1A-0-1 ENGINE 4G1 SERIES CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-0-3 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1 REWORK DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-3 TORQUE SPECIFICATIONS . . .
11A-0-2 NOTES E Mitsubishi Motors Corporation Nov.
4G1 ENGINE (E - W) - General Information GENERAL INFORMATION E Mitsubishi Motors Corporation Nov.
11A-0-4 E Mitsubishi Motors Corporation 4G1 ENGINE (E - W) - General Information Nov.
4G1 ENGINE (E - W) - General Information 11A-0-5 Descriptions 4G13 12-VALVE- CARBURETOR 4G13 12-VALVE- MPI Type In-line OHV, SOHC In-line OHV, SOHC Number of cylinders 4 4 Combustion chamber Pentroof type Pentroof type Total displacement dm3 1,299 1,299 Cylinder bore mm 71.0 71.0 Piston stroke mm 82.0 82.0 Compression ratio 9.5 9.
11A-0-6 4G1 ENGINE (E - W) - General Information Descriptions 4G13 16-VALVE- MPI 4G18 16-VALVE- MPI Type In-line OHV, SOHC In-line OHV, SOHC Number of cylinders 4 4 Combustion chamber Pentroof type Pentroof type Total displacement dm3 1,299 1,584 Cylinder bore mm 71.0 76.0 Piston stroke mm 82.0 87.3 Compression ratio 10 9.
4G1 ENGINE (E - W) - General Information 11A-0-7 Descriptions 4G15- CARBURETTOR 4G15- MPI Type In-line OHV, SOHC In-line OHV, DOHC Number of cylinders 4 4 Combustion chamber Semi spherical type Pentroof type Total displacement dm3 1,468 1,468 Cylinder bore mm 75.5 75.5 Piston stroke mm 82.0 82.0 Compression ratio 9.0 9.
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11A-1-1 4G1 ENGINE (E - W) - Specifications 1. SPECIFICATIONS SERVICE SPECIFICATIONS Item Standard Limit Intake (primary) 38.78 38.28 Intake (secondary) 38.78 38.28 Exhaust 39.10 38.60 Intake 36.99 36.49 Exhaust 36.85 36.35 Intake 34.67 38.28 Exhaust 34.26 38.60 SOHC 45.93 - 45.94 - DOHC 25.95 - 25.97 - Flatness of cylinder head gasket surface mm 0.05 or less - Cylinder head gasket surface grinding limit (including grinding of cylinder block gasket surface) mm - 0.
11A-1-2 4G1 ENGINE (E - W) - Specifications Item Standard Limit Intake 100.75 100.25 Exhaust 101.05 105.55 Intake 111.56 111.06 Exhaust 114.71 114.21 Intake 106.35 105.85 Exhaust 106.85 106.35 Intake 46.1 45.6 Exhaust 46.8 46.3 SOHC 16-VALVE 50.9 50.4 DOHC 49.1 48.6 Intake 226/40.0 - Exhaust 284/39.6 - SOHC 16-VALVE 216/44.2 - DOHC 177/40.0 - Valve spring squareness 2_ 4_ Valve seat contact width mm 0.9 - 1.3 - SOHC 12-VALVE 6.6 - SOHC 16-VALVE 5.
A-1-2a 4G1 ENGINE (E - W) - Specifications Item Standard Limit Crankshaft end play mm 0.05 - 0.18 0.25 Crankshaft journal diameter mm 48.0 - Crankshaft pin diameter mm 42.0 - Crankshaft journal oil clearance mm 0.02 - 0.04 0.1 Cylinder block gasket surface flatness mm 0.05 or less - Cylinder block gasket surface grinding limit (including grinding of cylinder head gasket surface) mm - 0.2 Cylinder block overall height mm 256 - Cylinder block cylindricity mm 0.01 - 4G13 71.
11A-1-2b 4G1 ENGINE (E - W) - Specifications Intentionally blank E Mitsubishi Motors Corporation Nov. Dec.
11A-1-3 4G1 ENGINE (E - W) - Specifications REWORK DIMENSIONS Item Standard Limit 0.05 O. S. 12.050 - 12.068 - 0.25 O. S. 12.250 - 12.268 - 0.50 O. S. 12.500 - 12.518 - 0.05 O. S. 10.550 - 10.568 - 0.25 O. S. 10.750 - 10.768 - 0.50 O. S. 11.000 - 11.018 - 0.05 O. S. 10.550 - 10.568 - 0.25 O. S. 10.750 - 10.768 - 0.50 O. S. 11.000 - 11.018 - 0.3 O. S. 27.300 - 27.325 - 0.6 O. S. 27.600 - 27.625 - 0.3 O. S. 32.300 - 32.325 - 0.6 O. S. 32.600 - 32.625 - 0.3 O. S. 35.
11A-1-4 4G1 ENGINE (E - W) - Specifications TORQUE SPECIFICATIONS Item Nm Alternator and ignition system Water pump pulley bolt 9 Alternator brace (alternator side) 22 Alternator brace (tightened with water pump) 23 Alternator pivot bolt 44 Oil level gauge guide 23 Crankshaft bolt 125 Spark plug 25 Distributor 11 Ignition coil 10 Camshaft position sensor 9 Camshaft position sensor support 13 Camshaft position sensing cylinder 21 Timing belt Timing belt cover 11 Timing belt tens
4G1 ENGINE (E - W) - Specifications Item Nm Thermo valve 27 Water temperature gauge unit 11 Water temperature sensor 29 Water pump 13 11A-1-5 Exhaust manifold and intake manifold Boost sensor 5 Solenoid valve assembly 9 Intake manifold 17 Intake manifold stay (MPI) M8 17 M10 21 Intake manifold stay (carburetor) 29 Exhaust manifold cover 29 Exhaust manifold M8 17 M10 29 Oxygen sensor 44 Rocker arms, rocker shafts, and camshaft Fuel pump cover 12 Rocker cover 4 Rocker shaf
11A-1-5a 4G1 ENGINE (E - W) - Specifications Item Nm Crankshaft and cylinder block Flywheel 132 Drive plate 132 Rear plate 10 Bell housing cover 10 Rear oil seal case 11 Bearing cap bolt 51 Oil pressure switch 18 Knock sensor 23 E Mitsubishi Motors Corporation Nov. Dec.
4G1 ENGINE (E - W) - Specifications 11A-1-5b Intentionally blank E Mitsubishi Motors Corporation Nov. Dec.
11A-1-6 4G1 ENGINE (E - W) - Specifications NEW TIGHTENING METHOD USING PLASTIC REGION TIGHTENING BOLTS Parts of the engine use plastic region tightening bolts. The tightening procedure for these is different from that of conventional bolts and is described in relevant parts of this manual. Note that plastic region tightening bolts have fixed service limits. These limits are indicated in relevant parts of this manual and must be strictly observed.
4G1 ENGINE (E - W) - Specifications 11A-1-7 FORM-IN-PLACE GASKET The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the fluid feed line.
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4G1 ENGINE (E - W) - Special Tools 11A-2-1 2.
11A-2-2 Tool E Mitsubishi Motors Corporation 4G1 ENGINE (E - W) - Special Tools Number Name Use MD998760 Valve stem seal installer Installation of valve stem seals (SOHC 12-VALVE) MD998780 Piston pin setting tool Removal and press-fitting of piston pins MB991659 Guide-D Guide for removal and press-fitting of piston pins MD998772 Valve spring compressor Compression of valve springs MD998440 Leak-down tester Testing of automatic lash adjusters (DOHC) MD998442 Air bleed wire Testing of au
11A-3-1 4G1 ENGINE (E - W) - Alternator and Ignition System 3. ALTERNATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION 12 12 Nm 13 6 7 44 Nm 10 22 Nm 25 Nm 11 1 5 23 Nm 23 Nm 9 Nm 2 3 9 8 4 123 Nm Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Drive belt* 5. Water pump pulley 6. Alternator brace 7. Alternator AA" "BA 8. Crankshaft bolt 9. Crankshaft pulley E Mitsubishi Motors Corporation Nov. Dec. 1995 1998 10. 11. "AA 12. 13.
11A-3-1a 4G1 ENGINE (E - W) - Alternator and Ignition System REMOVAL AND INSTALLATION 25 Nm 10 12 Nm 12 11 13 44 Nm 22 Nm 6 7 23 Nm 5 1 23 Nm 9 9 Nm 2 3 8 125 Nm 4 Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Drive belt* 5. Water pump pulley 6. Alternator brace 7. Alternator AA" "BA 8. Crankshaft bolt 9. Crankshaft pulley E Mitsubishi Motors Corporation Nov. Dec. 1995 1998 10. 11. "AA 12. 13.
4G1 ENGINE (E - W) - Alternator and Ignition System 11A-3-1b REMOVAL AND INSTALLATION 10 10 Nm 9 Nm 13 25 Nm 12 11 6 14 15 7 13 Nm 44 Nm 21 Nm 22 Nm 1 5 23 Nm 9 Nm 23 Nm 2 3 8 9 125 Nm 4 Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Drive belt* 5. Water pump pulley 6. Alternator brace 7. Alternator AA" "BA 8. Crankshaft bolt 9. Crankshaft pulley E Mitsubishi Motors Corporation Nov. Dec. 1995 1998 10. 11. 12. 13. "CA 14. 15.
11A-3-2 4G1 ENGINE (E - W) - Alternator and Ignition System REMOVAL AND INSTALLATION 10 25 Nm 12 11 11 Nm 13 6 7 44 Nm 22 Nm 1 5 23 Nm 9 Nm 23 Nm 2 3 9 8 4 103 Nm Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Drive belt* 5. Water pump pulley 6. Alternator brace 7. Alternator AA" "BA 8. Crankshaft bolt 9. Crankshaft pulley E Mitsubishi Motors Corporation Nov. 1995 10. 11. "AA 12. 13.
4G1 ENGINE (E - W) - Alternator and Ignition System 11A-3-3 REMOVAL SERVICE POINT AA" CRANKSHAFT BOLT REMOVAL (1) Lock the flywheel or drive plate in position using the special tool shown in the illustration, then loosen the crankshaft bolts. MD998781 INSTALLATION SERVICE POINTS Alignment mark 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 bolts.
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11A-4-1 4G1 ENGINE (E - W) - Timing Belt 4. TIMING BELT REMOVAL AND INSTALLATION 12 13 11 88 Nm 11 Nm 1 10 5 23 Nm 35 Nm 8 9 6 3 4 7 9 Nm 2 Removal steps 1. Timing belt upper cover 2. Timing belt lower cover AA" "CA 3. Timing belt "BA 4. Tensioner spring "BA 5. Timing belt tensioner 6. Crankshaft angle sensor E Mitsubishi Motors Corporation Nov. Dec. 1995 1998 7. 8. 9. AB" "AA 10. 11. 12. 13.
11A-4-2 4G1 ENGINE (E - W) - Timing Belt REMOVAL AND INSTALLATION 12 11 Nm 11 Nm 13 3 11 Nm 9 1 88 Nm 8 23 Nm 5 11 10 6 35 Nm 35 Nm 7 4 2 Removal steps 1. Timing belt upper cover 2. Timing belt lower cover AA" "DA 3. Timing belt AA" "BA 4. Tensioner spring AA" "BA 5. Timing belt tensioner 6. Idler pulley 7. Crankshaft pulley E Mitsubishi Motors Corporation Nov. 1995 AB" "AA 8. 9. 10. 11. 12. 13.
4G1 ENGINE (E - W) - Timing Belt 11A-4-3 REMOVAL SERVICE POINTS MD998715 MB990767 AA" TIMING BELT / TENSIONER SPRING / TIMING BELT TENSIONER REMOVAL (1) Using pliers, grip the tensioner spring projection (marked “A” in the diagram)and remove it from the oil pump case stopper. Then, remove the tensioner spring. (2) Remove the timing belt tensioner. (3) If the timing belt is to be reused, chalk an arrow on the belt to indicate the direction of rotation before removing it.
11A-4-4 4G1 ENGINE (E - W) - Timing Belt (7) Abnormal wear on teeth Canvas worn exposing rubber Initial stage: Canvas worn (fluffy canvas fibers, rubbery texture gone, white discoloration, canvas texture indistinct) Missing tooth Final stage: Canvas worn, exposing rubber (tooth width reduced) (8) Missing teeth 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.
4G1 ENGINE (E - W) - Timing Belt 11A-4-5 (3) Grip the other tensioner spring projection and fit it onto the oil pump case lug as shown in the illustration. (4) Move the timing belt tensioner in the direction shown and temporarily tighten the bolt. "CA TIMING BELT INSTALLATION (1) Align the camshaft timing mark with the timing mark on the cylinder head. (2) Align the crankshaft timing mark with the timing mark on the front case.
11A-4-6 4G1 ENGINE (E - W) - Timing Belt "DA TIMING BELT INSTALLATION (1) Place the camshaft sprocket timing marks at the positions shown. NOTE After aligning the sprocket timing marks, let go of the sprockets. The exhaust camshaft sprocket will rotate by one tooth in the direction shown and remain stable in this position. (2) Align the crankshaft timing mark with the timing mark on the front case.
4G1 ENGINE (E - W) - Fuel and Emission Control Systems 11A-5-1 5. FUEL AND EMISSION CONTROL SYSTEMS REMOVAL AND INSTALLATION 17 Nm 7 8 9 2 3 10 21 Nm 11 4 12 5 6 11 Nm 22 Nm 1 Removal steps 1. Breather tube 2. Fuel hose 3. Fuel pump 4. Gasket 5. Insulator 6. Gasket E Mitsubishi Motors Corporation Nov. 1995 7. 8. 9. 10. 11. Carburetor Upper gasket Spacer Lower gasket EGR valve (vehicles with automatic transmission for GCC only) 12.
11A-5-2 4G1 ENGINE (E - W) - Fuel and Emission Control Systems REMOVAL AND INSTALLATION 11 Nm 3 11 18 Nm 1 6 2 9 5 4 9 Nm 21 Nm 10 8 7 12 13 15 14 18 Nm Removal steps 1. Throttle body assembly 2. Gasket 3. Fuel return pipe "BA 4. Fuel pressure regulator 5. O-ring 6. Insulator 7. Insulator E Mitsubishi Motors Corporation Nov. 1995 "AA 8. 9. 10. 11. 12. 13. 14. 15.
4G1 ENGINE (E - W) - Fuel and Emission Control Systems 11A-5-2a REMOVAL AND INSTALLATION 9 Nm 3 11 Nm 18 Nm 11 1 2 6 5 4 9 21 Nm 10 8 7 9 Nm 12 13 Removal steps 1. Throttle body assembly 2. Gasket 3. Fuel return pipe "BA 4. Fuel pressure regulator 5. O-ring 6. Insulator 7. Insulator E Mitsubishi Motors Corporation Nov. Dec. 1995 1998 "AA 8. 9. 10. 11. 12. 13.
11A-5-2b 4G1 ENGINE (E - W) - Fuel and Emission Control Systems Intentionally blank E Mitsubishi Motors Corporation Nov. Dec.
4G1 ENGINE (E - W) - Fuel and Emission Control Systems REMOVAL AND INSTALLATION 11 Nm 3 11 18 Nm 1 6 2 9 5 4 10 8 7 9 Nm Removal steps 1. Throttle body assembly 2. Gasket 3. Fuel return pipe "BA 4. Fuel pressure regulator 5. O-ring 6. Insulator E Mitsubishi Motors Corporation Nov. 1995 7. "AA 8. 9. 10. 11.
11A-5-4 4G1 ENGINE (E - W) - Fuel and Emission Control Systems INSTALLATION SERVICE POINTS "AA INJECTOR INSTALLATION (1) Fit a new O-ring and grommet onto the injector. (2) Apply spindle oil or gasoline to the injector O-ring. (3) Fit the injector onto the delivery pipe, turning it to the left and right as it goes in. (4) Check that the injector rotates smoothly. Caution If the injector does not rotate smoothly, its O-ring may be binding.
11A-6-1 4G1 ENGINE (E - W) - Water Pump and Water Hose 6. WATER PUMP AND WATER HOSE REMOVAL AND INSTALLATION 22 Nm 1 2 27 Nm 27 Nm 4 11 Nm 12 3 11 5 6 8 9 23 Nm 10 12 Nm 14 13 13 Nm Removal steps 1. Water hose 2. Water hose 3. Water hose "FA 4. Thermo valve (engines with EGR) "FA 5. Thermo valve "DA 6. Water temperature gauge unit 7. Water inlet fitting E Mitsubishi Motors Corporation Nov. 1995 "CA 8. 9. 10. "BA 11. "BA 12. "BA 13. "AA 14.
11A-6-2 4G1 ENGINE (E - W) - Water Pump and Water Hose REMOVAL AND INSTALLATION 22 Nm 11 2 6 29 Nm 7 3 11 Nm 12 Nm 4 8 9 5 23 Nm 10 1 12 13 Nm Removal steps 1. Water hose 2. Water hose "EA 3. Water temperature sensor "DA 4. Water temperature gauge unit 5. Water inlet fitting "CA 6. Thermostat 7. Thermostat case E Mitsubishi Motors Corporation Nov. 1995 "BA "BA "BA "AA PWEE9520 8. 9. 10. 11. 12.
11A-6-2a 4G1 ENGINE (E - W) - Water Pump and Water Hose REMOVAL AND INSTALLATION 2 12 Nm 1 9 12 Nm 29 Nm 11 23 Nm 10 3 12 8 7 4 6 5 11 Nm 22 Nm 13 Nm Removal steps 1. Water hose 2. Water hose "EA 3. Water temperature sensor "DA 4. Water temperature gauge unit 5. Water inlet fitting "CA 6. Thermostat 7. Thermostat case E Mitsubishi Motors Corporation Nov. Dec. 1995 1998 "BA "BA "BA "AA PWEE9520 PWEE9520-A 8. 9. 10. 11. 12.
11A-6-2b 4G1 ENGINE (E - W) - Water Pump and Water Hose REMOVAL AND INSTALLATION 2 12 Nm 23 Nm 1 5 6 12 Nm 10 7 11 25 Nm 9 29 Nm 3 8 4 11 Nm 12 23 Nm 13 Nm Removal steps 1. Water hose 2. Water hose "EA 3. Water temperature sensor "DA 4. Water temperature gauge unit 5. Water outlet fitting 6. Gasket E Mitsubishi Motors Corporation Nov. Dec. 1995 1998 "CA 7. 8. 9. "BA 10. "BA 11. "AA 12.
11A-6-3 4G1 ENGINE (E - W) - Water Pump and Water Hose REMOVAL AND INSTALLATION 12 Nm 11 2 1 12 Nm 29 Nm 8 3 7 10 22 Nm 9 6 12 23 Nm 4 5 11 Nm 13 Nm Removal steps 1. Water hose 2. Water hose "EA 3. Water temperature sensor "DA 4. Water temperature gauge unit 5. Water inlet fitting "CA 6. Thermostat 7. Thermostat case E Mitsubishi Motors Corporation Nov. 1995 "BA "BA "BA "AA PWEE9520 8. 9. 10. 11. 12.
11A-6-4 4G1 ENGINE (E - W) - Water Pump and Water Hose INSTALLATION SERVICE POINTS "AA WATER PUMP INSTALLATION (1) Apply a 3 mm bead of form-in-place gasket (FIPG) to the mounting surface. Specified sealant: Mitsubishi Genuine equivalent. Part No. MD970389 or "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. Caution 1.
11A-6-5 4G1 ENGINE (E - W) - 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 equivalent. E Mitsubishi Motors Corporation Nov. 1995 PWEE9520 Part No.
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11A-7-1 4G1 ENGINE (E - W) - Intake and Exhaust Manifolds 7. INTAKE AND EXHAUST MANIFOLDS REMOVAL AND INSTALLATION 1 3 4 8 17 Nm 7 5 2 29 Nm 30 Nm 17 Nm 6 Removal steps 1. Engine hanger 2. Intake manifold stay 3. Intake manifold 4. Intake manifold gasket E Mitsubishi Motors Corporation Nov. 1995 5. 6. 7. 8.
11A-7-2 4G1 ENGINE (E - W) - Intake and Exhaust Manifolds REMOVAL AND INSTALLATION 1 3 44 Nm 4 5 9 17 Nm 8 7 29 Nm 17 Nm 21 Nm 17 Nm 2 6 Removal steps 1. Engine hanger 2. Intake manifold stay 3. Intake manifold 4. Intake manifold gasket 5. Oxygen sensor (vehicles for Hong Kong only) E Mitsubishi Motors Corporation Nov. 1995 6. 7. 8. 9.
4G1 ENGINE (E - W) - Intake and Exhaust Manifolds 11A-7-2a REMOVAL AND INSTALLATION 6 5 Nm 9 Nm 7 1 2 4 17 Nm 5 29 Nm 9 11 10 3 17 Nm 19 Nm 21 Nm 17 Nm 8 29 Nm Removal steps 1. Boost sensor 2. Engine hanger 3. Intake manifold stay 4. Intake manifold 5. Intake manifold gasket 6. Solenoid valve assembly E Mitsubishi Motors Corporation Nov. Dec. 1995 1998 PWEE9520 PWEE9520-A 7.
11A-7-2b 4G1 ENGINE (E - W) - Intake and Exhaust Manifolds REMOVAL AND INSTALLATION 5 11 8 13 Nm 1 3 54 Nm 4 9 10 7 11 Nm 8 17 Nm 83 Nm 12 2 6 29 Nm 30 Nm 17 Nm Removal steps 1. Engine hanger 2. Intake manifold stay 3. Intake manifold 4. Intake manifold gasket 5. Air hose 6. Exhaust manifold cover E Mitsubishi Motors Corporation Nov. 1995 July 1999 "AA 7. Air pipe "AA 8. Reed valve and bracket 9. Reed valve 10. Reed valve bracket “A” 11.
11A-7-3 4G1 ENGINE (E - W) - Intake and Exhaust Manifolds REMOVAL AND INSTALLATION 1 3 4 17 Nm 9 8 6 44 Nm 17 Nm 5 29 Nm 17 Nm 21 Nm 2 7 Removal steps 1. Engine hanger 2. Intake manifold stay 3. Intake manifold 4. Intake manifold gasket 5. Oxygen sensor E Mitsubishi Motors Corporation Nov. 1995 29 Nm 6. 7. 8. 9.
11A-7-4 4G1 ENGINE (E - W) - Intake and Exhaust Manifolds INSTALLATION SERVICE POINTS Reed valve and bracket Pipe nut (reed valve side) Pipe clamp bolt Air pipe Reed valve bracket “B” Pipe nut (exhaust manifold side) E Mitsubishi Motors Corporation Nov. 1995 July 1999 "AA REED VALVE, BRACKET AND AIR PIPE INSTALLATION (1) Insert the lower end of the air pipe into the exhaust manifold, then tighten the pipe nut temporarily.
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4G1 ENGINE (E - W) - Rocker Arms and Camshafts 11A-8-1 8. ROCKER ARMS AND CAMSHAFTS REMOVAL AND INSTALLATION 1 3 6 4 4 Nm 2 9 31 Nm 5 14 7 12 11 13 19 20 21 15 Nm 18 17 22 16 15 10 Apply engine oil to all moving parts before installation. 8 Removal steps 1. Breather hose 2. P.C.V. hose 3. P.C.V. valve 4. P.C.V. valve gasket 5. Oil filler cap 6. Rocker cover 7. Rocker cover gasket "FA 8. Camshaft oil seal "EA 9. Rocker arm and shaft assembly "EA 10.
11A-8-1a 4G1 ENGINE (E - W) - Rocker Arms and Camshafts REMOVAL AND INSTALLATION 4 2 1 5 31 Nm 35 Nm 3 10 14 6 11 7 18 12 13 19 20 9 Nm 15 16 9 Nm 17 8 21 9 Removal steps 1. Breather hose 2. P.C.V. hose 3. Oil filler cap 4. P.C.V. valve 5. P.C.V. valve gasket 6. Rocker cover 7. Rocker cover gasket 8. Oil seal "FA 9. Oil seal "EA 10. Rocker arms and rocker arm shaft IN "EA 11.
4G1 ENGINE (E - W) - Rocker Arms and Camshafts 11A-8-1b Intentionally blank E Mitsubishi Motors Corporation Nov. Dec.
11A-8-2 4G1 ENGINE (E - W) - Rocker Arms and Camshafts REMOVAL AND INSTALLATION Apply engine oil to all moving parts before installation. 2 5 1 3 4 6 4 Nm 7 9 24 Nm 8 11 Nm 11 13 12 10 14 15 Removal steps 1. Breather hose 2. P.C.V. hose 3. P.C.V. valve 4. P.C.V. valve gasket 5. Oil filler cap "HA 6. Rocker cover 7. Rocker cover gasket A 8. Rocker cover gasket B E Mitsubishi Motors Corporation Nov. Dec. 1995 1998 "GA "FA "BA "AA "AA PWEE9520 PWEE9520-A 9. 10. 11. 12. 13. 14. 15.
4G1 ENGINE (E - W) - Rocker Arms and Camshafts 11A-8-3 INSPECTION 1. CAMSHAFT (1) Measure the cam heights and replace the camshaft if any height exceeds the specified limit. Intake Exhaust Standard value mm Limit mm SOHC 12-VALVE 38.78 38.28 SOHC 16-VALVE 36.99 36.49 DOHC 34.67 34.17 SOHC 12-VALVE 39.10 38.60 SOHC 16-VALVE 36.85 36.35 DOHC 34.26 33.76 2. LASH ADJUSTERS Caution 1. The lash adjusters are precision-engineered mechanisms.
11A-8-4 4G1 ENGINE (E - W) - Rocker Arms and Camshafts (3) While gently pushing down the internal steel ball using special tool MD998442, move the plunger through 5 to 10 strokes until it slides smoothly. In addition to eliminating stiffness in the plunger, this operation will remove dirty oil. MD998442 Diesel fuel Caution The steel ball spring is extremely weak, so the lash adjuster’s functionality may be lost if the air bleed wire is pushed in hard.
4G1 ENGINE (E - W) - Rocker Arms and Camshafts 11A-8-5 (7) Place the lash adjuster in container C. Then, gently push down the internal steel ball using special tool MD998442. 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.
11A-8-6 4G1 ENGINE (E - W) - Rocker Arms and Camshafts NOTE Replace the lash adjuster if the time measurement is out of specification. MD998442 (13)Place the lash adjuster in container C again, then gently push down the internal steel ball using special tool MD998442. (14)Stand the lash adjuster with its plunger at the top, then push the plunger downward firmly until it moves through its greatest possible stroke.
4G1 ENGINE (E - W) - Rocker Arms and Camshafts 11A-8-7 "BA BEARING CAP INSTALLATION (1) Position the camshaft dowel pins as shown. NOTE With the camshaft dowel pins in this position, the camshaft notches for tightening cylinder head bolt are correctly positioned. (2) Bearing caps Nos. 2 to 5 are the same shape. Be sure to install them in order of their cap numbers and check the identification marks to ensure that the intake and exhaust sides are not reversed.
11A-8-8 4G1 ENGINE (E - W) - Rocker Arms and Camshafts "EA ROCKER ARM / ROCKER SHAFT ASSEMBLY INSTALLATION (1) Assemble the rocker arms and rocker shaft, paying attention to the identification marks. Then mount the assembly on the cylinder head.
4G1 ENGINE (E - W) - Rocker Arms and Camshafts 11A-8-9 "HA ROCKER COVER INSTALLATION (1) Apply the specified sealant to the area shown, then fit the rocker cover. Specified sealant: 3M ATD part No. 8660 or equivalent VALVE CLEARANCE ADJUSTMENT Timing belt side (1) Position the No. 1 cylinder at top dead center on the compression stroke. (2) Adjust the valve clearance at the points shown in the illustration. (3) Loosen the adjusting screw locknut.
11A-8-10 4G1 ENGINE (E - W) - Rocker Arms and Camshafts Timing belt side (1) Position the No. 1 cylinder at top dead center on the compression stroke. (2) Adjust the valve clearance at the points shown in the illustration. (3) Loosen the adjusting screw locknut. (4) Using a feeler gauge, adjust the valve clearance by turning the adjusting screw. 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.
11A-9-1 4G1 ENGINE (E - W) - Cylinder Head and Valves 9. CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION 2 1 9 10 4 5 11 22 15 16 18 6 13 14 17 21 12 19 20 7 8 3 Apply engine oil to all moving parts before installation. Removal steps AA" "DA 1. Cylinder head bolt 2. Cylinder head assembly 3. Cylinder head gasket AB" "CA 4. Retainer lock 5. Valve spring retainer "BA 6. Valve spring 7. Intake valve (primary) 8. Intake valve (secondary) AB" "CA 9. Retainer lock 10.
11A-9-1a 4G1 ENGINE (E - W) - Cylinder Head and Valves REMOVAL AND INSTALLATION 1 4 8 9 5 10 14 6 15 12 17 13 2 16 20 19 11 18 3 7 Apply engine oil to all moving parts before installation. Removal steps AA" "DA 1. Cylinder head bolt 2. Cylinder head assembly 3. Cylinder head gasket AB" "CA 4. Retainer lock 5. Valve spring retainer "BA 6. Valve spring 7. Exhaust valve AB" "CA 8. Retainer lock 9. Valve spring retainer "BA 10.
4G1 ENGINE (E - W) - Cylinder Head and Valves 11A-9-1b Intentionally blank E Mitsubishi Motors Corporation Nov. Dec.
11A-9-2 4G1 ENGINE (E - W) - Cylinder Head and Valves REMOVAL AND INSTALLATION 2 1 9 8 10 4 14 20 5 6 12 15 17 13 16 19 11 18 7 3 Apply engine oil to all moving parts before installation. AA" "DA AB" "CA "BA AB" "CA "BA Removal steps 1. Cylinder head bolt 2. Cylinder head assembly 3. Cylinder head gasket 4. Retainer lock 5. Valve spring retainer 6. Valve spring 7. Intake valve 8. Retainer lock 9. Valve spring retainer 10. Valve spring E Mitsubishi Motors Corporation Nov. 1995 11.
4G1 ENGINE (E - W) - Cylinder Head and Valves 11A-9-3 REMOVAL SERVICE POINTS SOHC AA" CYLINDER HEAD BOLT REMOVAL MB991653 DOHC MB991653 SOHC MD998772 AB" RETAINER LOCK REMOVAL (1) Tag removed valves, springs, and other components, noting their cylinder numbers and locations to facilitate reassembly. Store these components safely. DOHC MD998772 MD998735 E Mitsubishi Motors Corporation Nov.
11A-9-4 4G1 ENGINE (E - W) - Cylinder Head and Valves AC" VALVE STEM SEAL REMOVAL INSPECTION 1. CYLINDER HEAD (1) Before cleaning the cylinder head, check it for water leaks, gas leaks, cracks, and other damage. (2) Remove all oil, water scale, sealant, and carbon. After cleaning the oil passages, blow air through them to verify that they are not blocked. (3) Check for distortion in the cylinder head gasket surface using a straight edge and thickness gauge.
4G1 ENGINE (E - W) - Cylinder Head and Valves 11A-9-5 (3) Measure the valve’s total length. If the measurement is less than specified, replace the valve. Standard mm Intake Exhaust Limit mm SOHC 12-VALVE 100.75 100.25 SOHC 16-VALVE 111.56 111.06 DOHC 106.35 105.85 SOHC 12-VALVE 101.05 100.55 SOHC 16-VALVE 114.71 114.21 DOHC 106.85 106.35 3. VALVE SPRINGS (1) Measure the valve spring’s free height. If the measurement is less than specified, replace the spring.
11A-9-6 4G1 ENGINE (E - W) - Cylinder Head and Valves 4. VALVE GUIDES (1) Measure the clearance between the valve guide and valve stem. If the clearance exceeds the specified limit, replace either or both components. Valve guide Standard mm Intake Guide I. D. Stem O. D. 1EN0279 Exhaust Valve stem end Valve projection Spring seating surface SOHC 12-VALVE 0.020 - 0.050 0.10 SOHC 16-VALVE 0.020 - 0.047 0.10 DOHC 0.020 - 0.047 0.10 SOHC 12-VALVE 0.050 - 0.085 0.15 SOHC 16-VALVE 0.030 - 0.
4G1 ENGINE (E - W) - Cylinder Head and Valves 0.9 - 1.3 mm VALVE SEAT CORRECTION SERVICE POINTS 0.9 - 1.3 mm 65_ 65_ 15_ 44_ 11A-9-7 44_ 15_ (1) Before correcting the valve seat, check the clearance between the valve guide and valve. If necessary, replace the valve guide. (2) Using the appropriate special tool or seat grinder, correct the valve seat to achieve the specified seat width and angle. (3) After correcting the valve seat, lap the valve and valve seat using lapping compound.
11A-9-8 4G1 ENGINE (E - W) - Cylinder Head and Valves VALVE GUIDE REPLACEMENT SERVICE POINTS (1) Using a press, push the valve guide out toward the cylinder block side. (2) Rebore the valve guide hole in the cylinder head to match the oversize valve guide that is to be fitted. Caution Do not install a valve guide of the same size again. Valve guide hole diameters (SOHC 12-VALVE) 0.05 O.S.: 12.050 - 12.068 mm 0.25 O.S.: 12.250 - 12.268 mm 0.50 O.S.: 12.500 - 12.
4G1 ENGINE (E - W) - Cylinder Head and Valves Painted end Spring retainer 11A-9-9 "BA VALVE SPRING INSTALLATION (1) Install the valve spring such that its painted end is on the rocker arm side. Stem seal Spring seat SOHC MD998772 "CA RETAINER LOCK INSTALLATION DOHC MD998772 MD998735 "DA CYLINDER HEAD BOLT INSTALLATION (1) Before reusing the cylinder head bolt, check that its nominal length does not exceed the specified limit. Replace the bolt if this measurement exceeds the limit. Limit: 103.
11A-9-10 4G1 ENGINE (E - W) - Cylinder Head and Valves Timing belt side 8 6 1 3 9 10 4 2 5 7 (7) Apply paint marks to the cylinder head bolt heads and cylinder head as shown. (8) In accordance with the tightening sequence, tighten each bolt by 90_. (9) Tighten each bolt by a further 90_ and check that the paint marks on the bolt head and cylinder head are aligned. 90_ 90_ E Mitsubishi Motors Corporation (4) Tighten the bolts in the sequence shown until each is torqued to 49 Nm.
11A-10-1 4G1 ENGINE (E - W) - Oil Pump and Oil Pan 10. OIL PUMP AND OIL PAN REMOVAL AND INSTALLATION Apply engine oil to all moving parts before installation. 10 Nm 12 13 13 Nm 14 5 7 6 16 15 18 Nm 10 9 11 7 Nm 8 44 Nm 4 1 3 2 39 Nm Removal steps "EA 1. Oil filter 2. Drain plug "DA 3. Gasket 4. Transmission stay (Rear wheel drive) AA" "CA 5. Oil pan 6. Oil screen 7. Gasket 8. Relief valve 9. Relief valve spring E Mitsubishi Motors Corporation Nov. Dec. 1995 1998 23 Nm 10.
11A-10-2 MD998727 4G1 ENGINE (E - W) - Oil Pump and Oil Pan MD998727 REMOVAL SERVICE POINTS AA" OIL PAN REMOVAL (1) Remove the oil pan mounting bolts. (2) Knock the special tool between the oil pan and cylinder block as shown in the illustration. (3) Tapping the side of the special tool, slide the tool along the oil pan/cylinder block seal and thus remove the oil pan. INSPECTION 1. OIL PUMP (1) Fit the rotor into the front case. (2) Check the tip clearance using a thickness gauge. Standard value: 0.
11A-10-3 4G1 ENGINE (E - W) - Oil Pump and Oil Pan INSTALLATION SERVICE POINTS "AA FRONT OIL SEAL CASE INSTALLATION (1) Clean the sealant application surfaces on the cylinder block and front oil seal case. (2) Apply a 3 mm bead of form-in-place gasket to the entire circumference of the oil pan flange. Specified sealant: Mitsubishi Genuine equivalent. Part No.
11A-10-4 4G1 ENGINE (E - W) - Oil Pump and Oil Pan "EA OIL FILTER INSTALLATION (1) Clean the filter mounting surface on the front case. (2) Apply engine oil to the oil filter’s O-ring. (3) Screw on the oil filter until the O-ring is seated on the mounting surface. Then, give the oil filter one further turn such that it is torqued to approximately 14 Nm. Caution The oil filter must be tightened using a commercially available filter wrench.
4G1 ENGINE (E - W) - Pistons and Connecting Rods 11. PISTONS AND CONNECTING RODS REMOVAL AND INSTALLATION 6 7 8 9 10 4 12 11 5 Apply engine oil to all moving parts before installation. 3 2 1 Removal steps 1. Connecting rod nut 2. Connecting rod cap 3. Connecting rod bearing 4. Piston and connecting rod assembly 5. Connecting rod bearing "CA 6. Piston ring No. 1 "GA AA" "FA "EA "DA E Mitsubishi Motors Corporation Nov. 1995 "CA 7. Piston ring No. 2 "BA 8. Oil ring AB" "AA 9. Piston pin 10.
11A-11-2 4G1 ENGINE (E - W) - Pistons and Connecting Rods REMOVAL SERVICE POINTS Cylinder No. AA" CONNECTING ROD CAP REMOVAL (1) Mark the cylinder number on the side of the connecting rod big end to facilitate reassembly. DEN0050 AB" PISTON PIN REMOVAL (1) Insert the Push Rod (special tool) from the front arrow mark side, then fit guide D. (2) Mount the piston and connecting rod assembly on the Piston Pin Setting Base (special tool) with the piston’s front mark pointing upward.
4G1 ENGINE (E - W) - Pistons and Connecting Rods 11A-11-3 2. CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE METHOD) (1) Wipe all oil off the crankshaft pin and connecting rod bearing. (2) On the pin, place a plastic gauge that is cut to the same length as the bearing’s width. The plastic gauge must be centered on the pin in parallel with the pin’s axis. (3) Gently place the connecting rod cap in position and tighten the bolts to the specified torque.
11A-11-4 4G1 ENGINE (E - W) - Pistons and Connecting Rods (8) Mount the piston and connecting rod on the Piston Pin Setting Base (special tool) with the piston’s front mark pointing upward. (9) Install the piston pin using a press. If the press-fitting load is out of specification, replace the piston pin and piston assembly or the connecting rod, or both.
11A-11-5 4G1 ENGINE (E - W) - Pistons and Connecting Rods "CA PISTON RING No. 2 / PISTON RING No. 1 INSTALLATION (1) Using piston ring expander, fit No. 2 and No. 1 piston ring into position. Piston ring expander NOTE 1. The ring end is provided with identification mark. Item 7EN0452 Identification mark Identification mark No. 2 ring Size mark No. 1 No. 2 Side rail No. 1 ring Piston pin No. 2 ring and spacer No.
11A-11-6 4G1 ENGINE (E - W) - Pistons and Connecting Rods "EA CONNECTING ROD BEARING INSTALLATION 4G18 4G13, 4G15 Color code positions No. 1 No. 4 No. 3 No. 1 No. 4 No. 3 No. 2 No. 2 Identification mark positions A A No. 1 No. 2 B B No. 3 No. 4 P No. 1 No. 2 No. 4 No. 3 (1) Select bearings according to crankshaft and connecting rod identification marks or color codes, referring to the following table.
4G1 ENGINE (E - W) - Pistons and Connecting Rods Cylinder No. 11A-11-7 "FA CONNECTING ROD CAP INSTALLATION (1) Aligning the marks made during disassembly, fit the bearing cap onto the connecting rod. If the connecting rod is new and has no index mark, ensure that the bearing locking notches are both on the same side. Locking notch DEN0051 (2) Check that the connecting rod big end side clearance confirms with specifications. Standard value: 0.10 - 0.25 mm Limit: 0.
11A-11-8 4G1 ENGINE (E - W) - Pistons and Connecting Rods Caution 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. E Mitsubishi Motors Corporation Nov. Dec.
11A-12-1 4G1 ENGINE (E - W) - Crankshaft and Cylinder Block 12. CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION 22 Nm Apply engine oil to all moving parts before installation. 23 132 Nm 10 Nm 1 12 18 Nm 11 Nm 16 22 14 24 2 13 15 132 Nm 5 4 3 10 Nm 6 21 7 132 Nm 20 A 9 8 19 18 51 Nm 11 17 E Mitsubishi Motors Corporation Nov. Dec.
11A-12-2 4G1 ENGINE (E - W) - Crankshaft and Cylinder Block Removal steps 1. Flywheel bolt 2. Flywheel 3. Flywheel bolt 4. Adapter plate 5. Flywheel 6. Adapter plate 7. Crankshaft bushing 8. Drive plate bolt 9. Adapter plate 10. Drive plate 11. Crankshaft bushing 12. Rear plate 13. Bell housing cover "DA 14. 15. 16. "CA 17. "CA 18. "BA 19. 20. "BA 21. AA" "AA 22. 23.
4G1 ENGINE (E - W) - Crankshaft and Cylinder Block 11A-12-3 REMOVAL SERVICE POINTS MD998054 AA" OIL PRESSURE SWITCH REMOVAL (1) Disconnect the oil pressure switch terminals. (2) Using the special tool, remove the oil pressure switch. Caution The thread is coated with sealant. Take care not to bend it when removing the oil pressure switch. INSPECTION Plastic gauge 6EN0550 1. CRANKSHAFT OIL CLEARANCE The crankshaft oil clearance can be measured easily using a plastic gauge.
11A-12-4 4G1 ENGINE (E - W) - Crankshaft and Cylinder Block (4) Using a cylinder gauge, measure each cylinder’s bore and cylindricity. If any cylinder is severely worn, bore all the cylinders to oversize and replace the piston and piston rings accordingly. Take measurements at the points shown. 12 mm 6EN0553 Piston O. D. Thrust direction 6EN0554 Standard value: Cylinder bore: 4G13 engine: 71.0 mm 4G15 engine: 75.5 mm 4G18 engine: 76.0 mm Cylindricity: 0.01 mm or less 3.
4G1 ENGINE (E - W) - Crankshaft and Cylinder Block 11A-12-5 "BA CRANKSHAFT BEARING INSTALLATION 4G18 4G13, 4G15 Color code positions (type 1) No. 4 No. 4 No. 3 No. 3 No. 1 No. 1 No. 5 No. 2 No. 5 No. 2 Color code positions (type 2) No. 3 No. 3 No. 2 No. 2 No. 5 No. 4 No. 1 No. 4 No. 5 No. 1 Identification mark positions No. 1 No. 3 No. 2 No. 2 No. 1 No. 4 No. 5 No. 3 No. 4 No.
11A-12-6 4G1 ENGINE (E - W) - Crankshaft and Cylinder Block Crankshaft journal Cylinder block bearing diameter Bearing Range Color code Identification mark Journal diameter mm Identification mark Identification mark 1 Yellow 1 47.995 - 48.000 0 1 1 2 2 3 0 2 1 3 2 4 0 3 1 4 2 5 2 None 3 2 White 3 Timing belt side Cylinder block journal bore diameter Grooveless Grooved Upper bearing (Nos. Lower bearing (Nos. 1, 2, 4, and 5) 1, 2, 4, and 5) Grooveless 47.985 - 49.
4G1 ENGINE (E - W) - Crankshaft and Cylinder Block Arrow indicating front of engine 11A-12-7 "CA BEARING CAP INSTALLATION (1) On the bottom surface of each bearing cap is the cap’s number and an arrow. Starting at the timing belt side, fit the bearing caps in numerical order. Ensure that the arrows point toward the timing belt side. Cap No. 3EN0174 (2) After fitting the bearing caps, measure the end play in the crankshaft. If the measurement exceeds the specified limit, replace the crankshaft bearings.
NOTES