Mitsubishi SOHC-4G63, SOHC-4G64 Workshop Manual

ENGINE

4G6 SERIES

CONTENTS

11A-0-1

GENERAL INFORMATION 11A-0-3

1. SPECIFICATIONS 11A-1-1
SERVICE SPECIFICATIONS 11A-1-1

TORQUE SPECIFICATIONS 11A-1-4
NEW TIGHTENING METHOD -

BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA 11A-1-9
SEALANTS 11A-1-9
FORM-IN-PLACE GASKET 11A-1-10

2. SPECIAL TOOLS 11A-2-1

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

3a. INTAKE MANIFOLD (GDI) 11A-3a-1

4. TIMING BELT 11A-4-1

4a. EXHAUST MANIFOLD (GDI) 11A-4a-1

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

5a. FUEL PARTS (GDI) 11A-5a-1

6. WATER PUMP AND INTAKE MANIFOLD 11A-6-1

6a. WATER PUMP AND WATER HOSE (GDI) 11A-6a-1

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7. EXHAUST MANIFOLD 11A-7-1

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

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

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

10. FRONT CASE, COUNTERBALANCE SHAFTS AND OIL PAN 11A-10-1

11. PISTON AND CONNECTING ROD 11A-11-1

12. CRANKSHAFT, FLYWHEEL AND DRIVE PLATE 11A-12-1

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RevisedPWEE9616-A

11A-0-2

NOTES

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PWEE9616

4G6 ENGINE <E-W> -

General Information

GENERAL INFORMATION

SOHC-4G63

Descriptions Specifications

Type In-line OHV, SOHC

Number of cylinders 4

Combustion chamber Pentroof type

11A-0-3

Total displacement dm

Cylinder bore mm 85.0

Piston stroke mm 88.0

Compression ratio 10

Valve timing Intake valve Opens (BTDC) 18_

Lubrication system Pressure feed, full-flow filtration

Oil pump type Involute gear type

3

Closes (ABDC) 58_

Exhaust valve Opens (BBDC) 58_

Closes (ATDC) 18_

1,997

SOHC-4G64

Descriptions Specifications

Type In-line OHV, SOHC

Number of cylinders 4

Combustion chamber Pentroof type

Total displacement dm

Cylinder bore mm 86.5

Piston stroke mm 100.0

Compression ratio 10

Valve timing Intake valve Opens (BTDC) 16_

Lubrication system Pressure feed, full-flow filtration

Oil pump type Involute gear type

E

3

Closes (ABDC) 53_

Exhaust valve Opens (BBDC) 50_

Closes (ATDC) 16_

Aug. 1998Mitsubishi Motors Corporation

2,351

RevisedPWEE9616-A

11A-0-4

t

GDI

Descriptions Specifications

Type In-line OHV, SOHC

Number of cylinders 4

Combustion chamber Pentroof + curved top piston type

4G6 ENGINE <E-W> -

General Information

Total displacement dm

Cylinder bore mm 86.5

Piston stroke mm 100.0

Compression ratio 11.5

Valve timing Intake valve Opens (BTDC) 16_

Lubrication system Pressure feed, full-flow filtration

Oil pump type Involute gear type

3

Closes (ABDC) 60_

Exhaust valve Opens (BBDC) 56_

Closes (ATDC) 16_

2,351

NOTE
GDI is a trademark of Mitsubishi Motors Corporation.

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4G6 ENGINE <E-W> -

Specifications

1. SPECIFICATIONS

SERVICE SPECIFICATIONS

Items Standard value Limit

Timing belt

Auto-tensioner rod projection length mm 12 -

11A-1-1

Auto-tensioner rod pushed-in amount [when pushed with a force of 98

- 196 N] mm

Rocker arms and camshaft

Camshaft cam height mm 4G63

SOHC

4G64
SOHC

Lash adjuster leak down time
[diesel fuel at 15 - 20_C] seconds/mm

Camshaft journal outer diameter mm 45 -

Rocker arms and camshaft (GDI)

Camshaft cam height mm

Lash adjuster leak down time
[diesel fuel at 15 - 20_C] seconds/mm

Camshaft journal outer diameter mm 26 -

Intake 35.79 35.29

Exhaust 37.14 36.64

Intake 37.39 36.89

Exhaust 37.14 36.64

Intake 37.39 36.89

Exhaust 36.83 36.33

1.0 or less -

3 - 20/1.0 -

3 - 20/1.0 -

Cylinder head and valves

Cylinder head flatness of gasket surface mm Less than 0.05 0.2

Cylinder head grinding limit of gasket surface mm
Total resurfacing depth of both cylinder head and cylinder block

Cylinder head overall height mm

Cylinder head bolt shank length mm - Maximum 99.4

Valve thickness of valve head (margin) mm SOHC

Valve overall height mm SOHC

SOHC 120 -

GDI 132 -

Intake 1.0 0.5

Exhaust 1.2 0.7

GDI

GDI

Intake 1.0 0.5

Exhaust 1.5 1.0

Intake 112.30 111.80

Exhaust 114.11 113.61

Intake 105.5 105.0

Exhaust 105.7 105.2

- 0.2

Valve stem outer diameter mm 6.0 -

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11A-1-2

Items LimitStandard value

4G6 ENGINE <E-W> -

Specifications

Valve thickness to valve guide clearance SOHC
mm

GDI

Valve face angle mm 45_ - 45.5_ -

Valve spring free length mm

Valve spring load/installed height N/mm

Valve spring out-of-squareness

Valve seat valve contact width mm 0.9 - 1.3 -

Valve guide inner diameter mm

Valve guide projection from cylinder head
upper surface mm

SOHC 51.0 50.0

GDI 48.3 47.3

SOHC 267/44.2 -

GDI 294/40.0 -

SOHC 2_ or less Maximum 4_

GDI 1.5_ or less Maximum 4_

SOHC 6.0 -

GDI 6.6 -

SOHC 14.0 -

GDI 19.5 -

Intake 0.02 - 0.05 0.10

Exhaust 0.03 - 0.07 0.15

Intake 0.02 - 0.05 0.10

Exhaust 0.05 - 0.09 0.15

Valve stem projection mm

Oversize rework dimensions of valve guide
hole (SOHC) mm

Oversize rework dimensions of valve guide
hole (GDI) mm

Intake oversize rework dimensions of valve
seat hole (SOHC) mm

Intake oversize rework dimensions of valve
seat hole (GDI) mm

Exhaust oversize rework dimensions of
valve seat hole (SOHC) mm

SOHC 49.30 49.80

GDI

0.05 Oversize diameter 11.05 - 11.07 -

0.25 Oversize diameter 11.25 - 11.27 -

0.50 Oversize diameter 11.50 - 11.52 -

0.05 Oversize diameter 12.05 - 12.07 -

0.25 Oversize diameter 12.25 - 12.27 -

0.50 Oversize diameter 12.50 - 12.52 -

0.3 Oversize diameter 34.30 - 34.33 -

0.6 Oversize diameter 34.60 - 34.63 -

0.3 Oversize diameter 35.30 - 35.33 -

0.6 Oversize diameter 35.60 - 35.63 -

0.3 Oversize diameter 34.30 - 34.33 -

0.6 Oversize diameter 34.60 - 34.63 -

Intake 49.20 49.70

Exhaust 48.40 48.90

Exhaust oversize rework dimensions of
valve seat hole (GDI) mm

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Aug. 1998Mitsubishi Motors Corporation

0.3 Oversize diameter 33.30 - 33.33 -

0.6 Oversize diameter 33.60 - 33.63 -

RevisedPWEE9616-A

4G6 ENGINE <E-W> -

Items LimitStandard value

Front case, counterbalance shaft and oil pan

Specifications

11A-1-3

Oil pump side clearance mm

Oil pressure at curb idle speed kPa [Oil temperature is 75 to 90_C] 78 or more -

Piston and connecting rod

Piston outer diameter mm

Piston ring side clearance mm

Piston ring end gap mm

Piston pin outer diameter mm 22.0 -

Piston pin press-in load N (Room temperature) 7,350 - 17,200 -

Crankshaft pin oil clearance mm 0.02 - 0.05 0.1

Connecting rod big end side clearance mm 0.10 - 0.25 0.4

Drive gear 0.08 - 0.14 -

Driven gear 0.06 - 0.12 -

4G63 85.0 -

4G64 86.5 -

No. 1 0.02 - 0.06 0.1

No. 2 0.02 - 0.06 0.1

No. 1 0.25 - 0.35 0.8

No. 2 0.40 - 0.55 0.8

Oil ring side rail 0.10 - 0.40 1.0

Crankshaft, flywheel and drive plate

Crankshaft end play mm 0.05 - 0.25 0.40

Crankshaft journal outer diameter mm 57.0 -

Crankshaft pin outer diameter mm 45.0 -

Crankshaft journal oil clearance mm 0.02 - 0.04 0.1

Bearing cap bolt shank length mm - Maximum 71.1

Piston to cylinder clearance mm 0.02 - 0.04 -

Cylinder block flatness of gasket surface mm 0.05 0.1

Cylinder block grinding limit of gasket surface mm
Total resurfacing depth of both cylinder head and cylinder block

Cylinder block overall height mm

Cylinder block inner diameter mm

Cylindricity mm 0.01 -

4G63 284 -

4G64 290 -

4G63 85.0 -

4G64 86.5 -

- 0.2

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11A-1-4

4G6 ENGINE <E-W> -

Specifications

TORQUE SPECIFICATIONS

Items Nm

Alternator and ignition system

Water pump pulley 9

Adjusting bolt 10

Lock bolt 22

Alternator brace 23

Alternator pivot nut 44

Crankshaft pulley 25

Ignition coil (Multipoint fuel injection) 10

Spark plug 25

Distributor (Carburetor) 12

Camshaft position sensing cylinder (Multipoint fuel injection) 22

Camshaft position sensor support (Multipoint fuel injection) 14

Camshaft position sensor (Multipoint fuel injection) 10

Oil level gauge guide 13

Idler pulley bracket (M8) (Vehicle for Hong Kong) 22

Idler pulley bracket (M10) (Vehicle for Hong Kong) 49

Idler pulley (Vehicle for Hong Kong) 49

Intake manifold (GDI)

Vacuum pipe and hose (Flange bolt) 11

Vacuum pipe and hose (Bolt, washer assembly) 8.8

Solenoid valve 8.8

Vacuum pipe 11

Throttle body 11

Intake manifold stay (M6) 8.8

Intake manifold stay (M8) 30

Air intake plenum resonator (Flange bolt) 11

Air intake plenum resonator (Bolt, washer assembly) 8.8

EGR valve 23

EGR valve support 23

Intake manifold 19

Timing belt

Timing belt cover flange bolt 11

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4G6 ENGINE <E-W> -

Items Nm

Timing belt cover washer bolt 9

Power steering bracket 49

Crankshaft angle sensor (Multipoint fuel injection) 9

Tensioner arm 22

Tensioner puller 48

Auto tensioner 23

Idler pulley 35

Engine support bracket 49

Oil pump sprocket 54

Crankshaft bolt 118

Tensioner “B” 18

Counterbalance shaft sprocket 45

Specifications

11A-1-5

Camshaft sprocket bolt 88

Exhaust manifold (GDI)

Exhaust manifold cover 13

Exhaust manifold (M10) 49

Exhaust manifold (M8) 29

Engine hanger 11

Fuel and emission parts

Carburetor (Carburetor) 17

Fuel vapor separator (Carburetor) 23

Throttle body (Multipoint fuel injection) 18

EGR valve (Except General Export) 22

Injectors and delivery pipe (Multipoint fuel injection) 12

Fuel pressure regulator (Multipoint fuel injection) 9

Fuel part (GDI)

Fuel low pressure pipe (M6) 8.8

Fuel low pressure pipe (M8) 18

Fuel pump return nipple 8.8

Clamp A 8.8

Fuel pipe bracket 11

Fuel feed pipe 11

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11A-1-6

Items Nm

Fuel pump 4.9 ® 17 ± 2

Harness bracket 8.8

Fuel return pipe 11

Fuel high pressure regulator 18

Fuel pressure sensor 18

Pump camshaft case 23

Injector holder 22

Delivery pipe and injector assembly 11

Engine hanger 11

Water pump and intake manifold

Engine coolant temperature sensor 29

Engine coolant temperature gauge unit 11

4G6 ENGINE <E-W> -

Specifications

Water inlet fitting 13

Thermostat housing 24

Water inlet pipe 13

Water pump 14

Oil level gauge guide 14

Intake manifold stay 31

Intake manifold 19

Engine hanger 11

Detonation sensor (Multipoint fuel injection) 23

Water pump and water hose (GDI)

Engine coolant temperature sensor 29

Engine coolant temperature gauge unit 11

Water inlet fitting 12

Water outlet fitting 12

Thermostat housing 23

Water inlet pipe 12

Water pump 13

Knock sensor 22

Exhaust manifold

Exhaust manifold cover 13

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4G6 ENGINE <E-W> -

Items Nm

Heat protector 13

Exhaust manifold (M8) 29

Exhaust manifold (M10) 49

Water outlet fitting 13

Rocker arms and camshaft

Rocker cover 3.4

Rocker arm shaft 31

Rocker arms and camshafts (GDI)

Camshaft position sensor 8.8

Cover 9.8

Camshaft position sensing cylinder 21

Camshaft position sensing support 13

Specifications

11A-1-7

Beam camshaft cap 20

Cylinder head and valves

Cylinder head bolt
[Tighten to 78 Nm and then completely loosen before finally tightening with above procedure.]

Front case, counterbalance shaft and oil pan

Drain plug 39

Oil pan 6.9

Oil level sensor (For Europe) 8.8

Stiffener (For Europe) 21

Oil screen 18

Oil pressure switch (4G63) 19

Oil pressure switch (4G64) 9.8

Relief plug 44

Oil filter bracket 18

Plug 23

20 + 90_ +90_

Flange bolt 36

Oil pump cover bolt 16

Oil pump cover screw 9.8

Front case 23

Transmission stay (GDI engine) 21

Oil level gauge guide 12

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Aug. 1999Mitsubishi Motors Corporation

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11A-1-8

Items Nm

Oil pan lower 6.9

Baffle plate 6.9

Oil pan upper 6.9

Piston and connecting rod

Connecting rod cap 20 + 90_ ® 100_

Crankshaft, flywheel and drive plate

Flywheel bolt 132

Drive plate bolt 132

Rear plate 11

Bell housing cover 8.8

Oil seal case bolt 11

Bearing cap bolt 25 + 90_ ® 100_

4G6 ENGINE <E-W> -

Specifications

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Aug. 1999Mitsubishi Motors Corporation

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4G6 ENGINE <E-W> -

Specifications

11A-1-9

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 some parts of the engine. The
tightening method for the bolts 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.

Areas where the bolts are in use:

D

(1) Cylinder head bolts
(2) Main bearing cap bolts
(3) Connecting rod cap bolts
Tightening method

D

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.

SEALANTS

Item Specified sealant Quantity

Cam position sensor support Mitsubishi Genuine Part No. MD970389 or

equivalent

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

Thermostat case Mitsubishi Genuine Part No. MD970389 or

equivalent

Water outlet fitting Mitsubishi Genuine Part No. MD970389 or

equivalent

Beam camshaft cap Mitsubishi Genuine Part No. MD970389 or

equivalent

Cylinder head Mitsubishi Genuine Part No. MD970389 or

equivalent

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

Oil pan Mitsubishi Genuine Part No. MD970389 or

equivalent

Oil seal case Mitsubishi Genuine Part No. MD970389 or

equivalent

As required

As required

As required

As required

As required

As required

As required

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Aug. 1998Mitsubishi Motors Corporation

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11A-1-10

4G6 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 vulcanisation (RTV) type and is supplied in a 100-gram
tube (Part No. MD970389). Since the RTV hardens as it reacts with the moisture in the atmospheric
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. MD997110 can only be used for engine oil sealing.

Disassembly

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

Surface Preparation

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

Form-in-Place Gasket Application

When assembling parts with the FIPG, you must observe some precautions, but the procedures is very
simple as in the case of a conventional precut gasket.
Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the
bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is
hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When
the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do
not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time
(about one hour) has passed after installation is completed.
The FIPG application procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.

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4G6 ENGINE (E-W) -

Special Tools

2. SPECIAL TOOLS

Tool Number Name Use

11A-2-1

MB990767 Crankshaft pulley

holder

MD990938 Handle Installation of crankshaft rear oil seal

MB991603 Silent shaft bearing

puller stopper

MB991654 Cylinder head bolt

wrench (12)

Holding camshaft sprocket
Use with MD998719.

Use with MD998776.

Guide stopper for removal and installation of
counterbalance shaft rear bearing
Use with MD998372.

Removal and installation of cylinder head bolt

MD998162 Plug wrench Removal and installation of front case cap plug

Use with MD998783.

MD998285 Crankshaft front oil

seal guide

MD998371 Silent shaft bearing

puller

MD998372 Silent shaft bearing

puller

Guide for installation of crankshaft front oil seal
Use with MD998375.

Removal of counterbalance shaft front bearing

Removal of counterbalance shaft rear bearing

MD998375 Crankshaft front

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Installation of crankshaft front oil seal

seal installer

PWEE9616

11A-2-2

Tool UseNameNumber

MD998440 Leak down tester Leak down test of lash adjuster

4G6 ENGINE (E-W) -

Special Tools

MD998441 Lash adjuster

retainer

MD998442 Lash adjuster wire Air bleeding of lash adjuster

MD998443 Lash adjuster

holder

MD998705 Silent shaft bearing

installer

Air bleeding of lash adjuster

Retainer for holding lash adjuster in rocker arm
at time of removal and installation of rocker
shaft assembly

Installation of counterbalance shaft front and
rear bearing

MD998713 Camshaft oil seal

installer

MD998719 Pulley holder pin Holding camshaft sprocket

MD998727 Oil pan remover Removal of oil pan

MD998735 Valve spring

compressor

Installation of camshaft oil seal

Use with MB990767.

Removal and installation of valve and related
parts

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4G6 ENGINE (E-W) -

Tool UseNameNumber

MD998738 Set screw Adjustment of timing belt tension

Special Tools

11A-2-3

MD998767 Tensioner puller

socket wrench

MD998772 Valve spring

compressor

MD998774 Valve stem seal

installer

MD998775 Valve stem seal

installer

Adjustment of timing belt tension

Removal and installation of valve and related
parts

Installation of valve stem seal

Installation of valve stem seal

MD998776 Crankshaft rear oil

seal installer

MD998778 Crankshaft

sprocket puller

MD998780 Piston setting tool Removal and installation of piston pin

MD998781 Flywheel stopper Holding of flywheel and drive plate

Installation of crankshaft rear oil seal
Use with MB990938.

Removal of crankshaft sprocket

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11A-2-4

Tool UseNameNumber

4G6 ENGINE (E-W) -

Special Tools

MD998783 Plug wrench

retainer

MD998785 Sprocket stopper Holding silent shaft sprocket

Removal and installation of front case cap plug

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4G6 ENGINE (E-W) -

Alternator and Ignition System

3. ALTERNATOR AND IGNITION SYSTEM

REMOVAL AND INSTALLATION <CARBURETOR>

6

11A-3-1

8

12 Nm

10 Nm

22 Nm

3

24 Nm

9Nm

2

25 Nm

4

7

10

9

44 Nm

5

1

25 Nm

Removal steps

1. Drive belt

2. Water pump pulley

3. Alternator brace

4. Alternator

5. Crankshaft pulley

6. Spark plug cable

7. Spark plug

8. High tension cable

"BA 9. Distributor assembly

10. O-ring

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11A-3-2

4G6 ENGINE (E-W) -

Alternator and Ignition System

REMOVAL AND INSTALLATION <MULTIPOINT FUEL INJECTION>

10 Nm

7

10 Nm

22 Nm

3

24 Nm

9Nm

2

25 Nm

4

44 Nm

5

6

10 Nm

9

10

8

11

22 Nm

14 Nm

r

1

Removal steps

1. Drive belt

2. Water pump pulley

3. Alternator brace

4. Alternator

5. Crankshaft pulley

6. Spark plug cable

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Dec. 1996Mitsubishi Motors Corporation

25 Nm

7. Ignition coil assembly

8. Spark plug

9. Camshaft position sensor

"AA 10. Camshaft position sensing support

11. Camshaft position sensing cylinder

PWEE9616

4G6 ENGINE (E-W) -

REMOVAL AND INSTALLATION (GDI)

6

Alternator and Ignition System

25 Nm

12

49 Nm

11A-3-3

9.8 Nm

11

9.8 Nm

22 Nm

23 Nm

4

8

9

49 Nm

22 Nm

Removal steps

1. Oil level gauge

2. Oil level gauge guide

3. O-ring

4. Drive belt

5. Water pump pulley

6. Alternator

7. Alternator brace

7

49 Nm

8.8 Nm

25 Nm

1

5

13 Nm

2

3

10

8. Idler pulley bracket
(Vehicle for Hong Kong)

9. Idler pulley
(Vehicle for Hong Kong)

10. Crankshaft pulley

11. Ignition coil

12. Spark plug

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Aug. 1999Mitsubishi Motors Corporation

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11A-3-4

4G6 ENGINE (E-W) -

INSTALLATION SERVICE POINTS

"AA

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

Alternator and Ignition System

CAMSHAFT POSITION SENSOR SUPPORT
INSTALLATION

the area shown.

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or
equivalent

Stud bolt

"BA

DISTRIBUTOR ASSEMBLY INSTALLATION

(1) Turn the crankshaft to bring No. 1 cylinder to the top

dead center on compression stroke.

(2) Align the mating marks on the distributor housing with

that of the coupling key.

(3) Install the distributor assembly on the engine while aligning

the stud bolt used for securing the distributor with the
slot in the mounting flange of the distributor.

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4G6 ENGINE (E-W) -

Intake Manifold (GDI)

3a. INTAKE MANIFOLD (GDI)

REMOVAL AND INSTALLATION (SPACE WAGON)

11A-3a-1

23 Nm

30 Nm

14

16

11 Nm

8.8 Nm

12

13

15

3

8.8 Nm

4

17

10

11 Nm

23 Nm

11 Nm

11

8.8 Nm

1

19 Nm

2

11 Nm

5

7

6

8.8 Nm

19 Nm

18

19

9

8.8 Nm

30 Nm

8

Removal steps

1. Vacuum pipe and hose
(1999 model vehicles for Hong
Kong)

2. Solenoid valve (1999 model ve­hicles for Hong Kong)

3. Vacuum pipe and hose
(Vehicles for Europe and 2000
model vehicles for Hong Kong)

4. Solenoid valve
(Vehicles for Europe and 2000
model vehicles for Hong Kong)

5. Vacuum pipe

6. Throttle body

E

Aug. 1999Mitsubishi Motors Corporation

"DA 7. Throttle body gasket
"CA 8. Intake manifold stay
"BA 9. Air intake plenum resonator

10. Gasket

11. Water hose

12. EGR valve

13. Gasket

"AA 14. Hose clamp
"AA 15. EGR support
"AA 16. Gasket

17. Gasket

18. Intake manifold

19. Gasket

RevisedPWEE9616-B

11A-3a-2

4G6 ENGINE (E-W) -

REMOVAL AND INSTALLATION (GALANT)

Intake Manifold (GDI)

8.8 Nm

8.8 Nm

1

2

23 Nm

5

30 Nm

11

13

12

8

11 Nm

9

3

4

23 Nm

19 Nm

10

14

15

16

7

19 Nm

11 Nm

8.8 Nm

Removal steps

1. Vacuum pipe and hose

2. Solenoid valve

3. Throttle body

"DA 4. Throttle body gasket
"CA 5. Intake manifold stay
"BA 6. Air intake plenum resonator

7. Gasket

8. Water hose

E

Aug. 1999Mitsubishi Motors Corporation

6

9. EGR valve

10. Gasket

"AA 11. Hose clamp
"AA 12. EGR support
"AA 13. Gasket

14. Gasket

15. Intake manifold

16. Gasket

RevisedPWEE9616-B

4G6 ENGINE (E-W) -

Intake Manifold (GDI)

11A-3a-3

Hose clamp

Intake
manifold
stay

Intake manifold side

Cylinder head side

INSTALLATION SERVICE POINTS

"AA

(1) Install the gasket, EGR support and hose clamp to the

(2) Install the EGR support assembly to the intake manifold

(3) Tighten the fasteners on the cylinder head side to the

"BA

(1) Install the mounting bolts on the throttle body side without

"CA

(1) Tighten the fasteners to the specified torque after

EGR SUPPORT / HOSE CLAMP / GASKET
INSTALLATION

cylinder head in that order and tighten the fasteners
temporarily.

with the gasket attached on the mating surface, and tighten
the fasteners to the specified torque.

specified torque.

AIR INTAKE PLENUM RESONATOR
INSTALLATION

fail.

INTAKE MANIFOLD STAY INSTALLATION

confirming that the intake manifold stay is in close contact
with the air intake plenum resonator and the cylinder
block.

Air intake
plenum
resonator

Projection

"DA

THROTTLE BODY GASKET INSTALLATION

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

E

Aug. 1999Mitsubishi Motors Corporation

AddedPWEE9616-B

4G6 ENGINE (E-W) -

4. TIMING BELT

REMOVAL AND INSTALLATION (SOHC)

45 Nm

18

45 Nm

17

16

Timing Belt

20

11A-4-1

14 Nm

11 Nm

14

9Nm

18 Nm

13

1

15

48 Nm

23 Nm

23

22

5

9Nm

49 Nm

49 Nm

3

4

88 Nm

19

7

22 Nm

21

6

12

8

35 Nm

11

9

118 Nm

10

54 Nm

2

Removal steps

1. Timing belt front upper cover

2. Timing belt front lower cover

3. Power steering bracket

4. Crankshaft position sensor
(Multipoint fuel injection)

AA""KA 5. Timing belt

"JA 6. Tensioner pulley

7. Tensioner arm

"IA 8. Auto tensioner

9. Idler pulley

AC""HA 10. Oil pump sprocket
AD""GA 11. Crankshaft bolt

E

Aug. 1999Mitsubishi Motors Corporation

AE" 12. Crankshaft sprocket

13. Flange (Multipoint fuel injection)

14. Flange (Carburetor)

15. Tensioner “B”

AF""FA 16. Timing belt “B”
AG""EA 17. Counterbalance shaft sprocket

"DA 18. Spacer

AH" 19. Crankshaft sprocket “B”

"CA 20. Engine support bracket

AI""AA 21. Camshaft sprocket bolt

22. Camshaft sprocket

23. Timing belt rear cover

RevisedPWEE9616-B

11A-4-2

4G6 ENGINE (E-W) -

REMOVAL AND INSTALLATION (GDI)

Timing Belt

21

88 Nm

29

2

11 Nm

9Nm

30

1

22

25

3.4 Nm

6

48 Nm

7

23

26

24

27

23 Nm

8

23 Nm

13

11 Nm

31

12

118 Nm

49 Nm

11 Nm

32

5

45 Nm

18 Nm

15

18

17

28

3

4

48 Nm

14

9

Removal steps

1. Front upper cover

2. Front lower cover

3. Power steering pump bracket stay

4. Power steering bracket

AB""LA 5. Timing belt

"JA 6. Tensioner pulley

7. Tensioner arm

"IA 8. Auto tensioner

9. Idle pulley

10. Crankshaft position sensor

AC""HA 11. Oil pump sprocket
AD""GA 12. Crankshaft bolt
AE" 13. Crankshaft sprocket

14. Flange

15. Tensioner B

AF""FA 16. Timing belt B
AG""EA 17. Counterbalance shaft sprocket

E

Aug. 1999Mitsubishi Motors Corporation

11

54 Nm

16

10

33

20

19

AH" 19. Crankshaft sprocket B

AJ""BA 29. Camshaft sprocket bolt

8.8 Nm

"DA 18. Spacer

20. Crankshaft key

21. Breather hose

22. PCV hose

23. PCV valve

24. PCV valve gasket

25. Oil filler cap

26. Rocker cover

27. Rocker cover gasket

"CA 28. Engine support bracket

30. Camshaft sprocket

31. Timing belt rear right cover

32. Timing belt rear left upper cover

33. Timing belt rear left lower cover

49 Nm

RevisedPWEE9616-B

4G6 ENGINE (E-W) -

REMOVAL SERVICE POINTS

AA"

(1) Mark belt running direction for reinstallation.

TIMING BELT REMOVAL

NOTE
(1) Water or oil on the belt shorten its life drastically,

so the removed timing belt, sprocket, and tensioner
must be free from oil and water. These parts should
not be washed. Replace parts if seriously
contaminated.

(2) If there is oil or water on each part, check front case

oil seals, camshaft oil seal and water pump for leaks.

Timing Belt

11A-4-3

Timing mark

AB"

TIMING BELT REMOVAL

(1) If the timing belt is to be reused, chalk an arrow mark

on the back surface of the belt so that the belt can be
reinstalled in the same direction.

(2) Place the exhaust camshaft sprocket in a position where

the timing mark for No. 1 cylinder is positioned about
one tooth before the top dead center of the compression
stroke.

Caution

The camshaft sprocket on the exhaust side can

D

turn very easily because of the valve spring
tension. Use care not to allow your fingers to get
caught by the sprocket.

(3) Loosen the lock nut of the tensioner pulley, then remove

the timing belt.

AC"

OIL PUMP SPROCKET REMOVAL

(1) Remove the plug on the left side of cylinder block.
(2) Insert a screwdriver (shank diameter 8 mm) to block the

counterbalance shaft.
(3) Remove the nut.
(4) Remove the oil pump sprocket.

E

Aug. 1998Mitsubishi Motors Corporation

RevisedPWEE9616-A

11A-4-4

4G6 ENGINE (E-W) -

Timing Belt

6EN1322

AD"

CRANKSHAFT BOLT LOOSENING

(1) Hold the drive plate with the special tool as shown.
(2) Remove the crankshaft bolt.

AE"

CRANKSHAFT SPROCKET REMOVAL

(1) If it is difficult to remove the sprocket, use the special

tool.

AF"

TIMING BELT “B” REMOVAL

(1) Make a mark on the back of the timing belt indicating

the direction of rotation so it may be reassembled in the

same direction if it is to be reused.

NOTE

(1) Water or oil on the belt shortens its life drastically,

so the removed timing belt, sprocket, and tensioner
must be free from oil and water. These parts should
not be washed. Replace parts if seriously
contaminated.

(2) If there is oil or water on each part check front case

oil seals, camshaft oil seal and water pump for leaks.

MD998785

E

Aug. 1998Mitsubishi Motors Corporation

AG"

COUNTERBALANCE SHAFT SPROCKET
REMOVAL

(1) Set the special tool as shown to prevent the

counterbalance shaft sprocket from turning together.
(2) Loosen the bolt and remove the sprocket.

RevisedPWEE9616-A

4G6 ENGINE (E-W) -

Timing Belt

11A-4-5

AH"

CRANKSHAFT SPROCKET “B” REMOVAL

(1) If it is difficult to remove the sprocket, use the special

tool.

AI"

CAMSHAFT SPROCKET BOLT LOOSENING

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

camshaft sprocket in position.
(2) Loosen the camshaft bolt.

AJ"

CAMSHAFT SPROCKET BOLT LOOSENING

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

and then remove the camshaft sprocket mounting bolt.

INSTALLATION SERVICE POINTS

"AA

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

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

"BA

(1) Using a wrench, hold the camshaft at its hexagon and

E

Aug. 1998Mitsubishi Motors Corporation

CAMSHAFT SPROCKET BOLT TIGHTENING

camshaft sprocket in position.

CAMSHAFT SPROCKET BOLT TIGHTENING

tighten the bolt to the specification.

RevisedPWEE9616-A

11A-4-6

4G6 ENGINE (E-W) -

Timing Belt

Sharp
edge

Counter­balance
shaft

MD998785

"CA

ENGINE SUPPORT BRACKET INSTALLATION

(1) Coat the bolts illustrated with sealant before tightening.

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

"DA

SPACER INSTALLATION

(1) Install the spacer with the chamfered end toward the

oil seal.

"EA

COUNTERBALANCE SHAFT SPROCKET
INSTALLATION

(1) Install the counterbalance shaft sprocket and screw the

bolt.
(2) Install special tool MD998785 as shown in the illustration

to lock the counterbalance shaft.
(3) Tighten the bolt, and then remove the special tool.

Timing
marks
(onfront
case)

E

"FA

TIMING BELT “B” INSTALLATION

(1) Align timing marks on the crankshaft sprocket “B” and

counterbalance shaft sprocket with the marks on the front

Timing
marks

case respectively.
(2) Install the timing belt “B” on the crankshaft sprocket “B”

and counterbalance shaft sprocket. There should be no

slack on the tension side.

(3) Make sure that the relationship between the tensioner

pulley center and the bolt center is as shown in the

illustration.

Aug. 1998Mitsubishi Motors Corporation

RevisedPWEE9616-A

4G6 ENGINE (E-W) -

(4) Move the tensioner “B” in the direction of arrow while

lifting with a finger to give a sufficient tension to the tension
side of timing belt. In this condition, tighten bolt to secure
tensioner “B”. When the bolt is tightened, use care to
prevent shaft from turning together. If shaft is turned
together, belt will be overtensioned.

(5) Check to ensure that timing marks on sprockets and front

case are in alignment.

(6) Press with index finger the center of span on the tension

side of timing belt “B”. The bolt must deflect 5 - 7 mm.

Timing Belt

11A-4-7

"GA

CRANKSHAFT BOLT TIGHTENING

(1) Using the special tool, hold the flywheel or drive plate.
(2) Install the crankshaft pulley in position.

"HA

OIL PUMP SPROCKET INSTALLATION

(1) Insert a Phillips screwdriver (shank diameter 8 mm shaft)

through the plug hole on the left side of the cylinder

block to block the left counterbalance shaft.
(2) Install the oil pump sprocket.
(3) Apply a proper amount of engine oil to the bearing surfaces

of the nuts.
(4) Tighten the nuts to the specified torque.

6EN0564

"IA

AUTO TENSIONER INSTALLATION

(1) If the auto tensioner rod is in its fully extended position,

reset it as follows.

B

A

(2) Clamp the auto-tensioner in the vise with soft jaws.
(3) Push in the rod little by little with the vise until the set

hole A in the rod is aligned with the hole B in the cylinder.

6AE0049

E

Aug. 1998Mitsubishi Motors Corporation

RevisedPWEE9616-A

11A-4-8

4G6 ENGINE (E-W) -

(4) Insert a wire (1.4 mm in diameter) into the set holes.
(5) Unclamp the auto tensioner from the vise.

6AE0050

(6) Install the auto tensioner to front case and tighten to

the specified torque.

Caution

Leave the wire installed in the auto tensioner.

D

Timing Belt

Small holes

6EN0350

6EN1323

"JA

TENSIONER PULLEY INSTALLATION

(1) Install the tensioner pulley in such direction that its two

small holes are arranged vertically.

"KA

TIMING BELT INSTALLATION

(1) Check that the timing belt tensioner and spring have been

installed in position. (See

"JA

)

(2) Align timing mark on camshaft sprocket with timing mark

on cylinder head.

E

Aug. 1998Mitsubishi Motors Corporation

(3) Align timing mark on crankshaft sprocket with timing mark

on front case.

RevisedPWEE9616-A

Oil pump
sprocket
timingmarks

Plug

4G6 ENGINE (E-W) -

(4) Align the timing mark on oil pump sprocket with its mating

mark.

6EN1327

(5) Remove the plug on cylinder block and insert a Phillips

screwdriver (shank diameter 8 mm) through the hole
(Engine with counterbalance shafts).
If it can be inserted as deep as 60 mm or more, the
timing marks are correctly aligned. If the inserted depth
is only 20 - 25 mm, turn the oil pump sprocket one turn
and realign timing marks. Then check to ensure that the
screwdriver can be inserted 60 mm or more. Keep the

Screwdriver

6EN1026

screwdriver inserted until installation of timing belt is
finished.

Timing Belt

11A-4-9

(6) Install the timing belt on the crankshaft sprocket, idler

pulley, camshaft sprocket, and tensioner pulley in that
order.

(7) Lift up the tensioner pulley in the direction of arrow and

tighten the center bolt.
(8) Check that all timing marks are lined up.
(9) Remove the screwdriver inserted in step (5) and fit the

plug.
(10)Give the crankshaft a quarter counterclockwise turn. Then,

turn it clockwise until the timing marks are lined up again.

6EN0899

(11)Install the special tools, Socket Wrench and Torque

Wrench, on the tensioner pulley, and loosen the tensioner

MD998767

pulley center bolt.

NOTE

If the special tool is not available, use a commercially

available torque wrench that is capable of measuring

0 - 5 Nm.

(12)Torque to 3.5 Nm with the torque wrench.
(13)Holding the tensioner pulley with the special tool and

6EN0900

E

Aug. 1998Mitsubishi Motors Corporation

torque wrench, tighten the center bolt to specification.

RevisedPWEE9616-A

11A-4-10

4G6 ENGINE (E-W) -

(14)After giving two clockwise turns to the crankshaft, let

it alone for approx. 15 minutes. Then, make sure that

the auto tensioner setting wire moves freely.

NOTE

If the wire does not move freely, repeat step (10) above

until it moves freely.

(15)Remove the auto tensioner setting wire.

(16)Measure the distance “A” (between the tensioner arm

and auto tensioner body).

Standard value: 3.8 - 4.5 mm

Timing Belt

Timing mark

Timing mark

"LA

TIMING BELT INSTALLATION

(1) Place the exhaust side camshaft sprocket in a position

where its timing mark is one tooth offset from the timing

mark on the rocker cover in the counterclockwise direction.

NOTE

Even if the timing marks on the sprocket and the rocker

cover are brought into alignment, the exhaust camshaft

is forced back by the valve spring tension. It is stabilized

at a position one tooth before the timing mark.

(2) Align the timing mark on the intake side camshaft sprocket

with that on the rocker cover.

NOTE

Even if the timing marks on the sprocket and the cover

are brought into alignment, the intake camshaft is forced

to turn one tooth in the clockwise direction by the valve

spring tension and stabilized there.

(3) Place the timing mark on the crankshaft sprocket one

tooth this side from the mated timing mark as in the case

of the camshaft sprocket.

E

Aug. 1998Mitsubishi Motors Corporation

AddedPWEE9616-A

Oil pump
sprocket
timingmarks

Plug

4G6 ENGINE (E-W) -

(4) Align the timing mark on oil pump sprocket with its mating

mark.

6EN1327

(5) Remove the plug on cylinder block and insert a Phillips

screwdriver (shank diameter 8 mm) through the hole

(Engine with counterbalance shafts).

If it can be inserted as deep as 60 mm or more, the

timing marks are correctly aligned. If the inserted depth

is only 20 - 25 mm, turn the oil pump sprocket one turn

and realign timing marks. Then check to ensure that the

screwdriver can be inserted 60 mm or more. Keep the

Screwdriver

6EN1026

screwdriver inserted until installation of timing belt is

finished.

Timing Belt

11A-4-11

Timing mark

(6) Remove the Phillips screwdriver. Place the oil pump

sprocket in a position where its timing mark is one tooth

offset from the mated timing mark in the counterclockwise

direction.

6EN1327

(7) Fit the timing belt over the exhaust side camshaft sprocket,

and secure it at the illustrated position using a paper

clip.

(8) Turn the intake side camshaft sprocket as shown to a

position where its timing mark is one tooth offset from

the mated timing mark in the counterclockwise direction.

Then, fit the timing belt over the sprocket and secure

it with a paper clip.

NOTE

The intake camshaft will be turned a little clockwise by

the valve spring tension and stabilized in position even

if the belt is clipped at one tooth offset position.

E

Aug. 1998Mitsubishi Motors Corporation

AddedPWEE9616-A

11A-4-12

4G6 ENGINE (E-W) -

Timing Belt

17 cogs

Timing mark

Crankshaft
sprocket

(9) Check to ensure that the timing marks on the intake

camshaft sprocket side are in alignment when the exhaust

camshaft sprocket is turned clockwise to align the timing

marks.

NOTE

The timing belt span between the intake and exhaust

sprockets will have 17 cogs.

(10)Fit the timing belt over the idler pulley, oil pump sprocket

and crankshaft sprocket in this order.

NOTE

Be careful that the belt does not become slack.

Oil pump
sprocket

(11)Fit the timing belt over the tensioner pulley.

NOTE

When fitting the timing belt over the tensioner pulley,

turn the intake side camshaft sprocket a little

counterclockwise, as this will facilitate the work.

Crankshaft
sprocket

(12)Turn the crankshaft pulley a little in the illustrated direction

to pull up the timing belt at the idler pulley side.
(13)Check to ensure that the timing marks on the crankshaft

sprocket, oil pump sprocket and exhaust camshaft

sprocket are all offset one tooth from the corresponding

timing marks in the counterclockwise direction.

(14)Using the special tool, turn the tensioner pulley in the

illustrated direction to strain the timing belt. Then, secure

MD998767

the tensioner temporarily by tightening the retaining bolt

lightly.

NOTE

There must be no slack in the timing belt between the

intake and exhaust camshafts.

(15)Turn the crankshaft to align the timing mark with the mark

for No. 1 cylinder top dead center in the compression

stroke.

E

Aug. 1998Mitsubishi Motors Corporation

AddedPWEE9616-A

MD998767

MD998738

4G6 ENGINE (E-W) -

(16)Set the special tool as shown and screw it in up to the

position where the wire inserted in the auto-tensioner

when installing it can be moved lightly.

(17)Loosen the retaining bolt of the tensioner pulley.

Caution

Loosening the retaining bolt can cause the intake

D

and exhaust camshafts to turn, resulting in
slackened timing belt. Use care that the timing
belt does not come off the sprockets at this time.

(18)Pull up the slack of the timing belt by turning the tensioner

in illustrated direction using the special tool and a torque

wrench (0 - 5 Nm).
(19)From this position, turn back the tensioner until the torque

wrench reading becomes 3.5 Nm, then secure it by

tightening the retaining bolt.
(20)Remove the special tool attached in step (16).
(21)Rotate the crankshaft clockwise 2 turns. Then, leave it

intact 15 minutes.
(22)Check to see that the wire inserted when installing the

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

out lightly, the timing belt is being tensioned properly.

If so, remove the wire. In addition, check that the rod

protrusion from the auto-tensioner meets the standard

value, which is also an indication of properly tensioned

timing belt.

Timing Belt

11A-4-13

Standard value: 3.8 - 4.5 mm

(23)If the wire cannot be removed with a light force, repeat

steps (16) through (21) until the proper belt tensioner

is obtained.

INSPECTION

TIMING BELT

Replace belt if any of the following conditions exist.

(1) Hardening of back rubber.

Back side is glossy without resilience and leaves no indent

when pressed with fingernail.

E

Aug. 1998Mitsubishi Motors Corporation

AddedPWEE9616-A

11A-4-14

4G6 ENGINE (E-W) -

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

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

they are sharp as if cut by a knife.

Timing Belt

98 to 196 N

12 mm

Movement

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

AUTO TENSIONER

(1) Check the auto tensioner for possible leaks and replace

as necessary.
(2) Check the rod end for wear or damage and replace as

necessary.
(3) Measure the rod protrusion. If it is out of specification,

replace the auto tensioner.

Standard value: 12 mm

6EN0161

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

its protrusion.
(5) If the measured value is 1 mm or more shorter than the

value obtained in step (3), replace the auto tensioner.

6EN1033

E

Aug. 1998Mitsubishi Motors Corporation

AddedPWEE9616-A

4G6 ENGINE (E-W) -

4a. EXHAUST MANIFOLD (GDI)

REMOVAL AND INSTALLATION

Exhaust Manifold (GDI)

11 Nm

5

4

11A-4a-1

29 Nm

49 Nm

2

Removal steps

1. Exhaust manifold cover (Vehicle for Europe)

2. Exhaust manifold (Vehicle for Europe)

3. Exhaust manifold (Vehicle for Hong Kong)

4. Exhaust manifold gasket

5. Engine hanger

13 Nm

1

29 Nm

49 Nm

3

13 Nm

E

Aug. 1998Mitsubishi Motors Corporation

AddedPWEE9616-A

4G6 ENGINE (E-W) -

Fuel and Emission Control Parts

5. FUEL AND EMISSION CONTROL PARTS

REMOVAL AND INSTALLATION <CARBURETOR>

17 Nm

5

11A-5-1

2

6

23 Nm

22 Nm

4

7

1

8

3

Removal steps

1. Fuel hose

2. Fuel hose

3. Fuel vapor separator

4. Water hose

5. Carburetor

6. Gasket

7. EGR valve (For GCC)

8. Gasket (For GCC)

E

Dec. 1996Mitsubishi Motors Corporation

PWEE9616

11A-5-2

4G6 ENGINE (E-W) -

Fuel and Emission Control Parts

REMOVAL AND INSTALLATION <MULTIPOINT FUEL INJECTION - GALANT>

3

14

6

12 Nm

9Nm

8

11

10

12

9

13

5

22 Nm

18 Nm

4

1

2

7

Removal steps

1. Throttle body

"CA

E

2. Throttle body gasket

3. EGR valve (With EGR valve)

4. Cover (Without EGR valve)

5. EGR valve gasket

6. Injectors and delivery pipe

7. Insulator

Aug. 1998Mitsubishi Motors Corporation

"BA

"AA

8. Fuel pressure regulator

9. O-ring

10. Insulator

11. Injectors

12. O-ring

13. Grommet

14. Delivery pipe

RevisedPWEE9616-A

4G6 ENGINE (E-W) -

Fuel and Emission Control Parts

REMOVAL AND INSTALLATION
<MULTIPOINT FUEL INJECTION - SPACE WAGON>

11A-5-3

12 Nm

5

9Nm

6

22 Nm

4

13

15

3

18 Nm

14

10

9

11

12

1

2

8

7

Removal steps

1. Throttle body

"CA

E

2. Throttle body gasket

3. EGR valve

4. EGR valve gasket

5. Fuel hose

6. Fuel return pipe

7. Injectors and delivery pipe

8. Insulator

Aug. 1998Mitsubishi Motors Corporation

"BA

"AA

9. Fuel pressure regulator

10. O-ring

11. Insulator

12. Injectors

13. O-ring

14. Grommet

15. Delivery pipe

RevisedPWEE9616-A

11A-5-4

Grommet

O-ring

4G6 ENGINE (E-W) -

Fuel and Emission Control Parts

INSTALLATION SERVICE POINTS

"AA

(1) Before installing an injector, the rubber O-ring must be

(2) Install injector top end. Be careful not to damage O-ring

INJECTORS INSTALLATION

lubricated with a drop of clean engine oil to aid in

installation.

during installation.

1EN0388

"BA

FUEL PRESSURE REGULATOR INSTALLATION

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

Insert the fuel pressure regulator into the delivery pipe

being careful not to damage the O-ring.

Caution

Be sure not to let engine oil get into the delivery

D

pipe.

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

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

Remove the fuel pressure regulator and check the O-ring

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

and check once again.

GALANT SPACE WAGON

Projection

E

Projection

Aug. 1998Mitsubishi Motors Corporation

"CA

GASKET INSTALLATION

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

AddedPWEE9616-A

4G6 ENGINE (E-W) -

Fuel Part (GDI)

5a. FUEL PART (GDI)

REMOVAL AND INSTALLATION (1999 MODEL SPACE WAGON)

11A-5a-1

26

11 Nm

11 Nm

37

8.8 Nm

11 Nm

6

15

8

11 Nm

8.8 Nm

14

17

18

7

16

18 Nm

8.8 Nm

2

3

1

11

10

4.9 Nm

9

8.8 Nm

17 Nm±2Nm

®

19

22

21

20

12

18 Nm

4

13

5

30

23

29

34

35

36

11 Nm

32

33

38

31

22 Nm

27
28

24

23 Nm

25

E

Aug. 1999Mitsubishi Motors Corporation

RevisedPWEE9616-B

11A-5a-2

"FA

"FA

"EA

"EA

4G6 ENGINE (E-W) -

Removal steps

1. Fuel hose

2. Fuel low pressure pipe

3. O-ring

4. Fuel pump return nipple

5. O-ring

6. Clamp A

7. Fuel pipe bracket

8. Fuel feed pipe

9. Backup ring

10. O-ring

11. Backup ring

12. Fuel pump

13. O-ring

14. Harness bracket

15. Fuel return pipe

16. Backup ring

17. O-ring

18. Backup ring

19. Fuel high pressure regulator

Fuel Part (GDI)

"DA

"CA

"BA

"AA
"AA
"AA
"AA

20. Fuel pressure sensor

21. Backup ring

22. O-ring

23. Pump camshaft case

24. O-ring

25. O-ring

26. Injector harness

27. Washer

28. Injector holder

29. Delivery pipe and injector assembly

30. Insulator

31. Injector washer

32. Injector

33. Corrugated washer

34. Backup ring

35. O-ring

36. Backup ring

37. Delivery pipe

38. Engine hanger

E

Aug. 1999Mitsubishi Motors Corporation

RevisedPWEE9616-B

4G6 ENGINE (E-W) -

Fuel Part (GDI)

11A-5a-2a

REMOVAL AND INSTALLATION (2000 MODEL SPACE WAGON and GALANT)

30

11 Nm

11 Nm

41

38

39

40

36

11

18 Nm

8.8 Nm

2

8.8 Nm

11 Nm

6

15

8.8 Nm

14

17

8

11 Nm

18

10

7

4.9 Nm

9

8.8 Nm

17 Nm±2Nm

®

16

19

26

25

3

1

24

23

18 Nm

20

18 Nm

34

22 Nm

12

4

13

22

21

5

27

28

31

33

37

11 Nm

42

35

32

23 Nm

29

E

Aug. 1999Mitsubishi Motors Corporation

AddedPWEE9616-B

11A-5a-2b

"FA

10. O-ring

11. Backup ring

"FA

"EA

"EA
"DA

12. Fuel pump

13. O-ring

14. Harness bracket

15. Fuel return pipe

16. Backup ring

17. O-ring

18. Backup ring

19. Fuel high pressure regulator

20. Fuel pressure sensor

21. Backup ring (GALANT and SPACE

22. O-ring (GALANT and SPACE

4G6 ENGINE (E-W) -

Removal steps

1. Fuel hose

2. Fuel low pressure pipe

3. O-ring

4. Fuel pump return nipple

5. O-ring

6. Clamp A

7. Fuel pipe bracket

8. Fuel feed pipe

9. Backup ring

(GALANT and SPACE WAGON for
Hong Kong)

WAGON for Hong Kong)

WAGON for Hong Kong)

Fuel Part (GDI)

23. Flange
(SPACE WAGON for Europe)

"DA

"CA

"BA

"AA
"AA
"AA
"AA

24. Fuel pressure sensor
(SPACE WAGON for Europe)

25. Backup ring
(SPACE WAGON for Europe)

26. O-ring
(SPACE WAGON for Europe)

27. Pump camshaft case

28. O-ring

29. O-ring

30. Injector harness

31. Washer

32. Injector holder

33. Delivery pipe and injector assembly

34. Insulator

35. Injector washer

36. Injector

37. Corrugated washer

38. Backup ring

39. O-ring

40. Backup ring

41. Delivery pipe

42. Engine hanger

E

Aug. 1999Mitsubishi Motors Corporation

AddedPWEE9616-B

Cut surface

Backup ring

Corrugated washer

4G6 ENGINE (E-W) -

INSTALLATION SERVICE POINTS

"AA

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

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

BACKUP RING / CORRUGATED WASHER
INSTALLATION

thicker backup ring must be so installed that the inside
cut surface is directed as shown in the illustration.

it to the injector as shown.

Caution

Always replace the corrugated washer with new

D

one. Reused corrugated washer can cause fuel
or gas leaks.

Fuel Part (GDI)

11A-5a-3

Injector
gasket

Mating marks

Insulator

"BA

DELIVERY PIPE AND INJECTOR ASSEMBLY
INSTALLATION

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

in the delivery pipe.

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

dose not rotate smoothly, remove it to check for damaged
O-ring. Damaged O-ring must be replaced with a new
one. Reinstall the injector and check for smooth rotation
again.

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

delivery pipe.

(5) Install the injector gaskets and insulators on the cylinder

head. The insulator can drop off easily. Apply vaseline
to it before installation so that it may be held in position.

(6) Install the delivery pipe and injector assembly onto the

cylinder head, tighten the fasteners temporarily.

(7) Install the injector holders and the washers to the assembly

and tighten the fasteners to the specified torque.

Caution

Strictly observe the specified torque.

D

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

assembly to the specified torque in the order given in
the illustration.

3

E

1 2

Aug. 1998Mitsubishi Motors Corporation

4

AddedPWEE9616-A

11A-5a-4

4G6 ENGINE (E-W) -

Fuel Part (GDI)

Grooved

Camshaft

O-ring

Coupling

"CA

PUMP CAMSHAFT CASE INSTALLATION

(1) Lubricate the O-ring (smaller one for oil passage) with

vaseline and install it in the pump camshaft case.

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

one) in the case.

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

while aligning its coupling with the groove in the camshaft
end.

NOTE
The key of the coupling and the groove in the camshaft
end are both arranged offset with respect to the camshaft
center.

(4) Tighten the pump camshaft case mounting bolts to the

specified torque.

Backup ring
(Mountable in
eitherdirection)

Backup ring

Backup ring

Cut surface

Cut surface

O-ring

"DA

FUEL PRESSURE SENSOR INSTALLATION

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

its inside cut surface in the illustrated direction.

(2) Install the fuel pressure sensor straight into the fuel

pressure regulator with labeled surface upward.

(3) Tighten the fuel pressure sensor mounting bolt to the

specified torque.

"EA

FUEL HIGH PRESSURE REGULATOR / FUEL
RETURN PIPE INSTALLATION

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

camshaft case and tighten the 3 bolts lightly (with
somewhat larger torque than finger tight). Tightening to
the specification is to be carried out in the step described
in "FA.

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

fuel return pipe. Note that the larger backup ring must
be installed with the inside cut surface in the direction
shown in the illustration.

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

oil or gasoline.

(4) Insert the fuel return pipe ends straight in the respective

mounting holes of the pressure regulator and the delivery
pipe. Be sure to insert the pipe fully to the stop using
care not to twist it.

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

torque.

E

Aug. 1998Mitsubishi Motors Corporation

AddedPWEE9616-A

4G6 ENGINE (E-W) -

Fuel Part (GDI)

11A-5a-5

Backup ring
(Mountable in
either direction)

Backup ring

1

4

O-ring

Cut surface

3

2

"FA

FUEL PUMP / FUEL FEED PIPE INSTALLATION

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

camshaft case, and secure it temporarily with 4 bolts
(tighten somewhat with a larger torque than finger tight).

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

feed pipe. Note that the larger backup ring must be
installed with the inside cut surface in the direction shown
in the illustration.

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

oil or gasoline.

(4) Insert the fuel feed pipe ends straight in the respective

mounting holes of the fuel and the delivery pipe. Be sure
to insert the pipe fully to the stop using care not to twist
it.

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

torque.

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

to the specified torque.

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

Nm, tighten the fuel pump mounting bolts in the following
order.

1) Tighten the bolts to 4.9 Nm in the order given in
the illustration.

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

Caution

Strictly observe the specified tightening torque.

D

Deviation from the specification can cause
problems such as leakage or the like.

(8) Clamp the fuel return pipe and feed pipe using the fuel

pipe bracket and clamp A, and tighten them lightly.
(9) Secure the fuel pipe bracket to the cam cap temporarily.
(10)Tighten the bolts which are securing the pipes temporarily

to the specified torque.
(11)Tighten the bolts on the beam cam shaft side which have

been temporarily tightened to the specified torque.

E

Aug. 1998Mitsubishi Motors Corporation

AddedPWEE9616-A

4G6 ENGINE (E-W) -

Water Pump and Intake Manifold

6. WATER PUMP AND INTAKE MANIFOLD

REMOVAL AND INSTALLATION <CARBURETOR>

1

15

11A-6-1

13 Nm

24 Nm

6

20 Nm

14 Nm

11

12

31 Nm

13

14

16

9

2

12 Nm

17

8

11 Nm

7

10

3

4

5

13 Nm

8

Removal steps

1. Water hose

2. Water hose

"CA 3. Engine coolant temperature gauge

unit

4. Water inlet fitting

5. Thermostat

"BA 6. Thermostat housing
"AA 7. Water inlet pipe
"AA 8. O-ring

E

Dec. 1996Mitsubishi Motors Corporation

14 Nm

9. Water pump

10. Water pump gasket

11. Oil level gauge

12. Oil level gauge guide

13. O-ring

14. Intake manifold stay

15. Intake manifold

16. Intake manifold gasket

17. Engine hanger

PWEE9616

11A-6-2

4G6 ENGINE (E-W) -

Water Pump and Intake Manifold

REMOVAL AND INSTALLATION <MULTIPOINT FUEL INJECTION - GALANT>

13 Nm

24 Nm

16

1

7

19 Nm

14 Nm

15

31 Nm

12

13

10

17

11 Nm

18

2

9

11 Nm

8

11

4

13 Nm

19

6

9

23 Nm

5

29 Nm

3

14

14 Nm

Removal steps

1. Water hose

2. Water hose

"DA 3. Engine coolant temperature sensor
"CA 4. Engine coolant temperature gauge

unit

5. Water inlet fitting

6. Thermostat

"BA 7. Thermostat housing
"AA 8. Water inlet pipe
"AA 9. O-ring

10. Water pump

11. Water pump gasket

12. Oil level gauge

13. Oil level gauge guide

14. O-ring

15. Intake manifold stay

16. Intake manifold

17. Intake manifold gasket

18. Engine hanger

19. Detonation sensor

E

Aug. 1998Mitsubishi Motors Corporation

RevisedPWEE9616-A

4G6 ENGINE (E-W) -

Water Pump and Intake Manifold

REMOVAL AND INSTALLATION
<MULTIPOINT FUEL INJECTION - SPACE WAGON>

3

24 Nm

1

11A-6-3

13 Nm

8

19 Nm

31 Nm

16

11

17

18

10

11 Nm

11 Nm

9

19

5

2

13 Nm

10

6

7

29 Nm

4

13

14 Nm

14

12

14 Nm

Removal steps

1. Water hose

2. Water hose

3. Water hose

"DA 4. Engine coolant temperature sensor
"CA 5. Engine coolant temperature gauge

unit

6. Water inlet fitting

7. Thermostat

"BA 8. Thermostat housing
"AA 9. Water inlet pipe

E

Aug. 1998Mitsubishi Motors Corporation

"AA 10. O-ring

11. Water pump

12. Water pump gasket

13. Oil level gauge

14. Oil level gauge guide

15. O-ring

16. Intake manifold stay

17. Intake manifold

18. Intake manifold gasket

19. Engine hanger

15

RevisedPWEE9616-A

11A-6-4

4G6 ENGINE (E-W) -

Water Pump and Intake Manifold

O-ring

3 mm diameter
bead sealant

Water pipe

6EN0594

6EN1168

INSTALLATION SERVICE POINTS

"AA

(1) Wet the O-ring (with water) to facilitate assembly.

"BA

"CA

WATER PIPE / O-RING INSTALLATION

Caution

Keep the O-ring free of oil or grease.

D

SEALANT APPLICATION TO THERMOSTAT
HOUSING

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or
equivalent

NOTE

(1) Be sure to install the housing quickly while the sealant

is wet (within 15 minutes).

(2) After installation, keep the sealed area away from

the oil and coolant for approx. 1 hour.

SEALANT APPLICATION TO ENGINE COOLANT
TEMPERATURE GAUGE UNIT

9EN0092

9EN0091

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

"DA

SEALANT APPLICATION TO ENGINE COOLANT
TEMPERATURE SENSOR

Specified sealant:

3M Nut Locking Part No. 4171 or equivalent

E

Aug. 1998Mitsubishi Motors Corporation

AddedPWEE9616-A

4G6 ENGINE (E-W) -

Water Pump and Water Hose (GDI)

6a. WATER PUMP AND WATER HOSE (GDI)

REMOVAL AND INSTALLATION

12 Nm

11 Nm

11A-6a-1

22 Nm

13

11

9

2

12 Nm

12

7

4

23 Nm

1

29 Nm

3

9

6

8

5

10

12 Nm

13 Nm

Removal steps

1. Water hose

"EA 2. Water hose

3. Engine coolant temperature sensor

"DA 4. Engine coolant temperature gauge

unit

5. Water inlet fitting

6. Thermostat

E

Aug. 1998Mitsubishi Motors Corporation

"CA 7. Water outlet fitting
"BA 8. Thermostat housing
"AA 9. O-ring
"AA 10. Water inlet pipe

11. Water pump

12. Gasket

13. Knock sensor

AddedPWEE9616-A

11A-6a-2

4G6 ENGINE (E-W) -

Water Pump and Water Hose (GDI)

INSTALLATION SERVICE POINTS

"AA

(1) Replace the O-ring of the water inlet pipe, and then apply

O-RING / WATER INLET PIPE INSTALLATION

water to the O-ring to make installation easy.

Caution

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

D

Secure the water pipe after the thermostat case

D

has been reinstalled.

"BA

THERMOSTAT CASE INSTALLATION

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

to the location shown in the illustration.

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or
equivalent

"CA

WATER OUTLET FITTING INSTALLATION

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

to the location shown in the illustration.

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or
equivalent

"DA

ENGINE COOLANT TEMPERATURE GAUGE UNIT
INSTALLATION

(1) Apply the specified sealant to the threads.

Specified sealant:

3M ATD Part No. 8660 or equivalent

9EN0092

9EN0091

E

Aug. 1998Mitsubishi Motors Corporation

"EA

ENGINE COOLANT TEMPERATURE SENSOR
INSTALLATION

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

to the threads.

Specified sealant:

3M Nut Locking Part No. 4171 or equivalent

AddedPWEE9616-A

4G6 ENGINE (E-W) -

7. EXHAUST MANIFOLD

REMOVAL AND INSTALLATION (GALANT)

Exhaust Manifold

1

6

11A-7-1

13 Nm

29 Nm

4

13 Nm

13 Nm

Removal steps

"AA 1. Water outlet fitting

2. Heat protector
(Multipoint fuel injection)

3. Exhaust manifold cover
(Carburetor)

4. Engine hanger

5. Exhaust manifold

6. Exhaust manifold gasket

49 Nm

5

2

13 Nm

3

13 Nm

E

Aug. 1998Mitsubishi Motors Corporation

RevisedPWEE9616-A

11A-7-2

4G6 ENGINE (E-W) -

Exhaust Manifold

REMOVAL AND INSTALLATION (SPACE WAGON)

5

1

13 Nm

29 Nm

3

Removal steps

"AA 1. Water outlet fitting

2. Exhaust manifold cover

3. Engine hanger

4. Exhaust manifold

5. Exhaust manifold gasket

3 mm diameter
bead sealant

49 Nm

2

4

INSTALLATION SERVICE POINTS

"AA

SEALANT APPLICATION TO WATER OUTLET
FITTING

13 Nm

6EN1170

E

Aug. 1998Mitsubishi Motors Corporation

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or
equivalent

NOTE
(1) Be sure to install the water outlet fitting quickly while

the sealant is wet (within 15 minutes).

(2) After installation, keep the sealed area away from

the oil and coolant for approx. 1 hour.

RevisedPWEE9616-A

4G6 ENGINE (E-W) -

Rocker Arms and Camshaft

8. ROCKER ARMS AND CAMSHAFT

REMOVAL AND INSTALLATION

Apply engine oil to all
moving parts before
installation.

2

3

3.4 Nm

4

5

6

11A-8-1

1

14

11

12

11

10

12

17

11

10

13

31 Nm

8

12

11

12

10

16

10

15

15

15

18

15

9

7

Removal steps

1. Breather hose

2. P.C.V. hose

3. Oil filler cap

4. Rocker cover

5. Rocker cover gasket

6. Oil seal

"CA 7. Oil seal
AA""BA 8. Rocker arms and rocker arm shaft
AA""BA 9. Rocker arms and rocker arm shaft

E

Aug. 1998Mitsubishi Motors Corporation

"BA 10. Rocker shaft spring

11. Rocker arm A

12. Rocker arm B

13. Rocker arm shaft (Intake side)

"AA 14. Lash adjuster

15. Rocker arm C

16. Rocker arm shaft (Exhaust side)

"AA 17. Lash adjuster

18. Camshaft

RevisedPWEE9616-A

11A-8-2

4G6 ENGINE (E-W) -

REMOVAL SERVICE POINT

AA"

(1) Set special tool MD998443 to prevent the lash adjuster

INSTALLATION SERVICE POINTS

"AA

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

Rocker Arms and Camshaft

ROCKER ARMS AND ROCKER ARM SHAFTS
REMOVAL

Caution

If the lash adjuster is re-used, clean the lash

D

adjuster. (Refer to 11A-8-3.)

from coming free and falling to the floor.

LASH ADJUSTER INSTALLATION

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

Caution

If the lash adjuster is re-used, clean the lash

D

adjuster. (Refer to 11A-8-3.)

"BA

ROCKER SHAFT SPRING / ROCKER ARMS AND
ROCKER ARM SHAFT INSTALLATION

(1) Temporarily tighten the rocker shaft with the bolt so that

all rocker arms on the inlet valve side do not push the
valves.

(2) Fit the rocker shaft spring from the above and position

it so that it is right angles to the plug guide.

NOTE
Install the rocker shaft spring before installing the exhaust
side rocker arms and rocker arm shaft.

(3) Remove the special tool for securing the lash adjuster.
(4) Make sure that the notch in the rocker arm shaft is in

the direction as illustrated.

"CA

CAMSHAFT OIL SEAL INSTALLATION

MD998713

E

Aug. 1998Mitsubishi Motors Corporation

RevisedPWEE9616-A

Roller tip

4G6 ENGINE (E-W) -

INSPECTION

CAMSHAFT

(1) Measure the cam height.

ROCKER ARM

(1) Check the roller surface. If any dents, damage or seizure

(2) Check rotation of the roller. If it does not rotate smoothly

(3) Check the inside diameter. If damage or seizure is evident,

Rocker Arms and Camshaft

Item Standard value mm Limit mm

GALANT Intake 37.39 36.89

Exhaust 37.14 36.64

SPACE Intake 37.39 36.89
WAGON

Exhaust 36.83 36.33

11A-8-3

is evident, replace the rocker arm.

or if looseness is evident, replace the rocker arm.

replace the rocker arm.

Outside
cleaning

A

Inside
cleaning

B

Filling with
diesel fuel

C

LASH ADJUSTERS

Caution

The lash adjusters are precision-engineered

D

mechanisms. Do not allow them to become
contaminated by dirt or other foreign substances.
Do not attempt to disassemble the lash adjusters.

D

Use only fresh diesel fuel to clean the lash

D

adjusters.

(1) Prepare three containers and approximately five liters

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

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

surface.

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

E

Aug. 1998Mitsubishi Motors Corporation

RevisedPWEE9616-A

11A-8-4

4G6 ENGINE (E-W) -

Rocker Arms and Camshaft

MD998441

MD998442

Diesel fuel

(3) Fit special tool MD998441 onto the lash adjuster.
(4) While gently pushing down the internal steel ball using

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

Caution

The steel ball spring is extremely weak, so the

D

lash adjuster’s functionality may be lost if the
air bleed wire is pushed in hard.

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

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

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

Diesel fuel

MD998441

MD998442

MD998442

Diesel fuel

MD998442

(6) Fit special tool MD998441 onto the lash adjuster.
(7) Place the lash adjuster in container B. Then, gently push

down the internal steel ball using special tool MD998442
and move the plunger through 5 to 10 strokes until it
slides smoothly. This operation will clean the lash
adjuster’s pressure chamber.

Caution

The steel ball spring is extremely weak, so the

D

lash adjuster’s functionality may be lost if the
air bleed wire is pushed in hard.

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

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

Diesel fuel

E

Aug. 1998Mitsubishi Motors Corporation

RevisedPWEE9616-A

4G6 ENGINE (E-W) -

Rocker Arms and Camshaft

11A-8-5

MD998442

MD998441

MD998442

MD998441

Diesel
fuel

Diesel fuel

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

down the internal steel ball using special tool MD998442.

Caution

Do not use container C for cleaning. If cleaning

D

is performed in container C, foreign matter could
enter the pressure chamber when the chamber
is filled with diesel fuel.

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

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

(11)Remove special tool MD998441.

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

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

MD998440

Division = 1 mm

Lash adjuster

NOTE
If lash adjuster contracts, perform the operations (9)
through (12) again to fill it with diesel fuel completely.
Replace the lash adjuster if it still contracts after performing
these steps.

(13)Set the lash adjuster on the special tool MD998440 (leak

down tester).

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

0.5 mm), measure the time taken for it to move downward
by a further 1 mm.

Standard value:

3 - 20 seconds/1 mm [with diesel fuel at 15 ­20_C (59 - 68_F)]

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

E

Aug. 1998Mitsubishi Motors Corporation

AddedPWEE9616-A

11A-8-6

4G6 ENGINE (E-W) -

Rocker Arms and Camshaft

MD998442

MD998441

Diesel fuel

(15)Fit special tool MD998441 onto the lash adjuster.
(16)Place the lash adjuster in container C again, then gently

push down the internal steel ball using special tool
MD998442.

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

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

(18)Remove special tool MD998441.

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

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

NOTE
If lash adjuster contracts, perform the operations (15)
through (19) again to fill it with diesel fuel completely.
Replace the lash adjuster if it still contracts after performing
these steps.

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

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

E

Aug. 1998Mitsubishi Motors Corporation

AddedPWEE9616-A

4G6 ENGINE (E-W) -

Rocker Arms and Camshafts (GDI)

8a. ROCKER ARMS AND CAMSHAFTS (GDI)

REMOVAL AND INSTALLATION

20 Nm

7

11A-8a-1

11

8

Apply engine oil to all
moving parts before
installation.

9

10

9.8 Nm

2

3

6

5

21 Nm

12

4

Removal steps

1. Camshaft position sensor

2. Cover

3. Gasket

"DA 4. Camshaft position sensing cylinder

"CA 5. Camshaft position sensing cylinder

support

"BA 6. Oil seal

E

Aug. 1998Mitsubishi Motors Corporation

1

8.8 Nm

13 Nm

"BA 7. Beam camshaft cap
"BA 8. Beam camshaft cap gasket
"BA 9. Intake camshaft
"BA 10. Exhaust camshaft

11. Rocker arm

AA""AA 12. Lash adjuster

AddedPWEE9616-A

11A-8a-2

4G6 ENGINE (E-W) -

Rocker Arms and Camshafts (GDI)

REMOVAL SERVICE POINTS

AA"

LASH ADJUSTER REMOVAL

Caution

If the lash adjuster is re-used, clean the lash

D

adjuster. (Refer to 11A-8a-4.)

INSTALLATION SERVICE POINTS

"AA

(1) Fit the lash adjuster onto the rocker arm without allowing

LASH ADJUSTER INSTALLATION

Caution

If the lash adjuster is re-used, clean the lash

D

adjuster. (Refer to 11A-8a-4.)

diesel fuel to spill out.

Approx.

_

11

Timing belt
side

Beam camshaft cap

Timing belt side

Dowel pin

3mm

"BA

BEAM CAMSHAFT CAP GASKET / BEAM
CAMSHAFT CAP / CAMSHAFT / OIL SEAL
INSTALLATION

(1) Locate the camshaft dowel pins as illustrated.

(2) Applya3mmthick continuous bead of sealant to the

bottom surface of the beam camshaft cap along the
groove.

Specified sealant:

Mitsubishi genuine Part No. MD970389 or
equivalent

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

head upper surface.

Specified sealant:

Mitsubishi genuine Part No. MD970389 or
equivalent

Aug. 1998Mitsubishi Motors Corporation

E

E

Aug. 1998Mitsubishi Motors Corporation

(4) Install the beam camshaft cap gasket.

AddedPWEE9616-A

AddedPWEE9616-A

4G6 ENGINE (E-W) -

Timing belt side

MD998713

Rocker Arms and Camshafts (GDI)

11A-8a-3

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

becomes dry and hard.

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

in the illustration.

Specified torque: 20 Nm

(7) Install the camshaft oil seal before the sealant applied

becomes dry and hard.

(8) Wipe off squeezed out excess sealant from the

circumference of the beam camshaft cap.

Camshaft
position
sensor

Paint mark

"CA

CAMSHAFT POSITION SENSING CYLINDER
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

"DA

CAMSHAFT POSITION SENSING CYLINDER
INSTALLATION

(1) Set the No. 1 cylinder to the compression top dead center

position (so that dowel pin of the exhaust camshaft is
at the top).

(2) Install the camshaft position sensing cylinder so that the

white paint mark is facing in the direction shown in the
illustration.

E

Aug. 1998Mitsubishi Motors Corporation

INSPECTION

CAMSHAFT

(1) Measure the cam height.

Standard value:

Intake 35.79 mm
Exhaust 37.14 mm

Limit:

Intake 35.29 mm
Exhaust 36.64 mm

AddedPWEE9616-A

11A-8a-4

Outside
cleaning

4G6 ENGINE (E-W) -

Inside
cleaning

Filling with
diesel fuel

Rocker Arms and Camshafts (GDI)

LASH ADJUSTER

Caution

The lash adjusters are precision-engineered

D

mechanisms. Do not allow them to become
contaminated by dirt or other foreign substances.
Do not attempt to disassemble the lash adjusters.

D

Use only fresh diesel fuel to clean the lash

D

adjusters.

(1) Prepare three containers and approximately five liters

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

A

MD998442

B

C

Diesel fuel

Diesel
fuel

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

surface.

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

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

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

Caution

The steel ball spring is extremely weak, so the

D

lash adjuster’s functionality may be lost if the
air bleed wire is pushed in hard.

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

E

Aug. 1998Mitsubishi Motors Corporation

AddedPWEE9616-A

Diesel fuel

MD998442

4G6 ENGINE (E-W) -

MD998442

Diesel fuel

Rocker Arms and Camshafts (GDI)

11A-8a-5

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

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

Caution

Make sure the oil hole in the side of the body

D

is pointing toward container A. Do not point the
oil hole at yourself or other people.

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

down the internal steel ball using special tool MD998442
and move the plunger through 5 to 10 strokes until it
slides smoothly. This operation will clean the lash
adjuster’s pressure chamber.

Caution

The steel ball spring is extremely weak, so the

D

lash adjuster’s functionality may be lost if the
air bleed wire is pushed in hard.

Diesel fuel

MD998442

MD998442

Diesel fuel

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

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

Caution

Make sure the oil hole in the side of the body

D

is pointing toward container A. Do not point the
oil hole at yourself or other people.

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

down the internal steel ball using special tool MD998442.

Caution

Do not use container C for cleaning. If cleaning

D

is performed in container C, foreign matter could
enterthepressure chamber whenchamber is filled
with diesel fuel.

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

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

MD998442

E

Diesel fuel

Aug. 1998Mitsubishi Motors Corporation

AddedPWEE9616-A

11A-8a-6

MD998440

4G6 ENGINE (E-W) -

Division = 1 mm

Lash adjuster

Rocker Arms and Camshafts (GDI)

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

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

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

(10)Set the lash adjuster on the special tool MD998440 (leak

down tester).

Lash
adjuster

MD998442

Nut

Diesel fuel

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

as illustrated.

(12)After the plunger has moved downward slightly measure

the time taken for it to move downward by a further 1
mm.

Standard value:

3 - 20 second/1 mm [with diesel fuel at 15 - 20_C
(59 - 68_F)]

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

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

push down the internal steel ball using special tool
MD998442.

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

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

E

Aug. 1998Mitsubishi Motors Corporation

AddedPWEE9616-A

MD998442

4G6 ENGINE (E-W) -

Diesel fuel

Rocker Arms and Camshafts (GDI)

11A-8a-7

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

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

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

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

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

E

Aug. 1998Mitsubishi Motors Corporation

AddedPWEE9616-A

4G6 ENGINE (E-W) -

Cylinder Head and Valves

9. CYLINDER HEAD AND VALVES

REMOVAL AND INSTALLATION (SOHC)

11A-9-1

2

1

8

20

9

10

4

5

15

6

14

17

12

13

16

19

11

18

7

3

Removal steps

AA""EA 1. Cylinder head bolt

2. Cylinder head assembly

"DA 3. Cylinder head gasket
AB""CA 4. Retainer lock

5. Valve spring retainer

"BA 6. Valve spring

7. Intake valve

AB""CA 8. Retainer lock

9. Valve spring retainer

"BA 10. Valve spring

Apply engine oil to all
moving parts before
installation.

11. Exhaust valve

AC""AA 12. Valve stem seal

13. Valve spring seat

AC""AA 14. Valve stem seal

15. Valve spring seat

16. Intake valve guide

17. Exhaust valve guide

18. Intake valve seat

19. Exhaust valve seat

20. Cylinder head

E

Aug. 1998Mitsubishi Motors Corporation

RevisedPWEE9616-A

11A-9-2

4G6 ENGINE (E-W) -

REMOVAL AND INSTALLATION (GDI)

Cylinder Head and Valves

16

1

8

9

10

4

20

5

14

15

6

17

12

13

19

11

18

7

3

2

Removal steps

AA""EA 1. Cylinder head bolt

2. Cylinder head assembly

3. Cylinder head gasket

AB""CA 4. Retainer lock

5. Valve spring retainer

"BA 6. Valve spring

7. Intake valve

AB""CA 8. Retainer lock

9. Valve spring retainer

"BA 10. Valve spring

Apply engine oil to all
moving parts before
installation.

11. Exhaust valve

AC""AA 12. Valve stem seal

13. Valve spring seat

AC""AA 14. Valve stem seal

15. Valve spring seat

16. Intake valve guide

17. Exhaust valve guide

18. Intake valve seat

19. Exhaust valve seat

20. Cylinder head

E

Aug. 1998Mitsubishi Motors Corporation

RevisedPWEE9616-A

MB991654

4G6 ENGINE (E-W) -

REMOVAL SERVICE POINTS

PRECAUTION FOR REMOVED PARTS

Keep removed parts in order according to the cylinder number
and intake/exhaust.

Cylinder Head and Valves

11A-9-3

MB991654

9EN0061

MD998772

AA"

CYLINDER HEAD BOLTS REMOVAL

(1) Using the special tool, loosen the cylinder head bolts.

Loosen evenly, little by little.

AB"

RETAINER LOCK REMOVAL

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

to indicate their cylinder No. and location for reassembly.

9EN0062

MD998772

E

Aug. 1998Mitsubishi Motors Corporation

RevisedPWEE9616-A

11A-9-4

4G6 ENGINE (E-W) -

Cylinder Head and Valves

AC"

VALVE STEM SEAL REMOVAL

(1) Do not reuse removed stem seal.

MD998737

MD998774

9EN0065

INSTALLATION SERVICE POINTS

"AA

(1) Install the valve spring seat.
(2) The special tool must be used to install the valve stem

"BA

(1) Direct the valve spring end with identification color toward

VALVE STEM SEAL INSTALLATION

seal. Improper installation could result in oil leaks past
the valve guide.

Caution

Do not reuse removed valve stem seals.

D

VALVE SPRING INSTALLATION

the spring retainer.

E

Aug. 1998Mitsubishi Motors Corporation

RevisedPWEE9616-A

4G6 ENGINE (E-W) -

Cylinder Head and Valves

11A-9-5

MD998772

9EN0062

MD998772

"CA

RETAINER LOCK INSTALLATION

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

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

"DA

CYLINDER HEAD GASKET IDENTIFICATION

Shank length

Timing belt side

6EN0782

Identification mark: 4G63N

"EA

CYLINDER HEAD BOLT INSTALLATION

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

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

Limit: Max. 99.4 mm

(2) Apply engine oil to the bolt threads and to the washers.

(3) Using the special tool (MB991654) and according to the

tightening sequence, tighten the bolts to the specified
torque.

Tightening torque: 78 Nm

(4) Loosen all bolts fully.
(5) Retighten the loosened bolts to a torque of 20 Nm in

the specified tightening sequence.

E

Aug. 1998Mitsubishi Motors Corporation

RevisedPWEE9616-A

11A-9-6

90

90

4G6 ENGINE (E-W) -

_

_

Paint mark

6AE0297

Cylinder Head and Valves

(6) Make paint marks on the cylinder head bolt heads and

cylinder head.

(7) Give a 90_turn to the cylinder head bolts in the specified

tightening sequence.

(8) Give another 90_turn to the cylinder head bolts and

make sure that the paint mark on the head of each cylinder
head bolt and that on the cylinder head are on the same
straight line.

Caution

If the bolt is turned less than 90_, proper fastening

D

performance may not be expected. When
tightening the bolt, therefore, be careful to give
a sufficient turn to it.
If the bolt is overtightened, loosen the bolt

D

completely and then retighten it by repeating the
tightening procedure from step (1).

9EN0064

INSPECTION

CYLINDER HEAD

(1) Check the cylinder head gasket surface for flatness by

using a straightedge and thickness gauge.

Standard value: 0.05 mm
Limit: 0.2 mm

(2) If the service limit is exceeded, correct to meet

specification.

Grinding limit: *0.2 mm

* Includes combined with cylinder block grinding.

Cylinder head height (Specification when new):

SOHC 119.9 - 120.1 mm
GDI 131.9 - 132.1 mm

E

Aug. 1998Mitsubishi Motors Corporation

RevisedPWEE9616-A

4G6 ENGINE (E-W) -

VALVE

(1) Check the valve face for correct contact. If incorrect, reface

(2) If the margin exceeds the service limit, replace the valve.

(3) Measure valve’s total length. If measurement is less than

Cylinder Head and Valves

11A-9-7

using a valve refacer. Valve seat contact should be
maintained uniform at the center of valve face.

Item Standard value mm Limit mm

SOHC Intake 1.0 0.5

Exhaust 1.2 0.7

GDI Intake 1.0 0.5

Exhaust 1.5 1.0

specified, replace the valve.

Item Standard value mm Limit mm

SOHC Intake 112.30 111.80

Exhaust 114.11 113.61

GDI Intake 105.5 105.0

Exhaust 105.7 105.2

Out of
square

Free
height

1EN0264

VALVE SPRING

(1) Measure the free height of spring and, if it is smaller

than the limit, replace.

Item Standard value mm Limit mm

SOHC 51.0 50.0

GDI 48.3 47.3

(2) Measure the squareness of the spring and, if the limit

is exceeded, replace.

Item Standard value mm Limit mm

SOHC 2_ 4_

GDI 1.5_ 4_

E

Aug. 1998Mitsubishi Motors Corporation

AddedPWEE9616-A

11A-9-8

Valve
guide

4G6 ENGINE (E-W) -

VALVE GUIDE

(1) Measure the clearance between the valve guide and valve

Cylinder Head and Valves

stem. If the limit is exceeded, replace the valve guide
or valve, or both.

Item Standard value mm Limit mm

SOHC Intake 0.02 - 0.05 0.10

Exhaust 0.03 - 0.07 0.15

GDI Intake 0.02 - 0.05 0.10

Exhaust 0.05 - 0.09 0.15

Valve stem end

VALVE SEAT

(1) Assemble the valve, then measure the valve stem

Valve stem
projection

projection between the end of the valve stem and the
spring seating surface. If the measurement exceeds the
specified limit, replace the valve seat.

Spring seating
surface

DEN0212

Item Standard value mm Limit mm

SOHC Intake 49.30 49.80

Exhaust 49.30 49.80

GDI Intake 49.20 49.70

Exhaust 48.40 48.90

VALVE SEAT RECONDITIONING PROCEDURE

0.9 - 1.3 mm

43.5_-44

E

Aug. 1998Mitsubishi Motors Corporation

_

6EN0491

(1) Before correcting the valve seat, check for clearance

between the valve guide and valve and, if necessary,
replace the valve guide.

(2) Using the seat grinder, correct to obtain the specified

seat width and angle.

(3) After correcting the valve seat, lap the valve and valve

seat using lapping compound. Then, check the valve
stem projection (refer to VALVE SEAT in INSPECTION).

AddedPWEE9616-A

4G6 ENGINE (E-W) -

Cylinder Head and Valves

11A-9-9

Height of
seat ring

0.5 - 1 mm

Oversize I.D.

0.5 - 1 mm

1EN0275

VALVE SEAT REPLACEMENT PROCEDURE

(1) Cut the valve seat to be replaced from the inside to thin

the wall thickness. Then, remove the valve seat.

(2) Rebore the valve seat hole in the cylinder head to a

selected oversize valve seat diameter.

Valve seat ring hole diameter

Item Standard value mm

SOHC Intake 0.30 O.S. 34.30 - 34.33

0.60 O.S. 34.60 - 34.63

Exhaust 0.30 O.S. 31.80 - 31.83

0.60 O.S. 32.60 - 32.63

GDI Intake 0.30 O.S. 35.30 - 35.33

0.60 O.S. 35.60 - 35.63

Exhaust 0.30 O.S. 33.30 - 33.33

0.60 O.S. 33.60 - 33.63

(3) Before fitting the valve seat, either heat the cylinder head

up to approximately 250_C (482_F) or cool the valve
seat in liquid nitrogen, to prevent the cylinder head bore
from galling.

(4) Using a valve seat cutter, correct the valve seat to the

specified width and angle.
See “VALVE SEAT RECONDITIONING PROCEDURE”.

E

Aug. 1998Mitsubishi Motors Corporation

AddedPWEE9616-A

11A-9-10

4G6 ENGINE (E-W) -

VALVE GUIDE REPLACEMENT PROCEDURE

(1) Force the valve guide out toward the cylinder block using

(2) Machine the valve guide hole in the cylinder head to

Cylinder Head and Valves

a press.

the size of the oversize valve guide to be installed.

Caution

Do not use the valve guide of the same size as

D

the removed one.

Valve gauge hole diameters in cylinder head

Item Standard value mm

SOHC 0.05 O.S. 11.05 - 11.07

0.25 O.S. 11.25 - 11.27

0.50 O.S. 11.50 - 11.52

GDI 0.05 O.S. 12.05 - 12.07

0.25 O.S. 12.25 - 12.27

0.50 O.S. 12.50 - 12.52

Protrusion

1EN0106

(3) Press-fit the valve guide until it protrude specified value

(SOHC 14 mm, GDI 19.5 mm) as shown in the illustration.

Caution

Press the valve guide from the cylinder head top

D

surface.
Valve guide for intake valve and that for exhaust

D

valve are different in length. (45.5 mm for intake
valve; 50.5 mm for exhaust valve)

(4) After the valve guide has been installed, insert a new

valve to check for smooth sliding motion.

E

Aug. 1998Mitsubishi Motors Corporation

AddedPWEE9616-A

4G6 ENGINE (E-W) -

Front Case, Counterbalance Shafts and Oil Pan

11A-10-1

10. FRONT CASE, COUNTERBALANCE SHAFTS AND OIL PAN

REMOVAL AND INSTALLATION <GDI ENGINE - VEHICLE FOR EUROPE AND
SOHC ENGINE>

18 Nm

(4G64)

9.8 Nm

18

Apply engine oil to all
moving parts before
installation.

(SOHC)

18

23 Nm

(GDI)

19

17

16

13

1

23 Nm

15

14

44 Nm

10

27

12

11

23 Nm

25

20

28

26

36 Nm

9.8 Nm

23

22

24

23 Nm

16 Nm

39 Nm

8.8 Nm

4

19 Nm

(4G63)

21

2

13

18 Nm

3

6.9 Nm

30

33

31

32

9

29

21 Nm

8

7

6

5

Removal steps

"OA 1. Oil filter

2. Drain plug

"NA 3. Drain plug gasket

4. Oil level sensor
(Vehicle for Europe)

5. Transmission stay (GDI engine)

AA""LA 6. Oil pan

7. Oil screen

8. Oil screen gasket

9. Stiffener (SOHC engine - vehicle
for Europe)

AD""KA 10. Plug

11. O-ring

AE""JA 12. Flange bolt

"IA 13. Oil pressure switch

14. Relief plug

15. Relief plug gasket

16. Relief spring

17. Relief plunger

E

Aug. 1999Mitsubishi Motors Corporation

21 Nm

18. Oil filter bracket

19. Oil filter bracket gasket

"HA 20. Front case assembly

21. Front case gasket

22. Oil pump cover

"GA 23. Oil pump driven gear
"GA 24. Oil pump drive gear
"FA 25. Crankshaft front oil seal
"EA 26. Oil pump oil seal
"DA 27. Counterbalance shaft oil seal

28. Front case

29. Counterbalance shaft, left

30. Counterbalance shaft, right

AF""CA 31. Counterbalance shaft front bearing
AG""BA 32. Counterbalance shaft rear bearing,

left

AG""AA 33. Counterbalance shaft rear bearing,

right

RevisedPWEE9616-B

11A-10-2

4G6 ENGINE (E-W) -

Front Case, Counterbalance Shafts and Oil Pan

REMOVAL AND INSTALLATION <GDI ENGINE - VEHICLE FOR HONG KONG>

34

32

18 Nm

14

9.8 Nm

Apply engine oil to all
moving parts before
installation.

23 Nm

23 Nm

20

28

19

18

17

11

16

15

23 Nm

1

44 Nm

12

13

26

29

36 Nm

21

24

27

9.8 Nm

23

25

16 Nm

23 Nm

39 Nm

22

18 Nm

6.9 Nm

2

6.9 Nm

3

31

21 Nm

33

30

6.9 Nm

7

10

6

9

5

12 Nm

4

8

Removal steps

"OA 1. Oil filter

2. Drain plug

"NA 3. Drain plug gasket

4. Transmission stay

5. Oil level gauge guide

AB""MA 6. Oil pan lower

7. Baffle plate

AC""MA 8. Oil pan upper

9. Oil screen

10. Gasket

AD""KA 11. Plug

12. O-ring

AE""JA 13. Flange bolt

"IA 14. Oil pressure switch

15. Relief plug

16. Gasket

17. Relief spring

18. Relief plunger

E

Aug. 1998Mitsubishi Motors Corporation

19. Oil filter bracket

20. Oil filter bracket gasket

"HA 21. Front case assembly

22. Gasket

23. Oil pump cover

"GA 24. Oil pump driven gear
"GA 25. Oil pump drive gear
"FA 26. Crankshaft front oil seal
"EA 27. Oil pump oil seal
"DA 28. Counterbalance shaft oil seal

29. Front case

30. Counterbalance shaft, left

31. Counterbalance shaft, right

AF""CA 32. Counterbalance shaft front bearing
AG""BA 33. Counterbalance shaft rear bearing,

left

AG""AA 34. Counterbalance shaft rear bearing,

right

RevisedPWEE9616-A

4G6 ENGINE (E-W) -

Front Case, Counterbalance Shafts and Oil Pan

11A-10-3

A

MD998727

6EN0698

REMOVAL SERVICE POINTS

AA"

(1) Remove all oil pan bolts.
(2) Drive in the special tool between the cylinder block and

AB"

(1) Apply a wood block to the oil pan side and remove the

AC"

(1) Remove all bolts.
(2) Screw a bolt into bolt hole A shown to remove the oil

OIL PAN REMOVAL

oil pan.

NOTE
Never use a screwdriver or chisel, instead of the service
tool, as a deformed oil pan flange will result in oil leakage.

OIL PAN LOWER REMOVAL

oil pan lower by tapping lightly on it with a plastic hammer.

Caution

Do not use a scraper or special tool to remove

D

the oil pan.

OIL PAN UPPER REMOVAL

pan.

Caution

Do not use a scraper or special tool to remove

D

the oil pan.

A

Plug

MD998162

MD998783

Screwdriver

AD"

PLUG REMOVAL

(1) If the plug is too tight, hit the plug head with a hammer

two to three times, and the plug will be easily loosened.

AE"

FLANGE BOLT REMOVAL

(1) Remove the plug on the side of cylinder block.
(2) Insert a Phillips screwdriver (shank diameter 8 mm) into

the plug hole to lock the counterbalance shaft.

6EN1026

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Aug. 1998Mitsubishi Motors Corporation

RevisedPWEE9616-A

11A-10-4

4G6 ENGINE (E-W) -

6EN0565

Front Case, Counterbalance Shafts and Oil Pan

(3) Loosen the flange bolt.

MB991603

AF"

COUNTERBALANCE SHAFT FRONT BEARING
REMOVAL

(1) Using the special tool, remove the counterbalance shaft

front bearing from the cylinder block.

NOTE
Be sure to remove the front bearing first.
If it has not been removed, the Rear Bearing Puller cannot
be used.

AG"

COUNTERBALANCE SHAFT REAR BEARING
REMOVAL

(1) Using the special tool, remove the left counterbalance

shaft rear bearing from the cylinder block.

NOTE
When removing the left counterbalance shaft rear bearing,
install the special tool (MB991603) in front of the cylinder
block.

INSTALLATION SERVICE POINTS

"AA

(1) Apply engine oil to the outer surface of bearing.
(2) Using special tools, install right rear bearing. Make sure

MD998705

6EN1034

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Aug. 1998Mitsubishi Motors Corporation

RIGHT COUNTERBALANCE SHAFT REAR
BEARING INSTALLATION

that oil hole of bearing is aligned with oil hole of cylinder
block.

RevisedPWEE9616-A

4G6 ENGINE (E-W) -

Front Case, Counterbalance Shafts and Oil Pan

11A-10-5

MB991603

MB991603

MD998705

Rear bearing

6EN0557

"BA

LEFT COUNTERBALANCE SHAFT REAR
BEARING INSTALLATION

(1) Install the special tool (Guide Plate) to the cylinder block.
(2) Apply engine oil to the rear bearing outer circumference

and bearing hole in the cylinder block.

(3) Using the special tool, install the rear bearing.

NOTE
The left rear bearing has no oil holes.

"CA

COUNTERBALANCE SHAFT FRONT BEARING
INSTALLATION

(1) Using special tools, install front bearing.

E

MD998705

Cylinder block

MD998705

Aug. 1998Mitsubishi Motors Corporation

Bearing

6EN1035

"DA

COUNTERBALANCE SHAFT OIL SEAL
INSTALLATION

RevisedPWEE9616-A

11A-10-6

4G6 ENGINE (E-W) -

Front Case, Counterbalance Shafts and Oil Pan

"EA

"FA

OIL PUMP OIL SEAL INSTALLATION

CRANKSHAFT FRONT OIL SEAL INSTALLATION

(1) Using the special tool, install the crankshaft front oil seal

into the front case.

"GA

OIL PUMP DRIVEN GEAR / OIL PUMP DRIVE
GEAR INSTALLATION

(1) Apply engine oil amply to the gears and line up the

alignment marks.

"HA

FRONT CASE ASSEMBLY INSTALLATION

(1) Set the special tool on the front end of crankshaft and

apply a thin coat of engine oil to the outer circumference
of the special tool to install the front case.

(2) Install the front case assembly through a new front case

gasket and temporarily tighten the flange bolts (other
than those for tightening the filter bracket).

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Aug. 1998Mitsubishi Motors Corporation

RevisedPWEE9616-A

4G6 ENGINE (E-W) -

Front Case, Counterbalance Shafts and Oil Pan

11A-10-7

6EN0564

"IA

SEALANT APPLICATION TO OIL PRESSURE
SWITCH

(1) Coat the threads of switch with sealant and install the

switch using the special tool.

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

Keeptheend of the thread portion clear or sealant.

D

Avoid an overtightening.

D

"JA

FLANGE BOLT INSTALLATION

(1) Insert a Phillips screwdriver into a hole in the left side

of the cylinder block to lock the silent shaft.

(2) Secure the oil pump driven gear onto the left

counterbalance shaft by tightening the flange bolt to
specified torque.

Bolt hole
portion

E

MD998162

MD998783

Groove
portion

Aug. 1998Mitsubishi Motors Corporation

6EN0213

"KA

PLUG INSTALLATION

(1) Install a new O-ring to the groove of front case.
(2) Using the special tool, install the plug and tighten to

specified torque.

"LA

OIL PAN INSTALLATION

(1) Clean both mating surfaces of oil pan and cylinder block.
(2) Apply a 4 mm wide bead of sealant to the entire

circumference of the oil pan flange.

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or
equivalent

RevisedPWEE9616-A

11A-10-8

4G6 ENGINE (E-W) -

Front Case, Counterbalance Shafts and Oil Pan

NOTE
(1) Be sure to install the oil pan quickly while the sealant

is wet (within 15 minutes).

(2) After installation, keep the sealed area away from

the oil and coolant for approx. one hour.

(3) Note the difference in bolt lengths at the location shown.

Oil pan upper

Groove
portion

Timing belt side

Bolt hole portion

"MA

OIL PAN UPPER / OIL PAN LOWER
INSTALLATION

(1) Clean both mating surfaces of oil pan and cylinder block.
(2) Apply a 4 mm wide bead of sealant to the entire

circumference of the oil pan upper flange.

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or
equivalent

NOTE
(1) Be sure to install the oil pan quickly while the sealant

is wet (within 15 minutes).

(2) After installation, keep the sealant area away from

the oil and coolant for approx. one hour.

(3) Note the difference in bolt lengths at the location shown.

M6´16
mm

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Aug. 1998Mitsubishi Motors Corporation

RevisedPWEE9616-A

4G6 ENGINE (E-W) -

Front Case, Counterbalance Shafts and Oil Pan

11A-10-9

Oil pan lower

Groove
portion

6

(4) Clean both mating surfaces of oil pan lower and oil pan

upper.

(5) Apply a 4 mm wide bead of sealant to the entire

circumference of the oil pan lower flange.

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or
equivalent

Bolt hole
portion

NOTE
(1) Be sure to install the oil pan quickly while the sealant

is wet (within 15 minutes).

(2) After installation, keep the sealant area away from

the oil and coolant for approx. one hour.

8

1

(6) Tighten the oil pan lower mounting bolts in the sequence

shown in the illustration.

4

Drain plug
gasket

3

2

9

5

7

"NA

DRAIN PLUG GASKET INSTALLATION

(1) Install the drain plug gasket in the shown direction.

Oil pan side

7EN0307

OIL FILTER INSTALLATION

Bracket side

"OA

(1) Clean the installation surface of the filter bracket.
(2) Apply engine oil to the O-ring of the oil filter.
(3) Screw the oil filter in until the O-ring contacts the bracket.

Then tighten 3/4 turn (tightening torque: 16 Nm).

NOTE
For the oil filter MD135737, tighten one turn (Tightening
torque: 14 Nm) after the O-ring contacts the bracket.

6EN0591

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Aug. 1998Mitsubishi Motors Corporation

AddedPWEE9616-A

11A-10-10

4G6 ENGINE (E-W) -

Front Case, Counterbalance Shafts and Oil Pan

INSPECTION

FRONT CASE

(1) Check oil holes for clogging and clean if necessary.
(2) Check the left counterbalance shaft front bearing section

for wear, damage and seizure. If there is anything wrong
with the section, replace the front case.

(3) Check the front case for cracks and other damage.

Replace cracked or damaged front case.

OIL SEAL

(1) Check the oil seal lip for wear and damage. Replace

oil seal if necessary.

(2) Check the oil seal lip for deterioration. Replace oil seal

if necessary.

COUNTERBALANCE SHAFT

(1) Check oil holes for clogging.
(2) Check journals for seizure, damage and contact with

bearing. If there is anything wrong with the journal, replace
the counterbalance shaft, bearing or front case assembly.

OIL PUMP

(1) Assemble the oil pump gear to the front case and rotate

it to ensure smooth rotation with no looseness.

(2) Ensure that there is no ridge wear on the contact surface

between the front case and the gear surface of the oil
pump cover.

(3) Check the side clearance.

Standard value:

Drive gear 0.08 - 0.14 mm
Driven gear 0.06 - 0.12 mm

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Aug. 1998Mitsubishi Motors Corporation

AddedPWEE9616-A

4G6 ENGINE (E-W) -

Piston and Connecting Rod

11. PISTON AND CONNECTING ROD

REMOVAL AND INSTALLATION

Apply engine oil to all
moving parts before
installation.

6
7
8

11A-11-1

4

10

11

9

5

12

Removal steps

"GA 1. Nut

AA""FA 2. Connecting rod cap

"EA 3. Connecting rod bearing
"DA 4. Piston and connecting rod assem-

bly

"EA 5. Connecting rod bearing
"CA 6. Piston ring No. 1

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Dec. 1996Mitsubishi Motors Corporation

3

2
1

"CA 7. Piston ring No. 2
"BA 8. Oil ring

AB""AA 9. Piston pin

10. Piston

11. Connecting rod

12. Bolt

PWEE9616

11A-11-2

4G6 ENGINE (E-W) -

REMOVAL SERVICE POINTS

AA"

(1) Mark the cylinder number on the side of the connecting

(2) Keep the removed connecting rods, caps, and bearings

Piston and Connecting Rod

CONNECTING ROD CAP REMOVAL

rod big end for correct reassembly.

in order according to the cylinder number.

AB"

PISTON PIN REMOVAL

(1) Insert the special tool, Push Rod, into the piston from

the side on which the front mark is stamped in the piston
head, and attach the guide C to the push rod end.

(2) Place the piston and connecting rod assembly on the

special tool, Piston Pin Setting Base, with the front mark
facing upward.

(3) Using a press, remove the piston pin.

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Dec. 1996Mitsubishi Motors Corporation

NOTE
Keep the disassembled pistons, piston pins and
connecting rods in order according to the cylinder number.

PWEE9616

4G6 ENGINE (E-W) -

INSTALLATION SERVICE POINTS

"AA

(1) Measure the following dimensions of the piston, piston

(2) Obtain dimension L (to be used later) from the above

(3) Insert the special tool, Push Rod, into the piston pin and

(4) Assemble the connecting rod in the piston with their front

(5) Apply engine oil to the entire periphery of the piston pin.
(6) Insert the piston pin, push rod and guide A assembly

Piston and Connecting Rod

11A-11-3

PISTON PIN INSTALLATION

pin and connecting rod.
A: Piston pin insertion hole length
B: Distance between piston bosses
C: Piston pin length
D: Connecting rod small end width

measurements by using by following formula.

L=

(A - C) - (B - D)

2

attach the guide A to the push rod end.

marks facing the same direction.

having assembled in step (3) from the guide A side into
the piston pin hole on the front marked side.

3mm+L

(7) Screw the guide B into the guide A until the gap between

both guides amounts to the value L obtained in step
(2) plus 3 mm.

(8) Place the piston and connecting rod assembly onto the

piston setting base with the front marks directed upward.

(9) Press-fit the piston pin using a press.

If the press-fitting force required is less than the standard
value, replace the piston and piston pin set or/and the
connecting rod.

Standard value: 7,350 - 17,200 N

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Dec. 1996Mitsubishi Motors Corporation

PWEE9616

11A-11-4

4G6 ENGINE (E-W) -

(10)Check that the piston moves smoothly

Piston and Connecting Rod

Side rail gap

Upper
side rail

Spacer

Lower side rail

6EN1237

1EN0269

"BA

OIL RING INSTALLATION

(1) Fit the oil ring spacer into the piston ring groove.

NOTE

1. The side rails and spacer may be installed in either
direction.

2. New spacers and side rails are colored for
identification of their sizes.

Size Identification color

Standard None

0.50 mm oversize Red

1.00 mm oversize Yellow

(2) Install the upper side rail.

To install the side rail, first fit one end of the rail into
the piston groove, then press the remaining portion into
position by finger. See illustration.
Use of ring expander to expand the side rail end gap
can break the side rail, unlike other piston rings.

Caution

Do not use piston ring expander when installing

D

side rail.

(3) Install the lower side rail in the same procedure as

described in step (2).

(4) Make sure that the side rails move smoothly in either

direction.

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Dec. 1996Mitsubishi Motors Corporation

PWEE9616

4G6 ENGINE (E-W) -

Piston and Connecting Rod

11A-11-5

Identification mark

Identification mark

Side mark

9EN0524

No. 1

No. 2

"CA

PISTON RING NO. 2 / PISTON RING NO. 1
INSTALLATION

(1) Using piston ring expander, fit No. 2 and then No. 1 piston

ring into position.

NOTE

1. The ring end is provided with identification mark.

Item Identification mark

No. 1 ring 4G63 SOHC 1R

4G64 GDI T

No. 2 ring 4G63 SOHC 2R

4G64 GDI 2T

2. Install piston rings with identification mark facing up,
to the piston crown side.

3. Size marks on position rings are as follows.

Size Size mark

Standard None

0.50 mm oversize 50

1.00 mm oversize 100

Timing belt side

"DA

PISTON AND CONNECTING ROD ASSEMBLY
INSTALLATION

(1) Liberally coat engine oil on the circumference of the piston,

piston ring, and oil ring.

(2) Arrange the piston ring and oil ring gaps (side rail and

spacer) as shown in the figure.

(3) Rotate the crankshaft so that crank pin is on the center

of cylinder bore.

(4) Use suitable thread protectors on the connecting rod bolts

before inserting piston and connecting rod assembly into
the cylinder block.
Care must be taken not to nick the crank pin.

(5) Using a suitable piston ring compressor tool, install the

piston and connecting rod assembly into the cylinder block.

"EA

CONNECTING ROD BEARINGS INSTALLATION

When the bearing needs replacing, select and install a proper
bearing by the following procedure.
(1) Measure the crankshaft pin diameter and confirm its

classification from the following table. In the case of a
crankshaft supplied as a service part, identification colors
of its pins are painted at the positions shown in the
illustration.

Aug. 1998Mitsubishi Motors Corporation

E

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Aug. 1998Mitsubishi Motors Corporation

RevisedPWEE9616-A

RevisedPWEE9616-A

11A-11-6

4G6 ENGINE (E-W) -

(2) The connecting rod bearing identification mark is stamped

Crankshaft pin Connecting rod bearing

Classi­fication

Identification mark

1 None Yellow 44.995 - 45.000 1 1.478 - 1.491

2 None None 44.985 - 44.995 2 1.491 - 1.495

3 None White 44.980 - 44.985 3 1.495 - 1.499

(3) Select a proper bearing from the above table on the basic

Piston and Connecting Rod

at the position shown in the illustration.

Identifica­tion mark

Produc­tion part

Connecting rod I.D.: 48.000 - 48.015 mm

of the identification data confirmed under items (1) and
(2).

[Example]
If the measured value of a crankshaft pin outer diameter
is 44.996 mm, the pin is classified as “1” in the table.
In case the crankshaft is also replaced by a spare part,
check the identification colors of the pins painted on the
new crankshaft. If the color is yellow, for example, the
pin is classified as “1”. In the above cases, select the
connection rod bearing having identification mark “1”.

Identifi­cation
color

Service
part

O. D. mm Identi-

fication
mark

Thickness mm

"FA

CONNECTING ROD CAP NUT INSTALLATION

(1) Verifying the mark made during disassembly, install the

bearing cap to the connecting rod. If the connecting rod
is new with no index mark, make sure that the bearing
locking notches come on the same side as shown.

(2) Make sure that the connecting rod big end side clearance

meets the specification.

Standard value: 0.10 - 0.25 mm
Limit: 0.4 mm

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Dec. 1996Mitsubishi Motors Corporation

PWEE9616

4G6 ENGINE (E-W) -

Piston and Connecting Rod

11A-11-7

Paint
mark

90_- 100

"GA

CONNECTING ROD CAP NUT INSTALLATION

Caution

If thecylinder head hasbeeninstalled beforeinstalling

D

the connecting rod cap nut, be sure to remove the
spark plugs.

(1) Since the connecting rod cap bolts and nuts are torqued

using the plastic area tightening method, the bolts should
be examined BEFORE reuse. If the bolt threads are
“necked down”, the bolt should be replaced.
Necking can be checked by running a nut with fingers
to the full length of the bolt threads. If the nut does not

_

Paint mark

run down smoothly, the bolt should be replaced.

(2) Before installation of each nut, apply engine oil to the

thread portion and bearing surface of the nut.

(3) Install each nut to the bolt and tighten it with fingers.

Then tighten the nuts alternately to install the cap properly.
(4) Tighten the nuts to a torque of 20 Nm.
(5) Make a paint mark on the head of each nut.

Nut

Bolt

(6) Make a paint mark on the bolt end at the position 90

to 100_from the paint mark made on the nut in the direction

_

of tightening the nut.

6AE0298

(7) Give a 90_to 100_turn to the nut and make sure that

the paint mark on the nut and that on the bolt are in

alignment.

Caution

If the nut is turned less than 90_, proper fastening

D

performance may not be expected. When
tightening the nut, therefore, be careful to give
a sufficient turn to it.
Ifthe nutisovertightened (exceeding100_),loosen

D

the nut completely and then retighten it by
repeating the tightening procedure from step (1).

INSPECTION

PISTON RING

(1) Check the piston ring for damage, excessive wear, and

breakage and replace if defects are evident. If the piston

has been replaced with a new one, the piston rings must

also be replaced with new ones.
(2) Check for the clearance between the piston ring and

ring groove. If the limit is exceeded, replace the ring or

piston, or both.

Standard value: 0.02 - 0.06 mm

Limit: 0.1 mm

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Dec. 1996Mitsubishi Motors Corporation

PWEE9616

11A-11-8

4G6 ENGINE (E-W) -

(3) Install the piston ring into the cylinder bore. Force it down

Piston and Connecting Rod

with a piston, its crown being in contact with the ring,

to correctly position it at right angles to the cylinder wall.

Then, measure the end gap with a feeler gauge. If the

ring gap is excessive, replace the piston ring.

Standard value:

No. 1 ring 0.25 - 0.35 mm
No. 2 ring 0.40 - 0.55 mm
Oil ring 0.10 - 0.40 mm

Limit:

No. 1, No. 2 ring 0.8 mm
Oil ring 1.0 mm

Plastigage

CRANKSHAFT PIN OIL CLEARANCE
(PLASTIC GAUGE METHOD)

(1) Remove oil from the crankshaft pin and connecting rod

bearing.
(2) Cut the Plastigage to the same length as the width of

the bearing and place it on the crankshaft pin in parallel

with its axis.

(3) Install the connecting rod cap carefully and tighten the

nuts to specified torque.
(4) Carefully remove the connecting rod cap.
(5) Measure the width of the Plastigage at its widest part

by using a scale printed on the Plastigage package.

Standard value: 0.02 - 0.05 mm

Limit: 0.1 mm

E

Dec. 1996Mitsubishi Motors Corporation

PWEE9616