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

4G9 ENGINE (E-W) -

Timing Belt

REMOVAL AND INSTALLATION <DOHC-GDI for CARISMA>

11 Nm

11A-4-2c

49 Nm

11 Nm

88 Nm

48 Nm

13 Nm

48 Nm

11 Nm

35 Nm

9.8 Nm

11 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

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 Added

PWEE9502-E

11A-4-2d

4G9 ENGINE (E-W) -

Timing Belt

REMOVAL AND INSTALLATION <DOHC-GDI for PAJERO io>

11 Nm

49 Nm

11 Nm

88 Nm

48 Nm

35 Nm

15 16

48 Nm

11 Nm

9.8 Nm

11 Nm

13 Nm

Removal steps

1. Timing belt front upper cover

2. Timing belt front lower cover

3. Accesory mount

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. Bracket

12. Crankshaft angle sensor

13. Crankshaft sprocket

14. Crankshaft sensing plate

15. Crankshaft spacer

16. Crankshaft key

AB""AA 17. Camshaft sprocket bolt

18. Camshaft sprocket

19. Timing belt rear cover

20. Timing belt rear cover

Dec. 1998Mitsubishi Motors Corporation Added

PWEE9502-E

4G9 ENGINE (E-W) -

REMOVAL SERVICE POINTS

AA"

(1) Mark belt running direction for reinstallation.

TIMING BELT REMOVAL

Timing Belt

11A-4-3

MD998719

MD998754

MB990767

AB"

CAMSHAFT SPROCKET BOLT REMOVAL

<With rocker cover removed> (Except SOHC)

(1) Use a wrench to hold the hexagonal part of the camshaft,

and then remove the camshaft sprocket mounting bolt.

MD998719

MD998754

INSTALLATION SERVICE POINTS

MB990767

Nov. 1995Mitsubishi Motors Corporation Revised

"AA

PWEE9502-A

CAMSHAFT SPROCKET BOLT INSTALLATION

11A-4-4

4G9 ENGINE (E-W) -

Timing belt

Exhaust side

“A”

Pliers

Tensioner pulley fixing bolt

Tensioner

“B”

"BA

TIMING BELT TENSIONER INSTALLATION

(1) Let the pulley of the timing belt tensioner comr closest

to the exhaust side. Temporarily tighten the tensioner pulley fixing bolt.

"CA

TENSIONER SPRING INSTALLATION

(1) Insert the tip A (shorter one) of the tensioner spring into

the oil pump case.

(2) Use pliers or similar tool to pinch the tip B (longer one),

and then hook it to the tensioner bracket arm.

"DA

TIMING BELT INSTALLATION

(1) Turn the crankshaft sprocket by three teeth from the timing

mark.

Caution Aligning the timing marks positions the piston to the topdeadcentre.Then, if the camshaft turns, the valves may hit and damage the pistons.

Timing mark

Timing marks

(2) Check that the timing belt tensioner and tensioner spring

are installed correctly. (Refer to the service points B and C.)

(3) Align the timing marks on the camshaft sprocket to that

on the cylinder head.

(4) Align the timing mark on the crankshaft sprocket to that

on the oil pump case.

(5) Place the timing belt over th e sprocket according in the

following order.

1. Crankshaft sprocket

2. Water pump sprocket

3. Camshaft sprocket

4. Tension pulley

May 1995Mitsubishi Motors Corporation

PWEE9502

MD998716

4G9 ENGINE (E-W) -

(6) Slightly loosen the tensioner pulley fixing bolt which is

tightened temporarily to tighten the belt by a force of the tensioner spring.

(7) Turn th e crankshaft clockwise by two turns. (8) Check that the timing marks are aligned. (9) Tighten the fixing bolt of the tensioner pulley.

Timing Belt

11A-4-5

Set hole (A)

Set hole (B)

"EA

AUTO-TENSIONER INSTALLATION

(1) If the auto-tensioner rod is fully extended, set it in the

retracted position with the following procedure.

1) Hold the auto-tensioner in a vice, being careful not to tilt it.

2) Slowly close the vice to force the rod in to align hole (A) of the rod with the set hole (B).

3) Insert a 2.0-mm-Allen key in diameter or similar into the set holes.

4) Remove the auto-tensioner from the vice.

(2) Install the auto-tensioner

Leave the align key until installation of the timing belt is completed.

Nov. 1995Mitsubishi Motors Corporation Revised

PWEE9502-A

11A-4-6

4G9 ENGINE (E-W) -

Timing Belt

Timing mark

Timing marks

Paper clip

"FA

TIMING BELT INSTALLATION

(1) Make sure that the auto-tensioner is installed properly.

(Refer to service point F.)

(2) Align the timing mark on each sprocket with the

corresponding mark on the timing belt.

(3) Turn the crankshaft sprocket one half the tooth width

counterclockwise.

(4) Fit t he timing belt to the intake camshaft sprocket and

secure with a paper clip at the illustrated position.

Timing mark

(5) Use two wrenches to fit the timing belt to the exhaust

sprocket while aligning the timing marks.

Timing mark

Nov. 1995Mitsubishi Motors Corporation Revised

PWEE9502-A

4G9 ENGINE (E-W) -

(6) Secure the timing belt with a paper clip at the illustrated

position.

(7) Fit the belt to the idler pulley water pump sprocket,

crankshaft sprocket and tensioner pulley in that order.

Idler pulley

Water pump sprocket

Timing Belt

11A-4-7

Tensioner pulley

Crankshaft sprocket

(8) Raise the tensioner pulley in the direction of an arrow

and tighten the tensioner pulley bolt. (9) Remove the two paper clips. (10)Make sure that all timing marks are in alignment. (11)Give a 1/4 counterclockwise turn to the crankshaft. Then

turn the crankshaft clockwise to align the timing marks

again.

May 1995Mitsubishi Motors Corporation

PWEE9502

11A-4-8

MD998767

4G9 ENGINE (E-W) -

(12)Install the special tool and a torque wrench to the tensioner

pulley. (13)Using torque wrench, torque to 2.6 Nm. (14)While holding the tensioner pulley to prevent it from

turning, tighten the center bolt to the specified torque. (15)Give two clockwise turns to the crankshaft and leave

as it is for approx. 15 minutes. (16)Check if the Allen wrench inserted during installation of

the auto-tensioner can be pulled out lightly. If it can be

pulled out lightly, the belt is properly tensioned. Therefore,

pull out the wrench. The belt is also properly tensioned

if the auto-tensioner projection is of standard value.

Standard value: 3.8 - 4.5 mm

Timing Belt

Peeling

Cracks

(17)If the wrench cannot be pulled out lightly, repeat the steps

(12) through (15) to obtain appropriate belt tension.

INSPECTION

11300200077

TIMING BELT

Replace belt if any of th e following conditions exist. (1) Hardening of back rubber.

Back side is glossy without resilience and leaves no indent

when pressed with fingernail.

(2) Cracks on rubber back. (3) Cracks or peeling of canvas. (4) Cracks on tooth bottom. (5) Cracks on belt sides.

Cracks

May 1995Mitsubishi Motors Corporation

PWEE9502

Rounded edge

Abnormal wear (Fluffy strand)

Rubber exposed

Tooth missing and canvas fiber exposed

4G9 ENGINE (E-W) -

(6) Abnormal wear of belt sides. The sides are normal if

they are sharp as if cut by a knife.

(7) Abnormal wear on teeth. (8) Missing tooth.

Timing Belt

11A-4-9

98 to 196 N

11 mm

Stroke

TENSIONER PULLER, IDLER PULLEY

(1) Check the pulley for smooth rotation, excessive play,

abnormal noise. Replace it if necessary.

AUTO-TENSIONER

(1) Check the tensioner for oil leaks. Replace it if necessary. (2) Check the rod end for wear or damage. Replace the

tensioner if necessary. (3) Measure the rod projection length. If not within the

standard value, replace the tensioner.

Standard value: 11 mm

(4) Press the rod by a force of 98 to 196 N and measure

the rod stroke. If not within the standard value, replace

the tensioner.

Standard value: 1 mm or less

May 1995Mitsubishi Motors Corporation

PWEE9502

4G9 ENGINE (E-W) -

Fuel and Emission Control System

5. FUEL AND EMISSION CONTROL SYSTEM

REMOVAL AND INSTALLATION <SOHC-CARBURETOR>

11A-5-1

21 Nm

18 Nm

17 Nm

21 Nm

Removal steps

1. Breather tube

2. Fuel hose

3. Fuel hose

4. Fuel pump

5. Gasket

6. Insulator

7. Gasket

8. Carburetor

9. Gasket

10. EGR valve

11. Gasket

Nov. 1996Mitsubishi Motors Corporation

PWEE9502-B

Revised

11A-5-2

4G9 ENGINE (E-W) -

Fuel and Emission Control System

REMOVAL AND INSTALLATION <SOHC-MPI for other than PAJERO iO>

12 Nm

19 Nm

10 Nm

9Nm

21 Nm

9Nm

Removal steps

1. Vacuum hose and pipe assembly

2. Throttle body

"CA 3. Gasket

4. Vacuum hose

5. Fuel hose

"BA 6. Fuel pressure regulator

7. O-ring

8. Delivery pipe and injector

9. Insulator

11 Nm

10. Insulator

"AA 11. Injector

12. O-ring

13. Grommet

14. Delivery pipe

15. Fuel return pipe

16. Solenoid valve assembly

17. EGR valve

18. Gasket

July 1999Mitsubishi Motors Corporation Revised

PWEE9502-F

4G9 ENGINE (E-W) -

Fuel and Emission Control System

REMOVAL AND INSTALLATION <SOHC-MPI for PAJERO io>

11A-5-3

12 Nm

9Nm

19 Nm

9Nm

Removal steps

1. Vacuum hose and pipe assembly

2. Throttle body

"CA 3. Gasket

4. Vacuum hose

5. Fuel hose

"BA 6. Fuel pressure regulator

7. O-ring

8. Delivery pipe and injector

9. Insulator

10. Insulator

"AA 11. Injector

12. O-ring

13. Grommet

14. Delivery pipe

15. Fuel return pipe

16. Solenoid valve assembly

9Nm

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

11A-5-4

4G9 ENGINE (E-W) -

Fuel and Emission Control System

REMOVAL AND INSTALLATION <DOHC>

11 Nm

23 Nm

18 Nm

10 Nm

23 Nm

9Nm

Removal steps

1. Vacuum pipe assembly

2. Throttle body assembly

"CA 3. Gasket

4. Throttle body stay (MIVEC)

5. Vacuum hose

6. Fuel hose

"BA 7. Fuel pressure regulator

8. O-ring

9. Delivery pipe and injector

10. Insulator

11. Insulator

"AA 12. Injector

13. O-ring

14. Grommet

15. Delivery pipe

16. Fuel return pipe

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

4G9 ENGINE (E-W) -

Fuel and Emission Control System

INSTALLATION SERVICE POINTS

"AA

(1) Apply a small amount of new engine oil to the O-ring.

(2) While turning th e injector to the left and right, install it

(3) Check that the injector turns smoothly. If it does not turn

Injector connector

Delivery pipe

(4) Check that the clearance between the injector connector

11A-5-5

INJECTORS INSTALLATION

Caution

Be sure not to let engine oil get into the delivery

pipe.

to t he delivery pipe.

smoothly, the O-ring may be trapped. Remove the injector

and check the O-ring for damage, and then re-insert it

into the delivery pipe and check once again.

and the delivery pipe is uniform (A = B).

<SOHC-MPI for other than PAJERO io>

Projection

"BA

FUEL PRESSURE REGULATOR INSTALLATION

(1) Apply a small amount of new engine oil to the O-ring.

Insert the fuel pressure regulator into the delivery pipe

being careful not to damage the O-ring.

Caution

Be sure not to let engine oil get into the delivery

pipe.

(2) Check that the fuel pressure regulator turns smoothly.

If it does not turn smoothly, the O-ring may be trapped.

Remove the fuel pressure regulator and check the O-ring

for damage, and then re-insert it into the delivery pipe

and check once again.

"CA

GASKET INSTALLATION

(1) Position the projection as shown in the illustration.

Dec. 1998Mitsubishi Motors Corporation Added

PWEE9502-E

11A-5-6

<SOHC-MPI forPAJEROio>

Projection

4G9 ENGINE (E-W) -

Fuel and Emission Control System

Dec. 1998Mitsubishi Motors Corporation Added

PWEE9502-E

4G9 ENGINE (E-W) -

Throttle Body and EGR System (GDI)

5a. THROTTLE BODY AND EGR SYSTEM (GDI)

REMOVAL AND INSTALLATION <For CARISMA>

18 Nm

11A-5a-1

18 Nm

9Nm

18 Nm

24 Nm

9Nm

30 Nm

18 Nm

Removal steps

1. Air intake plenum resonator

2. O-ring

"BA 3. Intake manifold stay

4. Water hose

5. Water hose

6. Throttle body

"AA 7. Throttle body gasket

8. Ignition harness

9. Water hose

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

10. EGR valve

11. EGR valve gasket

12. Engine hanger

13. EGR valve support

14. Gasket

15. Water hose

16. Air by-pass valve

17. Air by-pass valve gasket

11A-5a-2

4G9 ENGINE (E-W) -

Throttle Body and EGR System (GDI)

REMOVAL AND INSTALLATION <For PAJERO io>

18 Nm

23 Nm

18 Nm

11 Nm

13 Nm

18 Nm

Removal steps

1. Water hose

2. Water hose

3. Water hose

4. Water hose

5. Water hose

6. Water hose clamp

7. Water pipe

8. Water pipe

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

"AA 10. Throttle body gasket

9. Throttle body

11. EGR valve

12. EGR valve gasket

13. EGR valve support

14. Gasket

15. Engine hanger

4G9 ENGINE (E-W) -

Throttle Body and EGR System (GDI)

11A-5a-3

Bolt

Intake manifold stay

Cylinder block

Tab

Intake manifold

Bolt

INSTALLATION SERVICE POINTS

"AA

"BA

(1) Tighten the four bolts at the top and bottom of the stay

(2) Check that the stay seating surface is in close contact

(3) Tighten the four bolts to the specified torque.

THROTTLE BODY GASKET

INTAKE MANIFOLD STAY INSTALLATION

handtight.

with the bosses on the intake manifold and the cylinder

block.

Dec. 1998Mitsubishi Motors Corporation Added

PWEE9502-E

4G9 ENGINE (E-W) -

Intake and Exhaust Manifold

6. INTAKE AND EXHAUST MANIFOLD

REMOVAL AND INSTALLATION <SOHC-CARBURETOR>

20 Nm

11A-6-1

20 Nm

12 Nm

14 Nm

12 Nm

29 Nm

18 Nm

13 Nm

30 Nm

"BA

Removal steps

1. Engine hanger

2. Intake manifold stay

3. Intake manifold

4. Intake manifold gasket

5. Oil level gauge

6. Oil level gauge guide

19 Nm

"AA "AA

13 Nm

7. O-ring

8. Exhaust manifold cover

9. Engine hanger

10. Exhaust manifold bracket A

11. Exhaust manifold bracket B

12. Exhaust manifold

13. Exhaust manifold gasket

Nov. 1996Mitsubishi Motors Corporation

PWEE9502-B

Revised

11A-6-2

4G9 ENGINE (E-W) -

Intake and Exhaust Manifold

REMOVAL AND INSTALLATION <SOHC-MPI>

20 Nm

12 Nm

20 Nm

30 Nm

14 Nm

29 Nm

18 Nm

13 Nm

Removal steps

1. Engine hanger

2. Intake manifold stay

3. Intake manifold

4. Intake manifold gasket

5. Oil level gauge

6. Oil level gauge guide

"AA "AA

19 Nm

7. O-ring

8. Exhaust manifold cover

9. Engine hanger

10. Exhaust manifold bracket A

11. Exhaust manifold bracket B

12. Exhaust manifold

13. Exhaust manifold gasket

Nov. 1996Mitsubishi Motors Corporation Revised

PWEE9502-B

4G9 ENGINE (E-W) -

Intake and Exhaust Manifold

REMOVAL AND INSTALLATION <DOHC>

20 Nm

12 Nm

20 Nm

11A-6-3

29 Nm

18 Nm

30 Nm

Removal steps

1. Engine hanger

2. Intake manifold stay

3. Intake manifold

4. Intake manifold gasket

5. Oil level gauge

6. Oil level gauge guide

"AA "AA

12 Nm

19 Nm

7. O-ring

8. Engine hanger

9. Exhaust manifold bracket A

10. Exhaust manifold bracket B

11. Exhaust manifold

12. Exhaust manifold gasket

14 Nm

Nov. 1996Mitsubishi Motors Corporation

PWEE9502-B

Revised

11A-6-4

Bracket A

Exhaust manifold

4G9 ENGINE (E-W) -

INSTALLATION SERVICE POINT

Bracket B

"AA

(1) Install temporarily the exhaust manifold brackets A and

(2) Check that both brackets are in close contact with the

Intake and Exhaust Manifold

EXHAUST MANIFOLD INSTALLATION

B as shown in the illustration.

bosses, and then tighten fully the bracket mounting bolts.

“UP” mark

"BA

INTAKE MANIFOLD STAY INSTALLATION

(1) Install the intake manifold stay with its “UP” mark directed

toward the intake manifold.

Nov. 1996Mitsubishi Motors Corporation

PWEE9502-B

Added

4G9 ENGINE (E-W) -

Intake Manifold (GDI)

6a. INTAKE MANIFOLD (GDI)

REMOVAL AND INSTALLATION <For CARISMA, SPACE STAR>

11 Nm

9Nm

11A-6a-1

11 Nm

19 Nm

9Nm

19 Nm

Removal steps

1. Air by-pass hose

2. V acuum pipe and hose

3. Bracket

4. Solenoid valve

5. Connector bracket

Jun. 1998Mitsubishi Motors Corporation

PWEE9502-D

6. Accelerator cable bracket

7. Vacuum hose

8. Vacuum pipe

9. Intake manifold

10. Intake manifold gasket

Revised

11A-6a-2

4G9 ENGINE (E-W) -

Intake Manifold (GDI)

REMOVAL AND INSTALLATION <For SPACE RUNNER>

11 Nm

9Nm

11 Nm

9Nm

19 Nm

Removal steps

1. Air by-pass hose

2. V acuum pipe and hose

3. Bracket

4. Solenoid valve

5. Connector bracket

6. Accelerator cable bracket

7. Vacuum hose

8. Vacuum pipe

9. Intake manifold

10. Intake manifold gasket

Jun. 1998Mitsubishi Motors Corporation Added

PWEE9502-D

4G9 ENGINE (E-W) -

Intake Manifold (GDI)

REMOVAL AND INSTALLATION <For PAJERO io>

11A-6a-3

9Nm

11 Nm

9Nm

23 Nm

19 Nm

9Nm

11 Nm

30 Nm

Removal steps

1. P.C.V. hose

2. V acuum pipe and hose

3. Solenoid valve

4. Fuel pump protector

5. Connector bracket

6. Branch tube

7. Gasket

"AA 8. Intake manifold stay

9. Intake manifold

10. Intake manifold gasket

Dec. 1998Mitsubishi Motors Corporation Added

PWEE9502-E

11A-6a-4

Intake manifold

Intake manifold stay

Cylinder block

4G9 ENGINE (E-W) -

INSTALLATION SERVICE POINT

"AA

(1) Check to ensure that the intake manifold stay is in close

contact with the intake manifold and the cylinder block

before tightening the respective mounting bolts to the

specified torque.

Intake Manifold (GDI)

INTAKE MANIFOLD STAY INSTALLATION

Dec. 1998Mitsubishi Motors Corporation Added

PWEE9502-E

4G9 ENGINE (E-W) -

Exhaust Manifold (GDI)

6b. EXHAUST MANIFOLD (GDI)

REMOVAL AND INSTALLATION <For CARISMA>

11A-6b-1

17 Nm

13 Nm

35 Nm

29 Nm

18 Nm

35 Nm

18 Nm

13 Nm

Removal steps

1. Oil level gauge

2. Oil level gauge guide

3. O-ring

4. Exhaust manifold cover

5. Engine hanger

"AA 6. Exhaust manifold bracket A "AA 7. Exhaust manifold bracket B

8. Exhaust manifold

9. Exhaust manifold gasket

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

11A-6b-2

4G9 ENGINE (E-W) -

Exhaust Manifold (GDI)

REMOVAL AND INSTALLATION <For PAJERO io>

13 Nm

18 Nm

29 Nm

Removal steps

1. Exhaust manifold cover

2. Engine hanger

"BA 3. Exhaust manifold bracket

4. Exhaust manifold

5. Exhaust manifold gasket

29 Nm

17 Nm

98 Nm

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

Bracket B

4G9 ENGINE (E-W) -

INSTALLATION SERVICE POINTS

"AA

(1) Slide the washers over the bolts with the chamfered side

toward the bolt.

(2) Install temporarily the exhaust manifold brackets A and

Bracket A

Exhaust manifold

B as shown in the illustration. (3) Check that both brackets are in close contact with the

bosses, and then tighten fully the bracket mounting bolts.

Exhaust Manifold (GDI)

11A-6b-3

EXHAUST MANIFOLD BRACKET INSTALLATION

Exhaust manifold

Bracket

Shear-droop

"BA

EXHAUST MANIFOLD BRACKET INSTALLATION

(1) The washers must be installed with the shear-drooped

side toward the bolts.

(2) Temporarily install the exhaust manifold bracket as shown

in the illustration. (3) Verify that the bracket is brought into close contact with

the boss on the exhaust manifold, then tighten the bolts

to the specified torque.

Dec. 1998Mitsubishi Motors Corporation Added

PWEE9502-E

4G9 ENGINE (E-W) -

Injector and Fuel Pump Assembly (GDI)

6c. INJECTOR AND FUEL PUMP ASSEMBLY (GDI)

REMOVAL AND INSTALLATION <For CARISMA>

9Nm

11 Nm

18 Nm

11A-6c-1

9Nm

11 Nm

22 Nm

11 Nm

17±2Nm

9Nm

23 Nm

Removal steps

1. Fuel hose

2. Fuel low pressure pipe

3. O-ring

4. Fuel nipple

5. O-ring

6. Clamp

"FA 7. Fuel feed pipe

8. Backup ring

9. O-ring

10. Backup ring

"FA 11. Fuel pump

12. O-ring

13. Harness bracket

14. Fuel return pipe

15. Backup ring

16. O-ring

17. Backup ring

"EA 18. Fuel high pressure regulator

19. Flange

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

"DA 20. Fuel pressure sensor

21. O-ring

22. Backup ring

"CA 23. Pump camshaft case

24. O-ring

25. O-ring

26. Harness bracket

27. Injector harness

28. Washer

29. Injector holder

"BA 30. Delivery pipe and injector

31. Insulator

32. Injector gasket

33. Injector

"AA 34. Corrugated washer "AA 35. Backup ring "AA 36. O-ring "AA 37. Backup ring

38. Delivery pipe

11A-6c-2

4G9 ENGINE (E-W) -

Injector and Fuel Pump Assembly (GDI)

REMOVAL AND INSTALLATION <For PAJERO io>

11 Nm

18 Nm

9Nm

11 Nm

17±2Nm

11 12 13

17 18 19

18 Nm

11 Nm

9Nm

22 Nm

Removal steps

1. Injector harness

2. Fuel hose

3. Fuel hose

4. Fuel hose

5. Fuel pipe

6. Fuel nipple

7. O-ring

8. Fuel nipple

9. O-ring

"FA 10. Fuel feed pipe

11. Backup ring

12. O-ring

13. Backup ring

"FA 14. Fuel pump

15. O-ring

16. Fuel return pipe

17. Backup ring

18. O-ring

19. Backup ring

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

"EA 20. Fuel high pressure regulator "DA 21. Fuel pressure sensor

22. Backup ring

23. O-ring

24. Spacer

25. washer

26. Injector holder

"BA 27. Delivery pipe and injector

28. Insulator

29. Injector gasket

"AA 30. Corrugated washer "AA 31. Backup ring "AA 32. O-ring "AA 33. Backup ring

34. Injector

35. Delivery pipe

4G9 ENGINE (E-W) -

Cut surface

Backup ring

Corrugated washer

Injector and Fuel Pump Assembly (GDI)

11A-6c-3

INSTALLATION SERVICE POINTS

"AA

(1) Attach the backup rings and O-ring to the injector. The

(2) Coat the corrugated washer with white vaseline and install

BACKUP RING / O-RING / CORRUGATED WASHER INSTALLATION

thicker backup ring must be so installed that the inside

cut surface is directed as shown in the illustration.

it to the injector as shown.

Caution

Always replace the corrugated washer with new one.

Reused corrugated washer can cause fuel or gas

leaks.

Mating marks

"BA

DELIVERY PIPE AND INJECTOR ASSEMBLY INSTALLATION

(1) Lubricate O-ring in the injector with spindle oil or gasoline. (2) Insert the injector straight into the injector mounting hole

in the delivery pipe. (3) Turn the injector clockwise and counterclockwise. If it

dose not rotate smoothly, remove it to check for damaged

O-ring. Damaged O-ring must be replaced with a new

one. Reinstall the injector and check for smooth rotation

again. (4) Align the mating mark on the injector with that on the

delivery pipe. (5) Install the injector gaskets and insulators on the cylinder

head. The insulator can drop off easily. Apply vaseline

to it before installation so that it may be held in position. (6) Install the delivery pipe and injector assembly onto the

cylinder head, then tighten the fasteners temporarily. (7) Install the injector holders and the washers to the assembly

and tighten the fasteners to the specified torque.

Caution

Strictly observe the specified torque.

Injector gasket

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

11A-6c-4

4G9 ENGINE (E-W) -

Injector and Fuel Pump Assembly (GDI)

O-ring

Coupling key

(8) Tighten the fasteners of the delivery pipe and injector

assembly to the specified torque in the order given in

the illustration.

Groove

"CA

PUMP CAMSHAFT CASE INSTALLATION

(1) Apply small amount of engine oil to the O-ring (larger

one) on the case.

(2) Install the pump camshaft case onto the cylinder head

while aligning the coupling keys of the case with the

grooves in the rear end face of the camshaft.

Camshaft

Backup ring

Cut surface

Backup ring

NOTE

The coupling keys and the grooves at the camshaft rear

end are offset with respect to the camshaft center.

(3) Tighten the case mounting bolts to the specified torque.

"DA

FUEL PRESSURE SENSOR INSTALLATION

(1) Install the backup ring to the fuel pressure sensor with

its inside cut surface in the illustrated direction. (2) Install the fuel pressure sensor straight into the fuel

pressure regulator with labeled surface upward. (3) Tighten the fuel pressure sensor mounting bolt to the

specified torque.

"EA

FUEL HIGH PRESSURE REGULATOR INSTALLATION

(1) Install the fuel high pressure regulator on the pump

camshaft case <for CARISMA> or onto the spacer <for

PAJERO io> and tighten the 3 bolts lightly (with somewhat

larger torque than fingertight). Tightening to the

specification is to be carried out in the step described

in "FA.

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

4G9 ENGINE (E-W) -

Cut surface

Backup ring

Injector and Fuel Pump Assembly (GDI)

11A-6c-5

(2) Fit the backup rings and the O-ring on both ends of the

fuel return pipe. Note that the larger backup ring must

be installed with th e inside cut surface in the direction

shown in the illustration. (3) Lubricate the O-rings on both ends of the pipe with spindle

oil or gasoline. (4) Insert the fuel return pipe ends straight in the respective

mounting holes of the pressure regulator and the delivery

pipe. Be sure to insert the pipe fully to the stop using

care not to twist it. (5) Tighten the bolts at both ends of the pipe to the specified

torque.

"FA

FUEL PUMP / FUEL FEED PIPE INSTALLATION

(1) Insert the fuel pump into the mounting hole in the pump

camshaft case <for CARISMA> or in the cylinder head

<for PAJERO io>, and secure it temporarily with 4 bolts

(tighten somewhat with a larger torque than fingertight). (2) Fit the backup rings and the O-ring on both ends of the

feed pipe. Note that the larger backup ring must be

installed with the inside cut surface in the direction shown

in the illustration. (3) Lubricate the O-rings on both ends of the pipe with spindle

oil or gasoline. (4) Insert the fuel feed pipe ends straight in the respective

mounting holes of the fuel and the delivery pipe. Be sure

to insert the pipe fully to the stop using care not to twist

it. (5) Tighten the bolts at ends of the pipe to the specified

torque. (6) Tighten the mounting bolts of the fuel pressure regulator

to the specified torque.

(7) Using a torque wrench having the minimum scale of 0.5

Nm, tighten the fuel pump mounting bolts in the following

order.

1) Tighten the bolts to 5 Nm in the order given in the

illustration.

2) Tighten the bolts to 17 Nm in the order given in the illustration. The torque variation among 4 bolts must be within 2 Nm.

Caution

Strictly observe the specified tightening torque. Deviation from the specification can cause problems such as leakage or the like.

Dec. 1998Mitsubishi Motors Corporation Added

PWEE9502-E

4G9 ENGINE (E-W) -

Water Pump and Water Hose

11A-7-1

7. WATER PUMP AND WATER HOSE

REMOVAL AND INSTALLATION <SOHC>

14 Nm

24 Nm

11301790016

10 Nm

29 Nm

24 Nm

14 Nm

"GA "FA

"EA

Removal steps

1. Water hose (Except carburetor engines)

2. Water hose

3. Engine coolant temperature sensor

4. Engine coolant temperature gauge unit

5. Water outlet fitting

6. Water inlet fitting

14 Nm

"DA "CA "BA "BA "BA "AA

14 Nm

7. Thermostat

8. Thermostat case

9. O-ring

10. Water inlet pipe

11. O-ring

12. Water pump

Nov. 1996Mitsubishi Motors Corporation

PWEE9502-B

Revised

11A-7-2

4G9 ENGINE (E-W) -

REMOVAL AND INSTALLATION<DOHC>

Water Pump and Water Hose

14 Nm

29 Nm

10 Nm

24 Nm

14 Nm24 Nm

"GA "FA

"EA

Removal steps

1. Water hose A

2. Water hose B

3. Engine coolant temperature sensor

4. Engine coolant temperature gauge unit

5. Water outlet fitting

6. Water inlet fitting

"DA "CA "BA "BA "BA "AA

14 Nm

7. Thermostat

8. Thermostat case

9. O-ring

10. Water inlet pipe

11. O-ring

12. Water pump

May 1995Mitsubishi Motors Corporation

PWEE9502

4G9 ENGINE (E-W) -

Water Pump and Water Hose

REMOVAL AND INSTALLATION <DOHC-GDI for PAJERO io>

23 Nm

24 Nm

11A-7-3

10 Nm

29 Nm

23 Nm

Removal steps

"GA 1. Engine coolant temperature sensor "FA 2. Engine coolant temperature gauge

unit

"IA 3. Water fitting "EA 4. Water outlet fitting

5. Water inlet fitting

"DA 6. Thermostat

24 Nm

13 Nm

23 Nm

"HA 7. Water by-pass fitting "BA 8. Water pipe "BA 9. O-ring "CA 10. Thermostat case "BA 11. Water pipe "BA 12. O-ring "AA 13. Water pump

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

11A-7-4

4G9 ENGINE (E-W) -

INSTALLATION SERVICE POINTS

"AA

(1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG)

Water Pump and Water Hose

WATER PUMP INSTALLATION

to the location shown in the illustration.

Specified sealant:

Mitsubishi Genuine Part No.MD970389 or equivalent

"BA

WATER INLET PIPE <SOHC, DOHC> / WATER PIPE <DOHC-GDI for PAJERO io> / O-RING INSTALLATION

(1) Replace the O-ring of the water inlet pipe <SOHC, DOHC>

or water pipe <DOHC - GDI for PAJERO io>, and then apply water to the O-ring to make installation easy.

Caution

1. Never apply any oil or grease to the O-ring.

2. Secure the water pipe after the thermostat case has been installed.

"CA

THERMOSTAT CASE INSTALLATION

(1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG)

to the location shown in the illustration.

Specified sealant:

Mitsubishi Genuine Part No.MD970389 or equivalent

"DA

THERMOSTAT INSTALLATION

(1) Install the thermostat so that the jiggle valve is facing

straight up.

Jiggle valve

<SOHC, DOHC>

"EA

WATER OUTLET FITTING INSTALLATION

(1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG)

to the location shown in the illustration.

Specified sealant:

Mitsubishi Genuine Part No.MD970389 or equivalent

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

4G9 ENGINE (E-W) -

<DOHC-GDI for PAJERO io>

Water Pump and Water Hose

11A-7-5

"FA

ENGINE COOLANT TEMPERATURE GAUGE UNIT INSTALLATION

(1) Apply the specified sealant to the threads.

Specified sealant:

3M ATD Part No.8660 or equivalent

"GA

ENGINE COOLANT TEMPERATURE SENSOR INSTALLATION

(1) When reusing the sensor, apply the specified sealant

to the threads.

Specified sealant:

3M Nut Locking Part No.4171 or equivalent

"HA

WATER BY-PASS FITTING INSTALLATION

(1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG)

to the location shown in the illustration.

Specified sealant:

Mitsubishi Genuine Part No.MD970389 or equivalent.

"IA

WATER FITTING INSTALLATION

(1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG)

to the location shown in the illustration.

Specified sealant:

Mitsubishi Genuine Part No.MD970389 or equivalent.

Dec. 1998Mitsubishi Motors Corporation Added

PWEE9502-E

4G9 ENGINE (E-W) -

Rocker Arms and Camshafts

11A-8-1

8. ROCKER ARMS AND CAMSHAFTS

REMOVAL AND INSTALLATION <SOHC>

35 Nm

11300540070

31 Nm

9Nm

"EA "DA "CA

9Nm

Removal steps

1. Breather hose

2. P.C.V. hose

3. Oil filler cap

4. Rocker cover

5. Rocker cover gasket

6. Oil seal

7. Oil seal

8. Rocker arm spring

9. Rocker arms and rocker arm shaft IN

10. Rocker arms and rocker arm shaft EX

"BA "AA

Apply engine oil to all moving parts before installation.

11. Rocker arm B

12. Rocker arm A

13. Rocker arm shaft

14. Adjusting screw

15. Nut

16. Rocker arm C

17. Rocker arm shaft

18. Adjusting screw

19. Nut

20. Camshaft

May 1995Mitsubishi Motors Corporation

PWEE9502

11A-8-2

4G9 ENGINE (E-W) -

Rocker Arms and Camshafts

REMOVAL AND INSTALLATION <DOHC>

11 Nm

24 Nm

3.5 Nm

Removal steps

1. Breather hose

2. P.C.V. hose

3. P.C.V. valve

4. P.C.V. valve gasket

5. Oil filler cap

"KA 6. Rocker cover

7. Rocker cover gasket A

8. Rocker cover gasket B

"JA 9. Semi-circular packing

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

AA""FA 15. Lash adjuster

"HA 11. Bearing cap "GA 12. Intake camshaft "GA 13. Exhaust camshaft

10. Oil seal

14. Rocker arm

Apply engine oil to all moving parts before installation.

4G9 ENGINE (E-W) -

Rocker Arms and Camshafts

REMOVAL AND INSTALLATION <DOHC-GDI>

11 Nm

11A-8-1

23 Nm

3.5 Nm

23 Nm

3.5 Nm

Apply engine oil to all moving parts before installation.

Removal steps

1. Breather hose

2. P.C.V hose

3. P.C.V valve

4. P.C.V valve gasket

5. Oil filler cap

6. Rocker cover

7. Rocker cover gasket

July 1997Mitsubishi Motors Corporation Added

PWEE9502-C

"LA "KA

"JA "JA

8. Oil seal

9. Beam camshaft cap

10. Gasket

11. Intake camshaft

12. Exhaust camshaft

13. Rocker arm

14. Lash adjuster

11A-8-2

4G9 ENGINE (E-W) -

Rocker Arms and Camshafts

Intentionally blank

July 1997Mitsubishi Motors Corporation Added

PWEE9502-C

4G9 ENGINE (E-W) -

Rocker Arms and Camshafts

REMOVAL AND INSTALLATION <DOHC-GDI for CARISMA>

11A-8-3

11 Nm

21 Nm

3.5 Nm

21 Nm

3.5 Nm

Apply engine oil to all moving parts before installation.

Removal steps

1. Breather hose

2. P.C.V. hose

3. P.C.V. valve

4. P.C.V. valve gasket

5. Oil filler cap

6. Rocker cover

7. Rocker cover gasket

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

AA""FA 14. Lash adjuster

"IA 9. Beam camshaft cap

8. Oil seal

10. Gasket

11. Intake camshaft

12. Exhaust camshaft

13. Rocker arm

11A-8-4

4G9 ENGINE (E-W) -

Rocker Arms and Camshafts

REMOVAL AND INSTALLATION <DOHC-GDI for PAJERO io>

11 Nm

3.5 Nm

2 3

21 Nm

Apply engine oil to all moving parts before installation.

Removal steps

1. Breather hose

2. P.C.V. valve

3. P.C.V. valve gasket

4. Oil filler cap

5. Rocker cover

6. Rocker cover gasket

7. Oil seal

8. Thrust case

9. O-ring

"IA 10. Beam camshaft cap

11. Gasket

12. Intake camshaft

13. Exhaust camshaft

14. Rocker arm

AA""FA 15. Lash adjuster

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

4G9 ENGINE (E-W) -

REMOVAL SERVICE POINT

AA"

INSTALLATION SERVICE POINTS

1 mm or less

"AA

(1) Install provisionally the screw to the rocker arm. Insert

Rocker Arms and Camshafts

11A-8-5

LASH ADJUSTER REMOVAL

Caution

If the lash adjuster is re-used, clean the lash adjuster. (Refer to 11A-8-10.)

ADJUSTING SCREW INSTALLATION

it so that the end of the screw is flush with the edge of the rocker arm or projects slightly (1 mm or less).

Timing belt side

Chamfered side

Oil holes

"BA

ROCKER ARM SHAFT INSTALLATION

(1) Place the end with the larger chamfered side toward the

timing belt side.

NOTE The rocker arm shaft for intake valves has eight oil holes.

(2) Install the shaft with the oil holes toward the cylinder

head.

"CA

ROCKER ARMS AND ROCKER ARM SHAFT INSTALLATION

(1) Move the rocker arms in the directions shown in the

illustration before tightening the rocker arm shaft bolts.

NOTE Move the rocker arms until they touch the rocker arm shaft mounting bosses on the cylinder head.

"DA

ROCKER ARM SPRING INSTALLATION

(1) Insert the rocker arm spring at an angle to the spark

plug guide and then install it so that it is at a right angle to the guide.

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

11A-8-6

4G9 ENGINE (E-W) -

Rocker Arms and Camshafts

MD998713

Slit

"EA

"FA

OIL SEAL INSTALLATION

LASH ADJUSTER INSTALLATION

Caution

If the lash adjuster is re-used, clean the lash adjuster. (Refer to 11A-8-10.)

(1) Fit the lash adjuster onto the cylinder head using care

not to allow diesel fuel to spill out.

"GA

CAMSHAFT INSTALLATION

(1) Apply engine oil to the camshaft journals and cam before

installing the camshaft. Use care not to confuse the intake camshaft with the exhaust camshaft.

NOTE The rear end of the intake camshaft is provided with a 4 mm-wide slit.

Journal

Dowel pins

"HA

BEARING CAP INSTALLATION

(1) Locate the camshaft dowel pins as illustrated.

(2) Apply sealant to the locations shown in the illustration.

Specified sealant:

3M ATD Part No. 8660 or equivalent

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

4G9 ENGINE (E-W) -

(3) The bearing caps No. 2 through No. 5 are of the same

Rocker Arms and Camshafts

11A-8-7

shape. Before they are installed, check the cap number and the intake and exhaust identification marks.

Cap No. IN or EX side

identification

<DOHC-GDI for CARISMA>

Dowel pin

<DOHC-GDI for PAJERO io>

Dowel pin

Approx. 106

Approx. 150

Identification mark (stamped on front and No. 2

through No. 5 bearing caps) L: Intake side R: Exhaust side

(4) Make sure that the rocker arms are installed in the

specified locations.

"IA

BEAM CAMSHAFT CAP INSTALLATION

(1) Locate the camshaft dowel pin as illustrated.

<DOHC-GDI for CARISMA>

3mm

Beam camshaft cap

<DOHC-GDI for PAJERO io>

Timing belt side

Beam camshaft cap

(2) Turn the crankshaft anticlockwise a quarter turn (90_).

<DOHC- GDI for CARISMA only>

(3) Apply a 3 mm thick continuous bead of sealant to the

bottom surface of the beam camshaft cap along the groove.

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or equivalent

3mm

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

11A-8-8

4G9 ENGINE (E-W) -

Rocker Arms and Camshafts

<DOHC-GDI for CARISMA>

<DOHC-GDI for PAJERO io>

Engine front side

<DOHC-GDI for CARISMA>

<DOHC-GDI for PAJERO io>

Engine front side

(4) Apply sealant to the illustrated position of the cylinder

head upper surface.

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or equivalent

(5) Install the beam camshaft cap before the sealant applied

becomes dry and hard.

(6) Tighten the bolts to the specified torque in the order shown

in the illustration.

M6 bolt 11Nm M8 bolt 21Nm

Caution The M8 bolts plated green cannot be reused. Always replace such bolts with M8 bolts finished by glossy plating which are available separately. The M8 bolt finished by glossy plating is reusable; if the caps have already been assembled with such bolts, then reassemble the caps using them.

(7) Install the camshaft oil seal (use the special tool) and

the thrust case <DOHC - GDI for PAJERO io> before the

MD998713

sealant applied becomes dry and hard.

(8) Wipe off squeezed out excess sealant from the

circumference of the beam camshaft cap.

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9502-E

4G9 ENGINE (E-W) -

Rocker Arms and Camshafts

11A-8-9

Timing mark

"JA

SEALANT APPLICATION ON SEMI-CIRCULAR PACKING

Specified sealant: 3M ATD Part No.8660 or equivalent

"KA

SEALANT APPLICATION ON ROCKER COVER

(1) Apply sealant to the areas indicated in the illustration.

Specified sealant: 3M ATD Part No.8660 or equivalent

VALVE CLEARANCE ADJUSTMENT

Adjust the valve clearance by the following procedure.

Adjustment values (when engine is cold):

When No.1 cylinder is at compression top dead centre

When No.4 cylinder is at compression top dead centre

Intake valve: 0.09 mm Exhaust valve: 0.20 mm

(1) Turn the crankshaft in the clockwise direction to align

the camshaft sprocket timing marks and to set the No.1 cylinder to the compression top dead centre position.

(2) The valve clearances at th e places indicated by arrows

in the illustration can be adjusted.

(3) Use a thickness gauge to adjust the clearance between

the ends of the valve stems and the adjusting screws.

(4) Hold the adjusting screws with a screwdriver so that they

do not turn, and then tighten the lock nuts.

(5) Turn the crankshaft once in the clockwise direction to

set the No.4 cylinder to the compression top dead centre position.

(6) Adjust the valve clearances indicated by arrows in th e

illustration by the same procedure as in steps (3) and (4) above.

Dec. 1998Mitsubishi Motors Corporation Added

PWEE9502-E

11A-8-10

4G9 ENGINE (E-W) -

INSPECTION CAMSHAFT

(1) Measure the cam height.

Rocker Arms and Camshafts

Standard

Limit mm

value mm

Intake 4G92- SOHC* side

4G92-SOHC*

37.34 36.84

37.78 37.28

4G93-SOHC 37.53 37.03

4G93-DOHC 35.49 34.99

4G93-DOHC- GDI*

Exhaust 4G92 - SOHC* side

4G92-SOHC*

36.79 36.29

35.49 34.99

37.83 37.33

4G93-SOHC 37.64 37.14

4G93-DOHC 35.20 34.70

4G93-DOHC- GDI*

*1: LANCER for Europe and CARISMA for Europe

: LANCER for general export and CARISMA for 6B model

: For CARISMA

: For PAJERO io

34.91 34.41

34.73 34.23

LASH ADJUSTER

Outside cleaning

Inside cleaning

Filling with diesel fuel

Caution

1. The lash adjusters are precision-engineered mechanisms. Do not allow them to become contained by dirt or other foreign substances.

2. Do not attempt to disassemble the lash adjusters.

3. Use only fresh diesel fuel to clean the lash adjusters.

(1) Prepare three containers and approximately five liters

of diesel fuel. Into each container, pour enough diesel fuel to completely cover a lash adjuster when it is standing upright. Then, perform the following steps with each lash adjuster.

(2) Place the lash adjuster in container A and clean its outside

surface.

NOTE Use a nylon brush if deposits are hard to remove.

Diesel fuel

Dec. 1998Mitsubishi Motors Corporation Added

PWEE9502-E

MD998442

Diesel fuel

4G9 ENGINE (E-W) -

(3) Whi l e gentl y pushing down the internal steel ball using

Diesel fuel

(4) Removal the lash adjuster from the container. Then, push

MD998442

Rocker Arms and Camshafts

11A-8-11

special tool, move the plunger through five to ten strokes until it slides smoothly. In additi on to elim i nati ng stiffness in the plunger, thi s operation will remove dirty oil.

Caution The steel ball spring is extremely weak, so the lash adjuster’s functionality may be lost if the air bleed wire is pushed in hard.

NOTE If the plunger remains stiff or the mechanism appears otherwise abnormal, replace the lash adjuster.

down the steel ball gently and push the plunger to eliminate diesel fuel from t he pressure chamber.

Caution Makesuretheoilhole in thesideofthe bodyispointing towardcontainerA.Donot pointtheoilholeat yourself or other people.

MD998442

Diesel fuel

MD998442

(5) Place the lash adjuster in container B. Then, gently push

down the internal steel ball using special tool and move the plunger through five to ten strokes until it slides smoothly. This operation will clean the lash adjuster’s pressure chamber.

Caution The steel ball spring is extremely weak, so the lash adjuster’s functionality may be lost if the air bleed wire is pushed in hard.

(6) Remove the lash adjuster from the container. Then, push

down the steel ball gently and push the plunger to eliminate diesel fuel from t he pressure chamber.

Caution Makesuretheoilhole in thesideofthe bodyispointing towardcontainerA.Donot pointtheoilholeat yourself or other people.

(7) Place the lash adjuster in container C. Then, gently push

down the internal steel ball using special tool.

MD998442

Caution Do not use container C for cleaning. If cleaning is performed in container C, foreign matter could enter the pressure chamber when chamber is filled with diesel fuel.

Diesel fuel

Dec. 1998Mitsubishi Motors Corporation Added

PWEE9502-E

11A-8-12

4G9 ENGINE (E-W) -

(8) Stand the lash adjuster with its plunger at the top, then

Rocker Arms and Camshafts

push the plunger downward firmly until it moves through its greatest possible stroke. Return the plunger slowly, then release the steel ball and allow the pressure chamber to fill with diesel fuel.

MD998442

MD998440

Diesel fuel

(9) Remove the lash adjuster from the container, then stand

the lash adjuster with its plunger at the top. Push the plunger firmly and check that it does not move. Also, check that the lash adjuster’s height matches that of a new lash adjuster.

NOTE If lash adjuster contracts, perform the operation (7) through (9) again to fill it with diesel fuel completely. Replace the lash adjuster if it still contracts after performing these steps.

(10)Set the lash adjuster on the special tool.

Division = 1 mm

Lash adjuster

MD998442

(11)Remove the bolt from the tester, then adjust the height

as illustrated.

(12)After the plunger has moved downward slightly (0.2 to

0.5 mm), measure the time taken for it to move downward

Nut

by a further 1 mm.

Standard value:

3 - 20 second/1 mm (with diesel fuel at 15 to 20_C)

NOTE Replace the lash adjuster if the time measurement is out of specification.

(13)Place the lash adjuster in container C again, then gently

push down the internal steel ball using special tool.

(14)Stand the lash adjuster with its plunger at the top, then

push the plunger downward firmly until it moves through its greatest possible stroke. Return the plunger slowly, then release the steel ball and allow the pressure chamber to fill with diesel fuel.

Diesel fuel

Dec. 1998Mitsubishi Motors Corporation Added

PWEE9502-E

4G9 ENGINE (E-W) -

(15)Remove the lash adjuster from the container, then stand

(16)Stand the lash adjuster upright to prevent diesel fuel

Rocker Arms and Camshafts

11A-8-13

the lash adjuster with its plunger at the top. Push the plunger firmly and check that it does not move. Also, check the lash adjuster’s height matches that of a new lash adjuster.

NOTE If lash adjuster contracts, perform the operations (13) through (15) again to fill it with diesel fuel completely. Replace the lash adjuster if it still contracts after performing these steps.

spilling out. Do not allow the lash adjuster to become contaminated by dirt or other foreign matter. Fit the lash adjuster onto the engine as soon as possible.

Dec. 1998Mitsubishi Motors Corporation Added

PWEE9502-E

4G9 ENGINE (E-W) -

Rocker Cover and Camshafts (MIVEC)

8a. ROCKER COVER AND CAMSHAFTS (MIVEC)

REMOVAL AND INSTALLATION

11A-8a-1

3.5 Nm 23 Nm

23 Nm

11 Nm

23 Nm

9Nm

Apply engine oil to all moving parts before installation.

Removal steps

1. Breather hose

2. PCV hose

3. Oil filler cap

"GA

"FA "EA

4. Rocker cover

5. Rocker cover gasket

6. Oil seal

7. Oil seal

8. Oil control valve

"DA "DA "CA "BA "AA

9. Arm spring holder

10. Camshaft bearing cap

11. Arm spring

12. Camshaft

13. Camshaft holder

14. Semi-circular packing

Nov. 1995Mitsubishi Motors Corporation

PWEE9502-A

Added

11A-8a-2

12 V

4G9 ENGINE (E-W) -

Valve

Rocker Cover and Camshafts (MIVEC)

INSPECTION

1. OIL CONTROL VALVE

(1) Connect a 12VDC power supply between terminals (1)

and (2) of the oil control valve and check if the valve operates smoothly.

2. CAMSHAFT

(1) Measure the cam heights. If the specified limit is

exceeded, replace the camshaft.

Unit: mm

ABAB AB AB

4G92 DOHC - MIVEC

Intake A 36.41 35.91

Intake B 33.58 33.08

Exhaust A 35.83 35.33

Exhaust B 34.24 33.74

Standard

value

Limit

Nov. 1995Mitsubishi Motors Corporation Added

PWEE9502-A

4G9 ENGINE (E-W) -

Rocker Cover and Camshafts (MIVEC)

11A-8a-3

Sealant

INSTALLATION SERVICE POINTS

"AA

(1) Apply the specified sealant to the area shown.

"BA

(1) Apply the specified sealant to the area shown.

"CA

(1) Ensure that the intake-side and exhaust-side camshafts

(2) Set the No. 1 piston at the top dead center and install

SEMI-CIRCULAR PACKING INSTALLATION

Specified sealant:

3M ATD Part No. 8660 or equivalent.

CAMSHAFT HOLDER ASSEMBLY INSTALLATION

Specified sealant:

3M ATD Part No. 8660 or equivalent

CAMSHAFT INSTALLATION

are not reversed. The exhaust-side camshaft is longer and has a slot in its rear end.

the camshafts with their cams for No. 1 cylinder directed upward so that the No. 1 cylinder becomes the top dead center on the compression stroke.

"DA

CAMSHAFT BEARING CAP / CAMSHAFT HOLDER INSTALLATION

(1) Confirm the identification mark on each bearing cap to

install the cap in the correct position.

Identification mark

L1: Front bearing for exhaust camshaft R1: Front bearing for intake camshaft

Nov. 1995Mitsubishi Motors Corporation

PWEE9502-A

Added

11A-8a-4

4G9 ENGINE (E-W) -

Sealant

Rocker Cover and Camshafts (MIVEC)

(2) Apply the specified sealant to the front and rear camshaft

bearing caps at the positions shown. Position t h e camshaft bearing caps and tighten their mounting bolts not numbered in the illustration. Then tighten the remaining (numbered) bolts in the order shown in the illustration to install the bearing caps and camshaft holder to the cylinder head.

Specified sealant:

3M ATD part No. 8660 or equivalent

Sealant

13713

10842612

Sealant

"EA

OIL CONTROL VALVE INSTALLATION

(1) Apply the specified sealant to the area shown.

Specified sealant:

3M ATD Part No. 8660 or equivalent

Sealant

"FA

MD998713

Nov. 1995Mitsubishi Motors Corporation Added

OIL SEAL INSTALLATION

PWEE9502-A

4G9 ENGINE (E-W) -

Rocker Cover and Camshafts (MIVEC)

11A-8a-5

MB991478

MB991477

"GA

ROCKER COVER INSTALLATION

Apply the specified sealant to th e area shown.

Specified sealant:

3M ATD part No. 8660 or equivalent

VALVE CLEARANCE ADJUSTMENT

Adjustment must be performed with the cylinder at the top dead center on the compression stroke.

(1) Inserting the special tool between one of two adjusting

screws and the valve and adjust the clearance.

MB991479

MB991477

(2) Then adjust the other adjusting screw in the same way.

MB991478

ROCKER ARM PISTON INSPECTION

(1) Screw in the special tool to the rocker arm piston for

high speed side rocker arm and check that the piston can be lifted up lightly by hand.

Nov. 1995Mitsubishi Motors Corporation

PWEE9502-A

Added

4G9 ENGINE (E-W) -

Rocker Arms and Rocker Shaft Caps (MIVEC)

8b. ROCKER ARMS AND ROCKER SHAFT CAPS (MIVEC)

REMOVAL AND INSTALLATION

11A-8b-1

11 Nm

Apply engine oil to all moving parts before installation.

Removal steps

1. Rocker shaft cap

2. Seal cap “A”

3. Seal cap “B”

4. Spring guide

5. Wave washer

Nov. 1995Mitsubishi Motors Corporation

PWEE9502-A

"AA

6. Intake rocker arm assembly “A”

7. Spring guide

8. Wave washer

9. Exhaust rocker arm assembly “A”

10. Camshaft holder

Added

11A-8b-2

4G9 ENGINE (E-W) -

Rocker Arms and Rocker Shaft Caps (MIVEC)

Timing belt side

Identification mark

INSTALLATION SERVICE POINT

"AA

(1) Install the rocker arm assemblies while checking the

ROCKER ARM ASSEMBLY INSTALLATION

identification marks at the positions shown to ensure that the intake and exhaust sides are not reversed.

Identification marks:

E: Intake I: Exhaust

Nov. 1995Mitsubishi Motors Corporation Added

PWEE9502-A

4G9 ENGINE (E-W) -

Cylinder Head and Valves

11A-9-1

9. CYLINDER HEAD AND VALVES

REMOVAL AND INSTALLATION <SOHC>

11300690072

AA""DA

AB""CA

"BA

AB""CA

"BA

Removal steps

1. Cylinder head bolt

2. Cylinder head assembly

3. Cylinder head gasket

4. Retainer lock

5. Valve spring retainer

6. Valve spring

7. Exhaust valve

8. Retainer lock

9. Valve spring retainer

10. Valve spring

AC""AA

Lubricate all internal parts with engine oil during reassembly.

11. Intake valve

12. Valve stem seal

13. Valve spring seat

14. Valve stem seal

15. Valve spring seat

16. Exhaust valve guide

17. Intake valve guide

18. Exhaust valve seat

19. Intake valve seat

20. Cylinder head

May 1995Mitsubishi Motors Corporation

PWEE9502

11A-9-2

4G9 ENGINE (E-W) -

REMOVAL AND INSTALLATION <DOHC>

Cylinder Head and Valves

10 Nm

"EA

AA""DA

AB""CA

"BA

AB""CA

"BA

Removal steps

1. Oil pressure switch

2. Cylinder head bolt

3. Cylinder head assembly

4. Cylinder head gasket

5. Retainer lock

6. Valve spring retainer

7. Valve spring

8. Exhaust valve

9. Retainer lock

10. Valve spring retainer

11. Valve spring

AC""AA

Lubricate all internal parts with engine oil during assembly.

12. Intake valve

13. Valve stem seal

14. Valve spring seat

15. Valve stem seal

16. Valve spring seat

17. Exhaust valve guide

18. Intake valve guide

19. Exhaust valve seat

20. Intake valve seat

21. Cylinder head

May 1995Mitsubishi Motors Corporation

PWEE9502

4G9 ENGINE (E-W) -

Cylinder Head and Valves

REMOVAL AND INSTALLATION <DOHC-MIVEC>

11A-9-3

10 Nm

"EA

AA""DA

AB""CA

"BA AD" AB""CA

"BA

Removal steps

1. Oil pressure switch

2. Cylinder head bolt

3. Cylinder head assembly

4. Cylinder head gasket

5. Retainer lock

6. Valve spring retainer

7. Valve spring

8. Intake valve

9. Retainer lock

10. Valve spring retainer

11. Valve spring

Nov. 1995Mitsubishi Motors Corporation

AD" AC""AA

AC""AA

PWEE9502-A

Apply engine oil to all moving parts before installation.

12. Exhaust valve

13. Valve stem seal

14. Valve spring seat

15. Valve stem seal

16. Valve spring seat

17. Intake valve guide

18. Exhaust valve guide

19. Intake valve seat

20. Exhaust valve seat

21. Cylinder head

Revised

11A-9-4

4G9 ENGINE (E-W) -

Cylinder Head and Valves

REMOVAL AND INSTALLATION <DOHC-GDI>

AA""DA

AB""CA

"BA AD" AB""CA

"BA

Removal steps

1. Cylinder head bolt

2. Cylinder head assembly

3. Cylinder head gasket

4. Retainer lock

5. Valve spring retainer

6. Valve spring

7. Intake valve

8. Retainer lock

9. Valve spring retainer

10. Valve spring

AD" AC""AA

AC""AA

Apply engine oil to all moving parts before installation.

11. Exhaust valve

12. Valve stem seal

13. Valve spring seat

14. Valve stem seal

15. Valve spring seat

16. Intake valve guide

17. Exhaust valve guide

18. Intake valve seat

19. Exhaust valve seat

20. Cylinder head

July 1997Mitsubishi Motors Corporation Added

PWEE9502-C

4G9 ENGINE (E-W) -

Cylinder Head and Valves

11A-9-5

Intentionally blank

July 1997Mitsubishi Motors Corporation

PWEE9502-C

Added

11A-9-4

4G9 ENGINE (E-W) -

Cylinder Head and Valves

SOHC

MB991653

DOHC, MIVEC

Except MIVEC

MB991653

MD998772

REMOVAL SERVICE POINTS

AA"

(1) Loosen the cylinder head bolts using the special tool.

AB"

(1) Store the removed valves, springs and other parts, tagged

CYLINDER HEAD BOLT REMOVAL

RETAINER LOCK REMOVAL

to indicate their cylinder No. and location to aid reassembly.

MIVEC

MD998772

MD998735

MD998784

Nov. 1995Mitsubishi Motors Corporation Revised

PWEE9502-A

4G9 ENGINE (E-W) -

Cylinder Head and Valves

11A-9-5

AC"

AD"

VALVE STEM SEAL REMOVAL

VALVE HANDLING PRECAUTIONS

(1) Sodium reacts violently with water or moisture generation

heat and liberating hydrogen. It must be handled with utmost care because otherwise the following dangerous conditions may result: Loss of eyesight if sodium gets in eyes. Burns if sodium contact skin. Fire hazard.

(2) Handling of Sodium-filled Exhaust Valves

Sodium-filled exhaust valves are not dangerous and may be handled in the same way as ordinary valves unless they are broken. Never try to break the valves and expose sodium to the air. When worn exhaust valves are to be discarded, have them disposed of by a salvage company equipped with special disposal system, notifying them that the valves contain sodium. Should the exhaust valves be broken, neutralize sodium using the method described below, and discard the valves in the same way as ordinary valves.

(3) How to Neutralize Sodium

Place a container filled with more than 10 liters of water in a well ventilated large space. Wear rubber gloves and goggles, and carefully take out broken valves from the cylinder head. Put a broken valve in the water-filled container and quickly get away from the container at least 2 or 3 m (6.6 or 10 ft.)

Nov. 1995Mitsubishi Motors Corporation

PWEE9502-A

Revised

11A-9-6

4G9 ENGINE (E-W) -

Cylinder Head and Valves

Caution

Valves must be neutralized one at a time.

Put a valve in the container only after sodium in the preceding one has completely reacted with water.

Keep fire away from the container during the neutralization. The resulting hydrogen gas is highly explosive. When the reaction has finished (there is no more generation of hydrogen gas), take the valves out of the container with large tweezers or the like.

NOTE The reaction occurs when water enters the cavity in the valve. Hydrogen gas may be trapped inside the valve, temporarily blocking the water passage. In such a case, wait until hydrogen gas in released a nd remaining sodium reacts with water. After the neutralization of sodium, water in the container contains sodium hydroxide and is highly alkaline. The water solution should be disposed of according to local regulations.

SOHC

MD998774

Caution

Do not let the solution contact the eyes or the skin.

Should it get in the eyes, immediately flush them with clean water thoroughly, and receive medical attention. When it contacts the skin, wash with ample amounts of clean water.

INSTALLATION SERVICE POINTS

"AA

(1) Install the vale spring seat. (2) Use the special tool to install the valve stem seal. Improper

VALVE STEM SEAL INSTALLATION

installation could result oil leaking past the valve guide.

Caution Do not reuse removed valve stem seals.

DOHC

MD998775

Nov. 1995Mitsubishi Motors Corporation Revised

PWEE9502-A

4G9 ENGINE (E-W) -

Cylinder Head and Valves

11A-9-7

Painted end

Except MIVEC

Spring retainer

Stem seal

Spring seat

MD998772

"BA

VALVE SPRING INSTALLATION

(1) Install the valve spring with the painted end on the rocker

arm side.

"CA

RETAINER LOCK INSTALLATION

(1) The valve spring, if excessively compressed, causes the

bottom end of retainer to be in contact with the stem seal, and damage it.

MIVEC

MD998772

MD998735

MD998784

"DA

CYLINDER HEAD BOLT INSTALLATION

(1) When installing the cylinder head bolts, check that the

shank length of each bolt meets the limit. If the limit is exceeded, replace the bolts.

Limit: Max. 96.4 mm

(2) Install the washers as illustrated. (3) Apply engine oil to the bolt threads and washers.

Shank length

Nov. 1995Mitsubishi Motors Corporation

PWEE9502-A

Revised

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

5. FUEL AND EMISSION CONTROL SYSTEM

5a. THROTTLE BODY AND EGR SYSTEM (GDI)

6. INTAKE AND EXHAUST MANIFOLD

6a. INTAKE MANIFOLD (GDI)

6b. EXHAUST MANIFOLD (GDI)

6c. INJECTOR AND FUEL PUMP ASSEMBLY (GDI)

7. WATER PUMP AND WATER HOSE

8. ROCKER ARMS AND CAMSHAFTS

8a. ROCKER COVER AND CAMSHAFTS (MIVEC)

8b. ROCKER ARMS AND ROCKER SHAFT CAPS (MIVEC)

9. CYLINDER HEAD AND VALVES