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11A-0-1
ENGINE
4G9 SERIES
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. 11A-0-3 |
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. 11A-1-1 |
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. 11A-1-1 |
REWORK DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. 11A-1-4 |
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
11A-1-5 |
NEW TIGHTENING METHOD–BY USE OF BOLTS TO BE |
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TIGHTENED IN PLASTIC AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
11A-1-7 |
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
11A-1-7 |
FORM-IN-PLACE GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
11A-1-8 |
2. SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
11A-2-1 |
3. ALTERNATOR AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . |
11A-3-1 |
4. TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
11A-4-1 |
5. FUEL AND EMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . |
11A-5-1 |
5a. THROTTLE BODY AND EGR SYSTEM (GDI) . . . . . . . . . . . . . . . . . |
11A-5a-1 |
6. INTAKE AND EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
11A-6-1 |
6a. INTAKE MANIFOLD (GDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
11A-6a-1 |
6b. EXHAUST MANIFOLD (GDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
11A-6b-1 |
6c. INJECTOR AND FUEL PUMP ASSEMBLY (GDI) . . . . . . . . . . . . . |
11A-6c-1 |
6d. INTAKE AND EXHAUST MANIFOLD |
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<4G94–GDI for PAJERO io> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
11A-6d-1 |
7. WATER PUMP AND WATER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
11A-7-1 |
8. ROCKER ARMS AND CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
11A-8-1 |
8a. ROCKER COVER AND CAMSHAFTS (MIVEC) . . . . . . . . . . . . . . . |
11A-8a-1 |
8b. ROCKER ARMS AND ROCKER SHAFT CAPS (MIVEC) . . . . . |
11A-8b-1 |
9. CYLINDER HEAD AND VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
11A-9-1 |
10. FRONT CASE AND OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
11A-10-1 |
11. PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
11A-11-1 |
12. CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE |
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PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
11A-12-1 |
www.mivec.co.nz
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E Mitsubishi Motors Corporation |
Mar. 2001 |
PWEE9502-I |
Revised |
11A-0-2
NOTES
www.mivec.co.nz
E Mitsubishi Motors Corporation |
May 1995 |
PWEE9502 |
4G9 ENGINE (E - W) - General Information |
11A-0-3 |
GENERAL INFORMATION
4G92
Descriptions |
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4G92-SOHC |
4G92-DOHC-MIVEC |
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Type |
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In-line OHV, SOHC |
In-line OHV, DOHC |
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Number of cylinders |
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4 |
4 |
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Combustion chamber |
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Pentroof type |
Pentroof type |
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Total displacement dm3 |
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1,597 |
1,597 |
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Cylinder bore mm |
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81.0 |
81.0 |
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Piston stroke mm |
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77.5 |
77.5 |
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Compression ratio |
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10.0 |
11.0 |
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Valve timing |
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Intake |
Opens |
20_, 14_* |
17_ (Low-speed cam) |
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valve |
(BTDC) |
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47.5_ (High-speed cam) |
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Closes |
42_, 58_* |
31_ (Low-speed cam) |
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(ABDC) |
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72.5_ (High-speed cam) |
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Exhaust |
Opens |
54_, 52_* |
41_ (Low-speed cam) |
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valve |
(BBDC) |
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70_ (High-speed cam) |
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Closes |
2_, 16_* |
11_ (Low-speed cam) |
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(ATDC) |
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35_ (High-speed cam) |
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Lubrication system |
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Pressure feed, full-flow filtration |
Pressure feed, full-flow filtration |
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Oil pump type |
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Trochoid type |
Trochoid type |
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Cooling system |
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Water-cooled forced circulation |
Water-cooled forced circulation |
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Water pump type |
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Centrifugal impeller type |
Centrifugal impeller type |
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*: LANCER for general export and CARISMA for 6B model
www.mivec.co.nz
E Mitsubishi Motors Corporation |
July 1997 |
PWEE9502-C |
Revised |
11A-0-4 |
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4G9 ENGINE (E-W) - General Information |
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4G93 |
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Descriptions |
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4G93-SOHC |
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4G93-DOHC |
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4G93-DOHC-GDI |
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Type |
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In-line OHV, SOHC |
In-line OHV, DOHC |
In-line OHV, DOHC |
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Number of cylinders |
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4 |
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4 |
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4 |
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Combustion chamber |
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Pentroof type |
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Pentroof type |
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Pentroof type |
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Total displacement dm3 |
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1,834 |
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1,834 |
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1,834 |
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Cylinder bore mm |
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81.0 |
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81.0 |
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81.0 |
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Piston stroke mm |
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89.0 |
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89.0 |
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89.0 |
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Compression ratio |
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10.0, 9.5 |
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10.5 |
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11.7*1, 12.0*2 |
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Valve timing |
Intake |
Opens |
14_ |
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20_ |
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15_ |
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valve |
(BTDC) |
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Closes |
50_ |
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60_ |
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56_ |
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(ABDC) |
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Exhaust |
Opens |
58_ |
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61_ |
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55_ |
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valve |
(BBDC) |
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Closes |
10_ |
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15_ |
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15_ |
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(ATDC) |
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Lubrication system |
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Pressure feed, full- |
Pressure feed, full- |
Pressure feed, full- |
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flow filtration |
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flow filtration |
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flow filtration |
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Oil pump type |
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Trochoid type |
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Trochoid type |
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Trochoid type |
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Cooling system |
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Water-cooled |
forced |
Water-cooled |
forced |
Water-cooled |
forced |
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circulation |
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circulation |
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circulation |
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Water pump type |
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Centrifugal |
impeller |
Centrifugal |
impeller |
Centrifugal |
impeller |
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type |
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type |
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type |
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*1: |
Up to 1999 model |
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www.mivec.co.nz |
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*2: |
From 2000 model |
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E Mitsubishi Motors Corporation |
May 2000 |
PWEE9502-G |
Revised |
4G9 ENGINE (E–W) – General Information |
11A-0-5 |
4G94
Descriptions |
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4G94–SOHC |
4G94–DOHC–GDI |
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Type |
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In-line OHV, SOHC |
In-line OHV, DOHC |
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Number of cylinders |
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4 |
4 |
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Combustion chamber |
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Pentroof type |
Pentroof type |
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Total displacement dm3 |
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1,999 |
1,999 |
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Cylinder bore mm |
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81.5 |
81.5 |
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Piston stroke mm |
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95.8 |
95.8 |
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Compression ratio |
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9.5 |
10.6 |
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Valve timing |
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Intake |
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Opens |
2_ |
15_ |
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valve |
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(BTDC) |
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Closes |
58_ |
51_ |
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(ABDC) |
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Exhaust |
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Opens |
58_ |
55_ |
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valve |
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(BBDC) |
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Closes |
10_ |
15_ |
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(ATDC) |
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Lubrication system |
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Pressure feed, full-flow filtration |
Pressure feed, full-flow filtration |
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Oil pump type |
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Trochoid type |
Trochoid type |
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Cooling system |
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Water-cooled forced circulation |
Water-cooled forced circulation |
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Water pump type |
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Centrifugal impeller type |
Centrifugal impeller type |
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www.mivec.co.nz
E Mitsubishi Motors Corporation |
MarJuly. 20011997 |
PWEE9502--CI |
Revised |
4G9 ENGINE (E–W) – Specifications
1. SPECIFICATIONS
SERVICE SPECIFICATIONS
Items |
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Standard value |
Limit |
Timing belt |
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Auto-tensioner rod protrusion amount (When removed from engine) |
11 |
– |
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mm |
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Auto-tensioner rod stroke mm |
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Within 1 |
– |
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Auto-tensioner rod protrusion amount (When checking with installed |
3.8 – 4.5 |
– |
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on engine) mm |
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Rocker arms and camshaft |
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Camshaft cam |
4G92–SOHC*1 |
Intake |
37.34 |
36.84 |
height mm |
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Exhaust |
36.79 |
36.29 |
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4G92–SOHC*2 |
Intake |
37.78 |
37.28 |
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Exhaust |
37.83 |
37.33 |
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4G92–SOHC*3 |
Intake |
36.92 |
36.42 |
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Exhaust |
36.70 |
36.65 |
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4G93–SOHC*4 |
Intake |
37.53 |
37.03 |
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Exhaust |
37.64 |
37.14 |
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4G93–SOHC*5 |
Intake |
37.11 |
36.61 |
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Exhaust |
37.15 |
36.65 |
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4G94–SOHC |
Intake |
37.91 |
37.41 |
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Exhaust |
37.70 |
37.20 |
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4G93–DOHC |
Intake |
35.31 |
34.81 |
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Exhaust |
35.20 |
34.70 |
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4G93–DOHC–GDI |
Intake |
35.49 |
34.99 |
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Exhaust |
34.73 |
34.23 |
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4G94–DOHC–GDI |
Intake |
35.49 |
34.99 |
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Exhaust |
34.91 |
34.41 |
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Valve clearance mm |
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Intake |
0.09 |
– |
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Exhaust |
0.20 |
– |
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Camshaft journal O.D. mm |
SOHC |
26.0 |
– |
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DOHC |
45.0 |
– |
Rocker cover and camshaft (MIVEC) |
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Camshaft height mm |
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Intake A |
36.41 |
36.91 |
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Intake B |
33.58 |
33.08 |
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Exhaust A |
35.83 |
35.33 |
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Exhaust B |
34.24 |
33.74 |
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Valve clearance (cold engine) mm |
Intake |
0.1 |
– |
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Exhaust |
0.2 |
– |
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*1: LANCER for Europe and CARISMA for Europe
*2: LANCER for general export and CARISMA for 6B model
*3: LANCER for Europe (from 2001 model) and CARISMA for Europe (from 2001 model) *4: Except for Europe
*5: For Europe
11A-1-1
www.mivec.co.nz
E Mitsubishi Motors Corporation |
Jun. 2002 |
PWEE9502-K |
Revised |
11A-1-2 |
4G9 ENGINE (E–W) – Specifications |
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Items |
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Standard value |
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Limit |
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Cylinder head and valve |
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Cylinder head gasket surface flatness mm |
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Less than 0.03 |
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0.2 |
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Grinding limit of cylinder head gasket surface mm |
– |
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0.2* |
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*Total resurfacing depth of both cylinder head and cylinder block |
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Cylinder head overall height mm |
SOHC |
119.9 – 120.1 |
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– |
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DOHC |
131.9 – 132.1 |
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– |
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DOHC–MIVEC |
119.8 – 120.0 |
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– |
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DOHC–GDI |
131.9 – 132.1 |
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– |
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Thickness of valve |
SOHC |
Intake |
1.0 |
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0.5 |
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head (margin) mm |
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Exhaust |
1.3 |
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0.8 |
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DOHC |
Intake |
1.0 |
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0.5 |
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Exhaust |
1.2 |
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0.7 |
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Valve overall height |
SOHC |
Intake |
110.15 |
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109.65 |
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mm |
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Exhaust |
113.70 |
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113.20 |
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DOHC |
Intake |
104.19 |
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103.69 |
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Exhaust |
103.87 |
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103.37 |
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DOHC–MIVEC |
Intake |
115.63 |
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115.13 |
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Exhaust |
115.63 |
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115.13 |
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DOHC–GDI |
Intake |
104.19 |
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103.69 |
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Exhaust |
103.87 |
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103.37 |
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Valve spring free length mm |
SOHC (with lash ad- |
50.9 |
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49.9 |
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juster) |
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SOHC (with adjust- |
49.5 |
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48.5 |
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ing screw) |
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DOHC |
45.0 |
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44.0 |
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DOHC–MIVEC |
51.5 |
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50.5 |
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DOHC–GDI |
44.8 |
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43.8 |
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Valve spring out-of-squareness |
|
Max. 2_ |
|
4_ |
|
|
|
|
|
|
|
|
|
Valve stem to valve |
Except DOHC–GDI |
Intake |
0.02 – 0.05 |
|
0.10 |
|
guide clearance mm |
for PAJERO io |
|
|
|
|
|
Exhaust |
0.05 – 0.09 |
|
0.15 |
||
|
|
|
|
|||
|
|
|
|
|
|
|
|
|
DOHC–GDI |
Intake |
0.02 – 0.05 |
|
0.10 |
|
|
for PAJERO io |
|
|
|
|
|
|
Exhaust |
0.04– 0.06 |
|
0.15 |
|
|
|
|
|
|||
|
|
|
|
|
|
|
|
Valve seat valve contact width mm |
|
0.9 – 1.3 |
|
– |
|
|
|
|
|
|
|
|
|
Valve guide projection from cylinder head |
SOHC |
14.0 |
|
– |
|
|
upper surface mm |
|
|
|
|
|
|
|
DOHC |
19.0 |
|
– |
|
|
|
|
|
|||
|
|
|
|
|
|
|
www.mivec.co.nz
E Mitsubishi Motors Corporation |
Jun. 2002 |
PWEE9502-K |
Revised |
4G9 ENGINE (E–W) – Specifications
|
Items |
|
|
|
Standard value |
Limit |
|
|
|
|
|
|
|
|
Valve stem projec- |
SOHC |
|
Intake |
49.30 |
49.80 |
|
tion mm |
|
|
|
|
|
|
|
Exhaust |
49.35 |
49.85 |
||
|
|
|
|
|||
|
|
|
|
|
|
|
|
|
DOHC |
|
Intake |
46.70 |
47.20 |
|
|
|
|
|
|
|
|
|
|
|
Exhaust |
46.65 |
47.15 |
|
|
|
|
|
|
|
|
|
DOHC–MIVEC |
|
Intake |
58.13 |
58.63 |
|
|
|
|
|
|
|
|
|
|
|
Exhaust |
57.85 |
58.35 |
|
|
|
|
|
|
|
|
|
DOHC–GDI |
|
Intake |
46.70 |
47.20 |
|
|
|
|
|
|
|
|
|
|
|
Exhaust |
46.65 |
47.15 |
|
|
|
|
|
|
|
|
Cylinder head bolt shank length mm |
|
– |
96.4 |
||
|
|
|
|
|
|
|
|
Valve stem O.D. mm |
|
|
|
6.0 |
– |
|
|
|
|
|
|
|
|
Valve face angle |
|
|
|
45_ – 45.5_ |
– |
|
|
|
|
|
||
|
Valve spring load/installed height N/mm |
|
SOHC |
216/44.2 |
– |
|
|
|
|
|
|
|
|
|
|
|
|
DOHC |
255/44.5 |
– |
|
|
|
|
|
|
|
|
|
|
|
DOHC–MIVEC |
255/44.5 |
– |
|
|
|
|
|
|
|
|
|
|
|
DOHC–GDI |
196/37.5 |
– |
|
|
|
|
|
|
|
|
Valve guide I.D. mm |
|
|
|
6.0 |
– |
|
Font case, oil pump and oil pan |
|
|
|
||
|
|
|
|
|||
|
|
|
|
|
||
|
Oil pump tip clearance mm |
|
0.06 – 0.18 |
– |
||
|
|
|
|
|
||
|
Oil pump side clearance mm |
|
0.04 – 0.10 |
– |
||
|
|
|
|
|
||
|
Oil pump body clearance mm |
|
0.10 – 0.18 |
0.35 |
||
|
Piston and connecting rod |
|
|
|
||
|
|
|
|
|||
|
|
|
|
|
||
|
Piston ring to piston ring groove clearance |
|
No. 1 |
0.03 – 0.07 |
0.1 |
|
|
mm |
|
|
|
|
|
|
|
|
No. 2 |
0.02 – 0.06 |
0.1 |
|
|
|
|
|
|||
|
|
|
|
|
|
|
|
Piston ring end gap |
No. 1 |
|
4G92, 4G93 |
0.25 – 0.40 |
0.8 |
|
mm |
|
|
|
|
|
|
|
|
4G94 |
0.15 – 0.30 |
0.8 |
|
|
|
|
|
|||
|
|
|
|
|
|
|
|
|
No. 2 |
|
0.40 – 0.55 |
0.8 |
|
|
|
|
|
|
|
|
|
|
Oil ring |
|
SOHC (4G92, 4G93) |
0.20 – 0.60 |
1.0 |
|
|
|
|
|
|
|
|
|
|
|
SOHC (4G94), |
0.10 – 0.35 |
1.0 |
|
|
|
|
DOHC |
|
|
|
|
|
|
|
|
|
|
Crankshaft pin oil clearance mm |
|
0.02 – 0.05 |
0.1 |
||
|
|
|
|
|
||
|
Piston pin press-in load N [Room temperature] |
|
4,500 – 14,700 |
– |
||
|
|
|
|
|
||
|
Connecting rod big end side clearance mm |
|
0.10 – 0.25 |
0.4 |
||
|
|
|
|
|
|
|
|
Piston pin O.D. mm |
|
|
|
19.0 |
– |
|
|
|
|
|
|
|
|
Piston O.D. mm |
|
|
4G92, 4G93 |
81.0 |
– |
|
|
|
|
|
|
|
|
|
|
|
4G94 |
81.5 |
– |
|
|
|
|
|
||
|
Crankshaft, cylinder block, flywheel and drive plate |
|
|
|||
|
|
|
|
|
||
|
Crankshaft journal oil clearance mm |
|
0.02 – 0.04 |
0.1 |
||
|
|
|
|
|
||
|
Cylinder block gasket surface flatness mm |
|
0.05 |
0.1 |
||
|
|
|
|
|||
|
Grinding limit of cylinder block gasket surface mm |
– |
0.2* |
|||
|
*Total resurfacing depth of both cylinder head and cylinder block |
|
|
|||
|
|
|
|
|
|
|
11A-1-3
www.mivec.co.nz
E Mitsubishi Motors Corporation |
Mar. 2001 |
PWEE9502-I |
Revised |
11A-1-4 |
4G9 ENGINE (E–W) – Specifications |
|
|
|||
|
Items |
|
|
Standard value |
|
Limit |
|
|
|
|
|||
|
|
|
|
|
|
|
|
Cylinder block overall height mm |
4G92 |
243.5 |
|
– |
|
|
|
|
|
|
|
|
|
|
|
4G93 |
263.5 |
|
– |
|
|
|
|
|
|
|
|
|
|
4G94 |
286.7 |
|
– |
|
|
|
|
|
|
|
|
Cylinder block I.D. mm |
|
4G92, 4G93 |
81.0 |
|
– |
|
|
|
|
|
|
|
|
|
|
4G94 |
81.5 |
|
– |
|
|
|
|
|
|
|
|
Piston to cylinder clearance mm |
|
|
0.02 – 0.04 |
|
– |
|
|
|
|
|
|
|
|
Bearing cap bolt shank length mm |
|
– |
|
71.1 |
|
|
|
|
|
|
|
|
|
Crankshaft end play mm |
|
|
0.05 – 0.25 |
|
0.4 |
|
|
|
|
|
|
|
|
Crankshaft journal O.D. mm |
|
|
50 |
|
– |
|
|
|
|
|
|
|
|
Crankshaft pin O.D. mm |
|
|
45 |
|
– |
|
|
|
|
|
|
|
REWORK DIMENSIONS |
|
|
|
|
|
|
|
Items |
|
|
|
|
Standard value |
|
|
|
|
|
||
|
Cylinder head and valve |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
||
|
Oversize rework dimensions of valve guide hole (both intake and |
0.05 O.S. |
|
11.05 – 11.07 |
||
|
exhaust) mm |
|
|
|
|
|
|
|
|
0.25 O.S. |
|
11.25 – 11.27 |
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
|
|
0.50 O.S. |
|
11.50 – 11.52 |
|
|
|
|
|
|
|
|
Oversize rework dimensions of intake valve |
SOHC |
0.30 O.S. |
|
31.80 – 31.83 |
|
|
seat hole mm |
|
|
|
|
|
|
|
|
0.60 O.S. |
|
32.10 – 32.13 |
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
|
DOHC |
0.30 O.S. |
|
34.30 – 34.32 |
|
|
|
|
|
|
|
|
|
|
|
0.60 O.S. |
|
34.60 – 34.62 |
|
|
|
|
|
|
|
|
Oversize rework dimensions of exhaust valve |
SOHC |
0.30 O.S. |
|
29.30 – 29.32 |
|
|
seat hole mm |
|
|
|
|
|
|
|
|
0.60 O.S. |
|
29.60 – 29.62 |
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
|
DOHC |
0.30 O.S. |
|
30.80 – 30.82 |
|
|
|
|
|
|
|
|
|
|
|
0.60 O.S. |
|
31.10 – 31.13 |
|
Crankshaft, flywheel and drive plate |
|
|
|
|
|
|
|
|
|
|
||
|
|
|
|
|||
|
Crankshaft out of roundness and taper of journal and pin mm |
|
|
0.005 |
||
|
|
|
|
|
|
|
NOTE |
|
|
|
|
|
|
O.D.: Outer diameter |
|
|
|
|
|
|
I.D.: Inner diameter |
|
|
|
|
|
|
O.S.: Oversize diameter |
|
|
|
|
|
|
www.mivec.co.nz
E Mitsubishi Motors Corporation |
Mar. 2001 |
PWEE9502-I |
Revised |
|
4G9 ENGINE (E–W) – Specifications |
||
TORQUE SPECIFICATIONS |
|
|
|
|
Items |
|
Nm |
|
|
||
|
Alternator and ignition system |
|
|
|
|
|
|
|
|
|
|
|
Oil level gauge |
|
13 |
|
|
|
|
|
Distributor |
|
12 |
|
|
|
|
|
Ignition coil |
|
10 |
|
|
|
|
|
Spark plug |
|
25 |
|
|
|
|
|
Crankshaft bolt |
|
182 ± 4 |
|
|
|
|
|
Alternator brace (M8) |
|
23 |
|
|
|
|
|
Alternator brace (M10) |
|
49 |
|
|
|
|
|
Lock bolt |
|
23 |
|
|
|
|
|
Adjusting bolt |
|
5 |
|
|
|
|
|
Power steering pump pulley |
|
25 |
|
|
|
|
|
Power steering pump bracket stay |
|
49 |
|
|
|
|
|
Power steering pump bracket (M8) |
|
21 |
|
|
|
|
|
Power steering pump bracket (M10) |
|
44 |
|
|
|
|
|
Alternator pivot bolt |
|
44 |
|
|
|
|
|
Center cover |
|
3 |
|
|
|
|
|
Ignition failure sensor (M6) |
|
5 |
|
|
|
|
|
Ignition failure sensor (M8) |
|
23 |
|
|
|
|
|
Ignition failure sensor bracket |
|
10 |
|
|
|
|
|
Cam position sensor |
|
9 |
|
|
|
|
|
Cam position sensor support |
|
13 |
|
|
|
|
|
Cam position sensing cylinder |
|
21 |
|
|
|
|
|
Engine cover |
|
2.9 |
|
Timing belt |
|
|
|
|
|
|
|
|
|
|
|
Camshaft sprocket bolt |
|
88 |
|
|
|
|
|
Cam position sensor |
|
9.8 |
|
|
|
|
|
Crank angle sensor |
|
9.8 |
|
|
|
|
|
Timing belt rear cover |
|
11 |
|
|
|
|
|
Timing belt rear upper cover |
|
11 |
|
|
|
|
|
Timing belt tensioner |
|
24 |
|
|
|
|
|
Engine support bracket, right |
|
49 |
|
|
|
|
|
Accessory mount |
|
49 |
|
|
|
|
|
Timing belt cover |
|
11 |
|
|
|
|
|
Tensioner pulley bolt |
|
49 |
|
|
|
|
|
Tensioner arm bolt |
|
44 |
|
|
|
|
|
Auto-tensioner bolt |
|
13 |
|
|
|
|
|
Idler pulley bolt |
|
36 |
|
|
|
|
11A-1-5
www.mivec.co.nz
E Mitsubishi Motors Corporation |
Jun. 2002 |
PWEE9502-K |
Revised |
11A-1-6 |
4G9 ENGINE (E–W) – Specifications |
|||
|
Items |
|
|
Nm |
|
|
|
||
|
Fuel system and emission system |
|
|
|
|
|
|
||
|
|
|
|
|
|
Breather tube |
|
|
21 |
|
|
|
|
|
|
Fuel pump |
|
|
18 |
|
|
|
|
|
|
Carburetor |
|
|
17 |
|
|
|
|
|
|
EGR valve |
|
|
21 |
|
|
|
|
|
|
Cover <Without EGR valve> |
|
|
12 |
|
|
|
|
|
|
Fuel return pipe |
|
|
9 |
|
|
|
|
|
|
Delivery pipe |
|
|
12 |
|
|
|
|
|
|
Fuel pressure regulator |
|
|
9 |
|
|
|
|
|
|
Throttle body stay <MIVEC> |
|
|
23 |
|
|
|
|
|
|
Throttle body stay <4G94> |
|
|
24 |
|
|
|
|
|
|
Throttle body |
|
|
19 |
|
|
|
|
|
|
Throttle cable bracket |
|
|
19 |
|
|
|
|
|
|
Stay |
|
|
24 |
|
|
|
|
|
|
Harness bracket |
|
|
11 |
|
|
|
|
|
|
Vacuum hose and pipe assembly <Engine with solenoid valve> (Flange bolt) |
|
11 |
|
|
|
|
|
|
|
Vacuum hose and pipe assembly <Engine with solenoid valve> (Bolt and |
|
9 |
|
|
washer assembly) |
|
|
|
|
|
|
|
|
|
Vacuum hose and pipe assembly <Engine without solenoid valve> |
|
10 |
|
|
|
|
|
|
|
Solenoid valve assembly |
|
|
9 |
|
Throttle body and EGR system (GDI) |
|
|
|
|
|
|
||
|
|
|
|
|
|
Air intake resonator |
|
|
9 |
|
|
|
|
|
|
Intake manifold stay (M8) |
|
|
20 |
|
|
|
|
|
|
Intake manifold stay (M10) |
|
|
30 |
|
|
|
|
|
|
Water hose clamp |
|
|
13 |
|
|
|
|
|
|
Water pipe |
|
|
11 |
|
|
|
|
|
|
Throttle body |
|
|
18 |
|
|
|
|
|
|
Throttle body stay |
|
|
24 |
|
<CARISMA from 2001 model, SPACE STAR from 2001 model, GALANT> |
|
|
|
|
|
|
|
|
|
Throttle body stay <For PAJERO io – 4G94> |
|
18 |
|
|
|
|
|
|
|
EGR valve (Bolt and washer assembly) |
|
18 |
|
|
|
|
|
|
|
EGR valve (Flange bolt) |
|
|
24 |
|
|
|
|
|
|
Engine hanger |
|
|
18 |
|
|
|
|
|
|
EGR valve support bolt |
|
|
18 |
|
|
|
|
|
|
EGR valve support nut |
|
|
23 |
|
|
|
|
|
|
Air by-pass valve |
|
|
9 |
|
|
|
|
|
www.mivec.co.nz
E Mitsubishi Motors Corporation |
JunMar.. 20021 |
PWEE9502--KI |
Revised |
|
|
4G9 ENGINE (E–W) – Specifications |
||
|
Items |
|
|
Nm |
|
|
|
||
|
Intake manifold and exhaust manifold |
|
|
|
|
|
|
||
|
|
|
|
|
|
Exhaust manifold (M8) |
|
|
18 |
|
|
|
|
|
|
Exhaust manifold (M10) |
|
|
29 |
|
|
|
|
|
|
Exhaust manifold bracket (M8) |
|
|
19 |
|
|
|
|
|
|
Exhaust manifold bracket (M10 Bolt and washer assembly) |
|
35 |
|
|
|
|
|
|
|
Exhaust manifold bracket (M10 Flange bolt) |
|
98 |
|
|
|
|
|
|
|
Engine hanger (Bolt with head mark “4”) |
|
12 |
|
|
|
|
|
|
|
Engine hanger (Bolt with head mark “7”) |
|
19 |
|
|
|
|
|
|
|
Oil level gauge guide |
|
|
14 |
|
|
|
|
|
|
Boost sensor |
|
|
5 |
|
|
|
|
|
|
Intake air temperature sensor |
|
|
13 |
|
|
|
|
|
|
Heat protector |
|
|
13 |
|
|
|
|
|
|
Intake manifold |
|
|
20 |
|
|
|
|
|
|
Intake manifold stay |
|
|
31 |
|
|
|
|
|
|
Oxygen sensor |
|
|
44 |
|
Intake manifold (GDI) |
|
|
|
|
|
|
|
|
|
|
|
||
|
Vacuum pipe and hose <Except for PAJERO io> |
|
11 |
|
|
|
|
|
|
|
Vacuum pipe and hose <For PAJERO io> |
|
9 |
|
|
|
|
|
|
|
Solenoid valve |
|
|
9 |
|
|
|
|
|
|
Fuel pump protector |
|
|
23 |
|
|
|
|
|
|
Connector bracket |
|
|
11 |
|
|
|
|
|
|
Branch tube (M6 x 14) |
|
|
11 |
|
|
|
|
|
|
Branch tube (M6 x 18) |
|
|
9 |
|
|
|
|
|
|
Intake manifold stay |
|
|
30 |
|
|
|
|
|
|
Accelerator cable bracket |
|
|
9 |
|
|
|
|
|
|
Vacuum pipe |
|
|
11 |
|
|
|
|
|
|
Intake manifold |
|
|
19 |
|
Exhaust manifold (GDI) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Oil level gauge guide |
|
|
13 |
|
|
|
|
|
|
Exhaust manifold cover |
|
|
13 |
|
|
|
|
|
|
Engine hanger bolt |
|
|
24 |
|
|
|
|
|
|
Engine hanger nut (M8) |
|
|
18 |
|
|
|
|
|
|
Engine hanger nut (M10) |
|
|
29 |
|
|
|
|
|
|
Exhaust manifold bracket (M8 × |
20) |
|
18 |
|
|
|
|
|
|
Exhaust manifold bracket (M8 × |
22) |
|
35 |
|
|
|
|
|
|
Exhaust manifold bracket (M8 × |
25) |
|
19 |
|
|
|
|
|
|
Exhaust manifold bracket (M10) |
|
|
35 |
|
|
|
|
|
|
Exhaust manifold bracket <For PAJERO io> |
|
98 |
|
|
|
|
|
|
11A-1-6a
www.mivec.co.nz
E Mitsubishi Motors Corporation |
Jun. 2002 |
PWEE9502-K |
Revised |
11A-1-6b |
4G9 ENGINE (E–W) – Specifications |
|||
|
Items |
|
|
Nm |
|
|
|
||
|
|
|
|
|
|
Exhaust manifold (M8) |
|
|
17 |
|
|
|
|
|
|
Exhaust manifold (M10) |
|
|
29 |
|
Injector and fuel pump assembly (GDI) |
|
|
|
|
|
|
||
|
|
|
|
|
|
Fuel low pressure pipe (M6) |
|
|
18 |
|
|
|
|
|
|
Fuel low pressure pipe (M8) |
|
|
9 |
|
|
|
|
|
|
Fuel nipple |
|
|
9 |
|
|
|
|
|
|
Clamp |
|
|
9 |
|
|
|
|
|
|
Fuel feed pipe |
|
|
11 |
|
|
|
|
|
|
Fuel pump |
|
|
17 |
|
|
|
|
|
|
Harness bracket |
|
|
11 |
|
|
|
|
|
|
Fuel pipe |
|
|
11 |
|
|
|
|
|
|
Fuel return pipe |
|
|
11 |
|
|
|
|
|
|
Fuel return pipe clamp |
|
|
9 |
|
|
|
|
|
|
Fuel high pressure regulator |
|
|
18 |
|
|
|
|
|
|
Fuel pressure sensor <Except for PAJERO io> |
|
23 |
|
|
|
|
|
|
|
Fuel pressure sensor <For PAJERO io> |
|
18 |
|
|
|
|
|
|
|
Spacer |
|
|
18 |
|
|
|
|
|
|
Pump camshaft case |
|
|
23 |
|
|
|
|
|
|
Injector holder |
|
|
22 |
|
|
|
|
|
|
Delivery pipe and injector |
|
|
11 |
|
Intake and exhaust manifold <4G94–GDI for PAJERO io> |
|
|
|
|
|
|
||
|
|
|
|
|
|
Vacuum pipe and hose |
|
|
9 |
|
|
|
|
|
|
Solenoid valve |
|
|
9 |
|
|
|
|
|
|
Fuel pump protector |
|
|
23 |
|
|
|
|
|
|
Connector bracket |
|
|
11 |
|
|
|
|
|
|
Intake manifold stay nut |
|
|
29 |
|
|
|
|
|
|
Intake manifold stay bolt |
|
|
31 |
|
|
|
|
|
|
Low pressure fuel pipe |
|
|
9 |
|
|
|
|
|
|
Intake manifold |
|
|
20 |
|
|
|
|
|
|
Exhaust manifold cover |
|
|
13 |
|
|
|
|
|
|
Engine hanger |
|
|
18 |
|
|
|
|
|
|
Exhaust manifold bracket |
|
|
98 |
|
|
|
|
|
|
Exhaust manifold (M8) |
|
|
17 |
|
|
|
|
|
|
Exhaust manifold (M10) |
|
|
29 |
|
Water pump and water hose |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Water pump |
|
|
24 |
|
|
|
|
|
|
Water inlet pipe |
|
|
14 |
|
|
|
|
|
|
Thermostat case |
|
|
24 |
|
|
|
|
|
www.mivec.co.nz
E Mitsubishi Motors Corporation |
Jun. 2002 |
PWEE9502-K |
Revised |
4G9 ENGINE (E–W) – Specifications |
11A-1-6c |
|
|
|
|
Items |
Nm |
|
|
|
|
Water inlet fitting <Except PAJERO io> |
19 |
|
|
|
|
Water inlet fitting <PAJERO io> |
24 |
|
|
|
|
Water by-pass fitting |
24 |
|
|
|
|
Water pipe |
14 |
|
|
|
|
Water outlet fitting <Except PAJERO io> |
19 |
|
|
|
|
Water outlet fitting <PAJERO io> |
24 |
|
|
|
|
Engine coolant temperature gauge unit |
10 |
|
|
|
|
Engine coolant temperature sensor |
29 |
|
|
|
|
Water fitting |
24 |
|
|
|
|
Rocker arms and camshaft |
|
|
Lock nut
Rocker arm shaft
Harness bracket
Rocker cover
Bearing cap bolt (M6)
Bearing cap bolt (M8)
Beam camshaft cap (M6)
Beam camshaft cap (M8)
Rocker cover and camshafts (MIVEC)
Rocker cover
Oil pump
Arm spring holder
Camshaft bearing cap (M6)
Camshaft bearing cap (M8)
Oil control valve
Rocker arms and rocker shaft caps (MIVEC)
Rocker shaft cap
Cylinder head and valves
CylInder head bolt
Oil pressure switch
Front case and oil pump
Oil pump cover
Oil pump case
Relief plug
Oil screen
Oil pan
Upper oil pan (M6)
9
31
10 |
www.mivec.co.nz |
|
3.5 |
||
|
||
11 |
|
|
24 |
|
|
11 |
|
|
21 |
|
|
4 |
|
|
11 |
|
|
11 |
|
|
11 |
|
|
23 |
|
|
9 |
|
|
11 |
|
74 Nm and then completely loosen, finally tighten 20 Nm + 90_ + 90_
10
10
14
44
19
9
9
E Mitsubishi Motors Corporation |
Jun. 2002 |
PWEE9502-K |
Revised |
11A-1-6d |
4G9 ENGINE (E–W) – Specifications |
|||
|
Items |
|
|
Nm |
|
|
|
||
|
|
|
|
|
|
Upper oil pan (M8) |
|
|
24 |
|
|
|
|
|
|
Lower oil pan |
|
|
11 |
|
|
|
|
|
|
Cover |
|
|
7 |
|
|
|
|
|
|
Baffle plate <DOHC–MPI> |
|
|
7 |
|
|
|
|
|
|
Baffle plate <Except DOHC–MPI> |
|
11 |
|
|
|
|
|
|
|
Drain plug |
|
|
39 |
|
|
|
|
|
|
Oil pressure switch |
|
|
10 |
|
|
|
|
|
|
Transmission stay |
|
|
23 |
|
Piston and connecting rod |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Connecting rod cap nut |
|
|
20 + 90_ to 100_ |
|
Crankshaft, cylinder block, flywheel and drive plate |
|
|
|
|
|
|
||
|
|
|
|
|
|
Bearing cap bolt |
|
|
25 + 90_ to 100_ |
|
|
|
|
|
|
Oil seal case |
|
|
11 |
|
|
|
|
|
|
Bell housing cover (Flange bolt) |
|
|
10 |
|
|
|
|
|
|
Bell housing cover (Bolt and washer assembly) |
|
9 |
|
|
|
|
|
|
|
Rear plate <SPACE STAR> |
|
|
10 |
|
|
|
|
|
|
Rear plate <Except SPACE STAR> |
|
11 |
|
|
|
|
|
|
|
Drive plate bolt |
|
|
98 |
|
|
|
|
|
|
Flywheel bolt |
|
|
98 |
|
|
|
|
|
|
Baffle plate |
|
|
9 |
|
|
|
|
|
|
Knock sensor |
|
|
23 |
|
|
|
|
|
www.mivec.co.nz
E Mitsubishi Motors Corporation |
Jun. 2002 |
PWEE9502-K |
Revised |
4G9 ENGINE (E-W) - Specifications |
11A-1-7 |
|
|
NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA
A new type of bolts, to be tightened in plastic area, is currently used for some parts of the engine. The tightening method for bolts of this type is different from the conventional one. Be sure to observe the method described in the text when tightening the bolts.
Service limits are provided for the bolts. Make sure that the service limits described in the text are strictly observed.
DAreas where the bolts are in use:
(1)Cylinder head bolts
(2)Main bearing cap bolts
(3)Connecting rod cap bolts
DTightening method
After tightening the bolts to the specified torque, tighten them another 90_ or 180_ (twice 90_). The tightening method varies on different areas. Observe the tightening method described in the text.
SEALANT
Items |
Specified sealant |
Quantity |
|
Water pump |
Mitsubishi Genuine Part No.MD970389 or equivalent |
As required |
|
Thermostat case |
Mitsubishi Genuine Part No.MD970389 or equivalent |
As required |
|
Water by-pass fitting |
Mitsubishi Genuine Part No.MD970389 or equivalent |
As required |
|
Water fitting |
Mitsubishi Genuine Part No.MD970389 or equivalent |
As required |
|
Engine coolant temperature sensor |
3M |
Nut Locking Part No.4171 or equivalent |
As required |
Engine coolant temperature gauge unit |
3M |
ATD Part No.8660 or equivalent |
As required |
Camshaft bearing cap |
3M |
ATD Part No.8660 or equivalent |
As required |
Semi-circular packing |
3M |
ATD Part No.8660 or equivalent |
As required |
Rocker cover |
3M |
ATD Part No.8660 or equivalent |
As required |
Beam camshaft cap |
Mitsubishi Genuine Part No.MD970389 or equivalent |
As required |
|
Cover |
3M |
ATD Part No.8660 or equivalent |
As required |
Cylinder head |
Mitsubishi Genuine Part No.MD970389 or equivalent |
As required |
|
Oil pressure switch |
3M |
ATD Part No.8660 or equivalent |
As required |
Water outlet fitting |
Mitsubishi Genuine Part No.MD970389 or equivalent |
As required |
|
Oil pump case |
Mitsubishi Genuine Part No.MD970389 or equivalent |
As required |
|
Oil pan/Upper oil pan/Lower oil pan |
Mitsubishi Genuine Part No.MD970389 or equivalent |
As required |
|
Oil seal case |
Mitsubishi Genuine Part No.MD970389 or equivalent |
As required |
|
Drive plate bolt |
3M |
Nut Locking Part No.4171 or equivalent |
As required |
Flywheel bolt |
3M |
Nut Locking Part No.4171 or equivalent |
As required |
Cam position sensor support |
Mitsubishi Genuine Part No.MD970389 or equivalent |
As required |
|
Oil control valve |
3M |
ATD Part No.8660 or equivalent |
As required |
Camshaft holder |
3M |
ATD Part No.8660 or equivalent |
As required |
|
|
|
|
www.mivec.co.nz
E Mitsubishi Motors Corporation |
July 2000 |
PWEE9502-H |
Revised |
11A-1-8 |
4G9 ENGINE (E - W) - Specifications |
FORM-IN-PLACE GASKET
The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to apply the gasket evenly without a break, while observing the correct bead size.
The FIPG used in the engine is a room temperature vulcanization (RTV) type and is supplied in a 100-gram tube (Part No. MD970389 or MD997110). Since the RTV hardens as it reacts with the moisture in the atomospheric air, it is normally used in the metallic flange areas. The FIPG, Part No. MD970389, can be used for sealing both engine oil and coolant, while Part No. 997110 can only be used for engine oil sealing.
Disassembly
The parts assembled with the FIPG can be easily disassembled without use of a special method. In some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces. For removal of the oil pan, the special tool “Oil Pan Remover” (MD998727) is available. Be sure to use the special tool to remove the oil pan. <Except aluminium die-cast oil pans>
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraperwww.mivec.co.nz
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure that there are no oils, greases and foreign substances deposited on the application surfaces. Do not forget to remove the old sealant remained in the bolt holes.
When assembling parts with the FIPG, you must observe some precautions, but the procedures is very simple as in the case of a conventional precut gasket.
Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time (about one hour) has passed after installation is completed.
The FIPG application procedure may vary on different areas. Observe the procedure described in the text when applying the FIPG.
E Mitsubishi Motors Corporation |
May 1995 |
PWEE9502 |
4G9 ENGINE (E - W) - Special Tools |
11A-2-1 |
2. SPECIAL TOOLS
Tool |
Number |
Name |
Use |
|
|
|
|
|
MB990938 |
Handle |
Use with MD998776 |
|
|
|
|
MB990767 |
Crankshaft pulley |
Holding camshaft sprocket when loosening |
|
holder |
and tightening of bolt. |
|
|
Use with MD998719 |
|
|
|
MD998440 |
Leak-down tester |
|
|
MD998442 |
Air bleed wire |
|
|
MD998713 |
Camshaft oil seal |
|
installer |
|
|
MD998716 |
Crankshaft wrench |
|
|
MD998717 |
Crankshaft front oil |
|
seal installer |
|
|
Air bleeding of lash adjuster |
|
Installation of camshaft oil seal |
|
Rotation of crankshaft when installing piston |
|
and timing belt. |
www.mivec.co.nz |
Installation of crankshaft front oil seal |
|
|
|
MB991653 |
Cylinder head bolt |
Tightening and loosening of cylinder head bolt |
|
wrench |
|
|
|
|
|
MB991659 |
Guide D |
Removal of piston pin (Use with MD998780) |
|
|
|
|
E Mitsubishi Motors Corporation |
Nov. 1995 |
PWEE9502-A |
Revised |
11A-2-2 |
4G9 ENGINE (E - W) - Special Tools |
Tool |
Number |
Name |
|
|
|
|
MD998719 |
Pulley holder pin |
|
|
(2) |
|
|
|
MD998727 |
Oil pan remover |
|
|
MD998754 Pin
MD998767 |
Tensioner pulley |
|
socket wrench |
|
|
MD998772 |
Valve spring |
|
compressor |
|
|
MD998774 |
Valve stem seal |
|
installer |
|
|
MD998775 |
Valve stem seal |
|
installer |
|
|
MD998776 |
Crankshaft rear oil |
|
seal installer |
|
|
Use |
|
|
|
Use with MB990767 |
|
|
|
Removal of the oil pan |
|
|
|
Use with MB990767 |
|
|
|
Adjustment of timing belt tension |
www.mivec.co.nz |
|
|
Removal and installation of valve and related |
|
parts |
|
|
|
Installation of valve stem seal |
|
|
|
Installation of valve stem seal |
|
|
|
Installation of crankshaft rear oil seal |
|
Use with MB990938 |
|
|
|
E Mitsubishi Motors Corporation |
Nov. 1995 |
PWEE9502-A |
Revised |
|
4G9 ENGINE (E - W) - Special Tools |
11A-2-3 |
||
|
|
|
|
|
Tool |
Number |
Name |
Use |
|
|
|
|
|
|
|
MD998780 |
SETTING TOOL |
Removal and installation of piston pin |
|
|
|
Piston pin |
|
|
|
|
|
|
|
MD998735 |
Valve spring |
Compression of valve spring |
|
compressor |
|
|
|
|
MD998781 |
Flywheel stopper |
Holding flywheel and drive plate |
|
|
|
MB991477 |
Valve adjusting |
Adjustment of valve clearance (MIVEC) |
|
wrench |
|
|
|
|
MB991478 |
Valve adjusting |
Adjustment of valve clearance (MIVEC) |
|
wrench feeler |
|
|
gauge set |
|
|
|
|
MB991479 |
Rocker arm |
Adjustment of valve clearance (MIVEC) |
|
piston checker |
|
|
|
|
MD998784 |
Valve spring |
Compression of valve spring (MIVEC) |
|
compressor |
(Use with MD998772) |
|
adapter |
|
|
|
|
www.mivec.co.nz
E Mitsubishi Motors Corporation |
Nov. 1995 |
PWEE9502-A |
Revised |
4G9 ENGINE (E–W) – Alternator and Ignition System |
11A-3-1 |
3. ALTERNATOR AND IGNITION SYSTEM
REMOVAL AND INSTALLATION <SOHC> (Engines with distributor)
25 Nm |
8 |
5 Nm |
|
|
23 Nm |
3 |
2 |
|
|
44 Nm
23 Nm
49 Nm
1
6
4
5
182 ± 4 Nm
Removal steps
1.Drive belt*
2.Alternator
3.Alternator brace AA" "BA 4. Crankshaft bolt
"BA 5. Crankshaft pulley "BA 6. Front flange
7.Spark plug cable
7
|
|
|
|
12 Nm |
|
|
|
|
9 |
|
|
|
|
|
|
|
|
|
|
|
10 |
|
www.mivec.co.nz |
|
|
|
|
21 Nm |
|
|
|
|
|
|
|
|
12 |
|
|
13 |
|
|
|
|
|
|
|
49 Nm |
|
|
|
44 Nm |
|
|
|
|
|
|
|
44 Nm |
|
|
11 |
|
|
|
25 Nm |
|
|
|
|
8. Spark plug
9. O-ring
10. Distributor
11. Power steering pump pulley
12. Power steering pump bracket stay
13. Power steering pump bracket
NOTE:
*: For details of adjustment, refer to the relevant model’s chassis workshop manual.
EMitsubishi Motors Corporation |
Apr. 2002 |
PWEE9502-J |
Revised |
11A-3-2 4G9 ENGINE (E–W) – Alternator and Ignition System
REMOVAL AND INSTALLATION <SOHC for other than PAJERO io> (Engines without distributor)
7 |
10 Nm |
|
9
25 Nm
2
5 Nm
23 Nm
3
44 Nm
23 Nm
49 Nm
1
6
4 |
5 |
182 ± 4 Nm
Removal steps
1.Drive belt*
2.Alternator
3.Alternator brace AA" "BA 4. Crankshaft bolt
"BA 5. Crankshaft pulley "BA 6. Front flange
7.Spark plug cable
8.Ignition coil
9.Spark plug
10.Ignition failure sensor (From 2001
model vehicles for Europe)
|
11 |
|
9 Nm |
12 |
|
|
|
|
|
13 Nm |
|
8 |
|
|
|
10 |
|
|
5 Nm |
|
|
13 21 Nm |
www.mivec.co.nz |
|
21 Nm |
|
|
|
|
15 |
16 |
|
49 Nm |
|
|
|
44 Nm |
|
44 Nm |
14 |
|
25 Nm |
|
|
11. Cam position sensor
"AA 12. Cam position sensor support
13.Cam position sensing cylinder
14.Power steering pump pulley
15.Power steering pump bracket stay
16.Power steering pump bracket
NOTE:
*: For details of adjustment, refer to the relevant model’s chassis workshop manual.
EMitsubishi Motors Corporation |
Apr. 2002 |
PWEE9502-J |
Revised |
4G9 ENGINE (E–W) – Alternator and Ignition System |
11A-3-2a |
REMOVAL AND INSTALLATION <SOHC for PAJERO io> (Engines without distributor)
5 Nm
10 Nm
10
11
|
|
|
www.mivec.co.nz |
Removal steps |
|
|
|
1. |
Drive belt* |
10. |
Ignition failure sensor (For Europe) |
2. |
Alternator |
11. |
Ignition failure sensor bracket |
3. |
Alternator brace |
|
(For Europe) |
AA" "BA 4. Crankshaft bolt |
12. |
Cam position sensor |
|
"BA 5. Crankshaft pulley |
"AA 13. |
Cam position sensor support |
|
"BA 6. Front flange |
14. |
Cam position sensing cylinder |
|
7. |
Spark plug cable |
15. |
Power steering pump pulley |
8. |
Ignition coil |
16. |
Power steering pump bracket stay |
9. |
Spark plug |
17. |
Power steering pump bracket |
NOTE
*: For details of adjustment, refer to the relevant model’s chassis workshop manual.
EMitsubishi Motors Corporation |
Jun. 2002 |
PWEE9502-K |
Revised |
11A-3-2b 4G9 ENGINE (E - W) - Alternator and Ignition System
Intentionally blank
www.mivec.co.nz
E Mitsubishi Motors Corporation |
Dec. 1998 |
PWEE9502-E |
Added |
4G9 ENGINE (E–W) – Alternator and Ignition System |
11A-3-3 |
REMOVAL AND INSTALLATION <DOHC>
7
3 Nm
10 Nm
9
8
5 Nm
2
23 Nm
3
44 Nm
23 Nm
29 Nm |
5 |
6 |
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182 ± 4 Nm |
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1
4
Removal steps
1.Drive belt*
2.Alternator
3.Alternator brace AA" "BA 4. Crankshaft bolt
"BA 5. Crankshaft pulley "BA 6. Front flange
7.Center cover
8.Ignition coil
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10 |
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25 Nm |
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11 |
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23 Nm |
www.mivec.co.nz |
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21 Nm |
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13 |
14 |
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49 Nm |
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44 Nm |
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44 Nm |
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12 |
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25 Nm |
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9. |
Spark plug cable |
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10. |
Spark plug |
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11. |
Ignition failure sensor |
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12. |
Power steering pump pulley |
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13. |
Power steering pump bracket stay |
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14. |
Power steering pump bracket |
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NOTE:
*: For details of adjustment, refer to the relevant model’s chassis workshop manual.
EMitsubishi Motors Corporation |
AprNov..20021995 |
PWEE9502-AJ |
Revised |
11A-3-4 4G9 ENGINE (E–W) – Alternator and Ignition System
REMOVAL AND INSTALLATION <DOHC–MIVEC>
3 Nm
8
5 Nm |
2 |
23 Nm |
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3 |
44 Nm
23 Nm
49 Nm |
5 |
6 |
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182 ± |
4 Nm |
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1 |
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4
Removal steps
1.Drive belt*
2.Alternator
3.Alternator brace AA" "BA 4. Crankshaft bolt
"BA 5. Crankshaft pulley "BA 6. Front flange
7.Center cover
8.Spark plug cable
9.Ignition coil
7
10 Nm
9 Nm
11
13 Nm
9
10 25 Nm
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12 |
www.mivec.co.nz |
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21 Nm |
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13 |
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21 Nm |
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15 |
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16 |
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49 Nm |
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14 |
44 Nm |
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44 Nm |
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25 Nm |
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10. Spark plug
11. Cam position sensor
"AA 12. Cam position sensor support
13.Cam position sensing cylinder
14.Power steering pump pulley
15.Power steering pump bracket stay
16.Power steering pump bracket
NOTE:
*: For details of adjustment, refer to the relevant model’s chassis workshop manual.
EMitsubishi Motors Corporation |
AprNov..20021995 |
PWEE9502-AJ |
RevisedAdded |
4G9 ENGINE (E–W) – Alternator and Ignition System |
11A-3-5 |
REMOVAL AND INSTALLATION
<DOHC–GDI for CARISMA, SPACE STAR, SPACE RUNNER, GALANT>
2.9 Nm
2
5 Nm
23 Nm
3
44 Nm
23 Nm
6
49 Nm |
5 |
|
1
4
182 ± 4 Nm
Removal steps
1.Drive belt*
2.Alternator
3.Alternator brace AA" "BA 4. Crankshaft bolt
"BA 5. Crankshaft pulley "BA 6. Front flange
7.Engine cover
8.Earth strap (From 2001 model for
CARISMA, From 2001 model for
SPACE STAR)
9.Ignition coil
10.Spark plug
7
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14 5 Nm |
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10 Nm |
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9 |
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8 |
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9 Nm |
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11 |
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25 Nm |
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10 |
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12 |
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13 |
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www.mivec.co.nz |
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13 Nm |
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21 Nm |
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21 Nm |
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16 |
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17 |
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49 Nm |
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44 Nm |
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44 Nm |
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15 |
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25 Nm |
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11. Cam position sensor
"AA 12. Cam position sensor support
13.Cam position sensing cylinder
14.Ignition failure sensor (From 2001 model for CARISMA, From 2001 model for SPACE STAR)
15.Power steering pump pulley
16.Power steering pump bracket stay
17.Power steering pump bracket
NOTE:
*: For details of adjustment, refer to the relevant model’s chassis workshop manual.
EMitsubishi Motors Corporation |
AprNov..20021995 |
PWEE9502-AJ |
Revised |
11A-3-6 4G9 ENGINE (E–W) – Alternator and Ignition System
REMOVAL AND INSTALLATION <DOHC–GDI for PAJERO io>
10 Nm
13
25 Nm
14
5 Nm
5
23 Nm
6
3
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44 Nm |
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23 Nm |
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44 Nm |
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8 |
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9 |
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182 ± |
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4 Nm |
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4 |
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7 |
11 |
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49 Nm |
44 Nm
25 Nm
Removal steps
9 Nm
13 Nm
17
16
21 Nm
1
13 Nm
2
3 
21 Nm
12
44 Nm
10
www.mivec.co.nz
1. |
Oil level gauge |
10. |
Power steering pump pulley |
2. |
Oil level gauge guide |
11. |
Power steering pump bracket stay |
3. |
O-ring |
12. |
Power steering pump bracket |
4. |
Drive belt* |
13. |
Ignition coil |
5. |
Alternator |
14. |
Spark plug |
6. |
Alternator brace |
15. |
Cam position sensor |
AA" "BA 7. Crankshaft bolt |
"AA 16. |
Cam position sensor support |
|
"BA 8. Crankshaft pulley |
17. |
Cam position sensing cylinder |
|
"BA 9. Front flange |
NOTE: |
|
*: For details of adjustment, refer to the relevant model’s |
|
chassis workshop manual. |
EMitsubishi Motors Corporation |
MarNov.. 20011995 |
PWEE9502--AI |
RevisedAdded |
4G9 ENGINE (E–W) – Alternator and Ignition System |
11A-3-7 |
REMOVAL SERVICE POINT
AA"CRANKSHAFT BOLT REMOVAL
(1)Use the special tool to hold the flywheel or the drive plate, and then loosen the crankshaft mounting bolts.
INSTALLATION SERVICE POINTS
Washer
Big chamfered side
"AACAM POSITION SENSOR SUPPORT
INSTALLATION
(1)Apply a 3 mm bead of form-in-place gasket (FIPG) to the area shown.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or equivalent.
"BAFRONT FLANGE / CRANKSHAFT PULLEY /
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CRANKSHAFT BOLT INSTALLATION |
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(1) |
Use the special tool to hold the flywheel or the drive |
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plate. |
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(2) |
Clean and then degrease the front flange contacting |
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surface of the crankshaft pulley. |
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NOTE |
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Degreasing is necessary to prevent decrease in the friction |
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between contacting surfaces. |
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(3) |
Clean the bolt hole in the crankshaft, the crankshaft |
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contacting surface and washer contacting surface of the |
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crankshaft pulley, and the washer. |
www.mivec.co.nz |
|
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|
(4)Apply an appropriately small amount of oil to the threads and seating surface of the crankshaft bolt.
(5)Tighten the crankshaft bolt to the specified torque of 182
± 4 Nm.
EMitsubishi Motors Corporation |
JunNov. 20021995 |
PWEE9502-KA |
Revised |
4G9 ENGINE (E–W) – Timing Belt |
11A-4-1 |
4. TIMING BELT
REMOVAL AND INSTALLATION <SOHC for CARISMA (Up to 1999 model), LANCER (Except from 2001 model for Europe), GALANT>
www.mivec.co.nz
Removal steps |
|
|
||
1. |
Timing belt |
front upper cover |
8. |
Crankshaft angle sensor |
2. |
Timing belt |
front lower cover |
"GA 9. |
(Engines without distributor) |
3. |
Engine support bracket, right |
Crankshaft sprocket |
||
AA" "DA 4. Timing belt |
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"GA 10. |
Crankshaft spacer |
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"CA 5. Tensioner spring |
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(Engines without distributor) |
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"BA 6. Timing belt tensioner |
"GA 11. |
Crankshaft sensing blade |
||
7. |
Timing belt |
rear cover |
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(Engines without distributor) |
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12. |
Crankshaft key |
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AB" "AA 13. |
Camshaft sprocket bolt |
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14. |
Camshaft sprocket |
EMitsubishi Motors Corporation |
Mar. 2001 |
PWEE9502-I |
Revised |
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