Mitsubishi 4G1 User Manual

ENGINE
4G1 SERIES
CONTENTS
11A-0-1
GENERAL INFORMATION 11A-0-3
1. SPECIFICATIONS 11A-1-1 SERVICE SPECIFICATIONS 11A-1-1 REWORK DIMENSIONS 11A-1-3 TORQUE SPECIFICATIONS 11A-1-4 NEW TIGHTENING METHOD-BY USE OF BOLTS TO BE
TIGHTENED IN PLASTIC AREA 11A-1-6 SEALANT 11A-1-6 FORM-IN-PLACE GASKET 11A-1-7
2. SPECIAL TOOLS 11A-2-1
3. ALTERNATOR AND IGNITION SYSTEM 11A-3-1
4. TIMING BELT 11A-4-1
5. FUEL AND EMISSION CONTROL SYSTEM 11A-5-1
6. WATER PUMP AND WATER HOSE 11A-6-1
7. INTAKE AND EXHAUST MANIFOLD 11A-7-1
8. ROCKER ARMS AND CAMSHAFT 11A-8-1
........................................................
......................................................
...........................................
.................................................
....................................
........................................
...............................
......................................
.................................................
........................
....................
.............................
............................
..............................
9. CYLINDER HEAD AND VALVES 11A-9-1
10. OIL PUMP AND OIL PAN 11A-10-1
11. PISTON AND CONNECTING ROD 11A-11-1
12. CRANKSHAFT, CYLINDER BLOCK 11A-12-1
E
Nov. 1995Mitsubishi Motors Corporation
.......................................
.................................
..............................
...........................
PWEE9520
11A-0-2
NOTES
E
Nov. 1995Mitsubishi Motors Corporation
PWEE9520
4G1 ENGINE (E-W) -

GENERAL INFORMATION

General Information
11A-0-3
E
Nov. 1995Mitsubishi Motors Corporation
PWEE9520
11A-0-4
4G1 ENGINE (E-W) -
General Information
E
Nov. 1995Mitsubishi Motors Corporation
PWEE9520
4G1 ENGINE (E-W) -
General Information
Descriptions 4G13 12-VALVE- CARBURETOR 4G13 12-VALVE- MPI
Type In-line OHV, SOHC In-line OHV, SOHC
Number of cylinders 4 4
Combustion chamber Pentroof type Pentroof type
11A-0-5
Total displacement dm
3
1,299 1,299
Cylinder bore mm 71.0 71.0
Piston stroke mm 82.0 82.0
Compression ratio 9.5 9.5
Number of Intake 8 8 valves
Exhaust 4 4
V alve timing Intake opens BTDC 14
Intake closes ABDC 48
Exhaust opens BBDC 55
Exhaust closes ATDC 13
_
_
_
_
BTDC 19
ABDC 43
BBDC 60
ATDC 8
_
_
_
_
Lubrication system Pressure feed, full-flow filtration Pressure feed, full-flow filtration
Oil pump type Trochoid type Trochoid type
Cooling system Water-cooled, forced circulation Water-cooled, forced circulation
Water pump type Centrifugal impeller type Centrifugal impeller type
E
E
Nov. 1995Mitsubishi Motors Corporation
Dec. 1998Mitsubishi Motors Corporation Revised
PWEE9520
PWEE9520-A
11A-0-6
4G1 ENGINE (E-W) -
General Information
Descriptions 4G13 16-VALVE- MPI 4G18 16-VALVE- MPI
Type In-line OHV, SOHC In-line OHV, SOHC
Number of cylinders 4 4
Combustion chamber Pentroof type Pentroof type
Total displacement dm
3
1,299 1,584
Cylinder bore mm 71.0 76.0
Piston stroke mm 82.0 87.3
Compression ratio 10 9.5
Number of Intake 8 8 valves
Exhaust 8 8
V alve timing Intake opens BTDC 17
Intake closes ABDC 39
Exhaust opens BBDC 49
Exhaust closes ATDC 7
_
_
_
_
BTDC 17
ABDC 39
BBDC 49
ATDC 7
_
_
_
_
Lubrication system Pressure feed, full-flow filtration Pressure feed, full-flow filtration
Oil pump type Trochoid type Trochoid type
Cooling system Water-cooled, forced circulation Water-cooled, forced circulation
Water pump type Centrifugal impeller type Centrifugal impeller type
E
E
Nov. 1995Mitsubishi Motors Corporation
Dec. 1998Mitsubishi Motors Corporation Revised
PWEE9520
PWEE9520-A
4G1 ENGINE (E-W) -
General Information
Descriptions 4G15-CARBURETTOR 4G15-MPI
Type In-line OHV, SOHC In-line OHV, DOHC
Number of cylinders 4 4
Combustion chamber Semi spherical type Pentroof type
11A-0-7
Total displacement dm
3
1,468 1,468
Cylinder bore mm 75.5 75.5
Piston stroke mm 82.0 82.0
Compression ratio 9.0 9.5
Number of Intake 8 8 valve
Exhaust 4 8
V alve timing Intake opens BTDC 14
Intake closes ABDC 48
Exhaust opens BBDC 55
Exhaust closes ATDC 13
_
_
_
_
BTDC 16
ABDC 40
BBDC 45
ATDC 15
_
_
_
_
Lubrication system Pressure feed, full-flow filtration Pressure feed, full-flow filtration
Oil pump type Trochoid type Trochoid type
Cooling system Water-cooled, forced circulation Water-cooled, forced circulation
Water pump type Centrifugal impeller type Centrifugal impeller type
E
E
Nov. 1995Mitsubishi Motors Corporation
Dec. 1998Mitsubishi Motors Corporation Added
PWEE9520
PWEE9520-A
NOTES
4G1 ENGINE (E-W) -
Specifications

1. SPECIFICATIONS

SERVICE SPECIFICATIONS

Item Standard Limit
Rocker arms, rocker shafts, and camshaft
11A-1-1
Camshaft cam SOHC 12-VALVE height mm
SOHC 16-VALVE
DOHC
Camshaft journal diameter mm
Cylinder head and valves
Flatness of cylinder head gasket surface mm 0.05 or less -
Cylinder head gasket surface grinding limit (including grinding of cylinder block gasket surface) mm
Cylinder head overall height mm
Cylinder head bolt nominal length mm - 103.2
V alve margin mm
Intake (primary) 38.78 38.28
Intake (secondary) 38.78 38.28
Exhaust 39.10 38.60
Intake 36.99 36.49
Exhaust 36.85 36.35
Intake 34.67 38.28
Exhaust 34.26 38.60
SOHC 45.93- 45.94 -
DOHC 25.95- 25.97 -
- 0.2
SOHC 12-VALVE 106.9- 107.1 -
SOHC 16-VALVE 119.9- 120.1 -
DOHC 131.9- 132.1 -
Intake 1.0 0.5
Exhaust 1.5 1.0
Valve stem diameter mm
V alve stem-to-guide SOHC 12-VALVE clearance mm
SOHC 16-VALVE
DOHC
V alve face angle 45_- 45.5
V alve stem projec- SOHC 12-VALVE tion mm
SOHC 16-VALVE
DOHC
SOHC 12-VALVE 6.6 -
SOHC 16-VALVE 5.5 -
DOHC 5.5 -
Intake 0.020- 0.050 0.10
Exhaust 0.050- 0.085 0.15
Intake 0.020 - 0.047 0.10
Exhaust 0.030 - 0.062 0.15
Intake 0.020- 0.047 0.10
Exhaust 0.030- 0.062 0.15
Intake 43.70 44.20
Exhaust 43.30 43.80
Intake 53.21 53.71
Exhaust 54.10 54.60
Intake 48.80 49.30
Exhaust 48.70 49.20
_
-
E
E
Nov. 1995Mitsubishi Motors Corporation
Dec. 1998Mitsubishi Motors Corporation Revised
PWEE9520
PWEE9520-A
11A-1-2
4G1 ENGINE (E-W) -
Specifications
Item LimitStandard
Overall valve length SOHC 12-VALVE mm
SOHC 16-VALVE
Intake 100.75 100.25
Exhaust 101.05 105.55
Intake 111.56 111.06
Exhaust 114.71 114.21
DOHC
Intake 106.35 105.85
Exhaust 106.85 106.35
V alve spring free SOHC 12-VALVE height mm
Intake 46.1 45.6
Exhaust 46.8 46.3
SOHC 16-VALVE 50.9 50.4
DOHC 49.1 48.6
Valve spring load/ SOHC 12-VALVE installed height N/ mm
mm
Intake 226/40.0 -
Exhaust 284/39.6 -
SOHC 16-VALVE 216/44.2 -
DOHC 177/40.0 -
Valve spring squareness 2
_
Valve seat contact width mm 0.9- 1.3 -
V alve guide internal diameter mm
SOHC 12-VALVE 6.6 -
_
4
SOHC 16-VALVE 5.5 -
DOHC 5.5 -
Valve guide projection mm
SOHC 12-VALVE 17.0 -
SOHC 16-VALVE 23.0 -
DOHC 23.0 -
Oil pump and oil 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
Pistons and connecting rods
Piston outside diameter mm
4G13 71.0 -
4G15 75.5 -
4G18 76.0 -
Piston ring side clearance mm
No. 1 ring 0.02- 0.06 -
No. 2 ring 0.02- 0.06 -
Piston ring end gap clearance
No. 1 ring 0.20- 0.35 0.8
No. 2 ring 0.35- 0.50 0.8
Oil ring 0.20- 0.50 1.0
Piston pin O. D. mm 18.0 -
Piston pin press-in load (at room temperature) N 4,900 - 14,700 -
Crankshaft pin oil clearance mm 0.02- 0.04 0.1
Connecting rod big end side clearance mm 0.10- 0.25 0.4
E
E
Nov. 1995Mitsubishi Motors Corporation
Dec. 1998Mitsubishi Motors Corporation Revised
PWEE9520
PWEE9520-A
4G1 ENGINE (E-W) -
Specifications
Item Standard Limit
Crankshaft and cylinder block
Crankshaft end play mm 0.05- 0.18 0.25
Crankshaft journal diameter mm 48.0 -
Crankshaft pin diameter mm 42.0 -
Crankshaft journal oil clearance mm 0.02- 0.04 0.1
Cylinder block gasket surface flatness mm 0.05 or less -
11A-1-2a
Cylinder block gasket surface grinding limit (including grinding of
- 0.2
cylinder head gasket surface) mm
Cylinder block overall height mm 256 -
Cylinder block cylindricity mm 0.01 -
Cylinder block I. D. mm
4G13 71.0 -
4G15 75.5 -
4G18 76.0 -
Piston-to-cylinder clearance mm 0.02-0.04 -
E
E
Nov. 1995Mitsubishi Motors Corporation
Dec. 1998Mitsubishi Motors Corporation Added
PWEE9520
PWEE9520-A
11A-1-2b
4G1 ENGINE (E-W) -
Specifications
Intentionally blank
E
E
E
Nov. 1995Mitsubishi Motors Corporation
Dec. 1998Mitsubishi Motors Corporation AddedPWEE9520-A
Dec. 1998Mitsubishi Motors Corporation Added
PWEE9520
PWEE9520-A
4G1 ENGINE (E-W) -
Specifications

REWORK DIMENSIONS

Item Standard Limit
Cylinder head and valves
11A-1-3
Cylinder head oversize valve guide SOHC 12-VALVE hole diameter mm
SOHC 16-VALVE
DOHC
Oversize valveseat SOHC Intake (primary) ring hole diametermm12-VALVE mm
Intake (secondary)
Exhaust
SOHC Intake 16-VALVE <4G13>
<4G13>
Exhaust
0.05 O. S. 12.050- 12.068 -
0.25 O. S. 12.250- 12.268 -
0.50 O. S. 12.500- 12.518 -
0.05 O. S. 10.550- 10.568 -
0.25 O. S. 10.750- 10.768 -
0.50 O. S. 11.000 - 11.018 -
0.05 O. S. 10.550- 10.568 -
0.25 O. S. 10.750- 10.768 -
0.50 O. S. 11.000 - 11.018 -
0.3 O. S. 27.300- 27.325 -
0.6 O. S. 27.600- 27.625 -
0.3 O. S. 32.300- 32.325 -
0.6 O. S. 32.600- 32.625 -
0.3 O. S. 35.300- 35.325 -
0.6 O. S. 35.600- 35.625 -
0.3 O. S. 28.300- 28.321 -
0.6 O. S. 28.600- 28.621 -
0.3 O. S. 26.300- 26.321 -
SOHC Intake 16-VALVE <4G18>
<4G18>
Exhaust
DOHC Intake
Exhaust
0.6 O. S. 26.600- 26.621 -
0.3 O. S. 30.300- 30.321 -
0.6 O. S. 30.600- 30.621 -
0.3 O. S. 28.300- 28.321 -
0.6 O. S. 28.600- 28.621 -
0.3 O. S. 31.300- 31.325 -
0.6 O. S. 31.600- 31.625 -
0.3 O. S. 27.800- 27.825 -
0.6 O. S. 28.100- 28.125 -
E
E
Nov. 1995Mitsubishi Motors Corporation
Dec. 1998Mitsubishi Motors Corporation Revised
PWEE9520
PWEE9520-A
11A-1-4
4G1 ENGINE (E-W) -
Specifications

TORQUE SPECIFICATIONS

Item Nm
Alternator and ignition system
Water pump pulley bolt 9
Alternator brace (alternator side) 22
Alternator brace (tightened with water pump) 23
Alternator pivot bolt 44
Oil level gauge guide 23
Crankshaft bolt 125
Spark plug 25
Distributor 11
Ignition coil 10
Camshaft position sensor 9
Camshaft position sensor support 13
Camshaft position sensing cylinder 21
Timing belt
Timing belt cover 11
Timing belt tensioner 23
Crankshaft angle sensor (Rear wheel drive) 9
Engine support bracket (left) 35
Idler pulley 35
Camshaft sprocket bolt 88
Fuel system
Delivery pipe 11
Fuel pressure regulator 9
Throttle body 18
Fuel pump 11
Breather tube 22
Carburetor 17
Air temperature sensor 13
EGR valve 21
Water pump
Water inlet fitting 22
Water inlet pipe assembly 12
Water inlet pipe
M6 12
M8 25
Fitting (Rear wheel drive) 23
Water outlet fitting (Rear wheel drive) 23
Thermostat case 23
E
E
Nov. 1995Mitsubishi Motors Corporation
Dec. 1998Mitsubishi Motors Corporation Revised
PWEE9520
PWEE9520-A
4G1 ENGINE (E-W) -
Specifications
Item Nm
Thermo valve 27
Water temperature gauge unit 11
Water temperature sensor 29
Water pump 13
Exhaust manifold and intake manifold
Boost sensor 5
Solenoid valve assembly 9
Intake manifold 17
11A-1-5
Intake manifold stay (MPI)
M8 17
M10 21
Intake manifold stay (carburetor) 29
Exhaust manifold cover 29
Exhaust manifold
M8 17
M10 29
Oxygen sensor 44
Rocker arms, rocker shafts, and camshaft
Fuel pump cover 12
Rocker cover 4
Rocker shaft assembly 31
Adjusting screw 15
Bearing cap
24
11
Cylinder head and valves
Cylinder head bolt 20 + 90_+90
_
Tighten to 49 Nm, then completely loosen and retighten as described.
Oil pump and oil pan
Transmission stay 23
Oil pan 7
Drain plug 39
Oil screen 18
Front case 13
Relief plug 44
Oil pump cover 10
Pistons and connecting rods
Connecting rod nut 17 + 90_to 100
E
E
Nov. 1995Mitsubishi Motors Corporation
Dec. 1998Mitsubishi Motors Corporation Revised
PWEE9520
PWEE9520-A
_
11A-1-5a
4G1 ENGINE (E-W) -
Specifications
Item Nm
Crankshaft and cylinder block
Flywheel 132
Drive plate 132
Rear plate 10
Bell housing cover 10
Rear oil seal case 11
Bearing cap bolt 51
Oil pressure switch 18
Knock sensor 23
E
E
Nov. 1995Mitsubishi Motors Corporation
Dec. 1998Mitsubishi Motors Corporation Added
PWEE9520
PWEE9520-A
4G1 ENGINE (E-W) -
Specifications
11A-1-5b
Intentionally blank
E
E
E
Nov. 1995Mitsubishi Motors Corporation
Dec. 1998Mitsubishi Motors Corporation AddedPWEE9520-A
Dec. 1998Mitsubishi Motors Corporation Added
PWEE9520
PWEE9520-A
11A-1-6
4G1 ENGINE (E-W) -
Specifications
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
Item Specified sealant Quantity
Water pump Mitsubishi Genuine Part No. MD970389 or equivalent As required
Thermo valve Mitsubishi Genuine Part No. MD970389 or equivalent As required
Engine coolant temperature sensor 3M Nut Locking Part No. 4171 or equivalent As required
Engine coolant temperature gauge unit 3M ATD Part No. 8660 or equivalent As required
Camshaft bearing cap 3M ATD Part No. 8660 or equivalent As required
Semi-circular packing 3M ATD Part No. 8660 or equivalent As required
Rocker cover 3M ATD Part No. 8660 or equivalent As required
Front oil seal case Mitsubishi Genuine Part No. MD970389 or equivalent As required
Oil pump Mitsubishi Genuine Part No. MD970389 or equivalent As required
Oil pressure switch 3M ATD Part No. 8660 or equivalent As 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 flat and thin gasket scraper may be lightly hammered in between the joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces. For removal of the oil pan, the special tool “Oil Pan Remover” (MD998727) is available. Be sure to use the special tool to remove the oil pan. <Except aluminium die-cast oil pans>
Surface Preparation
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure 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

Tool Number Name Use
MB990767 End yoke holder Holding camshaft sprocket when loosening or
11A-2-1
tightening bolt (used with MD998715)
MD99801 1 Crankshaft rear oil
seal installer
MD998054 Oil pressure switch
wrench
MD998304 Crankshaft front oil
seal installer
MD998305 Crankshaft 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
MD998713 Camshaft oil seal
installer
MD998715 Pin (2-off) Holding camshaft sprocket when loosening or
MD998727 Oil pan remover Removal of oil pan
MD998735 Valve 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
Tool UseNameNumber
4G1 ENGINE (E-W) -
Special Tools
MD998760 Valve stem seal
installer
MD998780 Piston pin setting
Installation of valve stem seals (SOHC 12-VALVE)
Removal and press-fitting of piston pins
tool
MB991659 Guide-D Guide for removal and press-fitting of piston
pins
MD998772 Valve spring com-
Compression of valve springs
pressor
MD998440 Leak-down tester Testing of automatic lash adjusters
(DOHC)
MD998442 Air bleed wire Testing of automatic lash adjusters
(DOHC)
MD998781 Flywheel stopper Locking flywheel in fixed position
MB991671 Valve stem
installer
Press-fitting of valve stem seals (SOHC 16-VALVE, DOHC)
MB991653 Cylinder head bolt
Removal and installation of cylinder head bolt
wrench (10)
E
E
Nov. 1995Mitsubishi Motors Corporation
Dec. 1998Mitsubishi Motors Corporation Revised
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. 1995Mitsubishi Motors Corporation
Dec. 1998Mitsubishi Motors Corporation Revised
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. 1995Mitsubishi Motors Corporation
Dec. 1998Mitsubishi Motors Corporation Added
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. 1995Mitsubishi Motors Corporation
Dec. 1998Mitsubishi Motors Corporation Added
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.
E
Nov. 1995Mitsubishi Motors Corporation
PWEE9520
NOTES
4G1 ENGINE (E-W) -

4. TIMING BELT

REMOVAL AND INSTALLATION <SOHC>
Timing Belt
11A-4-1
11 Nm
12
13
11
88 Nm
1
10
5
23 Nm
35 Nm
8
9
6
3
4
7
9Nm
AA""CA
"BA "BA
E
E
E
2
Removal steps
1. Timing belt upper cover
2. Timing belt lower cover
3. Timing belt
4. Tensioner spring
5. Timing belt tensioner
6. Crankshaft angle sensor <Rear wheel drive>
Nov. 1995Mitsubishi Motors Corporation
Dec. 1998Mitsubishi Motors Corporation RevisedPWEE9520-A
Dec. 1998Mitsubishi Motors Corporation Revised
AB""AA
PWEE9520
PWEE9520-A
7. Crankshaft sprocket
8. Spacer <Rear wheel drive>
9. Sensing blade <Rear wheel drive>
10. Camshaft sprocket bolt
11. Camshaft sprocket
12. Engine support bracket
13. Timing belt rear cover
11A-4-2
4G1 ENGINE (E-W) -
REMOVAL AND INSTALLATION <DOHC>
Timing Belt
12
11 Nm
11 Nm
3
11 Nm
13
9
1
88 Nm
8
23 Nm
5
11
10
6
35 Nm
35 Nm
7
4
2
AA""DA AA""BA AA""BA
E
Removal steps
1. Timing belt upper cover
2. Timing belt lower cover
3. Timing belt
4. Tensioner spring
5. Timing belt tensioner
6. Idler pulley
7. Crankshaft pulley
Nov. 1995Mitsubishi Motors Corporation
PWEE9520
AB""AA
8. Camshaft sprocket bolt
9. Camshaft sprocket
10. Engine support bracket
11. Timing belt rear cover (lower)
12. Timing belt rear cover (right)
13. Timing belt rear cover (left)
Loading...
+ 69 hidden pages