MITSUBISHI ENGINE 4G9 SERIES (E-W) WORKSHOP MANUAL FOREWORD This Workshop Manual contains procedures for removal, disassembly, inspection, adjustment, reassembly and installation, etc. for service mechanics. All information, illustrations and product descriptions contained in this manual are current as at the time of publication. We, however, reserve the right to make changes at any time without prior notice or obligation. 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. _ Missing sheets will be supplied upon request. ae MITSUBISHI MOTORS CORPORATION © witoubiohi tora Corporation May 2000 Engine ey Pub. No. PWEE9502-GINTRODUCTION EXPLANATION OF MANUAL CONTENTS. Maintenance and Servicing Procedures (1) A diagram of the component parts is provided near the front of each section in order to give the reader a better under- standing of the installed condition of component parts. (2) The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures. Bi: Indicates a non-reusable part. The tightening torque is provided where applicable. Classi ation of Major Maintenance/Service Points Removal steps: The part designation number corresponds to the number in the illustration to indicate removal steps. Disassembly steps: The part designation number corresponds to the number in the illustration to indicate disassembly steps. Installation steps: Specified in case installation is impossible in reverse order of removal steps. Omitted if installation is possible in reverse order of removal steps. 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. When there are major points relative to maintenance and servicing procedures {such as essential maintenance and service points, maintenance and service stan- dard values, information regarding the use of special tools, etc.), these are ar- ranged together as major maintenance and service points and explained in detail “> bad Indicates that there are essential points for removal or disassembly. Indicates that there are essential points for instalation or reassembly. Symbols for Lubrication, Sealants and Adhesives Information concerning the locations for lu- = brication and for application of sealants and adhesives is provided, by using symbols, in the diagram of component parts, or on the age following the component parts page, and explained. Grease (multipurpose grease unless there is a brand or type specified) Sealant or adhesive Brake fluid, automatic transmission fluid or air conditioner compressor oil am i : Engine oil or gear oilINTRODUCTION Indicates the group title, Indicates the section title, Indicates the group number. i 409 ENGINE (E-W) - Water Pump 7. WATER PUMP AND WATER HOSE REMOVAL AND INSTALLATION Denotes tightening tom torque. Indicates the section num- Indicates the Page number. a Denotes non-reusable part. ] This number corresponds to the number appearing in “Removal steps", “Disassembly steps’, “installation steps” or “Reassembly steps” ‘2M nose 8 Dea etremosnt case ag 3.enpre cos tanpuraue senser pag 200g F< Engr coutienperme go int ro War net poe Le BES Sin outer tng BBS thong ore ng PAS zWar pono Operating procedures, cau- tions, etc. on removal, installa- INSTALLATION SERVICE POINTS tion, disassembly and reas- pac WATER PUMP neTaLLanOn sembly are descil ‘CARR & 3 om garter of Farin Pion Gasket (IPC) ie actin sown fe sane SPiftaidat “Senvine Part No, MOOTO=89 or sautalers.LIST OF EFFECTIVE PAGES Page 118-04 A038 1100-4 AOS, 11A-t-1 to 11A1-6 11A-1-6a and 114-1-66 11A-1-6¢ and 11A-1-64 AIAG and 114-32 11A-3-2a and 11A-3-2b 1143-3 and 1143-4 1183-5 11836 and 183-7 Aa 11A4-1a and 11A-4-1b 118-42 M1A-4-2a and 1144-26 11A-4-2¢ and 11A-4-2d 1104-20 and 1-4-2 18-43 Ad 114-45 and 114-4-6 T1A-4-7 to 11A-4-9 ASH 1185-2 IAS to 1AS-6 11AGa-t to 118-523 11ASa4 MAS4 1106-2 1186-28 and 118-6-25 11A-6-3 and 11A-6-4 WA6a1 11A-Ga-ta and 11A-69-1b 11A-6a2 118-643 and 11A-Ga-4 1186-1 11A-6b-1a and 11A-6b-1b 11A-6b-2 and 11A-6b-3 110604 (© miteubiahi Motors Corporation Revision Date Code Dec. 1998 July 1997, May 2000 May 2000 May 2000 May 2000 May 2000 Dec. 1998 May 1995 Nov. 1995, May 2000 Dec. 1998 Nov. 1995, May 2000 Dec. 1998 May 2000 May 2000 Dec. 1998, Dec. 1998, May 2000 May 2000 Now. 1995, May 1995 Nov. 1995, May 1995, Nov. 1996 July 1999 Dec. 1998 May 2000 ‘May 2000 Nov. 1996 May 2000 May 2000 Nov. 1996 May 2000 May 2000 Jun, 1998 Dec. 1998 May 2000 May 2000 Dec. 1998 May 2000 m299990m SOOMMOOMO>MO> > OM2BMIO9H2H9H2HOM70 Remarks | Page 10-60-10 and 11A-6e-1b 11A-60-2 10 11A-60-5, Revised | 11A-6c-6 and 11A-6c-7 Added =| 1-7-1 Revised | 118-72 Revised | 11A-7-3t0 1-7-5 Added ABA 1A-B-1a and 11A-8-1b | 11A-6-2 and 118-83 118-8-3a and 11-8-36 Revised | 11084 MASS and 1A-8-6 1108-7 and 1188-8 Revised | 1188-9 1108-10 to 114-843, Revised | 1188-14 and 10-86-15 ‘Added 11A-Ba-1 to 11A-Ba-5 11A-8b-1 and 11A-8b-2 M1A-941 and 114-0-2 Revised | 110.93 Added 11A-9-3a and 11A-9-3 M1A9-4 10 149-8 1199 1189-10 Ao 118-9442 Revised A041 11A-10-2 Revised | | 11A-10-3 and 11A-10-4 Added 11A-10-5 and 114-106 MA10-7 Revised | 11A-11-1 Added Aan WAM1-8 10 11A-41-6 Revised | 11A-11-7 Added AAt-8 A124 WA-12-1a and 11A-12-1b Revised | 1812-2 Added A123 and A124 11A-12-5 and 118-126 Revised | 114-127 Missing sheets will be supplied upon request. May 2000 PWEESSC2-G Revision Code ° >> HHMHMHHHHOMB®OM >oRorO> ° momo mMO>OOo0 Date ‘May 2000 Dec. 1998 May 2000 Nov. 1996 May 2000 Dec. 1998 May 2000 May 2000 May 2000 May 2000 May 2000 Dec. 1998 ‘May 2000 Dec. 1998 May 2000 May 2000 Nov. 1995 Nov. 1995 May 1995 Nov. 1995 July 1997 Nov. 1995 July 1997 May 2000 July 1997, Nov. 1995 May 1995 May 2000 Dec. 1998 May 2000 Dec. 1998 May 1995 Nov. 1995 May 1995 ‘May 2000 May 1995 ‘May 2000 ‘May 2000 ‘May 2000 Nov. 1995 ‘May 2000 Dee. 1998 Remarks Added Added Revised Revised Added Revised Added Revised Revised Revised Added Revised Revised Revised Revised Revised Revised Revised Revised Revised11A-0-1 ENGINE 4G9 SERIES CONTENTS 11A-0-3 TAT TAA TAT TAA GENERAL INFORMATION 1. SPECIFICATIONS . SERVICE SPECIFICATIONS . REWORK DIMENSIONS . TORQUE SPECIFICATIONS NEW TIGHTENING METHOD-BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA . SEALANT ...... FORMAN-PLACE GASKET TAA-7 1A4-7 oe TAB 2 A241 2. SPECIAL TOOLS 3. ALTERNATOR AND IGNITION SYSTEM . TAS 4. TIMING BELT .. 2 WAM 5. FUEL AND EMISSION CONTROL SYSTEM 11AS-1 5a. THROTTLE BODY AND EGR SYSTEM (GDI) . . 11A-5a-1 6. INTAKE AND EXHAUST MANIFOLD 11A-6-4 6a. INTAKE MANIFOLD (GDI) - 11A-6a-1 Gb. EXHAUST MANIFOLD (GDI) cee TAB 6c. INJECTOR AND FUEL PUMP ASSEMBLY (GDI) = 11A-60-1 7. WATER PUMP AND WATER HOSE .. MATA 8. ROCKER ARMS AND CAMSHAFTS ... 110-81 8a, ROCKER COVER AND CAMSHAFTS (MIVEC) - 1A-Ba1 8b.ROCKER ARMS AND ROCKER SHAFT CAPS (MIVEC) ...... 11A-8b-1 9. CYLINDER HEAD AND VALVES . TAS 110-104 10.FRONT CASE AND OIL PUMP .. 11. PISTON AND CONNECTING ROD . WA1-1 12. CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND > DRIVE PLATE . . 11A612-4 (© Mtaublahi Motors Corporation Dec. 1008 PWEESSO2-E Revieed11A-0-2 NOTES (© eublani Motors Corporation May 1995 PweEsso24G9 ENGINE (E-W) General Information 11A-0-3 GENERAL INFORMATION 4G92 Descriptions. | 4@92-soHC '4G92-DOHC-MIVEC Type Inne OHV, SOHC Indine OHV, DOHC Number of cylinders 4 4 ‘Combustion chamber | Pentroof type "| Pentroot type Total displacement dm? 1,597 7 1,597 Cylinder bore mm le10 81.0 Piston stroke mm 75 [rs Compression ratio 100 110 ~ | Valvetiming | Intake | Opens | 20°, 14°" 17° (Low-speed cam) - valve | (BTDC) 47.8" (High-speed cam) Closes | 42°, 58°* 31° (Low-speed cam) (ABDC) 72.5° (High-speed cam) Exhaust. | Opens | 54°, 52°* - 41° (Low-speed cam) {valve | (BBDC) | 70° (High-speed cam) | Closes | 2°, 16°* 11° (Low-speed cam) | (aT0C) 35° (High-speed cam) Lubrication system Pressure feed, ful-low fitrtion | Pressure feed, fullfiow titration Oil pump type | Trochoid type Trochoid type | Cooling system Water-cooled forced circulation | Water-cooled forced circulation | Water pump type Centrifugal impeller type Centrifugal impeliertype *: LANCER for general export and CARISMA for 6B model (© Miteubiah! Motors Corporation uly 1007 PWEEDEO2-C Revieed11A-0-4 4G9 ENGINE (E-W) — General Information 4G93 Descriptions ‘4G93-SOHC. ‘4G98-DOHC ‘4G93-DOHC-GDI Type In-line OHV, SOHC | Indine OHV, DOHC _| In-line OHV, DOHC Number of cylinders 4 4 4 Combustion chamber Pentroo! type Pentroot type Pentroot type Total displacement dm? 1,834 1,834 1,834 Cylinder bore mm 810 810 810 Piston stroke mm 89.0 89.0 89.0 Compression ratio 10.0, 9.5 10.5 ur 202 | Valve timing | Intake | Opens | 14° 20° mr valve | (BTDC) | Closes | 50° 60° 56° - (ABDC) Exhaust | Opens — | 58° er 55° vaive | (@BDC) Closes | 10° 15° 15° (aTDC) Lubrication system Pressure feed, full | Pressure feed, full | Pressure feed, full flow filtration flow filtration flow filtration il pump type Trochoid type Trochoid type Trochoid type Cooling system Water-cooled forced | Water-cooled forced | Water-cooled forced | circulation circulation, circulation Water pump type Centrifugal impeller | Centrifugal impeller | Centrifugal impeller type ‘ype | type *: Up to 1999 model *2 From 2000 model Matis Motors Corporation May 200 Pwecssoao vised4G9 ENGINE (E-W) — General information 11A-0-5 4G94 Deseriptions “4G94-DOHC-GDI Type Inline OHV, DOHC | Number of cylinders 4 | Combustion chamber Penttroo! type - ~ | Total displacement dm? ~ [4,999 ~ Cylinder bore mm as Piston stroke mm 958 _ — ‘Compression ratio ~ 106 Valve timing | Intake 18° 7 a valve 1" ~ Exhaust 55° | valve Closes | 15° (aTDC) Lubrication system Pressure feed, full-flow filtration il pump type Trochoid type Cooling system Water-cooled forced circulation Water pump type Centrifugal impeller type {© Mitgublahi Motors Corporation May 2000 PweESs02.4G9 ENGINE (E-W) — Spec 11A-1-1 1. SPECIFICATIONS SERVICE SPECIFICATIONS tems Standard value Limit Timing belt _ ‘Auto-tensioner rod protrusion amount (When removed from engine) | 11 - mm’ ‘Auto-tensioner rod stroke mm Within 1 = ‘Auto-tensioner rod protrusion amount (When checking with installed | 3.8 - 4.5 - ‘on engine) mm Rocker arms and camshaft ‘Camshaft cam 4G92-SOHC™ [intake 37.34 height mm [Exnaust «| 96.79 - 4G92-S0HC2 | Intake 3778 Exhaust 37.83 4G92-SOHC'S Intake 36.92 Exhaust 36.70 a} 4G93-SOHC Intake 37.53 [Exhaust «| 97.64 ‘4G93-DOHC [Intake - 95.31 Exhaust 35.20 ~~ 4ges-DoHe-eo! Intake 95.49 | _ Exhaust 73 4G94-D0HC-GD|__| Intake 35.49 Exhaust 34.91 | Valve clearance mm Intake (0.09 = Exhaust 0.20 = ‘Camshaft journal 0.0. mm SOHC 26.0 = DOHC | 45.0 - Rocker cover and camshaft (MIVEC) ‘Camshaft height mm Intake A 36.41 36.91 Intake B 33.58 33.08 Exhaust A 35.83 35.33 Exhaust 34.24 33.74 ‘Valve clearance (cold engine) mm Intake Exhaust 02 = Cylinder head and valve Cylinder head gasket surface flatness mm Less than 0.08 0.2 Grinding limit of cylinder head gasket surface mm = 02 “Total resurfacing depth of both cylinder head and cylinder block LANCER for Europe and CARISMA for Europe LANCER for general export and CARISMA for 68 model LANCER for Europe (trom 2001 model) and CARISMA for Europe (trom 2001 model) (© miteubiahi Motors Corporation May 2000 PWEESECO-G Revised11A-1-2 4G9 ENGINE (E-W) — Specifications Items Standard value Limit inder head overall height mm ‘SOHC 119.9 - 120 = DOHC 131.9- 132.1. = DOHC-MIVEC 119.8 — 120.0 = DOHC-GDI 131.9- 182.1 = Thickness of valve | SOHC Intake 1.0 7 7 head (margin) mm Exhaust 737 a DOHC Intake 10 Exhaust 12 Valve overall height | SOHC "| Intake [110.15 mm Exhaust [113.70 DOHC. “| Intake 10419 Exhaust 103.87 DOHG-MIVEC Intake 115.63 Exhaust [115.63 DOHC-GDI Intake 104.19 Exhaust 103.87 Valve spring free length mm ‘SOHC (Except from | 50.9 - 2001 model vehicles for Europe) ‘SOHC (From 2001 | 49.5 485 model vehicles for Europe) DOHC 45.0 «| 44.0 DOHC-MiVEC [515 50.5 | DOHC-GDI 44.8 - 43.8 Valve spring out-of-squareness “Max. 2° ae Valve stem to valve | Except DOHC-GDI | Intake ~ [002-005 0.10 Quide clearance mm | for PAJERO io Exhaust 005 0.00 018 DOHG-GDI Intake 002-005 (010 for PAJERO io Exhaust 0.04- 0.06 0.15 Valve seat valve contact width mm 0.9-1.3 [= Valve guide projection from cylinder head | SOHC 14.0 ~ = upper surface mm tpone Teo = Valve stem projec- | SOHC Intake 49.30 tion mm Exhaust 49.35 DOHC [Intake | 48.70 | Exhaust 46.65 DOHC-MIVEC Intake 58.13 - Exhaust [57.85 DOHC-GDI Intake | 46.70 [ Exhaust 46.65 Cylinder head bolt shank length mm EE ‘© mitaubiani Motors Corporation May 2000, PWEESEO2-ns 11A-1 4G9 ENGINE (E-W) — Spec tems Standard value Limit Valve stem 0.0. mm 7 - = “| Valve face angle ~ ~ = Valve spring load/installed height Nimm SOHC = | DOHC 255/445 = DOHC-MIVEC 255/445 = DOHG-GDI 196/97.5 = Valve guide 1.D. mm 6.0 |= Font case, oil pump and oil pan - 7 Oilpump tip clearancemm 0.06 - 0.18 = _ ‘Oil pump side clearance mm 0.04 - 0.10 = od 0.10 - 0.18 0.35 Piston and connecting ~ : Piston ring to piston ring groove clearance | No. 1 (0.03 - 0.07 04 - mm No.2 002-006 «(| Ot Piston ring end gap | No. 1 4G92, 4693 0.25 - 0.40 08 mm [4co4 | 0.15-0.30 08 No.2 0.40-0.55 08 Oil ring 1 0.20-0.60 Oo | 0.10 - 0.95 10 Crankshaft pin oil clearance mm. _ [0.02 -0.05 4 Piston pin press-in load N [Room temperature] 4,500 ~ 14,700 = ‘Connecting rod big end side clearance mm [010-025 4 Piston pin 0.D. mm 19.0 = / Piston 0.0. mm 4692, 4693 81.0 = 4694 815 = Crankshaft, cylinder block, flywheel and drive plate _ Crankshaft journal oll clearance mm 0.02 - 0.04 ot ‘Cylinder block gasket surface flatness mm 0.05 O41 Grinding limit of cylinder block gasket surface mm = 02" | “Total resurfacing depth of both eylinder head and cylinder block Cylinder block overall height mm “4G92 243.5 ~ - 4693 263.5 = 4G94 286.7 = — | Cylinder block LD. mm 4692, 4693 81.0 = | 4G94 815 = Piston to cylinder clearance mm 0.02 - 0.04 = Bearing cap bott shank length mm = 7a — ‘Crankshaft end play mm. 0.05 — 0.25 0.4 - ‘Crankshaft journal 0.0. mm 50 - - Grankshaft pin 0.D. mm 45 = - ‘©Mbaublahi Motors Corporation May 2000 PWEESEO2.G Revised11A-1-4 4G9 ENGINE (E-W) — Specifications REWORK DIMENSIONS Items Cylinder head and valve ] Standard value Oversize rework dimensions of valve guide hole (both intake and | 0.05 0.S. 11.05 — 11.07 exhaust) mm 02508. _—*| 14.25- 11.27 (0500.8. 11.50 11.52 ‘Oversize rework dimensions of intake valve | SOHC 0.30 0.8. 31.80 ~ 31.83, Seat hole mm 0.6008. 32.10 - 32.13 DOHC 0.30 OS. 3490-3492 | 0.600. 3460-3462 | Oversize rework dimensions of exhaust valve | SOHC 03008. 29.30 29.52 seat hole mm 0600.8. 29.60 - 29.62 DOHC 03008. _—_—*| 80.80-30.82 06008. __—| 31.10-31.18 Crankshaft, flywheel and drive plate - - Crankshaft out of roundness and taper of journal and pin mm - (0.005 NOTE .D.: Outer diameter LD: Inner diameter OS: Oversize diameter TORQUE SPECIFICATIONS Items Tm Alternator and ignition system ~ ~ ~ Oillevel gauge [8 Distributor 12 - Ignition coil [10 Spark plug _ aE Crankshaft bolt - 181 - ‘Alternator brace (M8) |e - Alternator brace (M10) 149 - | Lock bolt 7 - 23 ‘Adjusting bolt | 10 ‘Adjusting bolt Tag —_ Power steering pump pulley 7 [e _ Power steering pump bracket stay ar) Power steering pump bracket (M8) : at “| Power steering pump bracket (M10) ab _ _ Alternator _ _ 44 Genter cover is {© mitaubishi Motore Corporation May 2000, PWEESSO24G9 ENGINE (E-W) — Specifications 11A-1-5 tems Nm Ignition failure sensor (M6) 5 Ignition failure sensor (M8) 23 Cam position sensor 9 ‘Cam position sensor support 13 ‘Cam position sensing cylinder ” 21 ~ Engine cover 29 Timing belt - - | Camshatt sprocket bolt 88 Cam position sensor 98 Crank angle sensor 98 - Timing belt rear cover - " ~ Timing belt tensioner _ 7 - [ea Engine support bracket, right Tag a Accessory mount 49 - Timing belt cover ~ 1" “Tensioner pulley bolt [49 Tensioner arm bolt 44 7 ‘Auto-tensioner bott - — 13 Idler pulley bolt | 36 Fuel system and emission system 7 " | Breather tube - 24 Fuel pump 6 Carburetor 7 EGR valve a Fuel retum pipe - 2 Delivery pipe 7 12 Fuel pressure regulator |e Throttle body stay a 23 —_ Throttle body 19 — ‘Vacuum hose and pipe assembly | 10, | Vacuum hose and pipe assembly 9 ‘Solenoid valve assembly 1 Solenoid valve assembly 9 Throttle body andEGR system (GDI) — ~ Air intake resonator — ye Intake manifold stay (M8) 20 - Intake manifold stay (M10) _—_ 30 Water hose clamp 13 (@Mtsubiehi Motors Corporation May 2000 PWEEDSO2-G Revised11A-1-6 4G9 ENGINE (E-W) - Specifications Items Nm ‘Water pipe 7 7 " Throttle body 18 | Throttle body stay EGR valve (Washer) 8 - EGA valve (Flange) [ea Engine hanger : 18 EGR valve support bot 18 EGR valve support nut 23 Air by-pass valve 9 Intake manifold and exhaust manifold - - Exhaust manifold (M8) 18 Exhaust manifold (M10) — 29° Exhaust manifold bracket (M8) - 19 Exhaust manifold bracket (M10) 35 Engine hanger — M42 ~ Oil level gauge guide [14 Boost sensor 5 Intake air temperature sensor [13 Heat protector — 3 Intake manifold 20 Intake manifold stay 30 ‘Oxygen sensor a [a4 Intake manifold (GDI) 7 ~ ‘Vacuum pipe and hose 1 ‘Vacuum pipe and hose ‘Solenoid valve 9 Fuel pump protector [3 Connector bracket ~ 1 Branch tube (M6 x14) _ 1 Branch tube (M6 x 18) [9 Intake manifold stay ~ 30 ‘Accelerator cable bracket 9 Vacuum pipe — 1 Intake manifold 19 Exhaust manifold (GD!) 7 —_ Oillevel gauge guide - 18 Exhaust manifold cover _ i Engine hangerbot 24 (© mitgublehiMotore Corporation May 2000 PWEESSC2-G Revieed4G9 ENGINE (E-W) - Specifications 11A-1-6a Items Nm Engine hanger nut (M8) 18 Engine hanger nut (M10) Exhaust manifold bracket (MB x 20) ; 18 Exhaust manifold bracket (MB x 22) _— 35 | Exhaust manifold bracket (MB x 25) _ 19 ~ Exhaust manifold bracket (M10) ~ 3 | Exhaust manifold bracket (For PAJERO io) ~ [98 Exhaust manifold (MB) 7 ~ Exhaust manifold (M10) — 29 Injector and fuel pump assembly (GD!) ~ Fuel low pressure pipe (M6) [8 Fuel low pressure pipe (M8) 9 Fuel nipple Clamp o Fuel feed pipe [n - Fuel pump 7 Harness bracket 1 7 Fuel pipe — " Fuel return pipe — [1 Fuel return pipe clamp _ a0 | Fuel high pressure regulator 18 “| Fuel pressure sensor 23 ~ | Fuel pressure sensor 18 Spacer 18 ~ Pump camshaft case 23 Injector holder ” Delivery pipe and injector ‘Water pump and water hose Water pump 24 ‘Water inlet pipe 14 Thermostat case 24 Water inlet fitting Water inlet fiting Water by-pass fitting Water pipe 13 Water outlet fiting cr ~ Water outlet fiting [23 — | Engine coolant temperature gauge unit 10 7 © witaubishi Motors Corporation May 2000, ‘PWEEDSO2-G Revised11A-1-6b 4G9 ENGINE (E-W) - Specifications Engine coolant temperature sensor Rocker arms and camshaft Lock nut Rocker arm shaft Hamess bracket Rocker cover | Bearing cap bolt (M6) Bearing cap bolt (M8) Beam camshaft cap (M6) Beam camshaft cap (M8) _ Rocker cover and camshafts (MIVEC) Rocker cover spring holder ‘Camshaft bearing cap (M6) Camshaft bearing cap (M8) Oil control valve Rocker shaft cap Rocker arms and rocker shaft caps (MIVEC) Nm | 29 128 Cylinder head and valves Cylinder head bolt | Oil pressure switch Front case and oll pump Oil pump cover 74 Nm and then completely loosen, finally tighten 20 Nm + 90° + 90° 10 il pump case Relief plug Oil screen Oilpan Upper oil pan Upper oil pan Upper oil pan Lower oll pan Cover Baffle plate Drain plug Oil pressure switch | Baffle plate mounting bolt (© MReubishi Motors Corporation May 2000 PWEEDSO2.G Revised4G9 ENGINE (E-W) — Specifications 11A-1-6c tems Nm ston and connecting rod. Connecting rod cap nut 20 + 90° to 100° ‘Crankshaft, cylinder block, flywheel and drive plate Bearing cap bolt oil Bell housing cover case 25 + 90° to 100° Rear plate " Drive plate bolt ~ - 2 “| Fiywhesl bot 38 Balle plate a Knook sensor 22 (© Mitsublehi Motors Corporation May 2000 PWEEDSO2.G11A-1-6d ‘© Mitaubiehi Motors Corporation 4G9 ENGINE (E-W) — Specific Intentionally blank May 2000 PESO.11A-1-7 NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA ‘A new type of bolts, to be tightened in plastic area, is currently used for some parts of the engine. The tightening method for bolts of this type is different from the conventional one. Be sure to observe the method described in the text when tightening the bolts. Service limits are provided for the bolts. Make sure that the service limits described in the text are strictly 4G9 ENGINE (E-W) - Specifications observed. . (1) Cylinder head bolts (2) Main bearing cap bolts (3) Connecting rod cap bolts © Tightening method After tightening the bolts to the specified torque, tighten them another 90° or 180° (twice 90°). The tightening method varies on different areas. Observe the tightening method described in the text. Areas where the bolts are in use: SEALANT items | Specified sealant ‘Quantity Water pump Mitsubishi Genuine Part No.MD970389 or equivalent | As required Thermostat case Mitsubishi Genuine Part No.MD970389 or equivalent | As required Water by-passfiting Mitsubishi Genuine Part No.MD970389 or equivalent | As required | Water fiting Mitsubishi Genuine Part No.MD970389 or equivalent | As required Engine coolant temperature sensor | 3M Nut Looking Part No.4171 or equivalent As required Engine coolant temperature gauge unit | 3M ATD Part No.8660 or equivalent _ As required | Camshatt bearing cap 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 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. Form-in-Place Gasket Application When assembling parts with the FIPG, you must observe some precautions, but the procedures is very simple as in the case of a conventional precut gasket. Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When the parts are mounted, make sure that the gasket is applied to the required area only. In addition, 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. The FIPG application procedure may vary on different areas. Observe the procedure described in the text when applying the FIPG. © Mtaubiahi Motors Corporation May 1905 PWEEDS024G9 ENGINE (E-W) — Special Tools 11A-2-1 2. SPECIAL TOOLS Too! | Number MB990767 _& Oo wacom 7 Name “Handle Crankshaft pulley holder Use Use with MD998776 Holding camshaft sprocket when loosening and tightening of bolt Use with MD898719 | B991659 Cylinder head bolt wrench | Guide D 2 MD998440 Leak-down tester | Leak-down test of lash adjuster fi £ | 4 mos98442 Air bleed wire Air bleeding of lash adjuster |996713 | Camshaft oil seal | Installation of camshaft oil seal © | Staller 998716 Crankshaft wrench Rotation of crankshaft when installing piston ©) and timing belt. "| MD998717 Crankshaft front oi! | Installation of crankshaft front oil seal ; o seal installer Tightening and loosening of cylinder head bolt Removal of piston pin (Use with MD998780) {© mteubishi Motors Corporation Nov. 199511A-2-2 4G9 ENGINE (E-W) - Special Tools Tool Number Name Use| MD998719 Pulley holder pin | Use with MB990767 § g (2) | ® ® i _ MD398727 Cll pan remover | Removal of the oil pan - | j j | MD998754 Use with MB990767 ~| ® ® MD998767 Tensioner pulley | Adjustment of timing belt tension ES socket wrench 1 ! | "| MD998772 Valve spring Removal and installation of valve and related compressor parts MD998774 " Installation of valve stem seal | mo998775 Valve stem seal | Installation of valve stem seal | installer | 998776 Crankshaft rear oil | Installation of crankshaft rear oil seal seal installer Use with MB99038 © mnaubieh Motor Corporation Now. 1985 PWEEDSOR-A Revie4G9 ENGINE (E-W) — Special Tools 11A-2-3 Tool Number Name Use — | MD998780 SETTING TOOL | Removal and installation of piston pin —_—| Piston pin | | MD998735 Valve spring ‘Compression of valve spring _ compressor e MD998781 Flywheel stopper | Holding flywheel and drive plate SZ | 1'MB991477 Valve adjusting ___ Adjustment of valve clearance (MIVEC) S wrench | MB991478 Valve adjusting | Adjustment of valve clearance (MIVEC) wrench feeler ‘gauge set | MB991479 Rocker arm 7 valve clearance (MIVEC) 2 | piston checker MD998784 Valve spring ‘Compression of valve spring (MIVEC) _ compressor (Use with MD998772) adapter (© taublahi Motors Corporation Nov. 1995 PWEEDSO2-A Revised4G9 ENGINE (E-W) - Alternator and Ignition System 11A-3-1 3. ALTERNATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION (Engines with distributor) 18 Nm SENOS64 Removal steps 1. Drive belt” 6. Flange 2. Alternator 7. Spark plug cable 3. Alternator brace 8. Spark plug 4A PB 4 Crankshatt bolt 9: O-ring 5. Crankshaft pulley 0. Distributor NOTE: *: For details of adjustment, refer to the relevant model's chassis workshop manual (© Mteubiehi Motors Corporation May 2000 PWEEDSO2-0 Revised11A-3-2 4G9 ENGINE (E-W) - Alternator and Ignition System REMOVAL AND INSTALLATION (Engines without distributor) Removal steps Drive belt” Alternator Alternator brace Crankshatt bolt Crankshatt pulley Front flange Spark plug cable Ignition: coil park plug

(Engines without distributor) \ 1 4 a Nm SENO273 Removal steps 4. Drive belt 7. Spark plug cable 2. Alternator 8. Ignition coil 3. Alternator brace 9. Spark plug AD PB 4 Crankshatt bolt 10. Cam position sensor 5. Crankshaft pulley Aq 11. Cam position sensor support 6. Front flange 12. Cam position sensing cylinder NOTE: "For details of adjustment, refer to the relevant model's chassis workshop manual. @mtaubiahi Motors Corporation Dec. 1908 PWEESSO2-E ‘Added11A-3-2b 4G9 ENGINE (E-W) — Alternator and Ignition System ‘© itaubieni Motors Corporation Dec. 1086 PWEESSOR-E ‘Added4G9 ENGINE (E-W) — Alternator and Ignition System REMOVAL AND INSTALLATION 3 Nm—@ 9ENOS65 Removal steps 1. Drive belt” 7. Center cover 2. Alternator 8. Ignition coil 3. Alternator brace 9. Spark plug cable Ap PB 4 Crankshatt bolt 10. Spark plug 5. Crankshaft pulley 411 Ignition failure sensor 6. Flange NOTE: *! For details of adjustment, refer to the relevant model's chassis workshop manual. (© miteubiahi Motors Corporation Nov. 1985 PWEEDSO2-A Revised11A-3-4 4G9 ENGINE (E-W) - Alternator and Ignition System REMOVAL AND INSTALLATION senor0 Removal steps 4. Drive belt 2. Alternator 3. Alternator brace AD PB 4 Crankshatt bolt 5. Crankshaft pulley 7. Center cover aS 10. Spark plug 41. Cam position sensor 6. Front flange D-A PB ish Motors Corporation Removal steps Drive beit” Alternator Alternator brace Crankshaft bolt Crankshaft pulley Front flange Engine cover Earth strap (From 2001 model for CARISMA, From 2001 model for SPACE STAR) Ignition coil May 2000 NOTE: 10. 11A-3-5 9ens056 Spark plug 41. Cam position sensor pad iz, 14. Cam position sensor support Cam position sensing cylinder Ignition failure sensor (From 2001 model for CARISMA, From 2001 model for SPACE STAR) *: For details of adjustment, refer to the relevant model's, chassis workshop manual. PweEss02. Revised11A-3-6 4G9 ENGINE (E-W) - Alternator and Ignition System REMOVAL AND INSTALLATION 10.Nm BN 25 Nm 9.Nm 49.Nm 23Nm l 6 ¢ 3 2 23 Nm 44m 4 SEN0954 Removal steps 1. Oil level gauge 10. Power steering pump pulley 2: Oil level gauge guide 11. Power steering pump bracket stay 3, O-ring 12. Power steering pump bracket 4. Drive bett* 13. Ignition coil 5. Alternator 44. Spark plug 6. Alternator brace 1. Cam position sensor Ap PB 7. Crankshatt bolt DeA-¢ 16. Cam position sensor support 8. Crankshaft pulley 17. Cam position sensing cylinder 9. Front flange NoTe: *: For details of adjustment, refer to the relevant model's chassis workshop manual. (© mitaublahi Motors Corporation Dec. 1980 PweEDse2-€ Revised4G9 ENGINE (E-W) - Alternator and Ignition System 11A-3-7 REMOVAL SERVICE POINT “44> CRANKSHAFT BOLT REMOVAL (1) Use the special tool to hold the flywheel or the drive plate, and then loosen the crankshaft mounting bolts. INSTALLATION SERVICE POINTS -A(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 Part No. MD970389 or equivalent. 9EN0713) > B-@ CRANKSHAFT BOLT INSTALLATION (1) Use the special tool to hold the flywheel or the drive plate, and then tighten the crankshaft mounting bolts. (@Mtaubiohi Motors Corporation Dec. 1900 PWEEDSO2-E Added4G9 ENGINE (E-W) — Timing Belt 11A-4-1 4. TIMING BELT REMOVAL AND INSTALLATION 9ENOOIB Removal steps 1. Timing belt front upper cover 8. Crankshaft angle sensor 2. Timing belt front lower cover {Engines without distributor) 3. Engine support bracket, right 9. Crankshaft sprocket <4Ap PD 4. Timing belt 10. Crankshaft spacer 5. Tensioner spring {Engines without distributor) 8. Timing belt tensioner 11. Crankshaft sensing plate 7. Timing belt rear cover {Engines without distributor) 12. Crankshaft key BP PAM 13. Camshaft sprocket bolt 44. Camshaft sprocket (© mitaublahi Motors Corporation May 2000, PWEEDSO2-G Revises11A-4-1a 4G9 ENGINE (E-W) — Timing Belt REMOVAL AND INSTALLATION 49. Nm 3 2 Removal steps Timing belt front upper cover Timing belt front lower cover Engine support bracket, right Timing belt Tensioner spring Timing belt tensioner Timing belt rear cover Crankshaft angle sensor (Engines without distributor) Ay pOd <=>! bBd PrNOMaoN (@Miaublahi Motors Corporation May 2000, sen105s Crankshaft sprocket 10. Crankshaft spacer Engines without distributor) rankshaft sensing plate (Engines without distributor) 42. Crankshaft key BP PA 13. Camshaft sprocket bott 14. Camshaft sprocket 1 PwEEDS02-6 Added4G9 ENGINE (E-W) — Timing Bett 11A-4-1b Intentionally blank (© titaubiahi Motors Corporation May 2000 PwEEDSO2-G ‘aed11A-4-2 4G9 ENGINE (E-W) — Timing Belt REMOVAL AND INSTALLATION 2 gENO274 Removal steps 4. Timing belt front upper cover 8. Crankshaft angle sensor 2. Timing belt front lower cover 9. Crankshaft sprocket 3, Accessory mount 10. Crankshaft spacer AD PDE 4 Timing bert 41. Crankshaft sensing plate PC 5. Tensioner spring 12. Crankshaft key PB 6. Timing belt tensioner 4B PAM 13. Camshatt sprocket bolt 7. Timing belt rear cover 14. Camshaft sprocket (© miteubiahi Motors Corporation Dec. 1998 PWEESSOZE Revised4G9 ENGINE (E-W) - Timing Belt 11A-4-2a REMOVAL AND INSTALLATION Removal steps 1. Timing belt upper cover 11. Cam position sensor 2. Timing belt lower cover 12. Crank angle sensor 3, Engine support bracket 18. Crankshaft sprocket AD PF 4 Timing belt 14. Sensing plate 5. Tensioner pulley 18. Crankshaft spacer 6. Tensioner arm 16. Crankshaft sprocket key 7. Shaft PAM 17. Camshatt sprocket bolt PE 8. Auto-tensioner 18. Camshaft sprocket 9. Timing belt rear cover 19. Timing belt rear cover 10. Idler pulley 20. Timing belt rear cover (C Mtoubiehi Motors Corporation Dec. 1908 PwEESSOZE Revised11A-4-2b 4G9 ENGINE (E-W) - Timing Belt REMOVAL AND INSTALLATION Removal steps Timing belt front upper cover . Timing belt front lower cover . Engine support bracket, right Timing belt Tensioner pulley Tensioner arm/ Shaft . Auto tensioner . Timing belt rear cover Idler pulley PF DEC Seenogsena ‘© maublani Motors Corporation Dec. 1996 1. 12 13. 14. 15.

e 1 5 6 " y abe hg Pl: Removal steps Timing belt front upper cover Timing belt front lower cover Engine support bracket, right 1 2 3 A> PF < 4 Timing belt 5, Tensioner pulley 6. Tensioner arm 7. Shatt 8, Auto tensioner Timing belt rear cover 10. Idler pulley Crankshaft angle sensor {Up to 1999 model rankshaft angle sensor (From 2000 model) DE (© mteubiehi Motors Corporation May 2000 16. 11Nm 49. Nm 9.8 Nm 9eN1057 Removal steps 1. Timing belt front upper cover 10. Idler pulley 2. Timing belt front lower cover 11. Crankshaft angle sensor 3, Engine support bracket, right 12. Crankshatt sprocket Am PF 4 Timing belt 48. Crankshaft spacer 5. Tensioner pulley 44. Crankshaft sensing plate 6. Tensioner arm 15. Crankshaft key 7. Shatt 4B PAM 16. Camshaft sprocket bolt PE 8 Auto tensioner 17. Camshatt sprocket 9. Timing belt rear cover 18. Timing belt rear upper cover (© mtaubieh! Motors Corporation May 2000, PwEEDSO2-G Revises4G9 ENGINE (E-W) - Timing Belt 11A-4-2e REMOVAL AND INSTALLATION 88 Nm 17 11.Nm 1 6 11m 41.Nm 8 3 13.Nm 49.Nm SENOSSS 2 Removal steps 1, Timing belt front upper cover 11, Bracket 2. Timing belt front lower cover 12. Crankshaft angle sensor 3, Accesory mount 13. Crankshaft sprocket AD PF 4 Timing belt 14. Crankshaft sensing plate 5. Tensioner pulley 15, Crankshaft spacer 6. Tensioner arm 16. Crankshaft key 7. Shaft PAM 17. Camshaft sprocket bolt DE 8. Auto tensioner 18. Camshatt sprocket 9. Timing belt rear cover 49. Timing belt rear cover 10. Idler pulley 20, Timing belt rear cover (@taubiohi Motors Corporation May 2000 PWEEDSO2-0 ‘aed11A-4-2f ‘© miteubiahi Motors Corporation May 2000 4G9 ENGINE (E-W) — Timing Belt Intentionally blank PWEESSC2-G ‘des4G9 ENGINE (E-W) — Timing Belt 11A-4-3 REMOVAL SERVICE POINTS <4Ap TIMING BELT REMOVAL. (1) Mark belt running direction for reinstallation. 48> CAMSHAFT SPROCKET BOLT REMOVAL, enor (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 >A CAMSHAFT SPROCKET BOLT INSTALLATION (© Witeublahi Motors Corporation Now. 1095 PWEESSO2-A Revised11A-4-4 4G9 ENGINE (E-W) — Timing belt pulley fixing (// G LAN genos70 ‘© mitsubiahi Motors Corporation May 1996 DB TIMING BELT TENSIONER INSTALLATION (1) Let the pulley of the timing belt tensioner come closest to the exhaust side. Temporarily tighten the tensioner pulley fixing bolt. DC-4 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. D-D-4TIMING 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 camshatt 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 Cc.) (3) Align the timing marks on the camshaft sprocket to that ‘on the cylinder head. (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 PWEEDSo24G9 ENGINE (E-W) - Timing Belt 11A-4-5 SENOIA3] SENOIAs (© miteubiahi Motors Corporation Nov. 1995 (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. D-E-4 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 tit 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. PWEEDSO2-A Revised11A-4-6 4G9 ENGINE (E-W) - Timing Belt Timing marks 9enos7a © Mitsubishi Motors Corporation Nov. 1995 DP-F<4 TIMING BELT INSTALLATION (1) Make sure that the auto-tensioner is installed properly. (Refer to service point F.) (2) Align the timing mark on each sprocket with the corresponding mark on the timing belt. (8) Turn the crankshaft sprocket one half the tooth width counterclockwise. (4) Fit the timing belt to the intake camshaft sprocket and secure with a paper clip at the illustrated position. (5) Use two wrenches to fit the timing belt to the exhaust sprocket while aligning the timing marks. PWEESSOE-A Revised4G9 ENGINE (E-W) — Timing Belt Idler pulley} ! water pump Sprocket Crankshaft sprocket 9EN0572 J SRA BS Jf KO? = KY (© Mteublahi Motors Corporation May 1995 11A-4-7 (6) Secure the timing belt with a paper clip at the illustrated position. (7) Fit the belt to the idler pulley water pump sprocket, crankshaft sprocket and tensioner pulley in that order. (8) Raise the tensioner pulley in the direction of an arrow and tighten the tensioner pulley bolt. (9) Remove the two paper clips. (10)Make sure that all timing marks are in alignment. (11)Give a 1/4 counterclockwise tum to the crankshaft. Then tum the crankshaft clockwise to align the timing marks again. PWEESSO24G9 ENGINE (E-W) — Timing Belt ‘ZBENOO6S Cracks Cracks Cracks: Z1ENO249 © wit May 1995 (12) Install the special tool and a torque wrench to the tensioner pulley. (13)Using torque wrench, torque to 2.6 Nm. (14)While holding the tensioner pulley to prevent it from turning, tighten the center bolt to the specified torque. (15)Give two clockwise turns to the crankshaft and leave as it is for approx. 15 minutes. (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, the belt is properly tensioned. Therefore, pull out the wrench. The belt is also properly tensioned if the auto-tensioner projection is of standard value. Standard value: 3.8 - 4.5 mm (17)If the wrench cannot be pulled out lightly, repeat the steps (12) through (15) to obtain appropriate belt tension. 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. ‘190020007 (2) Cracks on rubber back. (3) Cracks or peeling of canvas. (4) Cracks on tooth bottom. (5) Cracks on belt sides. PWEEDS024G9 ENGINE (E-W) — Timing Belt 11A-4-9 (lull strand) Pounded edge ‘Abnormal wear ZBENO067 Rubber exposed: Tooth missing ‘and canvas fiber exposed ‘ZBENOO6S 2EN0159 1mm ENO 98 to 196 N 4 sve SEN1033, (© witsubiehi Motors Corporation May 1995, (6) Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife. (7) Abnormal wear on teeth. (8) Missing tooth. TENSIONER PULLER, IDLER PULLEY (1) Check the pulley for smooth rotation, excessive play, abnormal noise. Replace it if necessary. AUTO-TENSIONER (1) Check the tensioner for oil leaks. Replace it if necessary. (2) Check the rod end for wear or damage. Replace the tensioner if necessary. (3) Measure the rod projection length. If not within the standard value, replace the tensioner. Standard value: 11 mm (4) Press the rod by a force of 98 to 196 N and measure the rod stroke. If not within the standard value, replace the tensioner, Standard value: 1 mm or less PwEED024G9 ENGINE (E-W) — Fuel and Emission Control System 11A-5-1 5. FUEL AND EMISSION CONTROL SYSTEM REMOVAL AND INSTALLATION 18. Nm Removal steps 1. Breather tube 2. Fuel hose 3, Fuel hose 4. Fuel pump 5. Gasket 6. Insulator 7. Gasket 8. Carburetor 9. Gasket 10. EGR valve 11. Gasket {© MitaubishiMotore Corporation Nov. 1996 PweEdso2-8 Reviees11A-5-2 4G9 ENGINE (E-W) jon Control System REMOVAL AND INSTALLATION eo 19 Nm 11. Nm SEN1027 Removal steps 1, Vacuum hose and pipe assembly 10. Insulator 2. Throttle body PA 11. Injector PC 3. Gasket 12. O-ting 4. Vacuum hose 13. Grommet 5. Fuel hose 14, Delivery pipe DB 6. Fuel pressure regulator 15. Fuel return pipe 7. O-ting 16. Solenoid valve assembly 8. Delivery pipe and injector 17. EGR valve 9. Insulator 18. Gasket (© mteubiohi Motors Corporation July 1990 PweEssoar Revises4G9 ENGINE (E-" — Fuel and Emission Control System 11A-5: REMOVAL AND INSTALLATION Removal steps 1. Vacuum hose and pipe assembly 2. Throttle body PC 3. Gasket 4, Vacuum hose 5. Fuel hose DB 6. Fuel pressure regulator 7. O-ring 8. Delivery pipe and injector (© mnaublahi Motore Corporation Dec. 1086 PWEESSOZE x Adi 12. 13. 14. 15. 16. Bo 15 19. Nm SeNosgs Insulator Insulator Delivery pipe Fuel return pipe Solenoid valve assembly Revised11A-5-4 4G9 ENGINE (E-W) — Fuel and Emission Control System REMOVAL AND INSTALLATION re" Removal steps Vacuum pipe assembly Throttle body assembly 1. 2 3G 4, 5 6 7. 8 8 asket Throttle body stay (MIVEC) Vacuum hose Fuel hose DB 7. Fuel pressure regulator -ring Delivery pipe and injector (© mitsubishi Motors Corporation Dec. 1998 PWEEDSO2 16. 9EN0632 Insulator Insulator Injector O-ring Grommet Dalivery pipe Fuel retum pipe Revises4G9 ENGINE (E-W) — Fuel and Emission Control System _11A-5-5 INSTALLATION SERVICE POINTS DA INJECTORS INSTALLATION (1) Apply a small amount of new engine oil to the O-ring Caution Be sure not to let engine oil get into the delivery pipe. (2) While turning the injector to the left and right, install it to the delivery pipe. (3) Check that the injector turns smoothly. If it does not turn smoothly, the O-ring may be trapped. Remove the injector and check the O-ring for damage, and then re-insert it into the delivery pipe and check once again. (4) Check that the clearance between the injector connector and the delivery pipe is uniform (A = B). Injector connector, 9EN0499 > B-4FUEL PRESSURE REGULATOR INSTALLATION (1) Apply a small amount of new engine oil to the O-ring Insert the fuel pressure regulator into the delivery pipe being careful not to damage the O-ring. Caution Be sure not to let engine oil get into the delivery pipe. (2) Check that the fuel pressure regulator turns smoothly. If it does not tum smoothly, the O-ring may be trapped. Remove the fuel pressure regulator and check the O-ring for damage, and then re-insert it into the delivery pipe and check once again. GASKET INSTALLATION (1) Position the projection as shown in the illustration, “ Projection 9eN0500| (© Mraubiohi Motors Corporation Dee. 1008 PweEDso2-e ‘dos11A-5-6 — 4G9 ENGINE (E-W) - Fuel and Emission Control System “ 9ENOBS? (© Mteublan! Motors Corporation Dec. 1066 PWEESSORE4G9 ENGINE (E-W) — Throttle Body and EGR System (GDI) 11A-5a-1 5a. THROTTLE BODY AND EGR SYSTEM (GDI) REMOVAL AND INSTALLATION 8 9eNoset Removal steps 4. Air intake plenum resonator 12. Engine hanger 2. O-ring 18. EGR valve support PB 3. Intake manifold stay 14. Gasket 4. Water hose 15. Water hose (Up to 1998 model for 5. Water hose (Up to 1998 model for CARISMA, SPACE RUNNER) CARISMA, SPACE RUNNER) 16. Air by-pass valve 6. Throttle body (Up to_1998 model for CARISMA, PA 7. Throttle body gasket PACE RUNNER) 8. Ignition hamess 17. Air by-pass valve gasket 9. Water hose (Up to 1998 model for CARISMA, 10. EGR valve ‘SPACE RUNNER) 11. EGR valve gasket ©@mnsubioh! Motors Corporation May 2000 Revised11A-Sa-2 4G9 ENGINE (E-W) - Throttle Body and EGR System (GDI) REMOVAL AND INSTALLATION 18. Nm Removal steps Intake manifold stay (For GALANT) Water hose Water hose Water hose Throttle body stay Throttle body PB popeps ‘© Miaubioh! Motors Corporation May 2000 PwEEDSO2-G bad 7. 8 10. 1 12. Sens058 Throttle body gasket Ignition hamess Water hose EGR valve EGR valve support Gasket4G9 ENGINE (E-W) - Throttle Body and EGR System (GDI) 11A-5a-3 REMOVAL AND INSTALLATION SENOSS6 Removal steps 4. Water hose 9, Throttle body 2. Water hose DPA 10. Throttle body gasket 3, Water hose 11. EGR valve 4; Water hose 12. EGR valve gasket 5. Water hose 18. EGR valve support 6. Water hose clamp 14. Gasket 7. Water pipe 15. Engine hanger 8. Water pipe (© mitaublahi Motors Corporation May 2000 PWEESEC2 Revises11A-5a-4 4G9 ENGINE (E-W) - Throttle Body and EGR System (GDI) “ip te 2000 model for GARISMA, 1999 model for SPACE STAR, SPACE RUNNERS “ Intake manitold Bott Intake manifold stay Bott Cylinder block eNo902 “ "intake manifold SL] Cinter-do ° Intake manifold stay Bott © mitgubiani Motors Corporation May 2000 INSTALLATION SERVICE POINTS DA THROTTLE BODY GASKET D-B-qINTAKE MANIFOLD STAY INSTALLATION (1) Tighten the four bolts at the top and bottom of the stay handtight. (2) Check that the stay seating surface is in close contact with the bosses on the intake manifold and the cylinder block. (3) Tighten the four bolts to the specified torque. PWEESSO-G. ‘died4G9 ENGINE (E-W) - Intake and Exhaust Manifold 11A-6-1 6. INTAKE AND EXHAUST MANIFOLD REMOVAL AND INSTALLATION 20 Nm senonse Removal steps 1. Engine hanger 7. Oring DB 2 Intake manifold stay 8. Exhaust manifold cover 8: Intake manifold 9. Engine hanger 4, Intake manifold gasket PAqq 10. Exhaust manifold bracket A 5. Oil level gauge DPAdd 11. Exhaust manifold bracket B 6. Oil level gauge guide 12. Exhaust manifold 13. Exhaust manifold gasket (© Mitsubishi Motors Corporation Nov. 1996 PWEESSO2-B Revised11A-6-2 4G9 ENGINE (E-W) — intake and Exhaust Manifold REMOVAL AND INSTALLATION 20 Nm 20.Nm 30 Nm Removal I steps Engine hanger Intake manifold stay . Intake manifold . Oil level gauge 1 2. 3. 4, Intake manifold gasket 5. 6. Oil level gauge guide (© miteubiahi Motors Corporation May 2000 PAd 10. padi 12. O-ring Exhaust manifold cover Engine hanger Exhaust manifold bracket A Exhaust manifold bracket B Exhaust manifold Exhaust manifold gasket4G9 ENGINE (E-W) — Intake and Exhaust Manifold 11A-6-2a REMOVAL AND INSTALLATION Removal steps Engine hanger Intake manifold stay Intake manifold Intake manifold gasket 5. Oil level gauge Oil level gauge guide ” O-ring ene ©itaubiahi Motors Corporation May 2000 PWEEDSO2-G 10. 12, 13. 14, 13. Nm sentoes . Oxygen sensor Engine hanger Exhaust manifold cover Exhaust manifold bracket B Exhaust manifold Exhaust manifold gasket Exhaust manifold bracket A11A-6-2b 4G9 ENGINE (E-W) — Intake and Exhaust Manifold Intentionally blank (© mitsubiahi Motors Corporation May 2000 PWEERSO2.G4G9 ENGINE (E-W) — Intake and Exhaust Manifold REMOVAL AND INSTALLATION Removal steps 1. Engine hanger 2. Intake manifold stay 3. Intake manifold 4, Intake manifold gasket 5. Oil level gauge 6. Oil level gauge guide (© Mtaubiah! Motors Corporation Now. 1996 A: vy > AA 1 11A-6-3 120 29 Nm M75 14Nm 19.Nm 9EN0576 . O-ring Engine hanger Exhaust manifold bracket A Exhaust manifold bracket B Exhaust manifold Exhaust manifold gasket11A-6-4 4G9 ENGINE (E-W) — Intake and Exhaust Manifold \ Tek INSTALLATION SERVICE POINT DA EXHAUST MANIFOLD INSTALLATION (1) Install temporarily the exhaust manifold brackets A and B as shown in the illustration. (2) Check that both brackets are in close contact with the bosses, and then tighten fully the bracket mounting bolts. Bracket A >B-qINTAKE MANIFOLD STAY INSTALLATION (1) Install the intake manifold stay with its “UP” mark directed toward the intake manifold. CU SENO817 (© mitsubien| Motors Corporation Now. 1996 PWEEDSO2-B ‘Nites4G9 ENGINE (E-W) — Intake Manifold (GDI) 11A-6a-1 6a. INTAKE MANIFOLD (GDI) REMOVAL AND INSTALLATION 11.Nm 4 9Nm SEN0890 Removal steps 1. Air by-pass hose 5, Connector bracket (Up to 1998 model for CARISMA, 6. Accelerator cable bracket PACE RUNNER) 7. Vacuum hose 2. Vacuum pipe and hose 8. Vacuum pipe 3. Bracket 9. Intake manifold 4. Solenoid valve 10. Intake manifold gasket (© Mitoubiehi Motors Corporation May 2000 PWEESSO2-011A-6a-1a 4G9 ENGINE (E-W, Intake Manifold (GDI) REMOVAL AND INSTALLATION 19.Nm 11.Nm 1 Sento62 Removal steps 1. Vacuum pipe and hose 4. Vacuum pipe 2. Purge hose 5. Intake manifold 3. Solenoid valve (©@Mtaubiohi Motors Corporation May 2000, PWEEDSO2-G ‘Adee4G9 ENGINE (E-W) - Intake Manifold (GDI) 11A-6a-1b | © Miteubiehi Motors Corporation May 2000 PWEEDSO2-G ‘Added11A-6a-2 4G9 ENGINE (E-W) - Intake Manifold (GDI) REMOVAL AND INSTALLATION Removal steps 1. Air by-pass hose 2. Vacuum pipe and hose 3, Bracket 4, Solenoid valve 5. Connector bracket @mnsudishi Motors Corporation Jun. 1998 PweEss02.0 9EN0983 6. Accelerator cable bracket 7. Vacuum hose 8. Vacuum pipe 9. Intake manifold 10. Intake manifold gasket ‘dso4G9 ENGINE (E-W) — Intake Manifold (GDI) 11A-6a-3 REMOVAL AND INSTALLATION Removal steps 1. PCV. hose 2. Vacuum pipe and hose 8. Solenoid valve 4. Fuel pump protector 5. Connector bracket (© Mteublahi Motors Corporation Dec. 1906 PweEDsere 9ENOS95, 6. Branch tube 7. Gasket DA 8. Intake manifold stay 9. Intake manifold 10. Intake manifold gasket11A-6a-4 4G9 ENGINE (E-W) — Intake Manifold (GDI) Intake manifold Intake manifold stay Cylinder block SENoses (© mnaublani Motors Corporation Dec. 1998 INSTALLATION SERVICE POINT DPA 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. PweEDsO2-E ‘aes4G9 ENGINE (E-W) — Exhaust Manifold (GDI) 11A-6b-1 6b. EXHAUST MANIFOLD (GDI) REMOVAL AND INSTALLATION 13. Nm SeNoBe2 Removal steps Oil level gauge Oil level gauge guide O-ring Exhaust manifold cover Engine hanger Exhaust manifold bracket A Exhaust manifold bracket B Exhaust manifold Exhaust manifold gasket pad pad ‘©Miteublahi Motors Corporation May 2000, PWEEDSO2-G Revised11A-6b-1a 4G9 ENGINE (E-W) - Exhaust Manifold (GDI) REMOVAL AND INSTALLATION SENs063 Removal steps Oil level gauge Oil level gauge guide rin ‘Oxygen sensor Engine hanger Exhaust manifold cover Exhaust manifold bracket B Heat protector Exhaust manifold Exhaust manifold gasket Exhaust manifold bracket A FB eenomaen> ©mnaubiehi Motors Corporation May 2000 PWEESSO2G.4G9 ENGINE (E-W) - Exhaust Manifold (GDI) 11A-6b-1b Intentionally blank @Miaubiahi Motors Corporation May 2000 PWEEDSO2-G ‘Added11A-6b-2 4G9 ENGINE (E-W) — Exhaust Manifold (GDI) REMOVAL AND INSTALLATION Removal steps 1. Exhaust manifold cover 4, Exhaust manifold 5. Exhaust manifold gasket (© miteubien! Motora Corporation Dec. 1908 PwEESsO2-€4G9 ENGINE (E-W) — Exhaust Manifold (GDI) 11A-6b-3 senoses SEN0960 © Mteubleh! Motors Corporation ec. 1998, INSTALLATION SERVICE POINTS DA EXHAUST MANIFOLD BRACKET INSTALLATION (1) Slide the washers over the bolts with the chamfered side toward the bolt. (2) Install temporarily the exhaust manifold brackets A and B as shown in the illustration (3) Check that both brackets are in close contact with the bosses, and then tighten fully the bracket mounting bolts. DB EXHAUST MANIFOLD BRACKET INSTALLATION (1) The washers must be installed with the shear-drooped side toward the bolts. (2) Temporarily install the exhaust manifold bracket as shown in the illustration, (8) Verify that the bracket is brought into close contact with the boss on the exhaust manifold, then tighten the bolts to the specified torque. PWEESSO2-E ses4G9 ENGINE (E-W) - Injector and Fuel Pump Assembly (GDI) 11A-6c-1 6c. INJECTOR AND FUEL PUMP ASSEMBLY (GDI) REMOVAL AND INSTALLATION 9.Nm UN 13. Nm val a Vit 27 14 Gy a x "Nm a//f Ns hi 3m 7 \ mis ‘sm s gio 9a , 18 4722Nm m2 9.Nm , i V/ 00 Removal steps 20 m22 19 P 23. Nm SeNoBas 4. Fuel hose D4 20. Fuel pressure sensor 2. Fuel low pressure pipe 21. O-ring 3, O-ring 22. Backup ring 4. Fuel nipple DP C-4 23. Pump camshatt case 5. O-ring 24. O-ring 6. Clamp 25. O-ring DF 7. Fuel feed pipe 26. Hamess bracket 8. Backup ring 27. Injector hamess 9. O-ting 28. Washer 10. Backup ring 29. Injector holder DF -€ 11. Fuel pump PB 30. Delivery pipe and injector 42. O-ring 31. Insulator 13. Harness bracket 32. Injector gasket 14, Fuel return pipe 33, Injector 415. Backup ring PPA-q 34, Corrugated washer 16. O-ring DA-@ 35. Backup ting 17. Backup ring PA 36. O-ring DE-€ 18. Fuel high pressure regulator DA-€ 37. Backup ring 49, Flange 38. Delivery pipe ‘© mteubiehi Motore Corporation May 2000 PWEEDSO2-G11A-6c-1a 4G9 ENGINE (E-W) - Injector and Fuel Pump Assembly (GDI) REMOVAL AND INSTALLATION Removal steps 1. Injector hamess 2, Flange lq 3: Fuel pressure sensor Dl) 4 Backup ring Pld. 5. O-ing BH 6. Fuel pipe PH 7. Backup ring BH 8. O-ring DH-q_ 9. Backup ring G4 10. Fuel pump PG 11. O-ring © Mitaubiah! Motors Corporation May 2000 PWEEss02- 11.Nm we 9EN1033 Washer Injector holder Delivery pipe and injector 15. Insulator Injector gasket Corrugated washer Backup ring O-ing Backup ring Injector Delivery pipe