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Mitsubishi 4G1 series Workshop Manual

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See also: Service Manual , User Manual
1. SPECIFICATIONS
NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE
TIGHTENED IN PLASTIC AREA
SEALANT
4. TIMING BELT
5. FUEL AND EMISSION CONTROL SYSTEM
6. WATER PUMP AND WATER HOSE
7. INTAKE AND EXHAUST MANIFOLD
8. ROCKER ARMS AND CAMSHAFT
9. CYLINDER HEAD AND VALVES
10. OIL PUMP AND OIL PAN
11. PISTON AND CONNECTING ROD
12. CRANKSHAFT, CYLINDER BLOCK
E
Mitsubishi Motors Corporation
ENGINE
4G1 SERIES
CONTENTS
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Nov. 1995
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PWEE9520
11A-0-1
11A-0-3
11A-1-1
11A-1-1
11A-1-3
11A-1-4
11A-1-6
11A-1-6
11A-1-7
11A-2-1
11A-3-1
11A-4-1
11A-5-1
11A-6-1
11A-9-1
11A-10-1
11A-11-1
11A-12-1

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Summary of Contents for Mitsubishi 4G1 series

  • Page 1 11A-0-1 ENGINE 4G1 SERIES CONTENTS GENERAL INFORMATION 11A-0-3 ......... . .
  • Page 2 11A-0-2 NOTES Mitsubishi Motors Corporation Nov. 1995 PWEE9520...

  • Page 3: General Information

    11A-0-3 4G1 ENGINE (E - W) - General Information GENERAL INFORMATION Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 4 11A-0-4 4G1 ENGINE (E - W) - General Information Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 5 Pressure feed, full-flow filtration 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 Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Revised...
  • Page 6 Pressure feed, full-flow filtration 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 Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Revised...
  • Page 7 Pressure feed, full-flow filtration 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 Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Added...
  • Page 8 NOTES...
  • Page 9 Valve stem projec- SOHC 12-VALVE Intake 43.70 44.20 tion mm Exhaust 43.30 43.80 SOHC 16-VALVE Intake 53.21 53.71 Exhaust 54.10 54.60 DOHC Intake 48.80 49.30 Exhaust 48.70 49.20 Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Revised...
  • Page 10 Piston pin press-in load (at room temperature) N 4,900 - 14,700 Crankshaft pin oil clearance mm 0.02 - 0.04 Connecting rod big end side clearance mm 0.10 - 0.25 Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A...
  • Page 11 Cylinder block overall height mm Cylinder block cylindricity mm 0.01 Cylinder block I. D. mm 4G13 71.0 4G15 75.5 4G18 76.0 Piston-to-cylinder clearance mm 0.02 - 0.04 Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Added...

  • Page 12: Specifications

    11A-1-2b 4G1 ENGINE (E - W) - Specifications Intentionally blank Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Mitsubishi Motors Corporation Dec. 1998 Dec. 1998 PWEE9520-A PWEE9520-A Added Added...

  • Page 13: Rework Dimensions

    DOHC Intake 0.3 O. S. 31.300 - 31.325 0.6 O. S. 31.600 - 31.625 Exhaust 0.3 O. S. 27.800 - 27.825 0.6 O. S. 28.100 - 28.125 Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Revised...

  • Page 14: Torque Specifications

    Air temperature sensor EGR valve Water pump Water inlet fitting Water inlet pipe assembly Water inlet pipe Fitting (Rear wheel drive) Water outlet fitting (Rear wheel drive) Thermostat case Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Revised...
  • Page 15 Transmission stay Oil pan Drain plug Oil screen Front case Relief plug Oil pump cover Pistons and connecting rods Connecting rod nut 17 + 90_ to 100_ Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Revised...
  • Page 16 4G1 ENGINE (E - W) - Specifications Item Crankshaft and cylinder block Flywheel Drive plate Rear plate Bell housing cover Rear oil seal case Bearing cap bolt Oil pressure switch Knock sensor Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Added...
  • Page 17 11A-1-5b 4G1 ENGINE (E - W) - Specifications Intentionally blank Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Mitsubishi Motors Corporation Dec. 1998 Dec. 1998 PWEE9520-A PWEE9520-A Added Added...
  • Page 18 SEALANTS Item Specified sealant Quantity Water pump Mitsubishi Genuine Part No. MD970389 or equivalent As required Thermo valve Mitsubishi Genuine Part No. MD970389 or equivalent As required Engine coolant temperature sensor 3M Nut Locking Part No. 4171 or equivalent...
  • Page 19 (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 Nov. 1995 PWEE9520...
  • Page 20 NOTES...

  • Page 21: Special Tools

    Installation of camshaft oil seal installer MD998715 Pin (2-off) Holding camshaft sprocket when loosening or tightening bolt (used with MB990767) MD998727 Oil pan remover Removal of oil pan MD998735 Valve spring com- Compression of valve springs pressor Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 22 Locking flywheel in fixed position MB991671 Valve stem Press-fitting of valve stem seals installer (SOHC 16-VALVE, DOHC) MB991653 Cylinder head bolt Removal and installation of cylinder head bolt wrench (10) Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Revised...
  • Page 23 NOTE 6. Alternator brace *: For details of adjustment, refer to the relevant model’s 7. Alternator chassis workshop manual. AA" "BA 8. Crankshaft bolt 9. Crankshaft pulley Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Revised...
  • Page 24 NOTE 6. Alternator brace *: For details of adjustment, refer to the relevant model’s 7. Alternator chassis workshop manual. AA" "BA 8. Crankshaft bolt 9. Crankshaft pulley Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Added...
  • Page 25 15. Cam position sensing cylinder 7. Alternator NOTE AA" "BA 8. Crankshaft bolt *: For details of adjustment, refer to the relevant model’s 9. Crankshaft pulley chassis workshop manual. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Added...
  • Page 26 4. Drive belt* 13. O-ring 5. Water pump pulley NOTE 6. Alternator brace *: For details of adjustment, refer to the relevant model’s 7. Alternator chassis workshop manual. AA" "BA 8. Crankshaft bolt 9. Crankshaft pulley Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 27 Alignment mark "BA CRANKSHAFT BOLT INSTALLATION (1) Lock the flywheel or drive plate in position using the special tool shown in the illustration, then tighten the crankshaft MD998781 bolts. Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 28 NOTES...

  • Page 29: Timing Belt

    "BA 5. Timing belt tensioner 11. Camshaft sprocket 6. Crankshaft angle sensor 12. Engine support bracket <Rear wheel drive> 13. Timing belt rear cover Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Mitsubishi Motors Corporation Dec. 1998 Dec. 1998...
  • Page 30 AA" "BA 4. Tensioner spring 11. Timing belt rear cover (lower) AA" "BA 5. Timing belt tensioner 12. Timing belt rear cover (right) 6. Idler pulley 13. Timing belt rear cover (left) 7. Crankshaft pulley Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 31 Cracked tooth base (6) Abnormal wear on the belt’s sides Rounded edge NOTE The sides of the belt are normal if they are sharp as if cut by a knife. Abnormal wear (exposed core wire) Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 32 (1) Lock the timing belt tensioner in the illustrated position. Timing belt tensioner (2) Fit one of the tensioner spring projections over the hooked portion of the timing belt tensioner and fit the tensioner onto the oil pump case. Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 33 This procedure utilizes the camshaft’s driving torque to apply tension evenly to the timing belt. Be sure to turn the crankshaft as described above. Do not turn the crankshaft in reverse. (6) Tighten the tensioner pulley mounting bolts. Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 34 This procedure utilizes the camshaft’s driving torque to apply tension evenly to the timing belt. Be sure to turn the crankshaft as described above. Do not turn the crankshaft in reverse. (9) Tighten the tensioner pulley mounting bolts. Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 35 7. Carburetor 2. Fuel hose 8. Upper gasket 3. Fuel pump 9. Spacer 4. Gasket 10. Lower gasket 5. Insulator 11. EGR valve (vehicles with automatic 6. Gasket transmission for GCC only) 12. Gasket Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 36 2. Gasket 9. O-ring 3. Fuel return pipe 10. Grommet "BA 4. Fuel pressure regulator 11. Delivery pipe 5. O-ring 12. EGR valve 6. Insulator 13. Gasket 7. Insulator 14. Air temperature sensor 15. Gasket Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 37 9. O-ring 3. Fuel return pipe 10. Grommet "BA 4. Fuel pressure regulator 11. Delivery pipe 5. O-ring 12. EGR valve 6. Insulator 13. Gasket 7. Insulator Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Added...
  • Page 38 11A-5-2b 4G1 ENGINE (E - W) - Fuel and Emission Control Systems Intentionally blank Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Added...
  • Page 39 9 Nm Removal steps 1. Throttle body assembly 7. Insulator 2. Gasket "AA 8. Injector 3. Fuel return pipe 9. O-ring "BA 4. Fuel pressure regulator 10. Grommet 5. O-ring 11. Delivery pipe 6. Insulator Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 40 (2) Check that the fuel pressure regulator rotates smoothly. If it does not rotate smoothly, the O-ring may be binding. If this occurs, remove the fuel pressure regulator, check the O-ring for damage, then re-insert the regulator into the delivery pipe. Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 41 "FA 4. Thermo valve (engines with EGR) "BA 11. Water inlet pipe "FA 5. Thermo valve "BA 12. O-ring "DA 6. Water temperature gauge unit "BA 13. O-ring 7. Water inlet fitting "AA 14. Water pump Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 42 "BA 9. Water inlet pipe "EA 3. Water temperature sensor "BA 10. O-ring "DA 4. Water temperature gauge unit "BA 11. O-ring 5. Water inlet fitting "AA 12. Water pump "CA 6. Thermostat 7. Thermostat case Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 43 "EA 3. Water temperature sensor "BA 10. O-ring "DA 4. Water temperature gauge unit "BA 11. O-ring 5. Water inlet fitting "AA 12. Water pump "CA 6. Thermostat 7. Thermostat case Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Added...
  • Page 44 "EA 3. Water temperature sensor 9. Gasket "DA 4. Water temperature gauge unit "BA 10. Water inlet pipe 5. Water outlet fitting "BA 11. O-ring 6. Gasket "AA 12. Water pump Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Added...
  • Page 45 "BA 9. Water inlet pipe "EA 3. Water temperature sensor "BA 10. O-ring "DA 4. Water temperature gauge unit "BA 11. O-ring 5. Water inlet fitting "AA 12. Water pump "CA 6. Thermostat 7. Thermostat case Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 46 (1) Apply a 3 mm bead of form-in-place gasket (FIPG) to the mounting surface. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent. "BA O-RING / WATER PIPE INSTALLATION (1) Replace the water inlet pipe O-rings with new ones, then apply water to the O-rings so that they can be inserted easily into the water pump and thermostat case.
  • Page 47 Water Pump and Water Hose "FA THERMO VALVE INSTALLATION (1) If the thermo valve is to be reused, apply the specified sealant to its thread. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent. Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 48 NOTES...

  • Page 49: Intake And Exhaust Manifolds

    30 Nm 17 Nm Removal steps 1. Engine hanger 5. Exhaust manifold cover 2. Intake manifold stay 6. Engine hanger 3. Intake manifold 7. Exhaust manifold 4. Intake manifold gasket 8. Exhaust manifold gasket Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 50 1. Engine hanger 6. Exhaust manifold cover 2. Intake manifold stay 7. Engine hanger 3. Intake manifold 8. Exhaust manifold 4. Intake manifold gasket 9. Exhaust manifold gasket 5. Oxygen sensor (vehicles for Hong Kong only) Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 51 8. Engine hanger 4. Intake manifold 9. Exhaust manifold cover 5. Intake manifold gasket 10. Exhaust manifold 6. Solenoid valve assembly <Without 11. Exhaust manifold gasket catalytic converter> Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Added...
  • Page 52 9. Reed valve 4. Intake manifold gasket 10. Reed valve bracket “A” 5. Air hose 11. Reed valve bracket “B” 6. Exhaust manifold cover 12. Exhaust manifold Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation July 1999 PWEE9520-B Revised...
  • Page 53 29 Nm Removal steps 1. Engine hanger 6. Exhaust manifold cover 2. Intake manifold stay 7. Engine hanger 3. Intake manifold 8. Exhaust manifold 4. Intake manifold gasket 9. Exhaust manifold gasket 5. Oxygen sensor Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 54 Be sure to tighten each nut correctly to the specified torque. Pipe nut (exhaust manifold side) (5) Tighten the reed valve and bracket mounting bolts to the specified torque. (6) Tighten the pipe clamp bolt. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation July 1999 PWEE9520-B Added...
  • Page 55 NOTES...
  • Page 56 19. Rocker arm shaft "EA 9. Rocker arm and shaft assembly "CA 20. Adjusting screw "EA 10. Rocker arm and shaft assembly 21. Nut 11. Rocker arm A 22. Camshaft Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Revised...
  • Page 57 "CA 19. Adjusting screw "FA 9. Oil seal 20. Nut "EA 10. Rocker arms and rocker arm shaft 21. Camshaft "EA 11. Rocker arms and rocker arm shaft Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A...
  • Page 58 11A-8-1b 4G1 ENGINE (E - W) - Rocker Arms and Camshafts Intentionally blank Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Added...
  • Page 59 5. Oil filler cap "AA 13. Camshaft "HA 6. Rocker cover 14. Roller rocker arm 7. Rocker cover gasket A 15. Lash adjuster 8. Rocker cover gasket B Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Revised...
  • Page 60 (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 Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Revised...
  • Page 61 Make sure the oil hole in the side of the body is pointing toward container B. Do not point the oil hole at yourself or other people. MD998442 Diesel fuel Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998...
  • Page 62 0.5 mm), measure the time taken for it to move downward by a further 1 mm. Lash adjuster Standard value: 3 - 20 second/1 mm [with diesel fuel at 15 - 20_C (59 - 68_F)] Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Revised...
  • Page 63 Slit installation. Ensure that the intake-side and exhaust-side camshafts are not reversed. NOTE There is a 4 mm-wide slot in the rear end of the exhaust-side camshaft. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Revised...
  • Page 64 NOTE The rocker arm shaft for intake valves have eight oil holes. (2) Place the section of the shaft with the oil holes toward Oil holes the cylinder head. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998...
  • Page 65 MD998713 DOHC MD998713 "GA SEMI-CIRCULAR PACKING INSTALLATION (1) Apply the specified sealant to the area shown. Sealant Specified sealant: 3M ATD Part No. 8660 or equivalent DEN0053 Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Added...
  • Page 66 (9) With the engine mounted on vehicle, warm up the engine. Then, check for valve clearance on hot engine and adjust if necessary. Standard value: on hot engine Intake 0.20 mm Exhaust 0.25 mm Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A...
  • Page 67 (9) With the engine mounted on vehicle, warm up the engine. Then, check for valve clearance on hot engine and adjust if necessary. Standard value: on hot engine Intake 0.20 mm Exhaust 0.25 mm Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A...

  • Page 68: Cylinder Head And Valves

    19. Intake valve seat (primary) AB" "CA 9. Retainer lock 20. Intake valve seat (secondary) 10. Valve spring retainer 21. Exhaust valve seat "BA 11. Valve spring 22. Cylinder head Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Revised...
  • Page 69 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 Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Added...
  • Page 70 11A-9-1b 4G1 ENGINE (E - W) - Cylinder Head and Valves Intentionally blank Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Added...
  • Page 71 16. Intake valve guide 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 Nov. 1995 PWEE9520...
  • Page 72 AA" CYLINDER HEAD BOLT REMOVAL MB991653 DOHC MB991653 AB" RETAINER LOCK REMOVAL SOHC MD998772 (1) Tag removed valves, springs, and other components, noting their cylinder numbers and locations to facilitate reassembly. Store these components safely. DOHC MD998772 MD998735 Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 73 (2) If the margin is less than specified, replace the valve. Contact (must be in center of Standard value: face) Margin Intake 1.0 mm Exhaust: 1.5 mm Limit: Intake: 0.5 mm 6EN0542 Exhaust: 1.0 mm Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Revised...
  • Page 74 49.1 48.6 1EN0264 (2) Measure the squareness of the spring. If the measurement exceeds the specified limit, replace the spring. Standard value: 2_ or less Limit: 4_ Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Revised...
  • Page 75 Standard mm Limit mm SOHC Intake 43.70 44.20 12-VALVE Exhaust 43.30 43.80 SOHC Intake 53.21 53.71 16-VALVE Exhaust 54.10 54.60 DOHC Intake 48.80 49.30 Exhaust 48.70 49.20 Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Revised...
  • Page 76 (3) Prevent galling of the cylinder head bore by cooling the valve seat with liquid nitrogen before press-fitting it. (4) Correct the valve seat to achieve the specified width and angle (refer to VALVE SEAT CORRECTION SERVICE POINTS). Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998...
  • Page 77 2. The valve stem seal must be installed using the correct special tool. Incorrect installation could result in oil leaking past the valve guide. SOHC 16-VALVE, DOHC MB991671 Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A...
  • Page 78 Replace the bolt if this measurement exceeds the limit. Limit: 103.2 mm (2) Fit the washer as shown. (3) Apply engine oil to the bolt’s thread and washer. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998...
  • Page 79 90_, they may not hold the cylinder head with sufficient strength. If the bolts are tightened by an angle exceeding 90_, completely remove them and carry out the installation procedure again. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998...

  • Page 80: Removal And Installation

    AA" "CA 5. Oil pan 15. Oil pump outer rotor 6. Oil screen 16. Oil pump inner rotor 7. Gasket 8. Relief valve 9. Relief valve spring Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Revised...
  • Page 81 (3) Check the side clearance using a straight edge and thickness gauge. Standard value: 0.04 - 0.10 mm (4) Check the body clearance using a thickness gauge. Standard value: 0.04 - 0.10 mm Limit: 0.35 mm Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 82 (2) Apply a 3 mm bead of form-in-place gasket to the entire circumference of the oil pan flange. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent. "BA FRONT OIL SEAL INSTALLATION (1) Place the special tool on the crankshaft’s front end and MD998305 apply engine oil to the its outer circumference.
  • Page 83 14 Nm. Caution The oil filter must be tightened using a commercially available filter wrench. If the filter is tightened by hand only, it will be insufficiently torqued, resulting in oil leaks. Mitsubishi Motors Corporation Nov. 1995 PWEE9520...

  • Page 84: Pistons And Connecting Rods

    "EA 3. Connecting rod bearing AB" "AA 9. Piston pin "DA 4. Piston and connecting rod assem- 10. Piston 11. Connecting rod 5. Connecting rod bearing 12. Bolt "CA 6. Piston ring No. 1 Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 85 Push in with piston No. 2 ring 0.35 - 0.50 Oil ring SOHC 0.20 - 0.50 12-VALVE, DOHC SOHC 0.10 - 0.40 16-VALVE End gap Piston ring Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Revised...
  • Page 86 A, piston pin, and Push Rod, starting with guide A. (7) Screw guide B into guide A. Leave a gap between the 3 mm two guides of 3 mm plus the value (L) calculated in step (2). Guide B Guide A Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 87 Caution Do not fit side rails using a piston ring expander since they may break. (3) After installing the side rails, check that they move 7EN0451 smoothly in both directions. Mitsubishi Motors Corporation Nov. 1995 PWEE9520...
  • Page 88 Do not strike the piston hard since the piston rings may break and the crank pin may be nicked. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec.
  • Page 89 Crankshaft Connecting rod identification Bearing identification color identification mark mark I, Yellow White None Yellow II, None White None Yellow III, White White None Yellow Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Revised...
  • Page 90 (6) Make paint marks on the bolts 90 to 100_ clockwise from Bolt the paint marks on the nuts. (7) Turn the nuts until their paint marks are aligned with the paint marks on the bolts. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998...
  • Page 91 1. If the nuts are turned by less than 90_, the cap may not be held on with sufficient strength. 2. If the nuts are turned by more than 100_, loosen them completely and carry out the tightening procedure again. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998...

  • Page 92: Crankshaft And Cylinder Block

    132 Nm 10 Nm 18 Nm 11 Nm 132 Nm 10 Nm 132 Nm 51 Nm Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Mitsubishi Motors Corporation Dec. 1998 Dec. 1998 PWEE9520-A PWEE9520-A Revised Revised...
  • Page 93 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 Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec.
  • Page 94 Standard value: 0.05 mm Limit: 0.1 mm (3) Check the cylinder walls for cracks and seizure marks. If defects are evident, bore all the cylinders to oversize or replace the cylinder block. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998...
  • Page 95 3M ATD Part No. 8660 or equivalent Caution Apply sealant 1. Apply sealant such that none is squeezed out past end of the thread. 2. Do not over-tighten the oil pressure switch. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A...
  • Page 96 (1) Select bearings according to the crankshaft identification marks or color codes, referring to the following table. If they are not identifiable, measure the crankshaft journals and choose bearings to match the measurements. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec.
  • Page 97 (5) The lower bearings are all grooveless. Lower bearing (Nos. 1, 2, 4, and 5) 1, 2, 4, and 5) Grooveless Upper and lower bearings (center) (No. 3) Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Added...
  • Page 98 Limit: 0.25 mm "DA REAR OIL SEAL INSTALLATION Oil seal MD998011 (1) Press-fit the rear oil seal using the special tool shown in the illustration. Oil seal case Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Dec. 1998 PWEE9520-A Added...
  • Page 99 NOTES...

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