Mitsubishi 4G6 User Manual
ENGINE
4G6 SERIES
CONTENTS
11A-0-1
GENERAL INFORMATION 11A-0-3
1. SPECIFICATIONS 11A-1-1
SERVICE SPECIFICATIONS 11A-1-1
TORQUE SPECIFICATIONS 11A-1-4
NEW TIGHTENING METHOD -
BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA 11A-1-9
SEALANTS 11A-1-9
FORM-IN-PLACE GASKET 11A-1-10
2. SPECIAL TOOLS 11A-2-1
3. ALTERNATOR AND IGNITION SYSTEM 11A-3-1
3a. INTAKE MANIFOLD (GDI) 11A-3a-1
4. TIMING BELT 11A-4-1
4a. EXHAUST MANIFOLD (GDI) 11A-4a-1
5. FUEL AND EMISSION CONTROL PARTS 11A-5-1
5a. FUEL PARTS (GDI) 11A-5a-1
6. WATER PUMP AND INTAKE MANIFOLD 11A-6-1
6a. WATER PUMP AND WATER HOSE (GDI) 11A-6a-1
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7. EXHAUST MANIFOLD 11A-7-1
8. ROCKER ARMS AND CAMSHAFT 11A-8-1
8a. ROCKER ARMS AND CAMSHAFTS (GDI) 11A-8a-1
9. CYLINDER HEAD AND VALVES 11A-9-1
10. FRONT CASE, COUNTERBALANCE SHAFTS AND OIL PAN 11A-10-1
11. PISTON AND CONNECTING ROD 11A-11-1
12. CRANKSHAFT, FLYWHEEL AND DRIVE PLATE 11A-12-1
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Aug. 1998Mitsubishi Motors Corporation
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RevisedPWEE9616-A
11A-0-2
NOTES
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Dec. 1996Mitsubishi Motors Corporation
PWEE9616
4G6 ENGINE <E-W> -
General Information
GENERAL INFORMATION
SOHC-4G63
Descriptions Specifications
Type In-line OHV, SOHC
Number of cylinders 4
Combustion chamber Pentroof type
11A-0-3
Total displacement dm
Cylinder bore mm 85.0
Piston stroke mm 88.0
Compression ratio 10
Valve timing Intake valve Opens (BTDC) 18_
Lubrication system Pressure feed, full-flow filtration
Oil pump type Involute gear type
3
Closes (ABDC) 58_
Exhaust valve Opens (BBDC) 58_
Closes (ATDC) 18_
1,997
SOHC-4G64
Descriptions Specifications
Type In-line OHV, SOHC
Number of cylinders 4
Combustion chamber Pentroof type
Total displacement dm
Cylinder bore mm 86.5
Piston stroke mm 100.0
Compression ratio 10
Valve timing Intake valve Opens (BTDC) 16_
Lubrication system Pressure feed, full-flow filtration
Oil pump type Involute gear type
E
3
Closes (ABDC) 53_
Exhaust valve Opens (BBDC) 50_
Closes (ATDC) 16_
Aug. 1998Mitsubishi Motors Corporation
2,351
RevisedPWEE9616-A
11A-0-4
t
GDI
Descriptions Specifications
Type In-line OHV, SOHC
Number of cylinders 4
Combustion chamber Pentroof + curved top piston type
4G6 ENGINE <E-W> -
General Information
Total displacement dm
Cylinder bore mm 86.5
Piston stroke mm 100.0
Compression ratio 11.5
Valve timing Intake valve Opens (BTDC) 16_
Lubrication system Pressure feed, full-flow filtration
Oil pump type Involute gear type
3
Closes (ABDC) 60_
Exhaust valve Opens (BBDC) 56_
Closes (ATDC) 16_
2,351
NOTE
GDI is a trademark of Mitsubishi Motors Corporation.
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Aug. 1998Mitsubishi Motors Corporation
AddedPWEE9616-A
4G6 ENGINE <E-W> -
Specifications
1. SPECIFICATIONS
SERVICE SPECIFICATIONS
Items Standard value Limit
Timing belt
Auto-tensioner rod projection length mm 12 -
11A-1-1
Auto-tensioner rod pushed-in amount [when pushed with a force of 98
- 196 N] mm
Rocker arms and camshaft
Camshaft cam height mm 4G63
SOHC
4G64
SOHC
Lash adjuster leak down time
[diesel fuel at 15 - 20_C] seconds/mm
Camshaft journal outer diameter mm 45 -
Rocker arms and camshaft (GDI)
Camshaft cam height mm
Lash adjuster leak down time
[diesel fuel at 15 - 20_C] seconds/mm
Camshaft journal outer diameter mm 26 -
Intake 35.79 35.29
Exhaust 37.14 36.64
Intake 37.39 36.89
Exhaust 37.14 36.64
Intake 37.39 36.89
Exhaust 36.83 36.33
1.0 or less -
3 - 20/1.0 -
3 - 20/1.0 -
Cylinder head and valves
Cylinder head flatness of gasket surface mm Less than 0.05 0.2
Cylinder head grinding limit of gasket surface mm
Total resurfacing depth of both cylinder head and cylinder block
Cylinder head overall height mm
Cylinder head bolt shank length mm - Maximum 99.4
Valve thickness of valve head (margin) mm SOHC
Valve overall height mm SOHC
SOHC 120 -
GDI 132 -
Intake 1.0 0.5
Exhaust 1.2 0.7
GDI
GDI
Intake 1.0 0.5
Exhaust 1.5 1.0
Intake 112.30 111.80
Exhaust 114.11 113.61
Intake 105.5 105.0
Exhaust 105.7 105.2
- 0.2
Valve stem outer diameter mm 6.0 -
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Aug. 1998Mitsubishi Motors Corporation
RevisedPWEE9616-A
11A-1-2
Items LimitStandard value
4G6 ENGINE <E-W> -
Specifications
Valve thickness to valve guide clearance SOHC
mm
GDI
Valve face angle mm 45_ - 45.5_ -
Valve spring free length mm
Valve spring load/installed height N/mm
Valve spring out-of-squareness
Valve seat valve contact width mm 0.9 - 1.3 -
Valve guide inner diameter mm
Valve guide projection from cylinder head
upper surface mm
SOHC 51.0 50.0
GDI 48.3 47.3
SOHC 267/44.2 -
GDI 294/40.0 -
SOHC 2_ or less Maximum 4_
GDI 1.5_ or less Maximum 4_
SOHC 6.0 -
GDI 6.6 -
SOHC 14.0 -
GDI 19.5 -
Intake 0.02 - 0.05 0.10
Exhaust 0.03 - 0.07 0.15
Intake 0.02 - 0.05 0.10
Exhaust 0.05 - 0.09 0.15
Valve stem projection mm
Oversize rework dimensions of valve guide
hole (SOHC) mm
Oversize rework dimensions of valve guide
hole (GDI) mm
Intake oversize rework dimensions of valve
seat hole (SOHC) mm
Intake oversize rework dimensions of valve
seat hole (GDI) mm
Exhaust oversize rework dimensions of
valve seat hole (SOHC) mm
SOHC 49.30 49.80
GDI
0.05 Oversize diameter 11.05 - 11.07 -
0.25 Oversize diameter 11.25 - 11.27 -
0.50 Oversize diameter 11.50 - 11.52 -
0.05 Oversize diameter 12.05 - 12.07 -
0.25 Oversize diameter 12.25 - 12.27 -
0.50 Oversize diameter 12.50 - 12.52 -
0.3 Oversize diameter 34.30 - 34.33 -
0.6 Oversize diameter 34.60 - 34.63 -
0.3 Oversize diameter 35.30 - 35.33 -
0.6 Oversize diameter 35.60 - 35.63 -
0.3 Oversize diameter 34.30 - 34.33 -
0.6 Oversize diameter 34.60 - 34.63 -
Intake 49.20 49.70
Exhaust 48.40 48.90
Exhaust oversize rework dimensions of
valve seat hole (GDI) mm
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Aug. 1998Mitsubishi Motors Corporation
0.3 Oversize diameter 33.30 - 33.33 -
0.6 Oversize diameter 33.60 - 33.63 -
RevisedPWEE9616-A
4G6 ENGINE <E-W> -
Items LimitStandard value
Front case, counterbalance shaft and oil pan
Specifications
11A-1-3
Oil pump side clearance mm
Oil pressure at curb idle speed kPa [Oil temperature is 75 to 90_C] 78 or more -
Piston and connecting rod
Piston outer diameter mm
Piston ring side clearance mm
Piston ring end gap mm
Piston pin outer diameter mm 22.0 -
Piston pin press-in load N (Room temperature) 7,350 - 17,200 -
Crankshaft pin oil clearance mm 0.02 - 0.05 0.1
Connecting rod big end side clearance mm 0.10 - 0.25 0.4
Drive gear 0.08 - 0.14 -
Driven gear 0.06 - 0.12 -
4G63 85.0 -
4G64 86.5 -
No. 1 0.02 - 0.06 0.1
No. 2 0.02 - 0.06 0.1
No. 1 0.25 - 0.35 0.8
No. 2 0.40 - 0.55 0.8
Oil ring side rail 0.10 - 0.40 1.0
Crankshaft, flywheel and drive plate
Crankshaft end play mm 0.05 - 0.25 0.40
Crankshaft journal outer diameter mm 57.0 -
Crankshaft pin outer diameter mm 45.0 -
Crankshaft journal oil clearance mm 0.02 - 0.04 0.1
Bearing cap bolt shank length mm - Maximum 71.1
Piston to cylinder clearance mm 0.02 - 0.04 -
Cylinder block flatness of gasket surface mm 0.05 0.1
Cylinder block grinding limit of gasket surface mm
Total resurfacing depth of both cylinder head and cylinder block
Cylinder block overall height mm
Cylinder block inner diameter mm
Cylindricity mm 0.01 -
4G63 284 -
4G64 290 -
4G63 85.0 -
4G64 86.5 -
- 0.2
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Aug. 1998Mitsubishi Motors Corporation
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11A-1-4
4G6 ENGINE <E-W> -
Specifications
TORQUE SPECIFICATIONS
Items Nm
Alternator and ignition system
Water pump pulley 9
Adjusting bolt 10
Lock bolt 22
Alternator brace 23
Alternator pivot nut 44
Crankshaft pulley 25
Ignition coil (Multipoint fuel injection) 10
Spark plug 25
Distributor (Carburetor) 12
Camshaft position sensing cylinder (Multipoint fuel injection) 22
Camshaft position sensor support (Multipoint fuel injection) 14
Camshaft position sensor (Multipoint fuel injection) 10
Oil level gauge guide 13
Idler pulley bracket (M8) (Vehicle for Hong Kong) 22
Idler pulley bracket (M10) (Vehicle for Hong Kong) 49
Idler pulley (Vehicle for Hong Kong) 49
Intake manifold (GDI)
Vacuum pipe and hose (Flange bolt) 11
Vacuum pipe and hose (Bolt, washer assembly) 8.8
Solenoid valve 8.8
Vacuum pipe 11
Throttle body 11
Intake manifold stay (M6) 8.8
Intake manifold stay (M8) 30
Air intake plenum resonator (Flange bolt) 11
Air intake plenum resonator (Bolt, washer assembly) 8.8
EGR valve 23
EGR valve support 23
Intake manifold 19
Timing belt
Timing belt cover flange bolt 11
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Aug. 1999Mitsubishi Motors Corporation
RevisedPWEE9616-B
4G6 ENGINE <E-W> -
Items Nm
Timing belt cover washer bolt 9
Power steering bracket 49
Crankshaft angle sensor (Multipoint fuel injection) 9
Tensioner arm 22
Tensioner puller 48
Auto tensioner 23
Idler pulley 35
Engine support bracket 49
Oil pump sprocket 54
Crankshaft bolt 118
Tensioner “B” 18
Counterbalance shaft sprocket 45
Specifications
11A-1-5
Camshaft sprocket bolt 88
Exhaust manifold (GDI)
Exhaust manifold cover 13
Exhaust manifold (M10) 49
Exhaust manifold (M8) 29
Engine hanger 11
Fuel and emission parts
Carburetor (Carburetor) 17
Fuel vapor separator (Carburetor) 23
Throttle body (Multipoint fuel injection) 18
EGR valve (Except General Export) 22
Injectors and delivery pipe (Multipoint fuel injection) 12
Fuel pressure regulator (Multipoint fuel injection) 9
Fuel part (GDI)
Fuel low pressure pipe (M6) 8.8
Fuel low pressure pipe (M8) 18
Fuel pump return nipple 8.8
Clamp A 8.8
Fuel pipe bracket 11
Fuel feed pipe 11
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Aug. 1999Mitsubishi Motors Corporation
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11A-1-6
Items Nm
Fuel pump 4.9 ® 17 ± 2
Harness bracket 8.8
Fuel return pipe 11
Fuel high pressure regulator 18
Fuel pressure sensor 18
Pump camshaft case 23
Injector holder 22
Delivery pipe and injector assembly 11
Engine hanger 11
Water pump and intake manifold
Engine coolant temperature sensor 29
Engine coolant temperature gauge unit 11
4G6 ENGINE <E-W> -
Specifications
Water inlet fitting 13
Thermostat housing 24
Water inlet pipe 13
Water pump 14
Oil level gauge guide 14
Intake manifold stay 31
Intake manifold 19
Engine hanger 11
Detonation sensor (Multipoint fuel injection) 23
Water pump and water hose (GDI)
Engine coolant temperature sensor 29
Engine coolant temperature gauge unit 11
Water inlet fitting 12
Water outlet fitting 12
Thermostat housing 23
Water inlet pipe 12
Water pump 13
Knock sensor 22
Exhaust manifold
Exhaust manifold cover 13
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Aug. 1999Mitsubishi Motors Corporation
RevisedPWEE9616-B
4G6 ENGINE <E-W> -
Items Nm
Heat protector 13
Exhaust manifold (M8) 29
Exhaust manifold (M10) 49
Water outlet fitting 13
Rocker arms and camshaft
Rocker cover 3.4
Rocker arm shaft 31
Rocker arms and camshafts (GDI)
Camshaft position sensor 8.8
Cover 9.8
Camshaft position sensing cylinder 21
Camshaft position sensing support 13
Specifications
11A-1-7
Beam camshaft cap 20
Cylinder head and valves
Cylinder head bolt
[Tighten to 78 Nm and then completely loosen before finally tightening with above procedure.]
Front case, counterbalance shaft and oil pan
Drain plug 39
Oil pan 6.9
Oil level sensor (For Europe) 8.8
Stiffener (For Europe) 21
Oil screen 18
Oil pressure switch (4G63) 19
Oil pressure switch (4G64) 9.8
Relief plug 44
Oil filter bracket 18
Plug 23
20 + 90_ +90_
Flange bolt 36
Oil pump cover bolt 16
Oil pump cover screw 9.8
Front case 23
Transmission stay (GDI engine) 21
Oil level gauge guide 12
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Aug. 1999Mitsubishi Motors Corporation
RevisedPWEE9616-B
11A-1-8
Items Nm
Oil pan lower 6.9
Baffle plate 6.9
Oil pan upper 6.9
Piston and connecting rod
Connecting rod cap 20 + 90_ ® 100_
Crankshaft, flywheel and drive plate
Flywheel bolt 132
Drive plate bolt 132
Rear plate 11
Bell housing cover 8.8
Oil seal case bolt 11
Bearing cap bolt 25 + 90_ ® 100_
4G6 ENGINE <E-W> -
Specifications
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Aug. 1999Mitsubishi Motors Corporation
RevisedPWEE9616-B
4G6 ENGINE <E-W> -
Specifications
11A-1-9
NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED IN
PLASTIC AREA
A new type of bolts, to be tightened in plastic area, is currently used some parts of the engine. The
tightening method for the bolts 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:
D
(1) Cylinder head bolts
(2) Main bearing cap bolts
(3) Connecting rod cap bolts
Tightening method
D
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.
SEALANTS
Item Specified sealant Quantity
Cam position sensor support Mitsubishi Genuine Part No. MD970389 or
equivalent
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
Thermostat case Mitsubishi Genuine Part No. MD970389 or
equivalent
Water outlet fitting Mitsubishi Genuine Part No. MD970389 or
equivalent
Beam camshaft cap Mitsubishi Genuine Part No. MD970389 or
equivalent
Cylinder head Mitsubishi Genuine Part No. MD970389 or
equivalent
Oil pressure switch 3M ATD Part No. 8660 or equivalent As required
Oil pan Mitsubishi Genuine Part No. MD970389 or
equivalent
Oil seal case Mitsubishi Genuine Part No. MD970389 or
equivalent
As required
As required
As required
As required
As required
As required
As required
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Aug. 1998Mitsubishi Motors Corporation
AddedPWEE9616-A
11A-1-10
4G6 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 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 vulcanisation (RTV) type and is supplied in a 100-gram
tube (Part No. MD970389). Since the RTV hardens as it reacts with the moisture in the atmospheric
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. MD997110 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.
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Aug. 1998Mitsubishi Motors Corporation
AddedPWEE9616-A
4G6 ENGINE (E-W) -
Special Tools
2. SPECIAL TOOLS
Tool Number Name Use
11A-2-1
MB990767 Crankshaft pulley
holder
MD990938 Handle Installation of crankshaft rear oil seal
MB991603 Silent shaft bearing
puller stopper
MB991654 Cylinder head bolt
wrench (12)
Holding camshaft sprocket
Use with MD998719.
Use with MD998776.
Guide stopper for removal and installation of
counterbalance shaft rear bearing
Use with MD998372.
Removal and installation of cylinder head bolt
MD998162 Plug wrench Removal and installation of front case cap plug
Use with MD998783.
MD998285 Crankshaft front oil
seal guide
MD998371 Silent shaft bearing
puller
MD998372 Silent shaft bearing
puller
Guide for installation of crankshaft front oil seal
Use with MD998375.
Removal of counterbalance shaft front bearing
Removal of counterbalance shaft rear bearing
MD998375 Crankshaft front
seal installer
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Dec. 1996Mitsubishi Motors Corporation
PWEE9616
Installation of crankshaft front oil seal
11A-2-2
Tool UseNameNumber
MD998440 Leak down tester Leak down test of lash adjuster
4G6 ENGINE (E-W) -
Special Tools
MD998441 Lash adjuster
retainer
MD998442 Lash adjuster wire Air bleeding of lash adjuster
MD998443 Lash adjuster
holder
MD998705 Silent shaft bearing
installer
Air bleeding of lash adjuster
Retainer for holding lash adjuster in rocker arm
at time of removal and installation of rocker
shaft assembly
Installation of counterbalance shaft front and
rear bearing
MD998713 Camshaft oil seal
installer
MD998719 Pulley holder pin Holding camshaft sprocket
MD998727 Oil pan remover Removal of oil pan
MD998735 Valve spring
compressor
Installation of camshaft oil seal
Use with MB990767.
Removal and installation of valve and related
parts
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Dec. 1996Mitsubishi Motors Corporation
PWEE9616
4G6 ENGINE (E-W) -
Tool UseNameNumber
MD998738 Set screw Adjustment of timing belt tension
Special Tools
11A-2-3
MD998767 Tensioner puller
socket wrench
MD998772 Valve spring
compressor
MD998774 Valve stem seal
installer
MD998775 Valve stem seal
installer
Adjustment of timing belt tension
Removal and installation of valve and related
parts
Installation of valve stem seal
Installation of valve stem seal
MD998776 Crankshaft rear oil
seal installer
MD998778 Crankshaft
sprocket puller
MD998780 Piston setting tool Removal and installation of piston pin
MD998781 Flywheel stopper Holding of flywheel and drive plate
Installation of crankshaft rear oil seal
Use with MB990938.
Removal of crankshaft sprocket
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Aug. 1998Mitsubishi Motors Corporation
RevisedPWEE9616-A
11A-2-4
Tool UseNameNumber
4G6 ENGINE (E-W) -
Special Tools
MD998783 Plug wrench
retainer
MD998785 Sprocket stopper Holding silent shaft sprocket
Removal and installation of front case cap plug
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Aug. 1998Mitsubishi Motors Corporation
AddedPWEE9616-A
4G6 ENGINE (E-W) -
Alternator and Ignition System
3. ALTERNATOR AND IGNITION SYSTEM
REMOVAL AND INSTALLATION <CARBURETOR>
6
11A-3-1
8
12 Nm
10 Nm
22 Nm
3
24 Nm
9Nm
2
25 Nm
4
7
10
9
44 Nm
5
1
25 Nm
Removal steps
1. Drive belt
2. Water pump pulley
3. Alternator brace
4. Alternator
5. Crankshaft pulley
6. Spark plug cable
7. Spark plug
8. High tension cable
"BA 9. Distributor assembly
10. O-ring
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Dec. 1996Mitsubishi Motors Corporation
PWEE9616
11A-3-2
4G6 ENGINE (E-W) -
Alternator and Ignition System
REMOVAL AND INSTALLATION <MULTIPOINT FUEL INJECTION>
10 Nm
7
10 Nm
22 Nm
3
24 Nm
9Nm
2
25 Nm
4
44 Nm
5
6
10 Nm
9
10
8
11
22 Nm
14 Nm
r
1
Removal steps
1. Drive belt
2. Water pump pulley
3. Alternator brace
4. Alternator
5. Crankshaft pulley
6. Spark plug cable
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Dec. 1996Mitsubishi Motors Corporation
25 Nm
7. Ignition coil assembly
8. Spark plug
9. Camshaft position sensor
"AA 10. Camshaft position sensing support
11. Camshaft position sensing cylinder
PWEE9616
4G6 ENGINE (E-W) -
REMOVAL AND INSTALLATION (GDI)
6
Alternator and Ignition System
25 Nm
12
49 Nm
11A-3-3
9.8 Nm
11
9.8 Nm
22 Nm
23 Nm
4
8
9
49 Nm
22 Nm
Removal steps
1. Oil level gauge
2. Oil level gauge guide
3. O-ring
4. Drive belt
5. Water pump pulley
6. Alternator
7. Alternator brace
7
49 Nm
8.8 Nm
25 Nm
1
5
13 Nm
2
3
10
8. Idler pulley bracket
(Vehicle for Hong Kong)
9. Idler pulley
(Vehicle for Hong Kong)
10. Crankshaft pulley
11. Ignition coil
12. Spark plug
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Aug. 1999Mitsubishi Motors Corporation
RevisedPWEE9616-B
11A-3-4
4G6 ENGINE (E-W) -
INSTALLATION SERVICE POINTS
"AA
(1) Apply a 3 mm bead of form-in-place gasket (FIPG) to
Alternator and Ignition System
CAMSHAFT POSITION SENSOR SUPPORT
INSTALLATION
the area shown.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or
equivalent
Stud bolt
"BA
DISTRIBUTOR ASSEMBLY INSTALLATION
(1) Turn the crankshaft to bring No. 1 cylinder to the top
dead center on compression stroke.
(2) Align the mating marks on the distributor housing with
that of the coupling key.
(3) Install the distributor assembly on the engine while aligning
the stud bolt used for securing the distributor with the
slot in the mounting flange of the distributor.
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Aug. 1998Mitsubishi Motors Corporation
AddedPWEE9616-A
4G6 ENGINE (E-W) -
Intake Manifold (GDI)
3a. INTAKE MANIFOLD (GDI)
REMOVAL AND INSTALLATION (SPACE WAGON)
11A-3a-1
23 Nm
30 Nm
14
16
11 Nm
8.8 Nm
12
13
15
3
8.8 Nm
4
17
10
11 Nm
23 Nm
11 Nm
11
8.8 Nm
1
19 Nm
2
11 Nm
5
7
6
8.8 Nm
19 Nm
18
19
9
8.8 Nm
30 Nm
8
Removal steps
1. Vacuum pipe and hose
(1999 model vehicles for Hong
Kong)
2. Solenoid valve (1999 model vehicles for Hong Kong)
3. Vacuum pipe and hose
(Vehicles for Europe and 2000
model vehicles for Hong Kong)
4. Solenoid valve
(Vehicles for Europe and 2000
model vehicles for Hong Kong)
5. Vacuum pipe
6. Throttle body
E
Aug. 1999Mitsubishi Motors Corporation
"DA 7. Throttle body gasket
"CA 8. Intake manifold stay
"BA 9. Air intake plenum resonator
10. Gasket
11. Water hose
12. EGR valve
13. Gasket
"AA 14. Hose clamp
"AA 15. EGR support
"AA 16. Gasket
17. Gasket
18. Intake manifold
19. Gasket
RevisedPWEE9616-B
11A-3a-2
4G6 ENGINE (E-W) -
REMOVAL AND INSTALLATION (GALANT)
Intake Manifold (GDI)
8.8 Nm
8.8 Nm
1
2
23 Nm
5
30 Nm
11
13
12
8
11 Nm
9
3
4
23 Nm
19 Nm
10
14
15
16
7
19 Nm
11 Nm
8.8 Nm
6
Removal steps
1. Vacuum pipe and hose
2. Solenoid valve
3. Throttle body
"DA 4. Throttle body gasket
"CA 5. Intake manifold stay
"BA 6. Air intake plenum resonator
7. Gasket
8. Water hose
E
Aug. 1999Mitsubishi Motors Corporation
"AA 11. Hose clamp
"AA 12. EGR support
"AA 13. Gasket
9. EGR valve
10. Gasket
14. Gasket
15. Intake manifold
16. Gasket
RevisedPWEE9616-B
4G6 ENGINE (E-W) -
Intake Manifold (GDI)
11A-3a-3
Hose clamp
Intake
manifold
stay
Intake manifold side
Cylinder head side
INSTALLATION SERVICE POINTS
"AA
(1) Install the gasket, EGR support and hose clamp to the
(2) Install the EGR support assembly to the intake manifold
(3) Tighten the fasteners on the cylinder head side to the
"BA
(1) Install the mounting bolts on the throttle body side without
"CA
(1) Tighten the fasteners to the specified torque after
EGR SUPPORT / HOSE CLAMP / GASKET
INSTALLATION
cylinder head in that order and tighten the fasteners
temporarily.
with the gasket attached on the mating surface, and tighten
the fasteners to the specified torque.
specified torque.
AIR INTAKE PLENUM RESONATOR
INSTALLATION
fail.
INTAKE MANIFOLD STAY INSTALLATION
confirming that the intake manifold stay is in close contact
with the air intake plenum resonator and the cylinder
block.
Air intake
plenum
resonator
Projection
"DA
THROTTLE BODY GASKET INSTALLATION
(1) Position the projection as shown in the illustration.
E
Aug. 1999Mitsubishi Motors Corporation
AddedPWEE9616-B
4G6 ENGINE (E-W) -
4. TIMING BELT
REMOVAL AND INSTALLATION (SOHC)
45 Nm
18
45 Nm
17
16
Timing Belt
20
11A-4-1
14 Nm
11 Nm
14
9Nm
18 Nm
13
1
15
48 Nm
23 Nm
23
22
5
9Nm
49 Nm
49 Nm
3
4
88 Nm
19
7
22 Nm
21
6
12
8
35 Nm
11
9
118 Nm
10
54 Nm
2
Removal steps
1. Timing belt front upper cover
2. Timing belt front lower cover
3. Power steering bracket
4. Crankshaft position sensor
(Multipoint fuel injection)
AA""KA 5. Timing belt
"JA 6. Tensioner pulley
7. Tensioner arm
"IA 8. Auto tensioner
9. Idler pulley
AC""HA 10. Oil pump sprocket
AD""GA 11. Crankshaft bolt
E
Aug. 1999Mitsubishi Motors Corporation
AE" 12. Crankshaft sprocket
13. Flange (Multipoint fuel injection)
14. Flange (Carburetor)
15. Tensioner “B”
AF""FA 16. Timing belt “B”
AG""EA 17. Counterbalance shaft sprocket
"DA 18. Spacer
AH" 19. Crankshaft sprocket “B”
"CA 20. Engine support bracket
AI""AA 21. Camshaft sprocket bolt
22. Camshaft sprocket
23. Timing belt rear cover
RevisedPWEE9616-B
11A-4-2
4G6 ENGINE (E-W) -
REMOVAL AND INSTALLATION (GDI)
Timing Belt
21
88 Nm
29
2
11 Nm
9Nm
30
1
22
25
3.4 Nm
6
48 Nm
7
23
26
24
27
23 Nm
8
23 Nm
13
11 Nm
31
12
118 Nm
49 Nm
11 Nm
32
5
45 Nm
18 Nm
15
18
17
28
3
4
48 Nm
14
9
Removal steps
1. Front upper cover
2. Front lower cover
3. Power steering pump bracket stay
4. Power steering bracket
AB""LA 5. Timing belt
"JA 6. Tensioner pulley
7. Tensioner arm
"IA 8. Auto tensioner
9. Idle pulley
10. Crankshaft position sensor
AC""HA 11. Oil pump sprocket
AD""GA 12. Crankshaft bolt
AE" 13. Crankshaft sprocket
14. Flange
15. Tensioner B
AF""FA 16. Timing belt B
AG""EA 17. Counterbalance shaft sprocket
E
Aug. 1999Mitsubishi Motors Corporation
11
54 Nm
16
10
33
20
19
AH" 19. Crankshaft sprocket B
AJ""BA 29. Camshaft sprocket bolt
8.8 Nm
"DA 18. Spacer
20. Crankshaft key
21. Breather hose
22. PCV hose
23. PCV valve
24. PCV valve gasket
25. Oil filler cap
26. Rocker cover
27. Rocker cover gasket
"CA 28. Engine support bracket
30. Camshaft sprocket
31. Timing belt rear right cover
32. Timing belt rear left upper cover
33. Timing belt rear left lower cover
49 Nm
RevisedPWEE9616-B
4G6 ENGINE (E-W) -
REMOVAL SERVICE POINTS
AA"
(1) Mark belt running direction for reinstallation.
TIMING BELT REMOVAL
NOTE
(1) Water or oil on the belt shorten its life drastically,
so the removed timing belt, sprocket, and tensioner
must be free from oil and water. These parts should
not be washed. Replace parts if seriously
contaminated.
(2) If there is oil or water on each part, check front case
oil seals, camshaft oil seal and water pump for leaks.
Timing Belt
11A-4-3
Timing mark
AB"
TIMING BELT REMOVAL
(1) If the timing belt is to be reused, chalk an arrow mark
on the back surface of the belt so that the belt can be
reinstalled in the same direction.
(2) Place the exhaust camshaft sprocket in a position where
the timing mark for No. 1 cylinder is positioned about
one tooth before the top dead center of the compression
stroke.
Caution
The camshaft sprocket on the exhaust side can
D
turn very easily because of the valve spring
tension. Use care not to allow your fingers to get
caught by the sprocket.
(3) Loosen the lock nut of the tensioner pulley, then remove
the timing belt.
AC"
OIL PUMP SPROCKET REMOVAL
(1) Remove the plug on the left side of cylinder block.
(2) Insert a screwdriver (shank diameter 8 mm) to block the
counterbalance shaft.
(3) Remove the nut.
(4) Remove the oil pump sprocket.
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Aug. 1998Mitsubishi Motors Corporation
RevisedPWEE9616-A
11A-4-4
4G6 ENGINE (E-W) -
Timing Belt
6EN1322
AD"
CRANKSHAFT BOLT LOOSENING
(1) Hold the drive plate with the special tool as shown.
(2) Remove the crankshaft bolt.
AE"
CRANKSHAFT SPROCKET REMOVAL
(1) If it is difficult to remove the sprocket, use the special
tool.
AF"
TIMING BELT “B” REMOVAL
(1) Make a mark on the back of the timing belt indicating
the direction of rotation so it may be reassembled in the
same direction if it is to be reused.
NOTE
(1) Water or oil on the belt shortens its life drastically,
so the removed timing belt, sprocket, and tensioner
must be free from oil and water. These parts should
not be washed. Replace parts if seriously
contaminated.
(2) If there is oil or water on each part check front case
oil seals, camshaft oil seal and water pump for leaks.
AG"
COUNTERBALANCE SHAFT SPROCKET
REMOVAL
(1) Set the special tool as shown to prevent the
MD998785
counterbalance shaft sprocket from turning together.
(2) Loosen the bolt and remove the sprocket.
E
Aug. 1998Mitsubishi Motors Corporation
RevisedPWEE9616-A
4G6 ENGINE (E-W) -
Timing Belt
11A-4-5
AH"
CRANKSHAFT SPROCKET “B” REMOVAL
(1) If it is difficult to remove the sprocket, use the special
tool.
AI"
CAMSHAFT SPROCKET BOLT LOOSENING
(1) Using the special tools shown in the illustration, lock the
camshaft sprocket in position.
(2) Loosen the camshaft bolt.
AJ"
CAMSHAFT SPROCKET BOLT LOOSENING
(1) Use a wrench to hold the hexagonal part of the camshaft,
and then remove the camshaft sprocket mounting bolt.
INSTALLATION SERVICE POINTS
"AA
(1) Using the special tools shown in the illustration, lock the
(2) Tighten the camshaft sprocket bolt to the specified torque.
"BA
(1) Using a wrench, hold the camshaft at its hexagon and
E
Aug. 1998Mitsubishi Motors Corporation
CAMSHAFT SPROCKET BOLT TIGHTENING
camshaft sprocket in position.
CAMSHAFT SPROCKET BOLT TIGHTENING
tighten the bolt to the specification.
RevisedPWEE9616-A
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