MITSUBISHI ENGINE 4G9 SERIES (E-W) WORKSHOP MANUAL FOREWORD This Workshop Manual contains procedures for | Engine .. 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 thse manual pages in the binder No. BN940001. File these pages according to the signs “Addod”, "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. 2a MITSUBISHI MOTORS CORPORATION Pub. No. PWEE9502-G © wsubie Motore Corporation May 2000INTRODUCTION EXPLANATION OF MANUAL CONTENTS laintenance and Servicing Procedures: (1) A diagram of the component parts is © Removal steps: provided near the front of each section in ‘The part designation number corresponds order to give the reader a better under- to the number in the illustration to indicate standing “of the installed condition of Temoval steps. component parts, © Disassembly steps: (2) The numbers provided within the diagram The part designation umber corresponds indicate the sequence for maintenance and to the number in the illustration to indicate servicing procedures. disassembly steps. 1: indicates a non-reusable par. © installation steps: The tightening torque is provided where ‘Specified in case installation is impossible applicable. 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. Classification of Major Maintenance/Service Points r 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. “4A ; Indicates that there are essential points for removal or disassembly. DPA-d : Indicates that there are essential points for installation or reassembly. Symbols for Lubrication, Sealants and Adhesives Information concerning the locations for hu it: Grease (multipurpose grease unless trication and tor application of sealants and there Is a brand oF type spectied) adhesives is provided, by using symbol, in . the diagram of component pats or on the sama : Sealant or adhesive care oneal ne ComPonent parts page, IM & Brake fig, auiomatic transmission fhid ‘oF air conditioner compressor oil SW = Engine oil or gear:INTRODUCTION Indicates the section ttle, 409 ENGINE (EW) - Water Pump and Water Hose 11A-7-1 7. WATER PUMP AND WATER HOSE REMOVAL AND INSTALLATION oy bog Taco Beg atm one peg ome ‘maa nit 8 ES thoi A evi pore INSTALLATION SERVICE POINTS~-—~—— Ad WATER PUMP INSTALLATION 18.3.9 dome of FomntnPac Caste (FF S'S Leadon ster tata ero, ‘Soci east inet “Ceruine Pan Mo. MORTON oF cutee ‘Denotes non-reusable part. J This number corresponds to the number appearing in “Removal steps”, “Disassembly steps”, “Installation steps" or “Reassembly steps”, Operating procedures, cau- tions, etc. on removal, installa- ion, disassembly and reas: sembly are described. — Pubiication number-Revision code iLIST OF EFFECTIVE PAGES Poge Revision Date Remarks | Page Revision Date Remarks Code Code AAO E Osc. 1998, WAée-laand11A6e-1b — G ~—- May 2000 Added A038 © duly 1997 11A60-2 10 114-665 E Dec. 1998 118-04 G —-May2000 Revised =| 11A+6e-6 and 114-8e-7 G May 2000 Added 11A05 G May 2000 Added HATA B Nov. 1986 {AAA to 1A4-6 G May 2000 Revised | 110-72 G May 2000 Revived 11A-1-6a and 1-1-6 G May 2000 Revised =| 114.7310 11A-7-5 E Dec. 1998 110-60 and 111-64 G May 2000 Added AB G May 2000 Revised E Dec, 1988 WAS-taand 114-8-1b G May 2000 Added May 1995 1A82 and 1883 G May 2000 Revised A Nov. 1995 118-830 and 114-8-36 G May 2000 Added 140-341 and 1143-2 G — May2000 Revised | 110-84 @ — May 2000 Revised WAs3-2a and 113-20 E Dec. 1998 MAGS and MABE E Dec. 1998 WABSand AGS A Nov. 1995 11A8-7 and 114-68 @ May 2000 Revised 11095 G — May2000 Revised | 1180-9 E Dec. 1998 WA and 1837 E Dec. 1998 WA8-10 10 18-813 G May 2000 Revised AT G — May2000 Revised | 118-14 and 11-8415 G May 2000 Added Ada and 11A4-1b G May 2000 Added 1ABa-1 to 1A-825 A Now 1995 11Aed-2 E Dec. 1998, 14A-8b-1 and HAB-2 A Now. 1995 114-2 and 1144-2 E Dee. 1998, 11A-G-4 and 118-92 May 1995 190-420 and 118-420 G — May2000 Revised | 11809 A Nov. 1995 11A-d2e and HAG G — May 2000 Added 11A-9-a and 119-30 © auy 1997 A443 A Nov. 1995, 11A9-4 10 1189-8, A Nov. 1985 Add May 1995 A998 © day 1997 WA4S and 1A46 A Nov. 1995 10-8410 G May 2000 Revised MA-8-7 to 10-49 May 1995 mAs © July 1997 ASA B Nov. 1996 11A8-42 A Nov. 1995 MAGE F July 1999 Revised | 11A-10-4 May 1995 A5-810 1A56 E Dec. 1998 1A-10-2 G@ May 2000 Revised WAS to 1523 G May 2000 Revised =| 11A-10-3and 11A-10-4 E Dec. 1998 A504 G May 2000 Added ANOS and 114-106 G May 2000 Revised A641 B Nov. 1996 114.107 E Dec. 1998 Ab? G@ — May 2000 Revised | 114-11-1 May 1985 A620 and 1186-25 @ May 2000 Added 1AM? A Nov. 1998 NAGS and NACH B Nov. 1996 TAS t0 TAM May 1995 Abe G — May2000 Revised | 11A41-7 G May 2000 Revised WASelaand TAGe1b = G May 2000 Added AB May 1995 tAGae Daun, 1998 Wadd G May 2000 Revieed T1AsGa-3 and 11A60-4 E Dec, 1998 WAd24aand 1At2-1b == G =~ May 2000 Revised ASb4 G — May2000 Revised | 11A-12.2 G May 2000 Revised WASb-taand 1A6b-1b G_——-May 2000 Added WAA2B and HATA A Nov. 1998 1AC6b-2 and 114-60-3 E Dec, 1998 WARS and 114-126 G May 2000 Revised WA6et G May 2000 Revised | 114-12-7 E Dee, 1998 Missing sheets will be supplied upon request. © mtgeieh ore Corporation May 2000 pw s602-0 Previa11A-0-1 ENGINE 4G9 SERIES CONTENTS, » A038 WAT-4 GENERAL INFORMATION ... 1. SPECIFICATIONS .. SERVICE SPECIFICATIONS . TAA REWORK DIMENSIONS. WA TORQUE SPECIFICATIONS TA-1-4 NEW TIGHTENING HETHOD_BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA a AAT SEALANT ... TAA FORM-IN-PLACE GASKET TAS 2.SPECIALTOOLS ... TA-2-1 3. ALTERNATOR AND IGNITION SYSTEM . TAB-1 4. TIMING BELT AML 5. FUEL AND EMISSION CONTROL SYSTEM TAS-1 Sa, THROTTLE BODY AND EGR SYSTEM (GDI) .. 11ASat 6. INTAKE AND EXHAUST MANIFOLD NA61 6a. INTAKE MANIFOLD (GDI) .. WA6a1 6b.EXHAUST MANIFOLD (GDI) ... A614 6c. INJECTOR AND FUEL PUMP ASSEMBLY (GD!) 1A-60-1 7. WATER PUMP AND WATER HOSE MATA 8. ROCKER ARMS AND CAMSHAFTS TAB 8a, ROCKER COVER AND CAMSHAFTS (MIVEC) NABe-1 ‘6b. ROCKER ARMS AND ROCKER SHAFT CAPS (MIVEC) ABT 9. CYLINDER HEAD AND VALVES TAS-1 10. FRONT CASE AND OIL PUMP . T1A-10-1 11, PISTON AND CONNECTING ROD ...........sseeeeeeee WATT 12, CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE. PLATE ... 1. WA ‘© Miteubieht Motors Corporition Dec. 1986 WEENIE Revieed11A-0-2 NOTES © mteubled Motors Corporation May 10054G9 ENGINE (E-W) — General information 11A-0-3 GENERAL INFORMATION 4G92 Descriptions 4G92-SOHC -4G92-DOHC-MIVEC Type Inline OHV, SOHC " HV, DOHC Number of cylinders 4 4 Combustion chamber Pentroot type Peniroof type Total displacement dm? 1,597 1,597 Cylinder bore mm 81.0 81.0 Piston stroke mm 75 778 ‘Compression ratio 10.0 11.0 Valve timing | intake | Opens | 20°, 14°* 17¢ (Low-speed cam) valve (8100) 47.5° (High-speed cam) Closes — | 42°, 58°" 81° (Low-speed cam) (ABDC) 72.5° (High-speed cam) Exhaust | Opens — | 54°, 52° 41° (Low-speed cam) valve (880C) 70° (High-speed cam) ae [Pr ed Lubrication system Pressure feed, ful-flow fitration | Pressure feed, fullfiow fitration il pump type Trochoid type Trochoid type Cooling system ‘Water-cooled forced circulation —_| Water-cooled forced circulation ‘Water pump type Centrifugal impeller type Centrifugal impeller type. *: LANCER for general export and CARISMA for 6B modal (© Miteublehi Metors Corporation July 1007 PWEESBORC11A-0-4 4G9 ENGINE (E-W) — General Information 4G93 Descriptions 4G93-SOHC 4G83-DOHC '4G93-DOHC-GDI Type In-line OHV, SOHC —_| In-line OHV, DOHC —_| In-line OHV, DOHC Number of cylinders 4 4 4 ‘Combustion chamber Pentroof type Pentroof type Pentroof type Total displacement dm? 1,834 1,834 1,834 Cylinder bore mm 81.0 810 81.0 Piston stroke mm 89.0 89.0 89.0 ‘Compression ratio 10.0, 95 105 11.74, 12.02 Valve timing | Intake [Opens | 14° 20° 18° valve {8TDC) Closes | 50° 60° 56° (ABDC) Exhaust | Opens 58° er 85° valve (BBDC) Closes | 10° 18° 18° (atoc) Lubrication system Pressure feed, full- | Pressure feed, (ul- | Pressure feed, full flow filtration flow fitration flow filtration Oil pump type Trochoid type Trochold type Trochoid type Cooling system Water-coolad forced | Water-cooled forced | Water-cooled forced circulation circulation cireuiation Water pump type Centrifugal impeller | Centritugal impeller | Centrifugal impeller type ‘ype type “1: Up to 1999 modal "2: From 2000 model © ameiahitcton Corporation — May 2000 Pweesee2-< ed4G9 ENGINE (E-W) — General Information 11A-0-5 4G94 Descriptions 4G94-DOHC-GDI Type Invfine OHV, DOHC Number of cylinders 4 Combustion chamber Pentroof type. Total displacement dm? 1,999 Cylinder bore mm B15, Piston stroke ram 95.8 ‘Compression ratio 106 Valve timing | intake | Opens | 15° valve (8T0C) Closes | 51° (ABDC) Exhaust | Opens | 55° valve (BDC) Closes | 15° (arpe) Lubrication system Pressure feed, full-flow fitration ‘il pump type Trochoid type Cooling system Waler-cooled forced circulation ‘Water pump type Centritugal impeller type G mitaubiahi Motors Corporeion say 20004G9 ENGINE (E-W) — Specifications 11A-1-1 1. SPECIFICATIONS SERVICE SPECIFICATIONS Items ‘Standard valve Limit Timing bett “Auto-teneioner rod protrusion amount (When removed from engine) | 11 = mm "Auto-tensioner rod stroke mm Within + = ‘Auto-tensioner rod protrusion amount {When checking with installed | 3.84.5 = | on engine) mm Rocker arms and camshaft ‘Camshati cam 4G92-S0HC"! Intake 37.34 6.84 helget mm | Exhaust 36.79 36.29 4G92-S0HC? Intake 37.78 37.28 Exhaust 37.83 37.33 “4692-S0HC" intake 36.92 36.42 Exhaust 36.70 36.65 4G93-SOHC intake 37.53 37.08 Exhaust S764 o7.44 “4693-DOHC Intake 35.31 wet Exhaust 36.20 34.70 4e03D0Ho-Gp! | Mntake 35.49 4.99 Exhaust 3473 34.28 ZG96.D0HO-GDI__| take 35.49 34.98 Exhaust 34at aaat Valve clearance mm Intake 08 = Exhaust 020 = ‘Camshatt joumal 0.0. mm ‘SOHC 26.0 = DOHC 45.0 = Rocker cover and camshaft (MIVEC) ‘Camshaft height mm Tatake A Sat 36.81 Tntake 8 33.58 33.08 Exhaust A 35.83 36.33 Exhaust B 24 33.78 Valve clearance (cold engine} mm Intake on ~ Exhaust 02 = Cylinder head and vatve Gylinder head gasket surlace flatness mm Less than 0.08 02 = rr Grinding limit of cylinder head gasket surface mm “Total resurtacing depth ot both cylinder head and cylinder block “1; LANCER for Europe and CARISMA for Europe "2: LANCER for gene’ ‘3; LANCER for ‘© Mitaubiahi Motors Corporation Mry2000 ral export and CARISMA for 6B model rope (from 2001 model) and CARISMA for Europe (trom 2001 mode!) PWEENS0261A-1-2 4G9 ENGINE (E-W) - Specifications Items Standard value Limit Cylinder head overall height mm ‘SOHC 1199-1201 = DOHC 131.9 - 132.1 = DOHG-MIVEG 118.8 — 120.0 = DOHG-GDI 131.9 192.1 = Thickness of valve | SOHC intake 10 Os head (margin) mm Exhaust 73 08 DOHC tniake 10 05 Exhaust 12 OF Valve overall height | SOHC inake Tots 108.65 = Exhaust 113.70 713.20 DOHC Talake 708.18 103.60 Exhaust 10387 103.37 DOHG-MIVEC Talake 11563 115.13 Exhaust 118.63 116.13 DOHC-GDI Tniake 104.19 103.69 Exhaust 70387 103.37 Valve spring free length mm SOHC (Except from | 50.9 49 2001 model vehicles {or Europe) SOHC (From 2001 | 49.8 485 model vehicles. for Europe) DOHG 45.0 440 DOHO-MIVEG 515 505 DOHC-aDI 448 438 Valva spring outobsquareness Max. 2° * Valve stem to valve | Except DOHO-€D) | Intake 0.02 - 0.05 010 guide clearance mm | for PAJERO le Exhaust 0050.09 015 DOHC-GDI iniake 002-005 010 for PAJERO io Exhaust 0.04-0.06 018 Valve seat valve contact width mm 09-13 = Valve guide projection from cylinder head | SOHC 140 = upper surface mm DOH 730 ~ Valve stem projec- | SOHC intake 49.80 49.80 {ton mm Exhaust 49.35 49.85 DOHC intake 46.70 47.20 Exhaust 46.65 47.15 DOHC-MIVEC intake 38.13 58.63 Exhaust 37.85 38.95 DOHG-GDI intake 46.70 47.20 Exhaust 46.65 47.15 Cylinder head bolt shank length mam = 96.4 ‘Danone Corporeton Mey 200 EERE fev4G9 ENGINE (E-W) — Specifications 11A-1-3 tems Standard value Limit Valve stem 0.0. mm 60 = Valve face angle 45° = 45.5° = Valve spring load/nstalled height Nimm SOHC 216/442 = DOHC 255/446 = DOHC-MIVEC 255/445 = DOHC-GDI 1967.5 = Valve guide 1. mm 60 = Font case, oll pump and oll pan Oil pump tip clearance mm 0.06 - 0.18 = Oil pump side clearance mm 0.04 - 0.10 = Oil pump body clearance mm 0.10 - 0.18 0.35 Piston and connecting rod Piston ring to piston ring groove clearance | No.1 0.03 - 0.07 4 mm No.2 0.02 - 0.06 on Piston ring end gap | No. 1 4692, 4693 0.25 = 0.40 08 ™ 4694 0.15 - 0.90 08 No.2 0.40 - 0.55 08 Oil ting ‘SOHC 020-060 10 DOHG 0.10 - 0.35 10 Crankshaft pin oll 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 0.10 - 0.25 04 Piston pin O.D. mm 19.0 = Piston 0.0. mm 4692, 4693 81.0 = 4Go4 a5 = Crankshaft, cylinder block, flywheel and drive plate Crankshaft journal oll clearance mm 0.02-0.04 or ‘Cylinder block gasket surface flatness mm 0.05 Oa Grinding limit of cylinder block gasket surface mm = 02" “Total resurfacing depth of both cylinder head and oylinder block Cylinder block overall height mm aGe2 243.5 = 4693, 263.5 = 4604 286.7 = Cylinder block LD. mm 4692, 4693 81.0 = 4G04 815 = Piston to cylinder clearance mm 0.02-0.04 = Bearing cap bolt shank length mm = At Crankshaft end play mm 0.05 - 0.25 oa (Crankshaft journal 0.0. mm. 50 = Crankshaft pin 0.0. mm 45 ‘D Mteubiehi Motors Corporation May 2000 PwREss02-S11A-1-4 4G9 ENGINE (E-W) — Specifications REWORK DIMENSIONS Toms ‘Standard value Cylinder head and valve Oversize rework dimensions of valve guide hole (both intake and | 0.05 0.8. 77.08 — 11.07 exhaust) mm 02808. 11.25 ~ 11.27 05008. 11.50~ 11.52 ‘Oversize rework dimensions of intake valve | SOHC 0300.8. 31.80- 31.63 seat hole mm 06008, 22.10 — 92.13 DOHC 03008 34.90 ~ 94.82 06008, 34.60 ~ 34.62 ‘Oversize rework dimensions of exhaust valve | SOHC 0300.8. 29.30 - 28.52 Seat ole mm 0600.8. 20.60 ~ 29.62 DOHC 0300.8. 30.80 - 90.82 06005 31.10- 31.18 Crankshaft, flywheel and drive plate Crankshaft out of roundness and taper of journal and pin mm 0.005 ‘Outer diameter LD: Inner diameter Oversize diameter TORQUE SPECIFICATIONS Ttems i ‘Alternator and ignition system Oil level gauge 13 Distributor 12 Ignition ool 10 ‘Spark plug 26 Grankshaft bolt 181 ‘Attemator brace (M8) 23 ‘Altemator brace (M10) 9 Lock bott 23 ‘Adjusting bolt | 10 ‘Adjusting bolt 49 Power steering pump pulley 25 Power steering pump bracket stay 49 Power steering pump bracket (M8) 21 Power steering pump bracket (M10) 4a Aerator pivot bolt 4a [Center cover 3 © vieubiah tore Corpornlon May 200 eweesioa ever4G9 ENGINE (E-W) — Specifications 11A-1-5 tems Nm Ignition failure sensor (M6) 5 Ignition failure sensor (Ma) 23 ‘Cam position sensor 9 ‘Cam position sensor support 13 ‘Cam position sensing cylinder 24 Engine cover 29 Timing belt Camshaft sprocket bolt 88 ‘Cam position sensor 98 Crank angle sensor 98 ‘Timing belt rear cover 11 ‘Timing belt tensioner 24 Engine support bracket, right 49 ‘Accessory mount 49 Timing belt cover 1" Tensioner pulley bolt 49 Tensioner arm bott “4 ‘Auto-tensioner bolt 13 Idler pulley bolt 36 Fuel system and emission system Breather tube 21 Fuel pump 18 Carburetor 7 EGR valve at Fuel retum pipe 9 Delivery pipe 12 Fuel pressure regulator 9 Throttle body stay 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 and EGR system (GDI) Air intake resonator 9 Intake manifold stay (MB) 20 Intake manifold stay (M10) 20 ‘Water hose clamp 13, \D Miteubiehi Motors Corporation May 200011A-1-6 4G9 ENGINE (E-W) — Specifications tems Nm Water pipe " Throttle body 18 Throttle body stay 24 EGR valve (Washer) 18 EGR vaive (Fiange) 24 Engine hanger 18 EGR valve support bolt 18 EGR valve support nut 23 Air by-pass valve 9 intake manifold and exhaust manifold Exhaust manifold (M8) 18 Exhaust manifold (M10) 29 Exhaust manifold bracket (M8) 19 Exhaust manifold bracket (M10) 35 Engine hanger 12 Cillevel gauge guide 14 Boost sensor 5 Intake air temperature sensor 13 Heat protector 13 Intake manifold 20 Intake manifold stay 30 ‘Oxygen sensor “4 Intake manitold (GDI) Vacuum pipe and hose 1 ‘Vacuum pipe and hose Solenoid valve 9 Fuel pump protector 23 ‘Connector bracket 1" Branoh tube (M6 x 14) n Branch tube (Mé x 18) ° Intake manifold stay 30 ‘Accelerator cable bracket 8 ‘Vacuum pipe 1" Intake manifold 19 Exhaust manifold (GO) Oillevel gauge guide 13 Exhaust manifold cover 13 Engine hanger bolt 24 ‘© aneublani Moore Corporation Mey 2000 PwEESSG2G4G9 ENGINE (E-W) — Specifications 11A-1-6a tems Nm Engine hanger nut (Me) 18 Engine hanger nut (M10) 29 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) 35 Exhaust manifold bracket (For PAJERO io) 98 Exhaust manifold (M8) 7 Exhaust manifold (M10) 29 Injector and fuel pump assembly (GDI) Fue! low pressure pipe (M6) 18 Fuel low pressure pipe (M8) 9 Fuel nippie 9 ‘Clamp Fuel feed pipe 1 Fuel pump 7 Hames bracket 1 Fuel pipe 1" Fuel return pipe 1 Fuel retum pipe clamp 9 Fuel high pressure regulator 8 Fuel pressure sensor 23 Fuel pressure sensor 18 Spacer 18 Pump camshaft case 23 Injector holder 22 Delivery pipe and injactor 1 Water pump and water hose ‘Water pump 24 Water inlet pipe 14 Thermostat case 26 Water inlet fiting 19 Water inte iting 23 Water by-pass fitting 23 Water pipe 18 ‘Water outlet fiting 14 ‘Water outlet fiting 23 Engine cootant temperature gauge 40 ‘Owitaubiai Wotore Corporation tay 2000 PwEENSO2G11A-1-6b 4G9 ENGINE (E-W) — Specifications tems Nm Engine coolant temperature sensor 29 Water fitting Rocker arms and camshatt Lock nut | Rocker arm shaft Harness bracket Rocker cover Bearing cap bolt (M6) 14 Bearing cap bolt (M8) 24 Beam camshaft cap (M6) io ‘Beam camshaft cap (MB) at Rocker cover and camshafts (MIVEC) Rocker cover Oilpump ‘Arm spring holder Camshaft bearing cap (M6) Camshaft bearing cap (M8) Oil control valve Rocker arms and rocker shaft caps (MIVEC) Rocker shaft cap 1 Cylinder head and valves Cylinder head bolt 74 Nm and then completely loosen, finally tighten 20 Nm + 90° + 90° Oil pressure switch 10 Front case and oll pump Oil pump cover 10 Oil pump case 4 Relief plug “4 Oil screen 19 Oil pan 7 Upper oil pan 7 Upper oll pan 1 Upper oll pan 24 Lower oll pan 7 Cover 7 Batfle plate 7 Drain plug Ey Oil pressure switch 10 Baffle plate mounting bolt 7 © Meubiah Motors Corporation May 2000 Pweessn2-c.4G9 ENGINE (E-W) - Specifications 11A-1-6¢ Items. Nm Piston and connecting rod ‘Connecting rod cap nut 20 + 90° to 100° Crankshaft, cylinder block, flywheel and drive plate Bearing cap bolt 25 + 90° to 100° Oll seal case uw Bell housing cover 9 Rear plate 1 Drive plate bolt 8 Flywheel bolt 96 Baffle plate 9 Knock sensor 22 ‘© Miteuolehi Motors Corporation — May 2000, PWEEDSID-G Added11A-1-6d 4G9 ENGINE (E-W) — Specifications @ameubledi Meters Corporation May 2000 Intentionally blank. sed4G9 ENGINE (E-W) — Specifications 11A-1-7 NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC ‘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 observed. © Areas where the bolts are in use: a fer head bolts (2) Main bearing cap bolts (3) Connecting tod 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. 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-pass fiting Mitsubishi Genuine Part No.M0970369 or equivalent | As required Water fitting Mitsubishi Genuine Part No.MD970389 or equivalent | As required Engine coolant temperature sensor | SM Nut Locking Part No.4171 or equivalent As required Engine coolant temperature gauge unit | SM ATD Part No.8660 or equivalent As required ‘Camshaft bearing cap ‘3M ATD Part No.8660 or equivalent As required ‘Semi-ciroular packing ‘3M ATD Part No.8660 or equivalent As required Rocker cover ‘3M ATD Part No.8660 or equivalent As required Beam camshaft cap Mitsubishi Genuine Part No.MD970389 or equivalent | As required Cylinder head Mitsubishi Genuine Part No.MD970389 or equivalent | As required Oil pressure switch ‘9M ATD Part No.8660 or equivalent As required Water outlet fitting Mitsubishi Genuine Part No.MD970389 or equivalent | As required Oil pump case Mitsubishi Genuine Part No.MD970389 or equivalent | As required Oil panvUpper oll paniLower cil pan_—_| Mitsubishi Genuine Part No.MD970389 or equivalent | As required Oil seal case Mitsubishi Genuine Part No.MD970389 or equivalent | As required Drive plate bolt ‘3M Nut Locking Part No.4171 or equivalent As required Flywheel bolt ‘3M Nut Locking Part No.4171 or equivalent As required Cam position sensor support Mitsubishi Genuine Part No.MD970389 or equivalent | As required Oil control valve 3M ATD Part No.8660 or equivalent As required Camshatt holder ‘3M ATD Part No.8660 or equivalent As required [@ mitaubiani Motors Corporation Dee. 190811A-1-8 4G9 ENGINE (E-W) - Specifications 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 @ bead couid 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 vulcanization (RTV) type and is supplied in a 100-gram tube (Part No. MD970389 or MD997110). Since the RTV hardens as it reacts with the moisture in the atomospheric 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. 997110 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 oll pan, 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 cils, 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. White the FIPG is still moist (in less than 18 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. ‘©-MtaubiahiMotors Corporation May 1996 PwEEDso24G9 ENGINE (E-W) — Special Tools 11A-2-1 2. SPECIAL TOOLS Too! ‘Number | Name Use aA | m8890996 Handle Use with MD@96776 | ‘MBS90767 Crankshaft pulley | Holding camshaft sprocket when loosening holder and tightening of bolt, Zo Use with MD898719 -——| 5 MD998440 Leak-down tester | Leak-down test of lash adjuster 4 " wpes6ea2 Air bleed wire Air bleeding of lash adjuster MDS98713 ‘Camshaft oil seal | Installation of camshaft oll seal Op) installer MD998716 ‘Crankshaft wrench | Rotation of crankshaft when installing piston &) and timing belt. 998717 Crankshaft front oil | Installation of crankshatt front oll seal ° 6» seal installer MB991653 ‘Cylinder head bolt | Tightening and loosening of cylinder head bolt ‘wrench (MB991659 Guide D Removal of piston pin (Use with MD998780} © mivbianl Motors Corporation Now. 1908 Pweegno2k Revises1A-2-2 4G9 ENGINE (E-W) — Special Tools T Number Tool Name Use MD398719 Pulley holder pin | Use with MB990767 | @ § g ® ® 0998727 | Oilpan remover | Removal of the oil pan j § M0998754 Pin Use with MB990767 ® ® . ‘MD998767 Tensioner pulley | Adjustment of timing belt tension i socket wrench ‘MDS98772 Valve spring Removal and installation of valve and related Ae compressor parts < a S ORNS | "MD998774 Valve stem seal | Installation of valve stem seal Sw installer MD998775 ‘Valve stem seal | installation of valve stem seal ZX = ‘MD988776 Crankshaft rear oil | Installation of crankshaft rear oll seal ‘ seal installer Use with MB99038 3 | ‘© Mieubleh Motors Gorportion Moy. 195 PwEERSO2-A4G9 ENGINE (E-W) - Special Tools 11A-2-3 Tool Number ‘Name Use MD996760 SETTING TOOL | Removal and installation of piston pin Piston pin | MD998735, ‘Valve spring Compression of valve spring | compressor | e M0996781 Flywheel stopper | Holding flywheel and drive plate ‘MB991477 Valve adjusting | Adjustment of valve clearance (MIVEC) wrench MB991478 Valve adjusting | Adjustment of valve clearance (MIVEC) wrench feeler gauge set piston checker MD998784 ‘Valve spring ‘Compression of valve spring (MIVEC) ‘compressor (Use with MD998772) adapter o> MB991479 Rocker arm ‘Adjustment of valve clearance (MIVEC) (C Meublehi Motors Corporation Now 1095 PwEESEE2-A ovioed4G9 ENGINE (E-W) — Alternator and Ignition System 11A-3-1 3. ALTERNATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION (Engines with distributor) Removal steps 1. Drive belt* 2 Altemator > poet Grnchet bon . Crankst 5. Crankshaft pulley ‘@Dtsubiahi Motors Corporation May 2000 8. Flange z Sear pg cable ar 5. Onng 10. Distr *!For details of adjustment, reler to the relevant model's chassis workshop manual.11A-3-2 4G9 ENGINE (E-W) — Alternator and Ignition System REMOVAL AND INSTALLATION (Engines without distributor) . Front flange . Spark plug cable }. Ignition coil 1 2 3. 4 Cran 5 Crankshaft pulley z 8 9. Spark plug ‘Deaublehi Motors Corporation May 2000 9ens089, 10. Ignition failure sensor (From 2001 ‘model vehicles for Europe) 11. Cam position sensor Add 12. Cam position sensor si 13. Cam position sensing cylinder NOTE: “For details of adjustment, refer to the relevant model's ‘chassis workshop manual.4G9 ENGINE (E-W) — Alternator and Ignition System __11A-3-2a REMOVAL AND INSTALLATION (Engines without distributor) e—10Nm €N0273. Removal steps 1. Drive belt* 7. Spark plug 2. Alternator 8. Ignition coil 3. Altemator brace & Spark ou AD PB 4 Crankshaft boit position sensor 5. Crankshaft pulley Ae It, Gam Postion Sensor support 6. Front flange 12. Cam position sensing cylinder For details of aajusiment, rater tote relevant mode's chassis workshop manual. ‘©atevbleht Motors Corporation Deo. 1808 ‘PwEEDEODE Ades11A-3-2b _4G9 ENGINE (E-W) — Alternator and Ignition System Intentionally blank ‘@Mtaubiahi Motors Corporation Dee. 1968 PWEESSE-E4G9 ENGINE (E-W) — Alternator and Ignition System 11A-3-3 REMOVAL AND INSTALLATION Removal steps 1. Drive belt” 3 AD PB 4. Crankshaft bolt 5. Crankshaft pulley 6. Flange ‘© MReublati Motors Corporation Nov. 1988 7. Center cover 8: Sra pay. abl . le 10, Spark plug 11. Ignition failure sensor NoTE: *: For details of adjustment, refer to the relevant modet's: chassis workshop manual. PwEESSODA Reviesd11A-3-4 4G9 ENGINE (E-W) ~ Alternator and Ignition System REMOVAL AND INSTALLATION sewort9 Removal steps 4. Drive belt 7. Center cover 2. Alternator 8. Spark plug cable 3. Altemator brace 9. Ignition coil AP PB 4. Crankshaft bolt 40. Spark plug 5, Grankshatt pulley 11. Gam position sensor 6. Front flange Ad 12, Gam position sensor support 3. Cam position sensing cylinder NOTE: *! For details of adjustment, refer to the relevant model's chassis workshop manual. ‘@Mtoubichi Motora Corporation Now 1996 PWEESSO2-A lied4G9 ENGINE (E-W) — Alternator and Ignition System 11A-3-5 REMOVAL AND INSTALLATION sensosa 10. Spark plug 11. Cam position sensor D>A-d 12, Cam positon sensor suppor AD PB 4 Crankshatt bot }3. Cam position sensing cylinder 5. Crankshaft pulley 14, Ignition failure sensor (From 2001 6. Front flange model for CARISMA, From 2001 7. Engine cover model for SPACE STAR) 8. Earth strap (From 2001 model for NOTE: CARISMA, From 2001 model for *:For details of adjustment, refer to the relevant model's SPACE STAR) chassis workshop manual. 9. Ignition coil |@DUlterbiahi Meters Corpormion May 2000 PWEESSO2O Revised11A-3-6 4G9 ENGINE (E-W) — Alternator and Ignition System REMOVAL AND INSTALLATION Removal steps 1. Oil fevel gauge 2. Gil level gauge guide 3. O-ting 4: Drive belt® 5, Altemator 6, Altemator brace 4A Bd 7. Crankshatt bolt 8. Crankshaft pulley 9, Front flange ‘@ueveiehi Motors Corporation — Dec. 1908, NOTE bad 9en0954 10. Power steering pump pulley 11; Power stesing pump bracket stay 12. Power steering pump bracket 18. Ignition colt . Cam position sensor support 17. Cam position sensing cylinder *: For details of adjustment, refer to the relevant mode's ‘chassis workshop manual.4G9 ENGINE (E-W) ~ Alternator and Ignition System 11A-3-7 oenor43| ‘© mieaudiehiMotore Corporation ve. 1008, REMOVAL SERVICE POINT <4Ap> CRANKSHAFT BOLT REMOVAL (1) Use the special tool 10 hold the flywheel or the drive Plate, and then loosen the crankshaft mounting bolts. INSTALLATION SERVICE POINTS D-ACAM 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. MD870389 or equivalent. Bd CRANKSHAFT BOLT INSTALLATION (1) Use the special tool to hold the flywheel or the drive plate, and then tighten the crankshaft mounting bos.4G9 ENGINE (E-W) — Timing Bett 11A-4-1 4. TIMING BELT REMOVAL AND INSTALLATION Ser bam 3 43. Nm SENOSIE Removal steps 1. Timing belt front upper cover 8. Grankshatt angie sensor 2. Timing belt front lower cover (Engines without distributor) 3, Engine support bracket, right 9. Crankshaft sprocket “> 4. Timing belt 10. Crankshaft spacer 5. Tensioner spring (Engines without distributor) DB 6. Timing belt tensioner 11. Cranksheft sensing plate 7. Timing belt rear cover {Engines without distributor) 12. Crankshatt key BP AM 13. Camshatt sprocket bolt 14. Camshaft sprocket ‘@MIteublshi Motors Coxporstion May 2000, PwEESse2-o. Reviees11A-4-1a REMOVAL AND INSTALLATION 4G9 ENGINE (E-W) - Timing Belt Removal steps 4, Timing belt front upper cover 2 Timing bat front ower cover ine support bracket, right pod : ming bel ‘0 BEG 2 Hones sioner spring <4 6. Timing belt tensioner 7. Timing belt rear cover 8. Crankshaft angle sensor (Engines without distributor) “> @Mtavbiadl Motors Corporation aay 2000, 23 Nm SENLO5S. 9. Grankshalt sprocket 10. Crankshaft spacer (Engines without distributor) 11. Crankshaft sensing plate 1 fEranes without distributor) 2. Crankshaft key 1 Ad 13. Camshaft sprocket bolt 14. Camshaft sprocket PweEss02.0,4G9 ENGINE (E-W) - Timing Belt 11A-4-1b Intentionally blank ‘DMitavblenittetore Corporation May 2000, PwEEDE02G Added11A-4-2 4G9 ENGINE (E-W) - Timing Belt REMOVAL AND INSTALLATION 11Nm 49.Nm 2 senoe7a Removal steps 1. Timing belt front upper cover ‘8. Crankshaft angie sensor 2. Timing belt front lower cover 8. Crankshaft sprocket 3. Accessory mount 10. Grankshaft spacer 11. Crankshaft sensing plate <<“ 4. Timing ben 45. Tensioner spring 12, Crankshaft key Jd 6. Timing belt tensioner PA 13. Camshaft sprocket bolt 7. Timing belt rear cover 14. Camshaft sprocket © tatsubiehi Motors Corporation Dec. 1908 ewensst2e4G9 ENGINE (E-W) — Timing Belt REMOVAL AND INSTALLATION 11Nm 1 Removal steps ing Tensioner pulley Tensioner arm Shatt Auto-tensioner Timing belt rear cover leler pulley Seenomnons Seaublodt Motors Corporation Deo. 1060 Timing belt upper cover Timing belt lower cover Engine support bracket 1 12. 13, 14. 15. 16.

88.Nm T1Ne \, 8 a as ae 7 35. Nm 4snm 16 [ 42 1413 11Nm 9 ae sf 139.Nm 98Nm " 49 Nm SENOS Removal steps 1. Timing belt front upper cover 14. Crankshaft angle sensor 2. Timing belt front lower cover 12. Crankshaft sprocket 3. Engine support bracket, right 13. Crankshaft spacer AD PF 4. Timing belt 14. Crankshaft sensing plate 5. Tensioner pulley 15. Crankshaft key 6. Tensioner arm EP PA 16. Camshaft sprocket bolt 7.8 17. Camshaft sprocket PE 8. Auto tensioner 18. Timing belt rear cover ‘9. Timing belt rear cover 49. Timing belt rear cover 10. Idler pulley ‘DMitsublan Hotore Corporation Dec. 1098 PWEESEODE Pavioes4G9 ENGINE (E-W) — Timing Belt 11A-4-2¢ REMOVAL AND INSTALLATION 2 118m 14Nm \ 4 88 Nm 8 11Nm , 6 | 10 “ve 4 oe oP 1 48Nm a” re. 8 11Nm ” 49. Nm 13m 9.8 Nm 2 98 Nm sensoss Removal steps 4. Timing belt front upper cover 2. Timing belt front lower cover 8. Engine support bracket, right AD PFA 4 Timing bolt 5. Tensioner pulley 6. Tensioner arm 7. Shaft DPE 8. Auto tensioner 10. Idler pul 41. Crankshaft angle sensor (Up to 1999 model) 12, Crankshaft angle sensor (From 2000 mode!) (@uaubledi Motors Corporation May 2000 18, Crankshaft sprocket 44, Crankshaft spacer 15. Crankshaft Sensing plate 16. Crankshaft key BP PAA 17. Camshaft sprocket bot 18. Camshaft sprocket 19. Timing belt rear cover (Up t 2000 model) 20. Shing Bet roar cover 24. Timing belt rear upper cover (Fron 2001 mode)11A-4-2d 4G9 ENGINE (E-W) — Timing Belt REMOVAL AND INSTALLATION 11m 1 49. Nm 2 seni05? Removal steps 1. Timing beit front upper cover 10. Idler pull 2. Timing belt front lower cover 41. Crankehall angle sensor 3. Engine support bracket, right 12. Crankshaft sprocket A> DFA 4 eg bet. 13. Crankshaft spacer 5, Tenstoner pulley 14. Crankshaft sensing plate 6. Tensioner arm 15. Ci ey 7. Shaft 46> PA 15. Camshaft sprocket bolt DE 8 Auto tensioner 17. Camshaft sprocket 9, Timing belt rear cover 18. Timing belt rear upper cover @eavdiohi Motor Corporation May 2000 Pweessen.c4G9 ENGINE (E-W) — Timing Belt 11A-4-2e REMOVAL AND INSTALLATION 11.Nm 49.Nm SENOSES Removal steps 1. Timing belt front upper cover 11. Bracket iming belt front lower cover 42. Crankshafl angle sensor Accesory mount 13. Crankshaft sprocket A> DF 4 Timing bet 14. Crankshaft sensing plate 5. Tensioner pulley 15. Crankshaft spacer 6. Tensioner arm 16. Crankshaft 7. Shaft Ad 17. Camshatt sprocket bolt DE. 8 Auto tensioner 18. Camshaft sprocket 9. Timing belt rear cover 49. Timing belt rear cover 10. Idler pulley 20. Timing belt rear cover © mitsubien Motors Corporation May 2000 Pwecss02011A-4-2f 4G9 ENGINE (E-W) — Timing Belt Intentionally blank. @Mreubishi Motor Corporation May 2000, PwEReSO2S4G9 ENGINE (E-W) — Timing Belt 11A-4-3 REMOVAL SERVICE POINTS <4Ap TIMING BELT REMOVAL (1) Mark beit running direction for reinstallation. 45> CAMSHAFT SPROCKET BOLT REMOVAL (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 PWEERSo2-A Pevinea11A-4-4 4G9 ENGINE (E-W) - Timing belt Bq 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. D>C-/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-q TIMING BELT INSTALLATION (1) Turn the crankshaft sprocket by three teeth from the timing mark. Caution Aligning the timing marks positions the piston to the top dead centre. Then, if the 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 c) (8) 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. (8) Place the timing belt over the sprocket according in the following order. 4. Crankshaft sprocket Water pump sprocket Camshaft sprocket Tension pulley Timing marks’ @ aon 940570) Eiateubleds Motor Corporation May 1095 PweEss024G9 ENGINE (E-W) - Timing Belt 11A-4-5 (6) Slightly loosen the tensioner pulley fixing bolt which is tightened temporarily to tighten the belt by a force of the tensioner spring. (2) Tum 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-tansioner 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. (© Mitaubleni Motors Corporation Now 1995 PWeEDsaa-A Revised11A-4-6 4G9 ENGINE (E-W) - Timing Belt Timing marks 7 ‘© Mitaubiaht Motors Corporation Nov. 1986 DF4 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. (3) 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.4G9 ENGINE (E-W) — Timing Beit 11A-4-7 Crankshaft sprocket genas72 [@emneubledi Motors Corporation — May 1098, (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 turn to the crankshaft. Then tum the crankshaft clockwise to align the timing marks again.11A-4-8 4G9 ENGINE (E-W) — Timing Belt DES 2) I 1 ZBENODES (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 tuming, tighten the center bolt to the specified torque. (15)Give two clockwise tums 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, ull 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. ‘1900200077 (2) Cracks on rubber back. (3) Cracks or peeling of canvas. (4) Cracks on tooth bottom. (5) Cracks on belt sides.4G9 ENGINE (E-W) — Timing Belt 11A-4-9 \ Abnormal wear (lutty strand) ‘ZOENO0S7 Rubber exposed. Tooth missing and canvas fiber exposed ‘ZBEN6S os —e. eo (lunsubleni Motors Corporation ay 1098 (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 tod stroke. If not within the standard value, replace ‘the tensioner. Standard value: 1 mm or less PweEsece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 8. Fuel hose 4. Fuel pump 5, Gasket 6. Insulator 7. Gasket 8: Carburetor 10. EGR valve 11, Gasket ‘©uteublati Motors Corporation ow. 1096 Pweesso2s Reviesd11A-5-2 4G9 ENGINE {E-W) - Fuel and Emission Control System REMOVAL AND INSTALLATION gewso27 Removal stops 1. Vacuum hose and pipe assembly 10. insulator 2. Throttle body Add 11. Injector Cd 3. Gasket 12. O-ring 4, Vacuum hose 13, Grommet peg iui hae 14 Dotvary pipe, 6. Fuel pressure regulator 15. Fuel return 7, O-tin 16, Solenoid valve assembly 8. Delivery pipe and injector 47. EGR valve 9, Insulator 18. Gasket ‘ witeublebi Motors Corporation July 1960 PwEESSIe-F4G9 ENGINE (E-W) — Fuel and Emission Control System _11A-5-3 REMOVAL AND INSTALLATION 2 m9 me 19 Nm 9 Nm seNogg8 Removal steps 1, Vacuum hose and pipe assembly 9. insulator 2. Throttle body 10. Insulator PCd 3. Gasket Ad 11. Injector 4: Vacuum hose 12. O-ring 5. Fuel hose 13. Grommet PB 6. Fuol pressure regulator 14. Delivery pipe 7. O-tin 45. Fuel retum pipe 8 Delivery pipe and injector 46. Solenoid valve assembly (© Meubitt Motors Corporation Dec. 1990 Pwersene-s11A-5-4 _4G9 ENGINE (E-W) — Fuel and Emission Control System REMOVAL AND INSTALLATION tr Nm senesz Removal steps 1, Vacuum pipe assembly 10. Insulator 3 rote bocy assembly 11. Insulator bCq 3. Gasket rAd 12. Injector 4 Thee Body stay (MIVEC) 13. O-ring 14. Grommet 15. Delivery pipe 16. Fuel return pipe 9. Delivery pipe and injector @amgubiehi Motors Corporation Dee. 1964 PWEDE Revieed4G9 ENGINE (E-W) - Fuel and Emission Contro! System 11A-5-5 INSTALLATION SERVICE POINTS D-Aq 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 tums smoothly. If it does not tum 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). PB FUEL 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 tums smoothly. If it does not turn 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. >C-4GASKET INSTALLATION (1) Position the projection as shown in the illustration.11A-5-6 _4G9 ENGINE (E-W) — Fuel and Emission Control System “ Rs a ©Maubleti Motors Comporatn Dec, 1000 PwEESSIO€4G9 ENGINE (E-W) — Throttle Body and EGR System (Gb!) 11A-Sa-1 5a. THROTTLE BODY AND EGR SYSTEM (GDI) REMOVAL AND INSTALLATION seuoses Removal steps 1. 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. Waler hose (Up to 1998 model for 5. Water hose (Up to 1998 mode! for CARISMA, SPACE RUNNER) CARISMA, SPACE RUNNER) 16. Air by-pass valve 6. Throttle bo Up to 1998 model for CARISMA, Ad 7. Throttle body gasket \CE RUNNER) 8. Ignition hamess 17. fir bypass valve gaaket 9. Water hose to 1998 model for CARISMA, 10. EGR valve \CE RUNNER) 11. EGR valve gasket ‘© Maubladi Motors Corporation May 2000 Revised11A-5a-2 _4G9 ENGINE (E-W) - Throttle Body and EGR System (GDI) REMOVAL AND INSTALLATION SEN1058 Removal steps 1. Intake manifold stay (For GALANT) pA 7. Throttle body gasket ped 2, Water hose ve 8. Ignition names 3. Water hose 9. Water hose ie, eee ei yoy 25 econ 6. Throttle body 12, Gasket ‘Oaublehi Motors Corporation May 2000 Revised4G9 ENGINE (E-W) — Throttle Body and EGR System (GDI) _11A-5a-3 REMOVAL AND INSTALLATION SEN0g56 Removal steps yee pif RE 2S sa 3. Water hose 11, EGR valve ¥ 4. Waler hose 12. EGR valve gasket 5. Water hose 13. EGR valve support & Water hose clamp: ¢ Gasket ha isi SS naw 8 Waler pipe ‘© Miteubiaht Motors Corporation May 2000, PwEees02 Pevleea11A-5a-4_4G9 ENGINE (E-W) — Throttle Body and EGR System (GDI) “ Intake marfokt stay Bolt seuso6o) ‘Dteaubleh| Motors Corporation May 2000 INSTALLATION SERVICE POINTS D-AqTHROTTLE BODY GASKET DB INTAKE MANIFOLD STAY INSTALLATION (1) Tighten the four bots atthe top and bottom of the stay hand (2) Check that the stay seating surface is in close contact wih the bosses on the intake manifold and the cylinder block. (8) Tighten the four bolts to the specified torque.4G9 ENGINE (E-W) — Intake and Exhaust Manifold 11A-6-1 6. INTAKE AND EXHAUST MANIFOLD REMOVAL AND INSTALLATION 20.Nm senonse Removal steps 4. Engine 7. On PE 2 lense manly stay & Stiaust mantold cover 3. Intake manifold 9. Engine hanger 4. Intake manifold gasket Add 10. Exhaust manifold bracket A 5 Oil level gat Ad 11. Exhaust manifold bracket B 12, Exhaust manifold ge 6. Oil level gauge guide suse 9 13, Exhaust manifold gasket ‘@Mtaubiehi Motors Corporation Now 1995 PHEESSO2-B Rovieed11A-6-2 4G9 ENGINE (E-W) — Intake and Exhaust Manifold REMOVAL AND INSTALLATION Removal steps 1. Engine hanger 2. Intake mani 3. Intake manifold 4. Intake manifold gasket 5. Oil level gauge 6. Oil level gauge guide © Meubiehi tor Corporation May 2000 ld stay 7. Orting 8. Exhaust manifold cover 9. Engine hanger PPA-q 10. Exhaust manifold bracket A DPA-d 11. Exhaust manifold bracket B 12. Exhaust manifold 13. Exhaust manifold gasket4G9 ENGINE (E-W) — Intake and Exhaust Manifold Removal steps 1. Engine hanger 4, Imake manifold gasket 2 BES BS ou SSS Ba oie 7. O-ring Sauge gu © Mteevniets Motors Corporation May 2000 PweRsse2.c. 11A-6-2a REMOVAL AND INSTALLATION 13. Nm senso: 8. Qaygen sensor fagine hanger 10. Exhaust marilld cover 11. Exhaust manifold bracket 8 12. Exhaust manifold 413. Exhaust manifold gasket 14. Exhaust manifold bracket A11A-6-2b 4G9 ENGINE (E-W) - Intake and Exhaust Manifold Intentionally blank ‘© mitsubleni Motors Corporation May 2000, PWEESSO2.C.4G9 ENGINE (E-W) — Intake and Exhaust Manifold 11A-6-3 REMOVAL AND INSTALLATION Removal steps 1. Engine hanger 7. O-ti 2 Intake mantold stay 8 Engine hanger 3. Intake manifold DPA 9. Exhaust manifold brackat A 4 etako maniokd gasket DPAd 10. Exhaust manifold bracket B 5 Oil te vel gauge 11. Exhaust manifold 6. Gil level gauge guide 12. Exhaust manitold gasket © telah Motore Corporation Now 1906 PweEoEO2 811A-6-4 4G9 ENGINE (E-W) — Intake and Exhaust Manifold INSTALLATION SERVICE POINT DPA 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. D>BINTAKE MANIFOLD STAY INSTALLATION (1) Install the intake manifoid stay with its “UP* mark directed toward the intake manifold. (@rmaubteni Motors Corporation Nov. 1996 PwEESEI2-B Asted4G9 ENGINE (E-W) - Intake Manifold (GDI) 11A-6a-1 6a. INTAKE MANIFOLD (GDI) REMOVAL AND INSTALLATION 9ENog90 Removal steps 1. Air by-pass hose 5. Connector bracket (Up to 1988 model for CARISMA, 6. Accelerator cable bracket SPACE RUNNER) 7. Vacuum hose 2. Vacuum pipe and hose 8. Vacuum pipe 3, Bracket 9. Intake manifold 4. Solenoid valve 10. Intake manifold gasket ‘© Mitoubiah thotora Corporation May 2000, PweEse028 Ravina11A-6a-1a 4G9 ENGINE (E-W) — Intake Manifold (GDI) REMOVAL AND INSTALLATION Seni062 Removal steps 1. Vacuum pipe and hose 4. Vacuum pipe 2, Purge hose 5. Intake manifold 3. Solenoid valve ‘@ettaubledi Motors Corporation May 2000, PWEESE02-<. aaaea‘@Mkaubistt Motor Corporation 4G9 ENGINE (E-W) - Intake Manifold (GDI) May 2000 Intentionally blank PweEss02.o, 11A-6a-1b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 8. Brack (© mmaubians rors Corporation Jun. 1988 PWEEDSO2D sEn0983 6. Accelerator cable bracket 7. Vacuum hose 8. Vacuum pipe 9 Intake manifold 10. Intake manifold gasket4G9 ENGINE (E-W) - Intake Manifold (GDI) 11A-6a-3 REMOVAL AND INSTALLATION sim) 6 % 1 TN 73 ‘ im Se Removal steps 1. PCN. hose 6. Branch tube 2. Vacuum pipe and hose 7. Gasket 3. Solenoid valve Ad 8. Intake manifold stay 4. Fuel pump protector 9. Intake manifold 5, Connector bracket 10, Intake manifold gasket © uiteublel Motors Corporation ac. 1068, PWEESEO2E Aes11A-6a-4 4G9 ENGINE (E-W) Intake manifold Intake manifold stay ‘© Muaublant Motors Corporation Deo. 1088 intake Manifold (GDI) INSTALLATION SERVICE POINT D>AdINTAKE 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.4G9 ENGINE (E-W) — Exhaust Manifold (GDI) 11A-6b-1 6b. EXHAUST MANIFOLD (GDI) REMOVAL AND INSTALLATION ‘senoaee Removal steps 1. Oil level gauge 2, Oil level gauge guide 8. O-ting 4. Exhaust manifold cover 5. Engine hanger DA 6. Exhaust manifold bracket A DA 7. Exhaust manifold bracket B 8. Exhaust manifold 9. Exhaust manifold gasket @Mtaublabt Motors Corpormtion May 2000, PweEese2-3. Pevieed11A-6b-1a 4G9 ENGINE (E-W) - Exhaust Manifold (GDI) REMOVAL AND INSTALLATION SENt083, Removal steps 1. Oil level gauge 2. Oil level gauge guide Be 3 8 g a 10. Exhaust manifold gasket 11, Exhaust manifold bracket A \Dumeubledt Motor Corporation Muy 2000, PWEESSO2G4G9 ENGINE (E-W) — Exhaust Manifold (GDI) ‘©Witevbiehi Motors Corporation Ney 2000 Intentionally blank 11A-6b-1b11A-6b-2 4G9 ENGINE (E-W) — Exhaust Manifold (GDI) REMOVAL AND INSTALLATION SEN0996 Removal steps 1. Exhaust manifold cover 2, Engine hanger PB 3. Exhaust manifold bracket 4: Exhaust manifold 5. Exhaust manifold gasket © emaubleni Motors Corporation Dec. 1068 Pweeseo2 =4G9 ENGINE (E-W) — Exhaust Manifold (GDI) 11A-6b-3 ‘enoges sENos60 ‘© meaublani Motors Corporation Deo. 1088 INSTALLATION SERVICE POINTS. PA-@EXHAUST MANIFOLD BRACKET INSTALLATION (1) Stide 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. Bq 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.4G9 ENGINE (E-W) - Injector and Fue! Pump Assembly (GDI) 11A-6c-1 6c. INJECTOR AND FUEL PUMP ASSEMBLY (GDI) REMOVAL AND INSTALLATION 27 4 "> Hy LYtekG es ? 7p gare Ay 9eN08a5 1. Fuel hose -D-4 20. Fuel pressure sensor 2. Fuel low pressure pipe 21. O-ring 8. O-ring 22. Backup ring 4. Fuel nipple PC 29. Pump camshatt case 5. O-ting 24. O-ring 6. Clamp 25. O-ting DF 7. Fuel feed pipe 26. Hamess bracket 8, Backup ing 27. Injector hamess 9. O-ring 28. Washer 10; Backup ring 29. Injector holder DF 11. Fus! pump 8-4 80. Delivery pipe and injector 2: Oring 3, Insulaton 3: Hames bracket 82. Injector gasket 14, Fuel retum pipe 33. Injector 15. Backup ring PpAqq 34. Corrugated washer 16. O-ring DPA-d 35. Backup ring 17. Backup ring PA 36. O-ring E418. Fuel high pressure regulator DAd 87. Backup ring 19. Flange’ ‘38. Delivery pipe Dmeublani Motors Corpocation May 2000 Pweesse2.c. Ravens11A-6c-1a_4G9 ENGINE (E-W) — Injector and Fuel Pump Assembly (GD!) REMOVAL AND INSTALLATION Removal steps 1. Injector harness 2 Flange 3. Fuel pressure sensor Backup ring 5. O-ring YYYYVyvvy RRaaaaeee a 6. Fuel pipe 7. Backup ring 8, O-ting 9. Backup ring . Fuel pu 1. ning ‘© Mitaublahi Motors Corporation May 2000, 11.Nm 9EN1033 ‘Washer Injector holder 14: Delivery pipe and injector 5. Insulator 6. Injector gasket Comugated washer Backup cng ri . O-ring Backup ring 1. Injector Delivery pipe4G9 ENGINE (E-W) — Injector and Fuel Pump Assembly (GDI) _11A-6c-1b [ Intentionally blank [Diteubient Motors Corporation Mwy 2000 PwEEo802.6 Ade11A-66-2 4G9 ENGINE (E-W) — Injector and Fuel Pump Assembly (GDI) REMOVAL AND INSTALLATION Removal steps 9. PF 10. n 12.0. 16. 7. 18. 19. ‘Stmeubtehi Motore Corporation Dec. 1908 NOMAD Injector harness. Fuel hose Fue! hose Fuel hose Fue! pipe Fuei nipple ing Fuel ripple Fue! feed pipe el feed pi Backup ring ing 18. Backup ring brass Fuel pump ering Fuel retum pipe Backup rin Oring PE 20. bd 2) 22. 23, O-ti 24, Spacer 25. 28 118 120 130 poNe 1 7 sors Fuel high pressure regulator 1. Fuel pressure sensor Backup ring ing f washer Injector holder Delivery pipe and injector Insulator . Injector gasket . Corrugated washer - Backup ring Delivery pipe4G9 ENGINE (E-W) Corrugated washer SENO894 Mating marks ‘© mewublehi Motors Corporation Ove. 1000 = Injector and Fuel Pump Assembly (GDI) 11A-6¢-3 INSTALLATION SERVICE POINTS. PA BACKUP RING / O-RING / CORRUGATED WASHER INSTALLATION (1) Attach the backup rings and O-ring to the injector. The thicker backup ring must be 30 installed that the inside cut surface is directed as shown in the illustration. (2) Coat the corrugated washer with white vaseline and install It to the injector as shown. Caution Always replace the corrugated washer with new one, Reused corrugated washer can cause fuel or gas leaks. >B-q DELIVERY PIPE AND INJECTOR ASSEMBLY INSTALLATION (1) Lubricate O-ring in the injector with spindle oil or gasoline, (2) Insert the injector straight into the injector mounting hole in the ry pipe. (3) Tum the injector clockwise and counterclockwise. If it dose not rotate smoothly, remove it to check for damaged O-ring. Damaged O-ring must be replaced with a new one. Reinstall the injector and check for smooth rotation again. (4) Align the mating mark on the injector with that on the delivery pipe. (5) Inetal the inector gaskets and insulators on the cylinder The ingulator can drop off easily. Apply vaseline toil before metalation so tet it may be held in position. (6) Install the delivery pipe and injector assembly onto the cylinder head, then tighten the fasteners temporarily. (7) Install the injector holders and the washers to the assembly and tighten the fasteners to the specified torque. Caution Strictly observe the specified torque.11A-6C-4 4G9 ENGINE (E-W) - Injector and Fuel Pump Assembly (GDI) ‘© ttaubteni Mehore Comporation Cut surface Backup ring ‘Dee. 1950 (8) Tighten the fasteners of the delivery pipe and injector assembly to the specified torque in the order given in the illustration. >C-4PUMP CAMSHAFT CASE INSTALLATION (1) Apply small amount of engine oil to the O-ring (larger ‘one) on the case. (2) Install the pump camshaft case onto the cylinder head while aligning the coupling keys of the case with the grooves in the rear end face of the camshaft. NOTE ‘The coupling keys and the grooves at the camshaft rear end are offset with respect to the camshaft center. (3) Tighten the case mounting bolts to the specified torque. D4 FUEL PRESSURE SENSOR INSTALLATION (1) Install the backup ring to the fuel pressure sensor with its inside cut surface in the illustrated direction, (2) Install the fuel pressure sensor straight into the fuel pressure regulator with labeled surface upward. (8) Tighten the fuel pressure sensor mounting bolt to the specified torque. b-E-q FUEL HIGH PRESSURE REGULATOR: INSTALLATION (1) Install the fuel high pressure regulator on the pump ‘camshatt case or onto the spacer and tighten the 3 bolts lightty (with somewhat Jarger torque than fingertight). ‘Tightening to the speciation is to be carried out in the step described in PF. Pweessice Revised4G9 ENGINE {E-W) - Injector and Fuel Pump Assembly (GDI) 11A-6c-5 Cut surface Backup ring 9EN0PI0 (2) Fit the backup rings and the O-ring on both ends of the fuel return pipe. Note that the larger backup ring must be installed with the inside cut surface in the direction shown in the illustration, (2) Lubricate the O-rings on both ends of the pipe with spindle oil or gasoline. (4) Insert the fuel retum pipe ends straight in the respective mounting holes of the pressure regulator and the delivery pipe. Be sure to insert the pipe fully to the stop using care not to twist It (6) Tighten the bolts at both ends of the pipe to the specified torque. DF-4 FUEL PUMP / FUEL FEED PIPE INSTALLATION (1) Insert the fuel pump into the mounting hole in the pump. camshaft case or in the cylinder head , and secure it temporarily with 4 bolts (lighten somewhat with a larger torque than fingertight). (2) Fit the backup rings and the O-ring on both ends of the feed pipe. Note that the larger backup ring must be installed with the inside cut surface in the direction shown in the illustration. (8) Lubricate the O-rings on both ends of the pipe with spindle oil or gasoline. (4) Insert the fuel feed pipe ends straight in the respective mounting holes of the fuel and the delivery pipe. Be sure to ingert the pipe fully to the stop using care not to twist it. (5) Tighten the bolts at ends of the pipe to the specified torque. (6) Tighten the mounting bolts of the fuel pressure requiator to the specified torque. (7) Using a torque wrench having the minimum scale of 0.5, Nm, tighten the fue! pump mounting bolts in the following order. 1) Tighten the bolts to 5 Nm in the order given in the illustration. 2) Tighten the bolts to 17 Nm in the order given in the illustration. The torque variation among 4 bolts must be within 2 Nm. Caution Strictly observe the specified tightening torque. Deviation from the specification can cause problems ‘such as leakage or the like. Pweessoe Acie11A-6c-6 4G9 ENGINE (E-W) - Injector and Fuel Pump Assembly (GDI) sEN085t, 7EN1498 7ens469 ‘Backup ring {fo sppeial entation) ®. Backup ring (thicker one) Cut surface Tensaaa © misvbleh Motors Corporation May 2000 G4 0-RING / FUEL PUMP INSTALLATION (1) Apply engine oil to the roller of the fuel pump and O-ring. (2) Insert the fuel pump into the mounting hole in the cylinder head and lightly tighten the four bolts. (3) Using a torque wrench (minimum graduations of 0.5 Nm), follow these steps to tighten the fuel pump mounting bolts. 1) Tighten the bolts to 4.9 Nm in the order shown, 2) Tighten the bolts to 17 + 2 Nm in the order shown. Variations in torque among the four bolts should be within 2. Nm. Caution Strictly observe the tightening order. A leak and other problem could result if the torque specifications and torquing order are not met. DH O-RING / BACKUP RING / FUEL PIPE INSTALLATION (1) Fit the backup rings and O-ring to both ends of the fuel pipe. Mount the backup ring (thicker one) so that its inner cut surface faces in the direction shown. (2) Coat the O-rings on both ends of the pipe with spindle oil or gasoline. (3) Insert the fuel pipe straight into the mounting hole in the delivery pipe. Insert ital the way into the hole, ensuring that it does not twist. (4) Tighten the bolts on both ends of the fuel pipe to the specified torque. Pweesse2. aed4G9 ENGINE (E-W) ~ Injector and Fuel Pump Assembly (GDI) 11A-6c-7 2 a wt pactuptring CU sulace Tensaas Fuel pressure sensor Tt & i 4 | > oe Det Nee Pe NS sentoas ‘C mmeubiehi Motors Corporation My 2000 bI I 14.Nm ‘9ENO577 Removal steps 1, Water hose PD 7. Thermostat (G3cept carburetor engines) PC 8. Thermostat case 2 bcd 3. DF 4. Engine coolant temperature gauge Bes tt: Onin 5. 6. ring, Engine coolant temperature sensor fater inlet pipe DP A¢ 12. Water pump . Water outlet fing Water inlet fitting ‘D2 mtevdiehitolore Comporstion Nov. 1606 Pweegsez-8 Revised11A-7-2 4G9 ENGINE (E-W) - Water Pump and Water Hose REMOVAL AND INSTALLATION 7 oa sg Nm 14.Nm 9EN0578 Removal steps 4, Water hose A (Except GDI engine) 6. Water inlet fitting 2. Water hose B (Except GDI engine) D-q 7. Thermostat PG 3. Engine coolant temperature sensor 8: Thermostat case PF-q 4. Engine coolant temperature gauge 5 unit wae inlet pipe PE 5. Water outlet fitting Bq! (Except GALANT} pad 12 Water pump ‘O mtgubiehi Motors Corporation May 2000, PHEESS02.0. Revised4G9 ENGINE (E-W) — Water Pump and Water Hose REMOVAL AND INSTALLATION Removal steps PGi 1. Engine coolant temperature sensor DF 2. Engine coolant temperature gauge - 9 DE 4. Water outlet fitting 5. Water iniet fiting 6. Thermostat @ateublahi Motor Corporation — Dec. 1908 PHEEDEOE SEN096S Dd 7. Water by-pass fitting 8. Water pipe 9. O-ring 10. Thermostat case Bq 11. Water pipe BBS 12 Suing DA 13. Water pump 11A-7-3 Revises11A-7-4 4G9 ENGINE (E-W) - Water Pump and Water Hose ‘ 9N0579 ‘© Mitaubian Motore Corporation Dec. 1098 INSTALLATION SERVICE POINTS PA WATER PUMP INSTALLATION (1) Apply 3 mm diameter of Form-In-Piace Gasket (FIPG) to the location shown in the illustration. Specified sealant WMitsubleh Genuine Part No.MD970369 or equivalent Bq WATER INLET PIPE / WATER PIPE / O-RING INSTALLATION (1) Replace the O-ring of the water inlet pipe ‘or water pipe , and then apply water to the O-ting to make installation easy. Caution 1. Never apply any oil or grease to the O-ring. 2. Secure the water pipe after the thermostat case has been installed. C AD oe e007) Se | : seNo968 © aateublehi Motors Corporation Dec. 1088 11A-7-5 > F-q ENGINE COOLANT TEMPERATURE GAUGE UNIT INSTALLATION (1) Apply the specified sealant to the threads. Specified sealant: 9M ATD Part No.8660 or equivalent > GENGINE COOLANT TEMPERATURE SENSOR INSTALLATION (1) When reusing the sensor, apply the specified sealant to the threads, ‘Specified sealant: ‘3M Nut Locking Part No.4171 or equivatent Hq WATER BY-PASS FITTING INSTALLATION (1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG) to the location shown in the illustration, ‘Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent. Bld WATER FITTING INSTALLATION (1) Apply 9 mm dlameter of Formin-Piace Gasket (FIP) the location shown in the illustration. Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent.4G9 ENGINE (E-W) — Rocker Arms and Camshafts 11A-8-1 8. ROCKER ARMS AND CAMSHAFTS s00sa0070 REMOVAL AND INSTALLATION —— Apply engine oil to @ alimovng parts before installation, 9EN0580 Removal steps 1. Breather hose 11. Rocker arm B 2, PCW. hose 42. Rocker arm A 3. Oi fier cap PPB 13. Rocker arm shaft 4. Rocker cover DA 14. Adjusting screw 5. Rocker cover gasket 15. Nut & Oil seal 18. Rocker arm G DE 7. Oil seal Bd 17, Rocker arm shaft BD 8. Rocker arm spring PA 18. Adjusting scrow C49. Rocker arms and racker arm shaft 49. Nut 20. Camshaft 3 IN Booker arms and rocker arm shaft DMiwubiehl Motors Corporation way 2000 Pweeee2-¢ Revised11A-8-1a 4G9 ENGINE (E-W) — Rocker Arms and Camshafts REMOVAL AND INSTALLATION ————__ Sm APPIY encine oil to all ‘moving parts before installation. seNto64 41. Rocker arm B- 12. Rocker arm A Bq 13. Rocker arm shaft Ay PF 14 15. Rocker arm C 16. Rocker arm shaft Am FATT Lash aduster locker arm spring 18. Cams : Rocker arms and rocker arm shaft IN 10. Boor arms and rocker arm shaft © mateubien Motors Corporation — May 2000 PWEERse2-G4G9 ENGINE (E-W) — Rocker Arms and Camshafts 11A-8-1b Intentionally blank ‘© Mtsubiahl Metore Corporation Way 2000 PwEESst2-6 Added11A-8-2 4G9 ENGINE (E-W) — Rocker Arms and Camshafts REMOVAL AND INSTALLATION ee] Apply engine oil to > roving pars al before installation. seno999 Removal steps 1. Breather hose 10. Gil seal 2. PCV. hose PH 11. Bearing cap 3. PCY. valve PG 12 Intake camshaft 4. PG. valve gasket PG 13. Exhaust camshaft 5. Oil filer cap 14. Rocker arm PK 6. Rocker cover 4A Fd 15. Lash adjuster 7. Rocker cover gasket A 8. Rocker cover gasket B Pu 9. Semi-circular packing DMteubledi Motors Corporation Way 2000 PWEERSOZS Revioes4G9 ENGINE (E-W) — Rocker Arms and Camshafts 11A-8-3 REMOVAL AND INSTALLATION Apply engine oil to AW aPimowng pats betore installation. senoses Removal steps 1. Breather hose 8. Oil seal 2 PCN. hose Dl 9. Beam camshatt cap 3. PCN. valve 10. Gasket 4. PCY. valve gasket 11. Intake camshaft 8. Oil filer cap 42. Exhaust camshaft 6. Rocker cover 13. Rocker arm 7. Rocker cover gasket 4AD Fd 14. Lash adjuster ‘lmtsublehi Motors Comeralon Way 2000 PweEgse2-c Reviood11A-8-3a 4G9 ENGINE (E-W) — Rocker Arms and Camshafts REMOVAL AND INSTALLATION DOHC. GDI for CARISMA (From 2001 model), SPACE STAR (From 2001 model), GALAI 3 1 Chester packit 2 - Circular packing 3 . Beam camshaft cap 4 13. Beam camshaft cap gasket 5. Oil filer cap 14. Intake camshaft 6 Rocker cover, intake 15. Exhaust camshaft 7, Rocker cover gasket, inake 16. Rocker arm 8. Rocker cover, exhaust AD PF 17. Lash adjuster 9. Rocker cover gasket, exhaust ‘© Mteubieni Motors Corporation Mey 2000,4G9 ENGINE (E-W) — Rocker Arms and Camshafts 11A-8-3b Intentionally blank. (© MlwublehI Motors Corporation May 200011A-8-4 4G9 ENGINE (E-W) ~ Rocker Arms and Camshafts REMOVAL AND INSTALLATION ———__ Apply engine oil 10 AW almoving parts before installation. @ttmubieht Motors Corporation Mny 2000 PWEESECOG Revised4G9 ENGINE (E-W) - Rocker Arms and Camshafts 11A-8-5 REMOVAL SERVICE POINT 4p LASH ADJUSTER REMOVAL Caution If the lash adjuster is re-used, clean the lash adjuster. (Refer to 11A-8-10.) INSTALLATION SERVICE POINTS DPA ADJUSTING SCREW INSTALLATION (1) Install provisionally the screw to the rocker arm. Insert it so that the end of the screw is flush with the edge of the rocker arm or projects slightly (1 mm or less). PB-qROCKER ARM SHAFT INSTALLATION ane Timing bet side (1) Place the end with the larger chamfered side toward the ch site timing belt side, wamtered NOTE The rocker arm shaft for intake valves has eight oil holes. (2) Install the shaft with the oil holes toward the cylinder head. Oi) Roles senosi >C-qROCKER ARMS AND ROCKER ARM SHAFT INSTALLATION (1) Move the rocker arms in the directions shown in the illustration before tightening the rocker arm shaft bolts. NOTE Move the rocker arms until they touch the rocker arm shaft mounting bosses on the cylinder head. b-D-4ROCKER ARM SPRING INSTALLATION (1) Insert the rocker asm spring at an angle to the spark plug guide and then install it so that it is at a right angle to the guide. a, ‘@ mitaudietd Motors Corporation Dec. 1088 Pweessoa-e Revised11A-8-6 4G9 ENGINE {E-W) - Rocker Arms and Camshafts Ed Oll. SEAL INSTALLATION >F-4.LASH ADJUSTER INSTALLATION Caution © If the lash adjuster is re-used, clean the lash adjuster, (Refer to 11A-8-10.) (1) Fit the lash adjuster onto the cylinder head using care not to allow diesel fuel to spill out. Gd CAMSHAFT INSTALLATION - (1) Apply engine oil to the camshaft journals and cam before installing the camshaft. Use care not to confuse the intake sit ‘camshaft with the exhaust camshaft. L NOTE The rear end of the intake camshaft is provided with a4 mm-wide slit. H4BEARING CAP INSTALLATION (1) Locate the camshaft dowel pins as illustrated, (2) Apply sealant to the locations shown in the illustration. Specified sealant: 3M ATD Part No. 8660 or equivalent 9eNO173| @mtavelahl Motore Corporation Dec. 1088 PwveEss02-€ Revieed4G9 ENGINE (E-W) — Rocker Arms and Camshafts 11A-8-7 Cap No. IN or EX side identification SENOS! “=DOHE-GDi for CARISMA Upto 2000 mode, ‘SPACE STAR (1990mouel, SPACE RUNNERS Dow! pin e O senorer “ " Dows! pin ae ee SENO9TO O “ “Engine front side En0972 ‘SPACE STAR (1899 mode), SPACE RUNNER> 8 senoge7 [ =BOHC-GBI tor CARISMA (Up 19 2000 moze, “DOREADI fer CARISNA (rom 2001 moaeh, SPACE STAR (From 2007 and GALANT, PAJERO io» “= Engine ont side seno73 r ane 7s ‘DMevblehi Motors Corporation May 2000 4G9 ENGINE (E-W) ~ Rocker Arms and Camshafts (4) Apply sealant to the illustrated position of the cylinder head upper surface. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent (6) Install the beam camshaft cap before the sealant applied becomes dry and hard. (©) Tighten the bolts to the specified torque in the order shown in the illustration. M6 bolt 11Nm M8 bolt 21Nm Caution The M8 bolts plated green cannot be reused. Always replace such bolts with M8 bolts finished by glossy plating which ai lable separately. ‘The M8 bolt finished by glossy plating is reusable; if the caps have already been assembled with such bolts, then reassemble the caps using them. (7) Install the camshaft oil seal (use the special tool) and the thrust case before the sealant applied becomes dry and hard. (8) Wipe off squeezed out excess sealant from the circumference of the beam camshaft cap. PWEEDSO2-G, Povteed4G9 ENGINE (E-W) - Rocker Arms and Camshafts 11A-8-9 J SEALANT APPLICATION ON SEMI-CIRCULAR —-= PACKING Specified sealant: 3M ATD Part No.8680 or equivalent »K- 36.70 36.65 4G93-SOHC [3764 | a7.14 4G93-DOHC 35.20 34.70 4G93-DOHG-GDI | 34.73 34.23 4G94-DOHC-GoI | 34.91 34a “1: LANCER for Europe and CARISMA for Europe “2: LANCER for general export and CARISMA for 68 model *8. LANCER for Europe {from 2001 model) and CARISMA for Europe (from 2001 mode!) LASH ADJUSTER (SOHC) Caution 1. The lash adjusters are precision-engineered mechanisms. Do not allow them to become contained by dirt or other foreign substances. 2. Donot attempt to disassemble the lash adjusters. 3. Use only fresh diesel fuel to clean the lash adjusters. (1) Prepare three containers and approximately five liters Outside inside th of diesel fuel. Into each container, pour enough diesel leaning AEG Seed tel fuel to completely cover a lash adjuster when itis standing upright. Then, perform the following steps with each lash GENI698 S Mteubiahl Motors Corporation May 2000 Pweesso23 Revieed4G9 ENGINE (E-W) — Rocker Arms and Camshafts 11A-8-11 surlace. NOTE Use a nylon brush if deposits are hard to remove. a (2) Place the lash adjuster in container A and clean its outside Diesel fuel (3) While gently pushing down the internal steel ball using special tool MD998442, move the plunger through 5 to 10 strokes unti it slides smoothly. In addition to eliminating suinass in the plunger, ts operation will remove dity oil. Caution 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. BEN1808 NOTE If the plunger remains stiff or the mechanism appears otherwise abnormal, replace the lash adjuster. (4) Remove the lash adjuster from the container. Then, push down the steel ball gently and push the plungerto eliminate diesel fuel from the pressure chamber. on ‘Wire or MD998442 [=> Disselfvet SENsa09 (5) 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 The steel ball spring is extremely weak, so the lash adjuster’s functionality may be lost if the air bleed Wire be MD998442 wire is pushed in hard. GEN1808 @Miewbieh! Motors Corporstion May 2000 PWEEEEO2G, Roviesd11A-8-12 4G9 ENGINE (E-W) — Rocker Arms and Camshafts Sy Wire or MD998442 ==" Dieseliuel == GEN1909) Wire or MDa9a442 Diese! tuel GEN1B10) GEN 1814 BEN1 708 ‘© mmeubleh Motors Corporation May 2000 (6) Remove the lash adjuster from the container. Then, push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber. (7) Place the lash adjuster in container C. Then, gently push down the internal steel ball using special tool MD998442., Caution Do not use container C for cleaning. If cleaning is performed in container C, foreign matter could enter ‘the pressure chamber when chamber Is filled with diesel fuel. (®) Stand the lash adjuster with its plunger at the top, then push the plunger downward firmiy until it moves through its greatest possible stroke. Retum the plunger slowly, then release the steel ball and allow the pressure chamber to fill with diesel fuel. {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 ifit stil contracts after performing these steps. (10)Stand the lash adjuster upright to prevent diesel fuel from spilling out. Do not allow the lash adjuster to become contaminated by dirt or other foreign matter. Fit the lash adjuster onto the engine as soon as possible,4G9 ENGINE (E-W) — Rocker Arms and Camshafts Outside inside Filing wit cleaning cleaning diesel uel gag e698 Diesel fuel GEW3699 ENI707 ‘© Megubish! Motors Corporation May 2000 11A-8-13 (DOHC) Caution 1. The lash adjusters are precision-engineered mechanisms. Do not allow them to become contained by dirt or other foreign substances. 2. Donot attempt to disassemble the lash adjusters. 3. Use only fresh diesel fuel to clean the lash adjusters. (1) Prepare three containers and approximately five liters of diesel fuel. Into each container, pour enough diesel fuel to completely cover a lash adjuster when it is standing Upright. Then, perform the following steps with each lash adjuster. (2) Place the lash adjuster in container A and clean its outside surface. NOTE Use a nylon brush if deposits are hard to remove. (8) While gently pushing down the internal stee! ball using special tool MD998442, move the plunger through 5 to 10 strokes untilit slides smoothly. In addition to eliminating stiffness in the plunger, this operation will remove dirty oil, Caution 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, NOTE If the plunger remains stiff or the mechanism appears otherwise abnormal, replace the lash adjuster. PWEESECR-G Revisee11A-8-14 4G9 ENGINE (E-W) — Rocker Arms and Camshafts yx A mosses Diesel uel SENL708 A Te mn mupgessag _Diesel fuel ‘GENL707 6EN1708 Diesel uel BEW1 709 BEN1710 |S imeubiehi Motors Corporation May 2000 (4) Remove the lash adjuster from the container. Then, push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber. Caution ‘Make sure the oll hole in the side of the body is pointing toward container A. Do not point the oll hole at yourself or other people. (8) Place the fash 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 wil clean the lash adjuster's pressure chamber, Caution 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. (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 Make sure the oil holein the side of the body is pointing toward container B. Do not point the oil hole at yourself, or other people. (7) Place the lash adjuster in container C. Then, gently push down the intemal stee! ball using special tool MD998442. Caution Do not use container C for cleaning, If cleaning is performed in container C, foreign matter could enter the pressure chamber when chamber is filled with 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 diese! fuel.