Mitsubishi 4G1, 4G13, 4G15, 4G18 General Information 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 SYSTEMS 11A-5-1

5a. INTAKE MANIFOLD AND THROTTLE BODY (GDI) 11A-5a-1

5b. EXHAUST MANIFOLD (GDI) 11A-5b-1

6. WATER PUMP AND WATER HOSE 11A-6-1

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7. INTAKE AND EXHAUST MANIFOLDS 11A-7-1

7a. FUEL SYSTEM (GDI) 11A-7a-1

8. ROCKER ARMS AND CAMSHAFTS 11A-8-1

8a. ROCKER ARMS AND CAMSHAFTS (GDI) 11A-8a-1

9. CYLINDER HEAD AND VALVES 11A-9-1

10. OIL PUMP AND OIL PAN 11A-10-1

11. PISTONS AND CONNECTING RODS 11A-11-1

12. CRANKSHAFT AND CYLINDER BLOCK 11A-12-1

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Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

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11A-0-2

NOTES

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PWEE9520

4G1 ENGINE (E-W) -

GENERAL INFORMATION

General Information

11A-0-3

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PWEE9520

11A-0-4

4G1 ENGINE (E-W) -

General Information

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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

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11A-0-6

4G1 ENGINE (E–W) – General Information

Descriptions 4G13 16-VALVE–CARBURETOR 4G13 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 1,299
Cylinder bore mm 71.0 71.0
Piston stroke mm 82.0 82.0
Compression ratio 9.5 10, 9.5*
Number of

Intake 8 8

1

valves

Exhaust 8 8

Valve timing Intake opens BTDC 12_ BTDC 17_

Intake closes ABDC 48_ ABDC 39_
Exhaust opens BBDC 48_ BBDC 49_

Exhaust closes ATDC 12_ 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

*1: LANCER for General Export

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4G1 ENGINE (E–W) – General Information

11A-0-7

Descriptions 4G15–

CARBURETTOR

4G15–MPI
12-VALVE

4G15–MPI
16-VALVE

4G15–GDI

Type In-line OHV, SOHC In-line OHV, SOHC In-line OHV, DOHC In-line OHV, DOHC

Number of cylinders 4 4 4 4

Combustion chamber Semi spherical type Semi spherical type Pentroof type Pentroof + Curved

piston head

Total displacement dm

3

1,468 1,468 1,468 1,468

Cylinder bore mm 75.5 75.5 75.5 75.5

Piston stroke mm 82.0 82.0 82.0 82.0

Compression ratio 9.0 9.0 9.5 11.0

Number

f

of valves

Intake 8 8 8 8

Exhaust 4 4 8 8

Valve
timing

Intake opens BTDC 14_ BTDC 14_ ,

BTDC 13_*

Intake closes ABDC 48_ ABDC 48_ ,

ABDC 47_*

1

1

BTDC 16_ BTDC 12_

ABDC 40_ ABDC 44_

Exhaust
opens

Exhaust
closes

Lubrication system Pressure feed,

BBDC 55_ BBDC 55_ ,

BBDC 56_*

ATDC 13_ ATDC 13_ ,

ATDC 8_*

1

Pressure feed,

full-flow filtration

full-flow filtration

1

BBDC 45_ BBDC 48_

ATDC 15_ ATDC 12_

Pressure feed,
full-flow filtration

Pressure feed,
full-flow filtration

Oil pump type Trochoid type Trochoid type Trochoid type Trochoid type

Cooling system Water-cooled,

forced circulation

Water pump type Centrifugal impeller

type

Water-cooled,
forced circulation

Centrifugal impeller
type

Water-cooled,
forced circulation

Centrifugal impeller
type

Water-cooled,
forced circulation

Centrifugal impeller
type

*1: Special low-emission engines on vehicles for Australia

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11A-0-8

4G1 ENGINE (E–W) – General Information

Descriptions 4G18 16-VALVE–CARBURETOR 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

1,584 1,584

Cylinder bore mm 76.0 76.0

Piston stroke mm 87.3 87.3

Compression ratio 9.5 9.5, 10*1*

Number of

Intake 8 8

2

valves

Exhaust 8 8

Valve timing Intake opens BTDC 12_ BTDC 17_ , BTDC 9_*1 , BTDC 17_*

Intake closes ABDC 48_ ABDC 39_ , ABDC 51_*1 , ABDC 43_*

Exhaust opens BBDC 48_ BBDC 49_ , BBDC 49_*1 , BBDC 53_*

Exhaust closes ATDC 12_ ATDC 7_ , ATDC 15_*1 , 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

2

2

2

2

*1: SPACE STAR for Europe

2

*

: LANCER for General Export

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4G1 ENGINE (E–W) – Specifications

1. SPECIFICATIONS

SERVICE SPECIFICATIONS

Item Standard Limit

Rocker arms and camshaft

Camshaft cam
height mm

SOHC 12-VALVE Intake (primary) 38.78 38.28

Intake (secondary) 38.78 38.28

1

2

39.01 38.51

38.97 38.47

SOHC 16-VALVE*

Exhaust*
Exhaust*

3

Intake 36.99 36.49
Exhaust 36.85 36.35

SOHC 16-VALVE*

4

Intake 36.86 36.36
Exhaust 36.68 36.18

SOHC 16-VALVE*

5

Intake 37.30 36.80
Exhaust 37.16 36.66

SOHC 16-VALVE*

6

Intake 37.17 36.67

11A-1-1

Exhaust 36.99 36.49

DOHC Intake 34.67 34.17

Exhaust 34.26 33.76

DOHC GDI Intake 34.85 34.35

Exhaust 34.59 34.09

Camshaft journal diameter mm SOHC 45.93 –45.94 –

SOHC 16-VALVE*

7

44.93–44.94 –

DOHC 25.95–25.97 –

Cylinder head and valves

Flatness of cylinder head gasket surface mm 0.05 or less –
Cylinder head gasket surface grinding limit (including grinding of

– 0.2

cylinder block gasket surface) mm
Cylinder head overall height mm SOHC 12-VALVE 106.9 –107.1 –

SOHC 16-VALVE 119.9–120.1 –

DOHC 131.9–132.1 –
Cylinder head bolt nominal length mm – 103.2
Valve margin mm Intake 1.0 0.5

Exhaust 1.5 1.0
Valve stem diameter mm SOHC 12-VALVE 6.6 –

SOHC 16-VALVE 5.5 –

DOHC 5.5 –

*1: With low pollution system

2

: Without low pollution system

*

3

: Except 2001 model front wheel drive vehicles

*

4

: 2001 model front wheel drive vehicles for Europe

*

5

: 2001 model front wheel drive vehicles for General Export

*

6

: 2002 model front wheel drive vehicles for Europe

*

7

: SOHC 16-VALVE MPI for Europe

*

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11A-1-2

4G1 ENGINE (E- W) -

Specifications

Item LimitStandard

V alve stem-to-guide SOHC 12-VALVE
clearance mm

SOHC 16-VALVE

Intake 0.020- 0.050 0.10

Exhaust 0.035- 0.050 0.15

Intake 0.020 - 0.047 0.10

Exhaust 0.030 - 0.057 0.15

DOHC

Intake 0.020- 0.047 0.10

Exhaust 0.030- 0.062 0.15

V alve face angle 45°- 45.5

V alve stem projec- SOHC 12-VALVE
tion mm

SOHC 16-VALVE

Intake 43.70 44.20

Exhaust 43.30 43.80

Intake 53.21 53.71

Exhaust 54.10 54.60

DOHC

Intake 48.80 49.30

Exhaust 48.70 49.20

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 -

SOHC 16-VALVE 5.5 -

DOHC 5.5 -

Valve guide projection mm

SOHC 12-VALVE 17.0 -

SOHC 16-VALVE 23.0 -

°

4

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

E

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Nov. 1995Mitsubishi Motors Corporation

Apr. 2000Mitsubishi Motors Corporation Revised

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4G1 ENGINE (E- W) -

Specifications

Item Standard Limit

Pistons and connecting rods

11A-1-2a

Piston outside diameter mm

4G13 71.0 -

4G15 75.5 -

4G18 76.0 -

Piston ring side clearance mm

No. 1 ring 0.03-0.07 -

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

4G13, 4G15 0.20 - 0.50 1.0

4G18 0.10 -0.40 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

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 -

Cylinder block gasket surface grinding limit (including grinding of

- 0.2

cylinder head gasket surface) mm

Cylinder block overall height mm 256 -

Cylinder bore cylindricity mm 0.01 -

Cylinder bore I. D. mm

4G13 71.0 -

4G15 75.5 -

4G18 76.0 -

Piston-to-cylinder clearance mm 0.02 - 0.04 -

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11A-1-2b

4G1 ENGINE (E-W) -

Specifications

Intentionally blank

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4G1 ENGINE (E–W) – Specifications

mm

<4G13>

<4G18>

REWORK DIMENSIONS

Item Standard Limit

Cylinder head and valves

11A-1-3

Cylinder head oversize valve guide
hole diameter mm

Oversize valve seat

SOHC

ring hole diametermm12-VALVE

SOHC 12-VALVE 0.05 O. S. 12.040–12.058 –

0.25 O. S. 12.240–12.258 –

0.50 O. S. 12.490–12.508 –

SOHC 16-VALVE 0.05 O. S. 10.550–10.568 –

0.25 O. S. 10.750–10.768 –

0.50 O. S. 11.000–11.018 –

DOHC 0.05 O. S. 10.550–10.568 –

0.25 O. S. 10.750–10.768 –

0.50 O. S. 11.000–11.018 –

DOHC GDI 0.05 O. S. 10.610–10.620 –

0.25 O. S. 10.810–10.820 –

0.50 O. S. 11.060–11.070 –

Intake (primary) 0.3 O. S. 27.300–27.325 –

0.6 O. S. 27.600–27.625 –

Intake (secondary) 0.3 O. S. 32.300–32.325 –

0.6 O. S. 32.600–32.625 –

Exhaust 0.3 O. S. 35.300–35.325 –

0.6 O. S. 35.600–35.625 –

SOHC
16-VALVE
<4G13>

Intake 0.3 O. S. 28.300–28.321 –

0.6 O. S. 28.600–28.621 –

Exhaust 0.3 O. S. 26.300–26.321 –

0.6 O. S. 26.600–26.621 –

SOHC
16-VALVE
<4G18>

Intake 0.3 O. S. 30.300–30.321 –

0.6 O. S. 30.600–30.621 –

Exhaust 0.3 O. S. 28.300–28.321 –

0.6 O. S. 28.600–28.621 –

DOHC Intake 0.3 O. S. 31.300–31.325 –

0.6 O. S. 31.600–31.625 –

Exhaust 0.3 O. S. 27.800–27.825 –

0.6 O. S. 28.100–28.125 –

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11A-1-4

4G1 ENGINE (E–W) – Specifications

TORQUE SPECIFICATIONS

Item Nm

Alternator and ignition system

Water pump pulley bolt 9
Alternator brace bolt (alternator side) 22
Alternator brace bolt (tightened with water pump) 23
Alternator pivot bolt 44
Oil level gauge guide bolt (Flange) 23
Oil level gauge guide bolt (Washer) 19
Crankshaft bolt (M12) 125
Crankshaft bolt (M14) 181
Spark plug 25
Distributor bolt 11
Ignition coil bolt 10
Ignition failure sensor bolt 5
Camshaft position sensor bolt 9
Camshaft position sensor support bolt 13
Camshaft position sensing cylinder bolt 21

Timing belt

Timing belt cover bolt 11
Timing belt tensioner bolt 23
Crankshaft angle sensor bolt 9
Bracket bolt 21
Engine support bracket bolt (M8) 21
Engine support bracket bolt, nut (M10) 35
Idler pulley bolt 35
Camshaft sprocket bolt 88

Fuel and emission control system

Vacuum pipe & hose bolt 9
Delivery pipe bolt 11
Fuel pressure regulator bolt 9
Throttle body bolt 18
Hose clamp bolt 10
Fuel pump bolt (SOHC 12-VALVE–CARBURETOR) 12
Fuel pump bolt (SOHC 16-VALVE–CARBURETOR) 19
Breather tube clamp bolt 22
Carburetor bolt 17
Air temperature sensor 13
Cover bolt (Except M8 × 16) 12

E

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4G1 ENGINE (E–W) – Specifications

Item Nm
Cover bolt (M8 × 16) 18

EGR valve bolt 21

11A-1-4a

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11A-1-4b

4G1 ENGINE (E–W) – Specifications

Intentionally blank

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4G1 ENGINE (E- W) -

Specifications

Item Nm

Intake manifold and throttle body (GDI)

Accelerator cable bolt 10

Throttle body bolt 19

Air intake plenum resonator bolt 10

Power plant stay right bolt 49

Intake manifold stay bolt 30

EGR valve bolt 19

EGR valve support bolt 19

EGR valve support nut 24

Intake manifold bolt, nut 20

Exhaust manifold (GDI)

Oxygen sensor 44

Exhaust manifold cover bolt 30

Exhaust manifold bracket bolt 35

11A-1-5

Exhaust manifold nut (M8) 18

Exhaust manifold nut (M10) 29

Power plant stay left bolt 35

Water pump and water hose

Water inlet fitting bolt 22

Water inlet pipe bolt (M8) 12

Water inlet pipe bolt (M10) 25

Fitting bolt 23

Water outlet fitting bolt (Front wheel drive) 23

Water outlet fitting bolt (Rear wheel drive) 18

Thermostat case bolt 23

Thermo valve 27

Engine coolant temperature gauge unit 11

Engine coolant temperature sensor 29

Water pump bolt 13

Exhaust manifold and intake manifold

Boost sensor bolt 5

Solenoid valve assembly bolt 9

Intake manifold bolt, nut 17

Intake manifold stay bolt <MPI> (M8) 17

Intake manifold stay bolt <MPI> (M10) 31

Intake manifold stay bolt <carburetor> 30

Engine hanger bolt 19

Exhaust manifold cover bolt 29

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11A-1-5a

Item Nm

Exhaust manifold nut (M8) 17

Exhaust manifold nut (M10) 29

Exhaust manifold bracket A bolt 35

Exhaust manifold bracket B bolt 35

Power plant stay right bolt 49

Power plant stay left bolt 35

Oxygen sensor 44

Fuel system (GDI)

Fuel pipe bolt 12

Fuel pump bolt 4.9®17±2

Flange bolt 24

Harness bracket bolt 9.8

Injector holder bolt 23

Delivery pipe and injector bolt 12

4G1 ENGINE (E- W) -

4G1 ENGINE (E- W) -

4G1 ENGINE (E- W) -

Specifications

Specifications

Specifications

Rocker arms and camshaft

Fuel pump cover bolt 12

Rocker cover bolt <SOHC> 3.5

Rocker cover bolt <DOHC> 4

Rocker shaft assembly bolt 31

Adjusting screw 15

Bearing cap bolt (M6) 11

Bearing cap bolt (M8) 24

Rocker arms and camshaft (GDI)

Engine hanger bolt 19

Rocker cover bolt 3.5

Beam camshaft cap bolt (M6) 11

Beam camshaft cap bolt (M8) 25

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 bolt 23

Oil pan bolt (M6) 7

Oil pan bolt (M8) 24

Drain plug 39

Oil screen bolt 19

Front case bolt 14

Relief plug 44

E

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4G1 ENGINE (E- W) -

Specifications

Item Nm

Oil pump cover bolt 10

Pistons and connecting rods

11A-1-5b

Connecting rod nut 17 + 90_to 100

Crankshaft and cylinder block

Flywheel bolt 132

Drive plate bolt <Except GDI> 132

Drive plate bolt <GDI> 98

Rear plate bolt 10

Bell housing cover bolt 10

Rear oil seal case bolt 11

Bearing cap bolt 34 + 30_to 34

Oil pressure switch 19

Knock sensor 23

_

_

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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.

D

Plastic region tightening bolts are used for the following applications:
(1) Cylinder head bolts
(2) Connecting rod cap bolts
(3) Bearing cap bolt

D

The tightening procedure is basically as follows:
After tightening a bolt to the specified torque, tighten it by a further 90_+90_,90_–100_or 30_–34_.
The exact tightening procedure differs depending on the bolt and is described in relevant parts of
this manual.

SEALANTS

Item Specified sealant Quantity

Cam position sensor support Mitsubishi Genuine Part No. MD970389 or equivalent As required

Water pump Mitsubishi Genuine Part No. MD970389 or equivalent As required

Thermo valve Mitsubishi Genuine Part No. MD970389 or equivalent As required

Thermostat housing Mitsubishi Genuine Part No. MD970389 or equivalent As required

Water outlet fitting 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

Beam camshaft cap Mitsubishi Genuine Part No. MD970389 or equivalent As required

Oil pump case Mitsubishi Genuine Part No. MD970389 or equivalent As required

Oil pan Mitsubishi Genuine Part No. MD970389 or equivalent As required

Oil pressure switch 3M ATD Part No. 8660 or equivalent As required

Rear 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

E

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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 an d 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

MB991614 Angle gauge Installation of crankshaft bearing caps

11A-2-1

tightening bolt (used with MD998715)

MB991653 Cylinder head bolt

wrench (10)

MB991659 Guide-D Guide for removal and press-fitting of piston

MB991671 Valve stem

installer

MD998011 Crankshaft rear oil

seal installer

Removal and installation of cylinder head bolts

pins

Press-fitting of valve stem seals
(SOHC 16-VALVE, DOHC)

Installation of crankshaft rear oil seal

MD998054 Oil pressure switch

wrench

MD998304 Crankshaft front oil

seal installer

MD998305 Crankshaft front oil

seal guide

E

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Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

Removal and installation of oil pressure switch

Installation of crankshaft front oil seal

Guide for installation of crankshaft front oil seal

11A-2-2

Tool UseNameNumber

MD998442 Air bleed wire Testing of automatic lash adjusters

4G1 ENGINE (E- W) -

Special Tools

(DOHC)

MD998713 Camshaft oil seal

Installation of camshaft oil seal

installer

MD998715 Pin (2-off) Holding camshaft sprocket when loosening or

tightening bolt (used with MB990767)

MD998727 Oil pan remover Removal of oil pan

MD998735 Valve spring com-

Compression of valve springs

pressor

MD998760 Valve stem seal

installer

MD998762 Circular packing

installer

MD998772 Valve spring com-

pressor

MD998780 Piston pin setting

tool

Installation of valve stem seals
(SOHC 12-VALVE)

Installing of circular packing

Compression of valve springs

Removal and press-fitting of piston pins

E

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Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

4G1 ENGINE (E–W) – Special Tools

Tool UseNameNumber

MD998781 Flywheel stopper Locking flywheel in fixed position

11A-2-3

MD998306 Crankshaft front oil

seal installer

MB991962 Crankshaft front oil

seal guide

Installation of crankshaft front oil seal

Guide for installation of crankshaft oil seal

E

E

Nov. 1995Mitsubishi Motors Corporation

Apr. 2003Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-G

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

9 Nm

12

12 Nm

13

7

44 Nm

10

25 Nm

11

1

5

23 Nm

2

8

4

M12 125 Nm
M14 181 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

AA""BA 8. Crankshaft bolt

"BA 9. Crankshaft pulley

E

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Nov. 1995Mitsubishi Motors Corporation

Apr. 2003Mitsubishi Motors Corporation Revised

9

PWEE9520

PWEE9520-G

3

10. Spark plug cable

11. Spark plug

"AA 12. Distributor

13. O-ring

NOTE

*: For details of adjustment, refer to the relevant model’s

chassis workshop manual.

11A-3-1a

4G1 ENGINE (E–W) – Alternator and Ignition System

REMOVAL AND INSTALLATION <SOHC 16-VALVE – FRONT WHEEL DRIVE (WITH
DISTRIBUTOR)>

22 Nm

23 Nm

6

9 Nm

25 Nm

44 Nm

10

12 Nm

11

12

13

7

23 Nm

5

1

9

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

AA""BA 8. Crankshaft bolt

"BA 9. Crankshaft pulley

2

3

8

M12 125 Nm
M14 181 Nm

10. Spark plug cable

11. Spark plug

"AA 12. Distributor

13. O-ring

NOTE

*: For details of adjustment, refer to the relevant model’s

chassis workshop manual.

E

E

Nov. 1995Mitsubishi Motors Corporation

Apr. 2003Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-G

4G1 ENGINE (E–W) – Alternator and Ignition System

11A-3-1b

REMOVAL AND INSTALLATION <SOHC 16-VALVE – FRONT WHEEL DRIVE (WITH
CAM POSITION SENSOR)>

10 Nm

10

11

9 Nm

25 Nm

10

12

16

14

5 Nm

15

22 Nm

23 Nm

4

6

9 Nm

44 Nm

11

13

21 Nm

13 Nm

7

1

23 Nm

5

9

2

3

8

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

AA""BA 8. Crankshaft bolt

"BA 9. Crankshaft pulley

E

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Nov. 1995Mitsubishi Motors Corporation

Apr. 2003Mitsubishi Motors Corporation Revised

M12 125 Nm
M14 181 Nm

NOTE

PWEE9520

PWEE9520-G

10. Spark plug cable

11. Ignition coil

12. Spark plug

13. Ignition failure sensor
(only vehicles for Europe)

14. Cam position sensor

"CA 15. Cam position sensor support

16. Cam position sensing cylinder

*: For details of adjustment, refer to the relevant model’s

chassis workshop manual.

11A-3-2

4G1 ENGINE (E–W) – Alternator and Ignition System

REMOVAL AND INSTALLATION <SOHC 16-VALVE – REAR WHEEL DRIVE>

10

10 Nm

25 Nm

12

13

9 Nm

22 Nm

6

23 Nm

4

9 Nm

11

7

44 Nm

5

14

15

13 Nm

21 Nm

1

23 Nm

2

3

8

125 Nm

9

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

AA""BA 8. Crankshaft bolt

"BA 9. Crankshaft pulley

E

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Nov. 1995Mitsubishi Motors Corporation

Feb. 2001Mitsubishi Motors Corporation Revised

NOTE

PWEE9520

PWEE9520-E

10. Spark plug cable

11. Ignition coil

12. Spark plug

13. Cam position sensor

"CA 14. Cam position sensor support

15. Cam position sensing cylinder

*: For details of adjustment, refer to the relevant model’s

chassis workshop manual.

4G1 ENGINE (E–W) – Alternator and Ignition System

REMOVAL AND INSTALLATION <DOHC>

10

25 Nm

11

11A-3-3

12

11 Nm

13

22 Nm

23 Nm

4

6

9 Nm

7

44 Nm

5

1

23 Nm

2

3

8

125 Nm

9

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

AA""BA 8. Crankshaft bolt

"BA 9. Crankshaft pulley

E

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Nov. 1995Mitsubishi Motors Corporation

Feb. 2001Mitsubishi Motors Corporation Revised

NOTE

PWEE9520

PWEE9520-E

10. Spark plug cable

11. Spark plug

"AA 12. Distributor

13. O-ring

*: For details of adjustment, refer to the relevant model’s

chassis workshop manual.