still contracts after performing these steps.

W) . Push the plunger firmly and check that it does not move. then stand the lash adjuster with its plunger at the top. E Mitsubishi Motors Corporation Dec. perform the operations (13) through (15) again to fill it with diesel fuel completely. 1998 PWEE9502-E Added . NOTE If lash adjuster contracts. Replace the lash adjuster if it still contracts after performing these steps. check the lash adjuster’s height matches that of a new lash adjuster. Fit the lash adjuster onto the engine as soon as possible.4G9 ENGINE (E .Rocker Arms and Camshafts 11A-8-13 (15)Remove the lash adjuster from the container. Also. (16)Stand the lash adjuster upright to prevent diesel fuel spilling out. Do not allow the lash adjuster to become contaminated by dirt or other foreign matter.

W) . Rocker cover gasket 6. 11. Oil seal "FA 7. ROCKER COVER AND CAMSHAFTS (MIVEC) REMOVAL AND INSTALLATION 9 Nm 11 Nm 3. 14. 10. Arm spring holder Camshaft bearing cap Arm spring Camshaft Camshaft holder Semi-circular packing Added . PCV hose 3.11A-8a-1 4G9 ENGINE (E . Breather hose 2. Oil control valve E Mitsubishi Motors Corporation Nov.Rocker Cover and Camshafts (MIVEC) 8a. 12. Rocker cover 5. 13. Oil seal "EA 8. Oil filler cap "GA 4.5 Nm 2 23 Nm 1 23 Nm 8 23 Nm 11 Nm 3 4 10 12 9 5 11 6 13 7 Apply engine oil to all moving parts before installation. 1995 "DA "DA "CA "BA "AA PWEE9502-A 9. 14 Removal steps 1.

41 35.33 Exhaust B 34.W) - Rocker Cover and Camshafts (MIVEC) INSPECTION 1.11A-8a-2 4G9 ENGINE (E .91 Intake B 33.74 4G92 DOHC. 1995 PWEE9502-A Added .24 33. OIL CONTROL VALVE (1) Connect a 12VDC power supply between terminals (1) and (2) of the oil control valve and check if the valve operates smoothly.83 35. replace the camshaft. 12 V Valve 2.58 33. If the specified limit is exceeded. Unit: mm A B A B A B A B Standard value Limit Intake A 36. CAMSHAFT (1) Measure the cam heights.08 Exhaust A 35.MIVEC E Mitsubishi Motors Corporation Nov.

(2) Set the No. 1 piston at the top dead center and install the camshafts with their cams for No. The exhaust-side camshaft is longer and has a slot in its rear end. 1 cylinder becomes the top dead center on the compression stroke. 1995 PWEE9502-A Added .4G9 ENGINE (E . Sealant Specified sealant: 3M ATD Part No. "BA CAMSHAFT HOLDER ASSEMBLY INSTALLATION (1) Apply the specified sealant to the area shown. 1 cylinder directed upward so that the No. Specified sealant: 3M ATD Part No. 8660 or equivalent.Rocker Cover and Camshafts (MIVEC) 11A-8a-3 INSTALLATION SERVICE POINTS Sealant "AA SEMI-CIRCULAR PACKING INSTALLATION (1) Apply the specified sealant to the area shown.W) . 8660 or equivalent "CA CAMSHAFT INSTALLATION (1) Ensure that the intake-side and exhaust-side camshafts are not reversed. Identification mark L1: Front bearing for exhaust camshaft R1: Front bearing for intake camshaft E Mitsubishi Motors Corporation Nov. "DA CAMSHAFT BEARING CAP / CAMSHAFT HOLDER INSTALLATION (1) Confirm the identification mark on each bearing cap to install the cap in the correct position.

Specified sealant: 3M ATD part No.W) - Rocker Cover and Camshafts (MIVEC) (2) Apply the specified sealant to the front and rear camshaft bearing caps at the positions shown. Specified sealant: 3M ATD Part No. Position the camshaft bearing caps and tighten their mounting bolts not numbered in the illustration. 1995 PWEE9502-A Added .11A-8a-4 4G9 ENGINE (E . 8660 or equivalent Sealant "FA OIL SEAL INSTALLATION MD998713 E Mitsubishi Motors Corporation Nov. Then tighten the remaining (numbered) bolts in the order shown in the illustration to install the bearing caps and camshaft holder to the cylinder head. 8660 or equivalent Sealant 9 5 1 3 7 13 14 11 12 6 2 4 8 10 Sealant Sealant "EA OIL CONTROL VALVE INSTALLATION (1) Apply the specified sealant to the area shown.

MB991477 (1) Inserting the special tool between one of two adjusting screws and the valve and adjust the clearance. Specified sealant: 3M ATD part No.W) .Rocker Cover and Camshafts (MIVEC) 11A-8a-5 "GA ROCKER COVER INSTALLATION Apply the specified sealant to the area shown. MB991479 E Mitsubishi Motors Corporation Nov. 8660 or equivalent VALVE CLEARANCE ADJUSTMENT Adjustment must be performed with the cylinder at the top dead center on the compression stroke. MB991478 MB991477 (2) Then adjust the other adjusting screw in the same way. 1995 PWEE9502-A Added .4G9 ENGINE (E . MB991478 ROCKER ARM PISTON INSPECTION (1) Screw in the special tool to the rocker arm piston for high speed side rocker arm and check that the piston can be lifted up lightly by hand.

Rocker Arms and Rocker Shaft Caps (MIVEC) 11A-8b-1 8b. ROCKER ARMS AND ROCKER SHAFT CAPS (MIVEC) REMOVAL AND INSTALLATION 4 5 10 5 6 4 6 4 5 8 7 9 6 4 5 8 6 7 9 7 8 9 7 8 3 9 2 1 2 Apply engine oil to all moving parts before installation. 8. Seal cap “B” 4. PWEE9502-A Intake rocker arm assembly “A” Spring guide Wave washer Exhaust rocker arm assembly “A” Camshaft holder Added . Rocker shaft cap 2. 7. Spring guide 5. Wave washer E Mitsubishi Motors Corporation Nov. "AA 9.W) . 10. 11 Nm Removal steps 1. 1995 "AA 6.4G9 ENGINE (E . Seal cap “A” 3.

Identification marks: E: Intake I: Exhaust E Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Added .11A-8b-2 4G9 ENGINE (E .W) Timing belt side Identification mark Rocker Arms and Rocker Shaft Caps (MIVEC) INSTALLATION SERVICE POINT "AA ROCKER ARM ASSEMBLY INSTALLATION (1) Install the rocker arm assemblies while checking the identification marks at the positions shown to ensure that the intake and exhaust sides are not reversed.

Removal steps AA" "DA 1. 20. AC" "AA 12. CYLINDER HEAD AND VALVES 11300690072 REMOVAL AND INSTALLATION <SOHC> 8 9 1 10 14 15 4 5 6 2 17 12 13 16 20 19 18 11 7 3 Lubricate all internal parts with engine oil during reassembly. Cylinder head gasket AB" "CA 4. Valve spring E Mitsubishi Motors Corporation May 1995 11. 13.Cylinder Head and Valves 9. 19. Cylinder head assembly 3. 18. Valve spring retainer "BA 6. Retainer lock 9. Valve spring retainer "BA 10. Cylinder head bolt 2. Retainer lock 5. Exhaust valve AB" "CA 8. Valve spring 7. PWEE9502 Intake valve Valve stem seal Valve spring seat Valve stem seal Valve spring seat Exhaust valve guide Intake valve guide Exhaust valve seat Intake valve seat Cylinder head . 16. AC" "AA 14.11A-9-1 4G9 ENGINE (E .W) . 17. 15.

20. Cylinder head assembly 4. Cylinder head gasket AB" "CA 5. Removal steps "EA 1. 21. 16. AC" "AA 15. AC" "AA 13. Valve spring E Mitsubishi Motors Corporation May 1995 12. Exhaust valve AB" "CA 9.W) . 14. 19.11A-9-2 4G9 ENGINE (E . 17. Valve spring retainer "BA 11. PWEE9502 Intake valve Valve stem seal Valve spring seat Valve stem seal Valve spring seat Exhaust valve guide Intake valve guide Exhaust valve seat Intake valve seat Cylinder head . Valve spring retainer "BA 7. Valve spring 8.Cylinder Head and Valves REMOVAL AND INSTALLATION <DOHC> 3 2 1 10 Nm 5 6 21 7 13 14 17 9 10 11 15 16 18 19 8 20 12 4 Lubricate all internal parts with engine oil during assembly. Cylinder head bolt 3. Oil pressure switch AA" "DA 2. Retainer lock 10. Retainer lock 6. 18.

Valve stem seal 16. Valve spring AD" 8. Retainer lock 10. Exhaust valve seat 21. Cylinder head bolt 3.11A-9-3 4G9 ENGINE (E . Intake valve guide 18. Oil pressure switch AA" "DA 2. Cylinder head assembly 4. Valve spring retainer "BA 11. Valve stem seal 14. Retainer lock 6. Valve spring retainer "BA 7. Valve spring seat AC" "AA 15.Cylinder Head and Valves REMOVAL AND INSTALLATION <DOHC . Valve spring E Mitsubishi Motors Corporation Nov.MIVEC> 3 1 10 Nm 2 9 10 11 15 16 18 21 5 6 7 13 14 17 20 12 19 8 4 Apply engine oil to all moving parts before installation.W) . Valve spring seat 17. Intake valve seat 20. Intake valve AB" "CA 9. 1995 AD" 12. Cylinder head PWEE9502-A Revised . Removal steps "EA 1. Cylinder head gasket AB" "CA 5. Exhaust valve AC" "AA 13. Exhaust valve guide 19.

Cylinder Head and Valves REMOVAL AND INSTALLATION <DOHC . Retainer lock 9. Valve spring retainer "BA 6. Intake valve guide 17. Removal steps AA" "DA 1. Exhaust valve guide 18. Valve spring E Mitsubishi Motors Corporation July 1997 AD" 11. Valve stem seal 13. Cylinder head bolt 2. Cylinder head gasket AB" "CA 4. Exhaust valve seat 20. Exhaust valve AC" "AA 12. Valve stem seal 15. Cylinder head assembly 3.GDI> 1 2 4 5 6 12 13 8 9 10 14 15 17 20 16 19 11 18 7 3 Apply engine oil to all moving parts before installation. Valve spring AD" 7. Cylinder head PWEE9502-C Added . Retainer lock 5.11A-9-4 3a 4G9 ENGINE (E . Valve spring retainer "BA 10. Intake valve seat 19. Intake valve AB" "CA 8. Valve spring seat 16. Valve spring seat AC" "AA 14.W) .

W) .4G9 ENGINE (E .Cylinder Head and Valves 11A-9-5 3b Intentionally blank E Mitsubishi Motors Corporation July 1997 PWEE9502-C Added .

springs and other parts. tagged to indicate their cylinder No. 1995 PWEE9502-A Revised .W) . and location to aid reassembly. MIVEC MD998772 MD998784 MD998735 E Mitsubishi Motors Corporation Nov.11A-9-4 4G9 ENGINE (E . MIVEC MB991653 Except MIVEC MD998772 AB" RETAINER LOCK REMOVAL (1) Store the removed valves. DOHC.Cylinder Head and Valves REMOVAL SERVICE POINTS SOHC MB991653 AA" CYLINDER HEAD BOLT REMOVAL (1) Loosen the cylinder head bolts using the special tool.

Put a broken valve in the water-filled container and quickly get away from the container at least 2 or 3 m (6.) E Mitsubishi Motors Corporation Nov. It must be handled with utmost care because otherwise the following dangerous conditions may result: Loss of eyesight if sodium gets in eyes.Cylinder Head and Valves 11A-9-5 AC" VALVE STEM SEAL REMOVAL AD" VALVE HANDLING PRECAUTIONS (1) Sodium reacts violently with water or moisture generation heat and liberating hydrogen. and discard the valves in the same way as ordinary valves. Wear rubber gloves and goggles. When worn exhaust valves are to be discarded. Burns if sodium contact skin. Should the exhaust valves be broken. Never try to break the valves and expose sodium to the air. (2) Handling of Sodium-filled Exhaust Valves Sodium-filled exhaust valves are not dangerous and may be handled in the same way as ordinary valves unless they are broken. Fire hazard. 1995 PWEE9502-A Revised . (3) How to Neutralize Sodium Place a container filled with more than 10 liters of water in a well ventilated large space.6 or 10 ft. neutralize sodium using the method described below. and carefully take out broken valves from the cylinder head. have them disposed of by a salvage company equipped with special disposal system.4G9 ENGINE (E .W) . notifying them that the valves contain sodium.

and receive medical attention. INSTALLATION SERVICE POINTS SOHC "AA VALVE STEM SEAL INSTALLATION (1) Install the vale spring seat. take the valves out of the container with large tweezers or the like. Improper installation could result oil leaking past the valve guide. (2) Use the special tool to install the valve stem seal.Cylinder Head and Valves Caution D Valves must be neutralized one at a time. In such a case. DOHC MD998775 E Mitsubishi Motors Corporation Nov. D Should it get in the eyes. D Put a valve in the container only after sodium in the preceding one has completely reacted with water. The resulting hydrogen gas is highly explosive. MD998774 Caution Do not reuse removed valve stem seals. wait until hydrogen gas in released and remaining sodium reacts with water. 1995 PWEE9502-A Revised . When the reaction has finished (there is no more generation of hydrogen gas). Keep fire away from the container during the neutralization. NOTE The reaction occurs when water enters the cavity in the valve. temporarily blocking the water passage. When it contacts the skin. wash with ample amounts of clean water. water in the container contains sodium hydroxide and is highly alkaline. After the neutralization of sodium. Hydrogen gas may be trapped inside the valve. The water solution should be disposed of according to local regulations. immediately flush them with clean water thoroughly.W) . Caution D Do not let the solution contact the eyes or the skin.11A-9-6 4G9 ENGINE (E .

96.4G9 ENGINE (E .4 mm (2) Install the washers as illustrated.W) . 1995 PWEE9502-A Revised . causes the bottom end of retainer to be in contact with the stem seal. MIVEC MD998772 MD998784 MD998735 "DA CYLINDER HEAD BOLT INSTALLATION (1) When installing the cylinder head bolts. Shank length E Mitsubishi Motors Corporation Nov.Cylinder Head and Valves Spring retainer Painted end 11A-9-7 "BA VALVE SPRING INSTALLATION (1) Install the valve spring with the painted end on the rocker arm side. Stem seal Spring seat Except MIVEC MD998772 "CA RETAINER LOCK INSTALLATION (1) The valve spring. replace the bolts. and damage it. if excessively compressed. If the limit is exceeded. check that the shank length of each bolt meets the limit. Limit: Max. (3) Apply engine oil to the bolt threads and washers.

If the bolt is overtightened. Specified sealant: 3M ATD Part No. Oil passage E Mitsubishi Motors Corporation Nov. proper fastening performance may not be expected.Cylinder Head and Valves Timing belt side 8 6 1 3 10 4 2 5 9 7 Caution 1.11A-9-8 4G9 ENGINE (E . Pain mark "EA SEALANT APPLICATION TO OIL PRESSURE SWITCH (1) Apply sealant to the threads of the switch. When tightening the bolt. (7) Make paint marks on the cylinder head bolt heads and cylinder head. be careful to give a sufficient turn to it. therefore. (8) Give a 90_ turn to the cylinder head bolts in the specified tightening sequence. 90_ 90_ (4) According to the tightening sequence. 2. If the bolt is turned less than 90_. (6) Retighten the loosened bolts to a torque of 20 Nm in the specified tightening sequence.W) . (5) Loosen all bolts fully. loosen the bolt completely and then retighten it by repeating the tightening procedure from step (1). 1995 PWEE9502-A Revised . (9) Give another 90_ turn to the cylinder head bolts and make sure that the paint mark on the head of each cylinder head bolt and that on the cylinder head are on the same straight line. tighten the bolts to the specified torque 74 Nm. 8660 or equivalent Caution Use care not to allow the sealant to plug the oil passage.

37 DOHC.Cylinder Head and Valves INSPECTION CYLINDER HEAD (1) Check the cylinder head gasket surface for flatness by using a straightedge and thickness gauge.9 .GDI 104.8 .20 DOHC 103. Valve should make a uniform contact with the seat at the centre of valve face. Standard value mm Intake Exhaust E Mitsubishi Motors Corporation July 1997 PWEE9502-C Limit mm SOHC 110.11A-9-9 4G9 ENGINE (E . replace the valve.15 109.GDI 103.63 115. correct to meet the specification.70 113.120.2 0.GDI> Valve seat contact Margin VALVE (1) Check the valve face for correct contact.2 mm (2) If the service limit is exceeded.9 .7 (3) Measure the overall height of the valve.65 DOHC 104.03 mm Limit: 0.87 103. replace the valve.13 DOHC.87 103. Standard value mm Intake Exhaust Limit mm 1.132.69 DOHC.MIVEC> 131.W) .3 0.132. Grinding limit:*0.2 mm *Includes/combined with cylinder block grinding Cylinder head height (Specification when new): 119. Standard value: 0.19 103.9 .0 0.5 SOHC 1.0 mm <DOHC . reface using a valve refacer.63 115.1 mm <SOHC> 131.1 mm <DOHC> 119.13 DOHC.MIVEC 115.1 mm <DOHC .69 SOHC 113. If the specified limit is exceeded. If incorrect. (2) If the margin is smaller than the service limit.8 DOHC 1.37 Revised .120.MIVEC 115.19 103.

35 49. then measure the valve stem projection between the end of the valve stem and the spring seating surface.0 DOHC.11A-9-10 4G9 ENGINE (E .MIVEC 51.5 DOHC.04 .63 DOHC.20 DOHC. Standard value: Intake: 0. DOHC.02 . Standard value mm Free height Limit mm SOHC 50.10 mm Exhaust: 0.9 49. replace the spring.70 47.MIVEC.15 mm E Mitsubishi Motors Corporation Dec. If the limit is exceeded.15 SOHC 49.09 mm <SOHC.65 47.0.GDI 46.70 47.9 DOHC 45. Standard value: 2_ or less Limit: 4_ Valve stem end Valve stem projection VALVE SEAT (1) Assemble the valve. If the measurement exceeds the specified limit.0.65 47. Spring seating surface Standard value mm Intake Exhaust Limit mm SOHC 49. or both.W) .0 44. If the measurement exceeds the specified limit.GDI for CARISMA> 0.35 DOHC.GDI 44.05 mm Exhaust: 0. DOHC.0.8 43.5 50. If the measurement is less than specified. replace the spring. DOHC.06 mm <DOHC .05 .80 DOHC 46.MIVEC 58.85 58.Cylinder Head and Valves Out of square VALVE SPRING (1) Measure the valve spring’s free height.30 49.GDI for PAJERO io> Valve guide Limit: Intake: 0.13 58.8 (2) Measure the squareness of the spring. replace the valve seat.20 VALVE GUIDE (1) Measure the clearnace between the valve guide and valve stem.15 DOHC. 1998 PWEE9502-E Revised .MIVEC 57.85 DOHC 46.GDI 46. replace the valve guide or valve.

to prevent the cylinder head bore from galling.30 .50 O.25 O.29.33 0. Valve guide hole diameters 0. VALVE GUIDE REPLACEMENT (1) Force the valve guide out toward the cylinder block using a press.80 .60 .80 .32. (4) Correct the valve seat to the specified width and angle.W) .10 .83 0.: 11.6 O.13 <DOHC>: 34. remove the valve seat. replace the valve and/or valve guide.0 mm Valve seat height Intake valve seat hole diameter 0. VALVE SEAT REPLACEMENT PROCEDURE (1) Cut the valve seat to be replaced from the inside to thin the wall thickness.4G9 ENGINE (E .3 mm 0.5 .3 O.30 .10 .S.: 11.07 0.05 . <SOHC>: 29.62 <DOHC>: 31. (2) Rebore the valve seat hole in the cylinder head to a selected oversize valve seat diameter. <SOHC>: 31.13 mm mm mm mm Oversize valve seat hole diameter (3) Before fitting the valve seat.60 .34.1.63 mm mm mm mm Exhaust valve seat hole diameter 0. correct the valve seat to achieve the specified seat width and angle.S.83 <DOHC>: 34. If necessary.9 . either heat the cylinder head up to approximately 250_C or cool the valve seat in liquid nitrogen.1.Cylinder Head and Valves 0.S.11. (2) Machine the valve guide hole in the cylinder head to the size of the oversize valve guide to be installed.3 O.11.S.50 .9 .30. 0.5 . <SOHC>: 29.0 mm Cut away 0. <SOHC>: 32.: 11.31.S. check the clearance between the valve guide and valve.1. (3) After correcting the valve seat.52 E Mitsubishi Motors Corporation July 1997 PWEE9502-C in cylinder head mm mm mm Revised .11.S. Then.31.S.05 O. Then. Caution Do not use the valve guide of the same size as the removed one.32 <DOHC>: 30.6 O. (2) Using the appropriate special tool or seat grinder.25 .29.3 mm 65_ 65_ 15_ 15_ 44_ 44_ 11A-9-11 VALVE SEAT RECONDITIONING PROCEDURE (1) Before correcting the valve seat. check the valve stem projection (refer to VALVE SEAT in INSPECTION).34.1. lap the valve and valve seat using lapping compound.27 0.

W) . E Mitsubishi Motors Corporation Nov. insert a new valve to check for smooth sliding motion. DOHC: 19 mm) as shown in the illustration.Cylinder Head and Valves (3) Press-fit the valve guide until it protrude specified value (SOHC: 14 mm. Valve guide for intake valve and that for exhaust valve are different in length. (45.11A-9-12 4G9 ENGINE (E . 1995 PWEE9502-A Added . Caution 1.5 mm for exhaust valve) Protrusion (4) After the valve guide has been installed. 50. Press the valve guide from the cylinder head top surface.5 mm for intake valve. 2.

Oil pan 6. 14. Oil pressure switch "EA 2. Relief plug E Mitsubishi Motors Corporation May 1995 "CA "BA AC" "AA AC" "AA PWEE9502 9.W) . 10. Oil filter 3. 11. FRONT CASE AND OIL PUMP REMOVAL AND INSTALLATION <SOHC> 10 Nm 14 12 13 1 15 16 10 Nm 7 6 19 Nm 10 9 11 8 44 Nm 14 Nm 2 3 7 Nm 39 Nm 4 5 Apply engine oil to all moving parts before installation. 15.4G9 ENGINE (E . Drain plug gasket AA" "DA 5. Oil screen gasket 8.Front Case and Oil Pump 11A-10-1 10. Removal steps "FA 1. Drain plug 4. 13. Relief spring Relief plunger Oil seal Oil pump case O-ring Oil pump case cover Outer rotor Inner rotor . Oil screen 7. 12. 16.

13. Oil screen 9. Relief plug Relief spring Relief plunger Oil seal Oil pump case O-ring Oil pump case cover Outer rotor Inner rotor Revised . "FA "EA AB" "DA "DA Removal steps 1. 1998 "CA "BA AC" "AA AC" "AA PWEE9502-D 10. Baffle plate <For CARISMA. Upper oil pan 7. SPACE STAR only> 6. Lower oil pan 8.11A-10-2 4G9 ENGINE (E . 12. 11. Oil screen gasket E Mitsubishi Motors Corporation Jun.Front Case and Oil pump REMOVAL AND INSTALLATION <DOHC> 10 Nm 10 Nm 14 16 15 17 18 1 6 9 8 19 Nm 7 Nm 5 12 11 10 13 14 Nm 2 7 Nm 44 Nm 3 4 39 Nm 24 Nm 7 Nm 7 Apply engine oil to all moving parts before installation. 16. Drain plug 4. Oil filter 3. Drain plug gasket 5. Oil pressure switch 2.W) . 17. 15. 14. 18.

17.11A-10-3 4G9 ENGINE (E . 14.Front Case and Oil pump REMOVAL AND INSTALLATION <DOHC . 18. Drain plug 4. 10 Nm 10 Nm 15 17 14 1 9 8 16 6 18 19 Nm 13 12 14 Nm 11 24 Nm 10 7 Nm 7 Nm 44 Nm 5 7 2 4 7 Nm 3 7 Nm 39 Nm "FA "EA AB" "DA "DA Removal steps 1. 13. 15. Oil pressure switch 2. Cover 6. Drain plug gasket 5. Lower oil pan 8.W) . Upper oil pan 7. Oil filter 3. 12. Relief plug Relief spring Relief plunger Oil seal Oil pump case O-ring Oil pump case cover Outer rotor Inner rotor Revised .GDI for PAJERO io> Apply engine oil to all moving parts before installation. Oil screen gasket E Mitsubishi Motors Corporation Dec. 16. Oil screen 9. 1998 "CA "BA AC" "AA AC" "AA PWEE9502-E 10. 11.

MD970389 or Revised . Specified sealant: Mitsubishi Genuine equivalent Dec.W) .Front Case and Oil Pump MD998727 REMOVAL SERVICE POINTS AA" OIL PAN REMOVAL (1) Knock in the special tool deeply between the oil pan and the cylinder block. AB" REMOVAL OF UPPER OIL PAN (1) At first remove the bolt (Length: 121 mm <DOHC. Caution Never use the special tool (oil pan remover). and the remove the other bolts. Alignment dots AC" OUTER ROTOR/INNER ROTOR REMOVAL (1) Make alignment dots on the outer and inner rotors for reference in reassembly. etc. (2) Hitting the side of the special tool. Then.11A-10-4 MD998727 4G9 ENGINE (E . DOHC. 116 mm <DOHC .GDI for PAJERO io>) which is nearest to flywheel. 1998 PWEE9502-E Part No. slide the special tool along the oil pan to remove the oil pan. INSTALLATION SERVICE POINTS Alignment dots "BA SEALANT APPLICATION TO OIL PUMP CASE 3 mm diameter bead sealant E Mitsubishi Motors Corporation "AA INNER ROTOR/OUTER ROTOR INSTALLATION (1) Apply engine oil to the rotors.GDI for CARISMA>. install the rotors ensuring that the alignment dots made at disassembly are properly aligned.

MD998717 Oil pump case MD998717 Crankshaft Guide Oil seal "DA OIL PAN/UPPER OIL PAN/LOWER OIL PAN INSTALLATION (1) Remove all the remaining gasket from the mating surfaces using a scraper or a wire brush.W) . Bolt hole portion LOWER OIL PAN <DOHC-GDI for PAJERO io> Groove portion E Mitsubishi Motors Corporation Bolt hole portion Dec. OIL PAN. See “Form-In-Place Gasket” in “SPECIFICATIONS”.Front Case and Oil Pump "CA CRANKSHAFT FRONT OIL SEAL INSTALLATION Using the special tool. (2) Apply a 4 mm diameter bead of sealant to the oil pan flange. knock the oil seal into the oil pump case.11A-10-5 4G9 ENGINE (E . 1998 PWEE9502-E Revised . DOHC. DOHC . UPPER OIL PAN Groove portion Bolt hole portion LOWER OIL PAN <SOHC.GDI for CARISMA> 4 mm diameter bead sealant Groove portion Specified sealant: Mitsubishi Genuine equivalent Part No. MD970389 or (3) Install the oil pan within 15 minutes after applying the sealant.

Oil passage INSPECTION 11300730026 OIL PUMP (1) Check the tip clearance.0. 8660 or equivalent Caution Use care not to allow the sealant to plug the oil passage.18 mm E Mitsubishi Motors Corporation Dec.W) . DOHC. (3) Screw in the oil filter until its O-ring comes in contact with the base.06 . <DOHC . Then tighten one more turn.11A-10-6 4G9 ENGINE (E . "FA SEALANT APPLICATION TO OIL PRESSURE SWITCH (1) Apply sealant to the threads of the switch. (2) Apply engine oil to the O-ring of the oil filter.Front Case and Oil Pump <SOHC. DOHC . 1998 PWEE9502-E Added .GDI for PAJERO io> "EA OIL FILTER INSTALLATION (1) Clean the filter installation surface of the cylinder block.GDI for CARISMA> (4) Tighten the lower oil pan mounting bolts in the sequence shown in the illustration. Standard value: 0. Specified sealant: 3M ATD Part No.

1998 PWEE9502-E Added . Standard value: 0. Standard value: 0.0.35 mm E Mitsubishi Motors Corporation Dec.Front Case and Oil Pump 11A-10-7 (2) Check the side clearance.4G9 ENGINE (E .0.10 mm (3) Check the body clearance.18 mm Limit: 0.04 .W) .10 .

4G9 ENGINE (E . Piston and connecting rod 5. 2 "BA 8. Piston ring No. Connecting rod 12. 6 7 8 9 4 10 12 11 5 3 2 1 "GA AA" "FA "EA "DA "EA "CA Removal steps 1. Piston pin 10. Piston 11.Piston and Connecting Rod 11. Connecting rod cap 3. Piston ring No. Nut 2. Oil ring AB" "AA 9. 1 E Mitsubishi Motors Corporation May 1995 "CA 7. PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION Lubricate all internal parts with engine oil during reassembly. Bolt PWEE9502 11A-11-1 . Connecting rod bearing 4.W) . Connecting rod bearing 6.

(2) Place the piston and connecting rod assembly on the Piston Pin Setting Base (special tool) with the front mark facing upward. Guide B Guide A: 18.Piston and Connecting Rod REMOVAL SERVICE POINTS Cylinder number Piston pin setting tool: MD998780 Guide A: 17.9 mm Push rod Front mark Front mark (1) Insert the Push Rod (special tool) into the piston from the side on which the front mark is stamped in the piston head.9 mm Guide C Guide A: 20. Guide D Base E Mitsubishi Motors Corporation Nov. piston pins and connecting rods in order according to the cylinder number. 1995 PWEE9502-A Revised . NOTE Keep the disassembled pistons. AB" PISTON PIN REMOVAL Piston pin setting tool (MD998780) consists of the parts shown in the illustration at left. (3) Using a press.9 mm Base Guide A: 21. Guide D (MB991659) is also used in combination with the Piston pin setting tool. and attach the guide D to the push rod end. remove the piston pin.9 mm Push rod AA" CONNECTING ROD CAP REMOVAL (1) Mark the cylinder number on the side of the connecting rod big end for correct reassembly.W) .11A-11-2 4G9 ENGINE (E . To remove the piston pin.

A: Piston pin insertion hole length B: Distance between piston bosses C: Piston pin length D: Connecting rod small end width (2) Calculate the following formula by substituting the measured value.C) .Piston and Connecting Rod 11A-11-3 INSTALLATION SERVICE POINTS C D Connecting rod Piston Piston pin A B (7) Screw the guide B into the guide A until the gap between both guides amounts to the value L obtained in step (2) plus 3 mm. piston pin and connecting rod.14.D))/2 (3) Insert the Push Rod (special tool) into the piston pin and attach the guide A to the push rod end.500 .700 N Front mark Guide A Base Guide B E Mitsubishi Motors Corporation May 1995 PWEE9502 . (4) Assemble the connecting rod in the piston with their front marks facing the same direction. push rod and guide A assembly having assembled in step (3) from the guide A side into the piston pin hole on the front marked side. 3 mm + L Guide B Guide A Push rod Piston pin Front mark "AA PISTON PIN INSTALLATION (1) Measure the following dimensions of the piston.(B . L = ((A . (9) Press-fit the piston pin using a press. (6) Insert the piston pin. (8) Place the piston and connecting rod assembly onto the piston setting base with the front marks directed upward. Standard value: 4. If the press-fitting force required is less than the standard value.4G9 ENGINE (E . (5) Apply engine oil to the entire periphery of the piston pin.W) . replace the piston and piston pin set or/and the connecting rod.

2/PISTON RING NO. Identification mark: No. unlike other piston rings. "CA PISTON RING NO. Caution Do not use piston ring expander when installing side rail. The side rails and spacer may be installed in either direction. 50 No. Side rail NOTE 1.00 mm O.1 0. (3) Make sure that the side rails move smoothly in either direction.S. Spacer Side rail end Size Identification colour Standard size None 0. then press the remaining portion into position by finger as shown in the illustration. install the piston rings with their side having identification marks facing up.W) .S. 2.50 mm O.00 mm O.S. Identification mark “T” Identification mark “2T” E Mitsubishi Motors Corporation Size mark Size Size mark Standard size None No. first fit one end of the rail into the piston groove.2 1. To install the side rail.2 ring: 2T NOTE The piston ring is stamped with the following size mark.1 ring: T No. New spacer and side rail are painted with the following identification colour according to the size. Install the upper side rail.1 INSTALLATION (1) Using piston ring expander. 100 May 1995 PWEE9502 . Yellow 3.S. Blue 1.Piston and Connecting Rod "BA OIL RING INSTALLATION (1) Fit the oil ring spacer into the piston ring groove. Use of piston ring expander to expand the side rail end gap can break the side rail.50 mm O.11A-11-4 4G9 ENGINE (E . and then install the lower side rail.

2 No. identification mark "EA CONNECTING ROD BEARING INSTALLATION (1) When the bearings are to be replaced. insert the piston and connecting rod assembly into the cylinder block.W) .4 No.3 No.D.D.1 ring Piston pin No. piston ring and oil ring.Piston and Connecting Rod Upper side rail No. identification mark Crankshaft journal O.4G9 ENGINE (E . select correct ones according to the identification marks stamped in the crankshaft. (2) Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in the illustration. (3) Face the front mark (arrow) on the top of the piston toward the camshaft sprocket. identification mark Identification mark (service part) Identification colour (Line production part) 1 S1 Brown 2 S2 Black 3 S3 Green Identification mark Identification colour E Mitsubishi Motors Corporation May 1995 PWEE9502 .2 ring and spacer 11A-11-5 "DA PISTON AND CONNECTING ROD INSTALLATION (1) Liberally coat engine oil on the circumference of the piston. Crankshaft Connecting rod bearing Pin O.D.1 Check digit Crank pin O. No. Lower side rail (4) Using a suitable piston ring compressor tool. Caution Do not strike the piston into the cylinder block because the piston ring or crank pin will be damaged.

apply engine oil to the thread portion and bearing surface of the nut.0. If the nut does not run down smoothly. "FA CONNECTING ROD CAP INSTALLATION (1) Mate the correct bearing cap with the correct connecting rod by checking with the alignment marks marked during disassembly. Then tighten the nuts alternately to install the cap properly.25 mm Limit: 0. be sure to remove the spark plugs. Standard value: 0.Piston and Connecting Rod Cylinder No.W) . If the bolt threads are “necked down”. the bolts should be examined BEFORE reuse. (1) Since the connecting rod cap bolts and nuts are torqued using the plastic area tightening method. the bolt should be replaced. (3) Install each nut to the bolt and tighten it with fingers. Notches (2) Check if the thrust clearance in the connecting rod big end is correct. If a new connecting rod has no alignment mark.11A-11-6 4G9 ENGINE (E .4 mm "GA CONNECTING ROD CAP NUT INSTALLATION Caution If the cylinder head has been installed before installing the connecting rod cap nut. position the notches for locking the bearing on the same side. Necking can be checked by running a nut with fingers to the full length of the bolt threads. (2) Before installation of each nut. (4) Tighten the nuts to a torque of 20 Nm.10 . E Mitsubishi Motors Corporation May 1995 PWEE9502 . the bolt should be replaced.

If the limit is exceeded.1: 0. (7) Give a 90_ to 100_ turn to the nut and make sure that the paint mark on the nut and that on the bolt are in alignment.8 mm Oil: 1.0. If the ring gap is excessive. or both. If the nut is overtightened (exceeding 100_). measure the end gap with a thickness gauge.02 .2: 0.07 mm No.2: 0.1: 0.60 mm DOHC: 0.10 . 2. loosen the nut completely and then retighten it by repeating the tightening procedure from step (1). INSPECTION 11300850074 PISTON RING (1) Check the clearance between the piston ring and ring groove.W) .40 mm No. to correctly position it at right angles to the cylinder wall.2: 0. be careful to give a sufficient turn to it. therefore. the piston crown being in contact with the ring.Piston and Connecting Rod Paint mark Paint mark 90_ . If the nut is turned less than 90_.0. replace the ring or piston. replace the piston ring. Push in by the piston Piston ring Standard value: No.20 .03 .1 mm No. (6) Make a paint mark on the bolt end at the position 90_ to 100_ from the paint mark made on the nut in the direction of tightening the nut.55 mm Piston ring gap Oil: SOHC: 0.25 . Caution 1. No.40 .35 mm Limit: No.1.2: 0.100_ Nut Bolt 11A-11-7 (5) Make a paint mark on the head of each nut.0 mm E Mitsubishi Motors Corporation May 1995 PWEE9502 .0.0. proper fastening performance may not be expected.06 mm Limit: No. Force the ring down with a piston. Standard value: No.1: 0.4G9 ENGINE (E .0. When tightening the nut.1 mm Install the piston ring into the cylinder bore. Then.0.

(3) Install the connecting rod cap carefully and tighten the bolts to specified torque.Piston and Connecting Rod CRANKSHAFT PIN OIL CLEARANCE (PLASTIGAGE METHOD) (1) Remove oil from crankshaft pin and connecting rod bearing.05 mm Limit: 0.02 . (2) Cut the Plastigage to the same length as the width of bearing and place it on crankshaft pin in parallel with its axis.11A-11-8 4G9 ENGINE (E .1 mm E Mitsubishi Motors Corporation May 1995 PWEE9502 .0.W) . (5) Measure the width of the Plastigage at its widest part by using a scale printed on the Plastigage package. (4) Carefully remove the connecting rod cap. Plastigage Standard value: 0.

4G9 ENGINE (E - W) - Crankshaft, Cylinder Block, Flywheel and Drive Plate

11A-12-1

12. CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE
PLATE
REMOVAL AND INSTALLATION
M/T <engines with conven-

22 Nm

11

22

tional flywheel>

11 Nm

14
24

1

13
2

98 Nm

M/T <engines with
flexible flywheel>

21 11 Nm
12

23

3

20

5 4
19

7
18
9 Nm

6 A

98 Nm

A/T

17
8
9

16

10

15

Apply engine oil to
all moving parts
before installation.

9 Nm

"FA
"FA

"FA

"EA
"DA

Removal steps
1. Flywheel bolt
2. Flywheel
3. Flywheel bolt
4. Plate
5. Adapter plate
6. Flywheel
7. Adapter plate
8. Drive plate bolt
9. Adapter plate
10. Drive plate
11. Rear plate
12. Bell housing cover <SOHC>
13. Rear oil seal case
14. Oil seal

98 Nm

"CA
"CA
"BA
"BA
"BA
AA" "AA

15. Baffle plate
<DOHC- MIVEC and DOHC - GDI>
16. Bearing cap bolt
17. Bearing cap
18. Crankshaft bearing, lower
19. Crankshaft
20. Thrust plate
21. Crankshaft bearing, upper
22. Knock sensor
<DOHC- MIVEC and DOHC - GDI>
23. Oil jet
<DOHC- MIVEC and DOHC - GDI>
24. Cylinder block

Caution
On the flexible wheel equipped engines, do not remove any of the bolts “A” of the flywheel shown
in the illustration.
The balance of the flexible flywheel is adjusted in an assembled condition. Removing the bolt,
therefore, can cause the flexible flywheel to be out of balance, giving damage to the flywheel.
E Mitsubishi Motors Corporation

July 1997

PWEE9502-C

Revised

11A-12-1a

4G9 ENGINE (E - W) - Crankshaft, Cylinder Block, Flywheel and Drive Plate

REMOVAL AND INSTALLATION <DOHC - GDI for PAJERO io>
2
11 Nm
22 Nm

16

1

9
17

8

98 Nm

4

7
3

11 Nm

98 Nm

15
6
5
14
13
12

Apply engine oil to
all moving parts
before installation.

11
10

Removal steps
"FA 1. Flywheel bolt <M/T>
2. Flywheel <M/T>
"FA 3. Drive plate bolt <A/T>
4. Adopter plate <A/T>
5. Drive plate <A/T>
6. Crankshaft adaptor <A/T>
7. Rear plate
"EA 8. Rear oil seal case
"DA 9. Oil seal

E Mitsubishi Motors Corporation

Dec. 1998

"CA 10. Bearing cap bolt
"CA 11. Bearing cap
"BA 12. Crankshaft bearing, lower
13. Crankshaft
"BA 14. Thrust plate
"BA 15. Crankshaft bearing, upper
16. Knock sensor
17. Cylinder block

PWEE9502-E

Added

4G9 ENGINE (E - W) - Crankshaft, Cylinder Block, Flywheel and Drive Plate

11A-12-1b

Intentionally blank

E Mitsubishi Motors Corporation

Dec. 1998

PWEE9502-E

Added

Cylinder Block.W) . E Mitsubishi Motors Corporation Nov. Flywheel and Drive Plate REMOVAL SERVICE POINT AA" OIL JET REMOVAL (1) Knock out the oil jets using an appropriate metal rod. 2 No. drive in the oil jet to the crankshaft journal until it seats to the bottom. 4 No.D. 2. Be careful not to scratch the cylinder wall. select correct ones and install them in the correct positions according to the identification marks stamped on the crankshaft and the top surface of the cylinder block. Crankshaft journal Cylinder Crankshaft bearing block bearing bore Identification mark Identification mark Identification mark (service parts) Identification colour (Line production parts) 1 0 1 Brown 1 2 Black 2 3 Green 0 2 Black 1 3 Green 2 4 Yellow 0 3 Green 1 4 Yellow 2 5 Pink* 2 3 *: Older bearings may be marked in red. 5 No.5 mm diameter pin punch. INSTALLATION SERVICE POINTS "AA OIL JET INSTALLATION (1) Using a 4.Crankshaft.D. 3 No.11A-12-2 4G9 ENGINE (E . identification mark "BA CRANKSHAFT BEARING INSTALLATION (1) When the bearings are to be replaced. Caution 1. identification mark Journal O. Do not reuse the removed oil jets. 1 Crank pin O. Check digit No. 1995 PWEE9502-A Revised .

replace the bolt. 71. 4 No. (4) Tighten the bearing cap bolts to 25 Nm torque in the tightening sequence. (2) When installing the bearing cap bolts.Crankshaft. 3 upper bearing with the grooved side towards the crank web. If the limit is exceeded.D.W) . 2 No. 1 IdentificaNo. (8) (7) (4) (1) (5) (9) (3) (2) (6) (10) Arrow E Mitsubishi Motors Corporation Nov.4G9 ENGINE (E .1 mm Length of shank (3) Apply engine oil to the threaded portion and bearing surface of the bolt. Serial No.D. Cylinder Block. Identification colour Identification colour "CA BEARING CAP/BEARING CAP BOLT INSTALLATION (1) Install the bearing caps so that their arrows are positioned on the time belt side. Front Oil groove Grooves Identification colour Identification mark (2) Install the bearings having an oil groove to the cylinder block. (4) Install the thrust bearings at the No. Limit: max. check that the shank length of each bolt meets the limit. Flywheel and Drive Plate 11A-12-3 No. support identification section mark I. 1995 PWEE9502-A Revised . 5 tion mark for cylinder block bearing Cylinder I. 3 No. (3) Install the bearings having no oil groove on the bearing caps.

(6) Make a paint mark on the area around the bolt bearing surface at location 90_ to 100_ in the direction of tightening the bolt. make sure that the crankshaft turns smoothly and the end play is correct. Standard value: 0. Make sure that the paint mark on the bolt and that on the area around the bolt bearing surface are in alignment. as referenced from the paint mark on the bolt head. proper fastening performance may not be expected. 2.11A-12-4 4G9 ENGINE (E .25 mm Limit: 0. Flywheel and Drive Plate Paint marks Paint marks 90_ . Caution 1. (8) After installing the bearing caps. When tightening the nut. replace crankshaft bearings.Crankshaft. Cylinder Block.05 . (7) Give a 90_ to 100_ turn to the bolts in the tightening sequence. be careful to give a sufficient turn to it. If the end play exceeds the limit. MD970389 or Revised . If the nut is overtightened (exceeding 100_).4 mm "DA OIL SEAL INSTALLATION MB990938 MD998776 "EA SEALANT APPLICATION TO OIL SEAL CASE Specified sealant: Mitsubishi Genuine equivalent E Mitsubishi Motors Corporation Nov. loosen the nut completely and then retighten it by repeating the tightening procedure from step (1). therefore.0. If the nut is turned less than 90_. 1995 PWEE9502-A Part No.W) .100_ (5) Make a paint mark on the head of each bolt.

(2) Install the crankshaft.Crankshaft.02 . (6) Measure the width of the Plastigauge at its widest part by using a scale printed on the Plastigauge package.0. (3) Cut the Plastigauge to the same length as the width of bearing and place it on the journal in parallel with its axis. INSPECTION Plastigauge CRANKSHAFT JOURNAL OIL CLEARANCE (PLASTIGAUGE METHOD) (1) Remove oil from the crankshaft journal and he crankshaft bearing. E Mitsubishi Motors Corporation Nov. If defects are evident. check the block top surface for warpage. Make sure that the surface is free from gasket chips and other foreign matter. Standard value: 0. (2) Apply engine oil to the flange of bolt.W) . (3) Apply engine oil into the thread holes of crankshaft. 4171 or equivalent (5) Tighten the bolts to specified torque. Standard value: 0. Cylinder Block. Grinding limit: 0. 1995 PWEE9502-A Revised .1 mm (2) If the distortion is excessive. Specified sealant: 3M Nut Locking Part No. (4) Apply specified sealant to the thread of bolts. Cylinder block height (when new): 243.05 mm or less Limit: 0.5 mm <4G92> 263. Flywheel and Drive Plate 11A-12-5 "FA DRIVE PLATE BOLT/FLYWHEEL BOLT INSTALLATION (1) Remove all the ramaining sealant from bolts and thread holes of crankshaft.1 mm Plastigauge CYLINDER BLOCK (1) Using a straightedge and thickness gauge. (4) Install the crankshaft bearing cap carefully and tighten the bolts to the specified torque.2 mm The total thickness of the stock allowed to be removed from cylinder block and mating cylinder head 0.04 mm Limit: 0.2 mm at maximum.5 mm <4G93> (3) Check the cylinder walls for scratches and seizure. correct (bored to oversize) or replace. (5) Carefully remove the crankshaft bearing cap.4G9 ENGINE (E . correct within the allowable limit or replace.

02 mm (honing margin) (4) Bore all cylinders to the calculated boring finish dimension. (3) Based on the measured piston O. measure the cylinder bore and cylindricity. and cylinder.00 .D.D. Size Identification mark 0. 2.01 mm or less 12 mm Centre Bottom BORING CYLINDER (1) Oversize pistons to be used should be determined on the basis of the largest bore cylinder. Cylinder Block. calculate the boring finish dimension. 1. Caution To prevent distortion that may result from temperature rise during honing.00 mm O.W) . + clearance between piston O. 3.) (6) Check the clearance between piston and cylinder.81. bore cylinders. Measure it in thrust direction as shown.11A-12-6 4G9 ENGINE (E . 1995 PWEE9502-A Revised . and cylinder) . No.00 NOTE Size mark is stamped on the piston top. Piston size identification Thrust direction Piston O.03 mm Out-of-roundness and taper of cylinder bore: 0. + (Clearance between piston O.S.Crankshaft. 4. A B Standard value: Cylinder inner diameter: 81.0.0. Do not bore only one cylinder to an oversize. Clearance between piston and cylinder: 0.D. in the order of No.02 . correct the cylinder to an oversize and replace the piston and piston rings. Boring finish dimension = Piston O.1 and No. (5) Hone to the final finish dimension (Piston O. Flywheel and Drive Plate (4) Using a cylinder gauge.. If worn badly.D. (2) Measure outside diameter of piston to be used.D. 0.D.S.50 mm O. Measure at the points shown in illustration. finish all of four cylinders to the same oversize.04 mm NOTE When boring cylinders. E Mitsubishi Motors Corporation Nov.50 1. No.

Cylinder Block. replace the flywheel assembly. A If judged unendurable for reuse. Limit: 9 mm Dowel pin 4ME0273 (4) Check the friction surface for runout in the following manner. replace the flywheel assembly. Runout Dowel pin Limit: 0. (5) Apply a thrust force of approx. 1998 PWEE9502-E Added . If the limit is exceeded.W) .Crankshaft. and determine whether it is serviceable or not in accordance with the criteria given in the following table.75 mm Flywheel 4ME0274 E Mitsubishi Motors Corporation Dec. (3) Turn the flywheel clockwise and anticlockwise to measure the distance over which the dowel pin moves freely. Flywheel and Drive Plate 11A-12-7 HYDRO-FLYWHEEL <DOHC . 4ME0272 Flywheel Distance moved Color Purple Judgment Reusable Dark blue Light blue Gray Not reusable (2) Measure the play in the circumferential direction using the following procedure.4G9 ENGINE (E .GDI for PAJERO io> (1) Check the rear side of the flywheel for color of the hatched area A in the illustration. and measure the runout at the dowel pin position. 98 N by hand on the flywheel to move it in the axial direction.

NOTES .