11A-0-1
ENGINE
4G6 SERIES
CONTENTS
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
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
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-0-3
4G6 ENGINE <E-W> - General Information
GENERAL INFORMATION
SOHC-4G63
Descriptions
Specifications
Type
In-line OHV, SOHC
Number of cylinders
Combustion chamber
Total displacement dm
Cylinder bore mm
Piston stroke mm
Compression ratio
Valve timing
4
Pentroof type
3
1,997
85.0
88.0
10
Intake valve
Opens (BTDC)
Closes (ABDC)
Opens (BBDC)
Closes (ATDC)
18_
58_
Exhaust valve
58_
18_
Lubrication system
Oil pump type
Pressure feed, full-flow filtration
Involute gear type
SOHC-4G64
Descriptions
Specifications
Type
In-line OHV, SOHC
Number of cylinders
Combustion chamber
Total displacement dm
Cylinder bore mm
Piston stroke mm
Compression ratio
Valve timing
4
Pentroof type
3
2,351
86.5
100.0
10
Intake valve
Opens (BTDC)
Closes (ABDC)
Opens (BBDC)
Closes (ATDC)
16_
53_
Exhaust valve
50_
16_
Lubrication system
Oil pump type
Pressure feed, full-flow filtration
Involute gear type
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-0-4
4G6 ENGINE <E-W> - General Information
GDIt
Descriptions
Specifications
Type
In-line OHV, SOHC
4
Number of cylinders
Combustion chamber
Total displacement dm
Cylinder bore mm
Piston stroke mm
Compression ratio
Valve timing
Pentroof + curved top piston type
3
2,351
86.5
100.0
11.5
Intake valve
Opens (BTDC)
Closes (ABDC)
Opens (BBDC)
Closes (ATDC)
16_
60_
Exhaust valve
56_
16_
Lubrication system
Oil pump type
Pressure feed, full-flow filtration
Involute gear type
NOTE
GDI is a trademark of Mitsubishi Motors Corporation.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-1-1
4G6 ENGINE <E-W> - Specifications
1. SPECIFICATIONS
SERVICE SPECIFICATIONS
Items
Standard value
12
Limit
Timing belt
Auto-tensioner rod projection length mm
-
-
Auto-tensioner rod pushed-in amount [when pushed with a force of 98 1.0 or less
- 196 N] mm
Rocker arms and camshaft
Intake
37.39
36.89
36.64
36.89
36.33
-
Camshaft cam height mm
4G63
SOHC
Exhaust
Intake
37.14
37.39
4G64
SOHC
Exhaust
36.83
Lash adjuster leak down time
[diesel fuel at 15 - 20_C] seconds/mm
3 - 20/1.0
Camshaft journal outer diameter mm
Rocker arms and camshaft (GDI)
Camshaft cam height mm
45
-
Intake
35.79
35.29
36.64
-
Exhaust
37.14
Lash adjuster leak down time
[diesel fuel at 15 - 20_C] seconds/mm
3 - 20/1.0
Camshaft journal outer diameter mm
Cylinder head and valves
26
-
Cylinder head flatness of gasket surface mm
Less than 0.05
-
0.2
0.2
Cylinder head grinding limit of gasket surface mm
Total resurfacing depth of both cylinder head and cylinder block
SOHC
GDI
120
132
-
-
-
Cylinder head overall height mm
Cylinder head bolt shank length mm
Maximum 99.4
Intake
1.0
0.5
Valve thickness of valve head (margin) mm SOHC
Exhaust
Intake
1.2
0.7
1.0
0.5
GDI
Exhaust
Intake
1.5
1.0
112.30
114.11
105.5
105.7
6.0
111.80
113.61
105.0
105.2
-
Valve overall height mm
SOHC
GDI
Exhaust
Intake
Exhaust
Valve stem outer diameter mm
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-1-2
4G6 ENGINE <E-W> - Specifications
Items
Standard value
Limit
Intake
0.02 - 0.05
0.03 - 0.07
0.02 - 0.05
0.05 - 0.09
45_ - 45.5_
51.0
0.10
Valve thickness to valve guide clearance SOHC
mm
Exhaust
Intake
0.15
0.10
GDI
Exhaust
0.15
Valve face angle mm
-
SOHC
GDI
50.0
Valve spring free length mm
48.3
47.3
SOHC
GDI
267/44.2
294/40.0
2_ or less
1.5_ or less
0.9 - 1.3
6.0
-
Valve spring load/installed height N/mm
Valve spring out-of-squareness
-
SOHC
GDI
Maximum 4_
Maximum 4_
Valve seat valve contact width mm
Valve guide inner diameter mm
-
SOHC
GDI
-
6.6
-
SOHC
GDI
14.0
-
Valve guide projection from cylinder head
upper surface mm
19.5
-
SOHC
GDI
49.30
49.80
Valve stem projection mm
Intake
49.20
49.70
Exhaust
48.40
48.90
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
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Oversize rework dimensions of valve guide
hole (SOHC) mm
Oversize rework dimensions of valve guide
hole (GDI) mm
0.3 Oversize diameter
0.6 Oversize diameter
0.3 Oversize diameter
0.6 Oversize diameter
0.3 Oversize diameter
0.6 Oversize diameter
0.3 Oversize diameter
0.6 Oversize diameter
34.30 - 34.33
34.60 - 34.63
35.30 - 35.33
35.60 - 35.63
34.30 - 34.33
34.60 - 34.63
33.30 - 33.33
33.60 - 33.63
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
Exhaust oversize rework dimensions of
valve seat hole (GDI) mm
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-1-3
4G6 ENGINE <E-W> - Specifications
Items
Front case, counterbalance shaft and oil pan
Drive gear
Driven gear
Standard value
Limit
0.08 - 0.14
0.06 - 0.12
78 or more
-
-
-
Oil pump side clearance mm
Oil pressure at curb idle speed kPa [Oil temperature is 75 to 90_C]
Piston and connecting rod
4G63
85.0
-
Piston outer diameter mm
Piston ring side clearance mm
Piston ring end gap mm
4G64
86.5
-
No. 1
0.02 - 0.06
0.02 - 0.06
0.25 - 0.35
0.40 - 0.55
0.10 - 0.40
22.0
0.1
0.1
0.8
0.8
1.0
-
No. 2
No. 1
No. 2
Oil ring side rail
Piston pin outer diameter mm
Piston pin press-in load N (Room temperature)
Crankshaft pin oil clearance mm
7,350 - 17,200
0.02 - 0.05
0.10 - 0.25
-
0.1
0.4
Connecting rod big end side clearance mm
Crankshaft, flywheel and drive plate
Crankshaft end play mm
0.05 - 0.25
0.40
Crankshaft journal outer diameter mm
Crankshaft pin outer diameter mm
Crankshaft journal oil clearance mm
Bearing cap bolt shank length mm
Piston to cylinder clearance mm
57.0
-
45.0
-
0.02 - 0.04
0.1
-
Maximum 71.1
0.02 - 0.04
-
Cylinder block flatness of gasket surface mm
0.05
-
0.1
0.2
Cylinder block grinding limit of gasket surface mm
Total resurfacing depth of both cylinder head and cylinder block
4G63
4G64
4G63
4G64
284
290
85.0
86.5
0.01
-
-
-
-
-
Cylinder block overall height mm
Cylinder block inner diameter mm
Cylindricity mm
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-1-4
4G6 ENGINE <E-W> - Specifications
TORQUE SPECIFICATIONS
Items
Nm
Alternator and ignition system
Water pump pulley
9
Adjusting bolt
10
22
23
44
25
10
25
12
22
14
10
13
22
49
49
Lock bolt
Alternator brace
Alternator pivot nut
Crankshaft pulley
Ignition coil (Multipoint fuel injection)
Spark plug
Distributor (Carburetor)
Camshaft position sensing cylinder (Multipoint fuel injection)
Camshaft position sensor support (Multipoint fuel injection)
Camshaft position sensor (Multipoint fuel injection)
Oil level gauge guide
Idler pulley bracket (M8) (Vehicle for Hong Kong)
Idler pulley bracket (M10) (Vehicle for Hong Kong)
Idler pulley (Vehicle for Hong Kong)
Intake manifold (GDI)
Vacuum pipe and hose (Flange bolt)
Vacuum pipe and hose (Bolt, washer assembly)
Solenoid valve
11
8.8
8.8
11
Vacuum pipe
Throttle body
11
Intake manifold stay (M6)
Intake manifold stay (M8)
Air intake plenum resonator (Flange bolt)
Air intake plenum resonator (Bolt, washer assembly)
EGR valve
8.8
30
11
8.8
23
23
19
EGR valve support
Intake manifold
Timing belt
Timing belt cover flange bolt
11
Mitsubishi Motors Corporation
Aug. 1999
PWEE9616-B
Revised
E
11A-1-5
4G6 ENGINE <E-W> - Specifications
Items
Nm
9
Timing belt cover washer bolt
Power steering bracket
49
9
Crankshaft angle sensor (Multipoint fuel injection)
Tensioner arm
22
48
23
35
49
54
118
18
45
88
Tensioner puller
Auto tensioner
Idler pulley
Engine support bracket
Oil pump sprocket
Crankshaft bolt
Tensioner “B”
Counterbalance shaft sprocket
Camshaft sprocket bolt
Exhaust manifold (GDI)
Exhaust manifold cover
Exhaust manifold (M10)
Exhaust manifold (M8)
Engine hanger
13
49
29
11
Fuel and emission parts
Carburetor (Carburetor)
Fuel vapor separator (Carburetor)
Throttle body (Multipoint fuel injection)
EGR valve (Except General Export)
Injectors and delivery pipe (Multipoint fuel injection)
Fuel pressure regulator (Multipoint fuel injection)
Fuel part (GDI)
17
23
18
22
12
9
Fuel low pressure pipe (M6)
Fuel low pressure pipe (M8)
Fuel pump return nipple
Clamp A
8.8
18
8.8
8.8
11
Fuel pipe bracket
Fuel feed pipe
11
Mitsubishi Motors Corporation
Aug. 1999
PWEE9616-B
Revised
E
11A-1-6
4G6 ENGINE <E-W> - Specifications
Items
Nm
Fuel pump
4.9 ® 17 ± 2
Harness bracket
Fuel return pipe
Fuel high pressure regulator
Fuel pressure sensor
Pump camshaft case
Injector holder
8.8
11
18
18
23
22
11
11
Delivery pipe and injector assembly
Engine hanger
Water pump and intake manifold
Engine coolant temperature sensor
Engine coolant temperature gauge unit
Water inlet fitting
29
11
13
24
13
14
14
31
19
11
23
Thermostat housing
Water inlet pipe
Water pump
Oil level gauge guide
Intake manifold stay
Intake manifold
Engine hanger
Detonation sensor (Multipoint fuel injection)
Water pump and water hose (GDI)
Engine coolant temperature sensor
Engine coolant temperature gauge unit
Water inlet fitting
29
11
12
12
23
12
13
22
Water outlet fitting
Thermostat housing
Water inlet pipe
Water pump
Knock sensor
Exhaust manifold
Exhaust manifold cover
13
Mitsubishi Motors Corporation
Aug. 1999
PWEE9616-B
Revised
E
11A-1-7
4G6 ENGINE <E-W> - Specifications
Items
Nm
13
29
49
13
Heat protector
Exhaust manifold (M8)
Exhaust manifold (M10)
Water outlet fitting
Rocker arms and camshaft
Rocker cover
3.4
31
Rocker arm shaft
Rocker arms and camshafts (GDI)
Camshaft position sensor
Cover
8.8
9.8
21
13
20
Camshaft position sensing cylinder
Camshaft position sensing support
Beam camshaft cap
Cylinder head and valves
Cylinder head bolt
20 + 90_ + 90_
[Tighten to 78 Nm and then completely loosen before finally tightening with above procedure.]
Front case, counterbalance shaft and oil pan
Drain plug
39
6.9
8.8
21
18
19
9.8
44
18
23
36
16
9.8
23
21
12
Oil pan
Oil level sensor (For Europe)
Stiffener (For Europe)
Oil screen
Oil pressure switch (4G63)
Oil pressure switch (4G64)
Relief plug
Oil filter bracket
Plug
Flange bolt
Oil pump cover bolt
Oil pump cover screw
Front case
Transmission stay (GDI engine)
Oil level gauge guide
Mitsubishi Motors Corporation
Aug. 1999
PWEE9616-B
Revised
E
11A-1-8
4G6 ENGINE <E-W> - Specifications
Items
Nm
6.9
6.9
6.9
Oil pan lower
Baffle plate
Oil pan upper
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
Oil seal case bolt
Bearing cap bolt
8.8
11
25 + 90_ ® 100_
Mitsubishi Motors Corporation
Aug. 1999
PWEE9616-B
Revised
E
11A-1-9
4G6 ENGINE <E-W> - Specifications
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.
D
Areas where the bolts are in use:
(1) Cylinder head bolts
(2) Main bearing cap bolts
(3) Connecting rod cap bolts
D
Tightening method
After tightening the bolts to the specified torque, tighten them another 90_ or 180_ (twice 90_). The
tightening method varies on different areas. Observe the tightening method described in the text.
SEALANTS
Item
Specified sealant
Quantity
Cam position sensor support
Mitsubishi Genuine Part No. MD970389 or As required
equivalent
Engine coolant temperature sensor
Engine coolant temperature gauge unit
Thermostat case
3M Nut Locking Part No. 4171 or equivalent
3M ATD Part No. 8660 or equivalent
As required
As required
Mitsubishi Genuine Part No. MD970389 or As required
equivalent
Water outlet fitting
Beam camshaft cap
Cylinder head
Mitsubishi Genuine Part No. MD970389 or As required
equivalent
Mitsubishi Genuine Part No. MD970389 or As required
equivalent
Mitsubishi Genuine Part No. MD970389 or As required
equivalent
Oil pressure switch
Oil pan
3M ATD Part No. 8660 or equivalent
As required
Mitsubishi Genuine Part No. MD970389 or As required
equivalent
Oil seal case
Mitsubishi Genuine Part No. MD970389 or As required
equivalent
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
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.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-2-1
4G6 ENGINE (E-W) - Special Tools
2. SPECIAL TOOLS
Tool
Number
Name
Use
MB990767
MD990938
MB991603
MB991654
MD998162
MD998285
MD998371
MD998372
MD998375
Crankshaft pulley Holding camshaft sprocket
holder
Use with MD998719.
Handle
Installation of crankshaft rear oil seal
Use with MD998776.
Silent shaft bearing Guide stopper for removal and installation of
puller stopper
counterbalance shaft rear bearing
Use with MD998372.
Cylinder head bolt Removal and installation of cylinder head bolt
wrench (12)
Plug wrench
Removal and installation of front case cap plug
Use with MD998783.
Crankshaft front oil Guide for installation of crankshaft front oil seal
seal guide Use with MD998375.
Silent shaft bearing Removal of counterbalance shaft front bearing
puller
Silent shaft bearing Removal of counterbalance shaft rear bearing
puller
Crankshaft
seal installer
front Installation of crankshaft front oil seal
Mitsubishi Motors Corporation
Dec. 1996
PWEE9616
E
11A-2-2
4G6 ENGINE (E-W) - Special Tools
Tool
Number
Name
Use
MD998440
Leak down tester
Leak down test of lash adjuster
MD998441
MD998442
MD998443
MD998705
MD998713
MD998719
MD998727
MD998735
Lash adjuster
retainer
Air bleeding of lash adjuster
Air bleeding of lash adjuster
Lash adjuster wire
Lash adjuster
holder
Retainer for holding lash adjuster in rocker arm
at time of removal and installation of rocker
shaft assembly
Silent shaft bearing Installation of counterbalance shaft front and
installer rear bearing
Camshaft oil seal Installation of camshaft oil seal
installer
Pulley holder pin
Oil pan remover
Holding camshaft sprocket
Use with MB990767.
Removal of oil pan
Valve spring
compressor
Removal and installation of valve and related
parts
Mitsubishi Motors Corporation
Dec. 1996
PWEE9616
E
11A-2-3
4G6 ENGINE (E-W) - Special Tools
Tool
Number
Name
Use
MD998738
Set screw
Adjustment of timing belt tension
MD998767
MD998772
MD998774
MD998775
MD998776
MD998778
MD998780
Tensioner
puller Adjustment of timing belt tension
socket wrench
Valve spring
compressor
Removal and installation of valve and related
parts
Valve stem seal Installation of valve stem seal
installer
Valve stem seal Installation of valve stem seal
installer
Crankshaft rear oil Installation of crankshaft rear oil seal
seal installer
Use with MB990938.
Crankshaft
sprocket puller
Removal of crankshaft sprocket
Piston setting tool
Removal and installation of piston pin
MD998781
Flywheel stopper
Holding of flywheel and drive plate
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-2-4
4G6 ENGINE (E-W) - Special Tools
Tool
Number
Name
Use
MD998783
Plug wrench
retainer
Removal and installation of front case cap plug
MD998785
Sprocket stopper
Holding silent shaft sprocket
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-3-1
4G6 ENGINE (E-W) - Alternator and Ignition System
3. ALTERNATOR AND IGNITION SYSTEM
REMOVAL AND INSTALLATION <CARBURETOR>
8
6
12 Nm
7
25 Nm
10
4
9
10 Nm
3
44 Nm
2
22 Nm
24 Nm
9 Nm
5
25 Nm
1
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
Mitsubishi Motors Corporation
Dec. 1996
PWEE9616
E
11A-3-2
4G6 ENGINE (E-W) - Alternator and Ignition System
REMOVAL AND INSTALLATION <MULTIPOINT FUEL INJECTION>
10 Nm
7
10 Nm
6
9
10
8
25 Nm
11
4
22 Nm
10 Nm
3
14 Nm
44 Nm
r
2
22 Nm
24 Nm
9 Nm
5
25 Nm
1
Removal steps
1. Drive belt
7. Ignition coil assembly
8. Spark plug
2. Water pump pulley
3. Alternator brace
4. Alternator
9. Camshaft position sensor
"AA 10. Camshaft position sensing support
11. Camshaft position sensing cylinder
5. Crankshaft pulley
6. Spark plug cable
Mitsubishi Motors Corporation
Dec. 1996
PWEE9616
E
11A-3-3
4G6 ENGINE (E-W) - Alternator and Ignition System
REMOVAL AND INSTALLATION (GDI)
9.8 Nm
11
25 Nm
12
49 Nm
6
7
9.8 Nm
22 Nm
1
8.8 Nm
5
4
23 Nm
13 Nm
8
9
2
49 Nm
3
25 Nm
10
49 Nm
22 Nm
Removal steps
1. Oil level gauge
8. Idler pulley bracket
2. Oil level gauge guide
3. O-ring
(Vehicle for Hong Kong)
9. Idler pulley
4. Drive belt
(Vehicle for Hong Kong)
10. Crankshaft pulley
11. Ignition coil
5. Water pump pulley
6. Alternator
7. Alternator brace
12. Spark plug
Mitsubishi Motors Corporation
Aug. 1999
PWEE9616-B
Revised
E
11A-3-4
4G6 ENGINE (E-W) - Alternator and Ignition System
INSTALLATION SERVICE POINTS
"AA CAMSHAFT POSITION SENSOR SUPPORT
INSTALLATION
(1) Apply a 3 mm bead of form-in-place gasket (FIPG) to
the area shown.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or
equivalent
"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
Stud bolt
the stud bolt used for securing the distributor with the
slot in the mounting flange of the distributor.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-3a-1
4G6 ENGINE (E-W) - Intake Manifold (GDI)
3a. INTAKE MANIFOLD (GDI)
REMOVAL AND INSTALLATION (SPACE WAGON)
2
11 Nm
8.8 Nm
11 Nm
8.8 Nm
3
8.8 Nm
4
11 Nm
16
12
13
5
14
11
7
6
1
8.8 Nm
23 Nm
23 Nm
19 Nm
17
18
15
10
11 Nm
19
30 Nm
19 Nm
9
8.8 Nm
30 Nm
8
Removal steps
1. Vacuum pipe and hose
"DA 7. Throttle body gasket
(1999 model vehicles for Hong
Kong)
"CA 8. Intake manifold stay
"BA 9. Air intake plenum resonator
10. Gasket
2. Solenoid valve (1999 model ve-
hicles for Hong Kong)
11. Water hose
3. Vacuum pipe and hose
(Vehicles for Europe and 2000
model vehicles for Hong Kong)
4. Solenoid valve
12. EGR valve
13. Gasket
"AA 14. Hose clamp
"AA 15. EGR support
"AA 16. Gasket
17. Gasket
(Vehicles for Europe and 2000
model vehicles for Hong Kong)
5. Vacuum pipe
18. Intake manifold
19. Gasket
6. Throttle body
Mitsubishi Motors Corporation
Aug. 1999
PWEE9616-B
Revised
E
11A-3a-2
4G6 ENGINE (E-W) - Intake Manifold (GDI)
REMOVAL AND INSTALLATION (GALANT)
8.8 Nm
8.8 Nm
1
2
8
11 Nm
9
11
3
4
23 Nm
19 Nm
13
23 Nm
5
10
14
15
16
12
7
19 Nm
30 Nm
11 Nm
8.8 Nm
6
Removal steps
1. Vacuum pipe and hose
2. Solenoid valve
9. EGR valve
10. Gasket
3. Throttle body
"AA 11. Hose clamp
"AA 12. EGR support
"AA 13. Gasket
14. Gasket
"DA 4. Throttle body gasket
"CA 5. Intake manifold stay
"BA 6. Air intake plenum resonator
7. Gasket
15. Intake manifold
16. Gasket
8. Water hose
Mitsubishi Motors Corporation
Aug. 1999
PWEE9616-B
Revised
E
11A-3a-3
4G6 ENGINE (E-W) - Intake Manifold (GDI)
INSTALLATION SERVICE POINTS
Intake manifold side
"AA EGR SUPPORT / HOSE CLAMP / GASKET
Cylinder head side
INSTALLATION
(1) Install the gasket, EGR support and hose clamp to the
cylinder head in that order and tighten the fasteners
temporarily.
(2) Install the EGR support assembly to the intake manifold
with the gasket attached on the mating surface, and tighten
the fasteners to the specified torque.
(3) Tighten the fasteners on the cylinder head side to the
specified torque.
Hose clamp
"BA AIR INTAKE PLENUM RESONATOR
INSTALLATION
(1) Install the mounting bolts on the throttle body side without
fail.
"CA INTAKE MANIFOLD STAY INSTALLATION
(1) Tighten the fasteners to the specified torque after
confirming that the intake manifold stay is in close contact
with the air intake plenum resonator and the cylinder
block.
Intake
manifold
stay
Air intake
plenum
resonator
"DA THROTTLE BODY GASKET INSTALLATION
(1) Position the projection as shown in the illustration.
Projection
Mitsubishi Motors Corporation
Aug. 1999
PWEE9616-B
Added
E
11A-4-1
4G6 ENGINE (E-W) - Timing Belt
4. TIMING BELT
REMOVAL AND INSTALLATION (SOHC)
20
45 Nm
18
45 Nm
17
16
15
23
5
14
18 Nm
88 Nm
13
22
19
7
21
9 Nm
22 Nm
1
48 Nm
49 Nm
49 Nm
3
6
4
14 Nm
12
10
54 Nm
11
8
9
23 Nm
35 Nm
118 Nm
11 Nm
2
9 Nm
Removal steps
1. Timing belt front upper cover
2. Timing belt front lower cover
3. Power steering bracket
AE"
12. Crankshaft sprocket
13. Flange (Multipoint fuel injection)
14. Flange (Carburetor)
15. Tensioner “B”
4. Crankshaft position sensor
(Multipoint fuel injection)
AF" "FA 16. Timing belt “B”
AG" "EA 17. Counterbalance shaft sprocket
"DA 18. Spacer
AA" "KA 5. Timing belt
"JA 6. Tensioner pulley
7. Tensioner arm
AH"
19. Crankshaft sprocket “B”
"CA 20. Engine support bracket
"IA 8. Auto tensioner
9. Idler pulley
AI" "AA 21. Camshaft sprocket bolt
22. Camshaft sprocket
AC" "HA 10. Oil pump sprocket
AD" "GA 11. Crankshaft bolt
23. Timing belt rear cover
Mitsubishi Motors Corporation
Aug. 1999
PWEE9616-B
Revised
E
11A-4-2
4G6 ENGINE (E-W) - Timing Belt
REMOVAL AND INSTALLATION (GDI)
21
25
3.4 Nm
22
7
1
6
48 Nm
23
26
27
24
23 Nm
8
2
23 Nm
31
11 Nm
13
12
11 Nm
118 Nm
49 Nm
11 Nm
32
9 Nm
5
18
17
3
30
45 Nm
18 Nm
4
88 Nm
28
20
15
29
10
33
48 Nm
8.8 Nm
19
16
49 Nm
14
11
9
54 Nm
Removal steps
1. Front upper cover
2. Front lower cover
"DA 18. Spacer
AH"
19. Crankshaft sprocket B
20. Crankshaft key
3. Power steering pump bracket stay
4. Power steering bracket
21. Breather hose
AB" "LA 5. Timing belt
"JA 6. Tensioner pulley
7. Tensioner arm
22. PCV hose
23. PCV valve
24. PCV valve gasket
25. Oil filler cap
"IA 8. Auto tensioner
9. Idle pulley
26. Rocker cover
10. Crankshaft position sensor
27. Rocker cover gasket
"CA 28. Engine support bracket
AC" "HA 11. Oil pump sprocket
AD" "GA 12. Crankshaft bolt
AJ" "BA 29. Camshaft sprocket bolt
AE"
13. Crankshaft sprocket
14. Flange
30. Camshaft sprocket
31. Timing belt rear right cover
15. Tensioner B
32. Timing belt rear left upper cover
33. Timing belt rear left lower cover
AF" "FA 16. Timing belt B
AG" "EA 17. Counterbalance shaft sprocket
Mitsubishi Motors Corporation
Aug. 1999
PWEE9616-B
Revised
E
11A-4-3
4G6 ENGINE (E-W) - Timing Belt
REMOVAL SERVICE POINTS
AA" TIMING BELT REMOVAL
(1) Mark belt running direction for reinstallation.
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.
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
D
Timing mark
The camshaft sprocket on the exhaust side can
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.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-4-4
4G6 ENGINE (E-W) - Timing Belt
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.
6EN1322
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.
MD998785
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-4-5
4G6 ENGINE (E-W) - Timing Belt
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 CAMSHAFT SPROCKET BOLT TIGHTENING
(1) Using the special tools shown in the illustration, lock the
camshaft sprocket in position.
(2) Tighten the camshaft sprocket bolt to the specified torque.
"BA CAMSHAFT SPROCKET BOLT TIGHTENING
(1) Using a wrench, hold the camshaft at its hexagon and
tighten the bolt to the specification.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-4-6
4G6 ENGINE (E-W) - Timing Belt
"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.
Counter-
balance
shaft
Sharp
edge
"EA COUNTERBALANCE SHAFT SPROCKET
INSTALLATION
(1) Install the counterbalance shaft sprocket and screw the
bolt.
MD998785
(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.
"FA TIMING BELT “B” INSTALLATION
(1) Align timing marks on the crankshaft sprocket “B” and
counterbalance shaft sprocket with the marks on the front
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.
Timing
marks
(onfront
case)
Timing
marks
(3) Make sure that the relationship between the tensioner
pulley center and the bolt center is as shown in the
illustration.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-4-7
4G6 ENGINE (E-W) - Timing Belt
(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.
"GACRANKSHAFT 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.
(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.
B
A
6AE0049
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-4-8
4G6 ENGINE (E-W) - Timing Belt
(4) Insert a wire (1.4 mm in diameter) into the set holes.
(5) Unclamp the auto tensioner from the vise.
6AE0050
6EN0350
6EN1323
(6) Install the auto tensioner to front case and tighten to
the specified torque.
Caution
D
Leave the wire installed in the auto tensioner.
"JA TENSIONER PULLEY INSTALLATION
(1) Install the tensioner pulley in such direction that its two
small holes are arranged vertically.
Small holes
"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.
(3) Align timing mark on crankshaft sprocket with timing mark
on front case.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-4-9
4G6 ENGINE (E-W) - Timing Belt
(4) Align the timing mark on oil pump sprocket with its mating
mark.
Oil pump
sprocket
timingmarks
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 inserted until installation of timing belt is
finished.
Plug
Screwdriver
6EN1026
(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
pulley center bolt.
MD998767
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
torque wrench, tighten the center bolt to specification.
6EN0900
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-4-10
4G6 ENGINE (E-W) - Timing Belt
(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
"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.
Timing mark
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.
Timing mark
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.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-4-11
4G6 ENGINE (E-W) - Timing Belt
(4) Align the timing mark on oil pump sprocket with its mating
mark.
Oil pump
sprocket
timingmarks
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 inserted until installation of timing belt is
finished.
Plug
Screwdriver
6EN1026
(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.
Timing mark
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.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-4-12
4G6 ENGINE (E-W) - Timing Belt
(9) Check to ensure that the timing marks on the intake
17 cogs
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.
Timing mark
(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
Crankshaft
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.
(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.
Crankshaft
sprocket
(14)Using the special tool, turn the tensioner pulley in the
illustrated direction to strain the timing belt. Then, secure
the tensioner temporarily by tightening the retaining bolt
lightly.
MD998767
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.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-4-13
4G6 ENGINE (E-W) - Timing Belt
(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.
MD998738
(17)Loosen the retaining bolt of the tensioner pulley.
Caution
D
Loosening the retaining bolt can cause the intake
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.
MD998767
(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.
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.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-4-14
4G6 ENGINE (E-W) - Timing Belt
(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.
(7) Abnormal wear on teeth.
(8) Missing tooth.
AUTO TENSIONER
12 mm
(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.
98 to 196 N
Movement
6EN1033
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-4a-1
4G6 ENGINE (E-W) - Exhaust Manifold (GDI)
4a. EXHAUST MANIFOLD (GDI)
REMOVAL AND INSTALLATION
11 Nm
29 Nm
5
4
49 Nm
29 Nm
3
13 Nm
49 Nm
13 Nm
2
1
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
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-5-1
4G6 ENGINE (E-W) - Fuel and Emission Control Parts
5. FUEL AND EMISSION CONTROL PARTS
REMOVAL AND INSTALLATION <CARBURETOR>
17 Nm
5
22 Nm
2
6
23 Nm
4
7
8
1
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)
Mitsubishi Motors Corporation
Dec. 1996
PWEE9616
E
11A-5-2
4G6 ENGINE (E-W) - Fuel and Emission Control Parts
REMOVAL AND INSTALLATION <MULTIPOINT FUEL INJECTION - GALANT>
3
5
22 Nm
12 Nm
9
18 Nm
9 Nm
4
8
12
13
1
11
14
10
2
7
6
Removal steps
1. Throttle body
"BA 8. Fuel pressure regulator
9. O-ring
"CA 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
10. Insulator
"AA 11. Injectors
12. O-ring
13. Grommet
14. Delivery pipe
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-5-3
4G6 ENGINE (E-W) - Fuel and Emission Control Parts
REMOVAL AND INSTALLATION
<MULTIPOINT FUEL INJECTION - SPACE WAGON>
22 Nm
6
12 Nm
4
5
15
18 Nm
13
14
3
1
12
11
10
2
9
9 Nm
8
7
Removal steps
1. Throttle body
"BA 9. Fuel pressure regulator
10. O-ring
"CA 2. Throttle body gasket
3. EGR valve
11. Insulator
4. EGR valve gasket
5. Fuel hose
"AA 12. Injectors
13. O-ring
6. Fuel return pipe
14. Grommet
7. Injectors and delivery pipe
8. Insulator
15. Delivery pipe
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-5-4
4G6 ENGINE (E-W) - Fuel and Emission Control Parts
INSTALLATION SERVICE POINTS
"AA INJECTORS INSTALLATION
(1) Before installing an injector, the rubber O-ring must be
lubricated with a drop of clean engine oil to aid in
installation.
(2) Install injector top end. Be careful not to damage O-ring
during installation.
Grommet
O-ring
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
D
Be sure not to let engine oil get into the delivery
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.
"CA GASKET INSTALLATION
GALANT
SPACE WAGON
(1) Position the projection as shown in the illustration.
Projection
Projection
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-5a-1
4G6 ENGINE (E-W) - Fuel Part (GDI)
5a. FUEL PART (GDI)
REMOVAL AND INSTALLATION (1999 MODEL SPACE WAGON)
26
18 Nm
8.8 Nm
11 Nm
8.8 Nm
8.8 Nm
15
18
2
14
17
6
8
3
1
11 Nm
11 Nm
7
16
11
4.9 Nm ®
17 Nm ± 2 Nm
10
19
22
9
8.8 Nm
21
20
12
18 Nm
11 Nm
4
5
13
23
30
37
34
35
36
22 Nm
24
27
28
32
33
23 Nm
31
25
29
11 Nm
38
Mitsubishi Motors Corporation
Aug. 1999
PWEE9616-B
Revised
E
11A-5a-2
4G6 ENGINE (E-W) - Fuel Part (GDI)
Removal steps
1. Fuel hose
"DA 20. Fuel pressure sensor
21. Backup ring
2. Fuel low pressure pipe
3. O-ring
22. O-ring
4. Fuel pump return nipple
5. O-ring
"CA 23. Pump camshaft case
24. O-ring
6. Clamp A
25. O-ring
7. Fuel pipe bracket
26. Injector harness
27. Washer
"FA 8. Fuel feed pipe
9. Backup ring
10. O-ring
28. Injector holder
"BA 29. Delivery pipe and injector assembly
30. Insulator
11. Backup ring
"FA 12. Fuel pump
31. Injector washer
32. Injector
13. O-ring
14. Harness bracket
"AA 33. Corrugated washer
"AA 34. Backup ring
"AA 35. O-ring
"EA 15. Fuel return pipe
16. Backup ring
17. O-ring
"AA 36. Backup ring
37. Delivery pipe
18. Backup ring
"EA 19. Fuel high pressure regulator
38. Engine hanger
Mitsubishi Motors Corporation
Aug. 1999
PWEE9616-B
Revised
E
11A-5a-2a
4G6 ENGINE (E-W) - Fuel Part (GDI)
REMOVAL AND INSTALLATION (2000 MODEL SPACE WAGON and GALANT)
18 Nm
8.8 Nm
11 Nm
8.8 Nm
30
15
8.8 Nm
2
6
14
17
16
8
3
1
11 Nm
18
7
11 Nm
11
26
22
19
4.9 Nm ®
17 Nm ± 2 Nm
10
25
21
8.8 Nm
9
24
23
18 Nm
12
11 Nm
4
13
20
5
18 Nm
27
34
41
38
39
40
22 Nm
28
31
32
36
37
23 Nm
35
29
33
11 Nm
42
Mitsubishi Motors Corporation
Aug. 1999
PWEE9616-B
Added
E
11A-5a-2b
4G6 ENGINE (E-W) - Fuel Part (GDI)
Removal steps
1. Fuel hose
23. Flange
2. Fuel low pressure pipe
3. O-ring
(SPACE WAGON for Europe)
"DA 24. Fuel pressure sensor
4. Fuel pump return nipple
5. O-ring
(SPACE WAGON for Europe)
25. Backup ring
6. Clamp A
(SPACE WAGON for Europe)
26. O-ring
7. Fuel pipe bracket
"FA 8. Fuel feed pipe
(SPACE WAGON for Europe)
"CA 27. Pump camshaft case
28. O-ring
9. Backup ring
10. O-ring
11. Backup ring
29. O-ring
"FA 12. Fuel pump
13. O-ring
30. Injector harness
31. Washer
14. Harness bracket
32. Injector holder
"EA 15. Fuel return pipe
16. Backup ring
"BA 33. Delivery pipe and injector assembly
34. Insulator
17. O-ring
18. Backup ring
35. Injector washer
36. Injector
"EA 19. Fuel high pressure regulator
"DA 20. Fuel pressure sensor
(GALANT and SPACE WAGON for
Hong Kong)
"AA 37. Corrugated washer
"AA 38. Backup ring
"AA 39. O-ring
"AA 40. Backup ring
41. Delivery pipe
21. Backup ring (GALANT and SPACE
WAGON for Hong Kong)
22. O-ring (GALANT and SPACE
WAGON for Hong Kong)
42. Engine hanger
Mitsubishi Motors Corporation
Aug. 1999
PWEE9616-B
Added
E
11A-5a-3
4G6 ENGINE (E-W) - Fuel Part (GDI)
INSTALLATION SERVICE POINTS
"AA BACKUP RING / CORRUGATED WASHER
INSTALLATION
(1) Attach the backup ring and O-ring to the injector. The
thicker backup ring must be so installed that the inside
cut surface is directed as shown in the illustration.
Cut surface
Backup ring
(2) Coat the corrugated washer with white vaseline and install
it to the injector as shown.
Caution
D
Always replace the corrugated washer with new
one. Reused corrugated washer can cause fuel
or gas leaks.
Corrugated washer
"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.
Mating marks
(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.
Injector
gasket
Insulator
Caution
D
Strictly observe the specified torque.
(8) Tighten the fasteners of the delivery pipe and injector
assembly to the specified torque in the order given in
the illustration.
3
4
1
2
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-5a-4
4G6 ENGINE (E-W) - Fuel Part (GDI)
"CA PUMP CAMSHAFT CASE INSTALLATION
Grooved
Coupling
(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.
Camshaft
NOTE
O-ring
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.
"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.
Cut surface
Backup ring
"EA FUEL HIGH PRESSURE REGULATOR / FUEL
RETURN PIPE INSTALLATION
Backup ring
(Mountable in
eitherdirection)
O-ring
(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.
Cut surface
Backup ring
(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.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-5a-5
4G6 ENGINE (E-W) - Fuel Part (GDI)
"FA FUEL PUMP / FUEL FEED PIPE INSTALLATION
Backup ring
(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.
(Mountable in
either direction)
O-ring
Cut surface
(3) Lubricate the O-rings on both ends of the pipe with spindle
oil or gasoline.
Backup ring
(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.
3
1
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.
4
Caution
2
D
Strictly observe the specified tightening torque.
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.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-6-1
4G6 ENGINE (E-W) - Water Pump and Intake Manifold
6. WATER PUMP AND INTAKE MANIFOLD
REMOVAL AND INSTALLATION <CARBURETOR>
13 Nm
24 Nm
6
1
15
3
4
11 Nm
5
13 Nm
14
20 Nm
8
2
7
16
8
31 Nm
11
17
12 Nm
14 Nm
10
12
9
13
14 Nm
Removal steps
1. Water hose
2. Water hose
9. Water pump
10. Water pump gasket
11. Oil level gauge
12. Oil level gauge guide
13. O-ring
"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
14. Intake manifold stay
15. Intake manifold
16. Intake manifold gasket
17. Engine hanger
Mitsubishi Motors Corporation
Dec. 1996
PWEE9616
E
11A-6-2
4G6 ENGINE (E-W) - Water Pump and Intake Manifold
REMOVAL AND INSTALLATION <MULTIPOINT FUEL INJECTION - GALANT>
13 Nm
24 Nm
7
16
1
11 Nm
4
5
17
6
19 Nm
13 Nm
2
9
29 Nm
15
8
3
31 Nm
9
23 Nm
19
12
18
11 Nm
14 Nm
11
13
10
14
14 Nm
Removal steps
1. Water hose
2. Water hose
10. Water pump
11. Water pump gasket
12. Oil level gauge
13. Oil level gauge guide
14. O-ring
"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
15. Intake manifold stay
16. Intake manifold
17. Intake manifold gasket
18. Engine hanger
19. Detonation sensor
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-6-3
4G6 ENGINE (E-W) - Water Pump and Intake Manifold
REMOVAL AND INSTALLATION
<MULTIPOINT FUEL INJECTION - SPACE WAGON>
3
13 Nm
24 Nm
8
1
11 Nm
5
17
6
7
18
13 Nm
2
19 Nm
29 Nm
10
9
4
10
16
31 Nm
19
13
11 Nm
11
14 Nm
14
15
12
14 Nm
Removal steps
1. Water hose
2. Water hose
3. Water hose
"AA 10. O-ring
11. Water pump
12. Water pump gasket
13. Oil level gauge
14. Oil level gauge guide
15. O-ring
"DA 4. Engine coolant temperature sensor
"CA 5. Engine coolant temperature gauge
unit
6. Water inlet fitting
16. Intake manifold stay
17. Intake manifold
18. Intake manifold gasket
19. Engine hanger
7. Thermostat
"BA 8. Thermostat housing
"AA 9. Water inlet pipe
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-6-4
4G6 ENGINE (E-W) - Water Pump and Intake Manifold
INSTALLATION SERVICE POINTS
"AA WATER PIPE / O-RING INSTALLATION
(1) Wet the O-ring (with water) to facilitate assembly.
Caution
Water pipe
D
Keep the O-ring free of oil or grease.
O-ring
6EN0594
6EN1168
9EN0092
9EN0091
"BA 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).
3 mm diameter
bead sealant
(2) After installation, keep the sealed area away from
the oil and coolant for approx. 1 hour.
"CA SEALANT APPLICATION TO ENGINE COOLANT
TEMPERATURE GAUGE UNIT
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
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-6a-1
4G6 ENGINE (E-W) - Water Pump and Water Hose (GDI)
6a. WATER PUMP AND WATER HOSE (GDI)
REMOVAL AND INSTALLATION
12 Nm
11 Nm
7
29 Nm
2
4
23 Nm
3
1
9
6
12 Nm
8
5
13
10
12 Nm
22 Nm
9
12
11
13 Nm
Removal steps
1. Water hose
"CA 7. Water outlet fitting
"BA 8. Thermostat housing
"AA 9. O-ring
"EA 2. Water hose
3. Engine coolant temperature sensor
"DA 4. Engine coolant temperature gauge
"AA 10. Water inlet pipe
11. Water pump
unit
5. Water inlet fitting
6. Thermostat
12. Gasket
13. Knock sensor
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-6a-2
4G6 ENGINE (E-W) - Water Pump and Water Hose (GDI)
INSTALLATION SERVICE POINTS
"AA O-RING / WATER INLET PIPE INSTALLATION
(1) Replace the O-ring of the water inlet pipe, and then apply
water to the O-ring to make installation easy.
Caution
D
D
Never apply any oil or grease to the O-ring.
Secure the water pipe after the thermostat case
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
"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
9EN0091
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-7-1
4G6 ENGINE (E-W) - Exhaust Manifold
7. EXHAUST MANIFOLD
REMOVAL AND INSTALLATION (GALANT)
1
13 Nm
6
29 Nm
4
13 Nm
49 Nm
2
13 Nm
5
13 Nm
3
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
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-7-2
4G6 ENGINE (E-W) - Exhaust Manifold
REMOVAL AND INSTALLATION (SPACE WAGON)
1
13 Nm
5
29 Nm
3
49 Nm
2
13 Nm
4
Removal steps
"AA 1. Water outlet fitting
2. Exhaust manifold cover
3. Engine hanger
4. Exhaust manifold
5. Exhaust manifold gasket
INSTALLATION SERVICE POINTS
3 mm diameter
bead sealant
"AA SEALANT APPLICATION TO WATER OUTLET
FITTING
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.
6EN1170
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-8-1
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.
1
2
3
3.4 Nm
4
5
6
31 Nm
13
8
12
11
10
12
11
10
12
17
11
10
16
12
11
10
15
15
14
15
18
15
9
7
Removal steps
"BA 10. Rocker shaft spring
11. Rocker arm A
1. Breather hose
2. P.C.V. hose
3. Oil filler cap
4. Rocker cover
12. Rocker arm B
13. Rocker arm shaft (Intake side)
"AA 14. Lash adjuster
15. Rocker arm C
5. Rocker cover gasket
6. Oil seal
16. Rocker arm shaft (Exhaust side)
"AA 17. Lash adjuster
"CA 7. Oil seal
18. Camshaft
AA" "BA 8. Rocker arms and rocker arm shaft
AA" "BA 9. Rocker arms and rocker arm shaft
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-8-2
4G6 ENGINE (E-W) - Rocker Arms and Camshaft
REMOVAL SERVICE POINT
AA" ROCKER ARMS AND ROCKER ARM SHAFTS
REMOVAL
Caution
D
If the lash adjuster is re-used, clean the lash
adjuster. (Refer to 11A-8-3.)
(1) Set special tool MD998443 to prevent the lash adjuster
from coming free and falling to the floor.
INSTALLATION SERVICE POINTS
"AA LASH ADJUSTER INSTALLATION
(1) Insert the lash adjuster to rocker arm, being careful not
to spill the diesel fuel. Then use the special tool to prevent
adjuster from falling while installing it.
Caution
D
If the lash adjuster is re-used, clean the lash
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
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-8-3
4G6 ENGINE (E-W) - Rocker Arms and Camshaft
INSPECTION
CAMSHAFT
(1) Measure the cam height.
Item
Standard value mm Limit mm
GALANT
Intake
37.39
37.14
37.39
36.83
36.89
36.64
36.89
36.33
Exhaust
Intake
SPACE
WAGON
Exhaust
ROCKER ARM
(1) Check the roller surface. If any dents, damage or seizure
is evident, replace the rocker arm.
(2) Check rotation of the roller. If it does not rotate smoothly
or if looseness is evident, replace the rocker arm.
(3) Check the inside diameter. If damage or seizure is evident,
replace the rocker arm.
Roller tip
LASH ADJUSTERS
Caution
D
The lash adjusters are precision-engineered
mechanisms. Do not allow them to become
contaminated by dirt or other foreign substances.
Do not attempt to disassemble the lash adjusters.
Use only fresh diesel fuel to clean the lash
adjusters.
D
D
(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.
Outside
cleaning
Inside
cleaning
Filling with
diesel fuel
A
B
C
(2) Place the lash adjuster in container A and clean its outside
surface.
NOTE
Use a nylon brush if deposits are hard to remove.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-8-4
4G6 ENGINE (E-W) - Rocker Arms and Camshaft
(3) Fit special tool MD998441 onto the lash adjuster.
MD998441
(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
D
The steel ball spring is extremely weak, so the
lash adjuster’s functionality may be lost if the
air bleed wire is pushed in hard.
Diesel fuel
MD998442
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.
MD998442
Diesel fuel
MD998441
(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
D
The steel ball spring is extremely weak, so the
lash adjuster’s functionality may be lost if the
air bleed wire is pushed in hard.
Diesel fuel
MD998442
(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.
MD998442
Diesel fuel
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-8-5
4G6 ENGINE (E-W) - Rocker Arms and Camshaft
(9) Place the lash adjuster in container C. Then, gently push
down the internal steel ball using special tool MD998442.
MD998442
Caution
D
Do not use container C for cleaning. If cleaning
is performed in container C, foreign matter could
enter the pressure chamber when the chamber
is filled with diesel fuel.
Diesel
fuel
MD998441
(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.
MD998442
(11)Remove special tool MD998441.
MD998441
Diesel fuel
(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.
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.
Division = 1 mm
MD998440
Standard value:
3 - 20 seconds/1 mm [with diesel fuel at 15 -
20_C (59 - 68_F)]
Lash adjuster
NOTE
Replace the lash adjuster if the time measurement is
out of specification.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-8-6
4G6 ENGINE (E-W) - Rocker Arms and Camshaft
(15)Fit special tool MD998441 onto the lash adjuster.
MD998442
(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.
MD998441
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.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-8a-1
4G6 ENGINE (E-W) - Rocker Arms and Camshafts (GDI)
8a. ROCKER ARMS AND CAMSHAFTS (GDI)
REMOVAL AND INSTALLATION
20 Nm
7
Apply engine oil to all
moving parts before
installation.
8
9
10
9.8 Nm
2
3
5
6
21 Nm
11
12
4
1
8.8 Nm
13 Nm
Removal steps
1. Camshaft position sensor
"BA 7. Beam camshaft cap
"BA 8. Beam camshaft cap gasket
"BA 9. Intake camshaft
"BA 10. Exhaust camshaft
11. Rocker arm
2. Cover
3. Gasket
"DA 4. Camshaft position sensing cylinder
"CA 5. Camshaft position sensing cylinder
support
AA" "AA 12. Lash adjuster
"BA 6. Oil seal
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-8a-2
4G6 ENGINE (E-W) - Rocker Arms and Camshafts (GDI)
REMOVAL SERVICE POINTS
AA" LASH ADJUSTER REMOVAL
Caution
D
If the lash adjuster is re-used, clean the lash
adjuster. (Refer to 11A-8a-4.)
INSTALLATION SERVICE POINTS
"AA LASH ADJUSTER INSTALLATION
Caution
D
If the lash adjuster is re-used, clean the lash
adjuster. (Refer to 11A-8a-4.)
(1) Fit the lash adjuster onto the rocker arm without allowing
diesel fuel to spill out.
"BA BEAM CAMSHAFT CAP GASKET / BEAM
CAMSHAFT CAP / CAMSHAFT / OIL SEAL
INSTALLATION
Dowel pin
(1) Locate the camshaft dowel pins as illustrated.
Approx.
11_
(2) Apply a 3 mm thick continuous bead of sealant to the
bottom surface of the beam camshaft cap along the
groove.
3 mm
Timing belt
side
Specified sealant:
Mitsubishi genuine Part No. MD970389 or
equivalent
Beam camshaft cap
(3) Apply sealant to the illustrated position of the cylinder
head upper surface.
Timing belt side
Specified sealant:
Mitsubishi genuine Part No. MD970389 or
equivalent
(4) Install the beam camshaft cap gasket.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-8a-3
4G6 ENGINE (E-W) - Rocker Arms and Camshafts (GDI)
(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
Timing belt side
(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.
MD998713
"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
Paint mark
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.
Camshaft
position
sensor
INSPECTION
CAMSHAFT
(1) Measure the cam height.
Standard value:
Intake
Exhaust
35.79 mm
37.14 mm
Limit:
Intake
Exhaust
35.29 mm
36.64 mm
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-8a-4
4G6 ENGINE (E-W) - Rocker Arms and Camshafts (GDI)
LASH ADJUSTER
Caution
D
The lash adjusters are precision-engineered
mechanisms. Do not allow them to become
contaminated by dirt or other foreign substances.
Do not attempt to disassemble the lash adjusters.
Use only fresh diesel fuel to clean the lash
adjusters.
D
D
(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.
Outside
cleaning
Inside
cleaning
Filling with
diesel fuel
A
B
C
(2) Place the lash adjuster in container A and clean its outside
surface.
NOTE
Use a nylon brush if deposits are hard to remove.
Diesel
fuel
(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
D
The steel ball spring is extremely weak, so the
lash adjuster’s functionality may be lost if the
air bleed wire is pushed in hard.
Diesel fuel
MD998442
NOTE
If the plunger remains stiff or the mechanism appears
otherwise abnormal, replace the lash adjuster.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-8a-5
4G6 ENGINE (E-W) - Rocker Arms and Camshafts (GDI)
(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
D
Make sure the oil hole in the side of the body
is pointing toward container A. Do not point the
oil hole at yourself or other people.
MD998442
Diesel fuel
(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
D
The steel ball spring is extremely weak, so the
lash adjuster’s functionality may be lost if the
air bleed wire is pushed in hard.
Diesel fuel
MD998442
(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
D
Make sure the oil hole in the side of the body
is pointing toward container A. Do not point the
oil hole at yourself or other people.
MD998442
Diesel fuel
(7) Place the lash adjuster in container C. Then, gently push
down the internal steel ball using special tool MD998442.
Caution
D
Do not use container C for cleaning. If cleaning
is performed in container C, foreign matter could
enter the pressure chamber when chamber is filled
with diesel fuel.
MD998442
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.
Diesel fuel
MD998442
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-8a-6
4G6 ENGINE (E-W) - 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).
Division = 1 mm
MD998440
Lash adjuster
(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.
Nut
Lash
adjuster
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.
Diesel fuel
MD998442
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-8a-7
4G6 ENGINE (E-W) - Rocker Arms and Camshafts (GDI)
(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.
Diesel fuel
MD998442
(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.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-9-1
4G6 ENGINE (E-W) - Cylinder Head and Valves
9. CYLINDER HEAD AND VALVES
REMOVAL AND INSTALLATION (SOHC)
1
2
8
20
9
10
15
4
14
17
5
6
12
13
16
19
11
18
7
3
Apply engine oil to all
moving parts before
installation.
Removal steps
AA" "EA 1. Cylinder head bolt
11. Exhaust valve
2. Cylinder head assembly
"DA 3. Cylinder head gasket
AB" "CA 4. Retainer lock
5. Valve spring retainer
AC" "AA 12. Valve stem seal
13. Valve spring seat
AC" "AA 14. Valve stem seal
15. Valve spring seat
"BA 6. Valve spring
16. Intake valve guide
17. Exhaust valve guide
18. Intake valve seat
19. Exhaust valve seat
20. Cylinder head
7. Intake valve
AB" "CA 8. Retainer lock
9. Valve spring retainer
"BA 10. Valve spring
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-9-2
4G6 ENGINE (E-W) - Cylinder Head and Valves
REMOVAL AND INSTALLATION (GDI)
8
1
9
10
14
4
20
5
6
15
17
12
13
19
11
16
18
7
3
2
Apply engine oil to all
moving parts before
installation.
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
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
7. Intake valve
17. Exhaust valve guide
18. Intake valve seat
AB" "CA 8. Retainer lock
9. Valve spring retainer
"BA 10. Valve spring
19. Exhaust valve seat
20. Cylinder head
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-9-3
4G6 ENGINE (E-W) - Cylinder Head and Valves
REMOVAL SERVICE POINTS
PRECAUTION FOR REMOVED PARTS
MB991654
Keep removed parts in order according to the cylinder number
and intake/exhaust.
AA" CYLINDER HEAD BOLTS REMOVAL
(1) Using the special tool, loosen the cylinder head bolts.
Loosen evenly, little by little.
9EN0061
MB991654
AB" RETAINER LOCK REMOVAL
MD998772
(1) Store removed valves, springs and other parts, tagged
to indicate their cylinder No. and location for reassembly.
9EN0062
MD998772
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-9-4
4G6 ENGINE (E-W) - Cylinder Head and Valves
AC" VALVE STEM SEAL REMOVAL
(1) Do not reuse removed stem seal.
INSTALLATION SERVICE POINTS
"AA VALVE STEM SEAL INSTALLATION
(1) Install the valve spring seat.
(2) The special tool must be used to install the valve stem
seal. Improper installation could result in oil leaks past
the valve guide.
MD998774
Caution
D
Do not reuse removed valve stem seals.
9EN0065
MD998737
"BA VALVE SPRING INSTALLATION
(1) Direct the valve spring end with identification color toward
the spring retainer.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-9-5
4G6 ENGINE (E-W) - Cylinder Head and Valves
"CA RETAINER LOCK INSTALLATION
MD998772
(1) The valve spring, if excessively compressed, causes the
bottom end of the retainer to be in contact with, and
damage, the stem seal.
9EN0062
MD998772
"DA CYLINDER HEAD GASKET IDENTIFICATION
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.
Shank length
6EN0782
(3) Using the special tool (MB991654) and according to the
tightening sequence, tighten the bolts to the specified
torque.
Timing belt side
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.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-9-6
4G6 ENGINE (E-W) - 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.
90_
(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.
90_
Caution
Paint mark
D
If the bolt is turned less than 90_, proper fastening
performance may not be expected. When
tightening the bolt, therefore, be careful to give
a sufficient turn to it.
6AE0297
D
If the bolt is overtightened, loosen the bolt
completely and then retighten it by repeating the
tightening procedure from step (1).
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
9EN0064
* Includes combined with cylinder block grinding.
Cylinder head height (Specification when new):
SOHC
GDI
119.9 - 120.1 mm
131.9 - 132.1 mm
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-9-7
4G6 ENGINE (E-W) - Cylinder Head and Valves
VALVE
(1) Check the valve face for correct contact. If incorrect, reface
using a valve refacer. Valve seat contact should be
maintained uniform at the center of valve face.
(2) If the margin exceeds the service limit, replace the valve.
Item
Standard value mm
Limit mm
0.5
SOHC
Intake
1.0
1.2
1.0
1.5
Exhaust
Intake
0.7
GDI
0.5
Exhaust
1.0
(3) Measure valve’s total length. If measurement is less than
specified, replace the valve.
Item
Standard value mm
112.30
Limit mm
111.80
113.61
105.0
SOHC
Intake
Exhaust
Intake
114.11
GDI
105.5
Exhaust
105.7
105.2
VALVE SPRING
Out of
square
(1) Measure the free height of spring and, if it is smaller
than the limit, replace.
Item
Standard value mm
Limit mm
50.0
SOHC
GDI
51.0
48.3
Free
height
47.3
(2) Measure the squareness of the spring and, if the limit
is exceeded, replace.
1EN0264
Item
Standard value mm
Limit mm
SOHC
GDI
2_
4_
1.5_
4_
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-9-8
4G6 ENGINE (E-W) - Cylinder Head and Valves
VALVE GUIDE
(1) Measure the clearance between the valve guide and valve
stem. If the limit is exceeded, replace the valve guide
or valve, or both.
Valve
guide
Item
Standard value mm
0.02 - 0.05
Limit mm
0.10
SOHC
Intake
Exhaust
Intake
0.03 - 0.07
0.15
GDI
0.02 - 0.05
0.10
Exhaust
0.05 - 0.09
0.15
VALVE SEAT
Valve stem end
(1) Assemble the valve, then measure the valve stem
projection between the end of the valve stem and the
spring seating surface. If the measurement exceeds the
specified limit, replace the valve seat.
Valve stem
projection
Item
Standard value mm
Limit mm
49.80
Spring seating
surface
SOHC
Intake
49.30
49.30
49.20
48.40
Exhaust
Intake
49.80
DEN0212
GDI
49.70
Exhaust
48.90
VALVE SEAT RECONDITIONING PROCEDURE
(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.
0.9 - 1.3 mm
(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).
43.5_ - 44_
6EN0491
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-9-9
4G6 ENGINE (E-W) - Cylinder Head and Valves
VALVE SEAT REPLACEMENT PROCEDURE
0.5 - 1 mm
(1) Cut the valve seat to be replaced from the inside to thin
the wall thickness. Then, remove the valve seat.
0.5 - 1 mm
(2) Rebore the valve seat hole in the cylinder head to a
selected oversize valve seat diameter.
Valve seat ring hole diameter
Height of
seat ring
Item
Standard value mm
34.30 - 34.33
34.60 - 34.63
31.80 - 31.83
32.60 - 32.63
35.30 - 35.33
35.60 - 35.63
33.30 - 33.33
33.60 - 33.63
SOHC
Intake
0.30 O.S.
0.60 O.S.
0.30 O.S.
0.60 O.S.
0.30 O.S.
0.60 O.S.
0.30 O.S.
0.60 O.S.
Exhaust
Intake
Oversize I.D.
1EN0275
GDI
Exhaust
(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”.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-9-10
4G6 ENGINE (E-W) - Cylinder Head and Valves
VALVE GUIDE REPLACEMENT PROCEDURE
(1) Force the valve guide out toward the cylinder block using
a press.
(2) Machine the valve guide hole in the cylinder head to
the size of the oversize valve guide to be installed.
Caution
D
Do not use the valve guide of the same size as
the removed one.
Valve gauge hole diameters in cylinder head
Item
Standard value mm
11.05 - 11.07
11.25 - 11.27
11.50 - 11.52
12.05 - 12.07
12.25 - 12.27
12.50 - 12.52
SOHC
0.05 O.S.
0.25 O.S.
0.50 O.S.
0.05 O.S.
0.25 O.S.
0.50 O.S.
GDI
(3) Press-fit the valve guide until it protrude specified value
(SOHC 14 mm, GDI 19.5 mm) as shown in the illustration.
Caution
D
Press the valve guide from the cylinder head top
surface.
Valve guide for intake valve and that for exhaust
valve are different in length. (45.5 mm for intake
valve; 50.5 mm for exhaust valve)
D
Protrusion
(4) After the valve guide has been installed, insert a new
valve to check for smooth sliding motion.
1EN0106
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
4G6 ENGINE (E-W) - Front Case, Counterbalance Shafts and Oil Pan11A-10-1
10. FRONT CASE, COUNTERBALANCE SHAFTS AND OIL PAN
REMOVAL AND INSTALLATION <GDI ENGINE - VEHICLE FOR EUROPE AND
SOHC ENGINE>
19 Nm
33
31
13
Apply engine oil to all
moving parts before
installation.
30
(4G63)
32
21
(SOHC)
20
18
23 Nm
9.8 Nm
29
9
22
28
23 Nm
23
21 Nm
24
(GDI)
18
19
8
27
7
16 Nm
18 Nm
6
25
12
11
26
18 Nm
39 Nm
17
16
3
10
15
14
(4G64)
23 Nm
2
36 Nm
13
5
4
23 Nm
8.8 Nm
1
6.9 Nm
44 Nm
9.8 Nm
21 Nm
Removal steps
"OA 1. Oil filter
2. Drain plug
18. Oil filter bracket
19. Oil filter bracket gasket
"NA 3. Drain plug gasket
4. Oil level sensor
(Vehicle for Europe)
"HA 20. Front case assembly
21. Front case gasket
22. Oil pump cover
5. Transmission stay (GDI engine)
"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
AA" "LA 6. Oil pan
7. Oil screen
8. Oil screen gasket
9. Stiffener (SOHC engine - vehicle
for Europe)
AD" "KA 10. Plug
29. Counterbalance shaft, left
30. Counterbalance shaft, right
11. O-ring
AE" "JA 12. Flange bolt
AF" "CA 31. Counterbalance shaft front bearing
"IA 13. Oil pressure switch
AG" "BA 32. Counterbalance shaft rear bearing,
14. Relief plug
left
15. Relief plug gasket
16. Relief spring
17. Relief plunger
AG" "AA 33. Counterbalance shaft rear bearing,
right
Mitsubishi Motors Corporation
Aug. 1999
PWEE9616-B
Revised
E
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
31
33
Apply engine oil to all
moving parts before
installation.
22
21
23 Nm
9.8 Nm
30
23
29
6.9 Nm
23 Nm
24
25
7
10
6
18 Nm
20
28
9
19
16 Nm
18 Nm
26
13
12
27
18
17
6.9 Nm
11
16
23 Nm
39 Nm
3
5
36 Nm
14
12 Nm
15
23 Nm
2
4
6.9 Nm
1
8
9.8 Nm
44 Nm
21 Nm
Removal steps
"OA 1. Oil filter
19. Oil filter bracket
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
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
AC" "MA 8. Oil pan upper
9. Oil screen
10. Gasket
"DA 28. Counterbalance shaft oil seal
29. Front case
AD" "KA 11. Plug
12. O-ring
30. Counterbalance shaft, left
31. Counterbalance shaft, right
AE" "JA 13. Flange bolt
"IA 14. Oil pressure switch
15. Relief plug
AF" "CA 32. Counterbalance shaft front bearing
AG" "BA 33. Counterbalance shaft rear bearing,
16. Gasket
left
17. Relief spring
AG" "AA 34. Counterbalance shaft rear bearing,
18. Relief plunger
right
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
4G6 ENGINE (E-W) - Front Case, Counterbalance Shafts and Oil Pan11A-10-3
REMOVAL SERVICE POINTS
AA" OIL PAN REMOVAL
MD998727
(1) Remove all oil pan bolts.
(2) Drive in the special tool between the cylinder block and
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.
6EN0698
AB" OIL PAN LOWER REMOVAL
(1) Apply a wood block to the oil pan side and remove the
oil pan lower by tapping lightly on it with a plastic hammer.
Caution
D
Do not use a scraper or special tool to remove
the oil pan.
AC" OIL PAN UPPER REMOVAL
A
(1) Remove all bolts.
(2) Screw a bolt into bolt hole A shown to remove the oil
pan.
Caution
D
Do not use a scraper or special tool to remove
the oil pan.
A
AD" PLUG REMOVAL
MD998162
(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.
MD998783
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.
Plug
Screwdriver
6EN1026
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-10-4
4G6 ENGINE (E-W) - Front Case, Counterbalance Shafts and Oil Pan
(3) Loosen the flange bolt.
6EN0565
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
MB991603
(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 RIGHT COUNTERBALANCE SHAFT REAR
BEARING INSTALLATION
(1) Apply engine oil to the outer surface of bearing.
(2) Using special tools, install right rear bearing. Make sure
that oil hole of bearing is aligned with oil hole of cylinder
block.
MD998705
6EN1034
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
4G6 ENGINE (E-W) - Front Case, Counterbalance Shafts and Oil Pan11A-10-5
"BA LEFT COUNTERBALANCE SHAFT REAR
BEARING INSTALLATION
MB991603
(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
Rear bearing
MB991603
The left rear bearing has no oil holes.
MD998705
6EN0557
"CA COUNTERBALANCE SHAFT FRONT BEARING
INSTALLATION
(1) Using special tools, install front bearing.
MD998705
MD998705
Bearing
Cylinder block
6EN1035
"DA COUNTERBALANCE SHAFT OIL SEAL
INSTALLATION
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-10-6
4G6 ENGINE (E-W) - Front Case, Counterbalance Shafts and Oil Pan
"EA OIL PUMP OIL SEAL INSTALLATION
"FA CRANKSHAFT FRONT OIL SEAL INSTALLATION
(1) Using the special tool, install the crankshaft front oil seal
into the front case.
"GAOIL 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).
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
4G6 ENGINE (E-W) - Front Case, Counterbalance Shafts and Oil Pan11A-10-7
"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
D
D
Keep the end of the thread portion clear or sealant.
Avoid an overtightening.
"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.
6EN0564
(2) Secure the oil pump driven gear onto the left
counterbalance shaft by tightening the flange bolt to
specified torque.
"KA PLUG INSTALLATION
MD998162
(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.
MD998783
"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
Groove
portion
Bolt hole
portion
6EN0213
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
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.
"MAOIL PAN UPPER / OIL PAN LOWER
Oil pan upper
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
Bolt hole portion
Groove
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.
(3) Note the difference in bolt lengths at the location shown.
Timing belt side
M6 ´ 16
mm
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
4G6 ENGINE (E-W) - Front Case, Counterbalance Shafts and Oil Pan11A-10-9
(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.
Oil pan lower
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or
equivalent
Bolt hole
portion
NOTE
Groove
portion
(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.
(6) Tighten the oil pan lower mounting bolts in the sequence
shown in the illustration.
8
6
1
3
4
5
2
7
9
"NA DRAIN PLUG GASKET INSTALLATION
(1) Install the drain plug gasket in the shown direction.
Oil pan side
Drain plug
gasket
7EN0307
"OAOIL FILTER INSTALLATION
Bracket side
(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
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
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
Driven gear
0.08 - 0.14 mm
0.06 - 0.12 mm
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
11A-11-1
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
4
10
12
9
11
5
3
2
1
Removal steps
"GA 1. Nut
"CA 7. Piston ring No. 2
AA" "FA 2. Connecting rod cap
"EA 3. Connecting rod bearing
"BA 8. Oil ring
AB" "AA 9. Piston pin
"DA 4. Piston and connecting rod assem-
bly
"EA 5. Connecting rod bearing
"CA 6. Piston ring No. 1
10. Piston
11. Connecting rod
12. Bolt
Mitsubishi Motors Corporation
Dec. 1996
PWEE9616
E
11A-11-2
4G6 ENGINE (E-W) - Piston and Connecting Rod
REMOVAL SERVICE POINTS
AA" CONNECTING ROD CAP REMOVAL
(1) Mark the cylinder number on the side of the connecting
rod big end for correct reassembly.
(2) Keep the removed connecting rods, caps, and bearings
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.
NOTE
Keep the disassembled pistons, piston pins and
connecting rods in order according to the cylinder number.
Mitsubishi Motors Corporation
Dec. 1996
PWEE9616
E
11A-11-3
4G6 ENGINE (E-W) - Piston and Connecting Rod
INSTALLATION SERVICE POINTS
"AA PISTON PIN INSTALLATION
(1) Measure the following dimensions of the piston, piston
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
(2) Obtain dimension L (to be used later) from the above
measurements by using by following formula.
(A - C) - (B - D)
L =
2
(3) Insert the special tool, Push Rod, into the piston pin and
attach the guide A to the push rod end.
(4) Assemble the connecting rod in the piston with their front
marks facing the same direction.
(5) Apply engine oil to the entire periphery of the piston pin.
(6) Insert the piston pin, push rod and guide A assembly
having assembled in step (3) from the guide A side into
the piston pin hole on the front marked side.
(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.
3 mm + L
(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
Mitsubishi Motors Corporation
Dec. 1996
PWEE9616
E
11A-11-4
4G6 ENGINE (E-W) - Piston and Connecting Rod
(10)Check that the piston moves smoothly
"BA OIL RING INSTALLATION
Upper
side rail
(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.
Spacer
Size
Identification color
Lower side rail
Standard
None
Red
6EN1237
0.50 mm oversize
1.00 mm oversize
Yellow
(2) Install the upper side rail.
Side rail gap
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
D
Do not use piston ring expander when installing
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.
1EN0269
Mitsubishi Motors Corporation
Dec. 1996
PWEE9616
E
11A-11-5
4G6 ENGINE (E-W) - Piston and Connecting Rod
"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
4G64 GDI
1R
T
No. 2 ring
4G63 SOHC
4G64 GDI
2R
2T
Identification mark
Identification mark
Side mark
2. Install piston rings with identification mark facing up,
to the piston crown side.
3. Size marks on position rings are as follows.
No. 1
Size
Size mark
None
50
No. 2
Standard
0.50 mm oversize
1.00 mm oversize
9EN0524
100
"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.
Timing belt side
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.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-11-6
4G6 ENGINE (E-W) - Piston and Connecting Rod
(2) The connecting rod bearing identification mark is stamped
at the position shown in the illustration.
Crankshaft pin
Connecting rod bearing
Classi-
fication
Identifica-
tion mark
Identifi-
cation
color
O. D. mm
Identi-
fication
mark
Thickness mm
Produc-
tion part
Service
part
1
2
3
None
None
None
Yellow
None
White
44.995 - 45.000
44.985 - 44.995
44.980 - 44.985
1
2
3
1.478 - 1.491
1.491 - 1.495
1.495 - 1.499
Identification mark
Connecting rod I.D.: 48.000 - 48.015 mm
(3) Select a proper bearing from the above table on the basic
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”.
"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
Mitsubishi Motors Corporation
Dec. 1996
PWEE9616
E
11A-11-7
4G6 ENGINE (E-W) - Piston and Connecting Rod
"GACONNECTING ROD CAP NUT INSTALLATION
Caution
D
If the cylinder head has been installed before installing
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
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.
Paint mark
90_ - 100_
Paint
mark
(5) Make a paint mark on the head of each nut.
(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.
(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.
Bolt
Nut
6AE0298
Caution
D
If the nut is turned less than 90_, proper fastening
performance may not be expected. When
tightening the nut, therefore, be careful to give
a sufficient turn to it.
If the nut is overtightened (exceeding 100_), loosen
the nut completely and then retighten it by
repeating the tightening procedure from step (1).
D
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
Mitsubishi Motors Corporation
Dec. 1996
PWEE9616
E
11A-11-8
4G6 ENGINE (E-W) - Piston and Connecting Rod
(3) Install the piston ring into the cylinder bore. Force it down
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
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.
Plastigage
(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
Mitsubishi Motors Corporation
Dec. 1996
PWEE9616
E
11A-12-1
4G6 ENGINE (E-W) - Crankshaft, Flywheel and Drive Plate
12. CRANKSHAFT, FLYWHEEL AND DRIVE PLATE
REMOVAL AND INSTALLATION
3
2
Apply engine oil to all
moving parts before
installation.
11 Nm
1
10
132 Nm
13
4
A
12
5
21
<GALANT>
7
9 Nm
11
11 Nm
132 Nm
8
6
9
19
20
18
<SPACE WAGON>
132 Nm
8
7
17
6
9
16
15
14
Removal steps
1. Flywheel bolt <M/T>
2. Adapter plate <M/T>
3. Flexible flywheel <M/T>
4. Adapter plate <M/T>
17. Crankshaft
"CA 18. Crankshaft bearing, upper
"BA 19. Crankshaft thrust bearing <GDI en-
gine>
5. Crankshaft bushing <M/T>
6. Drive plate bolt <A/T>
7. Adapter plate <A/T>
8. Drive plate <A/T>
AA" "AA 20. Oil jet <GDI engine>
21. Cylinder block
Caution
9. Crankshaft bushing <A/T>
10. Rear plate
On the flexible wheel equipped engines, do not
remove any of the bolts “A” of the flywheel shown
in the illustration.
The balance of the flexible flywheel is adjusted in
an assembled condition. Removing the bolt,
therefore, can cause the flexible flywheel to be out
of balance, giving damage to the flywheel.
11. Bell housing cover
"FA 12. Oil seal case
"EA 13. Oil seal
"DA 14. Bearing cap bolt
"DA 15. Bearing cap
"CA 16. Crankshaft bearing, lower
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-12-2
4G6 ENGINE (E-W) - Crankshaft, Flywheel and Drive Plate
REMOVAL SERVICE POINT
AA" OIL JET REMOVAL
(1) Knock out the oil jets using an appropriate metal rod.
Caution
D
D
Be careful not to scratch the cylinder wall.
Do not reuse the removed oil jets.
INSTALLATION SERVICE POINTS
"AA OIL JET INSTALLATION
(1) Using a 4.5 mm diameter pin punch, drive in the oil jet
to the crankshaft journal until it seats to the bottom.
"BA CRANKSHAFT THRUST BEARING INSTALLATION
(1) Install the two thrust bearing in the number 3 bearing
bore in the cylinder block. For easier installation, apply
engine oil to the bearings; this will help hold them in
position.
(2) The thrust bearings must be installed with their groove
side toward the crankshaft web.
Groove
"CA CRANKSHAFT BEARING INSTALLATION
Identification color of crankshaft journal
(1) From the following table, select a bearing whose size
is appropriate for the crankshaft journal outside diameter.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-12-3
4G6 ENGINE (E-W) - Crankshaft, Flywheel and Drive Plate
Bearing bore size
identification mark
No. 5
No. 3
No. 1 No. 2
No. 4
Bearing bore
identification
mark
Cylinder inner
diameter size
mark
Rear face of
cylinder block
Bottom of
cylinder block
Crankshaft journal outside diameter
Cylinder block
bearing bore
Crankshaft bearing
Crankshaft bearing
for No. 3
Identification color
Yellow
Size mm
Identification mark
Identification mark or Identification mark or
color
color
56.994 - 57.000
0
1
2
0
1
2
0
1
2
1 or Green
2 or Yellow
1 or Green
2 or Yellow
3 or None
2 or Yellow
3 or None
4 or Blue
5 or Red
0 or Black
1 or Green
2 or Yellow
1 or Green
2 or Yellow
3 or None
2 or Yellow
3 or None
4 or Blue
None
White
56.988 - 56.994
56.982 - 56.988
For example, if the crankshaft journal outside diameter
ID color is “yellow” and cylinder block bearing bore ID
mark is “1”, select a bearing whose ID mark is “2” or
ID color is “yellow” for number 1, 2, 4 and 5, and a bearing
whose ID mark is “1” or ID color is “green” for number
3.
Crankshaft bearing size
identification mark or color
If there is no ID color paint on the crankshaft, measure
the journal outside diameter and select a bearing
appropriate for the measured value.
Identification
mark or color
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-12-4
4G6 ENGINE (E-W) - Crankshaft, Flywheel and Drive Plate
(2) Install the bearings having an oil groove to the cylinder
block.
(3) Install the bearings having no oil groove to the bearing
cap.
Groove
Upper
Lower
"DA BEARING CAP / BEARING CAP BOLT
INSTALLATION
(1) Install the bearing caps so the arrow points to the timing
belt side.
(2) Before installing the bearing cap bolts, check that the
shank length of each bolt meets the limit. If the limit is
exceeded, replace the bolt.
Shank length
Limit: Max. 71.1 mm
(3) Apply engine oil to the threaded portion and bearing
surface of the bolt.
9EN0477
(4) Tighten the bolts to 25 Nm in the specified tightening
sequence.
Arrow mark
Paint mark
(5) Make a paint mark on the head of each bolt.
(6) Make a paint mark on the bearing cap at the position
90_ to 100_ from the paint mark made on the bolt in
the direction of tightening the bolt.
Paintmark
(7) According to the specified tightening sequence, give a
90_ to 100_ turn to each bolt and make sure that the
paint mark on the bolt and that on the cap are in alignment.
Caution
90_ - 100_
D
If the bolt is turned less than 90_, proper fastening
performance may not be expected. When
tightening the bolt, therefore, be careful to give
a sufficient turn to it.
If the bolt is overtightened (exceeding 100_),
loosen the bolt completely and then retighten it
by repeating the tightening procedure from step
(1).
6AE0299
D
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-12-5
4G6 ENGINE (E-W) - Crankshaft, Flywheel and Drive Plate
(8) After installing the bearing caps, make sure that the
crankshaft turns smoothly and the end play is correct.
If the end play exceeds the limit, replace No. 3 crankshaft
bearings.
Standard value: 0.05 - 0.18 mm
Limit: 0.25 mm
"EA OIL SEAL INSTALLATION
"FA SEALANT APPLICATION TO OIL SEAL CASE
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or
equivalent
NOTE
(1) Be sure to install the case 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.
INSPECTION
Plastigage
CRANKSHAFT OIL CLEARANCE (PLASTIGAGE
METHOD)
(1) Remove oil from the crankshaft journal and the crankshaft
bearing.
(2) Install the crankshaft.
(3) Cut the Plastigage to the same length as the width of
the bearing and place it on the journal in parallel with
its axis.
(4) Install the crankshaft bearing cap carefully and tighten
the bolts to the specified torque.
(5) Carefully remove the crankshaft bearing cap.
(6) Measure the width of the Plastigage at its widest part
by using a scale printed on the Plastigage package.
Standard value: 0.02 - 0.04 mm
Limit: 0.1 mm
Plastigage
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-12-6
4G6 ENGINE (E-W) - Crankshaft, Flywheel and Drive Plate
CYLINDER BLOCK
(1) Visually check for scratches, rust, and corrosion.
Use also a flaw detecting agent for the check. If defects
are evident, correct, or replace.
(2) Using a straightedge and feeler gauge, check the block
top surface for warpage. Make sure that the surface is
free from gasket chips and other foreign matter.
Standard value: 0.05 mm
Limit: 0.1 mm
(3) If the distortion is excessive, correct within the allowable
limit or replace.
Grinding limit: 0.2 mm
Includes/combined with cylinder head grinding
Cylinder block height (when new):
4G63 284 mm
4G64 290 mm
(4) Check cylinder walls for scratches and seizure. If defects
are evident, correct (bored to oversize) or replace.
(5) Using cylinder gauge, measure the cylinder bore and
cylindricity. If worn badly, correct cylinder to an oversize
and replace piston and piston rings. Measure at the points
shown in illustration.
Standard value:
Cylinder I.D.
4G63 85.00 - 85.03 mm
4G64 86.50 - 86.53 mm
Cylindricity 0.01 mm or less
BORING CYLINDER
(1) Oversize pistons to be used should be determined on
the basis of the largest bore cylinder.
Piston size identification
Size
Identification mark
0.50 O.S.
1.00 O.S.
0.50
1.00
NOTE
Size mark is stamped on the piston top.
(2) Measure outside diameter of piston to be used. Measure
it in thrust direction as shown.
(3) Based on the measured piston O.D. calculate boring finish
dimension.
Boring finish dimension = Piston O.D. + (clearance
between piston O.D. and cylinder) - 0.02 mm
(honing margin)
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
E
11A-12-7
4G6 ENGINE (E-W) - Crankshaft, Flywheel and Drive Plate
(4) Bore all cylinders to the calculated boring finish dimension.
Caution
D
To prevent distortion that may result from
temperature rise during honing, bore cylinders,
working from No. 2, No. 4, No. 1 to No. 3.
(5) Hone to final finish dimension (piston O.D. + clearance
between piston O.D. and cylinder).
(6) Check clearance between piston and cylinder.
Clearance between piston and cylinder:
0.02 - 0.04 mm
NOTE
When boring cylinders, finish all of four cylinders to same
oversize. Do not bore only one cylinder to an oversize.
Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Added
E
NOTES
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