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Mitsubishi 4G9 series Manual

4g9 series
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See also: Workshop Manual , Service Manual
E
Mitsubishi Motors Corporation
ENGINE
4G9 SERIES
CONTENTS
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Dec. 1998
PWEE9502-E
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11A-0-1
11A-6-1
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Revised

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Summary of Contents for Mitsubishi 4G9 series

  • Page 1: Table Of Contents

    11A-0-1 ENGINE 4G9 SERIES CONTENTS GENERAL INFORMATION 11A-0-3 ......... . .
  • Page 2 11A-0-2 NOTES Mitsubishi Motors Corporation May 1995 PWEE9502...

  • Page 3: General Information

    Oil pump type Trochoid type Trochoid type Cooling system Water-cooled forced circulation Water-cooled forced circulation Water pump type Centrifugal impeller type Centrifugal impeller type LANCER for general export and CARISMA for 6B model Mitsubishi Motors Corporation July 1997 PWEE9502-C Revised...
  • Page 4 Oil pump type Trochoid type Trochoid type Trochoid type Cooling system Water-cooled forced Water-cooled forced Water-cooled forced circulation circulation circulation Water pump type Centrifugal impeller Centrifugal impeller Centrifugal impeller type type type Revised Mitsubishi Motors Corporation July 1997 PWEE9502-C...

  • Page 5: Specifications

    *Total resurfacing depth of both cylinder head and cylinder block : LANCER for Europe and CARISMA for Europe : LANCER for general export and CARISMA for 6B model : For CARISMA : For PAJERO io Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 6 Exhaust 49.35 49.85 Intake 46.70 47.20 DOHC Exhaust 46.65 47.15 Intake 58.13 58.63 DOHC- MIVEC Exhaust 57.85 58.35 Intake 46.70 47.20 DOHC- GDI Exhaust 46.65 47.15 Cylinder head bolt shank length mm 96.4 Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 7 Cylinder block I.D. mm 81.0 Piston to cylinder clearance mm 0.02 - 0.04 Bearing cap bolt shank length mm 71.1 Crankshaft end play mm 0.05 - 0.25 Crankshaft journal O.D. mm Crankshaft pin O.D. mm Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...

  • Page 8: Rework Dimensions

    Adjusting bolt <SOHC- PAJERO io and DOHC- GDI for PAJERO io> Power steering pump pulley Power steering pump bracket stay Power steering pump bracket (M8) Power steering pump bracket (M10) Alternator pivot bolt Center cover Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 9 Solenoid valve assembly <SOHC- MPI for other than PAJERO io> Solenoid valve assembly <SOHC- MPI for PAJERO io> Throttle body and EGR system (GDI) Air intake resonator Intake manifold stay Water hose clamp Water pipe Throttle body Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 10 Exhaust manifold cover Engine hanger bolt Engine hanger nut (M8) Engine hanger nut (M10) Exhaust manifold bracket (M8 ´ 22) Exhaust manifold bracket (M8 ´ 20) Exhaust manifold bracket (M10) Exhaust manifold (M10) Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 11 Engine coolant temperature gauge unit Engine coolant temperature sensor Water fitting Rocker arms and camshaft Lock nut Rocker arm shaft Rocker cover Bearing cap bolt (M6) Bearing cap bolt (M8) Beam camshaft cap (M8) Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 12 20 + 90_ to 100_ Crankshaft, cylinder block, flywheel and drive plate Bearing cap bolt 25 + 90_ to 100_ Oil seal case Bell housing cover Rear plate Drive plate bolt Flywheel bolt Baffle plate Knock sensor Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...

  • Page 13: New Tightening Method - By Use Of Bolts To Be Tightened In Plastic Area

    Observe the tightening method described in the text. SEALANT Items Specified sealant Quantity Water pump Mitsubishi Genuine Part No.MD970389 or equivalent As required Thermostat case Mitsubishi Genuine Part No.MD970389 or equivalent As required Water by-pass fitting Mitsubishi Genuine Part No.MD970389 or equivalent...

  • Page 14: Form-In-Place Gasket

    (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 May 1995 PWEE9502...

  • Page 15: Special Tools

    Crankshaft front oil Installation of crankshaft front oil seal seal installer MB991653 Cylinder head bolt Tightening and loosening of cylinder head bolt wrench MB991659 Guide D Removal of piston pin (Use with MD998780) Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Revised...
  • Page 16 Valve stem seal Installation of valve stem seal installer MD998775 Valve stem seal Installation of valve stem seal installer MD998776 Crankshaft rear oil Installation of crankshaft rear oil seal seal installer Use with MB990938 Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Revised...
  • Page 17 Valve adjusting Adjustment of valve clearance (MIVEC) wrench feeler gauge set MB991479 Rocker arm Adjustment of valve clearance (MIVEC) piston checker MD998784 Valve spring Compression of valve spring (MIVEC) compressor (Use with MD998772) adapter Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Revised...

  • Page 18: Alternator And Ignition System

    7. Spark plug cable 3. Alternator brace 8. Spark plug AA" "BA 4. Crankshaft bolt 9. Distributor 5. Crankshaft pulley 10. O-ring NOTE: *: For details of adjustment, refer to the relevant model’s chassis workshop manual. Revised Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A...
  • Page 19 10. Cam position sensor 5. Crankshaft pulley "AA 11. Cam position sensor support 6. Front flange 12. Cam position sensing cylinder NOTE: *: For details of adjustment, refer to the relevant model’s chassis workshop manual. Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 20 10. Cam position sensor 5. Crankshaft pulley "AA 11. Cam position sensor support 6. Front flange 12. Cam position sensing cylinder NOTE: *: For details of adjustment, refer to the relevant model’s chassis workshop manual. Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Added...
  • Page 21 11A-3-2b 4G9 ENGINE (E - W) - Alternator and Ignition System Intentionally blank Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Added...
  • Page 22 9. Spark plug cable AA" "BA 4. Crankshaft bolt 10. Spark plug 5. Crankshaft pulley 11. Ignition failure sensor 6. Flange NOTE: *: For details of adjustment, refer to the relevant model’s chassis workshop manual. Revised Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A...
  • Page 23 5. Crankshaft pulley 11. Cam position sensor 6. Front flange "AA 12. Cam position sensor support 13. Cam position sensing cylinder NOTE: *: For details of adjustment, refer to the relevant model’s chassis workshop manual. Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Added...
  • Page 24 10. Cam position sensor 5. Crankshaft pulley "AA 11. Cam position sensor support 6. Front flange 12. Cam position sensing cylinder NOTE: *: For details of adjustment, refer to the relevant model’s chassis workshop manual. Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 25 AA" "BA 7. Crankshaft bolt "AA 16. Cam position sensor support 8. Crankshaft pulley 17. Cam position sensing cylinder 9. Front flange NOTE: *: For details of adjustment, refer to the relevant model’s chassis workshop manual. Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 26 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 CRANKSHAFT BOLT INSTALLATION (1) Use the special tool to hold the flywheel or the drive MD998781 plate, and then tighten the crankshaft mounting bolts.

  • Page 27: Timing Belt

    "CA 5. Tensioner spring (Engines without distributor) "BA 6. Timing belt tensioner 11. Crankshaft sensing plate 7. Timing belt rear cover (Engines without distributor) 12. Crankshaft key AB" "AA 13. Camshaft sprocket bolt 14. Camshaft sprocket Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 28 AA" "DA 4. Timing belt 11. Crankshaft sensing plate "CA 5. Tensioner spring 12. Crankshaft key "BA 6. Timing belt tensioner AB" "AA 13. Camshaft sprocket bolt 7. Timing belt rear cover 14. Camshaft sprocket Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 29 16. Crankshaft sprocket key 7. Shaft AB" "AA 17. Camshaft sprocket bolt "EA 8. Auto-tensioner 18. Camshaft sprocket 9. Timing belt rear cover 19. Timing belt rear cover 10. Idler pulley 20. Timing belt rear cover Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 30 AB" "AA 16. Camshaft sprocket bolt 7. Shaft 17. Camshaft sprocket "EA 8. Auto tensioner 18. Timing belt rear cover 9. Timing belt rear cover 19. Timing belt rear cover 10. Idler pulley Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 31 AB" "AA 16. Camshaft sprocket bolt 7. Shaft 17. Camshaft sprocket "EA 8. Auto tensioner 18. Timing belt rear cover 9. Timing belt rear cover 19. Timing belt rear cover 10. Idler pulley Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Added...
  • Page 32 7. Shaft AB" "AA 17. Camshaft sprocket bolt "EA 8. Auto tensioner 18. Camshaft sprocket 9. Timing belt rear cover 19. Timing belt rear cover 10. Idler pulley 20. Timing belt rear cover Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Added...
  • Page 33 <With rocker cover removed> (Except SOHC) (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 INSTALLATION MB990767 MD998719 MD998754 Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Revised...
  • Page 34 (4) Align the timing mark on the crankshaft sprocket to that on the oil pump case. Timing marks (5) Place the timing belt over the sprocket according in the following order. 1. Crankshaft sprocket 2. Water pump sprocket 3. Camshaft sprocket 4. Tension pulley Mitsubishi Motors Corporation May 1995 PWEE9502...

  • Page 35: 4G9 Engine (E

    3) Insert a 2.0-mm-Allen key in diameter or similar into the set holes. 4) Remove the auto-tensioner from the vice. (2) Install the auto-tensioner Leave the align key until installation of the timing belt is completed. Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Revised...
  • Page 36 Paper clip (5) Use two wrenches to fit the timing belt to the exhaust Timing mark sprocket while aligning the timing marks. Timing mark Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Revised...
  • Page 37 (9) Remove the two paper clips. (10)Make sure that all timing marks are in alignment. (11)Give a 1/4 counterclockwise turn to the crankshaft. Then turn the crankshaft clockwise to align the timing marks again. Mitsubishi Motors Corporation May 1995 PWEE9502...

  • Page 38: Timing Belt

    Back side is glossy without resilience and leaves no indent when pressed with fingernail. (2) Cracks on rubber back. (3) Cracks or peeling of canvas. Cracks (4) Cracks on tooth bottom. (5) Cracks on belt sides. Peeling Cracks Cracks Mitsubishi Motors Corporation May 1995 PWEE9502...

  • Page 39: Auto-Tensioner Bolt

    (4) Press the rod by a force of 98 to 196 N and measure the rod stroke. If not within the standard value, replace 98 to 196 N the tensioner. Stroke Standard value: 1 mm or less Mitsubishi Motors Corporation May 1995 PWEE9502...

  • Page 40: Fuel And Emission Control System

    21 Nm 21 Nm Removal steps 1. Breather tube 2. Fuel hose 3. Fuel hose 4. Fuel pump 5. Gasket 6. Insulator 7. Gasket 8. Carburetor 9. Gasket 10. EGR valve 11. Gasket Revised Mitsubishi Motors Corporation Nov. 1996 PWEE9502-B...

  • Page 41: Fuel Return Pipe

    5. Fuel hose 14. Delivery pipe "BA 6. Fuel pressure regulator 15. Fuel return pipe 7. O-ring 16. Solenoid valve assembly 8. Delivery pipe and injector 17. EGR valve 9. Insulator 18. Gasket Mitsubishi Motors Corporation July 1999 PWEE9502-F Revised...
  • Page 42 4. Vacuum hose 12. O-ring 5. Fuel hose 13. Grommet "BA 6. Fuel pressure regulator 14. Delivery pipe 7. O-ring 15. Fuel return pipe 8. Delivery pipe and injector 16. Solenoid valve assembly Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...

  • Page 43: Throttle Body Stay

    4. Throttle body stay (MIVEC) 13. O-ring 5. Vacuum hose 14. Grommet 6. Fuel hose 15. Delivery pipe "BA 7. Fuel pressure regulator 16. Fuel return pipe 8. O-ring 9. Delivery pipe and injector Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 44 "CA GASKET INSTALLATION <SOHC - MPI for other than PAJERO io> (1) Position the projection as shown in the illustration. Projection Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Added...
  • Page 45 11A-5-6 4G9 ENGINE (E - W) - Fuel and Emission Control System <SOHC - MPI for PAJERO io> Projection Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Added...

  • Page 46: 5A. Throttle Body And Egr System (Gdi)

    13. EGR valve support 5. Water hose 14. Gasket 6. Throttle body 15. Water hose "AA 7. Throttle body gasket 16. Air by-pass valve 8. Ignition harness 17. Air by-pass valve gasket 9. Water hose Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...

  • Page 47: Water Hose Clamp

    3. Water hose 11. EGR valve 4. Water hose 12. EGR valve gasket 5. Water hose 13. EGR valve support 6. Water hose clamp 14. Gasket 7. Water pipe 15. Engine hanger 8. Water pipe Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 48 (2) Check that the stay seating surface is in close contact with the bosses on the intake manifold and the cylinder Bolt block. (3) Tighten the four bolts to the specified torque. Intake manifold stay Bolt Cylinder block Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Added...

  • Page 49: Intake And Exhaust Manifold

    9. Engine hanger 4. Intake manifold gasket "AA 10. Exhaust manifold bracket A 5. Oil level gauge "AA 11. Exhaust manifold bracket B 6. Oil level gauge guide 12. Exhaust manifold 13. Exhaust manifold gasket Revised Mitsubishi Motors Corporation Nov. 1996 PWEE9502-B...
  • Page 50 9. Engine hanger 4. Intake manifold gasket "AA 10. Exhaust manifold bracket A 5. Oil level gauge "AA 11. Exhaust manifold bracket B 6. Oil level gauge guide 12. Exhaust manifold 13. Exhaust manifold gasket Mitsubishi Motors Corporation Nov. 1996 PWEE9502-B Revised...
  • Page 51 3. Intake manifold "AA 9. Exhaust manifold bracket A 4. Intake manifold gasket "AA 10. Exhaust manifold bracket B 5. Oil level gauge 11. Exhaust manifold 6. Oil level gauge guide 12. Exhaust manifold gasket Revised Mitsubishi Motors Corporation Nov. 1996 PWEE9502-B...
  • Page 52 Exhaust manifold "BA INTAKE MANIFOLD STAY INSTALLATION (1) Install the intake manifold stay with its “UP” mark directed toward the intake manifold. “UP” mark Added Mitsubishi Motors Corporation Nov. 1996 PWEE9502-B...

  • Page 53: 6A. Intake Manifold (Gdi)

    1. Air by-pass hose 6. Accelerator cable bracket 2. Vacuum pipe and hose 7. Vacuum hose 3. Bracket 8. Vacuum pipe 4. Solenoid valve 9. Intake manifold 5. Connector bracket 10. Intake manifold gasket Revised Mitsubishi Motors Corporation Jun. 1998 PWEE9502-D...
  • Page 54 1. Air by-pass hose 6. Accelerator cable bracket 2. Vacuum pipe and hose 7. Vacuum hose 3. Bracket 8. Vacuum pipe 4. Solenoid valve 9. Intake manifold 5. Connector bracket 10. Intake manifold gasket Mitsubishi Motors Corporation Jun. 1998 PWEE9502-D Added...
  • Page 55 1. P.C.V. hose 6. Branch tube 2. Vacuum pipe and hose 7. Gasket 3. Solenoid valve "AA 8. Intake manifold stay 4. Fuel pump protector 9. Intake manifold 5. Connector bracket 10. Intake manifold gasket Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Added...
  • Page 56 (1) Check to ensure that the intake manifold stay is in close contact with the intake manifold and the cylinder block Intake before tightening the respective mounting bolts to the manifold specified torque. stay Cylinder block Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Added...

  • Page 57: 6B.exhaust Manifold (Gdi)

    2. Oil level gauge guide 3. O-ring 4. Exhaust manifold cover 5. Engine hanger "AA 6. Exhaust manifold bracket A "AA 7. Exhaust manifold bracket B 8. Exhaust manifold 9. Exhaust manifold gasket Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 58 13 Nm 18 Nm 29 Nm 17 Nm 98 Nm 29 Nm Removal steps 1. Exhaust manifold cover 2. Engine hanger "BA 3. Exhaust manifold bracket 4. Exhaust manifold 5. Exhaust manifold gasket Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...

  • Page 59: Exhaust Manifold (M8)

    (2) Temporarily install the exhaust manifold bracket as shown in the illustration. (3) Verify that the bracket is brought into close contact with the boss on the exhaust manifold, then tighten the bolts Exhaust to the specified torque. manifold Bracket Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Added...

  • Page 60: 6C. Injector And Fuel Pump Assembly (Gdi)

    15. Backup ring "AA 34. Corrugated washer 16. O-ring "AA 35. Backup ring 17. Backup ring "AA 36. O-ring "EA 18. Fuel high pressure regulator "AA 37. Backup ring 19. Flange 38. Delivery pipe Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...

  • Page 61: Fuel Feed Pipe

    13. Backup ring "AA 32. O-ring "FA 14. Fuel pump "AA 33. Backup ring 15. O-ring 34. Injector 16. Fuel return pipe 35. Delivery pipe 17. Backup ring 18. O-ring 19. Backup ring Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 62 (7) Install the injector holders and the washers to the assembly and tighten the fasteners to the specified torque. Mating marks Caution Strictly observe the specified torque. Injector gasket Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 63 PAJERO io> and tighten the 3 bolts lightly (with somewhat larger torque than fingertight). Tightening to the Cut surface specification is to be carried out in the step described in "FA. Backup ring Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 64 The torque variation among 4 bolts must be within 2 Nm. Caution Strictly observe the specified tightening torque. Deviation from the specification can cause problems such as leakage or the like. <PAJERO io> Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Added...

  • Page 65: Water Pump And Water Hose Water Pump

    "GA 3. Engine coolant temperature sensor "BA 10. Water inlet pipe "FA 4. Engine coolant temperature gauge "BA 11. O-ring unit "AA 12. Water pump "EA 5. Water outlet fitting 6. Water inlet fitting Revised Mitsubishi Motors Corporation Nov. 1996 PWEE9502-B...
  • Page 66 "GA 3. Engine coolant temperature sensor "BA 9. O-ring "FA 4. Engine coolant temperature gauge "BA 10. Water inlet pipe unit "BA 11. O-ring "EA 5. Water outlet fitting "AA 12. Water pump 6. Water inlet fitting Mitsubishi Motors Corporation May 1995 PWEE9502...

  • Page 67: Water By-Pass Fitting

    "BA 9. O-ring "IA 3. Water fitting "CA 10. Thermostat case "EA 4. Water outlet fitting "BA 11. Water pipe 5. Water inlet fitting "BA 12. O-ring "DA 6. Thermostat "AA 13. Water pump Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 68 (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 "BA WATER INLET PIPE <SOHC, DOHC> / WATER PIPE <DOHC - GDI for PAJERO io> / O-RING INSTALLATION (1) Replace the O-ring of the water inlet pipe <SOHC, DOHC>...
  • Page 69 Specified sealant: Mitsubishi Genuine Part No.MD970389 equivalent. "IA WATER 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 equivalent. Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Added...

  • Page 70: Rocker Arms And Camshafts

    "EA 7. Oil seal "BA 17. Rocker arm shaft "DA 8. Rocker arm spring "AA 18. Adjusting screw "CA 9. Rocker arms and rocker arm shaft 19. Nut 20. Camshaft 10. Rocker arms and rocker arm shaft Mitsubishi Motors Corporation May 1995 PWEE9502...
  • Page 71 "GA 13. Exhaust camshaft 5. Oil filler cap 14. Rocker arm "KA 6. Rocker cover AA" "FA 15. Lash adjuster 7. Rocker cover gasket A 8. Rocker cover gasket B "JA 9. Semi-circular packing Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 72 3. P.C.V valve 10. Gasket 4. P.C.V valve gasket "JA 11. Intake camshaft 5. Oil filler cap "JA 12. Exhaust camshaft 6. Rocker cover 13. Rocker arm 7. Rocker cover gasket 14. Lash adjuster Mitsubishi Motors Corporation July 1997 PWEE9502-C Added...
  • Page 73 11A-8-2 2 b 4G9 ENGINE (E - W) - Rocker Arms and Camshafts Intentionally blank Mitsubishi Motors Corporation July 1997 PWEE9502-C Added...

  • Page 74: Beam Camshaft Cap (M8)

    3. P.C.V. valve 10. Gasket 4. P.C.V. valve gasket 11. Intake camshaft 5. Oil filler cap 12. Exhaust camshaft 6. Rocker cover 13. Rocker arm 7. Rocker cover gasket AA" "FA 14. Lash adjuster Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 75 11. Gasket 4. Oil filler cap 12. Intake camshaft 5. Rocker cover 13. Exhaust camshaft 6. Rocker cover gasket 14. Rocker arm 7. Oil seal AA" "FA 15. Lash adjuster 8. Thrust case Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 76 "DA ROCKER ARM SPRING INSTALLATION (1) Insert the rocker arm spring at an angle to the spark plug guide and then install it so that it is at a right angle to the guide. Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 77 "HA BEARING CAP INSTALLATION (1) Locate the camshaft dowel pins as illustrated. Dowel pins (2) Apply sealant to the locations shown in the illustration. Specified sealant: 3M ATD Part No. 8660 or equivalent Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 78 (3) Apply a 3 mm thick continuous bead of sealant to the bottom surface of the beam camshaft cap along the groove. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent Beam camshaft cap <DOHC - GDI for PAJERO io>...
  • Page 79 (4) Apply sealant to the illustrated position of the cylinder <DOHC - GDI for CARISMA> head upper surface. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent <DOHC - GDI for PAJERO io> Engine front side (5) Install the beam camshaft cap before the sealant applied <DOHC - GDI for CARISMA>...
  • Page 80 No.4 cylinder to the compression top dead centre position. (6) Adjust the valve clearances indicated by arrows in the When No.4 cylinder is at compression top illustration by the same procedure as in steps (3) and dead centre (4) above. Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Added...
  • Page 81 Then, perform the following steps with each lash adjuster. (2) Place the lash adjuster in container A and clean its outside surface. NOTE Use a nylon brush if deposits are hard to remove. Diesel fuel Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Added...
  • Page 82 Caution 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 Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Added...
  • Page 83 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 Dec. 1998 PWEE9502-E Added...
  • Page 84 (16)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 Dec. 1998 PWEE9502-E Added...

  • Page 85: 8A. Rocker Cover And Camshafts (Mivec)

    "DA 11. Arm spring "GA 4. Rocker cover "CA 12. Camshaft 5. Rocker cover gasket "BA 13. Camshaft holder 6. Oil seal "AA 14. Semi-circular packing "FA 7. Oil seal "EA 8. Oil control valve Added Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A...
  • Page 86 If the specified limit is exceeded, replace the camshaft. Unit: mm Standard Limit value 4G92 DOHC- MIVEC Intake A 36.41 35.91 Intake B 33.58 33.08 Exhaust A 35.83 35.33 Exhaust B 34.24 33.74 Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Added...
  • Page 87 HOLDER INSTALLATION (1) Confirm the identification mark on each bearing cap to install the cap in the correct position. Identification mark L1: Front bearing for exhaust camshaft R1: Front bearing for intake camshaft Added Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A...
  • Page 88 7 13 Sealant Sealant "EA OIL CONTROL VALVE INSTALLATION (1) Apply the specified sealant to the area shown. Specified sealant: 3M ATD Part No. 8660 or equivalent Sealant "FA OIL SEAL INSTALLATION MD998713 Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Added...
  • Page 89 ROCKER ARM PISTON INSPECTION (1) Screw in the special tool to the rocker arm piston for high speed side rocker arm and check that the piston can be lifted up lightly by hand. MB991479 Added Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A...

  • Page 90: 8B.rocker Arms And Rocker Shaft Caps (Mivec)

    "AA 6. Intake rocker arm assembly “A” 2. Seal cap “A” 7. Spring guide 3. Seal cap “B” 8. Wave washer 4. Spring guide "AA 9. Exhaust rocker arm assembly “A” 5. Wave washer 10. Camshaft holder Added Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A...
  • Page 91 "AA ROCKER ARM ASSEMBLY INSTALLATION (1) Install the rocker arm assemblies while checking the identification marks at the positions shown to ensure that the intake and exhaust sides are not reversed. Identification marks: E: Intake I: Exhaust Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Added...

  • Page 92: Cylinder Head And Valves

    16. Exhaust valve guide 7. Exhaust valve 17. Intake valve guide AB" "CA 8. Retainer lock 18. Exhaust valve seat 9. Valve spring retainer 19. Intake valve seat "BA 10. Valve spring 20. Cylinder head Mitsubishi Motors Corporation May 1995 PWEE9502...
  • Page 93 "BA 7. Valve spring 18. Intake valve guide 8. Exhaust valve 19. Exhaust valve seat AB" "CA 9. Retainer lock 20. Intake valve seat 10. Valve spring retainer 21. Cylinder head "BA 11. Valve spring Mitsubishi Motors Corporation May 1995 PWEE9502...
  • Page 94 "BA 7. Valve spring 18. Exhaust valve guide AD" 8. Intake valve 19. Intake valve seat AB" "CA 9. Retainer lock 20. Exhaust valve seat 10. Valve spring retainer 21. Cylinder head "BA 11. Valve spring Revised Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A...
  • Page 95 16. Intake valve guide AD" 7. Intake valve 17. Exhaust valve guide AB" "CA 8. Retainer lock 18. Intake valve seat 9. Valve spring retainer 19. Exhaust valve seat "BA 10. Valve spring 20. Cylinder head Mitsubishi Motors Corporation July 1997 PWEE9502-C Added...
  • Page 96 11A-9-5 3 b 4G9 ENGINE (E - W) - Cylinder Head and Valves Intentionally blank Added Mitsubishi Motors Corporation July 1997 PWEE9502-C...
  • Page 97 DOHC, MIVEC MB991653 AB" RETAINER LOCK REMOVAL Except MIVEC (1) Store the removed valves, springs and other parts, tagged MD998772 to indicate their cylinder No. and location to aid reassembly. MIVEC MD998772 MD998784 MD998735 Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Revised...
  • Page 98 Wear rubber gloves and goggles, and carefully take out broken valves from the cylinder head. Put a broken valve in the water-filled container and quickly get away from the container at least 2 or 3 m (6.6 or 10 ft.) Revised Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A...
  • Page 99 (1) Install the vale spring seat. (2) Use the special tool to install the valve stem seal. Improper installation could result oil leaking past the valve guide. Caution MD998774 Do not reuse removed valve stem seals. DOHC MD998775 Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Revised...
  • Page 100 If the limit is exceeded, replace the bolts. Limit: Max. 96.4 mm (2) Install the washers as illustrated. (3) Apply engine oil to the bolt threads and washers. Shank length Revised Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A...
  • Page 101 (1) Apply sealant to the threads of the switch. Specified sealant: 3M ATD Part No. 8660 or equivalent Caution Use care not to allow the sealant to plug the oil Oil passage passage. Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Revised...
  • Page 102 Standard value Limit mm Intake SOHC 110.15 109.65 DOHC 104.19 103.69 DOHC- MIVEC 115.63 115.13 DOHC- GDI 104.19 103.69 Exhaust SOHC 113.70 113.20 DOHC 103.87 103.37 DOHC- MIVEC 115.63 115.13 DOHC- GDI 103.87 103.37 Revised Mitsubishi Motors Corporation July 1997 PWEE9502-C...
  • Page 103 Intake: 0.02 - 0.05 mm Exhaust: 0.05 - 0.09 mm Valve <SOHC, DOHC, DOHC- MIVEC, DOHC- GDI for guide CARISMA> 0.04 - 0.06 mm <DOHC - GDI for PAJERO io> Limit: Intake: 0.10 mm Exhaust: 0.15 mm Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 104 Do not use the valve guide of the same size as the removed one. Valve guide hole diameters in cylinder head 0.05 O.S.: 11.05 - 11.07 mm 0.25 O.S.: 11.25 - 11.27 mm 0.50 O.S.: 11.50 - 11.52 mm Revised Mitsubishi Motors Corporation July 1997 PWEE9502-C...
  • Page 105 (45.5 mm for intake Protrusion valve; 50.5 mm for exhaust valve) (4) After the valve guide has been installed, insert a new valve to check for smooth sliding motion. Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Added...

  • Page 106: Front Case And Oil Pump

    "BA 12. Oil pump case AA" "DA 5. Oil pan 13. O-ring 6. Oil screen 14. Oil pump case cover 7. Oil screen gasket AC" "AA 15. Outer rotor 8. Relief plug AC" "AA 16. Inner rotor Mitsubishi Motors Corporation May 1995 PWEE9502...
  • Page 107 AB" "DA 6. Upper oil pan 16. Oil pump case cover "DA 7. Lower oil pan AC" "AA 17. Outer rotor 8. Oil screen AC" "AA 18. Inner rotor 9. Oil screen gasket Mitsubishi Motors Corporation Jun. 1998 PWEE9502-D Revised...
  • Page 108 AB" "DA 6. Upper oil pan 15. O-ring "DA 7. Lower oil pan 16. Oil pump case cover 8. Oil screen AC" "AA 17. Outer rotor 9. Oil screen gasket AC" "AA 18. Inner rotor Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 109 (1) Apply engine oil to the rotors. Then, install the rotors ensuring that the alignment dots made at disassembly are properly aligned. "BA SEALANT APPLICATION TO OIL PUMP CASE 3 mm diameter bead sealant Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised...
  • Page 110 (2) Apply a 4 mm diameter bead of sealant to the oil pan flange. See “Form-In-Place Gasket” in “SPECIFICATIONS”. Specified sealant: Bolt hole Mitsubishi Genuine Part No. MD970389 or Groove portion portion equivalent (3) Install the oil pan within 15 minutes after applying the sealant.
  • Page 111 3M ATD Part No. 8660 or equivalent Caution Use care not to allow the sealant to plug the oil Oil passage passage. INSPECTION 11300730026 OIL PUMP (1) Check the tip clearance. Standard value: 0.06 - 0.18 mm Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Added...
  • Page 112 4G9 ENGINE (E - W) - Front Case and Oil Pump (2) Check the side clearance. Standard value: 0.04 - 0.10 mm (3) Check the body clearance. Standard value: 0.10 - 0.18 mm Limit: 0.35 mm Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Added...

  • Page 113: Piston And Connecting Rod

    "EA 3. Connecting rod bearing AB" "AA 9. Piston pin "DA 4. Piston and connecting rod 10. Piston "EA 5. Connecting rod bearing 11. Connecting rod "CA 6. Piston ring No. 1 12. Bolt Mitsubishi Motors Corporation May 1995 PWEE9502...
  • Page 114 Front mark (3) Using a press, remove the piston pin. Front NOTE mark Keep the disassembled pistons, piston pins and connecting rods in order according to the cylinder number. Guide D Base Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Revised...
  • Page 115 Standard value: 4,500 - 14,700 N Piston pin Front mark Front mark Guide A Base Guide B Mitsubishi Motors Corporation May 1995 PWEE9502...
  • Page 116 No.2 ring: 2T NOTE Identification mark “T” The piston ring is stamped with the following size mark. Identification mark “2T” Size mark Size Size mark Standard size None No.1 0.50 mm O.S. 1.00 mm O.S. No.2 Mitsubishi Motors Corporation May 1995 PWEE9502...
  • Page 117 Crank pin O.D. No.2 Crankshaft Connecting rod bearing identification No.1 mark Pin O.D. Identification Identification colour (Line identification mark (service production part) mark part) Crankshaft journal O.D. identification Brown mark Black Green Identification mark Identification colour Mitsubishi Motors Corporation May 1995 PWEE9502...
  • Page 118 (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. Mitsubishi Motors Corporation May 1995 PWEE9502...
  • Page 119 Piston No.1: 0.25 - 0.40 mm Piston ring ring gap No.2: 0.40 - 0.55 mm Oil: SOHC: 0.20 - 0.60 mm DOHC: 0.10 - 0.35 mm Limit: No.1, No.2: 0.8 mm Oil: 1.0 mm Mitsubishi Motors Corporation May 1995 PWEE9502...
  • Page 120 (4) Carefully remove the connecting rod cap. Plastigage (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 May 1995 PWEE9502...

  • Page 121: Crankshaft, Cylinder Block, Flywheel And Drive Plate

    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. Mitsubishi Motors Corporation July 1997 PWEE9502-C...
  • Page 122 5. Drive plate <A/T> "BA 14. Thrust plate 6. Crankshaft adaptor <A/T> "BA 15. Crankshaft bearing, upper 7. Rear plate 16. Knock sensor "EA 8. Rear oil seal case 17. Cylinder block "DA 9. Oil seal Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Added...
  • Page 123 11A-12-1b 4G9 ENGINE (E - W) Crankshaft, Cylinder Block, Flywheel and Drive Plate Intentionally blank Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Added...
  • Page 124 Identification Identification Identification No. 1 cation mark mark mark mark (service colour (Line parts) production parts) Brown Black Green Black Green Yellow Green Yellow Pink* *: Older bearings may be marked in red. Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Revised...
  • Page 125 Length of shank (3) Apply engine oil to the threaded portion and bearing surface of the bolt. (4) Tighten the bearing cap bolts to 25 Nm torque in the tightening sequence. (10) Arrow Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Revised...
  • Page 126 If the end play exceeds the limit, replace crankshaft bearings. Standard value: 0.05 - 0.25 mm Limit: 0.4 mm "DA OIL SEAL INSTALLATION MB990938 MD998776 "EA SEALANT APPLICATION TO OIL SEAL CASE Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Revised...
  • Page 127 0.2 mm at maximum. Cylinder block height (when new): 243.5 mm <4G92> 263.5 mm <4G93> (3) Check the cylinder walls for scratches and seizure. If defects are evident, correct (bored to oversize) or replace. Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Revised...
  • Page 128 (6) Check the 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 the same oversize. Do not bore only one cylinder to an oversize. Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Revised...
  • Page 129 (5) Apply a thrust force of approx. 98 N by hand on the flywheel to move it in the axial direction, and measure the runout at the dowel pin position. If the limit is exceeded, replace the flywheel assembly. Limit: 0.75 mm Flywheel 4ME0274 Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Added...
  • Page 130 NOTES...

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