Mitsubishi 4G9, 4G92-SOHC, 4G92-DOHC-MIVEC, 4G93-SOHC, 4G93-DOHC User Manual

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ENGINE

4G9 SERIES

CONTENTS

11A-0-1

GENERAL INFORMATION 11A-0-3

1.SPECIFICATIONS 11A-1-1 SERVICE SPECIFICATIONS 11A-1-1 REWORK DIMENSIONS 11A-1-4 TORQUE SPECIFICATIONS 11A-1-4 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

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

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Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

11A-0-2

NOTES

May 1995Mitsubishi Motors Corporation

PWEE9502

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

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

July 1997Mitsubishi Motors Corporation Revised

PWEE9502-C

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

V alve timing Intake

Lubrication system Pressure feed, full-

Oil pump type Trochoid type Trochoid type Trochoid type

Cooling system Water-cooled forced

valve

Exhaust valve

Opens (BTDC)

Closes (ABDC)

Opens (BBDC)

Closes (ATDC)

1,834 1,834 1,834

flow filtration

circulation

Pressure feed, fullflow filtration

Water-cooled forced circulation

Pressure feed, fullflow filtration

Water-cooled forced circulation

Water pump type Centrifugal impeller

type

Centrifugal impeller type

July 1997Mitsubishi Motors Corporation

PWEE9502-C

Revised

4G9 ENGINE (E-W) -

Specifications

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 -

11A-1-1

Auto-tensioner rod protrusion amount (When checking with installed on engine) mm

Rocker arms and camshaft

Camshaft cam height mm

4G92-SOHC*

Intake 37.34 36.84

Exhaust 36.79 36.29

Intake 37.78 37.28

Exhaust 37.83 37.33

4G93-SOHC

Intake 37.53 37.03

Exhaust 37.64 37.14

4G93-DOHC

Intake 35.31 34.81

Exhaust 35.20 34.70

4G93-DOHC-GDI*

Intake 35.49 34.99

Exhaust 34.91 34.41

4G93-DOHC-GDI*

Intake 35.49 34.99

Exhaust 34.73 34.23

Valve clearance mm

Intake 0.09 -

Exhaust 0.20 -

3.8 - 4.5 -

Camshaft journal O.D. mm

SOHC 26.0 -

DOHC 45.0 -

Rocker cover and camshaft (MIVEC)

Camshaft height mm

Intake A 36.41 36.91

Intake B 33.58 33.08

Exhaust A 35.83 35.33

Exhaust B 34.24 33.74

Valve clearance (cold engine) mm

Intake 0.1 -

Exhaust 0.2 -

Cylinder head and valve

Cylinder head gasket surface flatness mm Less than 0.03 0.2

Grinding limit of cylinder head gasket surface mm

- 0.2*

*Total resurfacing depth of both cylinder head and cylinder block

*1: LANCER for Europe and CARISMA for Europe

: LANCER for general export and CARISMA for 6B model

: For CARISMA

: For PAJERO io

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

11A-1-2

Items Standard value Limit

4G9 ENGINE (E-W) -

Specifications

Cylinder head overall height mm

Thickness of valve SOHC head (margin) mm

DOHC

Valve overall height SOHC mm

DOHC

DOHC-MIVEC

DOHC-GDI

SOHC 119.9 - 120.1 -

DOHC 131.9 - 132.1 -

DOHC-MIVEC 119.8 - 120.0 -

DOHC-GDI 131.9 - 132.1 -

Intake 1.0 0.5

Exhaust 1.3 0.8

Intake 1.0 0.5

Exhaust 1.2 0.7

Intake 110.15 109.65

Exhaust 113.70 113.20

Intake 104.19 103.69

Exhaust 103.87 103.37

Intake 115.63 115.13

Exhaust 115.63 115.13

Intake 104.19 103.69

Exhaust 103.87 103.37

V alve spring free length mm

V alve spring out-of-squareness Max. 2_ 4_

Valve stem to valve Except DOHC-GDI guide clearance mm for PAJERO io

DOHC-GDI for PAJERO io

Valve seat valve contact width mm 0.9 - 1.3 -

V alve guide projection from cylinder head upper surface mm

V alve stem projec- SOHC tion mm

DOHC

SOHC 50.9 49.9

DOHC 45.0 44.0

DOHC-MIVEC 51.5 50.5

DOHC-GDI 44.8 43.8

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 -

Intake 49.30 49.80

Exhaust 49.35 49.85

Intake 46.70 47.20

Exhaust 46.65 47.15

DOHC-MIVEC

DOHC-GDI

Cylinder head bolt shank length mm - 96.4

Dec. 1998Mitsubishi Motors Corporation Revised

Intake 58.13 58.63

Exhaust 57.85 58.35

Intake 46.70 47.20

Exhaust 46.65 47.15

PWEE9502-E

4G9 ENGINE (E-W) -

Items LimitStandard value

Valve stem O.D. mm 6.0 -

V alve face angle 45_ - 45.5_ -

Specifications

11A-1-3

V alve spring load/installed height N/mm

V alve guide I.D. mm 6.0 -

Font case, 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

Piston and connecting rod

Piston ring to piston ring groove clearance mm

Piston ring end gap mm

No. 1 0.25 - 0.40 0.8

No. 2 0.40 - 0.55 0.8

Oil ring

SOHC 216/44.2 -

DOHC 255/44.5 -

DOHC-MIVEC 255/44.5 -

DOHC-GDI 196/37.5 -

No. 1 0.03 - 0.07 0.1

No. 2 0.02 - 0.06 0.1

SOHC 0.20 - 0.60 1.0

DOHC 0.10 - 0.35 1.0

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 81.0 -

Crankshaft, cylinder block, flywheel and drive plate

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

Cylinder block overall height mm

Cylinder block I.D. mm 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 -

4G92 243.5 -

4G93 263.5 -

- 0.2*

Crankshaft pin O.D. mm 45 -

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

11A-1-4

4G9 ENGINE (E-W) -

Specifications

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 SOHC seat hole mm

DOHC

Oversize rework dimensions of exhaust valve SOHC seat hole mm

DOHC

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

0.05 O.S. 11.05 - 11.07

0.25 O.S. 11.25 - 11.27

0.50 O.S. 11.50 - 11.52

0.30 O.S. 31.80 - 31.83

0.60 O.S. 32.10 - 32.13

0.30 O.S. 34.30 - 34.32

0.60 O.S. 34.60 - 34.62

0.30 O.S. 29.30 - 29.32

0.60 O.S. 29.60 - 29.62

0.30 O.S. 30.80 - 30.82

0.60 O.S. 31.10 - 31.13

TORQUE SPECIFICATIONS

Items Nm

Alternator and ignition system

Oil level gauge 13

Distributor 12

Ignition coil 10

Spark plug 25

Crankshaft bolt 181

Alternator brace (M10) 49

Alternator brace (M8) 23

Lock bolt 23

Adjusting bolt <Except SOHC for PAJERO io and DOHC- GDI for PAJERO io> 10

Adjusting bolt <SOHC - PAJERO io and DOHC - GDI for PAJERO io> 4.9

Power steering pump pulley 25

Power steering pump bracket stay 49

Power steering pump bracket (M8) 21

Power steering pump bracket (M10) 44

Alternator pivot bolt 44

Center cover 3

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

4G9 ENGINE (E-W) -

Items Nm

Ignition failure sensor 23

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 <DOHC> 9.8

Crank angle sensor 9.8

Timing belt rear cover 11

Timing belt tensioner 24

Engine support bracket, right 49

Accessory mount 49

Timing belt cover 11

Specifications

11A-1-5

Tensioner pulley bolt 49

Tensioner arm bolt 44

Auto-tensioner bolt 13

Idler pulley bolt 36

Fuel system and emission system

Breather tube 21

Fuel pump 18

Carburetor 17

EGR valve 21

Fuel return pipe 9

Delivery pipe 12

Fuel pressure regulator 9

Throttle body stay 23

Throttle body 19

Vacuum hose and pipe assembly <SOHC-MPI for other than PAJERO io> 10

Vacuum hose and pipe assembly <SOHC-MPI for PAJERO io> 9

Solenoid valve assembly <SOHC- MPI for other than PAJERO io> 11

Solenoid valve assembly <SOHC - MPI for PAJERO io> 9

Throttle body and EGR system (GDI)

Air intake resonator 9

Intake manifold stay 30

Water hose clamp 13

Water pipe 11

Throttle body 18

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

11A-1-6

Items Nm

EGR valve 18

Engine hanger 18

EGR valve support bolt 18

EGR valve support nut 23

Air by-pass valve 9

Intake manifold and exhaust manifold

Exhaust manifold (M10) 29

Exhaust manifold (M8) 18

Exhaust manifold bracket 19

Engine hanger 12

Oil level gauge guide 14

Boost sensor 5

Intake air temperature sensor 13

Heat protector 13

4G9 ENGINE (E-W) -

Specifications

Intake manifold 20

Intake manifold stay 30

Intake manifold (GDI)

V acuum pipe and hose <For CARISMA> 11

V acuum pipe and hose <For PAJERO io> 9

Solenoid valve 9

Fuel pump protector 23

Connector bracket 11

Branch tube (M6 x 18) 9

Branch tube (M6 x 14) 11

Intake manifold stay 30

Accelerator cable bracket 9

Vacuum pipe 11

Intake manifold 19

Exhaust manifold (GDI)

Oil level gauge guide 13

Exhaust manifold cover 13

Engine hanger bolt 18

Engine hanger nut (M8) 18

Engine hanger nut (M10) 29

Exhaust manifold bracket (M8 ´ 22) 35

Exhaust manifold bracket (M8 ´ 20) 18

Exhaust manifold bracket (M10) 98

Exhaust manifold (M10) 29

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

4G9 ENGINE (E-W) -

Items Nm

Exhaust manifold (M8) 17

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 return pipe 11

Fuel return pipe clamp 9

Fuel high pressure regulator 18

Fuel pressure sensor <For CARISMA> 23

Fuel pressure sensor <For PAJERO io> 18

Specifications

11A-1-6a

Spacer 18

Pump camshaft case 23

Injector holder 22

Delivery pipe and injector 11

Water pump and water hose

Water pump 24

Water inlet pipe 14

Thermostat case 24

Water inlet fitting <Except DOHC - GDI for PAJERO io> 19

Water inlet fitting <DOHC- GDI for PAJERO io> 23

Water by-pass fitting 23

Water pipe 13

Water outlet fitting <Except DOHC- GDI for PAJERO io> 14

Water outlet fitting <DOHC - GDI for PAJERO io> 23

Engine coolant temperature gauge unit 10

Engine coolant temperature sensor 29

Water fitting 23

Rocker arms and camshaft

Lock nut 9

Rocker arm shaft 31

Rocker cover 3.5

Bearing cap bolt (M6) 11

Bearing cap bolt (M8) 24

Beam camshaft cap (M8) 21

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

11A-1-6b

Items Nm

Beam camshaft cap (M6) 11

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,

Oil pressure switch 10

Front case and oil pump

4G9 ENGINE (E-W) -

Specifications

finally tighten 20 Nm + 90_ +90_

Oil pump cover 10

Oil pump case 14

Relief plug 44

Oil screen 19

Oil pan 7

Upper oil pan <Only M6 ´ 121> 7

Upper oil pan <Except M6 ´ 121> 11

Upper oil pan <M8> 24

Lower oil pan 7

Cover 7

Baffle plate <For CARISMA, SPACE STAR only> 7

Drain plug 39

Oil pressure switch 10

Baffle plate mounting bolt 7

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 9

Rear plate 11

Drive plate bolt 98

Flywheel bolt 98

Baffle plate 9

Knock sensor 22

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

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 A TD Part No.8660 or equivalent As required

Rocker cover 3M A TD Part No.8660 or equivalent As required

Beam camshaft cap Mitsubishi Genuine Part No.MD970389 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 A TD Part No.8660 or equivalent As required

Camshaft holder 3M ATD Part No.8660 or equivalent As required

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

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.

May 1995Mitsubishi Motors Corporation

PWEE9502

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

Nov. 1995Mitsubishi Motors Corporation Revised

PWEE9502-A

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 V alve stem seal

installer

MD998775 V alve stem seal

installer

MD998776 Crankshaft rear oil

seal installer

Removal and installation of valve and related parts

Installation of valve stem seal

Installation of crankshaft rear oil seal Use with MB990938

Nov. 1995Mitsubishi Motors Corporation

PWEE9502-A

Revised

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)

Compression of valve spring (MIVEC) (Use with MD998772)

Nov. 1995Mitsubishi Motors Corporation Revised

PWEE9502-A

4G9 ENGINE (E-W) -

Alternator and Ignition System

3. ALTERNATOR AND IGNITION SYSTEM

REMOVAL AND INSTALLATION <SOHC> (Engines with distributor)

11A-3-1

12 Nm

10 Nm

23 Nm

49 Nm

25 Nm

44 Nm

AA""BA

181 Nm

Removal steps

1. Drive belt*

2. Alternator

3. Alternator brace

4. Crankshaft bolt

5. Crankshaft pulley

Nov. 1995Mitsubishi Motors Corporation

6. Flange

7. Spark plug cable

8. Spark plug

9. Distributor

10. O-ring

NOTE:

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

chassis workshop manual.

PWEE9502-A

Revised

11A-3-2

4G9 ENGINE (E-W) -

Alternator and Ignition System

REMOVAL AND INSTALLATION <SOHC for other than PAJERO io> (Engines without distributor)

10 Nm

9Nm

13 Nm

10 Nm

23 Nm

49 Nm

25 Nm

21 Nm

44 Nm

Removal steps

1. Drive belt*

2. Alternator

3. Alternator brace

AA""BA 4. Crankshaft bolt

5. Crankshaft pulley

6. Front flange

Dec. 1998Mitsubishi Motors Corporation Revised

181 Nm

7. Spark plug cable

8. Ignition coil

9. Spark plug

10. Cam position sensor

"AA 11. Cam position sensor support

12. Cam position sensing cylinder

NOTE:

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

chassis workshop manual.

PWEE9502-E

4G9 ENGINE (E-W) -

Alternator and Ignition System

REMOVAL AND INSTALLATION <SOHC for PAJERO io> (Engines without distributor)

10 Nm

11A-3-2a

4.9 Nm

23 Nm

49 Nm

9Nm

21 Nm

25 Nm

44 Nm

13 Nm

Removal steps

1. Drive belt*

2. Alternator

3. Alternator brace

AA""BA 4. Crankshaft bolt

5. Crankshaft pulley

6. Front flange

Dec. 1998Mitsubishi Motors Corporation Added

181 Nm

7. Spark plug cable

8. Ignition coil

9. Spark plug

10. Cam position sensor

"AA 11. Cam position sensor support

12. Cam position sensing cylinder

NOTE:

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

chassis workshop manual.

PWEE9502-E

11A-3-2b

4G9 ENGINE (E-W) -

Alternator and Ignition System

Intentionally blank

Dec. 1998Mitsubishi Motors Corporation Added

PWEE9502-E

4G9 ENGINE (E-W) -

Alternator and Ignition System

REMOVAL AND INSTALLATION <DOHC>

11A-3-3

3Nm

10 Nm

23 Nm

29 Nm

181 Nm

25 Nm

23 Nm

44 Nm

AA""BA

Removal steps

1. Drive belt*

2. Alternator

3. Alternator brace

4. Crankshaft bolt

5. Crankshaft pulley

6. Flange

Nov. 1995Mitsubishi Motors Corporation

NOTE:

PWEE9502-A

7. Center cover

8. Ignition coil

9. Spark plug cable

10. Spark plug

11. Ignition failure sensor

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

chassis workshop manual.

Revised

11A-3-4

4G9 ENGINE (E-W) -

Alternator and Ignition System

REMOVAL AND INSTALLATION <DOHC-MIVEC>

10 Nm

23 Nm

3Nm

10 Nm

9Nm

13 Nm

25 Nm

44 Nm

21 Nm

23 Nm

AA""BA

49 Nm

181 Nm

Removal steps

1. Drive belt*

2. Alternator

3. Alternator brace

4. Crankshaft bolt

5. Crankshaft pulley

6. Front flange

7. Center cover

8. Spark plug cable

9. Ignition coil

10. Spark plug

11. Cam position sensor

"AA

NOTE:

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

chassis workshop manual.

12. Cam position sensor support

13. Cam position sensing cylinder

Nov. 1995Mitsubishi Motors Corporation Added

PWEE9502-A

4G9 ENGINE (E-W) -

Alternator and Ignition System

REMOVAL AND INSTALLATION <DOHC-GDI for CARISMA>

2.9 Nm

11A-3-5

10 Nm

23 Nm

49 Nm

9Nm

25 Nm

13 Nm

21 Nm

44 Nm

Removal steps

1. Drive belt*

2. Alternator

3. Alternator brace

AA""BA 4. Crankshaft bolt

5. Crankshaft pulley

6. Front flange

Dec. 1998Mitsubishi Motors Corporation Revised

181 Nm

7. Engine cover

8. Ignition coil

9. Spark plug

10. Cam position sensor

"AA 11. Cam position sensor support

12. Cam position sensing cylinder

NOTE:

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

chassis workshop manual.

PWEE9502-E

11A-3-6

4G9 ENGINE (E-W) -

Alternator and Ignition System

REMOVAL AND INSTALLATION <DOHC-GDI for PAJERO io>

10 Nm

4.9 Nm 23 Nm

23 Nm

44 Nm

25 Nm

9Nm

13 Nm

21 Nm

44 Nm

21 Nm

49 Nm

181 Nm

13 Nm

AA""BA

Removal steps

1. Oil level gauge

2. Oil level gauge guide

3. O-ring

4. Drive belt*

5. Alternator

6. Alternator brace

7. Crankshaft bolt

8. Crankshaft pulley

9. Front flange

44 Nm

25 Nm

"AA

NOTE:

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

chassis workshop manual.

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

16. Cam position sensor support

17. Cam position sensing cylinder

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

MD998781

4G9 ENGINE (E-W) -

REMOVAL SERVICE POINT

AA"

(1) Use the special tool to hold the flywheel or the drive

INSTALLATION SERVICE POINTS

"AA

(1) Apply a 3 mm bead of form-in-place gasket (FIPG) to

Alternator and Ignition System

11A-3-7

CRANKSHAFT BOLT REMOVAL

plate, and then loosen the crankshaft mounting bolts.

CAM POSITION SENSOR SUPPORT INSTALLATION

the area shown.

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or equivalent.

MD998781

"BA

CRANKSHAFT BOLT INSTALLATION

(1) Use the special tool to hold the flywheel or the drive

plate, and then tighten the crankshaft mounting bolts.

Dec. 1998Mitsubishi Motors Corporation Added

PWEE9502-E

4. TIMING BELT

REMOVAL AND INSTALLATION <SOHC for other than PAJERO io>

11A-4-1

11 Nm

49 Nm

88 Nm

11 Nm

9.8 Nm

23 Nm

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

8. Crankshaft angle sensor (Engines without distributor)

9. Crankshaft sprocket

10. Crankshaft spacer (Engines without distributor)

11. Crankshaft sensing plate (Engines without distributor)

12. Crankshaft key

AB""AA 13. Camshaft sprocket bolt

14. Camshaft sprocket

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

11A-4-2

4G9 ENGINE (E-W) -

Timing Belt

REMOVAL AND INSTALLATION <SOHC for PAJERO io>

11 Nm

49 Nm

88 Nm

23 Nm

11 Nm

9.8 Nm

Removal steps

1. Timing belt front upper cover

2. Timing belt front lower cover

3. Accessory mount

AA""DA 4. Timing belt

"CA 5. Tensioner spring "BA 6. Timing belt tensioner

7. Timing belt rear cover

8. Crankshaft angle sensor

9. Crankshaft sprocket

10. Crankshaft spacer

11. Crankshaft sensing plate

12. Crankshaft key

AB""AA 13. Camshaft sprocket bolt

14. Camshaft sprocket

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

4G9 ENGINE (E-W) -

REMOVAL AND INSTALLATION <DOHC>

Timing Belt

11 Nm

11A-4-2a

49 Nm

11 Nm

88 Nm

24 Nm

36 Nm

11 Nm

44 Nm

11 Nm

13 Nm

9.8 Nm

Removal steps

1. Timing belt upper cover

2. Timing belt lower cover

3. Engine support bracket

AA""FA 4. Timing belt

5. Tensioner pulley

6. Tensioner arm

7. Shaft

"EA 8. Auto-tensioner

9. Timing belt rear cover

10. Idler pulley

11. Cam position sensor

12. Crank angle sensor

13. Crankshaft sprocket

14. Sensing plate

15. Crankshaft spacer

16. Crankshaft sprocket key

AB""AA 17. Camshaft sprocket bolt

18. Camshaft sprocket

19. Timing belt rear cover

20. Timing belt rear cover

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

11A-4-2b

4G9 ENGINE (E-W) -

REMOVAL AND INSTALLATION <DOHC-MIVEC>

Timing Belt

11 Nm

88 Nm

11 Nm

48 Nm

35 Nm

48 Nm

11 Nm

49 Nm

Removal steps

1. Timing belt front upper cover

2. Timing belt front lower cover

3. Engine support bracket, right

AA""FA 4. Timing belt

5. Tensioner pulley

6. Tensioner arm

7. Shaft

"EA 8. Auto tensioner

9. Timing belt rear cover

10. Idler pulley

13 Nm

11 Nm

9.8 Nm

11. Crankshaft angle sensor

12. Crankshaft sprocket

13. Crankshaft spacer

14. Crankshaft sensing plate

15. Crankshaft key

AB""AA 16. Camshaft sprocket bolt

17. Camshaft sprocket

18. Timing belt rear cover

19. Timing belt rear cover

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

+ 100 hidden pages

Mitsubishi 4G9, 4G92-SOHC, 4G92-DOHC-MIVEC, 4G93-SOHC, 4G93-DOHC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

General Information

1. SPECIFICATIONS

SERVICE SPECIFICATIONS

REWORK DIMENSIONS

TORQUE SPECIFICATIONS

NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA

SEALANT

FORM-IN-PLACE GASKET

2. SPECIAL TOOLS

3. ALTERNATOR AND IGNITION SYSTEM

4. TIMING BELT