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 mmWithin 1-
Timing belt tension torque Nm (Reference value)2.5-
Auto-tensioner rod protrusion amount mm3.8 - 4.5-
NOTE
*1: Indicates the value measured within 4 minutes since the engine was started.
2
*
: Varies depending on the transmission oil temperature. For details, refer to P.11A-11.
3
*
: Indicates the value when more than 4 minutes have passed since the engine was started.
SEALANTS
ItemsSpecified sealantsRemarks
Beam camshaft cap
Cylinder head
Cam position sensor support
Oil pan
3M ATD Part No.8660 or equivalent-
MITSUBISHIGENUINEPART
MD970389 or equivalent
Semi-drying sealant
3
Flywheel or drive plate bolt3M Stud Locking 4170 or equivalent-
ENGINE <4G6> -
Special Tools
SPECIAL TOOLS
ToolNumberNameUse
11A-5
MB991502MUT-II sub
assembly
MB991668Belt tension meter
set
MB990767End yoke holderDHolding the camshaft sprocket
MD998719or
MD998754
Crankshaft pulley
holder pin
DMeasuring the drive belt tension
DChecking the ignition timing
DChecking the idle speed
DErasing diagnosis code
Measuring the drive belt tension
(used together with the MUT-II)
DHolding the crankshaft sprocket
DHolding the camshaft sprocket
DHolding the crankshaft sprocket
MD998713Camshaft oil seal
installer
MD998727Oil pan removerRemoval of oil pan
MD998781Flywheel stopperSecuring the flywheel
MD998776Crankshaft rear oil
seal installer
Press-in of the camshaft oil seal
Press-in of the crankshaft rear oil seal
MB990938HandlePress-in of the crankshaft rear oil seal
11A-6
ToolUseNameNumber
ENGINE <4G6> -
Special Tools/On-vehicle Service
MD998382Crankshaft front oil
seal installer
MD998285Crankshaft front oil
seal guide
MD998767Tensionpulley
socket wrench
GENERAL
SERVICE
TOOL
MZ203827
Engine lifterSupportingtheengineassemblyduring
Installation of crankshaft front oil seal
Timing belt tension adjustment
removal and installation of the transmission
MB991453Engine 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 Hz189 - 232
Tension N392 - 588
Deflection (Reference value) mm6.7 - 9.0
ENGINE <4G6> -
On-vehicle Service
11A-7
MB991668
(Microphone)
Alternator
pulley
15
15
_
_
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) Ifstronggustsofwindblowagainstthe
microphone or if there are any loud sources of
noisenearby,the valuesmeasuredby 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.
<When using the MUT-II>
Alternator
pulley
Alternator
pulley
Belt tension gauge
98 N
Water pump
pulley
Crankshaft
pulley
Water pump
pulley
Crankshaft
pulley
<When using a tension gauge>
Use a belt tension gauge to check that the belt tension is
within the standard value.
<Belt deflection check>
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.
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
ItemsWhen a used
belt is installed
Vibration frequency Hz201 - 222241 - 276
Tension N441 - 539637 - 833
Deflection
(Reference value) mm
7.2 - 8.45.0 - 6.4
When a new
belt is installed
Tightening torque: 5 Nm
ENGINE <4G6> -
On-vehicle Service
11A-9
<VehicleswithoutA/C>
Oil pump pulley
98 N
A
Crankshaft
pulley
<Vehicleswith A/C>
Oil pump pulley
98 N
Crankshaft
pulley
A
B
Tensioner pulley
Tensioner
pulley
B
A/C
compressor
pulley
POWER STEERING OIL PUMP AND AIR CONDITIONER
COMPRESSOR DRIVEBELT TENSION CHECK AND
ADJUSTMENT
11100130127
1.Check if the belt tension is within the standard value
using one of the methods below.
Standard value:
ItemsWhen
checked
Vibration
frequency
Hz
Tension N392 - 588441 - 539637 - 834
Deflection
(Reference
value) mm
108 - 132114 - 126137 - 157
11.7 - 15.312.5 - 14.38.8 - 11.0
When a
used belt is
installed
When a new
belt is
installed
<When measuring the vibration frequency>
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.
<When measuring the tension>
Use a belt tension gauge to measure the belt tension.
<When measuring the deflection>
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).
11A-10
ENGINE <4G6> -
On-vehicle Service
Idle speed r/min
900
800
700
600
-102050
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 outthe checkingwhile thetransmission 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:
ItemsIdle speed r/min
M/T600±100 (700±100)*
A/T650±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.
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
-102050
Transmission oil temperature_C
IDLE SPEED 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 outthe checkingwhile thetransmission 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.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.
_
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
GDIcomponentsby referringtoGROUP13ATroubleshooting.
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:
DDiagnosis output
DFuel pressure
DInjector
DIgnition coil, spark plug
DEGR control system
DEvaporative emission control system
DCompression 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
ItemsIdle speed r/min
M/T600±100 (700±100)*
A/T650±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
Crank angle sensor
connector
ENGINE <4G6> -
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
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.
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.Disconnecttheventilationhose fromthepositive
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.)
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.)
<LASH ADJUSTER AIR BLEEDING>
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.
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.
ENGINE <4G6> -
Crankshaft Pulley
11A-17
CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
Pre-removal Operation
Under Cover Removal
2
1
11200160303
Post-installation Operation
DDrive Belt Tension Adjustment (Refer to P.11A-6.)
DUnder Cover Installation
e
3
25 Nm
Removal steps
1. Drive belt (Power steering and
A/C)
2. Drive belt (Alternator)
3. Crankshaft pulley
11A-18
ENGINE <4G6> -
Camshaft and Camshaft Oil Seal
CAMSHAFT AND CAMSHAFT OIL SEAL
REMOVAL AND INSTALLATION
Pre-removal Operation
DAir Intake Hose Assembly Removal
DTiming Belt Removal (Refer to P.11A-30.)
DEngine Coolant Draining
DIntake Manifold Removal (Refer to GROUP 15.)
DFuel Pump (High Pressure) Removal (Refer to
GROUP 13A.)
12
10 Nm
11
Post-installation Operation
DFuel Pump (High Pressure) Installation (Refer to
GROUP 13A.)
DIntake Manifold Installation (Refer to GROUP 15.)
DTiming Belt Installation (Refer to P.11A-30.)
DAir Intake Hose Assembly Installation
DEngine Coolant Supplying
DDrive Belt Tension Adjustment (Refer to P.11A-6.)
11200190418
3.4 Nm
8
9
22 Nm
4
12 - 15 Nm
2
3
19 - 21 Nm
1
7
13
9Nm
10
5
10 - 12 Nm
88 Nm
6
"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
ENGINE <4G6> -
Lubrication points
<Seen from underneath
beam camshaft cap>
Sealant: 3M ATD Part No.8660 or equivalent
Camshaft and Camshaft Oil Seal
f3mm
11A-19
Sealant:
MITSUBISHI GENUINE PART
MD970389 or equivalent
<Seen from above cylinder head>
Lip section
Engine oil
Sealant: 3M ATD Part No.8660 or equivalent
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
28
20
Dowel pin
_
27
1923
Screw hole
Exhaust side
24
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
11
12
87
14
22
30
3
13
2
2117
4
29
15 16
5
61
910
18
25
26
ENGINE <4G6> -
Camshaft and Camshaft Oil Seal
11A-21
MD998713
90
"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
11A-22
ENGINE <4G6> -
Oil Pan
OIL PAN
REMOVAL AND INSTALLATION
Pre-removal a nd Post-installation Operation
DUnder Cover Removal and Installation
DEngine Oil Draining and Supplying (Refer to GROUP
12 - On-vehicle Service.)
6
f 4 ± 1mm
Groove
Sealant:
MITSUBISHIGENUINEPART
MD970389 or equivalent
Bolt
hole
9Nm
11200280207
DOil Level Gauge Removal and Installation
DFront Exhaust Pipe Removal and Installation (Refer
to GROUP 15.)
6
39 Nm
2
1
4
5
"AA
MD998727
Removal steps
1. Drain plug
2. Drain plug gasket
3. Transmission stay
MD998727
9Nm
9Nm
3
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
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
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