Mitsubishi Space Star 2000 User Manual
GENERAL
CONTENTS
00-1
HOW TO USE THIS MANUAL 2. . . . . . . . . . . . . .
Model Indications 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION 2. . . . . . . . . . . . . . . . . .
Models 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model code 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAJOR SPECIFICATIONS 4. . . . . . . . . . . . . . . . . .
00-2
(Multi Point Fuel Injection)
(Di
l)
(G
)
GENERAL – How To Use This Manual/Vehicle Identification
HOW TO USE THIS MANUAL
MODEL INDICATIONS
The following abbreviations are used in this manual for identification of model types.
MPI: Indicates the multi point fuel injection.
GD-D: Indicates the direct injection diesel.
GDI: Indicates the gasoline direct injection.
M/T: Indicates the manual transmission, or models equipped with the manual transmission.
A/T: Indicates the automatic transmission, or models equipped with the automatic transmission.
A/C: Indicates the air conditioner.
VEHICLE IDENTIFICATION
MODELS
Model code Engine model Transmission model Fuel supply system
DG1A
DG4A
DG5A
LNDEL6/R6
LNJEL6/R6
LNPEL6/R6
LNDFL6/R6
LNJFL6/R6
LNPFL6/R6
LNDCL6
LNJCL6/R6
LRJCL6/R6 F4A42
LNPCL6/R6 F5M42 <5M/T>
LRPCL6/R6 F4A42
4G13 MPI (1,299 mL) F5MR1 <5M/T> MPI
F9Q1 (1,870 mL) F5MV1 <5M/T> DI-D
4G93 GDI (1,834 mL) F5M42 <5M/T> GDI
<INVECS-II 4A/T with
Sports Mode>
<INVECS-II 4A/T with
Sports Mode>
rect Injection Diese
asoline Direct Injection
GENERAL – Vehicle Identification
2
Engine ty e
1: 1,299 mL etrol engine
,g
y
6
Trim level
D: Family
MODEL CODE
No. Items Contents
1 Development DG: MITSUBISHI SPACE STAR
2 Engine type 1: 1,299 mL petrol engine
3 Sort A: Passenger car
4 Body style L: 5-door
5 Transmission type N: 5-speed manual
6 Trim level D: Famil
00-3
4: 1,870 mL diesel engine
5: 1,834 mL petrol engine
transmission
R: 4-speed automatic
transmission
J: Comfort
P: Sport
7 Specification engine
feature
8 Steering wheel
location
9 Destination 6: For Europe
E: MPI
F: DI-D
C: GDI
L: Left hand
R: Right hand
00-4
Items
g
GENERAL – Major Specifications
MAJOR SPECIFICATIONS
9
*1
3
3
Items
Vehicle
dimensions
mm
DG1A DG4A
LNDEL6
/R6
Overall length 1 4,030
Overall width 2 1,715
Overall height
(unladen)
3 1,515,
1,555
45
12
LNJEL6
/R6
*1
LNPEL6
/R6
8
LNDFL6
/R6
LNJFL6
/R6
Wheelbase 4 2,500
Track-front 5 1,475
Track-rear 6 1,470
Overhang-front 7 835
Overhang-rear 8 695
Ground clear-
9 155
ance (unladen)
Vehicle
weight kg
Kerb weight 1,158 1,170 1,173 1,248 1,260 1,258
Max. gross vehicle
1,655 1,730
weight
Max. axle weight
855 920
rating-front
Max. axle weight
830 850
rating-rear
Seating capacity 5
Engine
Model No. 4G13 F9Q1
Total displacement
1,299 1,870
mL
Transmission
Model No. F5MR1 F5MV1
Type 5 speed-manual
Fuel system Fuel supply system Multi Point Fuel Injection Direct Injection Diesel
NOTE:
1
*
: Vehicles with roof rails
67
LNPFL6
/R6
GENERAL – Major Specifications
Items
g
00-5
Items
Vehicle
dimensions
mm
Vehicle
weight kg
Seating capacity 5
Engine
Transmission
Fuel system Fuel supply system Gasoline Direct Injection
NOTE:
1
*
: Vehicles with roof rails
Overall length 1 4,030
Overall width 2 1,715
Overall height
(unladen)
Wheelbase 4 2,500
Track-front 5 1,475
Track-rear 6 1,470
Overhang-front 7 835
Overhang-rear 8 695
Ground clear-
ance (unladen)
Kerb weight 1,228 1,240 1,238 1,255 1,253
Max. gross vehicle
weight
Max. axle weight
rating-front
Max. axle weight
rating-rear
Model No. 4G93
Total displacement
mL
Model No. F5M42 F4A42
Type 5 speed-manual INVECS-II 4A/T with Sports
DG5A
LNDCL6 LNJCL6/R6 LNPCL6/R6 LRJCL6/R6 LRPCL6/R6
3 1,515,
9 150
1,555
1,730
920
850
1,834
*1
Mode
NOTES
ENGINE
CONTENTS
ENGINE <4G9> 11A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE <4G1> 11B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE <F9Q1> 11C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11A-1
11A-2
ENGINE <4G9>
CONTENTS
GENERAL 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline of Changes 3. . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 3. . . . . . . . . . . . . . . . .
SEALANTS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 3. . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT AND CAMSHAFT OIL SEAL 5. . . .
CRANKSHAFT REAR OIL SEAL <A/T> 10. . . .
CYLINDER HEAD GASKET 12. . . . . . . . . . . . . . . .
ENGINE ASSEMBLY 15. . . . . . . . . . . . . . . . . . . . . .
General/Service Specifications/Sealants/Special ToolsENGINE <4G9> –
11A-3
GENERAL
OUTLINE OF CHANGES
Since the resin intake manifold is adopted, the fuel system is changed, and the vehicle with A/T is added
to the lineup, the following service adjustment procedures are made.
Other service procedures are the same as before.
SERVICE SPECIFICATIONS
Items Standard value Limit
Idle speed r/min A/T 650 ± 100 –
Cylinder head bolt shank length mm – 96.4
SEALANTS
Items Specified sealants Remarks
Beam camshaft cap and cylinder
head
Camshaft position sensor support MITSUBISHI GENUINE PART
Drive plate bolt 3M Stud locking 4170 or equivalent –
3M ATD Part No.8660 or equivalent
MD970389 or equivalent
SPECIAL TOOLS
Tool Number Name Use
MB990767 End yoke holder Holding the camshaft sprocket
MD998719 Crankshaft pulley
holder pin
MD998762 Circular packing
installer
Holding the camshaft sprocket
Press-fitting the circular packing
Semi-drying sealant
MD998713 Camshaft oil seal
installer
Press-fitting the camshaft oil seal
11A-4
Tool UseNameNumber
MD998781 Flywheel stopper Securing the drive plate
ENGINE <4G9> – Special Tools
MD998776 Crankshaft rear oil
seal installer
MB990938 Handle
MB991653 Cylinder head bolt
wrench
GENERAL
SERVICE
TOOL
MZ203827
MB991453 Engine hanger
Engine lifter Supporting the engine assembly during
assembly
Press-fitting the crankshaft rear oil seal
Cylinder head bolt removal and installation
removal and installation of the transmission
ENGINE <4G9> – Camshaft and Camshaft Oil Seal
CAMSHAFT AND CAMSHAFT OIL SEAL
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Prevention of Fuel Discharge <before removal only>
Fuel Leak Check <after installation only>
Air Bleeding the High Pressure Fuel Path
<after installation only>
[Refer to GROUP 13A – Fuel Pump (High pressure).]
3.0 Nm
Under Cover Removal and Installation
Engine Coolant Draining and Supplying
Air Cleaner Removal and Installation
11A-5
1
7.0 Nm
8
7
6
5
3
9
15
5.0 Nm
12
10 – 12 Nm
10
5.0 Nm
11
13
14
2
4
19
18
3.4 Nm
17
21
22
16
20
Removal steps
F 1. Engine cover
2. Crank angle sensor connector
3. Fuel pressure sensor
4. Oxygen sensor (front) connector
5. Control wiring harness and EGR
wiring harness combination
connector
6. Purge control solenoid valve
connector
7. Throttle position sensor connector
8. Throttle valve control servo
connector
9. Control wiring harness and injector
wiring harness combination
connector
10. Ignition coil connector
11. Ignition failure sensor connector
12. Camshaft position sensor connector
13. Engine coolant temperature sensor
connector
14. Engine coolant temperature gauge
unit connector
15. Control wiring harness
16. PCV hose
17. Breather hose
Ignition coil (Refer to GROUP 16.
Intake manifold (Refer to GROUP 15.)
Timing belt
18. Connector bracket (injector wiring
harness)
19. Rocker cover (intake side)
20. Rocker cover gasket
21. Rocker cover (exhaust side)
22. Rocker cover gasket
11A-6
ENGINE <4G9> – Camshaft and Camshaft Oil Seal
Apply engine oil to all
sliding parts during
installation.
25
10 – 12 Nm
21 – 25 Nm
10 – 12 Nm
29
31
30
32
21 – 25 Nm
33
22 Nm
23
88 Nm
35 Nm
26
24
23
28
27
12 – 15 Nm
AE 23. Camshaft sprocket
24. Idler pulley
25. Timing belt rear upper cover
D 26. Camshaft oil seal
27. Camshaft position sensor support
C 28. Circular packing
Fuel pump (high pressure) assembly
(Refer to GROUP 13A.)
B 29. Beam camshaft cap
30. Beam camshaft cap gasket
A 31. Camshaft (intake side)
A 32. Camshaft (exhaust side)
33. Camshaft position sensing cylinder
Lubrication points
Sealant: 3M ATD Part No.8660 or equivalent
ENGINE <4G9> – Camshaft and Camshaft Oil Seal
<Seen from underneath
φ3mm
beam camshaft cap>
11A-7
Sealant:
MITSUBISHI GENUINE PART
MD970389 or equivalent
Lip section
Engine oil
<Seen from above cylinder head>
Sealant: 3M ATD Part No.8660 or equivalent
11A-8
MB990767
MD998719
ENGINE <4G9> – Camshaft and Camshaft Oil Seal
REMOVAL SERVICE POINT
A CAMSHAFT SPROCKET REMOVAL
Camshaft sprocket side
Exhaust camshaft
Approx.
106
Dowel pin
Intake side Exhaust side
28 27 31 32
20 19 23 24
12 11 15 163
Screw hole
Approx.
101
INSTALLATION SERVICE POINTS
A CAMSHAFT INSTALLATION
1. Apply engine oil to journals and cams of the camshafts.
2. Install the camshafts on the cylinder head.
Caution
Be careful not to confuse the intake camshaft with
the exhaust one. There is a screw hole for the cam
position sensing cylinder mounting bolt on the
exhaust-side camshaft.
B BEAM CAMSHAFT CAP INSTALLATION
1. Place the camshaft dowel pin as shown in the illustration.
2. Tighten the beam camshaft cap mounting bolts to the
specified torque in the order shown in the illustration.
Tightening torque:
: 10 – 12 Nm
: 21 – 25 Nm
87 561
Intake side Exhaust
14 13 9 102
22 21 17 184
30 29 25 26
Front of engine
side
Press-fitting
depth 2 mm
MD998762
ENGINE <4G9> – Camshaft and Camshaft Oil Seal
C CIRCULAR PACKING INSTALLATION
Use the special tool to press-fit the circular packing as shown
in the illustration.
11A-9
MD998713
D CAMSHAFT OIL SEAL INSTALLATION
1. Apply engine oil to the entire circumference of the oil seal
lip.
2. Press-fit the oil seal as shown in the illustration.
E CAMSHAFT SPROCKET INSTALLATION
Use the special tool to secure the camshaft sprocket in the
same way as during removal, and then tighten the bolt to
the specified torque.
F ENGINE COVER INSTALLATION
1. Temporarily tighten the mounting bolt in the order of the
numbers shown in the illustration so that the engine cover
can move easily by hand.
2. Tighten the mounting bolt to the specified torque in the
order of the numbers shown in the illustration.
Tightening torque: 3.0 Nm
11A-10
ENGINE <4G9> – Crankshaft Rear Oil Seal <A/T>
CRANKSHAFT REAR OIL SEAL <A/T>
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Transmission Assembly Removal and Installation
(Refer to GROUP 23.)
3
4
1
93 – 103 Nm
2
Removal steps
AB 1. Drive plate bolts
B 2. Adapter plate
B 3. Drive plate
A 4. Crankshaft rear oil seal
MD998781
REMOVAL SERVICE POINT
A DRIVE PLATE BOLTS REMOVAL
Use the special tool to secure the drive plate, and remove
the bolts.
ENGINE <4G9> – Crankshaft Rear Oil Seal <A/T>
11A-11
Crankshaft
rear oil seal
MD990938
MD998776
Crankshaft
INSTALLATION SERVICE POINTS
A CRANKSHAFT REAR OIL SEAL INSTALLATION
1. Apply a small mount of engine oil to the entire
circumference of the oil seal lip.
2. Install the oil seal by tapping it as far as the chamfered
position of the oil seal case as shown in the illustration.
B DRIVE PLATE/ADAPTOR PLATE/DRIVE PLATE
BOLTS INSTALLATION
1. Clean off all sealant, oil and other substances which are
adhering to the threaded bolts, crankshaft thread holes
and the drive plate.
2. Apply oil to the bearing surface of the drive plate bolts.
3. Apply oil to the crankshaft thread holes.
4. Apply sealant to the threaded mounting holes.
Specified sealant: 3M Stud locking 4170 or equivalent
5. Use the special tool to secure the drive plate, and then
tighten the bolts to the specified torque.
Specified torque: 93 – 103 Nm
11A-12
ENGINE <4G9> – Cylinder Head Gasket
CYLINDER HEAD GASKET
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Engine Cover Removal and Installation
(Refer to P.11A-5.)
Prevention of Fuel Discharge <before removal only>
Fuel Leak Check <after installation only>
Air Bleeding the High Pressure Fuel Path<after
installation only>
[Refer to GROUP 13A – Fuel Pump (High-pressure).]
Under Cover Removal and Installation
Engine Coolant Draining and Supplying
Engine Oil Draining and Supplying
10 – 12 Nm
74 Nm → 0 Nm → 20 Nm
→ +90 → +90
12
Air Cleaner Removal and Installation
Intake Manifold Removal and Installation
(Refer to GROUP 15.)
Fuel Pump (high-pressure) Assembly Removal and
Installation (Refer to GROUP 13A.)
Timing Belt Rear Upper Cover Removal and
Installation (Refer to P.11A-5.)
Thermostat Case Assembly and Radiator upper hose
Removal and Installation
(Refer to GROUP 14 – Water Hose and Water Pipe.)
7
3.4 Nm
10
13
11
8
9
5
22 Nm
44 Nm
1
4
14
6
3
49 Nm
35 Nm
2
34 Nm
35 Nm
3
19 Nm
34 Nm
19 Nm
ENGINE <4G9> – Cylinder Head Gasket
Removal steps
1. Injector harness connector
2. Front exhaust pipe connection
3. Exhaust manifold bracket
4. Power steering oil pump bracket
stay
A 5. Power steering oil pump and brack-
et assembly
6. Engine oil level gauge assembly
7. Connector bracket (injector wiring
harness)
REMOVAL SERVICE POINTS
A POWER STEERING OIL PUMP AND BRACKET
Remove the power steering oil pump and bracket assembly
from the engine with the hose attached.
NOTE
Place the removed power steering oil pump in a place where
it will not be a hindrance when removing and installing the
cylinder head assembly, and tie it with a cord.
11A-13
8. Rocker cover (intake side)
9. Rocker cover gasket
10. Rocker cover (exhaust side)
11. Rocker cover gasket
BB 12. Cylinder head bolt
13. Cylinder head assembly
A 14. Cylinder head gasket
ASSEMBLY REMOVAL
MB991653
Intake side Front of engine
351082
1796 4
Exhaust side
B CYLINDER HEAD BOLT REMOVAL
Use the special tool to loosen the bolts in two or three stages
in the order of the numbers shown in the illustration, and
then remove the bolts.
INSTALLATION SERVICE POINTS
A CYLINDER HEAD GASKET INSTALLATION
1. Wipe off all oil and grease from the gasket mounting
surface.
2. Install so that the shapes of the cylinder head holes match
the shapes of the respective cylinder head gasket holes.
11A-14
ENGINE <4G9> – Cylinder Head Gasket
Burred side
Head bolt
A
Intake side Front of engine
washer
Cylinder
head
MB991653
351082
1796 4
Head bolt
(Engine
oil)
B CYLINDER HEAD BOLT INSTALLATION
1. When installing the cylinder head bolts, the length below
the head of the bolts should be within the limit.
If it is outside the limit, replace the bolts.
Limit (A): 96.4 mm
2. The head bolt washer should be installed with the burred
side caused by tapping out facing upwards.
3. Apply a small amount of engine oil to the thread section
and the washer of the cylinder head bolt.
4. Tighten the bolts by the following procedure.
Step Operation Remarks
1 Tighten to 74 Nm. Carry out in the order
shown in the illustration.
2 Fully loosen. Carry out in the reverse
order of that shown in the
illustration.
3 Tighten to 20 Nm. Carry out in the order
shown in the illustration.
4 Tighten 90 of a turn. In the order shown in the
illustration. Mark the
head of the cylinder head
bolt and cylinder head by
paint.
5 Tighten 90 of a turn. In the order shown in the
illustration. Check that
the painted mark of the
head bolt is lined up with
that of the cylinder head.
Exhaust side
Step 4
90
Painted mark
Caution
(1) Always make a tightening angle just 90. If it is
less than 90, the head bolt will be loosened.
(2) If it is more than 90, remove the head bolt and
repeat the procedure from step 1.
Step 5
90
Painted mark
ENGINE <4G9> – Engine Assembly
ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Engine Cover Removal and Installation
(Refer to P.11A-5.)
Prevention of Fuel Discharge <before removal only>
Air Bleeding the High Pressure Fuel Path
<after installation only>
[Refer to GROUP 13A – Fuel Pump (High pressure).]
11A-15
Fuel Leak Check <after installation only>
Drive Belt Tension Adjustment
Under Cover Removal and Installation
Air Cleaner Removal and Installation
Hood Removal and Installation
Radiator Assembly Removal (Refer to GROUP 14.)
20
9.0 Nm
17
18
2
3
1
9.0 Nm
7.0 Nm
4
6
7
9.0 Nm
5
8
5.0 Nm
11
9
5.0 Nm
10
14
12
13
15
19
16
Removal steps
1. Crank angle sensor connector
2. Fuel pressure sensor
3. Oxygen sensor (front) connector
4. Control wiring harness and EGR
wiring harness combination connector
5. Purge control solenoid valve connector
6. Throttle position sensor connector
7. Throttle valve control servo connector
8. Control wiring harness and injector
wiring harness combination connector
9. Ignition coil connector
10. Ignition failure sensor connector
11. Camshaft position sensor connector
12. Engine coolant temperature sensor
connector
13. Engine coolant temperature gauge
unit connector
14. Detonation sensor connector
15. Power steering oil pressure switch
connector
16. A/C compressor connector
17. Alternator connector
18. Engine oil pressure switch connector
19. Starter connector
20. Drive belt (Power steering and A/C)
11A-16
ENGINE <4G9> – Engine Assembly
Caution
Mounting locations marked by * should be provisionally tightened, and then fully tightened when
the body is supporting the full weight of the engine.
(Engine Oil)
12 Nm
67 Nm
29
30
23
57 Nm
24
22 Nm
28
21
26
27
5.0 Nm
25
22 Nm
A 21. Power steering oil pump
B 22. A/C compressor
23. Brake booster vacuum hose
connection
24. Vacuum hose connection
25. Heater hoses connection
D 26. Fuel return hoses connection
C 27. High-pressure fuel hose connection
22
98 – 118 Nm*
C 28. O-ring
Transmission assembly
(Refer to ’99 SPACE STAR Workshop
Manual.)
(Refer to GROUP 23. <A/T>)
CB 29. Engine mount Bracket
DA 30. Engine assembly
ENGINE <4G9> – Engine Assembly
REMOVAL SERVICE POINTS
A POWER STEERING OIL PUMP REMOVAL
Remove the power steering oil pump from the engine with
the hose attached.
NOTE
Place the removed power steering oil pump where it will not
be a hindrance when removing and installing the engine
assembly, and tie it with a cord.
B A/C COMPRESSOR REMOVAL
Disconnect the A/C compressor connector and remove the
compressor from the compressor bracket with the hose still
attached.
NOTE
Place the removed A/C compressor where it will not be a
hindrance when removing and installing the engine assembly,
and tie it with a cord.
11A-17
MB991453
MZ203827
C ENGINE MOUNT BRACKET REMOVAL
1. Support the engine with a garage jack.
2. Remove the mechanical hanger (recommended tool) which
was attached when the transmission assembly was
removed.
3. Hold the engine assembly with a chain block or similar
tool.
4. Place a garage jack against the engine oil pan with a
piece of wood in between, jack up the engine so that
the weight of the engine is no longer being applied to
the engine mount bracket, and then remove the engine
mount bracket.
D ENGINE ASSEMBLY REMOVAL
After checking that all cables, hoses and harness connectors,
etc., are disconnected from the engine, lift the chain block
slowly to remove the engine assembly upward from the engine
compartment.
INSTALLATION SERVICE POINTS
A ENGINE ASSEMBLY INSTALLATION
Install the engine assembly, checking that the cables, hoses,
and harness connectors are not clamped.
11A-18
ENGINE <4G9> – Engine Assembly
MB991453
MZ203827
B ENGINE MOUNT BRACKET INSTALLATION
1. Place a garage jack against the engine oil pan with a
piece of wood in between, and install the engine mount
bracket while adjusting the position of the engine.
2. Support the engine with the garage jack.
3. Remove the chain block and support the engine assembly
with the mechanical hanger (recommended tool).
C O-RING/HIGH-PRESSURE FUEL HOSE
INSTALLATION
1. Apply a small amount of new engine oil to the O-ring.
Caution
Do not let any engine oil get into the delivery pipe.
2. While turning the high-pressure fuel hose to the right and
left, install the delivery pipe, while being careful not to
damage the O-ring. After installing, check that the hose
turns smoothly.
3. If the hose does not turn smoothly, the O-ring is probably
being clamped. Disconnect the high-pressure fuel hose
and check the O-ring for damage. After this, re-insert the
delivery pipe and check that the hose turns smoothly.
4. Tighten to the specified torque.
Specified torque: 5.0 Nm
White mark
Blue mark
D FUEL RETURN HOSES INSTALLATION
Install so that the identification marks of the fuel return hoses
are at the positions shown in the illustration.
ENGINE <4G1>
CONTENTS
11B-1
GENERAL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline of Change 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION 2. . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . . . . .
SEALANT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 3. . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 4. . . . . . . . . . . . . . . . . . . . .
Ignition Timing Check and Adjustment 4. . . . . . . . . .
Lash Adjuster Check 5. . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT AND CAMSHAFT OIL SEAL 8. . . .
CRANKSHAFT FRONT OIL SEAL 10. . . . . . . . . .
CYLINDER HEAD GASKET 12. . . . . . . . . . . . . . . .
ENGINE ASSEMBLY 15. . . . . . . . . . . . . . . . . . . . . .
11B-2
ENGINE <4G1> –
General/General Information/Service
Specifications/Sealant
GENERAL
OUTLINE OF CHANGE
Since the catalytic converter internal-type exhaust manifold and the auto-lash adjuster are adopted, and
intake manifold and the ignition system are changed, the following service adjustment procedures are
made. Otherwise, the procedures are the same as that of the existing models.
GENERAL INFORMATION
Items 4G13
Auto-lash adjuster Equipped
SERVICE SPECIFICATIONS
Items Standard value Limit
Basic ignition timing 5 BTDC ± 3 –
Cylinder head bolt shank length mm – 103.2
SEALANT
Items Specified sealant Remarks
Camshaft position sensor support MITSUBISHI GENUINE PART
MD970389 or equivalent
Semi-drying sealant
ENGINE <4G1> – Special Tools
SPECIAL TOOLS
Tool Number Name Use
11B-3
MB991502 MUT-II sub
assembly
MB991668 Belt tension meter
set
MD998747 Crankshaft pulley
holder
MB990767 End yoke holder Holding the camshaft sprocket
MD998719 or
MD998754
Crankshaft pulley
holder pin
Measuring the drive belt tension
Checking the idle speed
Measuring the drive belt tension
(used together with MUT-II)
Holding the crankshaft pulley
MD998713 Camshaft oil seal
installer
MD998727 Oil pan remover Removing the oil pan
MD998781 Fly wheel stopper Securing the flywheel
MD998718 Crankshaft rear oil
seal installer
Press-in of the camshaft oil seal
Press-fitting the crankshaft rear oil seal
11B-4
Tool UseNameNumber
ENGINE <4G1> – Special Tools/On-vehicle Service
A
A: MD998304
B: MD998305
B
MB991653 Cylinder head bolt
GENERAL
SERVICE
TOOL
MZ203827
MB991453 Engine hanger as-
A: Crankshaft front
oil seal installer
B: Crankshaft front
oil seal guide
wrench
Engine lifter Supporting the engine assembly during
sembly
Press-fitting the crankshaft front oil seal
Cylinder head bolt removal and installation
removal and installation of the transmission
ON-VEHICLE SERVICE
IGNITION TIMING CHECK
1. Set the vehicle to the pre-inspection condition.
2. After turning the ignition switch to the LOCK (OFF) position,
connect the MUT-II to the diagnosis connector.
3. Connect a timing light.
4. Start the engine and run it at idle.
5. Select item No. 22 on the MUT-II and take a reading of the
engine speed. Check that the idle speed is at the standard
value.
Standard value: 750 ± 100 r/min
6. Select item No. 17 (actuator test function) on the MUT-II,
and set the ignition timing to the basic ignition timing.
7. Check the basic ignition timing.
Standard value: 5 BTDC ± 3
8. If the basic ignition timing is outside the standard value
range, check the MPI system while referring to GROUP 13B
– Troubleshooting.
9. Press the CLEAR key on the MUT-II to cancel the basic
ignition timing setting mode by the actuator test function.
Caution
If the mode is not cancelled, the basic ignition timing
setting mode will remain active for 27 minutes, and
problems with engine operation may result if the
vehicle is driven during this period.
ENGINE <4G1> – On-vehicle Service
10. Check that the ignition timing is at the standard ignition
timing.
Standard value: Approx. 10 BTDC
NOTE
(1) There should be no problems if the ignition timing
varies within a range of about 7.
(2) At high altitudes, advance the ignition timing by about
a further 5 from the standard value.
LASH ADJUSTER CHECK
If an abnormal noise (knocking) that seems to be coming
from the lash adjuster is heard after starting the engine and
does not stop, carry out the following check.
NOTE
(1) The abnormal noise which is caused by a problem
with the lash adjusters is generated after the engine
is started, and will vary according to the engine speed.
However, this noise is not related to the actual engine
load.
Because of this, if the noise does not occur immediately
after the engine is started, if it does not change in
accordance with the engine speed, or if it changes
in accordance with the engine load, the source of
the noise is not the lash adjusters.
(2) If there is a problem with the lash adjusters, the noise
will almost never disappear, even if the engine has
been run at idle to let it warm up.
The only case where the noise might disappear is
if the oil in the engine has not been looked after properly
and oil sludge has caused the lash adjusters to stick.
1. Start the engine.
2. Check that the noise occurs immediately after the engine
is started, and that the noise changes in accordance with
changes in the engine speed.
If the noise does not occur immediately after the engine
is started, or if it does not change in accordance with
the engine speed, the problem is not being caused by
the lash adjusters, so check for some other cause of the
problem. Moreover, if the noise does not change in
accordance with the engine speed, the cause of the
problem is probably not with the engine. (In these cases,
the lash adjusters are normal.)
11B-5
11B-6
ENGINE <4G1> – On-vehicle Service
3. While the engine is idling, check that the noise level does
not change when the engine load is varied.
If the noise level changes, the cause of the noise is probably
parts striking because of worn crankshaft bearings or
connecting rod bearings. (In such cases, the lash adjusters
are normal.)
4. After the engine has warmed up, run it at idle and check
if any noise can be heard.
If the noise has become smaller or disappeared, oil sludge
could make the lash adjusters stick. Clean the lash
adjusters. (Refer to the Engine Workshop Manual.) If not
improved, go to step 5.
5. Bleed air from the lash adjusters.
6. If the noise has not disappeared even after the air bleeding,
clean the lash adjusters. (Refer to the Engine Workshop
Manual.)
<LASH ADJUSTER AIR BLEEDING>
NOTE
(1) If the vehicle is parked on a slope for a long period
of time, the amount of oil inside the lash adjuster will
decrease, and air may get into the high pressure
chamber when starting the engine.
(2) After parking the vehicle for long periods, the oil drains
out of the oil passage, and it takes time for the oil
to be supplied to the lash adjuster, so air can get
into the high pressure chamber.
(3) If either of the above situations occur, the abnormal
noise can be eliminated by bleeding the air from inside
the lash adjusters.
Good
1. Check the engine oil and replenish or replace the oil if
necessary.
NOTE
(1) If there is a only small amount of oil, air will be drawn
in through the oil screen and will get into the oil
passage.
(2) If the amount of oil is greater than normal, then the
oil will being mixed by the crankshaft and a large
amount of air may get mixed into the oil.
(3) If the oil is degenerated, air and oil will not separate
easily in oil, and the amount of air mixed into the
oil will increase.
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