Mitsubishi ENGINE 4G9, ENGINE 4G6 SERVICE MANUAL

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Page 1

ENGINE

11A-1

CONTENTS

ENGINE <4G6> 11A............................................

ENGINE <4G9> 11B............................................

11109000276

Page 2

11A-2

ENGINE

<4G6>

CONTENTS

GENERAL INFORMATION 3..................

SERVICE SPECIFICATIONS 3.................

SEALANTS 4................................

SPECIAL TOOLS 5..........................

ON-VEHICLE SERVICE 6.....................

Drive Belt Tension Check and Adjustment 6......

Ignition Timing Check 10.......................

Idle Speed Check 11...........................

Idle Mixture Check 12..........................

Compression Pressure Check 13................

Manifold Vacuum Check 14.....................

Lash Adjuster Check 14........................

CRANKSHAFT PULLEY 17..................

CAMSHAFT AND CAMSHAFT OIL SEAL 18..

OIL PAN 22.................................

CRANKSHAFT OIL SEAL 24.................

CYLINDER HEAD GASKET 27...............

TIMING BELT AND TIMING BELT B 30......

ENGINE ASSEMBLY 37.....................

Page 3

ENGINE <4G6> -

General Information/Service Specifications

GENERAL INFORMATION

Items 4G64-GDI

Total displacement mL 2,350

Bore ´ Stroke mm 86.5 ´ 100.0

Compression ratio 11.5

Combustion chamber Pentroof + ball-in-piston

Camshaft arrangement DOHC

11A-3

Number of valve

V alve timing Intake

Fuel system Electronically controlled multipoint fuel injection

Rocker arm Roller type

Auto-lash adjuster Equipped

Intake 8

Exhaust 8

Opening BTDC 16_

Closing ABDC 60_

Exhaust

Opening BBDC 56_

Closing ATDC 16_

SERVICE SPECIFICATIONS

Items Standard value Limit

Alternator drive Vibration belt tension frequency Hz

Tension N

When checked 189 - 232 -

When a used belt is installed 201 - 222 -

When a new belt is installed 241 - 276 -

When checked 392 - 588 -

Deflection (Reference value) mm

When a used belt is installed 441 - 539 -

When a new belt is installed 637 - 833 -

When checked 6.7 - 9.0 -

When a used belt is installed 7.2 - 8.4 -

When a new belt is installed 5.0 - 6.4 -

Page 4

11A-4

Items LimitStandard value

ENGINE <4G6> -

Service Specifications/Sealants

Power steering Vibration oil pump and A/C compressor drive belt tension

Basic ignition timing 5_ BTDC ± 3_ -

Ignition timing Approx. 20_BTDC*

Idle speed r/min M/T 600 ± 100*

CO contents % 0.5 or less -

HC contents ppm 100 or less -

Compression pressure kPa - r/min 1,570 - 300 1,210 - 300

frequency Hz

Tension N

Deflection (Reference value) mm

A/T 650 ± 100 -

When checked 108 - 132 -

When a used belt is installed 114 - 126 -

When a new belt is installed 137 - 157 -

When checked 392 - 588 -

When a used belt is installed 441 - 539 -

When a new belt is installed 637 - 834 -

When checked 11.7 - 15.3 -

When a used belt is installed 12.5 - 14.3 -

When a new belt is installed 8.8 - 11.0 -

Compression pressure difference of all cylinder kPa - Max. 100

Intake manifold vacuum kPa - Min. 56*

Cylinder head bolt shank length mm - 99.4

Auto-tensioner push rod movement mm Within 1 -

Timing belt tension torque Nm (Reference value) 2.5 -

Auto-tensioner rod protrusion amount mm 3.8 - 4.5 -

NOTE

*1: Indicates the value measured within 4 minutes since the engine was started.

: Varies depending on the transmission oil temperature. For details, refer to P.11A-11.

: Indicates the value when more than 4 minutes have passed since the engine was started.

SEALANTS

Items Specified sealants Remarks

Beam camshaft cap Cylinder head

Cam position sensor support Oil pan

3M ATD Part No.8660 or equivalent -

MITSUBISHI GENUINE PART MD970389 or equivalent

Semi-drying sealant

Flywheel or drive plate bolt 3M Stud Locking 4170 or equivalent -

Page 5

ENGINE <4G6> -

Special Tools

SPECIAL TOOLS

Tool Number Name Use

11A-5

MB991502 MUT-II sub

assembly

MB991668 Belt tension meter

set

MB990767 End yoke holder D Holding the camshaft sprocket

MD998719 or MD998754

Crankshaft pulley holder pin

D Measuring the drive belt tension D Checking the ignition timing D Checking the idle speed D Erasing diagnosis code

Measuring the drive belt tension (used together with the MUT-II)

D Holding the crankshaft sprocket

D Holding the camshaft sprocket D Holding the crankshaft sprocket

MD998713 Camshaft oil seal

installer

MD998727 Oil pan remover Removal of oil pan

MD998781 Flywheel stopper Securing the flywheel

MD998776 Crankshaft rear oil

seal installer

Press-in of the camshaft oil seal

Press-in of the crankshaft rear oil seal

MB990938 Handle Press-in of the crankshaft rear oil seal

Page 6

11A-6

Tool UseNameNumber

ENGINE <4G6> -

Special Tools/On-vehicle Service

MD998382 Crankshaft front oil

seal installer

MD998285 Crankshaft front oil

seal guide

MD998767 Tension pulley

socket wrench

GENERAL SERVICE TOOL MZ203827

Engine lifter Supporting the engine assembly during

Installation of crankshaft front oil seal

Timing belt tension adjustment

removal and installation of the transmission

MB991453 Engine hanger

assembly

ON-VEHICLE SERVICE

DRIVE BELT TENSION CHECK AND ADJUSTMENT

ALTERNATOR DRIVE BELT TENSION CHECK

Check the drive belt tension in the following procedure.

Standard value:

Vibration frequency Hz 189 - 232

Tension N 392 - 588

Deflection (Reference value) mm 6.7 - 9.0

Page 7

ENGINE <4G6> -

On-vehicle Service

11A-7

MB991668 (Microphone)

Alternator pulley

10 - 20 mm

Water pump pulley

Crankshaft pulley

1. Connect the special tool (belt tension meter set) to the

MUT-II.

2. Connect the MUT-II to the diagnosis connector.

3. Turn the ignition switch to ON and select “Belt Tension Measurement” from the menu screen.

4. Hold the microphone to the middle of the drive belt between the pulleys (at the place indicated by the arrow), about 10 - 20 mm away from the rear surface of the belt and so that it is perpendicular to the belt (within an angle of ± 15_).

5. Gently tap the middle of the belt between the pulleys (the place indicated by the arrow) with your finger as shown in the illustration, and check that the vibration frequency of the belt is within the standard value.

Caution (1) The temperature of the surface of the belt should

be as close as possible to normal temperature.

(2) Do not let any contaminants such as water or

oil get onto the microphone.

(3) If strong gusts of wind blow against the

microphone or if there are any loud sources of noise nearby, the values measured by the microphone may not correspond to actual values.

(4) If the microphone is touching the belt while the

measurementis being made, the values measured by the microphone may not correspond to actual values.

(5) Do not take the measurement while the vehicle’s

engine is running.

Alternator pulley

Belt tension gauge

98 N

Water pump pulley

Crankshaft pulley

Water pump pulley

Crankshaft pulley

Use a belt tension gauge to check that the belt tension is within the standard value.

Apply 98 N of force to the middle of the drive belt between the pulleys (at the place indicated by the arrow) and check that the amount of deflection is within the standard value.

Page 8

11A-8

Adjusting bolt

Lock bolt

ENGINE <4G6> -

ALTERNATOR DRIVE BELT TENSION ADJUSTMENT

1. Loosen the nut of the alternator pivot bolt.

2. Loosen the lock bolt.

3. Use the adjusting bolt to adjust the belt tension and belt deflection to the standard values.

Standard value:

4. Tighten the nut of the alternator pivot bolt.

Tightening torque: 49 Nm

5. Tighten the lock bolt.

Tightening torque: 22 Nm

6. Tighten the adjusting bolt.

On-vehicle Service

Items When a used

belt is installed

Vibration frequency Hz 201 - 222 241 - 276

Tension N 441 - 539 637 - 833

Deflection (Reference value) mm

7.2 - 8.4 5.0 - 6.4

When a new belt is installed

Tightening torque: 5 Nm

Page 9

ENGINE <4G6> -

On-vehicle Service

11A-9

Oil pump pulley

98 N

Crankshaft pulley

Oil pump pulley

98 N

Crankshaft pulley

Tensioner pulley

A/C compressor pulley

POWER STEERING OIL PUMP AND AIR CONDITIONER COMPRESSOR DRIVE BELT TENSION CHECK AND ADJUSTMENT

11100130127

1. Check if the belt tension is within the standard value using one of the methods below.

Standard value:

Items When

checked

Vibration frequency Hz

Tension N 392 - 588 441 - 539 637 - 834

Deflection (Reference value) mm

108 - 132 114 - 126 137 - 157

11.7 - 15.3 12.5 - 14.3 8.8 - 11.0

When a used belt is installed

When a new belt is installed

With your finger tip lightly tap the centre of the belt between the pulleys in t he location shown by the arrow in the illustration and then measure the belt vibration frequency.

NOTE Refer to P.11A-7 for information regarding the vibration

frequency measurement method using MUT-II.

Use a belt tension gauge to measure the belt tension.

Apply 98 N of pressure against the location between the pulleys shown by the arrow in the illustration and then measure the deflection.

2. If the tension or deflection is outside the standard value, adjust by the following procedure.

(1) Loosen tensioner pulley fixing nut A. (2) Adjust the amount of belt deflection using adjusting

bolt B.

(3) Tighten fixing nut A.

Tightening torque: 25 Nm

(4) Check the belt deflection amount and tension, and

readjust if necessary.

Caution Check after turning the crankshaft once or more clockwise (right turn).

Page 10

11A-10

ENGINE <4G6> -

On-vehicle Service

Idle speed r/min

900

800

700

600

-10 20 50

Transmission oil temperature_C

IGNITION TIMING CHECK

1. Before inspection, set the vehicle to the pre-inspection condition. For vehicles with manual transmission, drive the vehicle for 15 minutes or more to warm the engine, and then carry out the checking while the transmission oil temperature is more than 50°C.

NOTE The idle speed in vehicles with manual transmission varies as shown in the illustration in accordance with the transmission oil temperature.

2. Turn off the ignition switch and then connect the MUT-II

to the diagnosis connector.

3. Set the timing light to the power supply line (terminal No.1) of the ignition coil No.1.

No.1 ignition coil

NOTE The power supply line is looped and also longer than the other ones.

4. Start the engine a nd let it run at idle.

5. Use the MUT-II to measure engine idle speed and check

that it is within the standard value.

Standard value:

Items Idle speed r/min

M/T 600±100 (700±100)*

A/T 650±100 (700±100)*

NOTE *: Indicates the values when more than 4 minutes have

passed since the idling condition was started.

6. Select No.17 of the MUT-II Actuator test.

NOTE At this time, the engine speed will become approximately 700 r/min.

7. Check that basic ignition timing is within the standard value.

Standard value: 5_BTDC±3

8. If the basic ignition timing is outside the standard value, inspect the GDI system while referring to GROUP 13A Troubleshooting.

Page 11

ENGINE <4G6> -

9. Press the MUT-II clear key (Select a forced driving cancel

mode) to release the Actuator test.

Caution If the test is not cancelled, a forced driving will continue for 27 minutes. Driving under this condition may damage the engine.

10. Check that ignition timing is at the standard value.

Standard value: approx. 20_BTDC

NOTE (1) The ignition timing will become approximately 5_BTDC

(2) The ignition timing may fluctuate within ±7_BTDC.

(3) In higher altitude, the ignition timing is more advanced

11. Remove the timing light.

12. Turn off the ignition switch and then remove the MUT-II.

On-vehicle Service

11A-11

after more than 4 minutes have passed since the basic ignition timing set mode was released.

This is normal.

than the standard value by approximately 5 degree.

Idle speed r/min

900

800

700

600

-10 20 50

Transmission oil temperature_C

IDLE SPEED CHECK

NOTE The idle speed in vehicles with manual transmission varies as shown in the illustration in accordance with the transmission oil temperature.

2. Turn off the ignition switch and then connect the MUT-II

to the diagnosis connector.

3. Check the basic ignition timing.

NOTE Refer to P.11A-10 concerning the check procedure of the basic ignition timing.

Standard value: 5_BTDC±3

4. Run the engine at idle for 2 minutes.

Page 12

11A-12

ENGINE <4G6> -

5. Check the idle speed. Select item No. 22 and take a reading of the idle speed.

Standard value:

NOTE (1) *: Indicates the values when more than 4 minutes

(2) The idle speed is controlled automatically by the idle

6. If the idle speed is outside the standard value, inspect the GDI components by referring to GROUP 13A Troubleshooting.

IDLE MIXTURE CHECK

1. Before inspection, set the vehicle to the pre-inspection condition.

2. Connect the MUT-II to the diagnosis connector.

3. Check that the basic ignition timing is within the standard value.

NOTE Refer to P.11A-10 concerning the check procedure of the basic ignition timing.

Standard value: 5_BTDC ± 3

4. Run the engine at 2,500 r/min for 2 minutes.

5. Set t he CO, HC tester.

6. Check the CO contents and the HC contents at idle.

NOTE This measurement should be performed in less than approximately 4 minutes since the engine speed become the idle speed.

Standard value

7. If there is a deviation from the standard value, check t he following items:

D Diagnosis output D Fuel pressure D Injector D Ignition coil, spark plug D EGR control system D Evaporative emission control system D Compression pressure

NOTE Replace the three way catalyst when the CO and HC contents are not within the standard value, even though the result of the inspection is normal on all items.

On-vehicle Service

Items Idle speed r/min

M/T 600±100 (700±100)*

A/T 650±100 (700±100)*

have passed since the idling condition was started.

speed control system.

CO contents: 0.5% or less HC contents: 100 ppm or less

Page 13

Crank angle sensor connector

ENGINE <4G6> -

COMPRESSION PRESSURE CHECK

1. Before inspection, check that the engine oil, starter and battery are normal. In addition, set the vehicle to the pre-inspection condition.

2. Remove all of t he ignition coils and spark plugs.

3. Disconnect the crank angle sensor connector.

NOTE Doing this will prevent the engine-ECU from carrying out ignition and fuel injection.

4. Cover the spark plug hole with a shop towel etc., and after the engine has been cranked, check that no foreign material is adhering to the shop towel.

Caution (1) Keep away from the spark plug hole when

(2) If compression is measured with water, oil, fuel,

On-vehicle Service

cranking. etc.,that has comefrom cracks inside the cylinder,

these materials will become heated and will gush out from the spark plug hole, which is dangerous.

11A-13

Compression gauge

5. Set compression gauge to one of the spark plug holes.

6. Crank the engine with the throttle valve fully open and measure the compression pressure.

Standard value (at engine speed of 300 r/min):

1,570 kPa

Limit (at engine speed of 300 r/min):

Min. 1,210 kPa

7. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit.

Limit: Max. 100 kPa

8. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps 6 and 7.

(1) If the compression increases after oil is added, the

cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface.

(2) If the compression does not rise after oil is added,

the cause is a burnt or defective valve seat, or pressure is leaking from the gasket.

9. Connect the crank angle sensor connector.

10. Install the spark plugs and ignition coils.

11. Use the MUT-II to erase the diagnosis codes.

NOTE This will erase the diagnosis code resulting from the crank angle sensor connector being disconnected.

Page 14

11A-14

ENGINE <4G6> -

Vacuum gauge

Plug

On-vehicle Service

MANIFOLD VACUUM CHECK

1. Before inspection, set the vehicle to the pre-inspection condition.

2. Disconnect the ventilation hose from the positive crankcase ventilation (PCV) valve, and then connect a vacuum gauge to the ventilation hose.

3. Check the intake manifold vacuum while the engine is idling.

Limit: Min. 56 kPa

LASH ADJUSTER CHECK

If an abnormal noise (knocking) that seems to be coming from the lash adjuster is heard after starting the engine and does not stop, carry out the following check.

NOTE (1) The abnormal noise which is caused by a problem

with the lash adjusters is generated after the engine is started, and will vary according to the engine speed. However, this noise is not related to the actual engine load. Because of this, if the noise does not occur immediately after the engine is started, if it does not change in accordance with the engine speed, or if it changes in accordance with the engine load, the source of the noise is not th e lash adjusters.

(2) If there is a problem with the lash adjusters, the noise

will almost never disappear, even if the engine has been run at idle to let it warm up. The only case where the noise might disappear is if the oil in the engine has not been looked after properly and oil sludge has caused the lash adjusters to stick.

1. Start the engine.

2. Check that the noise occurs immediately after the engine is started, and that the noise changes in accordance with changes in the engine speed. If the noise does not occur immediately after the engine is started, or if it does not change in accordance with the engine speed, the problem is not being caused by the lash adjusters, so check for some other cause of the problem. Moreover, if the noise does not change in accordance with the engine speed, the cause of the problem is probably not with the engine. (In these cases, the lash adjusters are normal.)

3. While the engine is idling, check that the noise level does not change when the engine load is varied (for example, by shifting from N ® D). If the noise level changes, the cause of the noise is probably parts striking because of worn crankshaft bearings or connecting rod bearings. (In such cases, the lash adjusters are normal.)

Page 15

ENGINE <4G6> -

4. After the engine has warmed up, run it at idle and check if any noise can be heard. If t he noise has become smaller or disappeared, oil sludge could make the lash adjusters stick. Clean the lash adjusters. (Refer to the Engine Workshop Manual.) If not improved, go to step 5.

5. Bleed air from the lash adjusters. (Refer to P.11A-15.)

6. If the noise has not disappeared even after the air bleeding, clean the lash adjusters. (Refer to the Engine Workshop Manual.)

NOTE (1) If the vehicle is parked on a slope for a long period

(2) After parking the vehicle for long periods, the oil drains

(3) If either of the above situations occur, the abnormal

On-vehicle Service

of time, the amount of oil inside the lash adjuster will decrease, and air may get into the high pressure chamber when starting the engine.

out of the oil passage, and it takes time for the oil to be supplied to the lash adjuster, so air can get into the high pressure chamber.

noise can be eliminated by bleeding the air from inside the lash adjusters.

11A-15

Good

1. Check the engine oil and replenish or replace the oil if necessary.

NOTE (1) If there is a only small amount of oil, air will be drawn

in through the oil screen and will get into the oil passage.

(2) If the amount of oil is greater than normal, then the

oil will being mixed by the crankshaft an d a large amount of air may get mixed into the oil.

(3) If the oil is degenerated, air and oil will not separate

easily in oil, and the amount of air mixed into the oil will increase.

Page 16

11A-16

ENGINE <4G6> -

High-pressure chamber

On-vehicle Service

(4) If the air which has been mixed in with the oil due

to any of the above reasons gets into the high pressure chamber of the lash adjuster, the air inside the high pressure chamber will be compressed when the valve is open and the lash adjuster will over-compress, resulting in abnormal noise when the valve closes. This is the same effect as if the valve clearance is adjusted to be too large by mistake. If the air inside the lash adjusters is then released, the operation of the lash adjusters will return to normal.

Drive pattern for air bleeding

Gradually open the throttle valve.

Approx. 3,000 r/min

Idle speed

15 seconds

Once

Close the throttle valve.

15 seconds

2. Run the engine at idle for 1 - 3 minutes to let it warm up.

3. With no load on the engine, repeat the drive pattern shown in the illustration at left and check if the abnormal noise disappears. (The noise should normally disappear after 10 - 30 repetitions, but if there is no change in the noise level after 30 repetitions or more, the problem is probably not due to air inside the lash adjusters.)

4. After the noise has disappeared, repeat the drive pattern shown in the illustration at left a further 5 times.

5. Run the engine at idle for 1 - 3 minutes and check that the noise has disappeared.

Page 17

ENGINE <4G6> -

Crankshaft Pulley

11A-17

CRANKSHAFT PULLEY

REMOVAL AND INSTALLATION

Pre-removal Operation

Under Cover Removal

11200160303

Post-installation Operation

D Drive Belt Tension Adjustment (Refer to P.11A-6.) D Under Cover Installation

25 Nm

Removal steps

1. Drive belt (Power steering and A/C)

2. Drive belt (Alternator)

3. Crankshaft pulley

Page 18

11A-18

ENGINE <4G6> -

Camshaft and Camshaft Oil Seal

CAMSHAFT AND CAMSHAFT OIL SEAL

REMOVAL AND INSTALLATION

Pre-removal Operation

D Air Intake Hose Assembly Removal D Timing Belt Removal (Refer to P.11A-30.) D Engine Coolant Draining D Intake Manifold Removal (Refer to GROUP 15.) D Fuel Pump (High Pressure) Removal (Refer to

GROUP 13A.)

10 Nm

Post-installation Operation

D Fuel Pump (High Pressure) Installation (Refer to

GROUP 13A.)

D Intake Manifold Installation (Refer to GROUP 15.) D Timing Belt Installation (Refer to P.11A-30.) D Air Intake Hose Assembly Installation D Engine Coolant Supplying D Drive Belt Tension Adjustment (Refer to P.11A-6.)

11200190418

3.4 Nm

22 Nm

12 - 15 Nm

19 - 21 Nm

9Nm

10 - 12 Nm

88 Nm

"EA

AA""DA

Removal steps

1. Cam position sensor

2. Cover

3. Gasket

4. Camshaft position sensing cylinder

5. Camshaft position sensor support

6. Camshaft sprocket

7. Timing belt rear cover

"CA "BA

"AA

8. Rocker cover

9. Rocker cover gasket

10. Camshaft oil seal

11. Beam camshaft cap

12. Beam camshaft cap gasket

13. Camshaft

Page 19

ENGINE <4G6> -

Lubrication points

Sealant: 3M ATD Part No.8660 or equivalent

Camshaft and Camshaft Oil Seal

f3mm

11A-19

Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

Lip section

Engine oil

Sealant: 3M ATD Part No.8660 or equivalent

Page 20

11A-20

MB990767

MD998715 or MD998719

ENGINE <4G6> -

Camshaft and Camshaft Oil Seal

REMOVAL SERVICE POINTS

AA"

CAMSHAFT SPROCKET REMOVAL

Camshaft sprocket side

Exhaust camshaft

Approx. 12

Intake side

Dowel pin

19 23

Screw hole

Exhaust side

INSTALLATION SERVICE POINTS

"AA

1. Apply engine oil to journals and cams of the camshafts.

2. Install the camshafts on the cylinder head.

"BA

1. Place the camshaft dowel pin as shown in the illustration.

2. Tighten the beam camshaft cap mounting bolts to the

CAMSHAFT INSTALLATION

Caution Be careful not to confuse the intake camshaft with the exhaust one. There is a screw hole for the cam position sensing cylinder mounting bolt on the exhaust-side camshaft.

BEAM CAMSHAFT CAP INSTALLATION

specified torque in the order shown in the illustration.

Tightening torque: 19 - 21 Nm

21 17

15 16

910

Page 21

ENGINE <4G6> -

Camshaft and Camshaft Oil Seal

11A-21

MD998713

"CA

CAMSHAFT OIL SEAL INSTALLATION

1. Apply engine oil to the entire circumference of the oil seal lip.

2. Press-fit the oil seal as shown in the illustration.

"DA

CAMSHAFT SPROCKET INSTALLATION

Use the special tool to secure the camshaft sprocket in the same way as during removal, and then tighten the bolt to the specified torque.

Tightening torque: 88 Nm

Dowel pin

"EA

Position the identification paint of cam position sensing

CAM POSITION SENSING CYLINDER INSTALLATION

cylinder as shown in the illustration.

Identification paint

Page 22

11A-22

ENGINE <4G6> -

Oil Pan

OIL PAN

REMOVAL AND INSTALLATION

Pre-removal a nd Post-installation Operation

D Under Cover Removal and Installation D Engine Oil Draining and Supplying (Refer to GROUP

12 - On-vehicle Service.)

f 4 ± 1mm

Groove

Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

Bolt hole

9Nm

11200280207

D Oil Level Gauge Removal and Installation D Front Exhaust Pipe Removal and Installation (Refer

to GROUP 15.)

39 Nm

"AA

MD998727

Removal steps

1. Drain plug

2. Drain plug gasket

3. Transmission stay

MD998727

9Nm

44 Nm

22 Nm

4. Bell housing cover

AA"

5. Oil level sensor

6. Oil pan

REMOVAL SERVICE POINT

AA"

After removing the oil pan mounting bolts, remove the oil pan with the special tool and a brass bar.

Caution Perform this slowly to avoid deformation of the oil pan flange.

OIL PAN REMOVAL

Page 23

Drain plug gasket

Oil pan side

ENGINE <4G6> -

INSTALLATION SERVICE POINT

"AA

Install the drain plug gasket in the direction so that it faces as shown in the illustration.

DRAIN PLUG GASKET INSTALLATION

Oil Pan

11A-23

Page 24

11A-24

ENGINE <4G6> -

Crankshaft Oil Seal

CRANKSHAFT OIL SEAL

REMOVAL AND INSTALLATION

<M/T>

<A/T>

11200310135

127-137 Nm

Lip section

Engine oil

"CA

Lip section

Crankshaft front oil seal removal steps

Timing belt (Refer to P.11A-30.)

1. Crankshaft sprocket B

2. Key

3. Crankshaft front oil seal

<A/T>

Crankshaft

(Engine oil: bolt washer surface)

<M/T>

Crankshaft

Sealant: 3M Stud locking 4170 or equivalent

Crankshaft rear oil seal removal steps

AA"D

AB""BA AB""BA AB""BA AB""BA

"AA

Transmission assembly

Clutch cover and disc <M/T>

4. Adapter plate

5. Flywheel <M/T>

6. Drive plate <A/T>

7. Adapter plate <M/T> 8 Crankshaft bushing <A/T>

9. Crankshaft rear oil seal

(Engine oil: bolt washer surface)

Page 25

ENGINE <4G6> -

Crankshaft Oil Seal

11A-25

<M/T>

Flywheel

Crankshaft rear oil seal

MD990938

MD998781

Bolt

Crankshaft

REMOVAL SERVICE POINTS

AA"

<M/T>: Refer to GROUP 22.

Caution Do not remove the flywheel mounting bolt shown by the arrow. If this bolt Is removed, the flywheel will become out of balance and damaged.

<A/T>: Refer to GROUP 23.

AB"

Use the special tool to secure the flywheel or drive plate, and remove the bolts.

TRANSMISSION ASSEMBLY REMOVAL

ADAPTER PLATE/FLYWHEEL <M/T>/DRIVE

PLATE <A/T> REMOVAL

INSTALLATION SERVICE POINTS

"AA

1. Apply a small mount of engine oil to the entire

2. Install the oil seal by tapping it as far as the chamfered

CRANKSHAFT REAR OIL SEAL INSTALLATION

circumference of the oil seal lip.

position of the oil seal case as shown in the illustration.

MD998776

Page 26

11A-26

ENGINE <4G6> -

Crankshaft Oil Seal

Crankshaft

Oil seal

"BA

DRIVE PLATE <A/T>/FLYWHEEL <M/T>/ADAPTER PLATE INSTALLATION

1. Clean off all sealant, oil and other substances which are adhering to the threaded bolts, crankshaft thread holes and the flywheel or drive plate.

2. Apply oil to the bearing surface of the flywheel or drive plate bolts.

3. Apply oil to the crankshaft thread holes.

4. Apply sealant to the threaded mounting holes.

Specified sealant: 3M Stud locking 4170 or equivalent

5. Use the special tool to hold the flywheel or drive plate in the same manner as removal, and install the bolt.

"CA

CRANKSHAFT FRONT OIL SEAL INSTALLATION

1. Apply a small amount of engine oil to the entire circumference of the oil seal lip.

2. Use the special tool to press-fit the oil seal unit it is flush with the oil seal case.

MD998382

MD998285 (Apply oil to entire circumference)

Page 27

ENGINE <4G6> -

Cylinder Head Gasket

11A-27

CYLINDER HEAD GASKET

REMOVAL AND INSTALLATION

Pre-removal a nd Post-installation Operation

D Fuel Discharge Prevention (Refer to GROUP 13A

- On-vehicle Service.) <Pre-removal only>

D Engine Coolant Draining and Supplying (Refer to

GROUP 14 - On-vehicle Service.)

D Engine Oil Draining and Supplying (Refer to GROUP

12 - On-vehicle Service.)

D Intake Manifold Removal and Installation (Refer to

GROUP 15.)

78 Nm®0Nm®20 Nm®+90

_ ®

+90

11200400542

D Fuel Pressure Regulator (High Pressure) and Fuel

Pump (High Pressure) Removal and Installation (Refer to GROUP 13A.)

D Thermostat Case Assembly Removal and Installation

(Refer to GROUP 14 - Water Hose and Pipe.)

D Timing Belt Removal and Installation (Refer to

P.11A-30.)

3.4 Nm

24 Nm

Removal steps

1. Injector harness connector

2. Front exhaust pipe connection

3. Water hose connection

4. Water pipe assembly mounting bolt

5. EGR valve and stay assembly

AA""BA

"AA

44 Nm

34 Nm

6. Engine oil level gauge

7. Rocker cover

8. Cylinder head bolt

9. Cylinder head assembly

10. Cylinder head gasket

Page 28

11A-28

MB991653

Intake side Front of engine

35108 2

1796 4

Exhaust side

ENGINE <4G6> -

REMOVAL SERVICE POINT

AA"

Use the special tool to loosen the bolts in two or three steps in the order of the numbers shown in the illustration, and then remove the bolts. If the washer is caught on valve spring and the bolt is not removed, pull up the bolt slightly and remove the bolt while tilting the washer by using a magnet, etc.

Cylinder Head Gasket

CYLINDER HEAD BOLT REMOVAL

INSTALLATION SERVICE POINTS

"AA

1. Wipe off all oil and grease from the gasket mounting

2. Install so that the shapes of the cylinder head holes match

"BA

Burred side

Head bolt

washer

Cylinder head

Head bolt

(Engine oil)

1. When installing the cylinder head bolts, the length below

2. The head bolt washer should be installed with the burred

3. Apply a small amount of engine oil to the thread section

CYLINDER HEAD GASKET INSTALLATION

surface.

the shapes of the respective cylinder head gasket holes.

CYLINDER HEAD BOLT INSTALLATION

the head of the bolts should be within the limit. If it is outside the limit, replace the bolts.

Limit (A): 99.4 mm

side caused by tapping out facing upwards.

and the washer of the cylinder head bolt.

Page 29

ENGINE <4G6> -

4. Tighten the bolts by the following procedure.

Step Operation Remarks

Cylinder Head Gasket

1 Tighten to 78 Nm. Carry out in the order

shown in the illustration.

2 Fully loosen. Carry out in the reverse

order of that shown in the illustration.

11A-29

MB991653

Intake side Front of engine

861 3 9

104257

Exhaust side

Step 4

Painted mark

Step 5

Painted mark

3 Tighten to 20 Nm. Carry out in the order

shown in the illustration.

4 Tighten 90_of a turn. In the order shown in the

illustration. Mark the head of the cylinder head bolt and cylinder head by paint.

5 Tighten 90_of a turn. In the order shown in the

illustration. Check that the painted mark of the head bolt is lined up with that of the cylinder head.

Caution

1. Always make a tightening angle just 90_. If it is less than 90_, the head bolt will be loosened.

2. If it is more than 90_, remove the head bolt and repeat the procedure from step 1.

Page 30

11A-30

ENGINE <4G6> -

Timing Belt and Timing Belt B

TIMING BELT AND TIMING BELT B

REMOVAL AND INSTALLATION

Pre-removal a nd Post-installation Operation

D Engine Cover Removal and Installation D Under Cover Removal and Installation D Crankshaft Pulley Removal and Installation (Refer to

P.11A-17.)

48 Nm

24 Nm

11200430473

D Engine Mount Bracket Removal and Installation (Refer

to GROUP 32 - Engine Mounting.)

22 Nm

9Nm

10-12 Nm

9Nm

19 Nm

108-127 Nm

9Nm

AA""EA

"FAD

"DA

Removal steps

1. Water pump pulley

2. Timing belt front upper cover

3. Timing belt front lower cover Timing belt tension adjustment

4. Timing belt

5. Auto tensioner

AB""CA

"BA "AA

AC""AA

6. Tensioner pulley assembly

7. Crankshaft position sensor

8. Crankshaft sprocket

9. Crankshaft sensing blade

10. Timing belt B tensioner

11. Timing belt B

Page 31

ENGINE <4G6> -

Timing Belt and Timing Belt B

11A-31

Crankshaft sprocket

Timing marks

MD998719 or MD998754

Centre bolt

REMOVAL SERVICE POINT

AA"

1. Turn the crankshaft clockwise (right turn) to align each

2. Loosen the tension pulley centre bolt.

3. Move the tension pulley to the water pump side, and

AB"

TIMING BELT REMOVAL

timing mark and to set the No. 1 cylinder at compression top dead centre.

Caution The crankshaft should always be turned only clockwise.

then remove the timing belt.

Caution If the timing belt is to be re-used, use chalk to mark (on its flat side) an arrow indicating the clockwise direction.

CRANKSHAFT SPROCKET REMOVAL

MB990767

AC"

TIMING BELT B REMOVAL

Caution If timing belt B is to be re-used, use chalk to mark it with an arrow on its flat side indicating the turning direction (to the right).

Page 32

11A-32

ENGINE <4G6> -

Timing Belt B and Timing Belt B

Counterbalance shaft sprocket

Timing marks

Crankshaft sprocket B

Centre of tensioner pulley

Centre of installation bolt

Shaft

Belt tension side

Timing marks

INSTALLATION SERVICE POINTS

"AA

1. Install timing belt B by the following procedure.

2. Adjust the tension of timing belt B by the following

TIMING BELT B/TIMING BELT B TENSIONER INSTALLATION

(1) Ensure that crankshaft sprocket B timing mark and

the counterbalance shaft sprocket timing mark are aligned.

(2) Fit timing belt B over crankshaft sprocket B and the

counterbalance shaft sprocket. Ensure that there is no slack in the belt.

procedure. (1) Temporarily fix the timing belt B tensioner such that

the centre of the tensioner pulley is to the left and above the centre of the installation bolt, and temporarily attach the tensioner pulley so that the flange is toward the front of the engine.

(2) Holding the timing belt B tensioner up with your finger

in the direction of the arrow, place pressure on t he timing belt so that the tension side of the belt is taut. Now tighten the bolt to fix the tensioner.

Caution Whentightening thebolt, ensure thatthe tensioner pulley shaft does not rotate with the bolt. Allowing it to rotate with the bolt can cause excessive tension on the belt.

Centre of tensioner pulley

Centre of installation bolt

Crankshaft sprocket

Crankshaft sensing blade

Crankshaft

Crankshaft sprocket B

3. To ensure that the tension is correct, depress the belt (point A) with a finger. If not, adjust.

Standard value: 5 - 7 mm

"BA

CRANKSHAFT SENSING BLADE INSTALLATION

Confirm the installation direction of crankshaft sensing blade and install it as shown in the illustration.

Page 33

ENGINE <4G6> -

Timing Belt and Timing Belt B

11A-33

Auto tensioner

98 - 196N

Movement

Push rod

"CA

CRANKSHAFT SPROCKET INSTALLATION

1. Apply the minimum amount of engine oil to the seat surface and thread of the crankshaft bolt.

2. Hold the crankshaft sprocket as same as for removal, and then tighten the bolt to the specified torque.

Tightening torque: 108 - 127 Nm

"DA

AUTO TENSIONER INSTALLATION

1. Apply 98 - 196 N force to the auto tensioner by pressing it against a metal (cylinder block, etc.), and measure the movement of the push rod.

Standard value: Within 1 mm

A: Length when it is free (not pressed) B: Length when it is pressed A - B: Movement

2. If it is out of the standard value, replace the auto tensioner.

3. Use a press or vice to gently compress the auto tensioner push rod until pin hole A of the push rod and pin hole B of the tensioner cylinder are aligned.

Set pin

Caution If the compression speed is too fast, the rod may become damaged, so be sure to carry out this operation slowly.

4. Once the holes are aligned, insert the set pin.

NOTE When replacing the auto tensioner with a new part, the pin will be in the auto tensioner.

5. Install the auto tensioner to the engine.

Page 34

11A-34

ENGINE <4G6> -

Timing Belt and Timing Belt B

Timing marks

Crankshaft sprocket

Timing marks

Plug

60 mm or more

Counterbalance shaft

Camshaft sprocket

Timing marks

Oil pump sprocket

8mm

Screwdriver

Cylinder block

"EA

TIMING BELT INSTALLATION

1. Align the timing marks on the camshaft sprocket, crankshaft sprocket and oil pump sprocket.

2. After aligning the timing mark on the oil pump sprocket, remove the cylinder block plug and insert a Phillips screwdriver with a diameter of 8 mm, and check to be sure that the screwdriver goes in 60 mm or more. If the screwdriver will only go in 20 - 25 mm before striking the counterbalance shaft, turn the sprocket once, realign the timing mark and check that the screwdriver goes in 60 mm or more. The screwdriver should not be taken out until the timing belt is installed.

Intake camshaft sprocket

Tensioner pulley

Crankshaft sprocket

Exhaust camshaft sprocket

Idler pulley

Oil pump sprocket

Paper clip

3. Install the timing belt by the following procedure. Take care not to slacken the belt at the tension side. (1) Install the timing belt to the crankshaft sprocket, oil

pump sprocket and idler pulley in that order.,

(2) Place the timing belt on the exhaust-side camshaft

sprocket, and hold it in the position shown in the illustration with a paper clip.

Page 35

ENGINE <4G6> -

Timing Belt and Timing Belt B

11A-35

Timing marks

Paper clip

(3) Place the timing belt on the intake-side sprocket while

using two wrenches to align the timing marks.

(4) Hold the belt in the position shown in t he illustration

with another paper clip. (5) Place the timing belt on the tensioner pulley. (6) Remove the two paper clips.

Caution

After installing the timing belt, apply force to turn

the camshaft sprocket in the reverse direction,

and recheck to be sure that the belt is fully

tensioned and that each timing mark is in the

proper position.

4. Set the tension pulley so that the pin holes of centre bolt are at the bottom, press the tension pulley lightly against the timing belt, and then provisionally tighten the centre bolt.

5. Check to be sure that all timing marks are aligned.

6. Adjust the timing belt tension.

50 Nm

MD998767

Tension direction

"FA

TIMING BELT TENSION ADJUSTMENT

1. After turning the crankshaft 1/4 of a revolution in t h e anticlockwise direction, turn it in the clockwise direction until the timing marks are aligned.

2. Loosen the tension pulley fixing bolt, and then use the special tool and a torque wrench to tighten the fixing bolt to the specified torque while applying tension to the timing belt.

Standard value: 3.5 Nm <Timing belt tension torque> Caution

When tightening the fixing bolt, make sure that the tension pulley does not turn with the bolt.

Page 36

11A-36

Auto tensioner

ENGINE <4G6> -

Timing Belt and Timing Belt B

3. Turn the crankshaft two revolutions in the clockwise direction so that the timing marks are aligned. After leaving it for 15 minutes, measure the amount of protrusion of the auto tensioner.

Standard value (A): 3.8 - 4.5 mm

4. If the amount of protrusion is outside the standard value, repeat the operation in steps (1) to (3).

5. Check again to be sure that the timing marks of each sprocket are aligned.

Page 37

ENGINE <4G6> -

Engine Assembly

11A-37

ENGINE ASSEMBLY

11200090015

REMOVAL AND INSTALLATION

Caution Mounting locations marked by * should be provisionally tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body.

Pre-removal a nd Post-installation Operation

D Fuel Discharge Prevention (Refer to GROUP 13A

- On-vehicle Service.) <Pre-removal only>

D Engine Cover Removal and Installation D Under Cover Removal and Installation D Engine Coolant Draining and Supplying (Refer to

GROUP 14 - On-vehicle Service.)

D Hood Removal and Installation (Refer to GROUP 42.) D Transmission Assembly Removal and Installation

(Refer to GROUP 22 or 23.)

D Drive Belt Tension Adjustment (Refer to P.11A-6.)

<Post-installation only>

67 Nm

57 Nm

98 - 118Nm*

AA" AB"

Removal steps

1. Drive belt (Power steering and A/C)

2. Engine harness connector

3. Earth cable connection

4. Alternator connector

5. Power steering hose clamp

6. A/C compressor

7. Power steering oil pump

8. Vacuum hose connection

AC""CA

"BA

AD""AA

9. Brake booster vacuum hose connection

10. Heater hose connection

11. Fuel return hose connection

12. Fuel pressure hose connection

13. Power steering oil reservoir

14. Engine mount bracket

15. Engine mount stopper

16. Engine assembly

Page 38

11A-38

ENGINE <4G6> -

REMOVAL SERVICE POINTS

AA" Disconnect the A/C compressor connector and remove the

compressor from the compressor bracket with the hose still attached.

NOTE Place the removed A/C compressor where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord.

Engine Assembly

A/C COMPRESSOR REMOVAL

MB991453

MZ203827

AB"

Remove the power steering oil pump and bracket assembly from the engine with the hose attached.

NOTE Place the removed power steering oil pump in a place where it will not be a hindrance when removing and installing the engine assembly, an d tie it with a cord.

AC"

1. Support the engine with a garage jack.

2. Remove the special tool which was attached when the

3. Hold the engine assembly with a chain block or similar

4. Place a garage jack against the engine oil pan with a

AD"

After checking that all cables, hoses and harness connectors, etc., are disconnected from the engine, lower the chain block slowly to remove the engine assembly downward from the engine compartment.

POWER STEERING OIL PUMP REMOVAL

ENGINE MOUNT BRACKET REMOVAL

transmission assembly was removed.

tool.

piece of wood in between, jack up the engine so that the weight of the engine is no longer being applied to the engine mount bracket, and then remove the engine mount bracket.

ENGINE ASSEMBLY REMOVAL

Page 39

ENGINE <4G6> -

INSTALLATION SERVICE POINTS

"AA

Install the engine assembly, checking that the cables, hoses, and harness connectors are not clamped.

Engine Assembly

ENGINE ASSEMBLY INSTALLATION

11A-39

Engine mount stopper

Engine mount bracket

Engine side

Arrow

"BA

ENGINE MOUNT STOPPER INSTALLATION

Clamp the engine mount stopper so that the arrow points in the direction as shown in the diagram.

"CA

ENGINE MOUNT BRACKET INSTALLATION

1. Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine mount bracket while adjusting the position of the engine.

2. Support the engine with the garage jack.

3. Remove the chain block and support the engine assembly with the special tool.

Page 40

NOTES

Page 41

ENGINE

<4G9>

CONTENTS

11B-1

GENERAL INFORMATION 2..................

SERVICE SPECIFICATIONS 2.................

SEALANTS 4................................

SPECIAL TOOLS 4..........................

ON-VEHICLE SERVICE 6.....................

Drive Belt Tension Check and Adjustment 6......

Ignition Timing Check 9........................

Idle Speed Check 10...........................

Idle Mixture Check 11..........................

Compression Pressure Check 12................

Manifold Vacuum Check 13.....................

Lash Adjuster Check 13........................

CRANKSHAFT PULLEY 16..................

CAMSHAFT AND CAMSHAFT OIL SEAL 17..

OIL PAN 21.................................

CRANKSHAFT OIL SEAL 23.................

CYLINDER HEAD GASKET 25...............

TIMING BELT 28............................

ENGINE ASSEMBLY 33.....................

Page 42

11B-2

ENGINE <4G9> -

General Information/Service Specifications

GENERAL INFORMATION

Items 4G93

Total displacement mL 1,834

Bore ´ Stroke mm 81.0 ´ 89.0

Compression ratio 12.5

Combustion chamber Pentroof + ball-in-piston

Camshaft arrangement DOHC

Number of valve

V alve timing Intake

Fuel system Electronically controlled multipoint fuel injection

Rocker arm Roller type

Auto-lash adjuster Equipped

Intake 8

Exhaust 8

Opening BTDC 15_

Closing ABDC 56_

Exhaust

Opening BBDC 55_

Closing ATDC 15_

SERVICE SPECIFICATIONS

Items Standard value Limit

Alternator drive Vibration belt tension frequency Hz

Tension N

When checked 143 - 185 -

When a used belt is installed 155 - 175 -

When a new belt is installed 203 - 234 -

When checked 294 - 490 -

Deflection (Reference value) mm

When a used belt is installed 343 - 441 -

When a new belt is installed 588 - 784 -

When checked 9.7 - 12.9 -

When a used belt is installed 10.5 - 12.0 -

When a new belt is installed 6.7 - 8.5 -

Page 43

ENGINE <4G9> -

Items LimitStandard value

Service Specifications

11B-3

Power steering Vibration oil pump and A/C compressor drive belt tension

Basic ignition timing 5_ BTDC ± 3_ -

Ignition timing Approx. 16_BTDC

Idle speed r/min M/T 600 ± 100*

CO contents % 0.5 or less -

frequency Hz

Tension N

Deflection (Reference value) mm

A/T 650 ± 100 -

When checked 1 14 - 139 -

When a used belt is installed 121 - 133 -

When a new belt is installed 145 - 166 -

When checked 392 - 588 -

When a used belt is installed 441 - 539 -

When a new belt is installed 637 - 833 -

When checked 10.0 - 12.0 -

When a used belt is installed 10.0 - 11.0 -

When a new belt is installed 7.0 - 9.0 -

(Approx. 6_BTDC)*

(750 ± 100)*

HC contents ppm 100 or less -

Compression pressure kPa - r/min 1,790 - 300 1,400 - 300

Compression pressure difference of all cylinder kPa - Max. 100

Intake manifold vacuum kPa - Min. 37

Cylinder head bolt shank length mm - 99.4

Timing belt tension torque Nm (Reference value) 2.5 - 4.0 -

Auto-tensioner rod protrusion amount mm 3.8 - 4.5 -

NOTE

*1: Varies depending on the transmission oil temperature. For details, refer to P. 11B-10.

: Indicates the value when more than 4 minutes have passed since the engine was started.

Page 44

11B-4

ENGINE <4G9> -

Sealants/Special Tools

SEALANTS

Items Specified sealants Remarks

Beam camshaft cap Cylinder head

Cam position sensor support Oil pan

Flywheel or drive plate bolt 3M Stud Locking 4170 or equivalent -

3M ATD Part No.8660 or equivalent -

MITSUBISHI GENUINE PART MD970389 or equivalent

SPECIAL TOOLS

Tool Number Name Use

MB991502 MUT-II sub

assembly

MB991668 Belt tension meter

set

MB990767 End yoke holder D Holding the camshaft sprocket

D Measuring the drive belt tension D Checking the ignition timing D Checking the idle speed D Erasing diagnosis code

Measuring the drive belt tension (used together with the MUT-II)

D Holding the crankshaft sprocket

Semi-drying sealant

MD998719 or MD998754

MD998713 Camshaft oil seal

MD998781 Flywheel stopper Securing the flywheel <M/T> or drive plate

Crankshaft pulley holder pin

Press-in of the camshaft oil seal

installer

<A/T>

Page 45

Tool UseNameNumber

ENGINE <4G9> -

Special Tools

11B-5

MD998776 Crankshaft rear oil

seal installer

MB990938 Handle

MD998717 Crankshaft front oil

seal installer

MD998767 Tension pulley

socket wrench

Press-in of the crankshaft rear oil seal

Press-in of the crankshaft front oil seal

Timing belt tension adjustment

GENERAL SERVICE TOOL MZ203827

MB991453 Engine hanger

Engine lifter Supporting the engine assembly during

assembly

removal and installation of the transmission

Page 46

11B-6

ENGINE <4G9> -

ON-VEHICLE SERVICE

DRIVE BELT TENSION CHECK AND ADJUSTMENT

ALTERNATOR DRIVE BELT TENSION CHECK

Check the drive belt tension by th e following procedure.

On-vehicle Service

Alternator pulley

Tap lightly with a finger.

MB991668 (Microphone)

10 - 20 mm

Crankshaft pulley

1. Connect the special tool (belt tension meter kit) to the

MUT-II.

2. Connect the MUT-II to the diagnosis connector.

3. Turn the ignition switch to ON and select “Belt Tension Measurement” from the menu screen.

Caution (1) The temperature of the surface of the belt should

be as close as possible to normal temperature.

(2) Do not let any contaminants such as water or

oil get onto the microphone.

(3) If strong gusts of wind blow against the

microphone or if there are any loud sources of noise nearby, the values measured by the microphone may not correspond to actual values.

(4) If the microphone is touching the belt while the

measurementis being made, the values measured by the microphone may not correspond to actual values.

(5) Do not take the measurement while the vehicle’s

engine is running.

Alternator pulley

Belt tension gauge

Crankshaft pulley

Use a belt tension gauge to check that the belt tension is within the standard value.

Page 47

ENGINE <4G9> -

On-vehicle Service

11B-7

Deflection

Alternator pulley

Adjusting bolt

Lock bolt

Pivot bolt

98 N

Crankshaft pulley

Apply 98 N of force to the middle of the drive belt between the pulleys (at the place indicated by the arrow) and check that the amount of deflection is within the standard value.

Standard value:

Vibration frequency Hz 143 - 185

Tension N 294 - 490

Deflection (Reference value) mm 9.7 - 12.9

ALTERNATOR DRIVE BELT TENSION ADJUSTMENT

1. Loosen the nut of the alternator pivot bolt.

2. Loosen the lock bolt.

3. Use the adjusting bolt to adjust the belt tension and belt deflection to the standard values.

Standard value:

Items When a used

belt is installed

Vibration frequency Hz 155 - 175 203 - 234

Tension N 343 - 441 588 - 784

Deflection (Reference value) mm

10.5 - 12.0 6.7 - 8.5

When a new belt is installed

NOTE Refer to P.11B-6 concerning the measurement procedure of the alternator drive belt tension.

4. Tighten the nut of the alternator pivot bolt.

Tightening torque: 44 Nm

5. Tighten the lock bolt.

Tightening torque: 22 Nm

6. Tighten the adjusting bolt.

Tightening torque: 5.0 Nm

Page 48

11B-8

ENGINE <4G9> -

On-vehicle Service

Oil pump pulley

98 N

Crankshaft pulley

Oil pump pulley

98 N

Crankshaft pulley

Tensioner pulley

A/C compressor pulley

POWER STEERING OIL PUMP AND AIR CONDITIONER COMPRESSOR DRIVE BELT TENSION CHECK AND ADJUSTMENT

11100130127

1. Check if the belt tension is within the standard value using one of the methods below.

Standard value:

Items When

checked

Vibration frequency Hz

Tension N 392 - 588 441 - 539 637 - 833

Deflection (Reference value) mm

1 14 - 139 121 - 133 145 - 166

10.0 - 12.0 10.0 - 11.0 7.0 - 9.0

When a used belt is installed

When a new belt is installed

With your finger tip lightly tap the centre of the belt between the pulleys in t he location shown by the arrow in the illustration and then measure the belt vibration frequency.

NOTE Refer to P.11B-6 for information regarding the vibration

frequency measurement method using MUT-II.

Use a belt tension gauge to measure the belt tension.

Apply 98 N of pressure against the location between the pulleys shown by the arrow in the illustration and then measure the deflection.

2. If the tension or deflection is outside the standard value, adjust by the following procedure.

(1) Loosen tensioner pulley fixing nut A. (2) Adjust the amount of belt deflection using adjusting

bolt B.

(3) Tighten fixing nut A.

Tightening torque: 25 Nm

(4) Check the belt deflection amount and tension, and

readjust if necessary.

Caution Check after turning the crankshaft once or more clockwise (right turn).

Page 49

ENGINE <4G9> -

On-vehicle Service

11B-9

Idle speed r/min

900

800

700

600

-10 20 50

Transmission oil temperature_C

IGNITION TIMING CHECK

NOTE The idle speed in vehicles with manual transmission varies as shown in the illustration in accordance with the transmission oil temperature.

2. Turn off the ignition switch and then connect the MUT-II

to the diagnosis connector.

3. Set the timing light to the power supply line (terminal No.1) of the ignition coil No.1.

NOTE The power supply line is looped and also longer than the other ones.

4. Start the engine a nd let it run at idle.

5. Use the MUT-II to measure engine idle speed and check

that it is within the standard value.

Standard value:

Items Idle speed r/min

M/T 600±100 (750±100)*

A/T 650±100 (750±100)*

NOTE *: Indicates the values when more than 4 minutes have

passed since the idling condition was started.

6. Select No.17 of the MUT-II Actuator test.

NOTE At this time, the engine speed will become approximately 750 r/min.

7. Check that basic ignition timing is within the standard value.

Standard value: 5_BTDC±3

8. If the basic ignition timing is outside the standard value, inspect t he GDI system while referring to GROUP 13B

- Troubleshooting.

9. Press the MUT-II clear key (Select a forced driving cancel

mode) to release the Actuator test.

Caution If the test is not cancelled, a forced driving will continue for 27 minutes. Driving under this condition may damage the engine.

Page 50

11B-10

ENGINE <4G9> -

10. Check that ignition timing is at the standard value.

Standard value: approx. 16_BTDC

NOTE (1) The ignition timing will become approximately 6_BTDC

(2) The ignition timing may fluctuate within ±7_BTDC.

11. Remove the timing light.

12. Turn off the ignition switch and then remove the MUT-II.

On-vehicle Service

after more than 4 minutes have passed since the basic ignition timing set mode was released.

This is normal.

Idle speed r/min

900

800

700

600

-10 20 50

Transmission oil temperature_C

IDLE SPEED CHECK

NOTE The idle speed in vehicles with manual transmission varies as shown in the illustration in accordance with the transmission oil temperature.

2. Turn off the ignition switch and then connect the MUT-II

to the diagnosis connector.

3. Check the basic ignition timing.

NOTE Refer to P.11B-9 concerning th e check procedure of the basic ignition timing.

Standard value: 5_BTDC±3

4. Run the engine at idle for 2 minutes.

5. Check the idle speed. Select item No. 22 and take a reading of the idle speed.

Standard value:

Items Idle speed r/min

M/T 600±100 (750±100)*

A/T 650±100 (750±100)*

NOTE (1) *: Indicates the values when more than 4 minutes

have passed since the idling condition was started.

(2) The idle speed is automatically controlled by the idle

speed control (ISC) system.

Page 51

ENGINE <4G9> -

6. If the idle speed is outside the standard value, inspect the GDI components by referring to GROUP 13B Troubleshooting.

IDLE MIXTURE CHECK

1. Before inspection, set the vehicle to the pre-inspection condition.

2. Connect the MUT-II to the diagnosis connector.

3. Check that the basic ignition timing is within the standard value.

NOTE Refer to P.11B-9 concerning th e check procedure of the basic ignition timing.

On-vehicle Service

11B-11

Standard value: 5_BTDC±3

4. Run the engine at 2,500 r/min for 2 minutes.

5. Set t he CO, HC tester.

6. Check the CO contents and the HC contents at idle.

NOTE This measurement should be performed in less than approximately 4 minutes since the engine speed become the idle speed.

Standard value

CO contents: 0.5% or less HC contents: 100 ppm or less

7. If there is a deviation from the standard value, check t he following items:

D Diagnosis output D Fuel pressure D Injector D Ignition coil, spark plug D EGR control system D Evaporative emission control system D Compression pressure

NOTE Replace the three way catalyst when the CO and HC contents are not within the standard value, even though the result of the inspection is normal on all items.

Page 52

11B-12

ENGINE <4G9> -

On-vehicle Service

Crank angle sensor connector

Compression gauge

COMPRESSION PRESSURE CHECK

1. Before inspection, check that the engine oil, starter and battery are normal. In addition, set the vehicle to the pre-inspection condition.

2. Remove all of t he ignition coils and spark plugs.

3. Disconnect the crank angle sensor connector.

NOTE Doing this will prevent the engine-ECU from carrying out ignition and fuel injection.

4. Cover the spark plug hole with a shop towel etc., and after the engine has been cranked, check that no foreign material is adhering to the shop towel.

Caution (1) Keep away from the spark plug hole when

cranking.

(2) If compression is measured with water, oil, fuel,

etc.,that has comefrom cracks inside the cylinder, these materials will become heated and will gush out from the spark plug hole, which is dangerous.

5. Set compression gauge to one of the spark plug holes.

6. Crank the engine with the throttle valve fully open and measure the compression pressure.

Standard value (at engine speed of 300 r/min):

1,790 kPa

Limit (at engine speed of 300 r/min):

Min. 1,400 kPa

7. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit.

Limit: Max. 100 kPa

(1) If the compression increases after oil is added, the

cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface.

(2) If the compression does not rise after oil is added,

the cause is a burnt or defective valve seat, or pressure is leaking from the gasket.

9. Connect the crank angle sensor connector.

10. Install the spark plugs and ignition coils.

11. Use the MUT-II to erase the diagnosis codes.

NOTE This will erase the diagnosis code resulting from the crank angle sensor connector being disconnected.

Page 53

Ventilation hose

PCV valve

ENGINE <4G9> -

Vacuum gauge

On-vehicle Service

11B-13

MANIFOLD VACUUM CHECK

1. Before inspection, set the vehicle to the pre-inspection condition.

2. Disconnect the ventilation hose from the positive crankcase ventilation (PCV) valve, and then connect a vacuum gauge to the ventilation hose.

3. Check the intake manifold negative pressure while the engine is idling.

Limit: Min. 37 kPa

LASH ADJUSTER CHECK

If an abnormal noise (knocking) that seems to be coming from the lash adjuster is heard after starting the engine and does not stop, carry out the following check.

NOTE (1) The abnormal noise which is caused by a problem

(2) If there is a problem with the lash adjusters, the noise

1. Start the engine.

2. Check that the noise occurs immediately after the engine is started, and that the noise changes in accordance with changes in the engine speed. If the noise does not occur immediately after the engine is started, or if it does not change in accordance with the engine speed, the problem is not being caused y the lash adjusters, so check for some other cause of the problem. Moreover, if the noise does not change in accordance with the engine speed, the cause of the problem is probably not with the engine. (In these cases, the lash adjusters are normal.)

Page 54

11B-14

ENGINE <4G9> -

5. Bleed air from the lash adjusters.

6. If the noise has not disappeared even after the air bleeding, clean the lash adjusters. (Refer to the Engine Workshop Manual.)

NOTE (1) If the vehicle is parked on a slope for a long period

(2) After parking the vehicle for long periods, the oil drains

(3) If either of the above situations occur, the abnormal

On-vehicle Service

of time, the amount of oil inside the lash adjuster will decrease, and air may get into the high pressure chamber when starting the engine.

out of the oil passage, and it takes time for the oil to be supplied to the lash adjuster, so air can get into the high pressure chamber.

noise can be eliminated by bleeding the air from inside the lash adjusters.

Good

1. Check the engine oil and replenish or replace the oil if necessary.

NOTE (1) If there is a only small amount of oil, air will be drawn

in through the oil screen and will get into the oil passage.

(2) If the amount of oil is greater than normal, then the

oil will being mixed by the crankshaft an d a large amount of air may get mixed into the oil.

(3) If the oil is degenerated, air and oil will not separate

easily in oil, and the amount of air mixed into the oil will increase.

Page 55

ENGINE <4G9> -

High-pressure chamber

On-vehicle Service

11B-15

(4) If the air which has been mixed in with the oil due

Drive pattern for air bleeding

Gradually open the throttle valve.

Approx. 3,000 r/min

Idle speed

15 seconds

Once

Close the throttle valve.

15 seconds

2. Run the engine at idle for 1 - 3 minutes to let it warm up.

4. After the noise has disappeared, repeat the drive pattern shown in the illustration at left a further 5 times.

5. Run the engine at idle for 1 - 3 minutes and check that the noise has disappeared.

Page 56

11B-16

ENGINE <4G9> -

Crankshaft Pulley

CRANKSHAFT PULLEY

REMOVAL AND INSTALLATION

Pre-removal Operation

Under Cover Removal

11200160303

Post-installation Operation

D Drive Belt Tension Adjustment (Refer to P.11B-6.) D Under Cover Installation

177 - 186 Nm

MD998719 or MD998754

(Engine oil)

Removal steps

1. Drive belt (Power steering and A/C)

2. Drive belt (Alternator)

MD990767

AA""AA

3. Crankshaft pulley bolt

4. Crankshaft pulley washer

5. Crankshaft pulley

REMOVAL SERVICE POINT

AA"

CRANKSHAFT PULLEY BOL T REMOVAL

INSTALLATION SERVICE POINT

"AA

When installing the crankshaft bolt, apply the minimum amount of engine oil to the bearing surface and thread of the bolt.

CRANKSHAFT PULLEY BOL T INSTALLATION

Page 57

ENGINE <4G9> -

Camshaft and Camshaft Oil Seal

CAMSHAFT AND CAMSHAFT OIL SEAL

REMOVAL AND INSTALLATION

Pre-removal a nd Post-installation Operation

D Air Intake Hose Removal and Installation D Timing Belt Removal and Installation

(Refer to P.11B-28.)

D Intake Manifold Removal and Installation

(Refer to GROUP 15.)

D Pump Camshaft Case Removal and Installation

(Refer to GROUP 13B - Fuel Pump (High Pressure).)

11B-17

12 - 15 Nm

21 - 25 Nm

3.4 Nm

Apply engine oil to all sliding parts during installation.

10 - 12 Nm

21 - 25 Nm

10 - 12 Nm

22 Nm

Removal steps

1. Connector bracket mounting bolt

2. Breather hose connection

3. PCV hose connection

4. Rocker cover

5. Rocker cover gasket

6. Cam position sensor support

7. Cam position sensing cylinder

(Injector Harness)

AA""DA

"CA

"BA

"AA "AA

10 - 12 Nm

88 Nm

8. Camshaft sprocket

9. Camshaft oil seal

10. Idler pulley

11. Timing belt rear cover

12. Beam camshaft cap

13. Beam camshaft cap gasket

14. Camshaft (exhaust side)

15. Camshaft (intake side)

35 Nm

Page 58

11B-18

ENGINE <4G9> -

Lubrication points

Camshaft and Camshaft Oil Seal

Sealant: 3M ATD Part No.8660 or equivalent

Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

f3mm

Lip section

Engine oil

Sealant: 3M ATD Part No.8660 or equivalent

Page 59

MB990767

MD998719

ENGINE <4G9> -

Camshaft and Camshaft Oil Seal

REMOVAL SERVICE POINT

AA"

CAMSHAFT SPROCKET REMOVAL

11B-19

Camshaft sprocket side

Exhaust camshaft

Approx. 106

Dowel pin

Intake side Exhaust side

28 27 31 32

20 19 23 24

12 11 15 163

Approx. 101

Screw hole

INSTALLATION SERVICE POINTS

"AA

1. Apply engine oil to journals and cams of the camshafts.

2. Install the camshafts on the cylinder head.

"BA

1. Place the camshaft dowel pin as shown in the illustration.

2. Tighten the beam camshaft cap mounting bolts to the

CAMSHAFT INSTALLATION

Caution Be careful not to confuse the intake camshaft with the exhaust one. There is a screw hole for the cam position sensing cylinder mounting bolt on the exhaust-side camshaft.

BEAM CAMSHAFT CAP INSTALLATION

specified torque in the order shown in the illustration.

Tightening torque:

: 10 - 12 Nm

: 21 - 25 Nm

87 561

Intake side Exhaust

14 13 9 102

22 21 17 184

30 29 25 26

Front of engine

side

Page 60

11B-20

ENGINE <4G9> -

Camshaft and Camshaft Oil Seal

MD998713

"CA

1. Apply engine oil to the entire circumference of the oil

2. Press-fit the oil seal as shown in the illustration.

"DA

Use the special tool to secure the camshaft sprocket in the same way as during removal, and then tighten the bolt to the specified torque.

Tightening torque: 88 Nm

CAMSHAFT OIL SEAL INSTALLATION

seal lip.

CAMSHAFT SPROCKET INSTALLATION

Page 61

ENGINE <4G9> -

OIL PAN

REMOVAL AND INSTALLATION

Pre-removal a nd Post-installation Operation

D Under Cover Removal and Installation D Front Exhaust Pipe Removal and Installation

(Refer to GROUP 15.)

Oil Pan

D Engine Oil Draining and Supplying (Refer to GROUP

12 - On-vehicle Service.)

11B-21

Groove

Bolt hole

Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

7Nm

39 Nm

7Nm

24 Nm

7Nm

49 Nm

7Nm

AA"

"AA

Removal steps

1. Lower oil pan

2. Drain plug

3. Drain plug gasket

7Nm

AB"

4. Cover

5. Upper oil pan

6. Baffle plate

Page 62

11B-22

Lower oil pan

ENGINE <4G9> -

REMOVAL SERVICE POINTS

AA"

Place a piece of wood against the lower oil pan, and tap the piece of wood with a hammer to remove the lower oil pan.

Caution Because the upper oil pan used is made from aluminium, the oil pan remover (MB998727) should not be used.

LOWER OIL PAN REMOVAL

Oil Pan

Drain plug gasket

Oil pan side

AB"

Insert a flat-tipped screwdriver into the notch of the upper oil pan as shown in the illustration, and turn it to remove the oil pan.

Caution Because the upper oil pan used is made from aluminium, the oil pan remover (MB998727) should not be used.

UPPER OIL PAN REMOVAL

INSTALLATION SERVICE POINT

"AA

Install the drain plug gasket in the direction so that it faces as shown in the illustration.

DRAIN PLUG GASKET INSTALLATION

Page 63

ENGINE <4G9> -

CRANKSHAFT OIL SEAL

REMOVAL AND INSTALLATION

93 - 103 Nm

<A/T>

<M/T>

Crankshaft Oil Seal

11B-23

<M/T>

Crankshaft

(Engine oil: bolt seat and threaded hole)

(Bolt thread)

Sealant: 3M Stud Locking 4170 or equivalent

<A/T>

(Engine oil: bolt seat and threaded hole)

Crankshaft

(Bolt thread)

Engine oil

Lip

"CA

Crankshaftfrontoil seal removal steps

Timing belt (Refer to P.11B-28.)

Crank angle sensor (Refer to GROUP 16.)

1. Crankshaft sprocket

2. Key

3. Crankshaft sensing blade

4. Crankshaft spacer

5. Crankshaft front oil seal

AA""BA AA""BA AA""BA AA""BA AA""BA

"AA

Crankshaft rear oil seal removal steps

Transmission assembly (M/T: Refer to GROUP 22.) (A/T: Refer to GROUP 23.)

Clutch cover and disc <M/T>

6. Plate <M/T>

7. Adapter plate

8. Flywheel <M/T>

9. Drive plate <A/T>

10. Adapter plate <M/T>

11. Crankshaft rear oil seal

Page 64

11B-24

MD998781

ENGINE <4G9> -

REMOVAL SERVICE POINT

AA"

Use the special tool to secure the flywheel or drive plate, and remove the bolts.

Crankshaft Oil Seal

PLATE <M/T>/ADAPTOR PLATE/FLYWHEEL <M/T>/DRIVE PLATE <A/T> REMOVAL

Crankshaft rear oil seal

MD990938

MD998776

Crankshaft

INSTALLATION SERVICE POINTS

"AA

1. Apply a small mount of engine oil to the entire

2. Install the oil seal by tapping it as far as the chamfered

"BA

1. Clean off all sealant, oil and other substances which are

2. Apply oil to the bearing surface of the flywheel or drive

3. Apply oil to the crankshaft thread holes.

4. Apply sealant to the threaded mounting holes.

5. Use the special tool to hold the flywheel or drive plate

CRANKSHAFT REAR OIL SEAL INSTALLATION

circumference of the oil seal lip.

position of the oil seal case as shown in the illustration.

DRIVE PLATE <A/T>/FLYWHEEL <M/T>/ADAPTOR PLATE/PLATE <M/T> INSTALLATION

adhering to the threaded bolts, crankshaft thread holes and the flywheel or drive plate.

plate bolts.

Specified sealant: 3M Stud locking 4170 or equivalent

in the same manner as removal, and install the bolt.

MD998717

Crankshaft

Oil seal

"CA

CRANKSHAFT FRONT OIL SEAL INSTALLATION

1. Apply a small amount of engine oil to the entire circumference of the oil seal lip.

2. Tap the oil seal unit it is flush with the oil seal case.

Page 65

ENGINE <4G9> -

CYLINDER HEAD GASKET

REMOVAL AND INSTALLATION

Cylinder Head Gasket

11B-25

Pre-removal a nd Post-installation Operation

D Prevention of Fuel Discharge <before removal only>

(Refer to GROUP 13B - On-vehicle Service.)

D Engine Coolant Draining and Supplying

(Refer to GROUP 14 - On-vehicle Service.)

D Engine Oil Draining and Supplying

(Refer to GROUP 12 - On-vehicle Service.)

D Timing Belt Removal and Installation

(Refer to P.11B-28.)

D Intake Manifold Removal and Installation

(Refer to GROUP 15.)

74 Nm®0Nm®20 Nm +90

_ ®

+90

D Fuel Pump (High pressure) and Fuel Pressure

Regulator (High pressure) Removal an d Installation (Refer to GROUP 13B.)

D EGR Valve Assembly Removal and Installation

(Refer to GROUP 17.)

D Thermostat Case Assembly and Radiator upper hose

Removal a n d Installation (Refer to GROUP 14 - Water Hose and Water Pipe.)

3.4 Nm

22 Nm

44 Nm

10 - 12 Nm

35 Nm

49 Nm

19 Nm

35 Nm

49 Nm

34 Nm

19 Nm

Page 66

11B-26

Removal steps

1. Injector harness connector

2. Front exhaust pipe connection

3. Exhaust manifold bracket

4. Power steering oil pump bracket stay

AA" 5. Power steering oil pump and

bracket assembly

ENGINE <4G9> -

Cylinder Head Gasket

6. Idler pulley

7. Timing belt rear cover

8. Engine oil level gauge assembly

9. Rocker cover

AB""BA 10. Cylinder head bolt

11. Cylinder head assembly

"AA 12. Cylinder head gasket

REMOVAL SERVICE POINTS

AA"

Remove the power steering oil pump and bracket assembly from the engine with the hose attached.

NOTE Place the removed power steering oil pump a nd bracket assembly in a place where it will not be a hindrance when removing and installing the cylinder head assembly, and tie it with a cord.

POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL

MB991653

Intake side Front of engine

35108 2

1796 4

Exhaust side

AB"

CYLINDER HEAD BOLT REMOVAL

Use the special tool to loosen the bolts in two or three steps in the order of the numbers shown in the illustration, and then remove the bolts.

INSTALLATION SERVICE POINTS

"AA

1. Wipe off all oil and grease from the gasket mounting

2. Install so that the shapes of the cylinder head holes match

CYLINDER HEAD GASKET INSTALLATION

surface.

the shapes of the respective cylinder head gasket holes.

Page 67

ENGINE <4G9> -

Cylinder Head Gasket

11B-27

Burred side

Head bolt

Intake side Front of engine

washer

Cylinder head

MB991653

861 3 9

104257

Head bolt

(Engine oil)

"BA

CYLINDER HEAD BOLT INSTALLATION

1. When installing the cylinder head bolts, the length below the head of the bolts should be within the limit. If it is outside the limit, replace the bolts.

Limit (A): 96.4 mm

2. The head bolt washer should be installed with the burred side caused by tapping out facing upwards.

3. Apply a small amount of engine oil to the thread section and the washer of the cylinder head bolt.

4. Tighten the bolts by the following procedure.

Step Operation Remarks

1 Tighten to 74 Nm. Carry out in the order

shown in the illustration.

2 Fully loosen. Carry out in the reverse

order of that shown in the illustration.

3 Tighten to 20 Nm. Carry out in the order

shown in the illustration.

4 Tighten 90_of a turn. In the order shown in the

illustration. Mark the head of the cylinder head bolt and cylinder head by paint.

5 Tighten 90_of a turn. In the order shown in the

illustration. Check that the painted mark of the head bolt is lined up with that of the cylinder head.

Exhaust side

Step 4

Painted mark

Step 5

Painted mark

Caution (1) Always make a tightening angle just 90_.Ifitis

less than 90_, the head bolt will be loosened.

(2) If it is more than 90_, remove the head bolt and

repeat the procedure from step 1.

Page 68

11B-28

ENGINE <4G9> -

TIMING BELT

REMOVAL AND INSTALLATION

Pre-removal a nd Post-installation Operation

D Engine Cover Removal and Installation D Under Cover Removal and Installation

Timing Belt

D Crankshaft Pulley Removal and Installation

(Refer to P.11B-16.)

20 - 25 Nm

49 Nm

9Nm

10 - 12 Nm

49 Nm

12 - 15 Nm

35 Nm

Removal steps

1. Alternator brace

2. Timing belt front upper cover

3. Power steering pump bracket stay

4. Timing belt front lower cover

5. Flange

Engine mount bracket (Refer to GROUP 32.)

AA""BA

"CAD

"AA

6. Engine support bracket Timing belt tension adjustment

7. Timing belt

8. Auto tensioner

9. Tensioner pulley and arm assembly

10. Idler pulley

Page 69

ENGINE <4G9> -

Timing Belt

11B-29

Timing marks

REMOVAL SERVICE POINT

AA"

1. Turn the crankshaft clockwise to align each timing mark.

2. Loosen the tensioner pulley center bolt and remove the

TIMING BELT REMOVAL

Caution The crankshaft must always be turned clockwise.

timing belt.

Caution If the timing belt is to be re-used, use chalk to mark (on its flat side) an arrow indicating the clockwise direction.

Auto tensioner

Contact piece

98-196 N

Contact piece

Movement

Push rod

INSTALLATION SERVICE POINTS

"AA

1. Apply 98 - 196 N force to the push rod of the auto tensioner

2. If it is out of the standard value, change the auto tensioner.

3. Use a press or vice to gently compress the auto tensioner

4. Once the holes are aligned, insert the set pin.

AUTO TENSIONER INSTALLATION

by pressing it against a metal (cylinder block, etc.), and measure the movement of the push rod.

Standard value:

Within 1 mm A: Length when it is free (not pressed) B: Length when it is pressed A - B: Movement

push rod until pin hole A of the push rod and pin hole B of the tensioner cylinder are aligned.

Caution If the compression speed is too fast, the push rod may become damaged, so be sure to carry out this operation slowly.

Set pin

NOTE When replacing the auto tensioner with a new part, the pin will be in the auto tensioner.

5. Install the auto tensioner to the engine.

Page 70

11B-30

ENGINE <4G9> -

Timing Belt

Camshaft sprocket

Timing marks

Crankshaft sprocket

Timing marks

Paper clip

"BA

TIMING BELT INSTALLATION

1. Align the timing marks of each camshaft sprocket and the crankshaft sprocket.

2. Loosen the tensioner pulley center bolt.

3. Move the crankshaft sprocket half a tooth width in the anti-clockwise direction.

4. Place the timing belt on the exhaust-side camshaft sprocket, and hold it in the position shown in the illustration with a paper clip.

Timing marks

5. Place the timing belt on the intake-side sprocket while using two wrenches to align the timing marks.

6. Hold the belt in the position shown in the illustration with another paper clip.

Page 71

Tensioner pulley

Crankshaft sprocket

Idler pulley

Water pump sprocket

ENGINE <4G9> -

7. Place the belt onto the idler pulley, water pump sprocket, crankshaft sprocket and tensioner pulley in that order.

8. Remove the two paper clips.

9. Lift the tensioner pulley in the direction of the arrow and tighten the tensioner pulley bolt.

10. Check to be sure that all timing marks are aligned.

11. Adjust the timing belt tension.

Timing Belt

11B-31

Fixing bolt

Pin hole

Tensioner pulley

2 mm Allen wrench

MD998767

"CA

TIMING BELT TENSION ADJUSTMENT

1. After turning the crankshaft a 1/4 turn anti-clockwise, turn it clockwise to the position where the timing marks are aligned.

2. Loosen the fixing bolt of the tensioner pulley and using the special tool and a torque wrench, apply tension to the timing belt; then tighten the fixing bolt at the specified torque.

Standard Value:

2.5 - 4.0 Nm {timing belt tension torque (reference value)}

Caution When tightening the fixing bolt, ensure that the tensioner pulley shaft doesn’t rotate with the bolt.

3. Take out the 2 mm Allen wrench from the auto tensioner. At this time, check to be sure that 2 mm Allen wrench can be pulled out easily. Turn the crankshaft clockwise 2 turns, a nd after leaving it in this position for 5 minutes or more, check again to be sure that the auto tensioner 2 mm Allen wrench can be pulled out or inserted easily.

Page 72

11B-32

ENGINE <4G9> -

NOTE Even if the 2 mm Allen wrench cannot be easily inserted, then it is satisfactory if the amount of protrusion of the auto tensioner rod is within the standard value.

Standard value (A): 3.8 - 4.5 mm

If it is outside the standard value, repeat the operations in steps 1 to 4.

4. Check to be sure that the timing marks on all sprockets are aligned.

Timing Belt

Page 73

ENGINE <4G9> -

Engine Assembly

11B-33

ENGINE ASSEMBLY

REMOVAL AND INSTALLATION

Caution Mounting locations marked by * should be provisionally tightened, and then fully tightened when the body is supporting the full weight of the engine.

Pre-removal a nd Post-installation Operation

D Prevention of Fuel Discharge <before removal only>

(Refer to GROUP 13B - On-vehicle Service.)

D Engine Coolant Draining and Supplying

(Refer to GROUP 14 - On-vehicle Service.)

O-ring

Engine oil

D Hood Removal and Installation (Refer to GROUP 42.) D Drive Belt Tension adjustment <after installation only>

(Refer to P.11B-6.)

8.8 Nm

Removal steps

1. Ignition coil connector

2. Cam position sensor connector

3. Engine coolant temperature sensor connector

4. Engine coolant temperature gauge unit connector

5. Detonation sensor connector

6. Purge solenoid valve connector

7. Fuel pressure sensor connector

"CA

8. Throttle valve control servo connector

9. Throttle position sensor connector

10. High-pressure fuel hose connection

11. Fuel return hose connection

12. Vacuum hose connection

13. Brake booster vacuum hose connection

Page 74

11B-34

ENGINE <4G9> -

Engine Assembly

67 Nm

12 Nm

22 Nm

44 Nm

49 Nm

57 Nm

98 - 118 Nm*

14. Crank angle sensor connector

15. Injector harness connector

16. Heater hose connection

17. Oxygen sensor connector

18. Alternator connector

19. Engine oil pressure switch connector

20. Drive belt (Power steering and A/C)

21. Power steering oil pump bracket stay

AA" 22. Power steering oil pump and

bracket assembly

AB" 23. A/C compressor

24. Power steering hose mounting bolt

D Transmission assembly

(Refer to GROUP 22.)

AC""BA 25. Engine mount bracket AD""AA 26. Engine assembly

Page 75

ENGINE <4G9> -

REMOVAL SERVICE POINTS

AA"

Remove the power steering oil pump and bracket assembly from the engine with the hose attached.

NOTE Place the removed power steering oil pump where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord.

Engine Assembly

POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL

11B-35

MB991453

MZ203827

AB"

Disconnect the A/C compressor connector and remove the compressor from the compressor bracket with the hose still attached.

NOTE Place the removed A/C compressor where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord.

AC"

1. Support the engine with a garage jack.

2. Remove the special tool which was attached when the

3. Hold the engine assembly with a chain block or similar

4. Place a garage jack against the engine oil pan with a

AD"

After checking that all cables, hoses and harness connectors, etc., are disconnected from the engine, lift the chain block slowly to remove the engine assembly downward from the engine compartment.

A/C COMPRESSOR REMOVAL

ENGINE MOUNT BRACKET REMOVAL

transmission assembly was removed.

tool.

piece of wood in between, jack up the engine so that the weight of the engine is no longer being applied to the engine mount bracket, and then remove the engine mount bracket.

ENGINE ASSEMBLY REMOVAL

Page 76

11B-36

ENGINE <4G9> -

INSTALLATION SERVICE POINTS

"AA

Install the engine assembly, checking that the cables, hoses, and harness connectors are not clamped.

Engine Assembly

ENGINE ASSEMBLY INSTALLATION

MB991453

MZ203827

"BA

1. Place a garage jack against the engine oil pan with a

2. Support the engine with the garage jack.

3. Remove the chain block and support the engine assembly

"CA

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

2. While turning the high-pressure fuel hose to the right

3. If the hose does not turn smoothly, the O-ring is probably

ENGINE MOUNT BRACKET INSTALLATION

piece of wood in between, and install the engine mount bracket while adjusting the position of the engine.

with the special tool.

HIGH-PRESSURE FUEL HOSE INSTALLATION

Caution Do not let any engine oil get into the delivery pipe.

and left, install the delivery pipe, while being careful not to damage the O-ring. After installing, check that the hose turns smoothly.

being clamped. Disconnect the high-pressure fuel hose and check the O-ring for damage. After this, re-insert the delivery pipe and check that the hose turns smoothly.

Mitsubishi ENGINE 4G9, ENGINE 4G6 SERVICE MANUAL

Specifications and Main Features

Frequently Asked Questions

User Manual

GENERAL INFORMATION

SERVICE SPECIFICATIONS

SEALANTS

Special Tools

ON-VEHICLE SERVICE

Crankshaft Pulley

Camshaft and Camshaft Oil Seal

Oil Pan

Crankshaft Oil Seal

Cylinder Head Gasket

Timing Belt and Timing Belt B

Engine Assembly

GENERAL INFORMATION

SERVICE SPECIFICATIONS

SEALANTS

SPECIAL TOOLS

ON-VEHICLE SERVICE

Crankshaft Pulley

Camshaft and Camshaft Oil Seal

OIL PAN

CRANKSHAFT OIL SEAL

CYLINDER HEAD GASKET

TIMING BELT

Engine Assembly