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Mitsubishi 4G6 and 4G6 EW Engine Factory Workshop Repair Manual
Mitsubishi 4G6 and 4G6 EW Engine Factory Workshop Repair Manual
ENGINE
4G6 SERIES (E–W)
WORKSHOP MANUAL
FOREWORD
FILING INSTRUCTION
Please keep these manual pages in the binder
No. BN940001.
File these pages according to the signs
“Added”, “Revised” and “Deleted” on the “List
of effective pages” which are interpreted
below.
Added:
File the pages with this sign additionally in
your manual.
Revised, Deleted:
Replace the existing pages with the
corresponding pages with this sign.
D Reassembly steps:
Specified in case reassembly is impossible
in reverse order of disassembly steps.
Omitted if reassembly is possible in reverse
order of disassembly steps.
Indicates the Indicates the Indicates the Indicates the Indicates the
group title. section title. group number. section num- page number.
ber.
15
3 4
11 Nm
5
13 Nm
11 15
17
12 Nm
14 Nm
14 Nm
Removal steps
1. Water hose 9. Water pump
2. Water hose 10. Water pump gasket
"CA 3. Engine coolant temper- 11. Oil level gauge
ature gauge unit 12. Oil level gauge guide
4. Water inlet fitting 13. O-ring
5. Thermostat 14. Intake manifold stay
"BA 6. Thermostat housing 15. Intake manifold
"AA 7. Water inlet pipe 16. Intake manifold gasket
"AA 8. O-ring 17. Engine hanger Operating procedures, cau-
tions, etc. on removal, installa-
Water pipe INSTALLATION SERVICE POINTS tion, disassembly and reas-
"AA WATER PIPE/O-RING INSTALLATION sembly are described.
(1) Wet the O-ring (with water) to facilitate assembly.
Caution
D Keep the O-ring free of oil or grease.
O-ring 6EN0594
11A-3a-3 and 11A-3a-4 C Jun. 2000 11A-10-1 and 11A-10-2 C Jun. 2000
11A-4-1 and 11A-4-2 D Mar. 2001 11A-10-3 to 11A-10-7 A Aug. 1998
11A-4-2a D Mar. 2001 11A-10-8 E Mar. 2002 Revised
11A-4-2b C Jun. 2000 11A-10-9 and 11A-10-10 A Aug. 1998
11A-4-3 and 11A-4-4 A Aug. 1998 11A-11-1 to 11A-11-4 Dec. 1996
11A-4-5 C Jun. 2000 11A-11-5 A Aug. 1998
11A-4-5a D Mar. 2001 11A-11-6 E Mar. 2002 Revised
11A-4-5b E Mar. 2002 Revised 11A-11-7 and 11A-11-8 Dec. 1996
11A-4-6 E Mar. 2002 Revised 11A-12-1 C Jun. 2000
11A-4-7 D Mar. 2001 11A-12-1a C Jun. 2000
11A-4-8 to 11A-4-12 A Aug. 1998 11A-12-1b D Mar. 2001
11A-4-13 to 11A-4-15 D Mar. 2001 11A-12-2 and 11A-12-3 E Mar. 2002 Revised
11A-4a-1 and 11A-4a-2 C Jun. 2000 11A-12-4 D Mar. 2001
11A-5-1 to 11A-5-3 C Jun. 2000 11A-12-5 to 11A-12-7 A Aug. 1998
ENGINE
4G6 SERIES
CONTENTS
Number of cylinders 4
Compression ratio 10
SOHC-4G64
Descriptions Specifications
Number of cylinders 4
Compression ratio 10
GDIt
Descriptions Specifications
Number of cylinders 4
NOTE
GDI is a trademark of Mitsubishi Motors Corporation.
*1: GDI-V
Timing belt
Auto-tensioner rod projection length mm 12 -
Auto-tensioner rod pushed-in amount [when pushed with a force of 98 1.0 or less -
- 196 N] mm
Rocker arms and camshaft
Valve thickness to valve guide clearance SOHC Intake 0.02 - 0.05 0.10
mm
Exhaust 0.03 - 0.07 0.15
GDI 294/40.0 -
GDI 6.6 -
Oversize rework dimensions of valve guide 0.05 Oversize diameter 11.05 - 11.07 -
hole (SOHC) mm
0.25 Oversize diameter 11.25 - 11.27 -
Oversize rework dimensions of valve guide 0.05 Oversize diameter 12.05 - 12.07 -
hole (GDI) mm
0.25 Oversize diameter 12.25 - 12.27 -
Intake oversize rework dimensions of valve 0.3 Oversize diameter 34.30 - 34.33 -
seat hole (SOHC) mm
0.6 Oversize diameter 34.60 - 34.63 -
Intake oversize rework dimensions of valve 0.3 Oversize diameter 35.30 - 35.33 -
seat hole (GDI) mm
0.6 Oversize diameter 35.60 - 35.63 -
Oil pressure at curb idle speed kPa [Oil temperature is 75 to 90_C] 78 or more -
4G64 86.5 -
4G64 290 -
4G64 86.5 -
Cylindricity mm 0.01 -
TORQUE SPECIFICATIONS
Items Nm
Adjusting bolt 5
Lock bolt 23
Alternator brace 23
Crankshaft pulley 25
Spark plug 25
Distributor (Carburetor) 12
Vacuum pipe 11
Throttle body 11
EGR valve 23
Intake manifold 19
Items Nm
Timing belt
Tensioner arm 22
Tensioner puller 48
Auto tensioner 23
Idler pulley 35
Tensioner “B” 18
Plug cap 32
Engine hanger 11
Carburetor 17
Throttle body 18
Cover (Carburetor) 12
EGR valve 22
Items Nm
Clamp A 8.8
Fuel pipe 11
Fuel fitting 12
Injector holder 22
Engine hanger 11
Thermostat housing 24
Water pump 14
Intake manifold 19
Engine hanger 11
Items Nm
Thermostat housing 23
Water pump 13
Knock sensor 22
Exhaust manifold
Heat protector 13
Oil pipe 11
Cover 9.8
Items Nm
Drain plug 39
Oil screen 18
Relief plug 44
Plug 23
Flange bolt 36
Front case 23
Rear plate 11
SEALANTS
Item Specified sealant Quantity
Cam position sensor support Mitsubishi Genuine Part No. MD970389 or As required
equivalent
Engine coolant temperature sensor 3M Nut Locking Part No. 4171 or equivalent As required
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Engine coolant temperature gauge unit 3M ATD Part No. 8660 or equivalent As required
FORM-IN-PLACE GASKET
The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket
fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead
size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick
a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the
fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to
apply the gasket evenly without a break, while observing the correct bead size.
The FIPG used in the engine is a room temperature vulcanisation (RTV) type and is supplied in a 100-gram
tube (Part No. MD970389). Since the RTV hardens as it reacts with the moisture in the atmospheric
air, it is normally used in the metallic flange areas. The FIPG, Part No. MD970389, can be used for
sealing both engine oil and coolant, while Part No. MD997110 can only be used for engine oil sealing.
Disassembly
The parts assembled with the FIPG can be easily disassembled without use of a special method. In
some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking
with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the
joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.
For removal of the oil pan, the special tool “Oil Pan Remover” (MD998727) is available. Be sure to use
the special tool to remove the oil pan. <Except aluminium die-cast oil pans>
Surface Preparation
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure
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that there are no oils, greases and foreign substances deposited on the application surfaces. Do not
forget to remove the old sealant remained in the bolt holes.
MB991603 Silent shaft bearing Guide stopper for removal and installation of
puller stopper counterbalance shaft rear bearing
Use with MD998372.
MB991654 Cylinder head bolt Removal and installation of cylinder head bolt
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wrench (12)
MD998162 Plug wrench Removal and installation of front case cap plug
Use with MD998783.
MD998285 Crankshaft front oil Guide for installation of crankshaft front oil seal
seal guide Use with MD998375.
MD998443 Lash adjuster Retainer for holding lash adjuster in rocker arm
holder at time of removal and installation of rocker
shaft assembly
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6
12 Nm
25 Nm 7
10
4
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5 Nm 9
3
44 Nm
23 Nm 2
23 Nm
9 Nm 5
25 Nm
1
Removal steps
1. Drive belt
2. Water pump pulley
3. Alternator brace
4. Alternator
5. Crankshaft pulley
6. Spark plug cable
7. Spark plug
8. High tension cable
"BA 9. Distributor assembly
10. O-ring
10 Nm
7
5 Nm
10 Nm
12 6
9 10
25 Nm 8
11
4
22 Nm
5 Nm
3
14 Nm
ProCarManuals.com
44 Nm
r
23 Nm
2
23 Nm
9 Nm 5
25 Nm
1
Removal steps
1. Drive belt 8. Spark plug
2. Water pump pulley 9. Camshaft position sensor
3. Alternator brace "AA 10. Camshaft position sensing support
4. Alternator 11. Camshaft position sensing cylinder
5. Crankshaft pulley 12. Ignition failure sensor
6. Spark plug cable (Vehicle for Europe)
7. Ignition coil assembly
5 Nm
9.8 Nm
13 10
8.8 Nm
11
25 Nm 15
12
8 16
49 Nm
6 14
5 Nm
7
5 Nm
1
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23 Nm 8.8 Nm
4 5
23 Nm
13 Nm
3
25 Nm
9
Removal steps
1. Oil level gauge 10. Earth strap (From 2001 model
2. Oil level gauge guide SPACE RUNNER and From 2001
3. O-ring model SPACE WAGON)
4. Drive belt 11. Ignition coil
5. Water pump pulley 12. Spark plug
6. Alternator 13. Ignition failure sensor (From 2001
7. Alternator brace (Up to 2000 model model GALANT for Europe)
SPACE RUNNER and Up to 2000 14. Ignition failure sensor (From 2001
model SPACE WAGON) model SPACE RUNNER for Europe
8. Alternator brace (GALANT for Eu- and From 2001 model SPACE
rope and From 2001 model WAGON for Europe)
SPACE RUNNER and From 2001 15. Cam position sensor
model SPACE WAGON) 16. O-ring
9. Crankshaft pulley
8.8 Nm 8.8 Nm 2 11 Nm
3
11 Nm
8.8 Nm 4 11 Nm
16
12
5
14
13 11
7
6
1 8.8 Nm
23 Nm
23 Nm 17 19 Nm
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15 18
11 Nm 10
30 Nm 19
19 Nm
8.8 Nm
30 Nm
8
Removal steps
1. Vacuum pipe and hose "DA 7. Throttle body gasket
(1999 model vehicles for Hong "CA 8. Intake manifold stay
Kong) "BA 9. Air intake plenum resonator
2. Solenoid valve (1999 model ve- 10. Gasket
hicles for Hong Kong) 11. Water hose
3. Vacuum pipe and hose 12. EGR valve
(Vehicles for Europe and 2000 13. Gasket
model vehicles for Hong Kong) "AA 14. Hose clamp
4. Solenoid valve "AA 15. EGR support
(Vehicles for Europe and 2000 "AA 16. Gasket
model vehicles for Hong Kong) 17. Gasket
5. Vacuum pipe 18. Intake manifold
6. Throttle body 19. Gasket
8.8 Nm
8.8 Nm
2
8
11 Nm
9
11 3
23 Nm 4 19 Nm
13
23 Nm
5
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10
14 15
12
16
7
19 Nm
30 Nm
11 Nm
8.8 Nm
Removal steps
1. Vacuum pipe and hose 9. EGR valve
2. Solenoid valve 10. Gasket
3. Throttle body "AA 11. Hose clamp
"DA 4. Throttle body gasket "AA 12. EGR support
"CA 5. Intake manifold stay "AA 13. Gasket
"BA 6. Air intake plenum resonator 14. Gasket
7. Gasket 15. Intake manifold
8. Water hose 16. Gasket
20 Nm
11 Nm
1
5
9 Nm
6
7
11 11 Nm
3
12 8.8 Nm
15 2
13
23 Nm
4
23 Nm 16
19 Nm
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14
10 17
11 Nm
30 Nm 18
19 Nm
9
8.8 Nm
30 Nm
8
Removal steps
1. Vacuum pipe and hose 10. Gasket
2. Solenoid valve 11. Water hose
3. Throttle body 12. EGR valve
"DA 4. Throttle body gasket 13. Gasket
5. Vacuum pipe "AA 14. EGR support
6. Throttle body fitting "AA 15. Gasket
7. Throttle body fitting gasket 16. Gasket
"CA 8. Intake manifold stay 17. Intake manifold
9. Air intake plenum resonator 18. Gasket
Air intake
plenum
resonator
Projection
20
45 Nm
45 Nm
18
17
16
15
18 Nm
14
13 23
88 Nm
5
19
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22
7 21
22 Nm
1
48 Nm 9 Nm
49 Nm
12
6 49 Nm
14 Nm 4 3
10
8 11
9
23 Nm 54 Nm
11 Nm 35 Nm 162 ± 5 Nm
9 Nm 2
Removal steps
1. Timing belt front upper cover AE" "GA 12. Crankshaft sprocket
2. Timing belt front lower cover "GA 13. Flange (Multipoint fuel injection)
3. Power steering bracket "GA 14. Flange (Carburetor)
4. Crankshaft position sensor 15. Tensioner “B”
(Multipoint fuel injection) AF" "FA 16. Timing belt “B”
AA" "KA 5. Timing belt AG" "EA 17. Counterbalance shaft sprocket
"JA 6. Tensioner pulley "DA 18. Spacer
7. Tensioner arm AH" "OA 19. Crankshaft sprocket “B”
"IA 8. Auto tensioner "CA 20. Engine support bracket
9. Idler pulley AI" "AA 21. Camshaft sprocket bolt
AC" "HA 10. Oil pump sprocket 22. Camshaft sprocket
AD" "GA 11. Crankshaft bolt 23. Timing belt rear cover
22 25 3.4 Nm
1
6
48 Nm 7
23 26
24
27
23 Nm
13 8
2 23 Nm
31
11 Nm
12
11 Nm
162 ± 5 Nm
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49 Nm 11 Nm
9 Nm 32
5 18
30 45 Nm 3
17 4
88 Nm 18 Nm
28
29 15
33 10
48 Nm 20
19 8.8 Nm
16
14 49 Nm
9
11
54 Nm
Removal steps
1. Front upper cover "DA 18. Spacer
2. Front lower cover AH" "OA 19. Crankshaft sprocket “B”
3. Power steering pump bracket stay 20. Crankshaft key
4. Power steering bracket 21. Breather hose
AB" "LA 5. Timing belt 22. PCV hose
"JA 6. Tensioner pulley 23. PCV valve
7. Tensioner arm 24. PCV valve gasket
"IA 8. Auto tensioner 25. Oil filler cap
9. Idle pulley 26. Rocker cover
10. Crankshaft angle sensor 27. Rocker cover gasket
AC" "HA 11. Oil pump sprocket "CA 28. Engine support bracket
AD" "GA 12. Crankshaft bolt AJ" "BA 29. Camshaft sprocket bolt
AE" "GA 13. Crankshaft sprocket 30. Camshaft sprocket
"GA 14. Flange 31. Timing belt rear right cover
15. Tensioner “B” 32. Timing belt rear left upper cover
AF" "FA 16. Timing belt “B” 33. Timing belt rear left lower cover
AG" "EA 17. Counterbalance shaft sprocket
25 3.4 Nm
1 22
6
48 Nm 7
23 26
24
27
23 Nm
8
13 23 Nm
2
34
11 Nm
12
162 ± 5 Nm
11 Nm
ProCarManuals.com
49 Nm 11 Nm
9 Nm 35
5
31 45 Nm 18 3
33
17 4
88 Nm 18 Nm
32 Nm 28
30 15
29
36
32 20
19
88 Nm
16 10
14 8.8 Nm 49 Nm
9 11
48 Nm 54 Nm
Removal steps
1. Front upper cover AH" "OA 19. Crankshaft sprocket “B”
2. Front lower cover 20. Crankshaft key
3. Power steering pump bracket stay 21. Breather hose
4. Power steering bracket 22. PCV hose
AB" "LA 5. Timing belt 23. PCV valve
"JA 6. Tensioner pulley 24. PCV valve gasket
7. Tensioner arm 25. Oil filler cap
"IA 8. Auto tensioner 26. Rocker cover
9. Idle pulley 27. Rocker cover gasket
10. Crankshaft position sensor "CA 28. Engine support bracket
AC" "HA 11. Oil pump sprocket AK" "NA 29. Plug cap
AD" "GA 12. Crankshaft bolt AL" "MA 30. V.V.T. sprocket bolt
AE" "GA 13. Crankshaft sprocket "MA 31. V.V.T. sprocket
"GA 14. Flange AJ" "BA 32. Camshaft sprocket bolt
15. Tensioner “B” 33. Camshaft sprocket
AF" "FA 16. Timing belt “B” 34. Timing belt rear right cover
AG" "EA 17. Counterbalance shaft sprocket 35. Timing belt rear left upper cover
"DA 18. Spacer 36. Timing belt rear left lower cover
E Mitsubishi Motors Corporation Mar. 2001 PWEE9616-D Revised
ProCarManuals.com 11A-4-2b 4G6 ENGINE (E - W) - Timing Belt
Intentionally blank
Counter-
Sharp balance
edge shaft
Timing
marks
(6) Lock the flywheel or drive plate using the special tool.
(7) Tighten the crankshaft bolt to the specified torque of 162
± 5 Nm.
6EN0564
6AE0049
Intentionally blank
6AE0050
6EN0350
ProCarManuals.com
Small holes
6EN1323
6EN1327
6EN0899
Timing mark
(2) Align the timing mark on the intake side camshaft sprocket
with that on the rocker cover.
NOTE
Even if the timing marks on the sprocket and the cover
are brought into alignment, the intake camshaft is forced
to turn one tooth in the clockwise direction by the valve
spring tension and stabilized there.
6EN1327
6EN1327
(7) Fit the timing belt over the exhaust side camshaft sprocket,
and secure it at the illustrated position using a paper
clip.
(10)Fit the timing belt over the idler pulley, oil pump sprocket
and crankshaft sprocket in this order.
NOTE
Be careful that the belt does not become slack.
Oil pump
sprocket
Crankshaft
sprocket
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Crankshaft
(12)Turn the crankshaft pulley a little in the illustrated direction
sprocket to pull up the timing belt at the idler pulley side.
(13)Check to ensure that the timing marks on the crankshaft
sprocket, oil pump sprocket and exhaust camshaft
sprocket are all offset one tooth from the corresponding
timing marks in the counterclockwise direction.
INSPECTION
TIMING BELT
Replace belt if any of the following conditions exist.
(1) Hardening of back rubber.
Back side is glossy without resilience and leaves no indent
when pressed with fingernail.
AUTO TENSIONER
12 mm (1) Check the auto tensioner for possible leaks and replace
as necessary.
(2) Check the rod end for wear or damage and replace as
necessary.
(3) Measure the rod protrusion. If it is out of specification,
replace the auto tensioner.
Standard value: 12 mm
6EN0161
98 to 196 N (4) Press the rod with a force of 98 to 196 N and measure
its protrusion.
(5) If the measured value is 1 mm or more shorter than the
Movement value obtained in step (3), replace the auto tensioner.
6EN1033
11 Nm
29 Nm
5
4
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49 Nm
29 Nm
3
13 Nm
49 Nm
13 Nm
2 1
Removal steps
1. Exhaust manifold cover (Vehicle for Europe)
2. Exhaust manifold (Vehicle for Europe)
3. Exhaust manifold (Vehicle for Hong Kong)
4. Exhaust manifold gasket
5. Engine hanger
11 Nm
29 Nm
8
7
49 Nm
13 Nm
29 Nm
ProCarManuals.com
13 Nm
4
35 Nm
1 13 Nm
3 2
49 Nm
Removal steps
1. Engine hanger (SPACE RUNNER and SPACE WAGON)
2. Exhaust manifold cover (Vehicle for Europe)
3. Exhaust manifold (Vehicle for Europe)
4. Exhaust manifold cover (SPACE WAGON for Hong Kong)
5. Exhaust manifold bracket (SPACE WAGON for Hong Kong)
6. Exhaust manifold (SPACE WAGON for Hong Kong)
7. Exhaust manifold gasket
8. Engine hanger (GALANT)
17 Nm
2 22 Nm
6 23 Nm
4
1 9
ProCarManuals.com
3
12 Nm
Removal steps
1. Fuel hose 6. Gasket
2. Fuel hose 7. EGR valve (With EGR valve)
3. Fuel vapor separator 8. Cover (Without EGR valve)
4. Water hose 9. Gasket
5. Carburetor
10
18 Nm
9 Nm 5
9
13
14
12 2
15
11 3
8
ProCarManuals.com
9 Nm
16
9 Nm
Removal steps
1. Vacuum hose and pipe assembly "BA 9. Fuel pressure regulator
2. Throttle body 10. O-ring
"CA 3. Throttle body gasket 11. Insulator
4. EGR valve (With EGR valve) "AA 12. Injectors
5. Cover (Without EGR valve) 13. O-ring
6. EGR valve gasket 14. Grommet
7. Injectors and delivery pipe 15. Delivery pipe
8. Insulator 16. Solenoid valve assembly
9 Nm
9 Nm
1
2
8
22 Nm
12 Nm
6
7 17 18 Nm
15 5
16
14 3
12
13 4
11
9 Nm
ProCarManuals.com
10
9
9 Nm
18
Removal steps
1. Vacuum hose and pipe assembly 10. Insulator
2. Vacuum hose and pipe assembly "BA 11. Fuel pressure regulator
3. Throttle body 12. O-ring
"CA 4. Throttle body gasket 13. Insulator
5. EGR valve "AA 14. Injectors
6. EGR valve gasket 15. O-ring
7. Fuel hose 16. Grommet
8. Fuel return pipe 17. Delivery pipe
9. Injectors and delivery pipe 18. Solenoid valve assembly
O-ring
1EN0388
ProCarManuals.com
26 18 Nm
11 Nm 8.8 Nm
8.8 Nm
8.8 Nm
15 14 2
6
17
8
3
11 Nm
18
11 Nm 1
7 16
11
10 4.9 Nm ®
17 Nm ± 2 Nm 19 22
9 8.8 Nm
21
ProCarManuals.com
20
12
11 Nm 18 Nm
4
13
5
37 30 23
34
22 Nm
35
24
36
32 27
33 28 23 Nm
29 31 25
11 Nm
38
Removal steps
1. Fuel hose "DA 20. Fuel pressure sensor
2. Fuel low pressure pipe 21. Backup ring
3. O-ring 22. O-ring
4. Fuel pump return nipple "CA 23. Pump camshaft case
5. O-ring 24. O-ring
6. Clamp A 25. O-ring
7. Fuel pipe bracket 26. Injector harness
"FA 8. Fuel feed pipe 27. Washer
9. Backup ring 28. Injector holder
10. O-ring "BA 29. Delivery pipe and injector assembly
11. Backup ring 30. Insulator
"FA 12. Fuel pump 31. Injector washer
13. O-ring 32. Injector
14. Harness bracket "AA 33. Corrugated washer
"EA 15. Fuel return pipe "AA 34. Backup ring
16. Backup ring "AA 35. O-ring
17. O-ring "AA 36. Backup ring
18. Backup ring 37. Delivery pipe
"EA 19. Fuel high pressure regulator 38. Engine hanger
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6
5 12 Nm
1
4
19 2
10
8.8 Nm
7 9
18 Nm 3
13
12
11 Nm 11
8 14
11 Nm 18 Nm
ProCarManuals.com
15
16
30 23
22 Nm
27 5 Nm ®
17 Nm ± 2 Nm
28
29 20
20 17
25
22 21
26
18
24 23 Nm
11 Nm
31
Removal steps
1. Clamp 17. O-ring
2. Fuel pipe bracket 18. O-ring
"GA 3. Fuel pipe 19. Injector harness
4. Backup ring 20. Washer
5. O-ring 21. Injector holder
6. Backup ring "BA 22. Delivery pipe and injector assembly
"DA 7. Fuel pressure sensor 23. Insulator
8. Backup ring 24. Injector washer
9. O-ring 25. Injector
"GA 10. Fuel fitting "AA 26. Corrugated washer
11. Backup ring "AA 27. Backup ring
12. O-ring "AA 28. O-ring
13. Backup ring "AA 29. Backup ring
"GA 14. Fuel pump 30. Delivery pipe
15. O-ring 31. Engine hanger
"CA 16. Pump camshaft case
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Backup ring
(2) Coat the corrugated washer with white vaseline and install
it to the injector as shown.
Caution
D Always replace the corrugated washer with new
one. Reused corrugated washer can cause fuel
or gas leaks.
Corrugated washer
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3 1 2 4
Backup ring
it.
(9) Tighten the bolts at ends of the fuel pipe to the specified
torque.
(10)Tighten the mounting bolts of the fuel fitting to the specified
torque (12±1 Nm).
15
3 4
11 Nm
5
13 Nm
14
20 Nm 2 8
7
16 8
31 Nm
11
ProCarManuals.com
17
12 Nm
14 Nm
12 10
13
14 Nm
Removal steps
1. Water hose 9. Water pump
2. Water hose 10. Water pump gasket
"CA 3. Engine coolant temperature gauge 11. Oil level gauge
unit 12. Oil level gauge guide
4. Water inlet fitting 13. O-ring
5. Thermostat 14. Intake manifold stay
"BA 6. Thermostat housing 15. Intake manifold
"AA 7. Water inlet pipe 16. Intake manifold gasket
"AA 8. O-ring 17. Engine hanger
11 Nm
4
5
17 6
19 Nm
13 Nm
2
9 29 Nm
15
8
31 Nm 9 3
23 Nm
19
12
18
ProCarManuals.com
11 Nm
14 Nm
13 11
10
14
14 Nm
Removal steps
1. Water hose 11. Water pump gasket
2. Water hose 12. Oil level gauge
"DA 3. Engine coolant temperature sensor 13. Oil level gauge guide
"CA 4. Engine coolant temperature gauge 14. O-ring
unit 15. Intake manifold stay
5. Water inlet fitting 16. Intake manifold
6. Thermostat 17. Intake manifold gasket
"BA 7. Thermostat housing 18. Engine hanger
"AA 8. Water inlet pipe 19. Detonation sensor
"AA 9. O-ring (Except General export)
10. Water pump
13 Nm
24 Nm
8
1
11 Nm
17 5
6
7
18
13 Nm
2
19 Nm 29 Nm
10
9
4
16 10
31 Nm
ProCarManuals.com
19
13
11 Nm
11
14 Nm
14
12
14 Nm 15
Removal steps
1. Water hose "AA 10. O-ring
2. Water hose 11. Water pump
3. Water hose 12. Water pump gasket
"DA 4. Engine coolant temperature sensor 13. Oil level gauge
"CA 5. Engine coolant temperature gauge 14. Oil level gauge guide
unit 15. O-ring
6. Water inlet fitting 16. Intake manifold stay
7. Thermostat 17. Intake manifold
"BA 8. Thermostat housing 18. Intake manifold gasket
"AA 9. Water inlet pipe 19. Engine hanger
O-ring 6EN0594
9EN0092
9EN0091
12 Nm
11 Nm
7
2 29 Nm
4
23 Nm
1 3
9
6
12 Nm
5
13 10
12 Nm
ProCarManuals.com
22 Nm
9
11 12
13 Nm
Removal steps
1. Water hose "CA 7. Water outlet fitting
"EA 2. Water hose "BA 8. Thermostat housing
3. Engine coolant temperature sensor "AA 9. O-ring
"DA 4. Engine coolant temperature gauge "AA 10. Water inlet pipe
unit 11. Water pump
5. Water inlet fitting 12. Gasket
6. Thermostat 13. Knock sensor
9EN0092
9EN0091
1
13 Nm
29 Nm
13 Nm
ProCarManuals.com
49 Nm
2
5 13 Nm
13 Nm
3
13 Nm
Removal steps
"AA 1. Water outlet fitting
2. Heat protector
(Multipoint fuel injection)
3. Exhaust manifold cover
(Carburetor)
4. Engine hanger
5. Exhaust manifold
6. Exhaust manifold gasket
1
13 Nm
5
29 Nm
49 Nm
2
ProCarManuals.com
13 Nm
4
Removal steps
"AA 1. Water outlet fitting
2. Exhaust manifold cover
3. Engine hanger
4. Exhaust manifold
5. Exhaust manifold gasket
13 Nm
29 Nm
13 Nm
49 Nm
ProCarManuals.com
13 Nm
3 4
49 Nm
2
Removal steps
"AA 1. Water outlet fitting
2. Exhaust manifold cover
3. Engine hanger
4. Exhaust manifold
5. Exhaust manifold gasket
3.4 Nm
31 Nm
13
8
ProCarManuals.com
12
11
12
11
12 10
11 16
12 10
11
10
15
10 15
14 15 18
17
15
(3) Remove the special tool for securing the lash adjuster.
(4) Make sure that the notch in the rocker arm shaft is in
the direction as illustrated.
ROCKER ARM
(1) Check the roller surface. If any dents, damage or seizure
is evident, replace the rocker arm.
(2) Check rotation of the roller. If it does not rotate smoothly
or if looseness is evident, replace the rocker arm.
(3) Check the inside diameter. If damage or seizure is evident,
replace the rocker arm.
Roller tip
ProCarManuals.com
LASH ADJUSTERS
Caution
D The lash adjusters are precision-engineered
mechanisms. Do not allow them to become
contaminated by dirt or other foreign substances.
D Do not attempt to disassemble the lash adjusters.
D Use only fresh diesel fuel to clean the lash
adjusters.
A B C
(2) Place the lash adjuster in container A and clean its outside
surface.
NOTE
Use a nylon brush if deposits are hard to remove.
MD998441 (3) Fit special tool MD998441 onto the lash adjuster.
(4) While gently pushing down the internal steel ball using
special tool MD998442, move the plunger through 5 to
10 strokes until it slides smoothly. In addition to eliminating
stiffness in the plunger, this operation will remove dirty
oil.
Caution
D The steel ball spring is extremely weak, so the
MD998442 Diesel fuel lash adjuster’s functionality may be lost if the
air bleed wire is pushed in hard.
NOTE
If the plunger remains stiff or the mechanism appears
otherwise abnormal, replace the lash adjuster.
ProCarManuals.com
(5) Remove the lash adjuster from the container. Then, push
down the steel ball gently and push the plunger to eliminate
diesel fuel from the pressure chamber.
MD998442
Diesel fuel
MD998441 (6) Fit special tool MD998441 onto the lash adjuster.
(7) Place the lash adjuster in container B. Then, gently push
down the internal steel ball using special tool MD998442
and move the plunger through 5 to 10 strokes until it
slides smoothly. This operation will clean the lash
adjuster’s pressure chamber.
Caution
D The steel ball spring is extremely weak, so the
MD998442 Diesel fuel lash adjuster’s functionality may be lost if the
air bleed wire is pushed in hard.
(8) Remove the lash adjuster from the container. Then, push
down the steel ball gently and push the plunger to eliminate
diesel fuel from the pressure chamber.
MD998442
Diesel fuel
(10)Stand the lash adjuster with its plunger at the top, then
MD998442
push the plunger downward firmly until it moves through
its greatest possible stroke. Return the plunger slowly,
then release the steel ball and allow the pressure chamber
to fill diesel fuel.
(11)Remove special tool MD998441.
MD998441
Diesel fuel
ProCarManuals.com
20 Nm
10
9.8 Nm
ProCarManuals.com
2
3
6 5
21 Nm
11 12
4
1
8.8 Nm
13 Nm
Removal steps
1. Camshaft position sensor 7. "BA Beam camshaft cap
2. Cover 8. "BA Beam camshaft cap gasket
3. Gasket 9. "BA Intake camshaft
"DA 4. Camshaft position sensing cylinder 10. "BA Exhaust camshaft
"CA 5. Camshaft position sensor support 11. Rocker arm
"BA 6. Oil seal AA" "AA 12. Lash adjuster
11 Nm
1 30 Nm
42 Nm
20 Nm
11 Nm
4
5 2.5 Nm
8
12
24 Nm
2 9
3 Apply engine oil to all
13 moving parts before
installation.
14
15
ProCarManuals.com
9.8 Nm
7
8
11 10
16 21 Nm
17
9
6
13 Nm
8.8 Nm
Removal steps
1. Oil pipe 10. "CA Camshaft position sensor support
2. Oil control valve 11. "BA Oil seal
3. Gasket 12. "BA Beam camshaft cap
4. Oil delivery body 13. "BA Beam camshaft cap gasket
5. Oil delivery plate 14. "BA Intake camshaft
6. Camshaft position sensor 15. "BA Exhaust camshaft
7. Cover 16. Rocker arm
8. Gasket AA" "AA 17. Lash adjuster
"DA 9. Camshaft position sensing cylinder
Intentionally blank
UP TO 2000 MODEL SPACE RUNNER, "BA BEAM CAMSHAFT CAP GASKET / BEAM
UP TO 2000 MODEL SPACE WAGON, CAMSHAFT CAP / CAMSHAFT / OIL SEAL
GALANT Dowel pin INSTALLATION
(1) Locate the camshaft dowel pins as illustrated.
Approx.
11°
3 mm
(2) Apply a 3 mm thick continuous bead of sealant to the
Timing belt bottom surface of the beam camshaft cap along the
side
groove.
Specified sealant:
Mitsubishi genuine Part No. MD970389 or
equivalent
(5) Install the beam camshaft cap before the sealant applied
becomes dry and hard.
(6) Tighten the bolts to the specified torque in the order shown
in the illustration.
Specified torque: 20 Nm
(7) Install the camshaft oil seal before the sealant applied
becomes dry and hard.
MD998713 (8) Wipe off squeezed out excess sealant from the
circumference of the beam camshaft cap.
INSPECTION
CAMSHAFT
(1) Measure the cam height.
Standard value:
Intake 35.79 mm
Exhaust 35.49 mm
Limit:
Intake 35.29 mm
Exhaust 34.99 mm
LASH ADJUSTER
Caution
D The lash adjusters are precision-engineered
mechanisms. Do not allow them to become
contaminated by dirt or other foreign substances.
D Do not attempt to disassemble the lash adjusters.
D Use only fresh diesel fuel to clean the lash
adjusters.
ProCarManuals.com
A B C
(2) Place the lash adjuster in container A and clean its outside
surface.
NOTE
Use a nylon brush if deposits are hard to remove.
Diesel
fuel
(3) While gently pushing down the internal steel ball using
special tool MD998442, move the plunger through 5 to
10 strokes until it slides smoothly. In addition to eliminating
stiffness in the plunger, this operation will remove dirty
oil.
Caution
D The steel ball spring is extremely weak, so the
lash adjuster’s functionality may be lost if the
air bleed wire is pushed in hard.
MD998442
Diesel fuel NOTE
If the plunger remains stiff or the mechanism appears
otherwise abnormal, replace the lash adjuster.
E Mitsubishi Motors Corporation Jun. 2000 PWEE9616-C Revised
4G6 ENGINE (E - W) - Rocker Arms and Camshafts (GDI) 11A-8a-5
(4) Removal the lash adjuster from the container. Then, push
down the steel ball gently and push the plunger to eliminate
diesel fuel from the pressure chamber.
Caution
D Make sure the oil hole in the side of the body
is pointing toward container A. Do not point the
MD998442 oil hole at yourself or other people.
Diesel fuel
(6) Remove the lash adjuster from the container. Then, push
down the steel ball gently and push the plunger to eliminate
diesel fuel from the pressure chamber.
Caution
D Make sure the oil hole in the side of the body
is pointing toward container A. Do not point the
MD998442 oil hole at yourself or other people.
Diesel fuel
(8) Stand the lash adjuster with its plunger at the top, then
push the plunger downward firmly until it moves through
its greatest possible stroke. Return the plunger slowly,
then release the steel ball and allow the pressure chamber
to fill with diesel fuel.
Diesel fuel
MD998442
(9) Remove the lash adjuster from the container, then stand
the lash adjuster with its plunger at the top. Push the
plunger firmly and check that it does not move. Also,
check that the lash adjuster’s height matches that of a
new lash adjuster.
NOTE
If lash adjuster contracts, perform the operations (7)
through (9) again to fill it with diesel fuel completely.
Replace the lash adjuster if it still contracts after performing
these steps.
Lash adjuster
ProCarManuals.com
(11)Remove the bolt from the tester, then adjust the height
as illustrated.
(12)After the plunger has moved downward slightly measure
the time taken for it to move downward by a further 1
Nut mm.
Lash
adjuster Standard value:
3 - 20 second/1 mm [with diesel fuel at 15 - 20_C
(59 - 68_F)]
NOTE
Replace the lash adjuster if the time measurement is
out of specification.
(13)Place the lash adjuster in container C again, then gently
push down the internal steel ball using special tool
MD998442.
(14)Stand the lash adjuster with its plunger at the top, then
push the plunger downward firmly until it moves through
its greatest possible stroke. Return the plunger slowly,
then release the steel ball and allow the pressure chamber
Diesel fuel to fill with diesel fuel.
MD998442
2 1
8
20 9
10
4
14
5 15
6 17
12
13
16 19
11
ProCarManuals.com
18
Removal steps
AA" "EA 1. Cylinder head bolt 11. Exhaust valve
2. Cylinder head assembly AC" "AA 12. Valve stem seal
"DA 3. Cylinder head gasket 13. Valve spring seat
AB" "CA 4. Retainer lock AC" "AA 14. Valve stem seal
5. Valve spring retainer 15. Valve spring seat
"BA 6. Valve spring 16. Intake valve guide
7. Intake valve 17. Exhaust valve guide
AB" "CA 8. Retainer lock 18. Intake valve seat
9. Valve spring retainer 19. Exhaust valve seat
"BA 10. Valve spring 20. Cylinder head
1 8
9
10
14
4 20
5 15
6
17
12
13
19
16 11
18
3
ProCarManuals.com
Removal steps
AA" "EA 1. Cylinder head bolt 11. Exhaust valve
2. Cylinder head assembly AC" "AA 12. Valve stem seal
3. Cylinder head gasket 13. Valve spring seat
AB" "CA 4. Retainer lock AC" "AA 14. Valve stem seal
5. Valve spring retainer 15. Valve spring seat
"BA 6. Valve spring 16. Intake valve guide
7. Intake valve 17. Exhaust valve guide
AB" "CA 8. Retainer lock 18. Intake valve seat
9. Valve spring retainer 19. Exhaust valve seat
"BA 10. Valve spring 20. Cylinder head
9EN0061
MB991654
ProCarManuals.com
9EN0062
MD998772
MD998737
9EN0062
MD998772
ProCarManuals.com
6EN0782
(6) Make paint marks on the cylinder head bolt heads and
cylinder head.
(7) Give a 90_ turn to the cylinder head bolts in the specified
90_ tightening sequence.
(8) 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.
90_
Paint mark
Caution
D If the bolt is turned less than 90_, proper fastening
6AE0297
performance may not be expected. When
tightening the bolt, therefore, be careful to give
a sufficient turn to it.
D If the bolt is overtightened, loosen the bolt
completely and then retighten it by repeating the
tightening procedure from step (1).
ProCarManuals.com
INSPECTION
CYLINDER HEAD
(1) Check the cylinder head gasket surface for flatness by
using a straightedge and thickness gauge.
Standard value: 0.05 mm
Limit: 0.2 mm
(2) If the service limit is exceeded, correct to meet
specification.
9EN0064 Grinding limit: *0.2 mm
* Includes combined with cylinder block grinding.
Cylinder head height (Specification when new):
SOHC 119.9 - 120.1 mm
GDI 131.9 - 132.1 mm
VALVE SPRING
Out of (1) Measure the free height of spring and, if it is smaller
square
than the limit, replace.
Item Standard value mm Limit mm
Free SOHC 51.0 50.0
height
GDI 48.3 47.3
VALVE GUIDE
(1) Measure the clearance between the valve guide and valve
stem. If the limit is exceeded, replace the valve guide
or valve, or both.
Valve
guide Item Standard value mm Limit mm
SOHC Intake 0.02 - 0.05 0.10
Exhaust 0.03 - 0.07 0.15
GDI Intake 0.02 - 0.05 0.10
Exhaust 0.05 - 0.09 0.15
ProCarManuals.com
VALVE SEAT
Valve stem end
(1) Assemble the valve, then measure the valve stem
projection between the end of the valve stem and the
Valve stem
projection spring seating surface. If the measurement exceeds the
specified limit, replace the valve seat.
Spring seating Item Standard value mm Limit mm
surface
SOHC Intake 49.30 49.80
Exhaust 49.30 49.80
DEN0212 GDI Intake 49.20 49.70
Exhaust 48.40 48.90
0.5 - 1 mm
(3) Before fitting the valve seat, either heat the cylinder head
up to approximately 250_C (482_F) or cool the valve
seat in liquid nitrogen, to prevent the cylinder head bore
from galling.
(4) Using a valve seat cutter, correct the valve seat to the
specified width and angle.
See “VALVE SEAT RECONDITIONING PROCEDURE”.
21
18 (SOHC) 20
23 Nm
9.8 Nm 29
9
28 22
23 Nm
23 21 Nm
24
18 (GDI)
19 27 8
ProCarManuals.com
18 Nm 16 Nm 7
6
25 26
18 Nm
12 39 Nm
17 3
10 11
(4G64) 16 23 Nm 2
15 36 Nm
13
14 4 5
23 Nm
8.8 Nm
1 6.9 Nm
9.8 Nm 44 Nm
21 Nm
Removal steps
"OA 1. Oil filter 18. Oil filter bracket
2. Drain plug 19. Oil filter bracket gasket
"NA 3. Drain plug gasket "HA 20. Front case assembly
4. Oil level sensor 21. Front case gasket
(Vehicle for Europe) 22. Oil pump cover
5. Transmission stay (GDI engine) "GA 23. Oil pump driven gear
AA" "LA 6. Oil pan "GA 24. Oil pump drive gear
7. Oil screen "FA 25. Crankshaft front oil seal
8. Oil screen gasket "EA 26. Oil pump oil seal
9. Stiffener (SOHC engine - vehicle "DA 27. Counterbalance shaft oil seal
for Europe) 28. Front case
AD" "KA 10. Plug 29. Counterbalance shaft, left
11. O-ring 30. Counterbalance shaft, right
AE" "JA 12. Flange bolt AF" "CA 31. Counterbalance shaft front bearing
"IA 13. Oil pressure switch AG" "BA 32. Counterbalance shaft rear bearing,
14. Relief plug left
15. Relief plug gasket AG" "AA 33. Counterbalance shaft rear bearing,
16. Relief spring right
17. Relief plunger
E Mitsubishi Motors Corporation Jun. 2000 PWEE9616-C Revised
11A-10-2 4G6 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan
34
32
Apply engine oil to all 31
moving parts before 33
installation.
22
21
23 Nm
9.8 Nm
30
29 23
6.9 Nm
23 Nm
24 25
7
10 6
18 Nm
20 9
28
19 16 Nm
ProCarManuals.com
26 18 Nm
27
13
18
11 12 23 Nm 6.9 Nm
17
14 36 Nm 3 5
16 12 Nm
15
23 Nm 2
39 Nm 4
1 6.9 Nm
9.8 Nm 44 Nm
8
21 Nm
Removal steps
"OA 1. Oil filter 19. Oil filter bracket
2. Drain plug 20. Oil filter bracket gasket
"NA 3. Drain plug gasket "HA 21. Front case assembly
4. Transmission stay 22. Gasket
5. Oil level gauge guide 23. Oil pump cover
AB" "MA 6. Oil pan lower "GA 24. Oil pump driven gear
7. Baffle plate "GA 25. Oil pump drive gear
AC" "MA 8. Oil pan upper "FA 26. Crankshaft front oil seal
9. Oil screen "EA 27. Oil pump oil seal
10. Gasket "DA 28. Counterbalance shaft oil seal
AD" "KA 11. Plug 29. Front case
12. O-ring 30. Counterbalance shaft, left
AE" "JA 13. Flange bolt 31. Counterbalance shaft, right
"IA 14. Oil pressure switch AF" "CA 32. Counterbalance shaft front bearing
15. Relief plug AG" "BA 33. Counterbalance shaft rear bearing,
16. Gasket left
17. Relief spring AG" "AA 34. Counterbalance shaft rear bearing,
18. Relief plunger right
MD998783
Plug
Screwdriver
6EN1026
6EN0565
MD998705
6EN1034
MD998705
6EN0557
ProCarManuals.com
MD998705
MD998705
Bearing
Cylinder block
6EN1035
(2) Install the front case assembly through a new front case
gasket and temporarily tighten the flange bolts (other
than those for tightening the filter bracket).
6EN0564
ProCarManuals.com
(2) Secure the oil pump driven gear onto the left
counterbalance shaft by tightening the flange bolt to
specified torque.
MD998783
NOTE
(1) Be sure to install the oil pan quickly while the sealant
is wet (within 15 minutes).
(2) After installation, keep the sealed area away from
the oil and coolant for approx. one hour.
M6 16
mm
8 (6) Tighten the oil pan lower mounting bolts in the sequence
6 shown in the illustration.
1
4
3
2 5
9 7
Drain plug
gasket
7EN0307
6EN0591
INSPECTION
FRONT CASE
(1) Check oil holes for clogging and clean if necessary.
(2) Check the left counterbalance shaft front bearing section
for wear, damage and seizure. If there is anything wrong
with the section, replace the front case.
(3) Check the front case for cracks and other damage.
Replace cracked or damaged front case.
OIL SEAL
(1) Check the oil seal lip for wear and damage. Replace
oil seal if necessary.
(2) Check the oil seal lip for deterioration. Replace oil seal
if necessary.
ProCarManuals.com
COUNTERBALANCE SHAFT
(1) Check oil holes for clogging.
(2) Check journals for seizure, damage and contact with
bearing. If there is anything wrong with the journal, replace
the counterbalance shaft, bearing or front case assembly.
OIL PUMP
(1) Assemble the oil pump gear to the front case and rotate
it to ensure smooth rotation with no looseness.
(2) Ensure that there is no ridge wear on the contact surface
between the front case and the gear surface of the oil
pump cover.
(3) Check the side clearance.
Standard value:
Drive gear 0.08 - 0.14 mm
Driven gear 0.06 - 0.12 mm
4
10
12
9
11
ProCarManuals.com
2
1
Removal steps
"GA 1. Nut "CA 7. Piston ring No. 2
AA" "FA 2. Connecting rod cap "BA 8. Oil ring
"EA 3. Connecting rod bearing AB" "AA 9. Piston pin
"DA 4. Piston and connecting rod assem- 10. Piston
bly 11. Connecting rod
"EA 5. Connecting rod bearing 12. Bolt
"CA 6. Piston ring No. 1
E Mitsubishi Motors Corporation Dec. 1996 PWEE9616
11A-11-2 4G6 ENGINE (E - W) - Piston and Connecting Rod
(1) Insert the special tool, Push Rod, into the piston from
the side on which the front mark is stamped in the piston
head, and attach the guide C to the push rod end.
(2) Place the piston and connecting rod assembly on the
special tool, Piston Pin Setting Base, with the front mark
facing upward.
(3) Using a press, remove the piston pin.
NOTE
Keep the disassembled pistons, piston pins and
connecting rods in order according to the cylinder number.
3 mm + L (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.
(8) Place the piston and connecting rod assembly onto the
piston setting base with the front marks directed upward.
(9) Press-fit the piston pin using a press.
If the press-fitting force required is less than the standard
value, replace the piston and piston pin set or/and the
connecting rod.
Standard value: 7,350 - 17,200 N
(2) Make sure that the connecting rod big end side clearance
meets the specification.
Standard value: 0.10 – 0.25 mm
Limit: 0.4 mm
alignment.
Caution
D If the nut is turned less than 90_, proper fastening
performance may not be expected. When
tightening the nut, therefore, be careful to give
a sufficient turn to it.
D If the nut is overtightened (exceeding 100_), loosen
the nut completely and then retighten it by
repeating the tightening procedure from step (1).
INSPECTION
PISTON RING
(1) Check the piston ring for damage, excessive wear, and
breakage and replace if defects are evident. If the piston
has been replaced with a new one, the piston rings must
also be replaced with new ones.
(2) Check for the clearance between the piston ring and
ring groove. If the limit is exceeded, replace the ring or
piston, or both.
Standard value: 0.02 - 0.06 mm
Limit: 0.1 mm
(3) Install the piston ring into the cylinder bore. Force it down
with a piston, its crown being in contact with the ring,
to correctly position it at right angles to the cylinder wall.
Then, measure the end gap with a feeler gauge. If the
ring gap is excessive, replace the piston ring.
Standard value:
No. 1 ring 0.25 - 0.35 mm
No. 2 ring 0.40 - 0.55 mm
Oil ring 0.10 - 0.40 mm
Limit:
No. 1, No. 2 ring 0.8 mm
Oil ring 1.0 mm
ProCarManuals.com
Plastigage
(3) Install the connecting rod cap carefully and tighten the
nuts to specified torque.
(4) Carefully remove the connecting rod cap.
(5) Measure the width of the Plastigage at its widest part
by using a scale printed on the Plastigage package.
Standard value: 0.02 - 0.05 mm
Limit: 0.1 mm
9 4
8 A
5
17
9 Nm
7
11 Nm
ProCarManuals.com
15
16 14
13
12
11
10
Removal steps
1. Flywheel bolt "BA 15. Crankshaft thrust bearing <GDI en-
2. Adapter plate gine>
3. Flexible flywheel AA" "AA 16. Oil jet <GDI engine>
4. Adapter plate 17. Cylinder block
5. Crankshaft bushing
6. Rear plate Caution
7. Bell housing cover On the flexible wheel equipped engines, do not
"FA 8. Oil seal case remove any of the bolts “A” of the flywheel shown
"EA 9. Oil seal in the illustration.
"DA 10. Bearing cap bolt The balance of the flexible flywheel is adjusted in
"DA 11. Bearing cap an assembled condition. Removing the bolt,
"CA 12. Crankshaft bearing, lower therefore, can cause the flexible flywheel to be out
13. Crankshaft
"CA 14. Crankshaft bearing, upper of balance, giving damage to the flywheel.
9
132 Nm
8 5
17 3
9 Nm 2
11 Nm 7
15
ProCarManuals.com
16 14 1
5 132 Nm
13
4
12
11
10
Removal steps
1. Drive plate bolt 7.
Bell housing cover
2. Adapter plate "FA 8.
Oil seal case
3. Drive plate (GDI engine and up to "EA 9.
Oil seal
2000 model GALANT with SOHC "DA 10.
Bearing cap bolt
engine, From 2001 model GALANT "DA 11.
Bearing cap
for General Export with SOHC "CA 12.
Crankshaft bearing, lower
engine) 13.
Crankshaft
4. Drive plate (SPACE RUNNER with "CA 14.
Crankshaft bearing, upper
SOHC engine, SPACE WAGON "BA 15.
Crankshaft thrust bearing
with SOHC engine, From 2001 <GDI engine>
model GALANT for Europe) AA" "AA 16. Oil jet <GDI engine>
5. Crankshaft bushing 17. Cylinder block
6. Rear plate
No. 2
No. 1 No. 3
No. 4 No. 5
Bearing bore
identification
mark
Cylinder inner
diameter size
mark
1 2 or Yellow
2 3 or None
1 3 or None
2 4 or Blue
1 4 or Blue
2 5 or Red
ProCarManuals.com
1 2 or Yellow 1 or Green
2 3 or None 2 or Yellow
1 3 or None 2 or Yellow
2 4 or Blue 3 or None
1 4 or Blue 3 or None
2 5 or Red 4 or Blue
Crankshaft bearing size For example, if the crankshaft journal outside diameter
identification mark or color ID color is “yellow” and cylinder block bearing bore ID
mark is “1”, select a bearing whose ID mark is “2” or
ID color is “yellow” for number 1, 2, 4 and 5, and a bearing
whose ID mark is “1” or ID color is “green” for number
3.
If there is no ID color paint on the crankshaft, measure
the journal outside diameter and select a bearing
Identification appropriate for the measured value.
mark or color
Lower
Arrow mark
Plastigage
INSPECTION
CRANKSHAFT OIL CLEARANCE (PLASTIGAGE
METHOD)
(1) Remove oil from the crankshaft journal and the crankshaft
bearing.
(2) Install the crankshaft.
(3) Cut the Plastigage to the same length as the width of
the bearing and place it on the journal in parallel with
its axis.
Plastigage
CYLINDER BLOCK
(1) Visually check for scratches, rust, and corrosion.
Use also a flaw detecting agent for the check. If defects
are evident, correct, or replace.
(2) Using a straightedge and feeler gauge, check the block
top surface for warpage. Make sure that the surface is
free from gasket chips and other foreign matter.
Standard value: 0.05 mm
Limit: 0.1 mm
BORING CYLINDER
(1) Oversize pistons to be used should be determined on
the basis of the largest bore cylinder.
Piston size identification
Size Identification mark
0.50 O.S. 0.50
1.00 O.S. 1.00
NOTE
Size mark is stamped on the piston top.
(2) Measure outside diameter of piston to be used. Measure
it in thrust direction as shown.
(3) Based on the measured piston O.D. calculate boring finish
dimension.
Boring finish dimension = Piston O.D. + (clearance
between piston O.D. and cylinder) - 0.02 mm
(honing margin)
ADMINISTRATION
T.MASAKI-MANAGER
OFFICE TECHNICAL SERVICE PLANNING TERO(V10-40)
1. Description:
Correction has been made to the installation procedures for the 4G6 engine crankshaft bearings.
2. Applicable Manuals:
Manual Pub. No. Language Page(s)
ENGINE 4G6 (E-W) PWEE9616 (English) 11A-12-1
Workshop Manual PWES9617 (Spanish) 11A-12-1a
PWEF9618 (French) 11A-12-3
PWEG9619 (German) 11A-12-4
PWED9620 (Dutch)
PWEW9621 (Swedish)
ENGINE 4G6 (W-E) PWEE9037 (English) 11B-12-1
Workshop Manual PWES9038 (Spanish) 11B-12-4
PWEF9039 (French) 11B-12-5
PWEG9040 (German)
PWED9041 (Dutch)
PWEW9042 (Swedish)
3. Details: ENGINE 4G6, (E-W) Workshop Manual
4G6 ENGINE (E-W) – Crankshaft, Flywheel and Drive Plate 11A-12-1
<Correct>
<Except thrust bearing-integrated type>
6EN2008
B
Removal steps
A► A
1. Flywheel bolt 15. Crankshaft thrust bearing <GDI engine>
2. Adapter plate 16. Oil jet <GDI engine>
3. Flexible flywheel 17. Cylinder block
<Incorrect>
4. Adapter plate
5. Crankshaft bushing Caution
6. Rear plate On the flexible wheel equipped engines, do not remove
F
7. Bell housing cover any of the bolts “A” of the flywheel shown in the
E
8. Oil seal case illustration.
D
9. Oil seal The balance of the flexible flywheel is adjusted in an
D
10. Bearing cap bolt assembled condition. Removing the bolt, therefore, can
C
11. Bearing cap cause the flexible flywheel to be out of balance, giving
12. Crankshaft bearing, lower damage to the flywheel.
C
13. Crankshaft
14. Crankshaft bearing, upper
2
ENGINE 4G6, (E-W) Workshop Manual
11A-12-1a 4G6 ENGINE (E-W) – Crankshaft, Flywheel and Drive Plate
6EN2009
Removal steps
F◄
1. Drive plate bolt 7. Bell housing cover
E ◄
2. Adapter plate 8. Oil seal case
D◄
3. Drive plate (GDI engine and up to 9. Oil seal
D◄
2000 model GALANT with SOHC 10. Bearing cap bolt
C◄
engine, From 2001 model GALANT for 11. Bearing cap
General Export with SOHC engine) 12. Crankshaft bearing, lower
C◄
4. Drive plate (SPACE RUNNER with 13. Crankshaft
Crankshaft bearing, upper <Incorrect>
B◄
SOHC engine, SPACE WAGON with 14.
A► A
SOHC engine, From 2001 model 15. Crankshaft thrust bearing <GDI engine>
GALANT for Europe) 16. Oil jet <GDI engine>
5. Crankshaft bushing 17. Cylinder block
6. Rear plate
<Correct>
<Except thrust bearing-integrated type>
3
ENGINE 4G6, (E-W) Workshop Manual
4G6 ENGINE (E-W) – Crankshaft, Flywheel and Drive Plate 11A-12-3
Bearing bore
identification
mark
Cylinder inner
diameter size
mark
<Incorrect>
Crankshaft journal outside diameter Cylinder block Crankshaft bearing Crankshaft bearing
bearing bore for No. 3
Identification color Size mm Identification mark Identification mark or Identification mark or
color color
ProCarManuals.com
Crankshaft bearing size For example, if the crankshaft journal outside diameter ID color
identification mark or color is “yellow” and cylinder block bearing bore ID mark is “1”,
select a bearing whose ID mark is “2” or ID color is “yellow” for
number 1, 2, 4 and 5, and a bearing whose ID mark is “1” or ID
color is “green” for number 3.
If there is no ID color paint on the crankshaft, measure the
journal outside diameter and select a bearing appropriate for
the measured value.
Identification mark
or color
6EN1096
4
<Correct>
Type 1 (Engine with thrust bearing that is integral with No.3 bearing)
Type 2 (Engine with thrust bearing that is separate from No.3 bearing)
Crankshaft journal outside diameter Cylinder block Crankshaft bearing Crankshaft bearing
bearing bore for No. 1, 2, 4, 5 for No. 3
Identification r color Size mm Identification mark Identification mark or Identification mark or
ProCarManuals.com
color color
Yellow 56.994 ~ 57.000 0 1 or Green 0 or Black
1 2 or Yellow 1 or Green
2 3 or None 2 or Yellow
None 56.988 ~ 56.994 0 2 or Yellow 1 or Green
1 3 or None 2 or Yellow
2 4 or Blue 3 or None
White 56.982 ~ 56.988 0 3 or None 2 or Yellow
1 4 or Blue 3 or None
2 5 or Red 4 or Blue
5
ENGINE 4G6, (E-W) Workshop Manual
11A-12-4 4G6 ENGINE (E-W) – Crankshaft, Flywheel and Drive Plate
Groove
(2) Install the bearings having an oil groove to the cylinder
block.
(3) Install the bearings having no oil groove to the bearing
cap.
Upper
NOTE
The No.3 bearing that is integral with the <Added>
Lower 6EN1558 thrust bearing has no grooves.
Arrow mark
6EN0624
6
SERVICE BULLETIN
QUALITY INFORMATION ANALYSIS
OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION
CAR
ADMINISTRATION
(EC)L400
T.Inoue - Manager
OFFICE SERVICE PUBLICATION (PA0-PD0)
1. Description:
On the 4G6 and 4D68 engines, the crankshaft identifications marks and their positions have been
changed.
2. Applicable Manuals:
Manual Pub. No. Language Page(s)
ENGINE 4G6 (W-E) PWEE9037 (English) 11B-11-8
WORKSHOP MANUAL PWES9038 (Spanish) 12-4
PWEF9039 (French)
PWEG9040 (German)
PWED9041 (Dutch)
PWEW9042 (Swedish)
ENGINE 4G6 (E-W) PWEE9616 (English) 11A-11-5, 6
WORKSHOP MANUAL PWES9617 (Spanish) 12-2, 3
PWEF9618 (French)
PWEG9619 (German)
PWED9620 (Dutch)
PWEW9621 (Swedish)
ENGINE 4G6 (W-E) PWEE9073 (English) 11B-12-4
WORKSHOP MANUAL PWES9674 (Spanish) 13-5
PWEF9075 (French)
PWEG9076 (German)
PWED9077 (Dutch)
PWEW9078 (Swedish)
ENGINE 4D6 (E-W) PWEE9609 (English) 11A-11-2
WORKSHOP MANUAL PWES9610 (Spanish) 12-2
PWEF9611 (French)
PWEG9612 (German)
PWED9613 (Dutch)
PWEW9614 (Swedisch)
CD-ROM PWEH9903R-C
(English, Spanish, Swedish)
PWEK9904R-C
(French, German, Dutch)
The crankshaft identification marks and their positions have been changed. <New>
In accordance with the table below, an identification mark has been stamped
On positions J and P.
Journal Pin
Classification Classi-
φD Indentification mark φd Indentification mark
fication
0
I φ 57 -0.006 0 I φ 45 0-0.005 I
-0.006 -0.005
II φ 57 -0.012 1 II φ 45 -0.015 II
-0.012 -0.015
III φ 57 -0.018 2 III φ 45 -0.020 III
Unit: mm
ProCarManuals.com
<Old> In accordance with the table below, an identification color has been painted at positions j1 through j5 and p1
through p4.
Journal Pin
Classi- Classi-
φD Indentification mark φd Indentification mark
fication fication
0
I φ 57 -0.006 Yellow I φ 45 0-0.005 Yellow
-0.006 -0.005
II φ 57 -0.012 No mark II φ 45 -0.015 No mark
-0.012 -0.015
III φ 57 -0.018 White III φ 45 -0.020 White
Unit: mm
3
<Connecting Rod Bearing Installation>
4
<Crankshaft Bearing Installation>
Cylinder 1 3 or none
bore size 2 4 or blue
mark 2 56.982 – 56.988 0 3 or none
1 4 or blue
2 5 or red
Bearing No. 3
Crankshaft journal O.D. Cylinder Crank-shaft
6EN1618 Identification Journal diameter block bearing
mark mm bearing
0 56.994 – 57.000 0 0 or black
Crankshaft bearing size identification mark 1 1 or green
or color showing position 2 2 or yellow
1 56.988 – 56.994 0 1 or green
1 2 or yellow
2 3 or none
2 56.982 – 56.988 0 2 or yellow
Identification mark or color 1 3 or none
6EN1096 2 4 or blue
Upper bearing