1. SPECIFICATIONS11A-1-1
SERVICE SPECIFICATIONS11A-1-1
REWORK DIMENSIONS11A-1-3
TORQUE SPECIFICATIONS11A-1-4
NEW TIGHTENING METHOD-BY USE OF BOLTS TO BE
TIGHTENED IN PLASTIC AREA11A-1-6
SEALANT11A-1-6
FORM-IN-PLACE GASKET11A-1-7
NEW TIGHTENING METHOD USING PLASTIC REGION TIGHTENING BOLTS
Parts of the engine use plastic region tightening bolts. The tightening procedure for these is different
from that of conventional bolts and is described in relevant parts of this manual. Note that plastic region
tightening bolts have fixed service limits. These limits are indicated in relevant parts of this manual and
must be strictly observed.
Plastic region tightening bolts are used for the following applications:
D
(1) Cylinder head bolts
(2) Connecting rod cap bolts
The tightening procedure is basically as follows:
D
After tightening a bolt to the specified torque, tighten it by a further 90_+90_or by a further 90–100°.
The exact tightening procedure differs depending on the bolt and is described in relevant parts of
this manual.
SEALANTS
ItemSpecified sealantQuantity
Water pumpMitsubishi Genuine Part No. MD970389 or equivalentAs required
Thermo valveMitsubishi Genuine Part No. MD970389 or equivalentAs required
Engine coolant temperature sensor3M Nut Locking Part No. 4171 or equivalentAs required
Engine coolant temperature gauge unit3M ATD Part No. 8660 or equivalentAs required
Camshaft bearing cap3M ATD Part No. 8660 or equivalentAs required
Semi-circular packing3M ATD Part No. 8660 or equivalentAs required
Rocker cover3M ATD Part No. 8660 or equivalentAs required
Front oil seal caseMitsubishi Genuine Part No. MD970389 or equivalentAs required
Oil pumpMitsubishi Genuine Part No. MD970389 or equivalentAs required
Oil pressure switch3M ATD Part No. 8660 or equivalentAs required
E
Nov. 1995Mitsubishi Motors Corporation
PWEE9520
4G1 ENGINE (E-W) -
Specifications
11A-1-7
FORM-IN-PLACE GASKET
The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket
fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead
size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick
a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the
fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to
apply the gasket evenly without a break, while observing the correct bead size.
The FIPG used in the engine is a room temperature 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 flatand thin gasket scraper may be lightly hammered in between the
joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.
For removal of the oil pan, the special tool “Oil Pan Remover” (MD998727) is available. Be sure to use
the special tool to remove the oil pan. <Except aluminium die-cast oil pans>
Surface Preparation
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure
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.
E
Nov. 1995Mitsubishi Motors Corporation
PWEE9520
NOTES
4G1 ENGINE (E-W) -
Special Tools
2. SPECIAL TOOLS
ToolNumberNameUse
MB990767End yoke holderHolding camshaft sprocket when loosening or
11A-2-1
tightening bolt (used with MD998715)
MD99801 1Crankshaft rear oil
seal installer
MD998054Oil pressure switch
wrench
MD998304Crankshaft front oil
seal installer
MD998305Crankshaft front oil
seal guide
Installation of crankshaft rear oil seal
Removal and installation of oil pressure switch
Installation of crankshaft front oil seal
Guide for installation of crankshaft front oil seal
MD998713Camshaft oil seal
installer
MD998715Pin (2-off)Holding camshaft sprocket when loosening or
MD998727Oil pan removerRemoval of oil pan
MD998735Valve spring com-
pressor
Installation of camshaft oil seal
tightening bolt (used with MB990767)
Compression of valve springs
E
Nov. 1995Mitsubishi Motors Corporation
PWEE9520
11A-2-2
ToolUseNameNumber
4G1 ENGINE (E-W) -
Special Tools
MD998760Valve stem seal
installer
MD998780Piston pin setting
Installation of valve stem seals
(SOHC 12-VALVE)
Removal and press-fitting of piston pins
tool
MB991659Guide-DGuide for removal and press-fitting of piston
pins
MD998772Valve spring com-
Compression of valve springs
pressor
MD998440Leak-down testerTesting of automatic lash adjusters
(DOHC)
MD998442Air bleed wireTesting of automatic lash adjusters
(DOHC)
MD998781Flywheel stopperLocking flywheel in fixed position
MB991671Valve stem
installer
Press-fitting of valve stem seals
(SOHC 16-VALVE, DOHC)
MB991653Cylinder head bolt
Removal and installation of cylinder head bolt
wrench (10)
E
E
Nov.1995MitsubishiMotorsCorporation
Dec. 1998Mitsubishi Motors CorporationRevised
PWEE9520
PWEE9520-A
4G1 ENGINE (E-W) -
Alternator and Ignition System
3. ALTERNATOR AND IGNITION SYSTEM
REMOVAL AND INSTALLATION <SOHC 12-VALVE>
11A-3-1
22 Nm
23 Nm
6
9Nm
12
12 Nm
13
7
44 Nm
10
25 Nm
11
1
5
23 Nm
2
4
AA""BA
E
E
8
123 Nm
Removal steps
1. Oil level gauge
2. Oil level gauge guide
3. O-ring
4. Drive belt*
5. Water pump pulley
6. Alternator brace
7. Alternator
8. Crankshaft bolt
9. Crankshaft pulley
Nov.1995MitsubishiMotorsCorporation
Dec. 1998Mitsubishi Motors CorporationRevised
9
PWEE9520
PWEE9520-A
3
10. Spark plug cable
11. Spark plug
"AA
NOTE
*: For details of adjustment, refer to the relevant model’s
chassis workshop manual.
12. Distributor
13. O-ring
11A-3-1a
4G1 ENGINE (E-W) -
Alternator and Ignition System
REMOVAL AND INSTALLATION <SOHC 16-VALVE-FRONT WHEEL DRIVE>
22Nm
23 Nm
6
9Nm
25 Nm
44 Nm
10
12 Nm
11
12
13
7
23 Nm
5
1
9
AA""BA
4
Removal steps
1. Oil level gauge
2. Oil level gauge guide
3. O-ring
4. Drive belt*
5. Water pump pulley
6. Alternator brace
7. Alternator
8. Crankshaft bolt
9. Crankshaft pulley
2
3
8
125 Nm
10. Spark plug cable
11. Spark plug
"AA
NOTE
*: For details of adjustment, refer to the relevant model’s
chassis workshop manual.
12. Distributor
13. O-ring
E
E
Nov.1995MitsubishiMotorsCorporation
Dec. 1998Mitsubishi Motors CorporationAdded
PWEE9520
PWEE9520-A
4G1 ENGINE (E-W) -
Alternator and Ignition System
REMOVAL AND INSTALLATION <SOHC 16-VALVE-REAR WHEEL DRIVE>
10
10 Nm
25Nm
12
13
11A-3-1b
9Nm
22Nm
6
23 Nm
4
9Nm
11
7
44 Nm
5
14
15
13 Nm
21 Nm
1
23 Nm
2
3
8
125 Nm
9
AA""BA
E
E
Removal steps
1. Oil level gauge
2. Oil level gauge guide
3. O-ring
4. Drive belt*
5. Water pump pulley
6. Alternator brace
7. Alternator
8. Crankshaft bolt
9. Crankshaft pulley
Nov.1995MitsubishiMotorsCorporation
Dec. 1998Mitsubishi Motors CorporationAdded
NOTE
PWEE9520
PWEE9520-A
10. Spark plug cable
11. Ignition coil
12. Spark plug
13. Cam position sensor
"CA
*: For details of adjustment, refer to the relevant model’s
chassis workshop manual.
14. Cam position sensor support
15. Cam position sensing cylinder
11A-3-2
4G1 ENGINE (E-W) -
Alternator and Ignition System
REMOVAL AND INSTALLATION <DOHC>
10
25 Nm
11
12
11 Nm
13
22Nm
23 Nm
4
6
9Nm
7
44 Nm
5
1
23 Nm
2
3
8
103 Nm
9
AA""BA
E
Removal steps
1. Oil level gauge
2. Oil level gauge guide
3. O-ring
4. Drive belt*
5. Water pump pulley
6. Alternator brace
7. Alternator
8. Crankshaft bolt
9. Crankshaft pulley
Nov. 1995Mitsubishi Motors Corporation
PWEE9520
10. Spark plug cable
11. Spark plug
"AA
NOTE
*: For details of adjustment, refer to the relevant model’s
chassis workshop manual.
12. Distributor
13. O-ring
MD998781
Alignment mark
4G1 ENGINE (E-W) -
REMOVAL SERVICE POINT
AA"
(1) Lock the flywheel or drive plate in position using the special
INSTALLATION SERVICE POINTS
"AA
(1) Turn the crankshaft clockwise until cylinder No. 1 is at
(2) Align the alignment marks on the distributor housing and
(3) Fit the distributor onto the engine, aligning the stud bolts
Alignment mark
Alternator and Ignition System
11A-3-3
CRANKSHAFT BOLT REMOVAL
tool shown in the illustration, then loosen the crankshaft
bolts.
DISTRIBUTOR INSTALLATION
top dead center on its compression stroke.
coupling.
with the slots in the distributor mounting flange.
MD998781
"BA
CRANKSHAFT BOLT INSTALLATION
(1) Lock the flywheel or drive plate in position using the special
tool shown in the illustration, then tighten the crankshaft
bolts.