Mitsubishi 4G1 Series General Information Manual
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Mitsubishi 4G1 Series General Information Manual

Mitsubishi 4G1 Series General Information Manual

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See also: Workshop Manual , Service Manual
1. SPECIFICATIONS
NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE
TIGHTENED IN PLASTIC AREA
SEALANT
7. INTAKE AND EXHAUST MANIFOLDS
8a. ROCKER ARMS AND CAMSHAFTS (GDI)
9. CYLINDER HEAD AND VALVES
10. OIL PUMP AND OIL PAN
11. PISTONS AND CONNECTING RODS
12. CRANKSHAFT AND CYLINDER BLOCK
E
E
Mitsubishi Motors Corporation
Mitsubishi Motors Corporation
ENGINE
4G1 SERIES
CONTENTS
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Nov. 1995
Aug. 2000
PWEE9520-D
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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-5a-1
11A-5b-1
11A-6-1
11A-7-1
11A-7a-1
11A-8-1
11A-8a-1
11A-9-1
11A-10-1
11A-11-1
11A-12-1
Revised

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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 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 Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Feb. 2001 PWEE9520-E Revised...
  • Page 7 Water pump type Centrifugal impeller Centrifugal impeller Centrifugal impeller Centrifugal impeller type type type type : Special low-emission engines on vehicles for Australia Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Feb. 2001 PWEE9520-E Revised...
  • Page 8 Cooling system Water-cooled, forced circulation Water-cooled, forced circulation Water pump type Centrifugal impeller type Centrifugal impeller type : SPACE STAR for Europe : LANCER for General Export Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Feb. 2001 PWEE9520-E Revised...

  • Page 9: Specifications

    : 2001 model front wheel drive vehicles for Europe : 2001 model front wheel drive vehicles for General Export : 2002 model front wheel drive vehicles for Europe : SOHC 16-VALVE MPI for Europe Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Feb.
  • Page 10 Oil pump and oil pan Oil pump tip clearance mm 0.06 - 0.18 Oil pump side clearance mm 0.04 - 0.10 Oil pump body clearance mm 0.10 - 0.18 0.35 Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Apr. 2000 PWEE9520-C Revised...
  • Page 11 Cylinder block overall height mm Cylinder bore cylindricity mm 0.01 Cylinder bore 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 Aug. 2000 PWEE9520-D Revised...
  • Page 12 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

    0.6 O. S. 28.600–28.621 – 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 Feb. 2001 PWEE9520-E Revised...

  • Page 14: Torque Specifications

    Hose clamp bolt Fuel pump bolt (SOHC 12-VALVE–CARBURETOR) Fuel pump bolt (SOHC 16-VALVE–CARBURETOR) Breather tube clamp bolt Carburetor bolt Air temperature sensor Cover bolt (Except M8 × 16) Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Apr. 2003 PWEE9520-G Revised...
  • Page 15 11A-1-4a 4G1 ENGINE (E–W) – Specifications Item Cover bolt (M8 × 16) EGR valve bolt Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Apr. 2003 PWEE9520-G Revised...
  • Page 16 11A-1-4b 4G1 ENGINE (E–W) – Specifications Intentionally blank Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2001 PWEE9520-F Added...
  • Page 17 Intake manifold bolt, nut Intake manifold stay bolt <MPI> (M8) Intake manifold stay bolt <MPI> (M10) Intake manifold stay bolt <carburetor> Engine hanger bolt Exhaust manifold cover bolt Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D...
  • Page 18 Tighten to 49 Nm, then completely loosen and retighten as described. Oil pump and oil pan Transmission stay bolt Oil pan bolt (M6) Oil pan bolt (M8) Drain plug Oil screen bolt Front case bolt Relief plug Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 19 Drive plate bolt <GDI> Rear plate bolt Bell housing cover bolt Rear oil seal case bolt Bearing cap bolt 34 + 30_ to 34_ Oil pressure switch Knock sensor Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 20 SEALANTS Item Specified sealant Quantity Cam position sensor support Mitsubishi Genuine Part No. MD970389 or equivalent As required Water pump Mitsubishi Genuine Part No. MD970389 or equivalent As required Thermo valve Mitsubishi Genuine Part No. MD970389 or equivalent...
  • Page 21 (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 22 NOTES...

  • Page 23: Special Tools

    MD998304 Crankshaft front oil Installation of crankshaft front oil seal seal installer MD998305 Crankshaft front oil Guide for installation of crankshaft front oil seal seal guide Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 24 Circular packing Installing of circular packing installer MD998772 Valve spring com- Compression of valve springs pressor MD998780 Piston pin setting Removal and press-fitting of piston pins tool Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 25 Locking flywheel in fixed position MD998306 Crankshaft front oil Installation of crankshaft front oil seal seal installer MB991962 Crankshaft front oil Guide for installation of crankshaft oil seal seal guide Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Apr. 2003 PWEE9520-G Revised...
  • Page 26 6. Alternator brace *: For details of adjustment, refer to the relevant model’s 7. Alternator chassis workshop manual. AA" "BA 8. Crankshaft bolt "BA 9. Crankshaft pulley Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Apr. 2003 PWEE9520-G Revised...
  • Page 27 6. Alternator brace *: For details of adjustment, refer to the relevant model’s 7. Alternator chassis workshop manual. AA" "BA 8. Crankshaft bolt "BA 9. Crankshaft pulley Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Apr. 2003 PWEE9520-G Revised...
  • Page 28 AA" "BA 8. Crankshaft bolt 16. Cam position sensing cylinder "BA 9. Crankshaft pulley NOTE *: For details of adjustment, refer to the relevant model’s chassis workshop manual. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Apr. 2003 PWEE9520-G...
  • Page 29 15. Cam position sensing cylinder 7. Alternator NOTE AA" "BA 8. Crankshaft bolt *: For details of adjustment, refer to the relevant model’s "BA 9. Crankshaft pulley chassis workshop manual. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Feb. 2001 PWEE9520-E Revised...
  • Page 30 6. Alternator brace *: For details of adjustment, refer to the relevant model’s 7. Alternator chassis workshop manual. AA" "BA 8. Crankshaft bolt "BA 9. Crankshaft pulley Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Feb. 2001 PWEE9520-E Revised...
  • Page 31 5. Drive belt 15. Cam position sensing cylinder 6. Water pump pulley 7. Alternator brace 8. Alternator assembly AA" "BA 9. Crankshaft bolt "BA 10. Crankshaft pulley Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Feb. 2001 PWEE9520-E Revised...
  • Page 32 "CA CAM 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 MD970389 equivalent Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2001 PWEE9520-F Revised...

  • Page 33: Timing Belt

    "CA 5. Timing belt tensioner 12. Camshaft sprocket 6. Crankshaft angle sensor 13. Engine support bracket <Without Distributor> 14. Timing belt rear cover "BA 7. Crankshaft sprocket Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Feb. 2001 PWEE9520-E Revised...
  • Page 34 "CA 4. Tensioner spring AB" "AA 10. Camshaft sprocket bolt "CA 5. Timing belt tensioner 11. Camshaft sprocket 6. Crankshaft angle sensor 12. Bracket <Without Distributor> 13. Engine support bracket Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Feb. 2001 PWEE9520-E Revised...
  • Page 35 AA" "CA 5. Timing belt tensioner 12. Timing belt rear cover (lower) 6. Idler pulley 13. Timing belt rear cover (right) "BA 7. Crankshaft sprocket 14. Timing belt rear cover (left) Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Feb. 2001 PWEE9520-E...
  • Page 36 AB" "AA 13. Camshaft sprocket bolt 5. Timing belt tensioner 6. Idler pulley 14. Camshaft sprocket 7. Crank angle sensor 15. Timing belt rear upper cover "BA 8. Crankshaft sprocket Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Feb. 2001 PWEE9520-E Revised...
  • Page 37 (3) Loosen the timing belt tensioner securing bolt. (4) Move the timing belt tensioner in the direction shown Securing bolt to remove the timing belt. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000...
  • Page 38 2. TENSIONER PULLEY AND IDLER PULLEY (1) Check that the pulleys turn smoothly without play and are not abnormally noisy. Replace either or both of the pulleys if necessary. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000...
  • Page 39 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 Mitsubishi Motors Corporation Feb. 2001...
  • Page 40 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 Mitsubishi Motors Corporation Feb.
  • Page 41 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 Mitsubishi Motors Corporation Feb.
  • Page 42 (if the timing belt is reused), put the timing belt over the inlet camshaft sprocket. After that, secure the belt at the position shown with a paper clip, etc. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Feb.
  • Page 43 Observe the number of turns of the sprocket mentioned above. Do not turn the crankshaft sprocket counterclockwise direction. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Feb.
  • Page 44 10. Spacer 4. Fuel pump 11. Lower gasket 5. Gasket 12. EGR valve <engine with EGR> 6. Insulator 13. Cover <engine without EGR> 7. Gasket 14. Gasket Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 45 2. Fuel hose 9. Upper gasket 3. Hose clamp 10. Spacer 4. Fuel pump 11. Lower gasket 5. Gasket 12. Cover 6. Insulator 13. Gasket 7. Gasket Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Added...
  • Page 46 11A-5-1b 4G1 ENGINE (E–W) – Fuel and Emission Control Systems Intentionally blank Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Added...
  • Page 47 "BA 6. Fuel pressure regulator 16. Gasket 7. O-ring 17. Air temperature sensor (Up to 8. Insulator 2000 model) 9. Insulator 18. Gasket (Up to 2000 model) "AA 10. Injector Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Apr. 2003 PWEE9520-G Revised...
  • Page 48 2. Throttle body assembly 9. O-ring 3. Gasket 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 Apr. 2003 PWEE9520-G Revised...
  • Page 49 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 Apr. 2003 PWEE9520-G Revised...
  • Page 50 7. Insulator "AA 8. Injector 2. Gasket 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 Mitsubishi Motors Corporation Apr. 2003 PWEE9520-G Revised...
  • Page 51 (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 52: Removal And Installation

    6. O-ring 15. P.C.V. hose 7. Power plant stay, right AA" "AA 16. Intake manifold "BA 8. Intake manifold stay 17. Gasket 9. Water hose 18. Insulator Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Added...
  • Page 53 "BA INTAKE MANIFOLD STAY INSTALLATION Ensure that the intake manifold stay is in close contact with the intake manifold and the cylinder block boss. After that, tighten the bolts to the specified torque. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug.
  • Page 54 1. Oxygen sensor 2. Exhaust manifold cover 3. Exhaust manifold bracket B 4. Exhaust manifold 5. Exhaust manifold gasket 6. Exhaust manifold bracket A 7. Power plant stay, left Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Added...
  • Page 55 "BA 11. Water inlet pipe "FA 5. Thermo valve "BA 12. O-ring "DA 6. Engine coolant temperature gauge "BA 13. O-ring unit "AA 14. Water pump 7. Water inlet fitting Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 56 3. Water hose 9. Gasket "FA "BA 10. Water inlet pipe 4. Thermo valve "DA 5. Engine coolant temperature gauge "BA 11. O-ring unit "BA 12. O-ring 6. Water inlet fitting "AA 13. Water pump Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Added...
  • Page 57 11A-6-1b 4G1 ENGINE (E - W) - Water Pump and Water Hose Intencionalmente en blanco Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Added...
  • Page 58 "EA 3. Engine coolant temperature sensor "BA 10. O-ring "DA 4. Engine coolant temperature gauge "BA 11. O-ring unit "AA 12. Water pump 5. Water inlet fitting "CA 6. Thermostat 7. Thermostat case Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 59 "BA 10. O-ring "DA 4. Engine coolant temperature gauge "BA 11. O-ring unit "AA 12. Water pump 5. Water inlet fitting "CA 6. Thermostat 7. Thermostat case Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 60 9. Gasket "DA 4. Engine coolant temperature gauge "BA 10. Water inlet pipe unit "BA 11. O-ring 5. Water outlet fitting "AA 12. Water pump 6. Gasket Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 61 "BA 10. O-ring "DA 4. Engine coolant temperature gauge "BA 11. O-ring "AA 12. Water pump unit 5. Water inlet fitting "CA 6. Thermostat 7. Thermostat case Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Apr. 2003 PWEE9520-G Added...
  • Page 62 11A-6-2d 4G1 ENGINE (E–W) – Water Pump and Water Hose Intentionally blank Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Apr. 2003 PWEE9520-G Added...
  • Page 63 "BA 10. O-ring "DA 4. Engine coolant temperature gauge "BA 11. O-ring unit "AA 12. Water pump 5. Water inlet fitting "CA 6. Thermostat 7. Thermostat case Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 64 2. Water inlet fitting "GA 6. Thermostat housing "CA 3. Thermostat "BA 7. Water inlet pipe "DA 4. Engine coolant temperature gauge "BA 8. O-ring unit "AA 9. Water pump Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 65 (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 66 "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. 1EN0511 "GA THERMOSTAT HOUSING INSTALLATION (1) Remove the old liquid gasket from the cylinder head (thermostat housing mounting surface) and the thermostat housing.

  • Page 67: Intake And Exhaust Manifolds

    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 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 68 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 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 69 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 Aug. 2000 PWEE9520-D Revised...
  • Page 70 2. Intake manifold stay 7. Exhaust manifold cover 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 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 71 6. Intake manifold gasket (Up to 2003 model) 7. Solenoid valve assembly 16. Power plant stay, left 8. Solenoid valve assembly (From 2004 model) 9. Oxygen sensor Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Apr. 2003 PWEE9520-G Revised...
  • Page 72 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 Aug. 2000 PWEE9520-D Revised...
  • Page 73 9. Exhaust manifold cover 4. Intake manifold stay 10. Exhaust manifold 5. Solenoid valve assembly 11. Exhaust manifold gasket 6. Intake manifold 12. Power plant stay left <CVT> Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Added...
  • Page 74 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 75 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 76 "AA 20. O-ring "DA 9. Fuel pressure sensor "AA 21. Backup ring "DA 10. O-ring 22. Injector "DA 11. Backup ring 23. Delivery pipe 12. Harness bracket Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Added...
  • Page 77 SENSOR INSTALLATION (1) Install the backup ring on the fuel pressure sensor with the inside cut surface facing the direction shown in the illustration. Cut surface Backup ring Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D...
  • Page 78 The torque variation of the four bolts should be within 2 Nm. Caution Observe the tightening order. Failure to observe the specified torques and tightening order will cause leakage, etc. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D...
  • Page 79 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 80 "CA 19. Adjusting screw "FA 9. Oil seal 20. Nut "EA 10. Rocker arms and rocker arm shaft, 21. Camshaft intake "EA 11. Rocker arms and rocker arm shaft, exhaust Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 81 8. Oil seal "DA 17. Rocker arm shaft "FA 9. Oil seal "IA 18. Lash adjuster AA" "EA 10. Rocker arms and rocker arm shaft, 19. Camshaft intake Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 82 5. Oil filler cap "AA 13. Camshaft "HA 6. Rocker cover 14. Roller rocker arm 7. Rocker cover gasket A AB" "JA 15. Lash adjuster 8. Rocker cover gasket B Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 83 Set special tool MD998443 to prevent the lash adjuster from coming free and falling to the floor. MD998443 AB" LASH ADJUSTER REMOVAL Caution If the lash adjuster is re-used, clean the lash adjuster. (Refer to 11A-8-6.) Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Added...
  • Page 84 11A-8-2b 4G1 ENGINE (E - W) - Rocker Arms and Camshafts Intentionallyblank Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Added...
  • Page 85 To fill outside fuel to completely cover a lash adjuster when it is standing inside diesel fuel upright. Then, perform the following steps with each lash adjuster. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Feb. 2001 PWEE9520-E Revised...
  • Page 86 The steel ball spring is extremely weak, so the lash adjuster’s functionality may be lost if the air bleed Diesel fuel wire is pushed in hard. Wire or MD998442 Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Apr. 2000...
  • Page 87 (10)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 Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Apr.
  • Page 88 (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 Apr. 2000 PWEE9520-C Revised...
  • Page 89 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 Apr. 2000...
  • Page 90 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 Apr. 2000 PWEE9520-C Added...
  • Page 91 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 92 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 93 Standard value: on cold engine Intake 0.09 mm Exhaust 0.17 mm (5) While holding the adjusting screw with a screwdriver, tighten the lock nut. Thickness gauge Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 94 Standard value: on cold engine Intake 0.09 mm Exhaust 0.17 mm (5) While holding the adjusting screw with a screwdriver, tighten the lock nut. Thickness gauge Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 95 (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 Aug. 2000 PWEE9520-D...
  • Page 96 5. Oil filler cap 6. Inlet rocker cover "BA 15. Exhaust camshaft 7. Gasket 16. Roller rocker arm 8. Exhaust rocker cover AA" "AA 17. Lash adjuster 9. Gasket Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Added...
  • Page 97 (2) Apply liquid gasket to the five grooves on the bottom surface of the beam camshaft cap by squeezing it to a thickness of 3 mm. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent. NOTE Install the beam camshaft cap within 15 minutes of application of liquid gasket.
  • Page 98 MD998762 "EA OIL SEAL INSTALLATION Using the special tool, install the oil seal. MD998713 "FA P.C.V. VALVE INSTALLATION Install the P.C.V. valve with its nipple directed as shown. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D...
  • Page 99 NOTE Diesel fuel MD998442 If the plunger remains stiff or the mechanism appears otherwise abnormal, replace the lash adjuster. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Added...
  • Page 100 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 Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D...
  • Page 101 (10)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 Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug.

  • Page 102: 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 103 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 104 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 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 105 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 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 106 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 107 (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 108 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 109 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 Apr. 2000 PWEE9520-C Revised...
  • Page 110 46° - 46.5° 15° <GDI - Intake side> 0.9 - 1.3 mm 65° 44° 20° <GDI - Exhaust side> 0.9 - 1.3 mm 65° 44° 15° Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 111 (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 Aug. 2000...
  • Page 112 1. Valve stem seals cannot be reused. 2. The valve stem seal must be installed using the correct special tool. Incorrect installation could result in oil leaking past the valve guide. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug.
  • Page 113 (1) The valve spring, if excessively compressed, causes the bottom end of retainer to be in contact with the stem seal, and damage it. DOHC MD998772 MD998735 Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 114 Body color: Grayish green Body color: Gray Embossed identification NOTE Embossed identification symbol: SD symbol: None The valve stem seal differs between the intake and exhaust sides. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Added...
  • Page 115 AA" "CA 6. Oil pan 15. Oil pump cover 7. Oil screen 16. Oil pump outer rotor 8. Gasket 17. Oil pump inner rotor 9. Relief valve Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 116 AA" "CA 5. Oil pan 14. Oil pump cover 6. Oil screen 15. Oil pump outer rotor 7. Gasket 16. Oil pump inner rotor 8. Relief valve 9. Relief valve spring Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Added...
  • Page 117 AA" "CA 4. Oil pan 12. O-ring 5. Oil screen 13. Oil pump cover 6. Gasket 14. Outer rotor 7. Relief valve 15. Inner rotor 8. Relief valve spring Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Added...
  • Page 118 (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: 0.10 – 0.18 mm Limit: 0.35 mm Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Feb. 2001 PWEE9520-E...
  • Page 119 Part MD970389 equivalent. "DA DRAIN PLUG GASKET INSTALLATION (1) Replace the drain plug gasket with a new one. Fit the Oil pan side new gasket as shown. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Apr. 2003 PWEE9520-G Revised...
  • Page 120 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 Mitsubishi Motors Corporation Aug. 2000...

  • Page 121: 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 122 0.20 - 0.35 Push in with piston No. 2 ring 0.35 - 0.50 Oil ring 4G13 0.20 - 0.50 4G15 4G18 0.10 - 0.40 Piston ring End gap Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 123 (6) Apply engine oil to the outside of the piston pin. (7) Into the front-mark side of the piston, insert the Guide A, piston pin, and Push Rod, starting with guide A. Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Apr.
  • Page 124 Do not fit side rails using a piston ring expander since they may break. (3) After installing the side rails, check that they move smoothly in both directions. 7EN0451 Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Apr. 2003...
  • Page 125 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 Aug.
  • Page 126 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 127 (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 128 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 129: Crankshaft And Cylinder Block

    Apply engine oil to all 132 Nm moving parts before 10 Nm installation. 19 Nm 11 Nm 132 Nm 10 Nm 132 Nm 34 Nm + 30_ to 34_ Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised...
  • Page 130 The balance of the flexible flywheel is adjusted in the 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 Apr.
  • Page 131 "EA 7. Rear oil seal case AA" "AA 17. Oil pressure switch "DA 8. Rear oil seal 18. Knock sensor 9. Bearing cap bolt 19. Cylinder block "CA 10. Bearing cap Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Added...
  • Page 132 11A-12-2b 4G1 ENGINE (E - W) - Crankshaft and Cylinder Block Intentionallyblank Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Added...
  • Page 133 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 134 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 135 (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 136 (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 Feb. 2001 PWEE9520-E Revised...
  • Page 137 Limit: 0.25 mm "DA REAR OIL SEAL INSTALLATION Oil seal MD998011 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 Aug. 2000 PWEE9520-D Revised...
  • Page 138 (1) Apply liquid gasket to the rear oil seal case at the illustrated position if it has no pre-formed gasket attached. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent Caution Squeeze the liruid gasket uniformly so that there is no break in the gasket nor is there too much gasket.
  • Page 139 Service Bulletins Click on the applicable bookmark to select the Service Bulletin.
  • Page 140 SERVICE BULLETIN QUALITY INFORMATION ANALYSIS OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION SERVICE BULLETIN No.: MSB-01E11-502 Date 2002-02-26 <Model> <M/Y> Subject: CORRECTION TO 4G1 ENGINE BEARING (EC)COLT/LANCER 95-10 IDENTIFICATION MARKS (EC)SPACE STAR 95-10 (EC)PAJERO iO 95-10 ENGINE Group: Draft No.: 01EN502...
  • Page 141 3.Details: 11A-11-6 4G1 ENGINE (E-W) – Pistons and Connecting Rods ³E CONNECTING ROD BEARING INSTALLATION 4G13, 4G15 4G18 Color code positions No.1 No.4 No.1 No.4 No.3 No.3 No.2 No.2 Identification mark positions No.2 No.4 No.3 No.1 No.1 No.4 1EN0619 No.2 No.3 (1) Select bearings according to crankshaft and connecting rod Identification color...
  • Page 142 <Correct> To replace the one on previous page. Identification mark Identification color 1EN0920...
  • Page 143 11A-12-6 4G1 ENGINE (E-W) – Crankshaft and Cylinder Block Crankshaft journal Cylinder block Bearing bearing diameter Range Color code Identification mark Journal diameter mm Identification Identification mark mark or color Yellow 47.995 – 48.000 or Brown or None or Blue None 47.985 –...
  • Page 144 SERVICE PUBLICATION & TRAINING INTERNATIONAL AFTER-SALES DEPARTMENT . MITSUBISHI MOTORS CORPORATION SERVICE BULLETIN NO. : MSB–02E11–505 DATE : 2002–09–20 <MODEL> <M/Y> (EC)LANCER(CK0A) (EC)LANCER(CK0A) 95–05 95 05 (EC)SPACE 95–05 4G1 ENGINE CRANKSHAFT BOLT – CHANGE TO SUBJECT : STAR(DG0A) STAR(DG0A) TORQUE AND TIGHTENING PROCEDURE...
  • Page 145 Details: M12 CRANKSHAFT BOLT In order to prevent the crankshaft bolt from loosening and thereby improve reliability, an increased tightening torque has been established as follows: <Tightening torque> Tightening torque Current torque Current torque New torque New torque Type Type 125 N@m 132 N@m 132 N@m + (35 to 55°)
  • Page 146 <Tightening procedure> 1. Prevent the flywheel or drive plate from rotating using the special tool. MD998781 2. Clean the crankshaft bolt hole. Crankshaft pulley 3. Clean and degrease the crankshaft pulley. Degrease Crankshaft bolt NOTE Crankshaft Washer Degreasing is necessary to prevent lack of frictional coefficient on the mating surfaces due to presence of oil or grease.
  • Page 147 M14 CRANKSHAFT BOLT <Tightening torque> The specified tightening torque for the crankshaft bolt is 181 N@m. <Tightening procedure> 1. Prevent the flywheel or drive plate from rotating using the special tool. MD998781 2. Clean the crankshaft bolt hole. Crankshaft pulley 3.

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