Mitsubishi Engine 4G1 (E-W) Workshop Manual

MITSUBISHI

4G1 SERIES (E–W)

WORKSHOP MANUAL

FOREWORD

ENGINE

This Workshop Manual contains procedures for
removal, disassembly, inspection, adjustment,
reassembly and installation, etc. for service
mechanics.
All information, illustrations and product
descriptions contained in this manual are current
as at the time of publication. We, however, reserve
the right to make changes at any time without
prior notice or obligation.

FILING INSTRUCTION

Please keep these manual pages in the binder
No. BN940001.

File these pages according to the signs
“Added”, “Revised” and “Deleted” on the “List
of effective pages” which are interpreted
below.

Added:

File the pages with this sign additionally in
your manual.

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11A

Revised, Deleted:

Replace the existing pages with the
corresponding pages with this sign.

Missing sheets will be supplied upon request.

E Mitsubishi Motors Corporation Aug. 2001

Pub. No. PWEE9520-F

INTRODUCTION

EXPLANATION OF MANUAL CONTENTS

Maintenance and Servicing Procedures

(1) A diagram of the component parts is

provided near the front of each section in
order to give the reader a better under­standing of the installed condition of
component parts.

(2) The numbers provided within the diagram

indicate the sequence for maintenance and
servicing procedures.
: Indicates a non-reusable part.
The tightening torque is provided where
applicable.

Classification of Major Maintenance/Service Points

When there are major points relative to maintenance and servicing procedures
(such as essential maintenance and service points, maintenance and service stan­dard values, information regarding the use of special tools, etc.), these are
arranged together as major maintenance and service points and explained in
detail.

AA" : Indicates that there are essential points for removal or disassembly.
"AA : Indicates that there are essential points for installation or reassembly.

D Removal steps:

The part designation number corresponds
to the number in the illustration to indicate
removal steps.

D Disassembly steps:

The part designation number corresponds
to the number in the illustration to indicate
disassembly steps.

D Installation steps:

Specified in case installation is impossible
in reverse order of removal steps. Omitted
if installation is possible in reverse order
of removal steps.

D Reassembly steps:

Specified in case reassembly is impossible
in reverse order of disassembly steps.
Omitted if reassembly is possible in reverse
order of disassembly steps.

Symbols for Lubrication, Sealants and Adhesives

Information concerning the locations for
lubrication and for application of sealants
and adhesives is provided, by using sym­bols, in the diagram of component parts, or
on the page following the component parts
page, and explained.

: Grease (multipurpose grease unless

there is a brand or type specified)

: Sealant or adhesive
: Brake fluid, automatic transmission fluid

or air conditioner compressor oil

: Engine oil or gear oil

INTRODUCTION

Indicates the
group title.

Indicates the
section title.

Indicates the
group number.

4G1 ENGINE (E–W) – Water Pump and Water Hose

6. WATER PUMP AND WATER HOSE

REMOVAL AND INSTALLATION <SOHC–CARBURETOR>

1

2

27 Nm

27 Nm

11 Nm

4

5

6

3

12 Nm

12

11

14

9

10

Indicates the
section num­ber.

11A-6-1

22 Nm

7

8

23 Nm

Indicates the
page number.

Denotes tightening
torque.

Denotes non-reusable part.

13

13 Nm

Mitsubishi Motors Corporation

E

Removal steps

1. Water hose

2. Water hose

3. Water hose

"FA

4. Thermo valve (engines with EGR)
(20) 5.

5. Thermo valve

"FA

Thermo valve

6.Water temperature gauge unit

"DA

7.Water inlet timing

Nov. 1995

8. Thermostat

"CA

9. Thermostat case

10.Gasket

"BA

11.Water inlet pipe

"BA

12.O-ring

"BA

13.O-ring

14.Water pump

"AA

INSTALLATION SERVICE POINTS

"AA

WATER PUMP INSTALLATION

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

mounting surface.

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or equivalent.

PWEE9520

This number corresponds to
the number appearing in
“Removal steps”,
“Disassembly steps”,
“Installation steps” or
“Reassembly steps”.

Operating procedures, cau­tions, etc. on removal, installa­tion, disassembly and reas­sembly are described.

Issue date

Publication number-Revision code

LIST OF EFFECTIVE PAGES

LIST OF EFFECTIVE PAGES

Page Revision

Page Revision

11A-0-1 D Aug. 2000
1 1A-0-2 to 11A-0-4 Nov. 1995
11A-0-5 A Dec. 1998
1 1A-0-6 to 11A-0-8 E Feb. 2001
11A-1-1 E Feb. 2001
1 1A-1-2 C Apr. 2000
11A-1-2a D Aug. 2000
11A-1-2b A Dec. 1998
11A-1-3 E Feb. 2001

11A-1-4 F Aug. 2001 Revised
11A-1-4a and 11A-1-4b F Aug. 2001 Added

11A-1-5 D Aug. 2000
1 1A-1-5a and 11A-1-5b D Aug. 2000
11A-1-6 D Aug. 2000
1 1A-1-7 Nov. 1995
1 1A-2-1 to 11A-2-3 D Aug. 2000
11A-3-1 E Feb. 2001
1 1A-3-1a and 11A-3-1b E Feb. 2001
1 1A-3-2 to 11A-3-4 E Feb. 2001

11A-3-5 F Aug. 2001 Revised

11A-4-1 E Feb. 2001
1 1A-4-1a and 11A-4-1b E Feb. 2001
11A-4-2 E Feb. 2001
1 1A-4-3 and 11A-4-4 D Aug. 2000
1 1A-4-5 to 11A-4-9 E Feb. 2001
11A-5-1 D Aug. 2000

1 1A-5-1a and 11A-5-1b D Aug. 2000

11A-5-2 F Aug. 2001 Revised

11A-5-2a D Aug. 2000
1 1A-5-2b C Apr. 2000
1 1A-5-3 and 11A-5-4 Nov. 1995
1 1A-5a-1 and 11A-5a-2 D Aug. 2000
11A-5b-1 D Aug. 2000
11A-6-1 D Aug. 2000
1 1A-6-1a and 11A-6-1b D Aug. 2000
11A-6-2 D Aug. 2000
1 1A-6-2a and 11A-6-2b D Aug. 2000
1 1A-6-3 to 11A-6-6 D Aug. 2000

Code

Code

Date Remarks Page Revision

Date Remarks Page Revision

Date Remarks

Code

Code

1 1A-7-1 and 11A-7-2 D Aug. 2000
1 1A-7-2a to 11A-7-2e D Aug. 2000
1 1A-7-3 Nov. 1995
11A-7-4 B July 1999
1 1A-7a-1 to 11A-7a-3 D Aug. 2000
11A-8-1 A Dec. 1998
1 1A-8-1a and 11A-8-1b D Aug. 2000
11A-8-2 D Aug. 2000
1 1A-8-2a and 11A-8-2b D Aug. 2000
11A-8-3 E Feb. 2001
1 1A-8-4 to 11A-8-6 C Apr . 2000
1 1A-8-6a and 11A-8-6b C Apr. 2000
1 1A-8-7 and 11A-8-8 A Dec. 1998
1 1A-8-9 to 11A-8-11 D Aug. 2000
1 1A-8a-1 to 11A-8a-6 D Aug. 2000
11A-9-1 A Dec. 1998
11A-9-1a A Dec. 1998
11A-9-1b D Aug. 2000
11A-9-2 D Aug. 2000
1 1A-9-3 Nov. 1995
1 1A-9-4 and 11A-9-5 A Dec. 1998
1 1A-9-6 C Apr. 2000
1 1A-9-7 to 11A-9-11 D Aug. 2000
11A-10-1 D Aug. 2000
1 1A-10-1a and 11A-10-1b D Aug. 2000
11A-10-2 E Feb. 2001
1 1A-10-3 Nov. 1995
11A-10-4 D Aug. 2000
1 1A-11-1 Nov. 1995
11A-11-2 D Aug. 2000
1 1A-11-3 Nov. 1995
1 1A-11-4 and 11A-11-5 D Aug. 2000
1 1A-11-6 to 11A-11-8 A Dec. 1998
1 1A-12-1 and 11A-12-2 D Aug. 2000
1 1A-12-2a and 11A-12-2b D Aug. 2000
1 1A-12-3 to 11A-12-5 A Dec. 1998
11A-12-6 E Feb. 2001
1 1A-12-7 and 11A-12-8 D Aug. 2000

Date Remarks

Missing sheets will be supplied upon request.

Missing sheets will be supplied upon request.

Aug. 2001Mitsubishi Motors Corporation Revised

E

E

July 1999Mitsubishi Motors Corporation Revised

PWEE9520-F

PWEE9520-B

ENGINE

4G1 SERIES

CONTENTS

11A-0-1

GENERAL INFORMATION 11A-0-3

1. SPECIFICATIONS 11A-1-1

SERVICE SPECIFICATIONS 11A-1-1

REWORK DIMENSIONS 11A-1-3

TORQUE SPECIFICATIONS 11A-1-4

NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE
TIGHTENED IN PLASTIC AREA 11A-1-6

SEALANT 11A-1-6

FORM-IN-PLACE GASKET 11A-1-7

2. SPECIAL TOOLS 11A-2-1

3. ALTERNATOR AND IGNITION SYSTEM 11A-3-1

4. TIMING BELT 11A-4-1

5. FUEL AND EMISSION CONTROL SYSTEMS 11A-5-1

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

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

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

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

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

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

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

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

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

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

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

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

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PWEE9520

PWEE9520-D

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11A-0-2

NOTES

E

Nov. 1995Mitsubishi Motors Corporation

PWEE9520

4G1 ENGINE (E-W) -

GENERAL INFORMATION

General Information

11A-0-3

E

Nov. 1995Mitsubishi Motors Corporation

PWEE9520

11A-0-4

4G1 ENGINE (E-W) -

General Information

E

Nov. 1995Mitsubishi Motors Corporation

PWEE9520

4G1 ENGINE (E-W) -

General Information

11A-0-5

Descriptions

4G13 12-VALVE-CARBURETOR 4G13 12-VALVE-MPI

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

Number of cylinders 4 4

Combustion chamber Pentroof type Pentroof type

Total displacement dm

3

1,299 1,299

Cylinder bore mm 71.0 71.0

Piston stroke mm 82.0 82.0

Compression ratio 9.5 9.5

Number of Intake 8 8
valves

Exhaust 4 4

Valve timing Intake opens BTDC 14

Intake closes ABDC 48

Exhaust opens BBDC 55

Exhaust closes ATDC 13

_

_

_

_

BTDC 19

ABDC 43

BBDC 60

ATDC 8

_

_

_

_

Lubrication system Pressure feed, full-flow filtration Pressure feed, full-flow filtration

Oil pump type Trochoid type Trochoid type

Cooling system Water-cooled, forced circulation Water-cooled, forced circulation

Water pump type Centrifugal impeller type Centrifugal impeller type

E

E

Nov. 1995Mitsubishi Motors Corporation

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-A

11A-0-6

4G1 ENGINE (E–W) – General Information

Descriptions

4G13 16-VALVE–CARBURETOR 4G13 16-VALVE–MPI
Type In-line OHV, SOHC In-line OHV, SOHC
Number of cylinders 4 4
Combustion chamber Pentroof type Pentroof type
Total displacement dm

3

1,299 1,299
Cylinder bore mm 71.0 71.0
Piston stroke mm 82.0 82.0
Compression ratio 9.5 10, 9.5*
Number of

Intake 8 8

1

valves

Exhaust 8 8

Valve timing Intake opens BTDC 12_ BTDC 17_

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

Exhaust closes ATDC 12_ ATDC 7_
Lubrication system Pressure feed, full-flow filtration Pressure feed, full-flow filtration
Oil pump type Trochoid type Trochoid type
Cooling system Water-cooled, forced circulation Water-cooled, forced circulation
Water pump type Centrifugal impeller type Centrifugal impeller type

*1: LANCER for General Export

E

E

Nov. 1995Mitsubishi Motors Corporation

Feb. 2001Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-E

4G1 ENGINE (E–W) – General Information

11A-0-7

Descriptions

4G15–
CARBURETTOR

4G15–MPI
12-VALVE

4G15–MPI
16-VALVE

4G15–GDI

Type In-line OHV, SOHC In-line OHV, SOHC In-line OHV, DOHC In-line OHV, DOHC
Number of cylinders 4 4 4 4
Combustion chamber Semi spherical type Semi spherical type Pentroof type Pentroof + Curved

piston head

Total displacement dm

3

1,468 1,468 1,468 1,468
Cylinder bore mm 75.5 75.5 75.5 75.5
Piston stroke mm 82.0 82.0 82.0 82.0
Compression ratio 9.0 9.0 9.5 11.0
Number

f

of valves

Intake 8 8 8 8
Exhaust 4 4 8 8

Valve
timing

Intake opens BTDC 14_ BTDC 14_ ,

BTDC 13_*

Intake closes ABDC 48_ ABDC 48_ ,

ABDC 47_*

1

1

BTDC 16_ BTDC 12_

ABDC 40_ ABDC 44_

Exhaust
opens

Exhaust
closes

Lubrication system Pressure feed,

BBDC 55_ BBDC 55_ ,

BBDC 56_*

ATDC 13_ ATDC 13_ ,

ATDC 8_*

1

Pressure feed,

full-flow filtration

full-flow filtration

1

BBDC 45_ BBDC 48_

ATDC 15_ ATDC 12_

Pressure feed,
full-flow filtration

Pressure feed,
full-flow filtration

Oil pump type Trochoid type Trochoid type Trochoid type Trochoid type

Cooling system Water-cooled,

forced circulation
Water pump type Centrifugal impeller

type

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

Water-cooled,
forced circulation

Centrifugal impeller
type

Water-cooled,
forced circulation

Centrifugal impeller
type

Water-cooled,
forced circulation

Centrifugal impeller
type

E

E

Nov. 1995Mitsubishi Motors Corporation

Feb. 2001Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-E

11A-0-8

4G1 ENGINE (E–W) – General Information

Descriptions

4G18 16-VALVE–CARBURETOR 4G18 16-VALVE–MPI
Type In-line OHV, SOHC In-line OHV, SOHC
Number of cylinders 4 4
Combustion chamber Pentroof type Pentroof type
Total displacement dm

3

1,584 1,584
Cylinder bore mm 76.0 76.0
Piston stroke mm 87.3 87.3
Compression ratio 9.5 9.5, 10*1*
Number of

Intake 8 8

2

valves

Exhaust 8 8

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

Intake closes ABDC 48_ ABDC 39_ , ABDC 51_*1 , ABDC 43_*
Exhaust opens BBDC 48_ BBDC 49_ , BBDC 49_*1 , BBDC 53_*
Exhaust closes ATDC 12_ ATDC 7_ , ATDC 15_*1 , ATDC 7_*

2

2

2

2

Lubrication system Pressure feed, full-flow filtration Pressure feed, full-flow filtration
Oil pump type Trochoid type Trochoid type
Cooling system Water-cooled, forced circulation Water-cooled, forced circulation
Water pump type Centrifugal impeller type Centrifugal impeller type

*1: SPACE STAR for Europe

2

*

: LANCER for General Export

E

E

Nov. 1995Mitsubishi Motors Corporation

Feb. 2001Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-E

4G1 ENGINE (E–W) – Specifications

1. SPECIFICATIONS

SERVICE SPECIFICATIONS

11A-1-1

Item

Rocker arms and camshaft

Camshaft cam

SOHC 12-VALVE Intake (primary) 38.78 38.28

height mm

SOHC 16-VALVE*

SOHC 16-VALVE*

SOHC 16-VALVE*

SOHC 16-VALVE*

DOHC Intake 34.67 34.17

DOHC GDI Intake 34.85 34.35

Standard Limit

Intake (secondary) 38.78 38.28
Exhaust*
Exhaust*

3

Intake 36.99 36.49

1
2

39.01 38.51

38.97 38.47

Exhaust 36.85 36.35

4

Intake 36.86 36.36
Exhaust 36.68 36.18

5

Intake 37.30 36.80
Exhaust 37.16 36.66

6

Intake 37.17 36.67
Exhaust 36.99 36.49

Exhaust 34.26 33.76

Exhaust 34.59 34.09

Camshaft journal diameter mm SOHC 45.93–45.94 –

SOHC 16-VALVE*

7

44.93–44.94 –

DOHC 25.95–25.97 –

Cylinder head and valves

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

– 0.2

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

SOHC 16-VALVE 119.9–120.1 –

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

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

SOHC 16-VALVE 5.5 –

DOHC 5.5 –

*1: With low pollution system

2

: Without low pollution system

*

3

: Except 2001 model front wheel drive vehicles

*

4

: 2001 model front wheel drive vehicles for Europe

*

5

: 2001 model front wheel drive vehicles for General Export

*

6

: 2002 model front wheel drive vehicles for Europe

*

7

: SOHC 16-VALVE MPI for Europe

*

E

E

Nov. 1995Mitsubishi Motors Corporation

Feb. 2001Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-E

11A-1-2

Item LimitStandard

4G1 ENGINE (E - W) -

Specifications

Valve stem-to-guide SOHC 12-VALVE
clearance mm

SOHC 16-VALVE

DOHC

Valve face angle 45°- 45.5

Valve stem projec- SOHC 12-VALVE
tion mm

SOHC 16-VALVE

DOHC

Overall valve length SOHC 12-VALVE
mm

SOHC 16-VALVE

Intake 0.020- 0.050 0.10

Exhaust 0.035- 0.050 0.15

Intake 0.020 - 0.047 0.10

Exhaust 0.030 - 0.057 0.15

Intake 0.020- 0.047 0.10

Exhaust 0.030- 0.062 0.15

Intake 43.70 44.20

Exhaust 43.30 43.80

Intake 53.21 53.71

Exhaust 54.10 54.60

Intake 48.80 49.30

Exhaust 48.70 49.20

Intake 100.75 100.25

Exhaust 101.05 105.55

Intake 111.56 111.06

Exhaust 114.71 114.21

°

-

DOHC

Valve spring free SOHC 12-VALVE
height mm

SOHC 16-VALVE 50.9 50.4

Valve spring load/ SOHC 12-VALVE
installed height N/
mm

mm

Valve spring squareness 2

Valve seat contact width mm 0.9- 1.3 -

Valve guide internal diameter mm

Valve guide projection mm

DOHC 49.1 48.6

SOHC 16-VALVE 216/44.2 -

DOHC 177/40.0 -

Intake 106.35 105.85

Exhaust 106.85 106.35

Intake 46.1 45.6

Exhaust 46.8 46.3

Intake 226/40.0 -

Exhaust 284/39.6 -

°

SOHC 12-VALVE 6.6 -

SOHC 16-VALVE 5.5 -

DOHC 5.5 -

SOHC 12-VALVE 17.0 -

SOHC 16-VALVE 23.0 -

°

4

DOHC 23.0 -

Oil pump and oil pan

Oil pump tip clearance mm 0.06- 0.18 -

Oil pump side clearance mm 0.04- 0.10 -

Oil pump body clearance mm 0.10- 0.18 0.35

E

E

Nov. 1995Mitsubishi Motors Corporation

Apr. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-C

4G1 ENGINE (E - W) -

Specifications

11A-1-2a

Item

Pistons and connecting rods

Piston outside diameter mm

Piston ring side clearance mm

Piston ring end gap
clearance

Piston pin O. D. mm 18.0 -

Piston pin press-in load (at room temperature) N 4,900- 14,700 -

Crankshaft pin oil clearance mm 0.02- 0.04 0.1

Connecting rod big end side clearance mm 0.10 - 0.25 0.4

Crankshaft and cylinder block

Crankshaft end play mm 0.05- 0.18 0.25

No. 1 ring 0.20- 0.35 0.8

No. 2 ring 0.35- 0.50 0.8

Oil ring

4G13 71.0 -

4G15 75.5 -

4G18 76.0 -

No. 1 ring 0.03- 0.07 -

No. 2 ring 0.02- 0.06 -

4G13, 4G15 0.20- 0.50 1.0

4G18 0.10 - 0.40 1.0

Standard Limit

Crankshaft journal diameter mm 48.0 -

Crankshaft pin diameter mm 42.0 -

Crankshaft journal oil clearance mm 0.02- 0.04 0.1

Cylinder block gasket surface flatness mm 0.05 or less -

Cylinder block gasket surface grinding limit (including grinding of
cylinder head gasket surface) mm

Cylinder block overall height mm 256 -

Cylinder bore cylindricity mm 0.01 -

Cylinder bore I. D. mm

Piston-to-cylinder clearance mm 0.02- 0.04 -

4G13 71.0 -

4G15 75.5 -

4G18 76.0 -

- 0.2

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

11A-1-2b

4G1 ENGINE (E-W) -

Specifications

Intentionally blank

E

E

E

Nov. 1995Mitsubishi Motors Corporation

Dec. 1998Mitsubishi Motors Corporation AddedPWEE9520-A

Dec. 1998Mitsubishi Motors Corporation Added

PWEE9520

PWEE9520-A

REWORK DIMENSIONS

mm

<4G13>

<4G18>

4G1 ENGINE (E–W) – Specifications

11A-1-3

Item

Cylinder head and valves

Cylinder head oversize valve guide
hole diameter mm

Oversize valve seat
ring hole diametermm12-VALVE

SOHC

Standard Limit

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

0.25 O. S. 12.240–12.258 –

0.50 O. S. 12.490–12.508 –

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

0.25 O. S. 10.750–10.768 –

0.50 O. S. 11.000–11.018 –

DOHC 0.05 O. S. 10.550–10.568 –

0.25 O. S. 10.750–10.768 –

0.50 O. S. 11.000–11.018 –

DOHC GDI 0.05 O. S. 10.610–10.620 –

0.25 O. S. 10.810–10.820 –

0.50 O. S. 11.060–11.070 –

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

0.6 O. S. 27.600–27.625 –

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

SOHC
16-VALVE

<4G13>

SOHC
16-VALVE
<4G18>

DOHC Intake 0.3 O. S. 31.300–31.325 –

0.6 O. S. 32.600–32.625 –

Exhaust 0.3 O. S. 35.300–35.325 –

0.6 O. S. 35.600–35.625 –

Intake 0.3 O. S. 28.300–28.321 –

0.6 O. S. 28.600–28.621 –

Exhaust 0.3 O. S. 26.300–26.321 –

0.6 O. S. 26.600–26.621 –

Intake 0.3 O. S. 30.300–30.321 –

0.6 O. S. 30.600–30.621 –

Exhaust 0.3 O. S. 28.300–28.321 –

0.6 O. S. 28.600–28.621 –

0.6 O. S. 31.600–31.625 –

Exhaust 0.3 O. S. 27.800–27.825 –

0.6 O. S. 28.100–28.125 –

E

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Nov. 1995Mitsubishi Motors Corporation

Feb. 2001Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-E

11A-1-4

4G1 ENGINE (E–W) – Specifications

TORQUE SPECIFICATIONS

Item

Alternator and ignition system

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

Nm

Timing belt

Timing belt cover bolt 11
Timing belt tensioner bolt 23
Crankshaft angle sensor bolt 9
Bracket bolt 21

Engine support bracket bolt (M8) 21
Engine support bracket bolt, nut (M10) 35
Idler pulley bolt 35
Camshaft sprocket bolt 88

Fuel and emission control system

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

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2001Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-F

4G1 ENGINE (E–W) – Specifications

11A-1-4a

Item
EGR valve bolt 21

Nm

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2001Mitsubishi Motors Corporation Added

PWEE9520

PWEE9520-F

11A-1-4b

4G1 ENGINE (E–W) – Specifications

Intentionally blank

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2001Mitsubishi Motors Corporation Added

PWEE9520

PWEE9520-F

4G1 ENGINE (E - W) -

Item Nm

Intake manifold and throttle body (GDI)

Accelerator cable bolt 10

Throttle body bolt 19

Air intake plenum resonator bolt 10

Power plant stay right bolt 49

Intake manifold stay bolt 30

EGR valve bolt 19

EGR valve support bolt 19

EGR valve support nut 24

Intake manifold bolt, nut 20

Exhaust manifold (GDI)

Oxygen sensor 44

Exhaust manifold cover bolt 30

Exhaust manifold bracket bolt 35

Specifications

11A-1-5

Exhaust manifold nut (M8) 18

Exhaust manifold nut (M10) 29

Power plant stay left bolt 35

Water pump and water hose

Water inlet fitting bolt 22

Water inlet pipe bolt (M8) 12

Water inlet pipe bolt (M10) 25

Fitting bolt 23

Water outlet fitting bolt (Front wheel drive) 23

Water outlet fitting bolt (Rear wheel drive) 18

Thermostat case bolt 23

Thermo valve 27

Engine coolant temperature gauge unit 11

Engine coolant temperature sensor 29

Water pump bolt 13

Exhaust manifold and intake manifold

Boost sensor bolt 5

Solenoid valve assembly bolt 9

Intake manifold bolt, nut 17

Intake manifold stay bolt <MPI> (M8) 17

Intake manifold stay bolt <MPI> (M10) 31

Intake manifold stay bolt <carburetor> 30

Engine hanger bolt 19

Exhaust manifold cover bolt 29

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

11A-1-5a

4G1 ENGINE (E - W) -

4G1 ENGINE (E - W) -

4G1 ENGINE (E - W) -

Specifications

Specifications

Specifications

Item

Exhaust manifold nut (M8) 17

Exhaust manifold nut (M10) 29

Exhaust manifold bracket A bolt 35

Exhaust manifold bracket B bolt 35

Power plant stay right bolt 49

Power plant stay left bolt 35

Oxygen sensor 44

Fuel system (GDI)

Fuel pipe bolt 12

Fuel pump bolt 4.9®17±2

Flange bolt 24

Harness bracket bolt 9.8

Injector holder bolt 23

Delivery pipe and injector bolt 12

Rocker arms and camshaft

Nm

Fuel pump cover bolt 12

Rocker cover bolt <SOHC> 3.5

Rocker cover bolt <DOHC> 4

Rocker shaft assembly bolt 31

Adjusting screw 15

Bearing cap bolt (M6) 11

Bearing cap bolt (M8) 24

Rocker arms and camshaft (GDI)

Engine hanger bolt 19

Rocker cover bolt 3.5

Beam camshaft cap bolt (M6) 11

Beam camshaft cap bolt (M8) 25

Cylinder head and valves

Cylinder head bolt 20 + 90_+90

Tighten to 49 Nm, then completely loosen and retighten as described.

Oil pump and oil pan

_

Transmission stay bolt 23

Oil pan bolt (M6) 7

Oil pan bolt (M8) 24

Drain plug 39

Oil screen bolt 19

Front case bolt 14

Relief plug 44

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

4G1 ENGINE (E - W) -

Item Nm

Oil pump cover bolt 10

Pistons and connecting rods

Specifications

11A-1-5b

Connecting rod nut 17 + 90_to 100

Crankshaft and cylinder block

Flywheel bolt 132

Drive plate bolt <Except GDI> 132

Drive plate bolt <GDI> 98

Rear plate bolt 10

Bell housing cover bolt 10

Rear oil seal case bolt 11

Bearing cap bolt 34 + 30_to 34

Oil pressure switch 19

Knock sensor 23

_

_

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

11A-1-6

4G1 ENGINE (E - W) -

Specifications

NEW TIGHTENING METHOD USING PLASTIC REGION TIGHTENING BOLTS

Parts of the engine use plastic region tightening bolts. The tightening procedure for these is different
from that of conventional bolts and is described in relevant parts of this manual. Note that plastic region
tightening bolts have fixed service limits. These limits are indicated in relevant parts of this manual and
must be strictly observed.

D

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

D

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

SEALANTS

Item

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

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

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

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

Water outlet fitting Mitsubishi Genuine Part No. MD970389 or equivalent As required

Engine coolant temperature sensor 3M Nut Locking Part No. 4171 or equivalent As required

Engine coolant temperature gauge unit 3M ATD Part No. 8660 or equivalent As required

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

Semi-circular packing 3M ATD Part No. 8660 or equivalent As required

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

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

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

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

Specified sealant Quantity

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

Rear oil seal case Mitsubishi Genuine Part No. MD970389 or equivalent As required

Drive plate bolt 3M Nut Locking Part No. 4171 or equivalent As required

E

E

Apr. 2000Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

4G1 ENGINE (E-W) -

Specifications

11A-1-7

FORM-IN-PLACE GASKET

The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket
fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead
size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick
a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the
fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to
apply the gasket evenly without a break, while observing the correct bead size.
The FIPG used in the engine is a room temperature vulcanization (RTV) type and is supplied in a 100-gram
tube (Part No. MD970389 or MD997110). Since the RTV hardens as it reacts with the moisture in the
atomospheric air, it is normally used in the metallic flange areas. The FIPG, Part No. MD970389, can
be used for sealing both engine oil and coolant, while Part No. 997110 can only be used for engine
oil sealing.

Disassembly

The parts assembled with the FIPG can be easily disassembled without use of a special method. In
some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking
with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the
joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.
For removal of the oil pan, the special tool “Oil Pan Remover” (MD998727) is available. Be sure to use
the special tool to remove the oil pan. <Except aluminium die-cast oil pans>

Surface Preparation

Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure
that there are no oils, greases and foreign substances deposited on the application surfaces. Do not
forget to remove the old sealant remained in the bolt holes.

Form-In-Place Gasket Application

When assembling parts with the FIPG, you must observe some precautions, but the procedures is very
simple as in the case of a conventional precut gasket.
Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the
bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is
hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When

the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do
not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time
(about one hour) has passed after installation is completed.
The FIPG application procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.

E

Nov. 1995Mitsubishi Motors Corporation

PWEE9520

NOTES

2. SPECIAL TOOLS

4G1 ENGINE (E - W) -

Special Tools

11A-2-1

Tool

Number Name Use

MB990767 End yoke holder Holding camshaft sprocket when loosening or

tightening bolt (used with MD998715)

MB991614 Angle gauge Installation of crankshaft bearing caps

MB991653 Cylinder head bolt

wrench (10)

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

Removal and installation of cylinder head bolts

pins

MB991671 Valve stem

installer

MD998011 Crankshaft rear oil

seal installer

MD998054 Oil pressure switch

wrench

MD998304 Crankshaft front oil

seal installer

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

Installation of crankshaft rear oil seal

Removal and installation of oil pressure switch

Installation of crankshaft front oil seal

MD998305 Crankshaft front oil

seal guide

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

Guide for installation of crankshaft front oil seal

11A-2-2

Tool UseNameNumber

MD998442 Air bleed wire Testing of automatic lash adjusters

4G1 ENGINE (E - W) -

Special Tools

(DOHC)

MD998713 Camshaft oil seal

installer

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

MD998727 Oil pan remover Removal of oil pan

MD998735 Valve spring com-

pressor

Installation of camshaft oil seal

tightening bolt (used with MB990767)

Compression of valve springs

MD998760 Valve stem seal

installer

MD998762 Circular packing

installer

MD998772 Valve spring com-

pressor

MD998780 Piston pin setting

tool

Installation of valve stem seals
(SOHC 12-VALVE)

Installing of circular packing

Compression of valve springs

Removal and press-fitting of piston pins

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

4G1 ENGINE (E - W) -

Tool UseNameNumber

MD998781 Flywheel stopper Locking flywheel in fixed position

Special Tools

11A-2-3

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Added

PWEE9520

PWEE9520-D

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

3. ALTERNATOR AND IGNITION SYSTEM

REMOVAL AND INSTALLATION <SOHC 12-VALVE>

11A-3-1

6

22 Nm

23 Nm

9 Nm

7

44 Nm

12

12 Nm

13

10

25 Nm

11

1

5

23 Nm

2

8

4

Removal steps

1. Oil level gauge

2. Oil level gauge guide

3. O-ring

4. Drive belt*

5. Water pump pulley

6. Alternator brace

7. Alternator

AA""BA 8. Crankshaft bolt

"BA 9. Crankshaft pulley

E

E

Nov. 1995Mitsubishi Motors Corporation

Feb. 2001Mitsubishi Motors Corporation Revised

125 Nm

9

PWEE9520

PWEE9520-E

3

10. Spark plug cable

11. Spark plug

"AA 12. Distributor

13. O-ring

NOTE

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

chassis workshop manual.

11A-3-1a

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

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

22 Nm

6

23 Nm

9 Nm

25 Nm

44 Nm

10

12 Nm

11

12

13

7

23 Nm

5

1

9

2

4

Removal steps

1. Oil level gauge

2. Oil level gauge guide

3. O-ring

4. Drive belt*

5. Water pump pulley

6. Alternator brace

7. Alternator

AA""BA 8. Crankshaft bolt

"BA 9. Crankshaft pulley

E

E

Nov. 1995Mitsubishi Motors Corporation

Feb. 2001Mitsubishi Motors Corporation Revised

3

8

125 Nm

10. Spark plug cable

11. Spark plug

"AA 12. Distributor

13. O-ring

NOTE

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

chassis workshop manual.

PWEE9520

PWEE9520-E

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

11A-3-1b

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

10 Nm

10

11

9 Nm

25 Nm

10

12

16

14

5 Nm

15

22 Nm

6

23 Nm

9 Nm

4

44 Nm

11

13

21 Nm

13 Nm

7

1

23 Nm

5

9

2

3

8

Removal steps

1. Oil level gauge

2. Oil level gauge guide

3. O-ring

4. Drive belt*

5. Water pump pulley

6. Alternator brace

7. Alternator

AA""BA 8. Crankshaft bolt

"BA 9. Crankshaft pulley

E

E

Nov. 1995Mitsubishi Motors Corporation

Feb. 2001Mitsubishi Motors Corporation Revised

125 Nm

NOTE

PWEE9520

PWEE9520-E

10. Spark plug cable

11. Ignition coil

12. Spark plug

13. Ignition failure sensor
(only vehicles for Europe)

14. Cam position sensor

"CA 15. Cam position sensor support

16. Cam position sensing cylinder

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

chassis workshop manual.

11A-3-2

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

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

10

10 Nm

25 Nm

12

13

9 Nm

6

7

22 Nm

23 Nm

9 Nm

4

44 Nm

8

5

125 Nm

11

14

15

13 Nm

21 Nm

1

23 Nm

2

3

9

Removal steps

1. Oil level gauge

2. Oil level gauge guide

3. O-ring

4. Drive belt*

5. Water pump pulley

6. Alternator brace

7. Alternator

AA""BA 8. Crankshaft bolt

"BA 9. Crankshaft pulley

E

E

Nov. 1995Mitsubishi Motors Corporation

Feb. 2001Mitsubishi Motors Corporation Revised

NOTE

PWEE9520

PWEE9520-E

10. Spark plug cable

11. Ignition coil

12. Spark plug

13. Cam position sensor

"CA 14. Cam position sensor support

15. Cam position sensing cylinder

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

chassis workshop manual.

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

REMOVAL AND INSTALLATION <DOHC>

10

25 Nm

11

11A-3-3

12

11 Nm

13

6

22 Nm

23 Nm

9 Nm

7

4

44 Nm

8

125 Nm

5

1

23 Nm

2

3

9

Removal steps

1. Oil level gauge

2. Oil level gauge guide

3. O-ring

4. Drive belt*

5. Water pump pulley

6. Alternator brace

7. Alternator

AA""BA 8. Crankshaft bolt

"BA 9. Crankshaft pulley

E

E

Nov. 1995Mitsubishi Motors Corporation

Feb. 2001Mitsubishi Motors Corporation Revised

NOTE

PWEE9520

PWEE9520-E

10. Spark plug cable

11. Spark plug

"AA 12. Distributor

13. O-ring

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

chassis workshop manual.

11A-3-4

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

REMOVAL AND INSTALLATION <DOHC–GDI>

10 Nm

25 Nm

7

9 Nm

11

13

12

15

22 Nm

9 Nm

5

8

44 Nm

9

125 Nm

14

13 Nm

21 Nm

1

6

2

19 Nm

3

4

10

Removal steps

1. Oil level gauge

2. Engine hanger

3. Oil level gauge guide

4. O-ring

5. Drive belt

6. Water pump pulley

7. Alternator brace

8. Alternator assembly

AA""BA 9. Crankshaft bolt

"BA 10. Crankshaft pulley

E

E

Nov. 1995Mitsubishi Motors Corporation

Feb. 2001Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-E

11. Ignition coil

12. Spark plug

13. Cam position sensor

"CA 14. Cam position sensor support

15. Cam position sensing cylinder

MD998781

Alignment mark

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

REMOVAL SERVICE POINT

AA" CRANKSHAFT BOLT REMOVAL

(1) Lock the flywheel or drive plate in position using the special

tool shown in the illustration, then loosen the crankshaft
bolts.

INSTALLATION SERVICE POINTS

"AA DISTRIBUTOR INSTALLATION

(1) Turn the crankshaft clockwise until cylinder No. 1 is at

top dead center on its compression stroke.

(2) Align the alignment marks on the distributor housing and

coupling.

(3) Fit the distributor onto the engine, aligning the stud bolts

with the slots in the distributor mounting flange.

Alignment mark

11A-3-5

MD998781

Crankshaft pulley

Crankshaft
bolt

Washer

Shear-drop

Degrease

Clean

Crankshaft

"BA CRANKSHAFT PULLEY / BOLT INSTALLATION

(1) Hold the flywheel or drive plate using the special tool.

(2) Clean the bolt hole in crankshaft, crankshaft bolt and

crankshaft pulley’s seating surface.

(3) Degrease the cleaned seating surface of the crankshaft

pulley.
(4) Install the crankshaft pulley.
(5) Apply oil to the threads of crankshaft bolt and the outer

surface of washer.
(6) Tighten the crankshaft bolt to the specified torque of 125

Nm.

"CA CAM POSITION SENSOR SUPPORT

INSTALLATION

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

the area shown.

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or
equivalent

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2001Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-F

4G1 ENGINE (E–W) – Timing Belt

4. TIMING BELT

REMOVAL AND INSTALLATION <SOHC – With timing belt rear cover>

11A-4-1

11 Nm

13

14

12

88 Nm

1

11

5

23 Nm

35 Nm

8

9

6

3

4

7

9 Nm

10

2

Removal steps

1. Timing belt upper cover

2. Timing belt lower cover

AA""DA 3. Timing belt

"CA 4. Tensioner spring
"CA 5. Timing belt tensioner

6. Crankshaft angle sensor
<Without Distributor>

"BA 7. Crankshaft sprocket

E

E

"BA 8. Spacer <Without Distributor>
"BA 9. Sensing blade <Without Distributor>
"BA 10. Flange <With Distributor>

AB""AA 11. Camshaft sprocket bolt

12. Camshaft sprocket

13. Engine support bracket

14. Timing belt rear cover

Nov. 1995Mitsubishi Motors Corporation

Feb. 2001Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-E

11A-4-1a

4G1 ENGINE (E–W) – Timing Belt

REMOVAL AND INSTALLATION <SOHC – Without timing belt rear cover>

11 Nm

1

88 Nm

23 Nm

10

11

35 Nm

13

12

5

21 Nm

8

21 Nm

35 Nm

6

9

3

4

7

9 Nm

2

Removal steps

1. Timing belt upper cover

2. Timing belt lower cover

AA""DA 3. Timing belt

"CA 4. Tensioner spring
"CA 5. Timing belt tensioner

6. Crankshaft angle sensor
<Without Distributor>

E

E

"BA 7. Crankshaft sprocket
"BA 8. Spacer <Without Distributor>
"BA 9. Sensing blade <Without Distributor>

AB""AA 10. Camshaft sprocket bolt

11. Camshaft sprocket

12. Bracket

13. Engine support bracket

Nov. 1995Mitsubishi Motors Corporation

Feb. 2001Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-E

4G1 ENGINE (E–W) – Timing Belt

REMOVAL AND INSTALLATION <DOHC>

11A-4-1b

13

11 Nm

1

88 Nm

9

10

23 Nm

11 Nm

3

11 Nm

14

11

5

12

11

6

35 Nm

35 Nm

8

4

7

2

Removal steps

1. Timing belt upper cover

2. Timing belt lower cover

AA""EA 3. Timing belt
AA""CA 4. Tensioner spring
AA""CA 5. Timing belt tensioner

6. Idler pulley

"BA 7. Crankshaft sprocket

E

E

Nov. 1995Mitsubishi Motors Corporation

Feb. 2001Mitsubishi Motors Corporation Revised

AB""AA 9. Camshaft sprocket bolt

PWEE9520

PWEE9520-E

"BA 8. Flange

10. Camshaft sprocket

11. Engine support bracket

12. Timing belt rear cover (lower)

13. Timing belt rear cover (right)

14. Timing belt rear cover (left)

11A-4-2

4G1 ENGINE (E–W) – Timing Belt

REMOVAL AND INSTALLATION <GDI>

11 Nm

15

11 Nm

1

3

88 Nm

2

13

14

23 Nm

4

35 Nm

5

9

6

10

8

35 Nm

11

7

9 Nm

21 Nm

35 Nm

21 Nm

12

Removal steps

1. Timing belt front upper cover

2. Timing belt front lower cover

AC""GA 3. Timing belt

4. Tensioner spring

"FA 5. Timing belt tensioner

6. Idler pulley

7. Crank angle sensor

"BA 8. Crankshaft sprocket

E

E

"BA 9. Spacer
"BA 10. Sensing blade

11. Bracket

12. Right engine support bracket

AB""AA 13. Camshaft sprocket bolt

14. Camshaft sprocket

15. Timing belt rear upper cover

Nov. 1995Mitsubishi Motors Corporation

Feb. 2001Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-E

MD998715

4G1 ENGINE (E - W) -

MB990767

Timing Belt

11A-4-3

REMOVAL SERVICE POINTS

AA"

(1) Using pliers, grip the tensioner spring projection (marked

(2) Remove the timing belt tensioner.
(3) If the timing belt is to be reused, chalk an arrow on the

AB"

(1) Using the special tools shown in the illustration, lock the

(2) Loosen the camshaft sprocket bolt.

TIMING BELT / TENSIONER SPRING / TIMING
BELT TENSIONER REMOVAL

“A” in the diagram)and remove it from the oil pump case
stopper. Then, remove the tensioner spring.

belt to indicate the direction of rotation before removing
it. This will ensure the timing belt is fitted correctly when
reused.

CAMSHAFT SPROCKET BOLT REMOVAL

camshaft sprocket in position.

Securing bolt

AC"

TIMING BELT REMOVAL

(1) If the timing belt is to be refused, it is necessary to install

it in the same direction as it was before. Mark an arrow
that shows the direction of rotation on the back surface
of the timing belt with chalk, etc.

(2) Using pliers and the like, hold the tensioner spring at

the illustrated position, and remove the spring.

Caution
Do not cause the end of the tensioner spring to give
damage to the timing belt.

(3) Loosen the timing belt tensioner securing bolt.
(4) Move the timing belt tensioner in the direction shown

to remove the timing belt.

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

11A-4-4

4G1 ENGINE (E - W) -

4G1 ENGINE (E - W) -

INSPECTION

1. TIMING BELT

Check the timing belt closely. Replace the belt with a new
one if any of the following defects is evident:
(1) Hardened backing rubber (the backing rubber is glossy,

non-elastic, and so hard that scratching with fingernails
leaves no mark)

Timing Belt

Timing Belt

Crack

Separation

Cracked tooth base

Rounded edge

Abnormal wear
(exposed core wire)

Canvas worn exposing
rubber

Missing tooth

Crack

Cracked side

(2) Surface cracks in the backing rubber
(3) Splits in the canvas and/or separation of the canvas and

rubber
(4) Cracks at the bases of teeth
(5) Cracks in the side of the belt

(6) Abnormal wear on the belt’s sides

NOTE

The sides of the belt are normal if they are sharp as

if cut by a knife.

(7) Abnormal wear on teeth

Initial stage:

Canvas worn (fluffy canvas fibers, rubbery texture gone,

white discoloration, canvas texture indistinct)

Final stage:

Canvas worn, exposing rubber (tooth width reduced)

(8) Missing teeth

2. TENSIONER PULLEY AND IDLER PULLEY

(1) Check that the pulleys turn smoothly without play and

are not abnormally noisy. Replace either or both of the

pulleys if necessary.

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

MD998715

4G1 ENGINE (E–W) – Timing Belt

INSTALLATION SERVICE POINTS

"AA CAMSHAFT SPROCKET BOLT INSTALLATION

MB990767

(1) Using the special tools shown in the illustration, lock the

camshaft sprocket in position.

(2) Tighten the camshaft sprocket bolt to the specified torque.

11A-4-5

Crankshaft
sprocket

Clean

Crankshaft
sprocket

Clean

Sensing
blade

Spacer

Degrease

Flange

Degrease

Crankshaft

Crankshaft

Timing belt
tensioner

"BA SENSING BLADE / SPACER / FLANGE /

CRANKSHAFT SPROCKET

Type with crank angle sensor:
(1) Clean the hole in the crankshaft sprocket.
(2) Clean and degrease the mating surfaces of the crankshaft

sprocket and crankshaft; sensing blade; and spacer.
NOTE

Degreasing is necessary to prevent decrease in friction
between the mating surfaces due to presence of oil.

Type without crank angle sensor:
(1) Clean the hole in the crankshaft sprocket.
(2) Clean and degrease the crankshaft sprocket, flange, and

sprocket fitting surface of the crankshaft.
NOTE

Degreasing is necessary to prevent decrease in friction
between the mating surfaces due to presence of oil.

"CA TIMING BELT TENSIONER / TENSIONER SPRING

INSTALLATION

(1) Lock the timing belt tensioner in the illustrated position.

(2) Fit one of the tensioner spring projections over the hooked

portion of the timing belt tensioner and fit the tensioner
onto the oil pump case.

E

E

Nov. 1995Mitsubishi Motors Corporation

Feb. 2001Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-E

11A-4-6

4G1 ENGINE (E–W) – Timing Belt4G1 ENGINE (E–W) – Timing Belt

(3) Grip the other tensioner spring projection and fit it onto

the oil pump case lug as shown in the illustration.

(4) Move the timing belt tensioner in the direction shown

and temporarily tighten the bolt.

"DA TIMING BELT INSTALLATION

(1) Align the camshaft timing mark with the timing mark on

the cylinder head.

(2) Align the crankshaft timing mark with the timing mark

on the front case.

(3) Keeping the tension side of the timing belt tight, fit the

timing belt onto the crankshaft sprocket, camshaft
sprocket, and tensioner pulley in that order.

(4) Loosen the tensioner pulley mounting bolts by 1/4 to

1/2 of a turn and allow the tensioner spring to apply tension
to the timing belt.

(5) Turn the crankshaft twice in the normal rotating direction

(clockwise) and check that the timing marks are correctly
aligned.

Caution
This procedure utilizes the camshaft’s driving torque
to apply tension evenly to the timing belt. Be sure
to turn the crankshaft as described above. Do not
turn the crankshaft in reverse.

(6) Tighten the tensioner pulley mounting bolts.

E

E

Nov. 1995Mitsubishi Motors Corporation

Feb. 2001Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-E

4G1 ENGINE (E–W) – Timing Belt4G1 ENGINE (E–W) – Timing Belt

"EA TIMING BELT INSTALLATION

(1) Place the camshaft sprocket timing marks at the positions

shown.
NOTE

After aligning the sprocket timing marks, let go of the
sprockets. The exhaust camshaft sprocket will rotate by
one tooth in the direction shown and remain stable in
this position.

(2) Align the crankshaft timing mark with the timing mark

on the front case.

11A-4-7

(3) Turn the exhaust camshaft sprocket in the direction shown

and fit the timing belt with the timing marks aligned.

(4) Use a bulldog clip to prevent the timing belt teeth from

jumping.

(5) Fit the timing belt onto the idler pulley , crankshaft sprocket,

and tensioner pulley in that order.
NOTE

When fitting the belt, keep the camshaft sprocket timing
marks correctly aligned and keep the tension side of the
belt tight.

(6) Loosen the tensioner pulley mounting bolts by

1

/4 to 1/
of a turn and allow the tensioner spring to apply tension
to the timing belt.

(7) Remove the bulldog clip.
(8) Turn the crankshaft twice in the normal rotating direction

(clockwise) and check that the timing marks are correctly
aligned.

2

Caution
This procedure utilizes the camshaft’s driving torque
to apply tension evenly to the timing belt. Be sure
to turn the crankshaft as described above. Do not
turn the crankshaft in reverse.

(9) Tighten the tensioner pulley mounting bolts.

E

E

Nov. 1995Mitsubishi Motors Corporation

Feb. 2001Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-E

11A-4-8

4G1 ENGINE (E–W) – Timing Belt

Securing bolt

"FA TIMING BELT TENSIONER AND TENSIONER

SPRING INSTALLATION

(1) Install the timing belt tensioner and the tensioner spring,

and temporarily tighten the timing belt tensioner securing
bolt.

(2) Using pliers and the like, secure the spring at the illustrated

position of the front case.

Caution
Do not cause the end of the tensioner spring to give
damage to the crankshaft sprocket.

Timing marks

"GA TIMING BELT INSTALLATION

(1) Align the timing marks on each camshaft sprocket.

NOTE
After the timing marks on the sprockets are aligned, the
sprockets can turn by about one tooth in the direction
shown and remain stable in this position.

(2) Align the crankshaft sprocket timing marks.

(3) While paying attention to the direction of rotation marked

on the timing belt (if the timing belt is reused), put the
timing belt over the inlet camshaft sprocket. After that,
secure the belt at the position shown with a paper clip,
etc.

E

E

Nov. 1995Mitsubishi Motors Corporation

Feb. 2001Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-E

4G1 ENGINE (E–W) – Timing Belt

11A-4-9

23 cogs

Timing marks

Securing bolt

(4) Adjust the timing belt so that 23 cogs will fall within the

range between the timing marks on the intake and exhaust
camshaft sprockets. Secure the belt at this position with
a paper clip, etc.

(5) While aligning the exhaust camshaft sprocket timing

marks, install the timing belt on the idler pulley, crankshaft
sprocket, and the timing belt tensioner in that order.

(6) Ensure that the timing marks on the exhaust camshaft

sprocket and on the crankshaft sprocket are in alignment.

(7) Loosen the timing belt tensioner securing bolt, which has

temporarily been tightened, a quarter to half turn. Utilizing
tensioner spring tension, give tension to the timing belt.

(8) Remove the paper clips, etc.

(9) Make two turns of the crankshaft sprocket in clockwise

direction to ensure that the timing marks on each camshaft
sprocket are in alignment.

Caution
Operation under item 9 above is performed in order
to give a constant tension to the timing belt by utilizing
camshaft driving torque. Observe the number of turns
of the sprocket mentioned above. Do not turn the
crankshaft sprocket counterclockwise direction.

E

E

Nov. 1995Mitsubishi Motors Corporation

Feb. 2001Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-E

4G1 ENGINE (E - W) -

Fuel and Emission Control Systems

5. FUEL AND EMISSION CONTROL SYSTEMS

REMOVAL AND INSTALLATION <SOHC 12-VALVE - CARBURETOR>

17 Nm

10 Nm

11A-5-1

4

12 Nm

31 Nm

3

8

12 Nm

9

10

2

11

13

21 Nm

12

5

14

6

7

1

Removal steps

1. Breather tube

2. Fuel hose

3. Hose clamp

4. Fuel pump

5. Gasket

6. Insulator

7. Gasket

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

8. Carburetor

9. Upper gasket

10. Spacer

11. Lower gasket

12. EGR valve <engine with EGR>

13. Cover <engine without EGR>

14. Gasket

11A-5-1a

4G1 ENGINE (E - W) -

Fuel and Emission Control Systems

REMOVAL AND INSTALLATION <SOHC 16-VALVE - CARBURETOR>

17 Nm

10 Nm

19 Nm

31 Nm

3

8

9

10

4

2

11

12 Nm

12

5

13

6

7

1

Removal steps

1. Breather tube

2. Fuel hose

3. Hose clamp

4. Fuel pump

5. Gasket

6. Insulator

7. Gasket

8. Carburetor

9. Upper gasket

10. Spacer

11. Lower gasket

12. Cover

13. Gasket

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Added

PWEE9520

PWEE9520-D

4G1 ENGINE (E–W) – Fuel and Emission Control Systems

11A-5-1b

Intentionally blank

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Added

PWEE9520

PWEE9520-D

11A-5-2

4G1 ENGINE (E–W) – Fuel and Emission Control Systems

REMOVAL AND INSTALLATION <SOHC–MPI – FRONT WHEEL DRIVE (EXCEPT
FROM 2001 model FOR EUROPE)>

11 Nm

9 Nm

3

11

18 Nm

1

6

9

5

4

10

8

7

2

21 Nm

14

M8 × 16 18 Nm
Except M8 × 16 12 Nm

12

Removal steps

1. Throttle body assembly

2. Gasket

3. Fuel return pipe

"BA 4. Fuel pressure regulator

5. O-ring

6. Insulator

7. Insulator

"AA 8. Injector

9. O-ring

13

15

16

18 Nm

1EN0814

10. Grommet

11. Delivery pipe

12. EGR valve (With EGR valve)

13. Cover (Without EGR valve)

14. Gasket

15. Air temperature sensor (Up to
2000 model)

16. Gasket (Up to 2000 model)

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2001Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-F

4G1 ENGINE (E - W) -

Fuel and Emission Control Systems

11A-5-2a

REMOVAL AND INSTALLATION <SOHC - MPI - FRONT WHEEL DRIVE (FROM
2001 model FOR EUROPE)>

21 Nm

12

6

11 Nm

13

9Nm

8

4

9Nm

5

11

1

9

10

3

18 Nm

7

2

Removal steps

1. Vacuum pipe and hose

2. Throttle body assembly

3. Gasket

"BA

4. Fuel pressure regulator

5. O-ring

6. Insulator

7. Insulator

"AA

8. Injector

9. O-ring

10. Grommet

11. Delivery pipe

12. EGR valve

13. Gasket

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

11A-5-2b

4G1 ENGINE (E - W) -

Fuel and Emission Control Systems

REMOVAL AND INSTALLATION <SOHC -MPI - REAR WHEEL DRIVE>

9Nm

4

9Nm

3

11 Nm

18 Nm

11

2

5

10

9

6

1

21 Nm

8

7

12

13

Removal steps

1. Throttle body assembly

2. Gasket

3. Fuel return pipe

"BA

4. Fuel pressure regulator

5. O-ring

6. Insulator

7. Insulator

"AA

8. Injector

9. O-ring

10. Grommet

11. Delivery pipe

12. EGR valve

13. Gasket

E

E

Nov. 1995Mitsubishi Motors Corporation

Apr. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-C

4G1 ENGINE (E-W) -

Fuel and Emission Control Systems

REMOVAL AND INSTALLATION <DOHC>

11 Nm

11A-5-3

9Nm

3

11

18 Nm

1

6

2

9

5

4

10

8

7

Removal steps

1. Throttle body assembly

2. Gasket

3. Fuel return pipe

"BA

4. Fuel pressure regulator

5. O-ring

6. Insulator

"AA

7. Insulator

8. Injector

9. O-ring

10. Grommet

11. Delivery pipe

E

Nov. 1995Mitsubishi Motors Corporation

PWEE9520

11A-5-4

4G1 ENGINE (E-W) -

Fuel and Emission Control Systems

INSTALLATION SERVICE POINTS

"AA

(1) Fit a new O-ring and grommet onto the injector.
(2) Apply spindle oil or gasoline to the injector O-ring.

(3) Fit the injector onto the delivery pipe, turning it to the

(4) Check that the injector rotates smoothly.

INJECTOR INSTALLATION

left and right as it goes in.

Caution
If the injector does not rotate smoothly, its O-ring
may be binding. If this occurs, remove the injector
from the delivery pipe, check the O-ring, and re-insert
the injector.

"BA

(1) Apply a little new engine oil to the O-ring, then insert

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

FUEL PRESSURE REGULATOR INSTALLATION

the fuel pressure regulator into the delivery pipe, taking
care not to damage the O-ring.

Caution
Ensure that no engine oil enters the delivery pipe.

If it does not rotate smoothly, the O-ring may be binding.
If this occurs, remove the fuel pressure regulator, check
the O-ring for damage, then re-insert the regulator into
the delivery pipe.

E

Nov. 1995Mitsubishi Motors Corporation

PWEE9520

4G1 ENGINE (E - W) -

Intake Manifold and Throttle Body (GDI)

INTAKE MANIFOLD AND THROTTLE BODY (GDI)

REMOVAL AND INSTALLATION

19 Nm

10 Nm

4

3

11A-5a-1

2

49 Nm

7

30 Nm

5

10 Nm

1

20 Nm

14

8

16

19 Nm

24 Nm

13

14

17

15

11

9

6

18

11

12

10

19 Nm

Removal steps

1. Accelerator cable

2. Water hose

3. Throttle body

4. Gasket

5. Air intake plenum resonator

6. O-ring

7. Power plant stay, right

"BA

E

E

8. Intake manifold stay

9. Water hose

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Added

PWEE9520-D

AA""AA

PWEE9520

10. Water hose

11. EGR valve

12. Gasket

13. EGR valve support

14. Gasket

15. P.C.V. hose

16. Intake manifold

17. Gasket

18. Insulator

11A-5a-2

4G1 ENGINE (E - W) -

Intake Manifold and Throttle Body (GDI)

REMOVAL SERVICE POINT

AA"

Disconnect the fuel pressure sensor connectors.

INTAKE MANIFOLD REMOVAL

INSTALLATION SERVICE POINTS

"AA

After installing the intake manifold, connect the fuel pressure
sensor connectors.

INTAKE MANIFOLD INSTALLATION

"BA

INTAKE MANIFOLD STAY INSTALLATION

Ensure that the intake manifold stay is in close contact with
the intake manifold and the cylinder block boss. After that,
tighten the bolts to the specified torque.

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Added

PWEE9520

PWEE9520-D

4G1 ENGINE (E - W) -

EXHAUST MANIFOLD (GDI)

REMOVAL AND INSTALLATION

Exhaust Manifold (GDI)

30 Nm

5

18 Nm

11A-5b-1

2

29 Nm

7

Removal steps

1. Oxygen sensor

2. Exhaust manifold cover

3. Exhaust manifold bracket B

4. Exhaust manifold

5. Exhaust manifold gasket

6. Exhaust manifold bracket A

7. Power plant stay, left

4

6

1

35 Nm

3

35 Nm

44 Nm

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Added

PWEE9520

PWEE9520-D

4G1 ENGINE (E - W) -

Water Pump and Water Hose

6. WATER PUMP AND WATER HOSE

REMOVAL AND INSTALLATION <SOHC 12-VALVE - CARBURETOR>

11A-6-1

3

12 Nm

1

2

27 Nm

4

27 Nm

11 Nm

22 Nm

12

5

11

6

8

7

9

23 Nm

10

14

13

13 Nm

Removal steps

1. Water hose

2. Water hose

3. Water hose

"FA
"FA
"DA

4. Thermo valve <engines with EGR>

5. Thermo valve

6. Engine coolant temperature gauge
unit

7. Water inlet fitting

"CA

"BA
"BA
"BA
"AA

8. Thermostat

9. Thermostat case

10. Gasket

11. Water inlet pipe

12. O-ring

13. O-ring

14. Water pump

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

11A-6-1a

4G1 ENGINE (E - W) -

Water Pump and Water Hose

REMOVAL AND INSTALLATION <SOHC 16-VALVE - CARBURETOR>

1

12 Nm

2

3

10

11

12 Nm

4

9

12

8

22 Nm

7

13

13 Nm

Removal steps

1. Water hose

2. Water hose

3. Water hose

"FA
"DA

4. Thermo valve

5. Engine coolant temperature gauge
unit

6. Water inlet fitting

"CA

"BA
"BA
"BA
"AA

23 Nm

7. Thermostat

8. Thermostat case

9. Gasket

10. Water inlet pipe

11. O-ring

12. O-ring

13. Water pump

5

6

E

Aug. 2000Mitsubishi Motors Corporation Added

PWEE9520-D

4G1 ENGINE (E - W) -

Water Pump and Water Hose

11A-6-1b

Intencionalmente en blanco

E

Aug. 2000Mitsubishi Motors Corporation Added

PWEE9520-D

11A-6-2

4G1 ENGINE (E - W) -

Water Pump and Water Hose

REMOVAL AND INSTALLATION <SOHC - MPI>

12 Nm

10

12

11

2

29 Nm

7

6

22 Nm

3

11 Nm

4

8

9

5

23 Nm

1

13 Nm

Removal steps

1. Water hose

2. Water hose

"EA
"DA

"CA

3. Engine coolant temperature sensor

4. Engine coolant temperature gauge
unit

5. Water inlet fitting

6. Thermostat

7. Thermostat case

"BA
"BA
"BA
"AA

8. Gasket

9. Water inlet pipe

10. O-ring

11. O-ring

12. Water pump

E

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520-D

4G1 ENGINE (E - W) -

Water Pump and Water Hose

11A-6-2a

REMOVAL AND INSTALLATION <SOHC 16-VALVE - MPI - FRONT WHEEL DRIVE>

2

12 Nm

1

9

12 Nm

10

12

13 Nm

11

29 Nm

23 Nm

3

8

7

4

6

5

11 Nm

22 Nm

Removal steps

1. Water hose

2. Water hose

"EA
"DA

"CA

E

E

3. Engine coolant temperature sensor

4. Engine coolant temperature gauge
unit

5. Water inlet fitting

6. Thermostat

7. Thermostat case

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

"BA
"BA
"BA
"AA

8. Gasket

9. Water inlet pipe

10. O-ring

11. O-ring

12. Water pump

11A-6-2b

4G1 ENGINE (E - W) -

Water Pump and Water Hose

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

25 Nm

29 Nm

11 Nm

1

12 Nm

11

2

12 Nm

18 Nm

5

6

10

7

9

3

8

4

12

13 Nm

Removal steps

1. Water hose

2. Water hose

"EA
"DA

3. Engine coolant temperature sensor

4. Engine coolant temperature gauge
unit

5. Water outlet fitting

6. Gasket

"CA

"BA
"BA
"AA

23 Nm

7. Thermostat

8. Fitting

9. Gasket

10. Water inlet pipe

11. O-ring

12. Water pump

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

4G1 ENGINE (E - W) -

Water Pump and Water Hose

REMOVAL AND INSTALLATION <DOHC>

12 Nm

2

12 Nm

10

9

11

11A-6-3

1

29 Nm

8

7

3

22 Nm

6

12

13 Nm

Removal steps

1. Water hose

2. Water hose

"EA
"DA

"CA

3. Engine coolant temperature sensor

4. Engine coolant temperature gauge
unit

5. Water inlet fitting

6. Thermostat

7. Thermostat case

"BA
"BA
"BA
"AA

23 Nm

8. Gasket

9. Water inlet pipe

10. O-ring

11. O-ring

12. Water pump

4

5

11 Nm

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

11A-6-4

4G1 ENGINE (E - W) -

Water Pump and Water Hose

REMOVAL AND INSTALLATION <DOHC - GDI>

29 Nm

22 Nm

1

12 Nm

8

5

12 Nm

23 Nm

11 Nm

4

8

6

3

2

22 Nm

7

9

13 Nm

Removal steps

"HA

"CA
"DA

1. Water outlet fitting

2. Water inlet fitting

3. Thermostat

4. Engine coolant temperature gauge
unit

"EA
"GA
"BA
"BA
"AA

5. Engine coolant temperature sensor

6. Thermostat housing

7. Water inlet pipe

8. O-ring

9. Water pump

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

4G1 ENGINE (E - W) -

INSTALLATION SERVICE POINTS

"AA

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

Water Pump and Water Hose

11A-6-5

WATER PUMP INSTALLATION

the mounting surface.

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or
equivalent.

"BA

O-RING / WATER PIPE INSTALLATION

(1) Replace the water inlet pipe O-rings with new ones, then

apply water to the O-rings so that they can be inserted
easily into the water pump and thermostat case.

Caution

1. Do not apply engine oil or any other oily substance
to the O-rings.

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

"CA

THERMOSTAT INSTALLATION

(1) Fit the thermostat such that its jiggle valve is at the top.

"DA

ENGINE COOLANT TEMPERATURE GAUGE UNIT
INSTALLATION

(1) If the engine coolant temperature gauge unit is to be

reused, apply the specified sealant to its thread.

Specified sealant:

3M ATD Part No. 8660 or equivalent.

"EA

ENGINE COOLANT TEMPERATURE SENSOR
INSTALLATION

(1) If the engine coolant temperature sensor is to be reused,

apply the specified sealant to its thread.

Specified sealant:

3M Nut Locking Part No. 4171 or equivalent.

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

11A-6-6

4G1 ENGINE (E - W) -

Water Pump and Water Hose

1EN0511

"FA

THERMO VALVE INSTALLATION

(1) If the thermo valve is to be reused, apply the specified

sealant to its thread.

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or
equivalent.

"GA

THERMOSTAT HOUSING INSTALLATION

(1) Remove the old liquid gasket from the cylinder head

(thermostat housing mounting surface) and the thermostat
housing.

(2) Apply liquid gasket to the thermostat housing mounting

surface by squeezing it to a thickness of 3 mm.

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or
equivalent.

Caution
Squeeze the liquid gasket uniformly so that there is
no break in the gasket nor is there too much gasket.

"HA

WATER OUTLET FITTING INSTALLATION

(1) Remove the old liquid gasket from the thermostat housing

(water outlet fitting mounting surface) and the water outlet
fitting.

(2) Apply liquid gasket to the water outlet fitting mounting

surface by squeezing it to a thickness of 3 mm.

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or
equivalent.

Caution
Squeeze the liquid gasket uniformly so that there is
no break in the gasket nor is there too much gasket.

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Added

PWEE9520

PWEE9520-D

4G1 ENGINE (E - W) -

Intake and Exhaust Manifolds

7. INTAKE AND EXHAUST MANIFOLDS

REMOVAL AND INSTALLATION <SOHC 12-VALVE - CARBURETOR>

1

3

4

8

11A-7-1

17 Nm

30 Nm

7

5

2

17 Nm

29 Nm

6

Removal steps

1. Engine hanger

2. Intake manifold stay

3. Intake manifold

4. Intake manifold gasket

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

5. Exhaust manifold cover

6. Engine hanger

7. Exhaust manifold

8. Exhaust manifold gasket

11A-7-2

4G1 ENGINE (E - W) -

Intake and Exhaust Manifolds

REMOVAL AND INSTALLATION <SOHC 16-VALVE - CARBURETOR>

1

3

4

8

17 Nm

30 Nm

7

17 Nm

5

29 Nm

2

29 Nm

19 Nm

6

Removal steps

1. Engine hanger

2. Intake manifold stay

3. Intake manifold

4. Intake manifold gasket

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

5. Exhaust manifold cover

6. Engine hanger

7. Exhaust manifold

8. Exhaust manifold gasket

4G1 ENGINE (E - W) -

Intake and Exhaust Manifolds

11A-7-2a

REMOVAL AND INSTALLATION <SOHC - CARBURETOR FOR CENTRAL AMERICA>

5

11

8

17 Nm

30 Nm

1

3

4

13 Nm

10

11 Nm

54 Nm

9

7

8

83 Nm

12

2

6

29 Nm

17 Nm

Removal steps

1. Engine hanger

2. Intake manifold stay

3. Intake manifold

4. Intake manifold gasket

5. Air hose

6. Exhaust manifold cover

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

"AA
"AA

7. Air pipe

8. Reed valve and bracket

9. Reed valve

10. Reed valve bracket “A”

11. Reed valve bracket “B”

12. Exhaust manifold

11A-7-2b

4G1 ENGINE (E - W) -

Intake and Exhaust Manifolds

REMOVAL AND INSTALLATION <SOHC 12-VALVE - MPI>

1

17 Nm

17 Nm

31 Nm

2

3

44 Nm

4

5

9

8

17 Nm

7

29 Nm

6

Removal steps

1. Engine hanger

2. Intake manifold stay

3. Intake manifold

4. Intake manifold gasket

5. Oxygen sensor <vehicles for Hong
Kong only>

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

6. Engine hanger

7. Exhaust manifold cover

8. Exhaust manifold

9. Exhaust manifold gasket

4G1 ENGINE (E - W) -

Intake and Exhaust Manifolds

11A-7-2c

REMOVAL AND INSTALLATION <SOHC 16-VALVE - MPI - FRONT WHEEL DRIVE
(FROM 2001 model for Europe)>

9Nm

17 Nm

9Nm

7

1

17 Nm

6

5Nm

30 Nm

10

2

5

13

30 Nm

12

4

18 Nm

17 Nm

31 Nm

3

Removal steps

1. Boost sensor

2. Engine hanger

3. Intake manifold stay

4. Intake manifold

5. Intake manifold gasket

6. Solenoid valve assembly

7. Solenoid valve assembly

8. Oxygen sensor

14

8

9

30 Nm

11

35 Nm

9. Engine hanger

10. Exhaust manifold cover

11. Exhaust monifold bracket A

12. Exhaust manifold

13. Exhaust manifold gasket

14. Exhaust manifold bracket B

35 Nm

35 Nm

44 Nm

19 Nm

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

11A-7-2d

4G1 ENGINE (E - W) -

Intake and Exhaust Manifolds

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

17 Nm

17 Nm

5Nm

1

31 Nm

6

9Nm

7

2

4

5

29 Nm

11

9

10

3

19 Nm

Removal steps

1. Boost sensor

2. Engine hanger

3. Intake manifold stay

4. Intake manifold

5. Intake manifold gasket

6. Solenoid valve assembly <Without
catalytic converter>

17 Nm

8

29 Nm

7. Solenoid valve assembly <With
catalytic converter>

8. Engine hanger

9. Exhaust manifold cover

10. Exhaust manifold

11. Exhaust manifold gasket

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

4G1 ENGINE (E - W) -

Intake and Exhaust Manifolds

11A-7-2e

REMOVAL AND INSTALLATION <SOHC 16-VALVE - MPI - FRONT WHEEL DRIVE
(EXCEPT FROM 2001 model FOR EUROPE)>

17 Nm

3

49 Nm

1

5

6

5Nm

9Nm

17 Nm

2

11

4

10

17 Nm

9

29 Nm

7

17 Nm

31 Nm

Removal steps

1. Boost sensor

2. Engine hanger

3. Power plant stay right <CVT>

4. Intake manifold stay

5. Solenoid valve assembly

6. Intake manifold

29 Nm

12

7. Intake manifold gasket

8. Engine hanger

9. Exhaust manifold cover

10. Exhaust manifold

11. Exhaust manifold gasket

12. Power plant stay left <CVT>

8

35 Nm

19 Nm

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Added

PWEE9520

PWEE9520-D

4G1 ENGINE (E-W) -

Intake and Exhaust Manifolds

REMOVAL AND INSTALLATION <DOHC>

1

3

4

17 Nm

11A-7-3

8

9

17 Nm

21 Nm

2

Removal steps

1. Engine hanger

2. Intake manifold stay

3. Intake manifold

4. Intake manifold gasket

5. Oxygen sensor

6

17 Nm

29 Nm

44 Nm

5

29 Nm

7

6. Exhaust manifold cover

7. Engine hanger

8. Exhaust manifold

9. Exhaust manifold gasket

E

Nov. 1995Mitsubishi Motors Corporation

PWEE9520

11A-7-4

4G1 ENGINE (E-W) -

Intake and Exhaust Manifolds

Reed valve and bracket

Pipe nut (reed valve side)

Air pipe

Reed valve
bracket “B”

Pipe nut (exhaust
manifold side)

Pipe clamp bolt

INSTALLATION SERVICE POINTS

"AA

(1) Insert the lower end of the air pipe into the exhaust

(2) Fit the upper end of the air pipe to the reed valve and

(3) Attach the reed valve and bracket assembly to the reed

(4) Tighten the nuts on both ends of the air pipe to the specified

(5) Tighten the reed valve and bracket mounting bolts to

(6) Tighten the pipe clamp bolt.

REED VALVE, BRACKET AND AIR PIPE
INSTALLATION

manifold, then tighten the pipe nut temporarily.

bracket assembly, then tighten the pipe nut temporarily.

valve bracket “B” and tighten the mounting bolts
temporarily.

torque.

Caution
The tightening torque of the reed valve side nut and
that of the exhaust manifold side nut are different
from each other.
Be sure to tighten each nut correctly to the specified
torque.

the specified torque.

E

E

Nov. 1995Mitsubishi Motors Corporation

July 1999Mitsubishi Motors Corporation Added

PWEE9520

PWEE9520-B

4G1 ENGINE (E - W) -

FUEL SYSTEM (GDI)

REMOVAL AND INSTALLATION

24 Nm

8

9.8 Nm

12 Nm

12 Nm

17 Nm

Fuel System (GDI)

2

5

4

3

11A-7a-1

9

11

10

15

23 Nm

13

14

12

19

21

18

16

20

22

23

17

6

1

7

Removal steps

1. Injector harness

"EA
"EA
"EA
"EA
"EA

"DA
"DA
"DA

E

E

2. Fuel pipe

3. Backup ring

4. O-ring

5. Backup ring

6. Fuel pump

7. O-ring

8. Flange

9. Fuel pressure sensor

10. O-ring

11. Backup ring

12. Harness bracket

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Added

PWEE9520

PWEE9520-D

"CA

"BA
"AA
"AA
"AA

13. Washer

14. Injector holder

15. Delivery pipe and injector

16. Insulator

17. Injector gasket

18. Corrugate washer

19. Backup ring

20. O-ring

21. Backup ring

22. Injector

23. Delivery pipe

11A-7a-2

Cut surface

Backup ring

4G1 ENGINE (E - W) -

INSTALLATION SERVICE POINTS

"AA

Install the backup rings and the O-rings on the injector. Install
the backup ring (thicker one) on the injector with the inside
cut surface facing the direction shown in the illustration.

BACKUP RING / O-RING INSTALLATION

Fuel System (GDI)

Corrugate washer

Matchmarks

"BA

CORRUGATE WASHER INSTALLATION

Apply white vaseline to the corrugate washer and install the
washer on the injector in the direction shown.

Caution
If the washer that has once been tightened is refused,
it will cause fuel leakage or gas leakage. Be sure
to use a new washer.

"CA

DELIVERY PIPE AND INJECTOR INSTALLATION

(1) Apply spindle oil or gasoline to injector O-rings.
(2) Insert the injector straight in the injector mounting hole

on the delivery pipe.

(3) Try to the turn the injector. If the injector dose not turn

smoothly, remove the injector and check the O-rings for
damage. If damage is evident, replace the O-rings and
reinstall the injector.

(4) Align the matchmark on the injector with that on the

delivery pipe.

(5) Install the delivery pipe and injector on the cylinder head

and tighten the bolts to the specified torque in the order
shown in the illustration.

3

1 2

4

"DA

BACKUP RING / O-RING / FUEL PRESSURE
SENSOR INSTALLATION

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

the inside cut surface facing the direction shown in the
illustration.

Cut surface

Backup ring

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Added

PWEE9520

PWEE9520-D

4G1 ENGINE (E - W) -

(2) Install the fuel pressure sensor in the direction shown,

paying attention to the shape of connector.

Fuel System (GDI)

11A-7a-3

Backup ring with
no directivity

Backup ring

O-ring

Cut surface

"EA

FUEL PUMP / BACKUP RING / O-RING / FUEL
PIPE INSTALLATION

(1) Apply engine oil to the roller and the O-ring of the fuel

pump.

(2) Insert the fuel pump in the mounting hole on the cylinder

head, and lightly tighten four bolts (a little more strongly
than you tighten them with fingers).

(3) Install the backup rings and the O-rings on both ends

of the fuel pipe. Install the backup ring (thicker one) with
the inside cut surface facing the direction shown in the
illustration.

(4) Apply spindle oil or gasoline to the O-rings on both ends

of the pipe.

(5) Insert the fuel pipe straight in the mounting hole on the

fuel pump. When the fuel pipe is inserted, use care not
to twist it and insert as far as it goes.

(6) Tighten the bolts on both ends of the pipe to the specified

torque.

(7) Using the torque wrench (minimum scale 0.5 Nm), tighten

the fuel pump mounting bolts by the following procedure.

1. Tighten the bolts to 4.9 Nm in the order as shown.

2. Tighten the bolts to 17 Nm in the order as shown.
The torque variation of the four bolts should be within
2 Nm.

Caution
Observe the tightening order. Failure to observe the
specified torques and tightening order will cause
leakage, etc.

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Added

PWEE9520

PWEE9520-D

4G1 ENGINE (E-W) -

Rocker Arms and Camshafts

8. ROCKER ARMS AND CAMSHAFTS

REMOVAL AND INSTALLATION <SOHC 12-VALVE>

1

3

4

2

5

7

6

4Nm

14

11A-8-1

9

31 Nm

12

11

15

10

8

13

16

19

20

21

15 Nm

18

17

22

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

"FA
"EA
"EA

E

E

8. Camshaft oil seal

9. Rocker arm and shaft assembly

10. Rocker arm and shaft assembly

11. Rocker arm A

Nov. 1995Mitsubishi Motors Corporation

Dec. 1998Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-A

"CA

12. Rocker arm spring

13. Rocker arm B

14. Rocker arm shaft

15. Rocker arm C

16. Wave washer

17. Spacer

18. Rocker arm D

19. Rocker arm shaft

20. Adjusting screw

21. Nut

22. Camshaft

11A-8-1a

4G1 ENGINE (E - W) -

Rocker Arms and Camshafts

REMOVAL AND INSTALLATION <SOHC 16-VALVE (With Adjusting screw)>

4

1

2

5

31 Nm

3.5 Nm

3

6

7

13

12

15

16

9Nm

9

10

14

11

18

19

20

9Nm

17

8

21

Apply engine oil to all
moving parts before
installation.

Removal steps

1. Breather hose

2. P.C.V. hose

3. Oil filler cap

4. P.C.V. valve

5. P.C.V. valve gasket

6. Rocker cover

7. Rocker cover gasket

8. Oil seal

"FA
"EA

"EA

E

E

9. Oil seal

10. Rocker arms and rocker arm shaft,
intake

11. Rocker arms and rocker arm shaft,
exhaust

Nov. 1995Mitsubishi Motors Corporation
Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

"DA
"CA

"DA
"CA

12. Rocker arm A

13. Rocker arm B

14. Rocker arm shaft

15. Adjusting screw

16. Nut

17. Rocker arm C

18. Rocker arm shaft

19. Adjusting screw

20. Nut

21. Camshaft

4G1 ENGINE (E - W) -

Rocker Arms and Camshafts

REMOVAL AND INSTALLATION <SOHC 16-VALVE (With Lash adjuster)>

2

11A-8-1b

4

1

5

3

3.5 Nm

31 Nm

10

6

14

11

7

17

13

12

15

9

Removal steps

1. Breather hose

2. P.C.V. hose

3. Oil filler cap

4. P.C.V. valve

5. P.C.V. valve gasket

6. Rocker cover

7. Rocker cover gasket

8. Oil seal

"FA

AA""EA

9. Oil seal

10. Rocker arms and rocker arm shaft,
intake

18

8

16

Apply engine oil to all
moving parts before
installation.

19

AA""EA

"DA
"IA

"DA
"IA

11. Rocker arms and rocker arm shaft,
exhaust

12. Rocker arm A

13. Rocker arm B

14. Rocker arm shaft

15. Lash adjuster

16. Rocker arm C

17. Rocker arm shaft

18. Lash adjuster

19. Camshaft

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

11A-8-2

4G1 ENGINE (E - W) -

Rocker Arms and Camshafts

REMOVAL AND INSTALLATION <DOHC>

Apply engine oil to all
moving parts before
installation.

2

1

10

4Nm

7

11 Nm

11

12

3

5

4

6

9

24 Nm

8

13

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

"HA

6. Rocker cover

7. Rocker cover gasket A

8. Rocker cover gasket B

14

15

"GA
"FA
"BA
"AA
"AA

AB""JA

9. Semi-circular packing

10. Camshaft oil seal

11. Bearing cap

12. Camshaft

13. Camshaft

14. Roller rocker arm

15. Lash adjuster

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

MD998443

4G1 ENGINE (E - W) -

REMOVAL SERVICE POINTS

AA"

Set special tool MD998443 to prevent the lash adjuster from
coming free and falling to the floor.

Rocker Arms and Camshafts

11A-8-2a

ROCKER ARMS AND ROCKER ARM SHAFTS
REMOVAL

Caution
If the lash adjuster is re-used, clean the lash adjuster.
(Refer to 11A-8-3.)

AB"

LASH ADJUSTER REMOVAL

Caution
If the lash adjuster is re-used, clean the lash adjuster.
(Refer to 11A-8-6.)

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Added

PWEE9520

PWEE9520-D

11A-8-2b

4G1 ENGINE (E - W) -

Rocker Arms and Camshafts

Intentionallyblank

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Added

PWEE9520

PWEE9520-D

4G1 ENGINE (E–W) – Rocker Arms and Camshafts

INSPECTION

1. CAMSHAFT

(1) Measure the cam heights and replace the camshaft if

any height exceeds the specified limit.

11A-8-3

Standard

Limit mm

value mm

Intake SOHC 12-VALVE*

SOHC 12-VALVE*
SOHC 16-VALVE*
SOHC 16-VALVE*
SOHC 16-VALVE*
SOHC 16-VALVE*

1

38.78 38.28

2

38.78 38.28

3

36.99 36.49

4

36.86 36.36

5

37.30 36.80

6

37.17 36.67

DOHC 34.67 34.17

Exhaust SOHC 12-VALVE*

SOHC 12-VALVE*
SOHC 16-VALVE*
SOHC 16-VALVE*
SOHC 16-VALVE*
SOHC 16-VALVE*

1

39.01 38.51

2

38.97 38.47

3

36.85 36.35

4

36.68 36.18

5

37.16 36.66

6

36.99 36.49

DOHC 34.26 33.76

*1: With low pollution system
*2: Without low pollution system
*3: Except 2001 model front wheel drive vehicles
*4: 2001 model front wheel drive vehicles for Europe
*5: 2001 model front wheel drive vehicles for General

Export

*6: 2002 model front wheel drive vehicles for Europe

2. LASH ADJUSTERS
(SOHC)

Caution

1. The lash adjusters are precision-engineered
mechanisms. Do not allow them to become
contaminated 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

To clean
outside

To clean
inside

To fill
diesel fuel

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.

A

E

E

B

C

Nov. 1995Mitsubishi Motors Corporation

Feb. 2001Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-E

11A-8-4

Wire or MD998442

4G1 ENGINE (E - W) -

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

Diesel fuel

(3) While gently pushing down the internal steel ball using

Diesel fuel

Rocker Arms and Camshafts

surface.

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

special tool MD998442, move the plunger through 5 to
10 strokes until it slides smoothly. In addition to eliminating
stiffness in the plunger, this 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.

Wire or MD998442

Diesel fuel

Diesel fuel

Wire or MD998442

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

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

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

down the internal steel ball using special tool MD998442
and move the plunger through 5 to 10 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.

E

E

Nov. 1995Mitsubishi Motors Corporation

Apr. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-C

Wire or MD998442

4G1 ENGINE (E - W) -

Wire or MD998442

Diesel fuel

Diesel fuel

Rocker Arms and Camshafts

11A-8-5

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

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

(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.

Wire or MD998442

Diesel fuel

(8) 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.

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

(10)Stand the lash adjuster upright to prevent diesel fuel from

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.

E

E

Nov. 1995Mitsubishi Motors Corporation

Apr. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-C

11A-8-6

To clean
outside

4G1 ENGINE (E - W) -

To clean
inside

To fill
diesel fuel

Rocker Arms and Camshafts

(DOHC)

Caution

1. The lash adjusters are precision-engineered
mechanisms. Do not allow them to become
contaminated 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.

A

B

C

(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

E

E

Nov. 1995Mitsubishi Motors Corporation

Apr. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-C

MD998442

4G1 ENGINE (E - W) -

(3) While gently pushing down the internal steel ball using

Diesel fuel

Rocker Arms and Camshafts

11A-8-6a

special tool MD998442, move the plunger through 5 to
10 strokes until it slides smoothly. In addition to eliminating
stiffness in the plunger, this 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.

MD998442

Diesel fuel

MD998442

Diesel fuel

MD998442

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

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

Caution
Make sure the oil hole in the side of the body is pointing
toward container A. Do not point the oil hole at yourself
or other people.

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

down the internal steel ball using special tool MD998442
and move the plunger through 5 to 10 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 the pressure chamber.

Caution
Make sure the oil hole in the side of the body is pointing
toward container B. Do not point the oil hole at yourself
or other people.

Diesel fuel

E

E

Nov. 1995Mitsubishi Motors Corporation

Apr. 2000Mitsubishi Motors Corporation Added

PWEE9520

PWEE9520-C

11A-8-6b

4G1 ENGINE (E - W) -

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

Rocker Arms and Camshafts

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.

MD998442

MD998442

Diesel fuel

Diesel fuel

(8) 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.

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

(10)Stand the lash adjuster upright to prevent diesel fuel from

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.

INSTALLATION SERVICE POINTS

"AA

Slit

E

E

Nov. 1995Mitsubishi Motors Corporation

Apr. 2000Mitsubishi Motors Corporation Added

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

CAMSHAFT INSTALLATION

installation. Ensure that the intake-side and exhaust-side
camshafts are not reversed.

NOTE
There is a 4 mm-wide slot in the rear end of the
exhaust-side camshaft.

PWEE9520

PWEE9520-C

4G1 ENGINE (E-W) -

Rocker Arms and Camshafts

11A-8-7

"BA

BEARING CAP INSTALLATION

(1) Position the camshaft dowel pins as shown.

NOTE
With the camshaft dowel pins in this position, the camshaft
notches for tightening cylinder head bolt are correctly
positioned.

(2) Bearing caps Nos. 2 to 5 are the same shape. Be sure

to install them in order of their cap numbers and check
the identification marks to ensure that the intake and
exhaust sides are not reversed.

Identification marks:

I: Intake
E: Exhaust

(3) Apply the specified sealant to the surfaces that are to

mate with the cylinder head. Then, tighten the bearing
cap bolts - for the middle caps first, then for the outer
caps, and soon. Tighten the bolts a little at a time such
that each bolt is tightened to the specified torque in the
final sequence.

Specified sealant:

3M ATD Part No. 8660 or equivalent

(4) Check that the rocker arms are installed correctly.

Chamfer

E

E

Oil holes

1 mm or less

"CA

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

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).

"DA

ROCKER ARM SHAFT INSTALLATION

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

flywheel side. <SOHC 12-VALVE>
Place the end with the larger chamfered side toward the
timing belt side. <SOHC 16-VALVE>

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

(2) Place the section of the shaft with the oil holes toward

the cylinder head.

Nov. 1995Mitsubishi Motors Corporation

Dec. 1998Mitsubishi Motors Corporation Added

PWEE9520

PWEE9520-A

11A-8-8

4G1 ENGINE (E-W) -

Rocker Arms and Camshafts

SOHC 12-VALVE

Timing belt side

Identification mark

SOHC 16-VALVE

Timing belt side

Identification
mark

SOHC

MD998713

"EA

ROCKER ARM / ROCKER SHAFT ASSEMBLY
INSTALLATION

(1) Assemble the rocker arms and rocker shaft, paying

attention to the identification marks. Then mount the
assembly on the cylinder head.

"FA

CAMSHAFT OIL SEAL INSTALLATION

DOHC

MD998713

E

E

Sealant

"GA

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

SEMI-CIRCULAR PACKING INSTALLATION

Specified sealant:

3M ATD Part No. 8660 or equivalent

DEN0053

Nov. 1995Mitsubishi Motors Corporation

Dec. 1998Mitsubishi Motors Corporation Added

PWEE9520

PWEE9520-A

4G1 ENGINE (E - W) -

Rocker Arms and Camshafts

11A-8-9

MD998443

Lash adjuster

"HA

ROCKER COVER INSTALLATION

(1) Apply the specified sealant to the area shown, then fit

the rocker cover.

Specified sealant:

3M ATD part No. 8660 or equivalent

"IA

LASH ADJUSTER INSTALLATION

(1) Insert the lash adjuster to rocker arm, being careful not

to spill diesel fuel. Use the special tool to prevent adjuster
from falling while installing it.

Caution
If the lash adjuster is re-used, clean the lash adjuster.
(Refer to 11A-8-3.)

"JA

LASH ADJUSTER INSTALLATION

Timing belt side

Thickness gauge

Caution
If the lash adjuster is re-used, clean the lash adjuster.
(Refer to 11A-8-6.)

Fit the lash adjuster onto the rocker arm without allowing
diesel fuel to spill out.

VALVE CLEARANCE ADJUSTMENT
<SOHC 12-VALVE>

(1) Position the No. 1 cylinder at top dead center on the

compression stroke.

(2) Adjust the valve clearance at the points shown in the

illustration.

(3) Loosen the adjusting screw locknut.
(4) Using a feeler gauge, adjust the valve clearance by turning

the adjusting screw.

Standard value: on cold engine

Intake 0.09 mm
Exhaust 0.17 mm

(5) While holding the adjusting screw with a screwdriver,

tighten the lock nut.

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

11A-8-10

4G1 ENGINE (E - W) -

Rocker Arms and Camshafts

Timing belt side

(6) Rotate clockwise the crankshaft one complete turn (360

degree).

(7) Adjust the valve clearance at points as shown in the

illustration.

(8) Repeat steps (3) to (5) to adjust the valve clearance

of remaining valves.

(9) With the engine mounted on vehicle, warm up the engine.

Then, check for valve clearance on hot engine and adjust
if necessary.

Standard value: on hot engine

Intake 0.20 mm
Exhaust 0.25 mm

_

Timing belt side

Thickness gauge

<SOHC 16-VALVE>

(1) Position the No. 1 cylinder at top dead center on the

compression stroke.

(2) Adjust the valve clearance at the points shown in the

illustration.

(3) Loosen the adjusting screw locknut.
(4) Using a feeler gauge, adjust the valve clearance by turning

the adjusting screw.

Standard value: on cold engine

Intake 0.09 mm
Exhaust 0.17 mm

(5) While holding the adjusting screw with a screwdriver,

tighten the lock nut.

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Revised

PWEE9520

PWEE9520-D

4G1 ENGINE (E - W) -

Rocker Arms and Camshafts

11A-8-11

Timing belt side

(6) Rotate clockwise the crankshaft one complete turn (360

degree).

(7) Adjust the valve clearance at points as shown in the

illustration.

(8) Repeat steps (3) to (5) to adjust the valve clearance

of remaining valves.

(9) With the engine mounted on vehicle, warm up the engine.

Then, check for valve clearance on hot engine and adjust
if necessary.

Standard value: on hot engine

Intake 0.20 mm
Exhaust 0.25 mm

_

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Added

PWEE9520

PWEE9520-D

4G1 ENGINE (E - W) -

Rocker Arms and Camshafts

ROCKER ARMS AND CAMSHAFTS (GDI)

REMOVAL AND INSTALLATION

11A-8a-1

3

6

3.5 Nm

2

4

5

7

11 Nm

3.5 Nm

25 Nm

8

9

12

11

13

15

14

Apply engine oil to all
moving parts before
installation.

Removal steps

1. Engine hanger

2. Breather hose

"FA

3. P.C.V. valve

4. Gasket

5. Oil filler cap

6. Inlet rocker cover

7. Gasket

8. Exhaust rocker cover

9. Gasket

10

16

17

"EA
"DA
"CA

"BA
"BA

AA""AA

19 Nm

1

10. Oil seal

11. Semi-circular packing

12. Beam camshaft cap

13. Gasket

14. Intake camshaft

15. Exhaust camshaft

16. Roller rocker arm

17. Lash adjuster

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Added

PWEE9520

PWEE9520-D

11A-8a-2

4G1 ENGINE (E - W) -

REMOVAL SERVICE POINT

AA"

INSTALLATION SERVICE POINTS

"AA

While using care not to spill diesel fuel in the lash adjuster,
install the lash adjuster on the rocker arm.

Rocker Arms and Camshafts

LASH ADJUSTER REMOVAL

Caution
If the lash adjuster is to be reused, be sure to clean
and inspect it before installation. (Refer to 11A-8a-4.)

LASH ADJUSTER INSTALLATION

Caution
If the lash adjuster is to be reused, be sure to clean
and inspect it before installation. (Refer to 11A-8a-4.)

Approx.

_

30

Approx.

_

17

"BA

EXHAUST CAMSHAFT / INTAKE CAMSHAFT
INSTALLATION

(1) Turn the crankshaft to place the No. 1 cylinder at top

dead center.

(2) Place dowel pins of the camshafts in the positions shown

in the illustration.

"CA

BEAM CAMSHAFT CAP INSTALLATION

(1) Remove deposits from the liquid gasket coating surfaces

of the beam camshaft cap and the cylinder head.

(2) Apply liquid gasket to the five grooves on the bottom

surface of the beam camshaft cap by squeezing it to
a thickness of 3 mm.

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or
equivalent.

NOTE
Install the beam camshaft cap within 15 minutes of
application of liquid gasket.

(3) Apply a suitable amount of liquid gasket to the ten positions

as shown on the top surface of the cylinder head.

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or
equivalent.

NOTE
Install the beam camshaft cap within 15 minutes after
application of liquid gasket.

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Added

PWEE9520

PWEE9520-D

4G1 ENGINE (E - W) -

Rocker Arms and Camshafts

11A-8a-3

Front of engine

MD998713

MD998762

(4) Install the beam camshaft and tighten the bolts to the

specified torque in the order shown in the illustration.

Tightening torque

11 Nm (M6)
25 Nm (M8)

(5) After tightening the bolts, completely wipe out the liquid

gasket that has overflowed the intake part before the
gasket is hardened (within 15 minutes after application
of liquid gasket).

"DA

SEMI-CIRCULAR PACKING INSTALLATION

Using the special tool, install the semi-circular packing.

"EA

OIL SEAL INSTALLATION

Using the special tool, install the oil seal.

"FA

P.C.V. VALVE INSTALLATION

Install the P.C.V. valve with its nipple directed as shown.

E

E

Nov. 1995Mitsubishi Motors Corporation

Aug. 2000Mitsubishi Motors Corporation Added

PWEE9520

PWEE9520-D