Table Of Contents - Mitsubishi 4G9 User Manual

Table of Contents

Table Of Contents1
General Information3
Technical Data3
Service Specifications6
1-16
Rework Dimensions9
Torque Specifications10
New Tightening Method - By Use Of Bolts To Be Tightened In Plastic Area16
Sealant16
Form-In-Place Gasket17
Disassembly17
Surface Preparation17
Form-In-Place Gasket Application17
Special Tools18
2-118
4G9 Engine (E18
Alternator And Ignition System21
Removal And Installation (Engines With Distributor)21
3-121
Removal And Installation (Sohc For Other Than Pajero) (Engines Without Distributor)22
Removal And Installation (Engines Without Distributor)23
Removal And Installation (Dohc)25
Removal And Installation (Dohc-Mivec)26
Removal And Installation (Dohc–Gdi For Carisma, Space Star, Space Runner, Galant)27
Removal And Installation (Dohc-Gdi For Pajero Io)28
Oil Level Gauge28
Ignition Coil28
Spark Plug28
Crankshaft Bolt28
Alternator Brace (M8)28
Power Steering Pump Pulley28
Cam Position Sensor Support28
Cam Position Sensing Cylinder28
Removal Service Point Aa" Crankshaft Bolt Removal29
Installation Service Points "Aa Cam Position Sensor Support29
"Ba Front Flange/Crankshaft Pulley/Crankshaft Bolt Installation29
Timing Belt Removal And Installation (Sohc For Carisma (Up For 1999 Model)30
4-130
Camshaft Sprocket Bolt30
Timing Belt Rear Cover30
Engine Support Bracket, Right30
Timing Belt Removal And Installation (Sohc For Carisma (From 2000 Model), Lancer (From 2001 Model For Europe), Space Star)31
Timing Belt Removal And Installation (Sohc For Pajero Io)33
Accessory Mount33
Timing Belt Cover33
Timing Belt Removal And Installation (Dohc)34
Timing Belt Removal And Installation (Dohc-Mivec)35
Timing Belt Removal And Installation (Dohc-Gdi For Carisma, Space Star, Space Runner)36
Timing Belt Removal And Installation (Dohc-Gdi For Galant)37
Timing Belt Removal And Installation (Dohc-Gdi For Pajero Io)38
Aa" Timing Belt Removal40
Ab" Camshaft Sprocket Bolt Removal40
"Aa Camshaft Sprocket Bolt Installation40
"Ba Timing Belt Tensioner Installation41
"Ca Tensioner Spring Installation41
"Da Timing Belt Installation41
"Ea Auto-Tensioner Installation42
"Fa Timing Belt Installation43
"Ga Crankshaft Sensing Blade/Crankshaft Spacer/Crankshaft Sprocket Installation45
Timing Belt Inspection45
Tensioner Pulley, Idler Pulley Inspection46
Fuel And Emission Control System47
Sohc Carburetor Removal And Installation47
5-147
Fuel And Emission Control System Removal And Installation (Sohc-Mpi For Other Tnan Pajero Io)48
Fuel And Emission Control System Removal And Installation (Sohc-Mpi For Pajero Io)49
Fuel And Emission Control System Removal And Installation (Dohc)50
"Aa Injectors Installation51
"Ba Fuel Pressure Regulator Installation51
"Ca Gasket Installation51
Throttle Body And Egr System Removal And Installation (Up To 2000 Model For Carisma, 1999 Model For Space Star, Spacer Runner)53
5A. Throttle Body And Egr System (Gdi)53
Throttle Body And Egr System Removal And Installation (From 2001 Model For Carisma, Space Star And Galant)54
Throttle Body And Egr System Removal And Installation (For Pajero Io - 4G93)55
Throttle Body And Egr System Removal And Installation (For Pajero Io - 4G94)56
Installation Service Points: "Aa Throttle Body Gasket57
"Ba Intake Manifold Stay Installation57
Intake And Exhaust Manifold58
Intake And Exhaust Manifold Removal And Installation (Sohc-Carburetor)58
6-158
Intake And Exhaust Manifold Removal And Installation (Sohc-Mpi-Front Wheel Drive (4G92 And 4G93–Except From 2001 Model For Europe))59
Intake And Exhaust Manifold Removal And Installation (Sohc-Mpi-Front Wheel Drive (4G92 And 4G93– From 2001 Model For Europe))60
Intake And Exhaust Manifold Removal And Installation (Sohc-Mpi-Front Wheel Drive (4G94)61
Intake And Exhaust Manifold Removal And Installation (Sohc-Mpi-Rear Wheel Drive (4G93 - Except From 2002 Model For Europe)62
Intake And Exhaust Manifold Removal And Installation (Sohc-Mpi-Rear Wheel Drive (4G93 - From 2002 Model For Europe)63
Intake And Exhaust Manifold Removal And Installation (Sohc-Mpi-Rear Wheel Drive (4G94)64
Intake And Exhaust Manifold Removal And Installation (Dohc)66
"Aa Exhaust Manifold Bracket Installation67
Rear Wheel Drive67
"Ba Intake Manifold Stay - Installation67
Intake Manifold (Gdi) Removal And Installatoin (Up To 2000 Model For Carisma, 1999 Model For Space Star, Space Runner)68
6A. Intake Manifold (Gdi)68
Intake Manifold (Gdi) Removal And Installation (From 2001 Model For Carisma, Space Star And Galant)69
Intake Manifold (Gdi) Removal And Installation (For Space Runner)71
Intake Manifold (Gdi) Removal And Installation (For Pajero Io)72
"Aa Intake Manifold Stay Installation73
Exhaust Manifold (Gdi) Removal And Installation (For Carisma, Space Star, Space Runner)74
6B. Exhaust Manifold (Gdi)74
Exhaust Manifold (Gdi) Removal And Installation (For Galant)75
Exhaust Manifold (Gdi) Removal And Installation (For Pajero Io)77
Exhaust Manifold Bracket Installation78
Injector And Fuel Pump Assembly (Gdi) (Up To 2000 Mode For Carisma, 1999 Model For Space Star, Space Runner)79
6C. Injector And Fuel Pump Assembly (Gdi)79
Injector And Fuel Pump Assembly (Gdi) (From 2001 Model For Carisma, Space Star And Galant)80
Injector And Fuel Pump Assembly (Gdi) (For Pajero Io - 4G94)81
Injector And Fuel Pump Assembly (Gdi) (For Pajero Io - 4G93)82
Backap Ring/O-Ring/Corrugated Washer Installation83
Delivery Pipe And Injector Assembly Installation83
Pump Camshaft Case Installation84
Fuel Pressure Sensor Installation84
Fuel High Pressure Regulator Installation84
Fuel Pump/Fuel Feed Pipe Installation85
O-Ring/Fuel Pump Installation86
O-Ring/Backup Ring/Fuel Pipe Installation86
O-Ring/Backup Ring/Fuel Pressure Sensor Installation87
Ja O-Ring/Fuel Pump Installation87
Intake And Exhaust Manifold <4G94 - Gdi For Pajero Io> Removal And Installation88
To Install The Exhaust Manifold Bracket89
Intake Manifold Stay Installation89
Water Pump And Water Hose Removal And Installation (Sohc - Front Wheel Drive)90
7-190
Water Pump And Water Hose Removal And Installation (Sohc - Rear Wheel Drive)91
Water Pump And Water Hose Removal And Installation (Dohc - Front Wheel Drive)92
Water Pump And Water Hose Removal And Installation (Dohc - Rear Wheel Drive)93
Water Pump Installation94
Water Inlet Pipe (Front Wheel Drive/Water Pipe, Rear Wheel Drive/O-Ring Installation)94
Thermostat Installation94
Water Outlet Fitting Installation94
Engine Coolant Temperature Gauge Unit Installation95
Engine Coolant Temperature Sensor Installation95
Water By-Pass Fitting Installation95
Rocker Arms And Camshafts Removal And Installation (Sohc (With Adjusting Screw))96
8-196
Rocker Arms And Camshafts Removal And Installation (Sohc (With Lash Adjuster))97
Rocker Arms And Camshafts Removal And Installation (Dohc)99
Rocker Arms And Camshafts Removal And Installation (Dohc-Gdi)100
Rocker Arms And Camshafts Removal And Installation (Dohc-Gdi For Carisma (Up To 2000 Model), Space Star (1999 Model), Space Runner)102
Rocker Arms And Camshafts Removal And Installation (Dohc-Gdi For Carisma, Space Star And Galant (From 2001 Model))103
Rocker Arms And Camshafts Removal And Installation (Dohc-Gdi For Pajero Io - 4G94)104
Rocker Arms And Camshafts Removal And Installation (Dohc-Gdi For Pajero Io - 4G93)105
Lash Adjuster Removal106
Adjusting Screw Installation106
Rocker Arm Shaft Installation106
Rocker Arms And Rocker Arm Shaft Installation106
Oil Seal Installation107
Lash Adjuster Installation107
Camshaft Installation107
Bearing Cap Installation107
Beam Camshaft Cap Installation108
Sealant Application On Semi-Circular Parking110
Sealant Application On Rocker Cover110
O-Ring/Cover Installation110
Valve Clearance Adjustment110
Camshaft Inspection113
Lash Adjuster (Sohc)113
Lash Adjuster (Dohc)116
Rocker Cover And Camshafts (Mivec) Removal And Installation119
Oil Control Valve Inspection120
Camshaft - Inspection120
Semi-Circular Packing Installation121
Camshaft Holder Assembly Installation121
Install The Camshaft121
Camshaft Bearing Cap/Camshaft Holder Installation121
Oil Control Valve Installation122
Installation Of The Oil Seal122
Rocker Cover Installation123
To Adjust The Valve Clearance123
Rocker Arm Piston Inspection123
Rocker Arms And Rocker Shaft Caps (Mivec) Removal And Installation124
Rocker Arm Assembly Installation125
Cylinder Head And Valves Removal And Installation (Sohc)126
9-1126
Cylinder Head And Valves Removal And Installation (Dohc)127
Cylinder Head And Valves Removal And Installation (Dohc-Mivec)128
Cylinder Head And Valves Removal And Installation (Dohc-Gdi)129
Cylinder Head Bolt Removal131
Retainer Lock Removal131
Valve Stem Seal Removal132
Valve Handling Precautions132
Valve Stem Seal Installation133
Valve Spring Installation134
Retainer Lock Installation134
Cylinder Head Bolt Installation134
Sealant Application To Oil Pressure Switch135
Cylinder Head Inspection136
Valve Inspection136
Valve Spring Inspection137
Valve Seat Inspection137
Valve Guide Inspection137
Valve Seat Reconditioning Procedure138
Valve Seat Replacement Procedure138
Valve Guide Replacement138
Front Case And Oil Pump Removal And Installation (Sohc (4G92, 4G93))140
10-1140
Front Case And Oil Pump Removal And Installation (Sohc (4G94 Except For Pajero Io))141
Front Case And Oil Pump Removal And Installation (Sohc (4G94 For Pajero Io))142
Front Case And Oil Pump Removal And Installation (Dohc (Except Gdi For Pajero Io))143
Front Case And Oil Pump Removal And Installation (Dohc-Gdi For Pajero Io)144
Oil Pan Removal145
Outer Rotor/Inner Rotor Removal145
Inner Rotor/Outer Rotor Installation145
Sealant Application To Oil Pump Case145
Crankshaft Front Oil Seal Installation146
Oil Pan/Upper Oil Pan/Lower Oil Pan Installation146
Oil Filter Installation147
Oil Pump Inspection147
Piston And Connecting Rod Removal And Installation149
11-1149
Connecting Rod Cap Removal150
Piston Pin Removal150
Piston Pin Installation151
Oil Ring Installation152
Piston Ring #2/Piston Ring #1 Installation153
Piston And Connecting Rod Installation153
Connecting Rod Bearing Installation154
Connecting Rod Cap Installation155
Connecting Rod Cap Nut Installation155
Piston Ring Instpection156
Crankshaft Pin Oil Clearance (Plastigauge Method)156
Crankshaft, Cylinder Block, Flywheel And Drive Plate Removal And Installation (Manual Transmission)157
Automatic Transmission Removal And Installation158
Crankshaft, Cylinder Block, Flywheel And Drive Plate Removal And Installation (Pajero Io)159
Oil Jet Removal160
Oil Jet Installation160
Crankshaft Bearing Installation160
Bearing Cap/Bearing Cap Bolt Installation162
To Install The Oil Seal163
Sealant Application To Oil Seal Case163
Drive Plate Bolt/Flywheel Bolt Installation163
Crankshaft Journal Oil Clearance (Plastigauge Method)163
Cylinder Block Inspection164
Boring Cylinder Inspection164
Hydro-Flywheel (Dohc-Gdi For Pajero Io) Inspection165
Service Bulletins167
Crankshaft Weight169