Mitsubishi 4G9 User Manual 2
www.mivec.co.nz
ENGINE
4G9 SERIES
CONTENTS
GENERAL INFORMATION 11A-0-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.SPECIFICATIONS 11A-1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 11A-1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REWORK DIMENSIONS 11A-1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS 11A-1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NEW TIGHTENING METHOD–BY USE OF BOLTS TO BE
TIGHTENED IN PLASTIC AREA 11A-1-7
SEALANT 11A-1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FORM-IN-PLACE GASKET 11A-1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . .
5a.THROTTLE BODY AND EGR SYSTEM (GDI) 11A-5a-1. . . . . . . . . . . . . . . . .
6.INTAKE AND EXHAUST MANIFOLD 11A-6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
6a.INTAKE MANIFOLD (GDI) 11A-6a-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6b.EXHAUST MANIFOLD (GDI) 11A-6b-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6c.INJECTOR AND FUEL PUMP ASSEMBLY (GDI) 11A-6c-1. . . . . . . . . . . . .
6d.INTAKE AND EXHAUST MANIFOLD
<4G94–GDI for PAJERO io> 11A-6d-1
7.WATER PUMP AND WATER HOSE 11A-7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.ROCKER ARMS AND CAMSHAFTS 11A-8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8a.ROCKER COVER AND CAMSHAFTS (MIVEC) 11A-8a-1. . . . . . . . . . . . . . .
8b.ROCKER ARMS AND ROCKER SHAFT CAPS (MIVEC) 11A-8b-1. . . . .
9.CYLINDER HEAD AND VALVES 11A-9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.FRONT CASE AND OIL PUMP 11A-10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.PISTON AND CONNECTING ROD 11A-11-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE
PLATE 11A-12-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11A-0-1
E
Mar . 2001Mitsubishi Motors Corporation Revised
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11A-0-2
NOTES
E
May 1995Mitsubishi Motors Corporation
PWEE9502
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4G9 ENGINE (E-W) -
General Information
GENERAL INFORMATION
4G92
Descriptions 4G92- SOHC 4G92-DOHC- MIVEC
Type In-line OHV, SOHC In-line OHV, DOHC
Number of cylinders 4 4
Combustion chamber Pentroof type Pentroof type
11A-0-3
Total displacement dm
Cylinder bore mm 81.0 81.0
Piston stroke mm 77.5 77.5
Compression ratio 10.0 11.0
V alve timing Intake
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
3
valve
Exhaust
valve
Opens
(BTDC)
Closes
(ABDC)
Opens
(BBDC)
Closes
(ATDC)
1,597 1,597
20_,14_* 17_(Low-speed cam)
47.5_(High-speed cam)
42_,58_* 31_(Low-speed cam)
72.5_(High-speed cam)
54_,52_* 41_(Low-speed cam)
70_(High-speed cam)
2_,16_* 11_(Low-speed cam)
35_(High-speed cam)
*: LANCER for general export and CARISMA for 6B model
E
July 1997Mitsubishi Motors Corporation Revised
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11A-0-4
4G9 ENGINE (E- W) -
General Information
4G93
Descriptions 4G93-SOHC 4G93-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
Cylinder bore mm 81.0 81.0 81.0
Piston stroke mm 89.0 89.0 89.0
Compression ratio 10.0, 9.5 10.5 11.7*1, 12.0*
Valve timing Intake
Lubrication system Pressure feed, full-
Oil pump type Trochoid type Trochoid type Trochoid type
Cooling system Water-cooled forced
3
valve
Exhaust
valve
Opens
(BTDC)
Closes
(ABDC)
Opens
(BBDC)
Closes
(ATDC)
1,834 1,834 1,834
_
14
_
50
_
58
_
10
flow filtration
circulation
_
20
_
60
_
61
_
15
Pressure feed, fullflow filtration
Water-cooled forced
circulation
_
15
_
56
_
55
_
15
Pressure feed, fullflow filtration
Water-cooled forced
circulation
2
Water pump type Centrifugal impeller
type
*1: Up to 1999 model
2
*
: From 2000 model
Centrifugal impeller
type
Centrifugal impeller
type
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May 2000Mitsubishi Motors Corporation Revised
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4G9 ENGINE (E–W) – General Information
4G94
Descriptions 4G94–SOHC 4G94–DOHC–GDI
Type In-line OHV, SOHC In-line OHV, DOHC
Number of cylinders 4 4
Combustion chamber Pentroof type Pentroof type
11A-0-5
Total displacement dm
Cylinder bore mm 81.5 81.5
Piston stroke mm 95.8 95.8
Compression ratio 9.5 10.6
Valve timing Intake
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
3
valve
Exhaust
valve
Opens
(BTDC)
Closes
(ABDC)
Opens
(BBDC)
Closes
(ATDC)
1,999 1,999
2_ 15_
58_ 51_
58_ 55_
10_ 15_
E
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July 1997Mitsubishi Motors Corporation Revised
Mar. 2001Mitsubishi Motors Corporation Revised
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4G9 ENGINE (E–W) – Specifications
GSC
GSC
GSC
GSC
GSC
SC
GC
4G93 DOHC GDI
4G94 DOHC GDI
1. SPECIFICATIONS
SERVICE SPECIFICATIONS
Items Standard value Limit
Timing belt
Auto-tensioner rod protrusion amount (When removed from engine)mm11 –
Auto-tensioner rod stroke mm Within 1 –
Auto-tensioner rod protrusion amount (When checking with installed
on engine) mm
Rocker arms and camshaft
Camshaft cam
height mm
Valve clearance mm Intake 0.09 –
Camshaft journal O.D. mm SOHC 26.0 –
Rocker cover and camshaft (MIVEC)
Camshaft height mm Intake A 36.41 36.91
Valve clearance (cold engine) mm Intake 0.1 –
4G92–SOHC*
4G92–SOHC*
4G92–SOHC*
4G93–SOHC*
4G93–SOHC*
4G94–SOHC
4G93–DOHC
4G93–DOHC–GDI
4G94–DOHC–GDI
1
2
3
4
5
Intake 37.34 36.84
Exhaust 36.79 36.29
Intake 37.78 37.28
Exhaust 37.83 37.33
Intake 36.92 36.42
Exhaust 36.70 36.65
Intake 37.53 37.03
Exhaust 37.64 37.14
Intake 37.11 36.61
Exhaust 37.15 36.65
Intake 37.91 37.41
Exhaust 37.70 37.20
Intake 35.31 34.81
Exhaust 35.20 34.70
Intake 35.49 34.99
Exhaust 34.73 34.23
Intake 35.49 34.99
Exhaust 34.91 34.41
Exhaust 0.20 –
DOHC 45.0 –
Intake B 33.58 33.08
Exhaust A 35.83 35.33
Exhaust B 34.24 33.74
Exhaust 0.2 –
3.8 – 4.5 –
11A-1-1
*1: LANCER for Europe and CARISMA for Europe
*2: LANCER for general export and CARISMA for 6B model
*3: LANCER for Europe (from 2001 model) and CARISMA for Europe (from 2001 model)
*4: Except for Europe
*5: For Europe
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Jun. 2002Mitsubishi Motors Corporation Revised
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11A-1-2
Items Standard value Limit
Cylinder head and valve
Cylinder head gasket surface flatness mm Less than 0.03 0.2
4G9 ENGINE (E–W) – Specifications
Grinding limit of cylinder head gasket surface mm
*Total resurfacing depth of both cylinder head and cylinder block
Cylinder head overall height mm SOHC 119.9 – 120.1 –
DOHC 131.9 – 132.1 –
DOHC–MIVEC 119.8 – 120.0 –
DOHC–GDI 131.9 – 132.1 –
Thickness of valve
head (margin) mm
Valve overall height
mm
SOHC Intake 1.0 0.5
Exhaust 1.3 0.8
DOHC Intake 1.0 0.5
Exhaust 1.2 0.7
SOHC Intake 110.15 109.65
Exhaust 113.70 113.20
DOHC Intake 104.19 103.69
Exhaust 103.87 103.37
DOHC–MIVEC Intake 115.63 115.13
Exhaust 115.63 115.13
DOHC–GDI Intake 104.19 103.69
Exhaust 103.87 103.37
– 0.2*
Valve spring free length mm SOHC (with lash ad-
juster)
SOHC (with adjust-
ing screw)
DOHC 45.0 44.0
DOHC–MIVEC 51.5 50.5
DOHC–GDI 44.8 43.8
Valve spring out-of-squareness Max. 2_ 4_
Valve stem to valve
guide clearance mm for PAJERO io
Valve seat valve contact width mm 0.9 – 1.3 –
Valve guide projection from cylinder head
upper surface mm
Except DOHC–GDI
DOHC–GDI
for PAJERO io
Intake 0.02 – 0.05 0.10
Exhaust 0.05 – 0.09 0.15
Intake 0.02 – 0.05 0.10
Exhaust 0.04– 0.06 0.15
SOHC 14.0 –
DOHC 19.0 –
50.9 49.9
49.5 48.5
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Jun. 2002Mitsubishi Motors Corporation Revised
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4G9 ENGINE (E–W) – Specifications
Items LimitStandard value
11A-1-3
Valve stem projection mm
Cylinder head bolt shank length mm – 96.4
Valve stem O.D. mm 6.0 –
V alve face angle 45_ – 45.5_ –
Valve spring load/installed height N/mm SOHC 216/44.2 –
Valve guide I.D. mm 6.0 –
Font case, oil pump and oil pan
Oil pump tip clearance mm 0.06 – 0.18 –
SOHC Intake 49.30 49.80
Exhaust 49.35 49.85
DOHC Intake 46.70 47.20
Exhaust 46.65 47.15
DOHC–MIVEC Intake 58.13 58.63
Exhaust 57.85 58.35
DOHC–GDI Intake 46.70 47.20
Exhaust 46.65 47.15
DOHC 255/44.5 –
DOHC–MIVEC 255/44.5 –
DOHC–GDI 196/37.5 –
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
mm
Piston ring end gap
mm
Crankshaft pin oil clearance mm 0.02 – 0.05 0.1
Piston pin press-in load N [Room temperature] 4,500 – 14,700 –
Connecting rod big end side clearance mm 0.10 – 0.25 0.4
Piston pin O.D. mm 19.0 –
Piston O.D. mm 4G92, 4G93 81.0 –
Crankshaft, cylinder block, flywheel and drive plate
No. 1 4G92, 4G93 0.25 – 0.40 0.8
No. 2 0.40 – 0.55 0.8
Oil ring SOHC (4G92, 4G93) 0.20 – 0.60 1.0
No. 1 0.03 – 0.07 0.1
No. 2 0.02 – 0.06 0.1
4G94 0.15 – 0.30 0.8
SOHC (4G94),
DOHC
4G94 81.5 –
0.10 – 0.35 1.0
Crankshaft journal oil clearance mm 0.02 – 0.04 0.1
Cylinder block gasket surface flatness mm 0.05 0.1
Grinding limit of cylinder block gasket surface mm
*Total resurfacing depth of both cylinder head and cylinder block
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Mar . 2001Mitsubishi Motors Corporation Revised
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– 0.2*
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11A-1-4
Items LimitStandard value
Cylinder block overall height mm 4G92 243.5 –
Cylinder block I.D. mm 4G92, 4G93 81.0 –
Piston to cylinder clearance mm 0.02 – 0.04 –
Bearing cap bolt shank length mm – 71.1
Crankshaft end play mm 0.05 – 0.25 0.4
Crankshaft journal O.D. mm 50 –
Crankshaft pin O.D. mm 45 –
4G9 ENGINE (E–W) – Specifications
4G93 263.5 –
4G94 286.7 –
4G94 81.5 –
REWORK DIMENSIONS
Items Standard value
Cylinder head and valve
Oversize rework dimensions of valve guide hole (both intake and
exhaust) mm
Oversize rework dimensions of intake valve
seat hole mm
Oversize rework dimensions of exhaust valve
seat hole mm
Crankshaft, flywheel and drive plate
Crankshaft out of roundness and taper of journal and pin mm 0.005
NOTE
O.D.: Outer diameter
I.D.: Inner diameter
O.S.: Oversize diameter
SOHC 0.30 O.S. 31.80 – 31.83
DOHC 0.30 O.S. 34.30 – 34.32
SOHC 0.30 O.S. 29.30 – 29.32
DOHC 0.30 O.S. 30.80 – 30.82
0.05 O.S. 11.05 – 11.07
0.25 O.S. 11.25 – 11.27
0.50 O.S. 11.50 – 11.52
0.60 O.S. 32.10 – 32.13
0.60 O.S. 34.60 – 34.62
0.60 O.S. 29.60 – 29.62
0.60 O.S. 31.10 – 31.13
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Mar . 2001Mitsubishi Motors Corporation Revised
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4G9 ENGINE (E–W) – Specifications
TORQUE SPECIFICATIONS
Items Nm
Alternator and ignition system
Oil level gauge 13
Distributor 12
Ignition coil 10
Spark plug 25
Crankshaft bolt 182 ± 4
Alternator brace (M8) 23
Alternator brace (M10) 49
Lock bolt 23
Adjusting bolt 5
Power steering pump pulley 25
Power steering pump bracket stay 49
Power steering pump bracket (M8) 21
11A-1-5
Power steering pump bracket (M10) 44
Alternator pivot bolt 44
Center cover 3
Ignition failure sensor (M6) 5
Ignition failure sensor (M8) 23
Ignition failure sensor bracket 10
Cam position sensor 9
Cam position sensor support 13
Cam position sensing cylinder 21
Engine cover 2.9
Timing belt
Camshaft sprocket bolt 88
Cam position sensor 9.8
Crank angle sensor 9.8
Timing belt rear cover 11
Timing belt rear upper cover 11
Timing belt tensioner 24
Engine support bracket, right 49
Accessory mount 49
Timing belt cover 11
Tensioner pulley bolt 49
Tensioner arm bolt 44
Auto-tensioner bolt 13
Idler pulley bolt 36
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Jun. 2002Mitsubishi Motors Corporation Revised
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11A-1-6
Items Nm
Fuel system and emission system
Breather tube 21
Fuel pump 18
Carburetor 17
EGR valve 21
Cover <Without EGR valve> 12
Fuel return pipe 9
Delivery pipe 12
Fuel pressure regulator 9
Throttle body stay <MIVEC> 23
Throttle body stay <4G94> 24
Throttle body 19
Throttle cable bracket 19
Stay 24
4G9 ENGINE (E–W) – Specifications
Harness bracket 11
Vacuum hose and pipe assembly <Engine with solenoid valve> (Flange bolt) 11
Vacuum hose and pipe assembly <Engine with solenoid valve> (Bolt and
washer assembly)
Vacuum hose and pipe assembly <Engine without solenoid valve> 10
Solenoid valve assembly 9
Throttle body and EGR system (GDI)
Air intake resonator 9
Intake manifold stay (M8) 20
Intake manifold stay (M10) 30
Water hose clamp 13
Water pipe 11
Throttle body 18
Throttle body stay
<CARISMA from 2001 model, SPACE STAR from 2001 model, GALANT>
Throttle body stay <For PAJERO io – 4G94> 18
EGR valve (Bolt and washer assembly) 18
9
24
EGR valve (Flange bolt) 24
Engine hanger 18
EGR valve support bolt 18
EGR valve support nut 23
Air by-pass valve 9
Mar . 2001Mitsubishi Motors Corporation RevisedPWEE9502-K
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4G9 ENGINE (E–W) – Specifications
Items Nm
Intake manifold and exhaust manifold
Exhaust manifold (M8) 18
Exhaust manifold (M10) 29
Exhaust manifold bracket (M8) 19
Exhaust manifold bracket (M10 Bolt and washer assembly) 35
Exhaust manifold bracket (M10 Flange bolt) 98
Engine hanger (Bolt with head mark “4”) 12
Engine hanger (Bolt with head mark “7”) 19
Oil level gauge guide 14
Boost sensor 5
Intake air temperature sensor 13
Heat protector 13
Intake manifold 20
Intake manifold stay 31
11A-1-6a
Oxygen sensor 44
Intake manifold (GDI)
Vacuum pipe and hose <Except for PAJERO io> 11
Vacuum pipe and hose <For PAJERO io> 9
Solenoid valve 9
Fuel pump protector 23
Connector bracket 11
Branch tube (M6 x 14) 11
Branch tube (M6 x 18) 9
Intake manifold stay 30
Accelerator cable bracket 9
V acuum pipe 11
Intake manifold 19
Exhaust manifold (GDI)
Oil level gauge guide 13
Exhaust manifold cover 13
Engine hanger bolt 24
Engine hanger nut (M8) 18
Engine hanger nut (M10) 29
Exhaust manifold bracket (M8 × 20) 18
Exhaust manifold bracket (M8 × 22) 35
Exhaust manifold bracket (M8 × 25) 19
Exhaust manifold bracket (M10) 35
Exhaust manifold bracket <For PAJERO io> 98
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Jun. 2002Mitsubishi Motors Corporation Revised
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11A-1-6b
Items Nm
Exhaust manifold (M8) 17
Exhaust manifold (M10) 29
Injector and fuel pump assembly (GDI)
Fuel low pressure pipe (M6) 18
Fuel low pressure pipe (M8) 9
Fuel nipple 9
Clamp 9
Fuel feed pipe 11
Fuel pump 17
Harness bracket 11
Fuel pipe 11
Fuel return pipe 11
Fuel return pipe clamp 9
Fuel high pressure regulator 18
4G9 ENGINE (E–W) – Specifications
Fuel pressure sensor <Except for PAJERO io> 23
Fuel pressure sensor <For PAJERO io> 18
Spacer 18
Pump camshaft case 23
Injector holder 22
Delivery pipe and injector 11
Intake and exhaust manifold <4G94–GDI for PAJERO io>
V acuum pipe and hose 9
Solenoid valve 9
Fuel pump protector 23
Connector bracket 11
Intake manifold stay nut 29
Intake manifold stay bolt 31
Low pressure fuel pipe 9
Intake manifold 20
Exhaust manifold cover 13
Engine hanger 18
Exhaust manifold bracket 98
Exhaust manifold (M8) 17
Exhaust manifold (M10) 29
Water pump and water hose
Water pump 24
Water inlet pipe 14
Thermostat case 24
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Jun. 2002Mitsubishi Motors Corporation Revised
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4G9 ENGINE (E–W) – Specifications
Items Nm
Water inlet fitting <Except PAJERO io> 19
Water inlet fitting <PAJERO io> 24
Water by-pass fitting 24
Water pipe 14
Water outlet fitting <Except PAJERO io> 19
Water outlet fitting <PAJERO io> 24
Engine coolant temperature gauge unit 10
Engine coolant temperature sensor 29
Water fitting 24
Rocker arms and camshaft
Lock nut 9
Rocker arm shaft 31
Harness bracket 10
Rocker cover 3.5
11A-1-6c
Bearing cap bolt (M6) 11
Bearing cap bolt (M8) 24
Beam camshaft cap (M6) 11
Beam camshaft cap (M8) 21
Rocker cover and camshafts (MIVEC)
Rocker cover 4
Oil pump 11
Arm spring holder 11
Camshaft bearing cap (M6) 11
Camshaft bearing cap (M8) 23
Oil control valve 9
Rocker arms and rocker shaft caps (MIVEC)
Rocker shaft cap 11
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 oil pump
Oil pump cover 10
Oil pump case 14
Relief plug 44
Oil screen 19
Oil pan 9
Upper oil pan (M6) 9
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Jun. 2002Mitsubishi Motors Corporation Revised
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11A-1-6d
Items Nm
Upper oil pan (M8) 24
Lower oil pan 11
Cover 7
Baffle plate <DOHC–MPI> 7
Baffle plate <Except DOHC–MPI> 11
Drain plug 39
Oil pressure switch 10
Transmission stay 23
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_
Oil seal case 11
Bell housing cover (Flange bolt) 10
4G9 ENGINE (E–W) – Specifications
Bell housing cover (Bolt and washer assembly) 9
Rear plate <SPACE STAR> 10
Rear plate <Except SPACE STAR> 11
Drive plate bolt 98
Flywheel bolt 98
Baffle plate 9
Knock sensor 23
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Jun. 2002Mitsubishi Motors Corporation Revised
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4G9 ENGINE (E- W) -
Specifications
11A-1-7
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 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.
D
Areas where the bolts are in use:
(1) Cylinder head bolts
(2) Main bearing cap bolts
(3) Connecting rod cap bolts
D
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 fitting Mitsubishi Genuine Part No.MD970389 or equivalent As required
Water 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
Cover 3M ATD Part No.8660 or equivalent As required
Cylinder head Mitsubishi Genuine Part No.MD970389 or equivalent As required
Oil pressure switch 3M 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 pan/Upper oil pan/Lower oil 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
Camshaft holder 3M ATD Part No.8660 or equivalent As required
E
July 2000Mitsubishi Motors Corporation Revised
PWEE9502-H
www.mivec.co.nz
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 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
May 1995Mitsubishi Motors Corporation
PWEE9502
www.mivec.co.nz
4G9 ENGINE (E-W) -
Special Tools
2. SPECIAL TOOLS
Tool Number Name Use
MB990938 Handle Use with MD998776
11A-2-1
MB990767 Crankshaft pulley
holder
MD998440 Leak-down tester Leak-down test of lash adjuster
MD998442 Air bleed wire Air bleeding of lash adjuster
MD998713 Camshaft oil seal
installer
Holding camshaft sprocket when loosening
and tightening of bolt.
Use with MD998719
Installation of camshaft oil seal
MD998716 Crankshaft wrench Rotation of crankshaft when installing piston
and timing belt.
MD998717 Crankshaft front oil
seal installer
MB991653 Cylinder head bolt
wrench
MB991659 Guide D Removal of piston pin (Use with MD998780)
Installation of crankshaft front oil seal
Tightening and loosening of cylinder head bolt
E
Nov. 1995Mitsubishi Motors Corporation Revised
PWEE9502-A
www.mivec.co.nz
11A-2-2
Tool UseNameNumber
4G9 ENGINE (E-W) -
Special Tools
MD998719 Pulley holder pin
(2)
MD998727 Oil pan remover Removal of the oil pan
MD998754 Pin Use with MB990767
MD998767 Tensioner pulley
socket wrench
Use with MB990767
Adjustment of timing belt tension
MD998772 Valve spring
compressor
MD998774 Valve stem seal
installer
MD998775 Valve stem seal
installer
MD998776 Crankshaft rear oil
seal installer
Removal and installation of valve and related
parts
Installation of valve stem seal
Installation of valve stem seal
Installation of crankshaft rear oil seal
Use with MB990938
E
Nov. 1995Mitsubishi Motors Corporation
PWEE9502-A
Revised
www.mivec.co.nz
4G9 ENGINE (E-W) -
Tool UseNameNumber
Special Tools
11A-2-3
MD998780 SETTING TOOL
Piston pin
MD998735 Valve spring
compressor
MD998781 Flywheel stopper Holding flywheel and drive plate
Removal and installation of piston pin
Compression of valve spring
MB991477 Valve adjusting
wrench
MB991478 Valve adjusting
wrench feeler
gauge set
MB991479 Rocker arm
piston checker
MD998784 Valve spring
compressor
adapter
Adjustment of valve clearance (MIVEC)
Adjustment of valve clearance (MIVEC)
Adjustment of valve clearance (MIVEC)
Compression of valve spring (MIVEC)
(Use with MD998772)
E
Nov. 1995Mitsubishi Motors Corporation Revised
PWEE9502-A
www.mivec.co.nz
4G9 ENGINE (E–W) – Alternator and Ignition System
3. ALTERNATOR AND IGNITION SYSTEM
REMOVAL AND INSTALLATION <SOHC> (Engines with distributor)
7
11A-3-1
12 Nm
5 Nm
23 Nm
23 Nm
49 Nm
25 Nm
3
2
8
9
10
44 Nm
21 Nm
12
13
1
6
4
5
49 Nm
44 Nm
11
25 Nm
44 Nm
182 ± 4 Nm
Removal steps
1. Drive belt*
2. Alternator
3. Alternator brace
AA""BA 4. Crankshaft bolt
"BA 5. Crankshaft pulley
"BA 6. Front flange
7. Spark plug cable
E
Apr. 2002Mitsubishi Motors Corporation Revised
PWEE9502-J
8. Spark plug
9. O-ring
10. Distributor
11. Power steering pump pulley
12. Power steering pump bracket stay
13. Power steering pump bracket
NOTE:
*: For details of adjustment, refer to the relevant model’s
chassis workshop manual.
www.mivec.co.nz
11A-3-2
4G9 ENGINE (E–W) – Alternator and Ignition System
REMOVAL AND INSTALLATION <SOHC for other than PAJERO io>
(Engines without distributor)
23 Nm
5 Nm
23 Nm
7
9
25 Nm
10 Nm
8
9 Nm
11
12
13 Nm
10
5 Nm
2
13
21 Nm
3
44 Nm
49 Nm
1
4
182 ± 4 Nm
Removal steps
1. Drive belt*
2. Alternator
3. Alternator brace
AA""BA 4. Crankshaft bolt
"BA 5. Crankshaft pulley
"BA 6. Front flange
7. Spark plug cable
8. Ignition coil
9. Spark plug
10. Ignition failure sensor (From 2001
model vehicles for Europe)
21 Nm
15
49 Nm
16
6
44 Nm
5
NOTE:
*: For details of adjustment, refer to the relevant model’s
chassis workshop manual.
44 Nm
25 Nm
11. Cam position sensor
"AA 12. Cam position sensor support
13. Cam position sensing cylinder
14. Power steering pump pulley
15. Power steering pump bracket stay
16. Power steering pump bracket
14
E
Apr. 2002Mitsubishi Motors Corporation Revised
PWEE9502-J
www.mivec.co.nz
4G9 ENGINE (E–W) – Alternator and Ignition System
REMOVAL AND INSTALLATION <SOHC for PAJERO io>
(Engines without distributor)
10 Nm
8
11A-3-2a
23 Nm
5 Nm
23 Nm
49 Nm
7
7
10 Nm
5 Nm
9 Nm
12
11
10
21 Nm
25 Nm
8
9
13
44 Nm
14
13 Nm
3
2
21 Nm
16 17
1
Removal steps
1. Drive belt*
2. Alternator
3. Alternator brace
AA""BA 4. Crankshaft bolt
"BA 5. Crankshaft pulley
"BA 6. Front flange
7. Spark plug cable
8. Ignition coil
9. Spark plug
E
4
182 ± 4 Nm
Jun. 2002Mitsubishi Motors Corporation Revised
5
6
PWEE9502-K
49 Nm
44 Nm
25 Nm
10. Ignition failure sensor (For Europe)
11. Ignition failure sensor bracket
(For Europe)
12. Cam position sensor
"AA 13. Cam position sensor support
14. Cam position sensing cylinder
15. Power steering pump pulley
16. Power steering pump bracket stay
17. Power steering pump bracket
NOTE
*: For details of adjustment, refer to the relevant model’s
chassis workshop manual.
15
44 Nm
www.mivec.co.nz
11A-3-2b
4G9 ENGINE (E-W) -
Alternator and Ignition System
Intentionally blank
E
Dec. 1998Mitsubishi Motors Corporation Added
PWEE9502-E
www.mivec.co.nz
4G9 ENGINE (E–W) – Alternator and Ignition System
REMOVAL AND INSTALLATION <DOHC>
3 Nm
9
11A-3-3
7
10 Nm
8
5 Nm
23 Nm
23 Nm
29 Nm
3
182 ± 4 Nm
1
4
10
25 Nm
11
2
23 Nm
44 Nm
21 Nm
6
5
14
44 Nm
49 Nm
44 Nm
13
12
25 Nm
Removal steps
1. Drive belt*
2. Alternator
3. Alternator brace
AA""BA 4. Crankshaft bolt
"BA 5. Crankshaft pulley
"BA 6. Front flange
7. Center cover
8. Ignition coil
E
E
Nov. 1995Mitsubishi Motors Corporation
Apr. 2002Mitsubishi Motors Corporation Revised
PWEE9502-A
PWEE9502-J
9. Spark plug cable
10. Spark plug
11. Ignition failure sensor
12. Power steering pump pulley
13. Power steering pump bracket stay
14. Power steering pump bracket
NOTE:
*: For details of adjustment, refer to the relevant model’s
chassis workshop manual.
www.mivec.co.nz
11A-3-4
4G9 ENGINE (E–W) – Alternator and Ignition System
REMOVAL AND INSTALLATION <DOHC–MIVEC>
5 Nm
23 Nm
3 Nm
8
7
10 Nm
9 Nm
11
13 Nm
9
25 Nm
10
2
3
21 Nm
12
13
23 Nm
49 Nm
182 ± 4 Nm
1
4
Removal steps
1. Drive belt*
2. Alternator
3. Alternator brace
AA""BA 4. Crankshaft bolt
"BA 5. Crankshaft pulley
"BA 6. Front flange
7. Center cover
8. Spark plug cable
9. Ignition coil
44 Nm
5
21 Nm
6
15
49 Nm
44 Nm
25 Nm
10. Spark plug
11. Cam position sensor
"AA 12. Cam position sensor support
13. Cam position sensing cylinder
14. Power steering pump pulley
15. Power steering pump bracket stay
16. Power steering pump bracket
NOTE:
*: For details of adjustment, refer to the relevant model’s
chassis workshop manual.
14
16
44 Nm
E
E
Nov. 1995Mitsubishi Motors Corporation Added
Apr. 2002Mitsubishi Motors Corporation Revised
PWEE9502-A
PWEE9502-J
www.mivec.co.nz
4G9 ENGINE (E–W) – Alternator and Ignition System
REMOVAL AND INSTALLATION
<DOHC–GDI for CARISMA, SPACE STAR, SPACE RUNNER, GALANT>
2.9 Nm
7
14
10 Nm
9
11A-3-5
5 Nm
5 Nm
23 Nm
23 Nm
49 Nm
8
9 Nm
11
25 Nm
10
12
2
13
13 Nm
21 Nm
3
44 Nm
6
21 Nm
5
16
17
1
4
182 ± 4 Nm
Removal steps
1. Drive belt*
2. Alternator
3. Alternator brace
AA""BA 4. Crankshaft bolt
"BA 5. Crankshaft pulley
"BA 6. Front flange
7. Engine cover
8. Earth strap (From 2001 model for
CARISMA, From 2001 model for
SPACE STAR)
9. Ignition coil
10. Spark plug
E
E
Nov. 1995Mitsubishi Motors Corporation
Apr. 2002Mitsubishi Motors Corporation Revised
PWEE9502-A
PWEE9502-J
49 Nm
44 Nm
25 Nm
11. Cam position sensor
"AA 12. Cam position sensor support
13. Cam position sensing cylinder
14. Ignition failure sensor (From 2001
model for CARISMA, From 2001
model for SPACE STAR)
15. Power steering pump pulley
16. Power steering pump bracket stay
17. Power steering pump bracket
NOTE:
*: For details of adjustment, refer to the relevant model’s
chassis workshop manual.
15
44 Nm
www.mivec.co.nz
11A-3-6
4G9 ENGINE (E–W) – Alternator and Ignition System
REMOVAL AND INSTALLATION <DOHC–GDI for PAJERO io>
10 Nm
13
5 Nm
23 Nm
23 Nm
44 Nm
6
3
4
182 ± 4 Nm
7
25 Nm
9 Nm
15
14
13 Nm
17
16
21 Nm
5
1
13 Nm
2
3
8
44 Nm
9
11
21 Nm
12
Removal steps
1. Oil level gauge
2. Oil level gauge guide
3. O-ring
4. Drive belt*
5. Alternator
6. Alternator brace
AA""BA 7. Crankshaft bolt
"BA 8. Crankshaft pulley
"BA 9. Front flange
49 Nm
44 Nm
44 Nm
25 Nm
"AA 16. Cam position sensor support
NOTE:
*: For details of adjustment, refer to the relevant model’s
chassis workshop manual.
10
10. Power steering pump pulley
11. Power steering pump bracket stay
12. Power steering pump bracket
13. Ignition coil
14. Spark plug
15. Cam position sensor
17. Cam position sensing cylinder
E
E
Nov. 1995Mitsubishi Motors Corporation Added
Mar . 2001Mitsubishi Motors Corporation Revised
PWEE9502-A
PWEE9502-I
www.mivec.co.nz
MD998781
4G9 ENGINE (E–W) – Alternator and Ignition System
REMOVAL SERVICE POINT
AA" CRANKSHAFT BOLT REMOVAL
(1) Use the special tool to hold the flywheel or the drive
plate, and then loosen the crankshaft mounting bolts.
INSTALLATION SERVICE POINTS
"AA CAM 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. MD970389 or
equivalent.
11A-3-7
MD998781
Crankshaft pulley
Crankshaft bolt
Washer
Big chamfered side
Front flange
Crankshaft
Clean
Degrease
"BA FRONT FLANGE / CRANKSHAFT PULLEY /
CRANKSHAFT BOLT INSTALLATION
(1) Use the special tool to hold the flywheel or the drive
plate.
(2) Clean and then degrease the front flange contacting
surface of the crankshaft pulley.
NOTE
Degreasing is necessary to prevent decrease in the friction
between contacting surfaces.
(3) Clean the bolt hole in the crankshaft, the crankshaft
contacting surface and washer contacting surface of the
crankshaft pulley, and the washer.
(4) Apply an appropriately small amount of oil to the threads
and seating surface of the crankshaft bolt.
(5) Tighten the crankshaft bolt to the specified torque of 182
± 4 Nm.
E
E
Nov. 1995Mitsubishi Motors Corporation
Jun. 2002Mitsubishi Motors Corporation Revised
PWEE9502-A
PWEE9502-K
www.mivec.co.nz
4G9 ENGINE (E–W) – Timing Belt
4. TIMING BELT
REMOVAL AND INSTALLATION <SOHC for CARISMA (Up to 1999 model),
LANCER (Except from 2001 model for Europe), GALANT>
11A-4-1
11 N m
49 Nm
88 Nm
14
13
11 N m
1
5
4
6
7
8
11 N m
10
11
9.8 Nm
12
9
23 Nm
3
2
Removal steps
1. Timing belt front upper cover
2. Timing belt front lower cover
3. Engine support bracket, right
AA""DA 4. Timing belt
"CA 5. Tensioner spring
"BA 6. Timing belt tensioner
7. Timing belt rear cover
E
Mar . 2001Mitsubishi Motors Corporation Revised
PWEE9502-I
8. Crankshaft angle sensor
(Engines without distributor)
"GA 9. Crankshaft sprocket
"GA 10. Crankshaft spacer
(Engines without distributor)
"GA 11. Crankshaft sensing blade
(Engines without distributor)
12. Crankshaft key
AB""AA 13. Camshaft sprocket bolt
14. Camshaft sprocket
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