> PF PE “© mitsubishi Motors Corporation Removal steps Timing belt front upper cover Timing belt front lower cover Engine support bracket, right Timing belt Tensioner pulley Tensioner arm Shaft Auto tensioner Timing belt rear cover Idler pulley Mar 2004 PG 12. PG 13. pod 14 15 21 +N 11m \ 4 88 Nm S 18 11Nm 1 5 6 | 40 2am ede ® L® | ¢ QO eum ? vant 48Nm 4” 12 % 9 20 8 3 71Nm 49. Nm 19.Nm Y 9.8 Nm " a 9.8. Nm oewioss Removal steps 1. Taning belt front upper cover PS 13. Crankshatt sprocket 2. Timing belt front lower cover PG 14. Crankshaft spacer 3. Engine support bracket, right PG 15. Crankshaft sensing blade AP PF 4. Timing bolt 16. Crankshaft key &, Tenstoner pulley E> PA 17, Gamshat sprocket bolt 6, Tensioner arm 48. Camshaft sprocket 7. Shaft 49. Timing belt rear-cover PE 6 Auto tonsioner (Upto 2000 model 8. Timing belt rear cover 20. Timing belt rear cover 10. Idler pulley (Up to 2000 model) 41; Granfahat angle sensor 21, Timing belt rear upper cover (Up to 1099 model (Fron 2001 ‘mode 12. Crankshaft angle sensor (From 2000 model) ‘© Mitsubishi Motors Corporation Mar. 2001 Pweesso2s Revised11A-4-2d 4G9 ENGINE (E-W) — Timing Belt REMOVAL AND INSTALLATION 88 Nm N 7 11Nm, 1 7 5 6 10 @ 35'Nm 48.Nm 12 § ° 8 11Nm " 49.Nm 13.Nm 9.8 Nm senso5? Removal steps 4, Timing belt front upper cover 10. Idler pulley 2; Timing belt front lower cover 11. Crankshaft angle sensor 3. Engine support bracket, right Gq 12 Crankshaft sprocket 4A PF 4. Timing belt PG 15. Crankshaft spacer 5, Tensioner pulley G4 14. Crankshaft sensing blade 6. Tensioner arm 15. Crankshaft key 7. Shaft BP PA 16. Camshaft sprocket bolt DE 5. Auto tensioner 47. Camshaft sprocket 9, Timing belt rear cover 18, Timing belt rear upper cover ‘© Mitsubishi Motors Corporation Mar. 2001 Pweesso2s Revised4G9 ENGINE (E-W) — Timing Belt 11A-4-2e REMOVAL AND INSTALLATION 49.Nm > PF PE “© mitsubishi Motors Corporation Removal steps Timing belt front upper cover Timing belt front lower cover Accesory mount Timing belt Tensioner pulley Tensioner arm Shaft Aulo tensioner Timing belt rear cover Idler pulley Mar 2004 PweED6O2S 1 12 bs 13. pod 14 oent087 Bracket Crankshaft angle sensor Crankshaft sprocket Crankshaft spacer Crankshaft sensing blade Crankshaft key Camshaft sprocket bolt Camshaft sprocket Timing belt rear cover <4G93> Timing belt reer cover <4G93> Timing belt rear upper cover <4Ga4> Revised11A-4-2f 4G9 ENGINE (E-W) - Timing Belt Intentionally blank {2 mteubieh Motore Corporation May 2000, PwEs802-6 ded4G9 ENGINE (E-W) - Timing Belt 11A-4-3 REMOVAL SERVICE POINTS 44> TIMING BELT REMOVAL (1) Mark belt running direction for reinstallation. “48> CAMSHAFT SPROCKET BOLT REMOVAL (Except SOHC) (1) Use a wrench to hold the hexagonal part of the camshaft, and then remove the camshaft sprocket mounting bolt INSTALLATION SERVICE POINTS >A CAMSHAFT SPROCKET BOLT INSTALLATION \D Mitsubishi Motors Corporation Nov. 1955, PwEESS02-A Revie11A-4-4 4G9 ENGINE (E-W) - Timing belt > B-< TIMING BELT TENSIONER INSTALLATION (1) Let the pulley of the timing belt tensioner comr closest to the exhaust side, Temporarily tighten the tensioner pulley fixing bolt. exhaust oa \ AX \ pulley fixing bow AN] Tents] PrC-4TENSIONER SPRING INSTALLATION (1) Insert the tip A (shorter one) of the tensioner spring into the oll pump case (2) Use pliers or similar tool to pinch the tip B (longer one), and then hook it to the tensioner bracket arm. D4 TIMING BELT INSTALLATION (1) Tumthe crankshaft sprocket by three teeth from the timing mark. Caution Aligning the timing marks positions the piston to the top dead centre. Then, ifthe camshaft turns, the valves may hit and damage the pistons. (2) Check that the timing belt tensioner and tensioner spring are installed correctly. (Refer to the service points B and c) (3) Align the timing marks on the camshaft sprocket to that on the cylinder head. (4) Align the timing mark on the crankshaft sprocket to that on the oil pump case. (6) Place the timing belt over the sprocket according in the following order. 1. Crankshaft sprocket 2. Water pump sprocket 3. Camshaft sprocket 4, Tension pulley genosra May 198 Pweesso24G9 ENGINE (E-W) - Timing Belt 11A-4-5 © Mitsubishi Motors Corporation Now 1998 © @ (8) (9) Slightly loosen the tensioner pulley fixing bolt which is tightened temporarily to tighten the belt by a force of the tensioner spring. Turn the crankshaft clockwise by two turns. Check that the timing marks are aligned Tighten the fixing bolt of the tensioner pulley. Eq AUTO-TENSIONER INSTALLATION (1) @) If the auto-tensioner rod is fully extended, set it in the retracted position with the following procedure. 1) Hold the auto-tensioner in a vice, being careful not to tit it 2) Slowly close the vice to force the rod in to align hole {A) of the rod with the set hole (8). 3) Insert a 2.0-mm-Allen key in diameter or similar into the set holes 4) Remove the auto-tensioner from the vi Install the auto-tensioner Leave the align key until installation of the timing belt is completed PWEESEO2.A Revie11A-4-6 4G9 ENGINE (E-W) - Timing Belt > F-q TIMING BELT INSTALLATION Timing marks (1) Make sure that the auto-tensioner is installed properly /~ (Refer to service point F) (2) Align the timing mark on each sprocket with the corresponding mark on the timing belt (3) Turn the crankshaft sprocket one half the tooth width counterclockwise. senasri =] — @) Fit the timing belt to the intake camshaft sprocket and ZN), Vi secure with a paper clip at the illustrated position. ay i \ (8) Use two wrenches to fit the timing belt to the exhaust sprocket while aligning the timing marks, (0 Mitsubishi Motors Corporation Nov. 1985, PwEESS02-A Revised4G9 ENGINE (E-W) - Timing Belt 11A-4-7 (©) Secure the timing belt with a paper clip at the illustrated position. (7) Fit the belt to the idler pulley water pump sprocket, crankshaft sprocket and tensioner pulley in that order. Ider pully Crankshaft sprocket gENosT2 (8) Raise the tensioner pulley in the direction of an arrow and tighten the tensioner pulley bolt, (9) Remove the two paper clips. (10)Make sure that ali timing marks are in alignment, (11)Give a 1/4 counterclockwise tum to the crankshaft. Then tur the crankshaft clockwise to align the timing marks again, (0 Mitsubishi Motors Corporation May 1895, Pweesso24G9 ENGINE (E-W) — Timing Belt eNo159 Crankshaft 2 Crankshaft sensing blade sprocket age shat f. Crankshaft spacer / fe wenn! Clean #1 Degrease Oil pump case” sens 109 ‘ZBENO066 Cracks a Cracks < w Cracks Z1ENO249 ‘© Mitsubishi Motors Corporation — Mar. 2001 (12)Install the special tool and a torque wrench to the tensioner pulley. (13)Using torque wrench, torque to 2.6 Nm. (14)While holding the tensioner pulley to prevent it from turing, tighten the center bolt to the specified torque. (15)Give two clockwise tums to the crankshaft and leave as it is for approx. 15 minutes. (16)Check if the Allen wrench inserted during installation of the auto-tensioner can be pulled out lightly. If it can be pulled out lightly, the belt is properly tensioned. Therefore, pull out the wrench. The belt is also properly tensioned if the auto-tensioner projection is of standard value. Standard value: 3.8 - 4.5 mm (17)If the wrench cannot be pulled out lightly, repeat the steps (12) through (15) to obtain appropriate belt tension. NOTE Check the tightening torque of the crankshaft bolt always after rotating the crankshaft counterclockwise using the crankshaft bolt. Retighten the bolt if the tightening torque is not up to specification, P>G-4CRANKSHAFT SENSING BLADE / CRANKSHAFT SPACER | CRANKSHAFT SPROCKET INSTALLATION (1) Clean and then degrease the following surfaces and parts: front surface of oil pump case, sprocket mounting surface of crankshaft, crankshaft spacer, orankshaft sensing blade, and crankshaft sprocket. NOTE Degreasing is necessary to prevent decrease in the friction belween contacting surfaces. (2) Clean the crankshaft contacting surface of the crankshaft sprocket. INSPECTION TIMING BELT Replace belt if any of the following conditions exist. (1) Hardening of back rubber. Back side is glossy without resilience and leaves no indent when pressed with fingernail ‘1900200077 (2) Cracks on rubber back. (3) Cracks of peeling of canvas. (4) Cracks on tooth bottom: (5) Cracks on belt sides. PweED6O2S Revised4G9 ENGINE (E-W) - Timing Belt 11A-4-9 Pounded edge ‘Abnormal wear (uty strana) ‘ZBENOO87 Fubbor exposed. Tooth missing PSS and.canvas | TS finer exposed KO ZBENOOSS 2oeN015e ‘9ENOMO 98 to 196 N stroke GEN1033 © Mitsubishi Motors Corporation May 1855, (©) Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife. (7) Abnormal wear on teeth. (8) Missing tooth TENSIONER PULLER, IDLER PULLEY (1) Check the pulley for smooth rotation, excessive play, abnormal noise. Replace it if necessary. AUTO-TENSIONER (1) Check the tensioner for oil leaks, Replace it if necessary. (2) Check the rod end for wear or damage. Replace the tensioner if necessary. (8) Measure the rod projection length. If not within the standard value, replace the tensioner. Standard value: 11 mm (4) Press the rod by a force of 98 to 196 N and measure the rod stroke. If not within the standard value, replace the tensioner. Standard value: 1 mm or less Pweesso24G9 ENGINE (E-W) - Fuel and Emission Control System 11A-5-1 5. FUEL AND EMISSION CONTROL SYSTEM REMOVAL AND INSTALLATION 18. Nm Removal steps 1, Breather tube 2. Fuel hose 3. Fuel hose 4. Fuel pump 5. Gasket 6. Insulator 7. Gasket 8. Carburetor 9. Gasket 10. EGR valve 11, Gasket © Mitsubishi Motors Corporation Nov. 1986, PwEEss028 Revised11A-5-2 4G9 ENGINE (E-W) — Fuel and Emission Control System REMOVAL AND INSTALLATION eo 10 J Engine with solenoid valve Flange 11 Nm Engine with solencid valve Washer 9 Nm Engine without solenoid valve 10Nm m3 axe Prareees Removal steps 1. Vacuum hose and pipe assembly DPAd¢ 15. Injector 2 Throttle body 44, O-ting PCq 5. Gasket 15. Grommet 4, Engine hanger (4G94) 16. Delivery pipe 5. Throttle body stay (4694) 17. Fuel retum pipe 6. Vacuum hose 18. Solenoid valve assembly 7, Fuel hose (Engine with solenoid valve) PE 8 Fuel pressure regulator 19. EGR valve 9. O-ring (Engine with EGR valve) 10. Delivery pipe and injector 20. Cover 11, Insulator (Engine without EGR valve) 12. Insulator 21, Gasket (© Mitsubishi Motors Corporation Mar. 2001, PWEEDSO24G9 ENGINE (E-W) — Fuel and Emission Control System 11A-5-3 REMOVAL AND INSTALLATION bee “© mitsubishi Motors Corporation Removal stops Stay (From 2002 model) Harness bracket Throttle cable bracket Vacuum hose and pipe assembly Throttle body Gasket Vacuum hose Ful hose Ful pressure regulator 40. O-ring 11, Delivery pipe and injector stun, 2002 PwEES602K 12 1 Dad 14. 5. 16 7 18, 19, 20 21 Insulator Insulator Injector O-ring Grommet Delivery pipe Fuel return pipe Solenoid valve assembly EGR valve Gasket Revised11A-5-4 — 4G9 ENGINE (E-W) - Fuel and Emission Control System REMOVAL AND INSTALLATION " Nm Removal steps Vacuum pipe assembly Throttle body assembly PCq 5. Gasket Throttle body stay (MIVEC) Vacuum hose Fuel hos 3° PB 7. Fuel pressure regulator O-ring Delivery pipe and injector ‘© Mitsubishi Motors Corporation Jun, 2002 PwEES602K 4 18Nm 23. Nm aenrie7 Insulator Insulator Injector O-ring Grommet Delivery pipe Fuel return pipe Solenoid valve Revised4G9 ENGINE (E-W) - Fuel and Emission Control System 11A-5-5 Injector connector Delivery pipe senoaso. ‘ Projection 9en0500| |) Mitsubishi Motors Corporation Dee. 1998, INSTALLATION SERVICE POINTS Ad INJECTORS INSTALLATION (1) Apply a small amount of new engine oil to the O-ring. Caution Be sure not to let engine oil get into the d pipe. (2) While turing the injector to the left and right, install it to the delivery pipe (3) Check that the injector turns smoothly, If it does not turn smoothly, the O-ring may be trapped. Remove the injector and check the O-ring for damage, and then re-insert it into the delivery pipe and check once again. (4) Check that the clearance between the injector connector and the delivery pipe is uniform (A = B). ery Bq FUEL PRESSURE REGULATOR INSTALLATION (1) Apply a small amount of new engine oil to the O-ring. Insert the fuel pressure regulator into the delivery pipe being careful not to damage the O-ring. Caution Be sure not to let engine oil get into the delivery Pipe. (2) Check that the fuel pressure regulator turns smoothly. If it does not turn smoothly, the O-ring may be trapped. Remove the fuel pressure regulator and check the O-ring for damage, and then re-insert it into the delivery pipe and check once again. C4 GASKET INSTALLATION (1) Position the projection as shown in the illustration. Pweessoze ‘ded11A-5-6 — 4G9 ENGINE (E-W) - Fuel and Emission Control System eee SENOUST {© Mitsubishi Motors Corporation ee 1998 Pweessoze ‘ded4G9 ENGINE (E-W) - Throttle Body and EGR System (GDI) 11A-5a-1 5a. THROTTLE BODY AND EGR SYSTEM (GDI) REMOVAL AND INSTALLATION pB« pad {2 mteubieh Motore Corporation May 2000, 1 1 Removal steps Air intake plenum resonator O-ring Intake manifold stay ‘Water hose Water hose (Up to 1998 model for CARISMA, SPACE RUNNER) Throttle body Throttle body gasket Ignition hamess Water hose EGR valve EGR valve gasket SSeeno wrens 12, 13. 14. 15. senoses Engine hanger EGR valve support Gasket Water hose (Up to 1998 model for CARISMA, SPACE RUNNER) Air by-pass valve (Up to. 1098 model for CARISMA, SPACE RUNNER) Air by-pass valve gasket (Up to. 1998 model for CARISMA, SPACE RUNNER) Revised11A-5a-2 4G9 ENGINE (E-W) - Throttle Body and EGR System (GDI) REMOVAL AND INSTALLATION 18.Nm Sens05e Removal steps PB 1. Intake manifold stay (For GALANT) DA 7. Throttle body gasket 2, Water hose 8. Ignition harness 8, Water hose 9, Water hose 4, Water hose 10. EGR valve 5. Throttle body stay 41. EGR valve support 6. Throttle body 12, Gasket {2 mteubieh Motore Corporation May 2000, PwEs802-6 Revised4G9 ENGINE (E-W) - Throttle Body and EGR System (GDI) 11A-5a-3 REMOVAL AND INSTALLATION Removal steps Water hose Water hose Water hose Water hose Water hose Water hose clamp Water pipe Water pipe @Nogpens {2 Mteubieh Motore Corporation ty 2000 PweEss02-4 9. pA 10. 1 12 13. 14. 15. SENO95 Throttle body Throttle body gasket EGR valve EGR valve gasket EGR valve support Gasket Engine hanger Revised11A-5a-4 4G9 ENGINE (E-W) - Throttle Body and EGR System (GDI) REMOVAL AND INSTALLATION Removal steps 1. Water hose 9. 2! Water hose: 10. 3. Water hose pad ii 4, Water hose: 12. 5. Water hose 13. 6. Water hose clamp 14. 7. Water pipe 15. 8 Water pipe 16. {2 Mteubieh Motore Corporation ty 2000 PweEss02-4 6 13.Nm senioae Throttle body stay Throttle body Throttle body gasket EGR valve EGR valve gasket EGR valve support Gasket Engine hanger Revised4G9 ENGINE (E-W) - Throttle Body and EGR System (GDI) 11A-5a-5 SHRI eee | Tad Lo INSTALLATION SERVICE POINTS \ Ealaisma.1998mode for SPACE STAR, t\ Add THROTTLE BODY GASKET ‘SPACE RUNNERS N00! ‘ 9EN1059 “ ~ Bq INTAKE MANIFOLD STAY INSTALLATION Intake manifold (1) Tighten the four bolts at the top and bottom of the stay hanatight. (2) Check that the stay seating surface is in close contact Bot with the bosses on the intake manifold and the cylinder J block, Intakes (3) Tighten the four bolts to the specified torque, manifold stay Bot ‘eytindor block — |i inakamanifold Intake marifold slay Bolt SEN1060 {D uteubieh Motore Corporation aly 2000 PweEss02-4 ded4G9 ENGINE (E-W) - Intake and Exhaust Manifold 11A-6-1 6. INTAKE AND EXHAUST MANIFOLD REMOVAL AND INSTALLATION 20 Nm W7-9 14Nm Bolt with head mark “4” 12 Nm ‘O——_ Bolt with head mark “7” 19 Nm Bolt with head mark “4" 12 Nm Bolt with head mark “7" 19 Nm senoese Removal steps 4. Engine hanger 7. Oxing PB 2 Intake manifold stay 8, Exhaust manifold cover 3. Intake manifold 9. Engine hanger 4: Intake manifold gasket PPAqq 10. Exhaust manifold bracket A 5. Oil level gauge DA 11. Exhaust manifold bracket B 6. Oil level gauge guide 412. Exhaust manifold 13. Exhaust manifold gasket ‘© Mitsubishi Motors Corporation Mar. 2001 Pweesso2s Revised11A-6-2 4G9 ENGINE (E-W) — Intake and Exhaust Manifold REMOVAL AND INSTALLATION } 6 m7 14m 20 Nm Bolt with head mark “4° 12 Nm Bolt with head mark “7" 19 Nm 31.Nm Bolt with head mark “4” 42 Nm senoass Bolt with head mark “7" 19 Nm Removal steps 41, Engine hanger 7. O-ting 2. Intake manifold stay 8, Exhaust manifold cover 3! Intake manifold 8, Engine hanger 4, Intake manifold gasket Ad 10. Exhaust manifold bracket A 5. Oil level gauge DA 11. Exhaust manifold bracket B 6. Oil level gauge guide 12. Exhaust manifold 13, Exhaust manifold gasket (© mitsubiehi Motors Corporstion Mar. 2001 PWeEDSO24 Revized4G9 ENGINE (E-W) - Intake and Exhaust Manifold 11A-6-2a REMOVAL AND INSTALLATION Removal steps Engine hanger Intake manifold stay Intake manifold Intake manifold gasket Oil level gauge Oil level gauge guide O-ring (© Mitsubishi Motors Corporation — Mar. 2001 PweED6O2S 10, n 12 3 14, 13.Nm aewso6s Oxygen sensor Engine hanger Exhaust manifold cover Exhaust manifold bracket B Exhaust manifold Exhaust manifold gasket Exhaust manifold bracket A Revised11A-6-2b 4G9 ENGINE (E-W) — Intake and Exhaust Manifold REMOVAL AND INSTALLATION Removal steps 4, Intake manifold stay 7, Exhaust manifold cover 2 Intake manifold 8, Engine hanger 3. Intake manifold gasket 49. Exhaust manifold bracket A 4: Oil level gauge DPAd 10. Exhaust manifold bracket B 5. Oil level gauge guide 41, Exhaust manifold 6. O-ring 12. Exhaust manifold gasket ‘© mitsubiehi Motors Corportion Mar. 2001 PWeEDSO244G9 ENGINE (E-W) - Intake and Exhaust Manifold 11A-6-2c REMOVAL AND INSTALLATION Europe — REAR WHEEL DRIVE (4G93 - Except from 2002 model for ‘urope)> 9EN1005 Removal steps 4, Oil level gauge 7. Intake manifold gasket 2, Oil level gauge guide 8, Exhaust manifold cover 3, O-ring 9, Engine hanger 4, Engine hanger Ad 10. Exhaust manifold bracket 5. Intake manifold stay 11, Exhaust manifold 6 Intake manifold 12. Exhaust manifold gasket ‘© Mitsubishi Motors Corporation Jun, 2002 Pweesso2 Revised11A-6-2d 4G9 ENGINE (E-W) — Intake and Exhaust Manifold REMOVAL AND INSTALLATION Removal steps 4, Oil level gauge 7. Intake manifold gasket 2 Ol level gauge guide 8, Exhaust manifold cover 3. O-ring ‘9, Engine hanger 4. Engine hanger DPA¢ 10. Exhaust manifold bracket 5, Intake manifold stay 11, Exhaust manifold 6 Intake manifold 12. Exhaust manifold gasket ‘© Mitsubishi Motors Corporation Jun, 2002 PwEES602K RevisedRemoval ing Intake “© mitsubishi Motors Corporation 4G9 ENGINE (E-W) - Intake and Exhaust Manifold 11A-6-2e REMOVAL AND INSTALLATION I steps. Oil level gauge Oil level gauge guide Engine hanger Intake manifold stay manifold stun, 2002 PwEES602K senr149 Intake manifold gasket Exhaust manifold cover Engine hanger Exhaust manifold bracket Exhaust manifold Exhaust manifold gasket aed11A-6-2f 4G9 ENGINE (E-W) — Intake and Exhaust Manifold Intentionally blank {© Mitsubishi Motors Corporation Jun. 2002 PwEES602K ae20 Nm 4G9 ENGINE (E-W) - Intake and Exhaust Manifold 11A-6-3 REMOVAL AND INSTALLATION Removal steps Engine hanger Intake manifold stay Intake © Miteubish Motors Conporstion manifold Mar 2004 Bolt with head mark “4” 12Nm Bolt with head mark “7” 19Nm Intake manifold gasket Oil level gauge Oil level gauge guide PWeESSO2S Boltwith headmark“4" 12Nm Boltwithheadmark“7" 19Nm ~V B7—o 14.Nm 19. Nm 9ENO576 O-ring Engine hanger Exhaust manifold bracket A Exhaust manifold bracket B Exhaust manifold Exhaust manifold gasket RevisedMe manifold 9eK0960 Intake manifold Intake manifold stay Cylinder block venoges Oh | ¢ "Up" atk igenoe17 ‘© Mitsubishi Motors Corporation Mar. 2001 4G9 ENGINE (E-W) — Intake and Exhaust Manifold INSTALLATION SERVICE POINT DP-A EXHAUST MANIFOLD BRACKET INSTALLATION (1) Install temporarily the exhaust manifold brackets A and B as shown in the illustration. (2) Check that both brackets are in close contact with the bosses, and then tighten fully the bracket mounting bolts. (1) Temporarily install the exhaust manifold bracket as shown in the illustration. (2) Verify that the braoket is brought into close contact with the boss on the exhaust manifold, then tighten the bolts to the specified torque. D-B-qINTAKE MANIFOLD STAY INSTALLATION (1) Check to ensure that the intake manifold stay is in close contact with the intake manifold and the cylider block before tightening the respective mounting bolts to the specified torque (1) Install the intake manifold stay with its “UP mark directed toward the intake manifold. PweED6O2S Revised4G9 ENGINE (E-W) - Intake Manifold (GDI) 11A-6a-1 6a. INTAKE MANIFOLD (GDI) REMOVAL AND INSTALLATION Removal steps 1. Air by-pass hose (Up to 1998 model for CARISMA, SPACE RUNNER) 2. Vacuum pipe and hose 3. Bracket 4, Solenoid valve {@ uteubien motor Corporation tay 2000, PwEEss02-< 9eNoB90 5. Connector bracket 6. Accelerator cable bracket 7. Vacuum hose &. Vacuum pipe 9. Intake manifold 10. Intake manifold gasket11A-6a-1a 4G9 ENGINE (E-W) - Intake Manifold (GDI) REMOVAL AND INSTALLATION 19.Nm 11m 1 SeNs082 Removal steps 1. Vacuum pipe and hose 4, Vacuum pipe 2. Purge hose 5 Intake manifold 3. Solenoid valve {@ uteubien motor Corporation tay 2000, PwEs802-0 aad4G9 ENGINE (E-W) - Intake Manifold (GDI) 11A-6a-1b Intentionally blank {2 mteubien Motore Corporation May 2000, PwEs802-0 is11A-6a-2 4G9 ENGINE (E-W) - Intake Manifold (GDI) REMOVAL AND INSTALLATION 11Nm, SEN0S83 Removal steps 4. Air by-pass hose 6. Accelerator cable bracket 2. Vacuum pipe and hose 7. Vacuum hose 3. Bracket 8. Vacuum pipe 4, Solenoid valve 9 Intake manifold 5. Connector bracket 10. Intake manifold gasket © Mitsubishi Motors Corporation Jun. 1998, PwEEs602.0 Adie4G9 ENGINE (E-W) - Intake Manifold (GDI) 11A-6a-3 REMOVAL AND INSTALLATION 23.Nm SEKOO95 Removal steps 1. POY. hose 6. Branch tube 2. Vacuum pipe and hose 7. Gasket 3. Solenoid valve PA 8 Intake manifold stay 4. Fuel pump protector 9 Intake manifold 5. Connector bracket 10. Intake manifold gasket {© Mitsubishi Motors Corporation Dee. 1988, Preessoze ‘ded11A-6a-4 4G9 ENGINE (E-W) - Intake Manifold (GDI) Intake manifold Intake manifold stay Cylinder block SEN061 {© Mitsubishi Motors Corporation Dee. 1988, INSTALLATION SERVICE POINT DA INTAKE MANIFOLD STAY INSTALLATION (1) Check to ensure that the intake manifold stay is in close contact with the intake manifold and the cylinder block before tightening the respective mounting bolts to the specified torque. Pweessoze ‘ded4G9 ENGINE (E-W) - Exhaust Manifold (GDI) 11A-6b-1 6b. EXHAUST MANIFOLD (GDI) REMOVAL AND INSTALLATION senosee Removal steps 1. Oil level gauge 2 Oil level gauge guide ring 4. Exhaust manifold cover 5. Engine hanger PA 6. Exhaust manifold bracket A PA 7. Exhaust manifold bracket 8 8. Exhaust manifold 9. Exhaust manifold gasket {2 mteubieh Motore Corporation May 2000, PwEs802-6 Revised11A-6b-1a REMOVAL AND INSTALLATION aewsoea Removal steps 1. Oil level gauge 2: Oil level gauge guide 3. O-ring 4. Oxygen sensor 5. Engine hanger 6. Exhaust manifold cover 7. Exhaust manifold bracket B 8. Heat protector 9. Exhaust manifold 10, Exhaust manifold gasket 11, Exhaust manifold bracket A {2 mteubieh Motore Corporation May 2000, PwEs802-6 ded4G9 ENGINE (E-W) - Exhaust Manifold (GDI) 11A-6b-1b Intentionally blank {2 mteubieh Motore Corporation May 2000, PwEs802-6 ded11A-6b-2 4G9 ENGINE (E-W) - Exhaust Manifold (GDI) REMOVAL AND INSTALLATION 98 Nm SENOS96 Removal steps 1, Exhaust manifold cover 2. Engine hanger DB 3 Exhaust manifold bracket 4, Exhaust manifold 5, Exhaust manifold gasket {© Mitsubishi Motors Corporation Dee. 1988, Preessoze Revised4G9 ENGINE (E-W) - Exhaust Manifold (GDI) 11A-6b-3 INSTALLATION SERVICE POINTS >A EXHAUST MANIFOLD BRACKET INSTALLATION Ko (1) Slide the washers over the bolts with the chamfered side toward the bolt a ewosea (2) Install temporarily the exhaust manifold brackets A and B as shown in the illustration (3) Check that both brackets are in close contact with the bosses, and then tighten fully the bracket mounting bolts, Bracket A Exhaust manifold > B EXHAUST MANIFOLD BRACKET INSTALLATION (1) The washers must be installed with the shear-drooped side toward the bolts. (2) Temporarily install the exhaust manifold bracket as shown in the illustration (3) Verify that the bracket is brought into close contact with the boss on the exhaust manifold, then tighten the bolts to the specified torque. senoaco {© Mitsubishi Motors Corporation Dee. 1988, Preessoze ‘ded4G9 ENGINE (E-W) - Injector and Fuel Pump Assembly (GDI) 11A-6c-1 6c. INJECTOR AND FUEL PUMP ASSEMBLY (GDI) REMOVAL AND INSTALLATION pre pre bed {2 mteubieh Motore Corporation May 2000, Removal steps 1. Fuel hose 2: Fuel low pressure pipe 3. O-ring 4, Fuel nipple 5. O-ring 6. Clamp 7. Fuel feed pipe 8. Backup ring 9. O-ring 10. Backup ring 11. Fuel pump’ 12. O-ring 13. Hames bracket 14, Fuel return pipe 15. Backup ring 18. O-ring 17. Backup ring 18. Fuel high pressure regulator 19. Flange ty : my senoses, Fuel pressure sensor O-ring Backup ring Pump camshaft case O-ring Orring Harness bracket Injector harness Washer Injector holder Delivery pipe and injector insulator Injector gasket Injector Corrugated washer Backup ring Orring Backup ring Delivery pipe Revised11A-6c-1a 4G9 ENGINE (E-W) - Injector and Fuel Pump Assembly (GDI) REMOVAL AND INSTALLATION & 22. Nm 9EN1033 Removal steps 1. Injector harness 12, Washer 2. Flange 18. Injector holder Pl 3 Fuel pressure sensor DPB 14. Delivery pipe and injector Bld 4 Backup ring 15, Insulator Pid 5. O-ring 16. Injector gasket PH 6. Fuel pipe Ad 17. Corrugated washer PH 7. Backup ring DA 18. Backup ring PH 8. Oring DA 19. O-ring DH 9. Backup ring DPA 20. Backup ring PG 10. Fuel pump 21. Injector PG 11. Oring 22. Delivery pipe {2 mteubieh Motore Corporation May 2000, PwEs802-6 ded4G9 ENGINE (E-W) - Injector and Fuel Pump Assembly (GD!) 11A-6c-1b REMOVAL AND INSTALLATION 22. Nm 6 teubie Motor Corporation Removal steps Fuel hose Fuel hose Injector hamess Flange Fuel pressure sensor Backup ring ring Fuel pipe Backup ring O-ring Backup ring Fuel pump. ©eNegsen= tty 2000 PweEss02-4 bud 13, 11.Nm we seniors O-ring Washer Injector holder Delivery pipe and injector Ineulator Injector gasket Corrugated washer Backup ring O-ring Backup ing Delivery pipe Revised11A-6c-2 4G9 ENGINE (E-W) - Injector and Fuel Pump Assembly (GDI) REMOVAL AND INSTALLATION 11m ° Removal st. 1. Injector hi Nm eps jarness Fuel hose Fuel hose Fuel hose Fuel pipe O-ring le Fuel nipple 2 3, 4 5. 6. Fuel nippl 7. 8 9. O-ring DPF 10. Fuel feod 11. Backup rit 12. O-ring 13, Backup ri DF¢ 14. Fuel pury 18. O-ring pipe ing ing Pp 16. Fuel return pipe 17. Backup rir 18. O-ring 19. Backup si 6 teubie Motor Corporation ing ing tty 2000 10 Hm 1722Nm DE 20. DD 21 22. 23. 2a. 25. 26. bBd 27, 28. 29. pA 50. Ad si Dad 52. DAd 33, 34. 38. no Leow “ism ‘9ENo962 Fuel high pressure regulator Fuel pressure sensor Backup ring O-ring Spacer Washer Injector holder Delivery pipe and injector Insulator Injector gasket Corrugated washer Backup ring O-ring Backup ring Injector Delivery pipe Revised4G9 ENGINE (E-W) - Injector and Fuel Pump Assembly (GDI) 11A-6c-3 joo Backup ring cut surtace eNO7OS Corrugated washor sen0892 “ Mating marks { Mitsubishi Motors Corporation ee 1988 INSTALLATION SERVICE POINTS DA BACKUP RING / O-RING / CORRUGATED WASHER INSTALLATION (1) Attach the backup rings and O-ring to the injector. The thicker backup ring must be so installed that the inside cut surface is directed as shown in the illustration. (2) Coat the corrugated washer with white vaseline and install it to the injector as shown, Caution Always replace the corrugated washer with new one. Reused corrugated washer can cause fuel or g leaks. > BDELIVERY PIPE AND INJECTOR ASSEMBLY INSTALLATION (1) Lubricate O-ring in the injector with spindle oil or gasoline. (2) Insert the injector straight into the injector mounting hole in the delivery pipe. (8) Turn the injector clockwise and counterclockwise. If it dose not rotate smoothly, remove it to check for damaged O-ring. Damaged O-ring must be replaced with a new one, Reinstall the injector and check for smooth rotation again. (4) Align the mating mark on the injector with that on the delivery pipe. (6) Install the injector gaskets and insulators on the cylinder head. The insulator can drop off easily. Apply vaseline to it before installation so that it may be held in position, (©) Install the delivery pipe and injector assembly onto the cylinder head, then tighten the fasteners temporarily. (2) Install the injector holders and the washersto the assembly and tighten the fasteners to the specified torque. Caution Strictly observe the specified torque. Pweessoze Revised11A-6c-4 4G9 ENGINE (E-W) - Injector and Fuel Pump Assembly (GDI) “ nn Coupling | =————— ring = key r 9 | A Oy \ camsnatt.* /4, a) = Cut surtace Backup ring senovor (>= C \/ Cut surtaco Backup ring genos10 |) Mitsubishi Motors Corporation Dee. 1998, (®) Tighten the fasteners of the delivery pipe and injector assembly to the specified torque in the order given in the illustration. C4 PUMP CAMSHAFT CASE INSTALLATION (1) Apply small amount of engine oil to the O-ring (larger one) on the case. (2) Install the pump camshaft case onto the cylinder head while aligning the coupling keys of the case with the grooves in the rear end face of the camshaft. NOTE The coupling keys and the grooves at the camshaft rear end are offset with respect to the camshaft center. (3) Tighten the case mounting bolts to the specified torque. }>D-FUEL PRESSURE SENSOR INSTALLATION (1) Install the backup ring to the fuel pressure sensor with its inside cut surface in the illustrated direction. (2) Install the fuel pressure sensor straight into the fuel pressure regulator with labeled surface upward (8) Tighten the fuel pressure sensor mounting bolt to the specified torque. DE FUEL HIGH PRESSURE REGULATOR INSTALLATION (1) Install the fuel high pressure regulator on the pump camshaft case or onto the spacer and tighten the 3 bolts lightly (with somewhat larger torque than fingertight). Tightening to the specification is to be carried out in the step described in PF. Pweessoze Revised4G9 ENGINE (E-W) - Injector and Fuel Pump Assembly (GDI) 11A-6c-5 Cut surface Backup ring seno9%0 ‘oENOgEs { Mitsubishi Motors Corporation ee 1988 (2) Fit the backup rings and the O-ring on both ends of the fuel return pipe. Note that the larger backup ring must be installed with the inside cut surface in the direction shown in the illustration, (9) Lubricate the O-rings on both ends of the pipe with spindle oil or gasoline. (4) Insert the fuel return pipe ends straight in the respective mounting holes of the pressure regulator and the delivery pipe. Be sure to insert the pipe fully to the stop using care not to twist it (6) Tighten the bolts at both ends of the pipe to the specified torque. D>F-4 FUEL PUMP / FUEL FEED PIPE INSTALLATION (1) Insert the fuel pump into the mounting hole in the pump. camshaft case or in the cylinder head , and secure it temporarily with 4 bolts (tighten somewhat with a larger torque than fingertight). (2) Fit the backup rings and the O-ring on both ends of the feed pipe, Note that the larger backup ring must be installed with the inside cut surface in the direction shown in the illustration (9) Lubricate the O-rings on both ends of the pipe with spindle oil or gasoline. (4) Insert the fuel feed pipe ends straight in the respective mounting holes of the fuel and the delivery pipe. Be sure to insert the pipe fully to the stop using care not to twist it (6) Tighten the bolts at ends of the pipe to the specified torque. (©) Tighten the mounting bolts of the fuel pressure regulator to the specified torque. (7) Using a torque wrench having the minimum scale of 0.5 Nm, tighten the fuel pump mounting bolts in the following order, 1) Tighten the bolts to 5 Nm in the order given in the illustration 2) Tighten the bolts to 17 Nm in the order given in the illustration. The torque variation among 4 bolts must be within 2 Nm, Caution Strictly observe the speci ightening torque. Deviation from the specification can cause problems such as leakage or the like. Pweessoze ‘ded11A-6c-6 4G9 ENGINE (E-W) - Injector and Fu seN085¢ 7ensa9 7ens4ag Boku ring (no sppcial orientation) Cut surface Backup ring hioker one) TeNseB4 {2 mteubieh Motore Corporation May 2000, Pump Assembly (GDI) G-O-RING / FUEL PUMP INSTALLATION (1) Apply engine oil to the roller of the fuel pump and O-ring. (2) Insert the fuel pump into the mounting hole in the cylinder head and lightly tighten the four bots. (3) Using a torque wrench (minimum graduations of 0.5 Nm), follow these steps to tighten the fuel pump mounting bolts. 4) Tighten the bolts to 4.9 Nm in the order shown: 2) Tighten the bolts to 17 + 2 Nm in the order shown. Variations in torque among the four bolts should be within 2 Nm. Caution Strictly observe the tightening order. A problem could reeult if the torque epe torquing order are not met. > H-0-RING / BACKUP RING / FUEL PIPE INSTALLATION (1) Fit the backup rings and O-ring to both ends of the fuel pipe. Mount the backup ring (thicker one) so thet its inner cut surface faces in the direction shown. (2) Coat the O-rings on both ends of the pipe with spindle oil or gasoline, (3) Insert the fuel pipe straight into the mounting hole in the delivery pipe. Insert it all the way into the hole, ensuring that it does not twist. (4) Tighten the bolts on both ends of the fuel pipe to the specified torque.4G9 ENGINE (E-W) - Injector and Fu ty 0 il cul surface Backup ring 7EN1485 at > Sy - @ Dotiveey a CREO oentoas 7eN1466 7eN1 869 {B uteubieh Motore Corporation ly 2000 Pump Assembly (GDI) 11A-6c-7 Iq O-RING / BACKUP RING / FUEL PRESSURE SENSOR INSTALLATION (1) Fit the backup ring to the fuel pressure sensor so that its inner cut surface faces in the direction shown. (2) Being attentive to the shape of the connector and label surface of the fuel pressure sensor, install the fuel pressure sensor in the direction shown, p> J4 O-RING / FUEL PUMP INSTALLATION (1) Apply engine oil to the O-ring, (2) Insert the fuel pump into the mounting hole in the cylinder head and lightly tighten the four bolts. (8) Using a torque wrench (minimum graduations of 0.5 Nm), follow these steps to tighten the fuel pump mounting bolts, 1) Tighten the bolts to 4.9 Nm in the order shown: 2) Tighten the bolts to 17 + 2 Nm in the order shown. Variations in torque among the four bolts should be within 2.Nm. Caution Strictly observe the tightening order. A leak and other problem could result if the torque specifications and torquing order are not met. PweEss02-4 Revised4G9 ENGINE (E-W) = intake and Exhaust Manifold <4G94-GD1 for PAJERO io» 11A-Gd-1 6d. INTAKE AND EXHAUST MANIFOLD <4G94-GDI for PAJERO io> REMOVAL AND INSTALLATION eeni071 Removal steps 1. PON. hose 9. Intake manifold 2. Purge hose 10. Intake manifold gasket 3. Vacuum pipe and hose 11. Exhaust manifold cover 4, Solenoid valve 12. Engine hanger 5. Fuel pump protector DPA 13. Exhaust manifold bracket 6. Connector bracket 14, Exhaust manifold PB 7. Intake manifold stay 15. Exhaust manifold gasket 8. Low pressure fuel pipe {2 Mteubieh Motore Corporation ty 2000 PweEss02-411A-6d-2 4G9 ENGINE (E-W) - intake and exhaust Manifold <4@94-GD! for PAJERO io» ZF = = oO ~ @ po ‘shear-droop oemoves Intake mantold Intake ‘manitole stay Cylinder block oenoge1 6 teubie Motor Corporation sty 2000 INSTALLATION SERVICE POINTS >A EXHAUST MANIFOLD BRACKET INSTALLATION (1) The washers must be installed with the shear-drooped side toward the bolts. (2) Temporarily install the exhaust manifold bracket as shown in the illustration (3) Verify that the bracket is brought into close contact with the boss on the exhaust manifold, then tighten the bolts to the specified torque > B4 INTAKE MANIFOLD STAY INSTALLATION (1) Check to ensure that the intake manifold stay is in close contact with the intake manifold and the cylinder block before tightening the respective mounting bolts to the specified torque.4G9 ENGINE (E-W) — Water Pump and Water Hose 11A-7-1 7. WATER PUMP AND WATER HOSE sr20r7e00%6 REMOVAL AND INSTALLATION 10. Nm 9ENO577 Removal steps 41, Water hose 6. Water inlet fitting (Except carburetor engines) pda 7 Thermostat 2, Water hose DC-q 8. Thermostat case G43. Engine coolant temperature sensor PE 9. O-ring DF 4. Engine coolant temperature gauge Bq 10. Water inlet pipe unit Bq 11. O-ring DE 5. Water outlet fitting Bad 12 Water pump ‘© Mitsubishi Motors Corporation Jun, 2002 Pweesso2 Revised11A-7-2 4G9 ENGINE (E-W) — Water Pump and Water Hose REMOVAL AND INSTALLATION 14.Nm ‘° 2am os mie > Se 24.Nm 2am 10 9 Removal steps + Water hose 8, Water inlt fing 2. Water hose Dd 10. Thermostat 3, Water hose DH-4 11. Water by-pass fitting 2 Water pe Bed 12 Water pos beg | Ene Et mpaan sens B13, Osing F-q 6. Engine coolant temperature gauge -C- ‘9ENO578 Removal steps 4. Water hose A (Except GDI engine) PD 7. Thermostat 2, Water hose B (Except GDI engine) DC 8. Thermostat case PG-4_ 3. Engine coolant temperature sensor PE 9. Onin DF 4. Engine coolant temperature gauge Bq 10. Weter inlet pipe unit Bq 11. O-ring DE 5. Water outlet fitting DA 12. Water pump 6. Water inlet fitting ‘© Mitsubishi Motors Corporation Jun, 2002 Pweesso2 Revised11A-7-4 4G9 ENGINE (E-W) — Water Pump and Water Hose REMOVAL AND INSTALLATION m2 wiz 24 Nin Removal steps PS 1. Engine coolant temperature sensor BF 2. Engine coolant temperature gauge unt Pl 3. Water fting DE 4. Water outlet fiting 5. Water inlet fiting PD 6. Thermostat ‘© Mtsubish Motors Cororion —dun.2002 Pweeosnek 9eN0965 Water by-pass fitting Water pipe Orrin Thermostat case ‘Water pipe O-ring ‘Water pump Revised4G9 ENGINE (E-W) — Water Pump and Water Hose 11A-7-5 INSTALLATION SERVICE POINTS. D-AWATER PUMP INSTALLATION (1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG) to the location shown in the illustration. Specified sealant: ishi Genuine Part No.MD970389 or Mi equivalent \ ee DP B-4WATER INLET PIPE WATER PIPE /O-RING INSTALLATION (1) Replace the O-ring of the water inlet pipe or water pipe , and then apply water to the O-ring to make installation easy. Caution 4. Never apply any oil or grease to the O-ring. 2. Secure the water pipe after the thermostat case has been installed. C4 THERMOSTAT CASE INSTALLATION (1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG) to the location shown in the illustration. Specified si Mitsubishi equivalent Genuine Part No.MD970389 or EN0506 D4 THERMOSTAT INSTALLATION (1) Install the thermostat so that the jiggle valve is facing straight up. Eq WATER OUTLET FITTING INSTALLATION (1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG) to the location shown in the illustration. Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent senoste ‘© Mitsubishi Motors Corporation Jun. 2002 Pweesso2 Revised11A-7-6 4G9 ENGINE (E-W) - Water Pump and Water Hose ‘ eEN0967 ‘aeoo7s eaco070 9EN0965 oO SENO96a ‘© Mitsubishi Motors Corporation Jun. 2002 DF ENGINE COOLANT TEMPERATURE GAUGE UNIT INSTALLATION (1) Apply the specified sealant to the threads. Specified sealant: 3M ATD Part No.8660 or equivalent P>G-4ENGINE COOLANT TEMPERATURE SENSOR INSTALLATION (1) When reusing the sensor, apply the specified sealant to the threads. Specified sealant: 3M Nut Locking Part No.4171 or equivalent D-H-<{WATER BY-PASS FITTING INSTALLATION (1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG) to the location shown in the illustration. Specified sealant: Mitsubishi Genuine equivalent. Part No.MD970389 or Dl WATER FITTING INSTALLATION (1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG) to the location shown in the illustration. Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent. Pweeosnek dco4G9 ENGINE (E-W) - Rocker Arms and Camshafts 11A-8-1 8. ROCKER ARMS AND CAMSHAFTS 1200840070 REMOVAL AND INSTALLATION 20 ——_ ‘Apply engine oil to ® al'moving paris before installation, ‘9ENOS80 Removal steps 4, Breather hose 11, Rocker arm B 2. PCV. hose 12. Rocker arm A 3. Oil flier cap PBq 13. Rocker arm shaft 4. Rocker cover DPA 14. Adjusting sorew 5. Rocker cover gasket 45, Nut 6. Oll seal 48. Rocker arm C DE 7. Oil seal PB-q 17. Rocker arm shaft PD 5. Rocker arm spring DPA-¢ 18. Adjusting sorew BC-q 9. Rocker arms and rocker arm shaft 49. Nut i 20. Camshaft IN 10. Rocker arms and rocker arm shaft EX ‘© Mitsubishi Motors Corporation Mar. 2001 Pweesso2s Revised11A-8-1a 4G9 ENGINE (E-W) — Rocker Arms and Camshafts REMOVAL AND INSTALLATION 18 — yp A°2Y engine oll to all AW moving pais. before installation sento6e Removal steps 4. Breather hose 41, Rooker arm B 2: PCY. hose 42. Rocker arm A 3. Oil filler cap PB 13. Rocker arm shaft 4. Rocker cover > PFA 1H Lash adjuster 5. Rocker cover gasket 45. Rocker arm C 6, Oil seal PB-q 16. Rocker arm shaft Ed 7 Oil seal 4p BFA 17. Lash adjuster DD 8 Rocker arm sprin 418. Camshaft bcd 9. Rocker arms and rocker arm shaft IN Rocker arms and rocker arm shaft Ex ‘© Mitsubishi Motors Corporation Mar. 2001 Pweesso2s Revised4G9 ENGINE (E-W) - Rocker Arms and Camshafts 11A-8-1b Intentionally blank {2 mteubieh Motore Corporation May 2000, wes602:6 ded11A-8-2 REMOVAL AND INSTALLATION Removal steps Breather hose PCV. hose PGW. valve PCY. valve gasket ii filer cap Rocker cover Rocker cover gasket A Rocker cover gasket 8 Semi-circular packing pKa PeNoasen= bid {2 mteubieh Motore Corporation May 2000, 4G9 ENGINE (E-W) - Rocker Arms and Camshafts = sp Apply engine oil to AW ali moving parts before installation, SENOS99 10. Oil seal Hq 11. Bearing cap PG 12. Intake camshaft DeGeq 19. Exhaust camchatt 14. Ab PF 15. Lash adjuster Revised4G9 ENGINE (E-W) - Rocker Arms and Camshafts 11A-8-2a REMOVAL AND INSTALLATION ™ moving parts before installation, Removal steps Breather hose PCY Valve gasket Oi filler cap Rocker cover Rocker cover gasket Noegsene (0 Mitsubishi Motors Corporation July 1887 ——____ Apply engine cil to all PwEEss02.¢ SeNoBeS: PL 8 Oil seat BK 9. Beam camshett cap Dud 11 Ink cemshat Died 12. Exhaust camshaft 13. Rocker arm 14, Lash adjuster11A-8-2b 4G9 ENGINE (E-W) - Rocker Arms and Camshafts © Mitsubishi Motors Corporation July 1887 PwEEss02.¢4G9 ENGINE (E-W) - Rocker Arms and Camshafts 11A-8-3 REMOVAL AND INSTALLATION ————_ Sap APP ensine cil to ®W aii moving parts before installation. Removal steps 1. Breather hose 8. Oil seal 2. PCV. hose D409. Beam camshaft cap 3. PCW. valve 10. Gasket 4. PCV. valve gasket 11. Intake camshaft 5. Oil filler cap 12. Exhaust camshaft 6. Rocker cover 1. Rocker arm 7. Rocker cover gasket 4A PF 4 14. Lash adjuster {@ uteubien motor Corporation Atay 2000, wes602:6 Revised11A-8-3a 4G9 ENGINE (E-W) - Rocker Arms and Camshafts REMOVAL AND INSTALLATION Removal steps PCV. hose PCV. valve PCW. valve gasket Breather hose ii filer Rocker cover, intake Rocker cover, exhaust e@nxparepa {2 mteubieh Motore Corporation May 2000, Rocker cover gasket, intake Rocker cover gasket, exhaust bid 10. Oil seal 11. Gireular packing 12. Beam camshaft cap 13. Beam camshaft cap gasket 14, Intake camshaft 15. Exhaust camshatt arm 18. Rocker 4Ab PF 17. Lash adjuster4G9 ENGINE (E-W) - Rocker Arms and Camshafts 11A-8-3b REMOVAL AND INSTALLATION —___ Apply engine oil to all Sup APY nai pi< 9 teubieh Motor Corporation moving parts before installation, Removal steps POW. valve PCV. valve gasket Breather hose ll filer cap Rocker cover, inlet Rocker cover gasket, inlet Rocker cover, exhaust Rocker cover gasket, exhaust Cover SeNogpen= ty 2000 10. O-ring 11. Oil seal 12, Beam camshaft cay Id 13. Beam camshaft cap gasket 14, Intake camshaft 15. Exhaust camshaft 18. Rocker arm 17. Lash adjuster Revised11A-8-4 4G9 ENGINE (E-W) - Rocker Arms and Camshafts REMOVAL AND INSTALLATION installation, Removal steps Breather hose valve PCV. valve gasket Oil filler cap Rocker cover Rocker cover gasket Gil seal Thrust case @Nogpens {2 mteubien Motore Corporation sty 2000 —— ‘Apply engine oil to all NIB moving parts" before 9, O-ring Dl 10. Beam camshaft cap 11. Gasket 12, Intake camshaft 13. Exhaust camshaft 14, Rocker arm Am PF 15. Lash adjuster Revised4G9 ENGINE (E-W) - Rocker Arms and Camshafts 11A-8-5 REMOVAL SERVICE POINT 4A LASH ADJUSTER REMOVAL Caution © If the lash adjuster is re-used, clean the lash adjuster. (Refer to 11A-8-10.) INSTALLATION SERVICE POINTS Sy Lunmoriess A ADJUSTING SCREW INSTALLATION SS | (1) Install provisionally the screw to the rocker arm. Insert Na it so that the end of the screw is flush with the edge Fe of the rocker arm or projects slightly (1 mm or less) ENOSI0 DB ROCKER ARM SHAFT INSTALLATION (1) Place the end with the larger chamfered side toward the timing belt side. NOTE The rocker arm shaft for intake valves has eight oil holes. (2) Install the shaft with the oil holes toward the cylinder head. ae Timing bolt side ‘Chamfored side oil nbies CROCKER ARMS AND ROCKER ARM SHAFT INSTALLATION (1) Move the rocker arms in the directions shown in the illustration before tightening the rocker arm shaft bolts. NOTE Move the rocker arms until they touch the rocker arm shaft mounting bosses on the cylinder head D4 ROCKER ARM SPRING INSTALLATION (1) Insert the rocker arm spring at an angle to the spark plug guide and then install it so that it is at a right angle to the guide. Lo) an sos apoce uecssze ied11A-8-6 4G9 ENGINE (E-W) - Rocker Arms and Camshafts dolinal Tho os :NO289 senors| { Mitsubishi Motors Corporation ee 1988 DE OIL SEAL INSTALLATION > F-q LASH ADJUSTER INSTALLATION Caution © If the lash adjuster is re-used, clean the lash adjuster. (Refer to 11A-8-10.) (1) Fit the lash adjuster onto the cylinder head using care not to allow diesel fuel to spill out (CAMSHAFT INSTALLATION Apply engine oil to the camshaft journals and cam before installing the camshaft. Use care not to confuse the intake camshaft with the exhaust camshaft. NOTE The rear end of the intake camshaft is provided with a 4 mm-wide slit. )-H-4 BEARING CAP INSTALLATION (1) Locate the camshaft dowel pins as illustrated. (2) Apply sealant to the locations shown in the illustration. Specified sealant: 3M ATD Part No. 8660 or equivalent Pweessoze Revised4G9 ENGINE (E-W) - Rocker Arms and Camshafts 11A-8-7 Cap No. IN oF EX side Fentitication| O° ° 6ENOINI “_DOHC- GDI for CARISMA Up te 2000 mode, ‘SPACE STAR (1880 modo), SPACE RUNNER? Dowel pin i O Senora? “@DOHC-GDI for CARISMA (From 2007 mode), SPACE STAR (From 2001 mod), GALANT, PAJERO le> "Dowel pia Approx, Approx. 408" 180° O ‘9EN0970 "=DOHC- GDifor CARISMA (Up 102000 moda), ‘SPACE STAR (1090 model), SPACE RUNNERS T Beam camshatt cap ena ‘Fem sat eons ALY PLeRO pea } Timing belt side wy — Boam camshaft oap ‘SENOSTE {© uteubie motor Corporation nay 2000, (3) The bearing caps No. 2 through No. 5 are of the same shape. Before they are installed, check the cap number and the intake and exhaust identification marks. Identification mark (stamped on front and No. 2 through No. 5 bearing caps) L: Intake side R: Exhaust side (4) Make sure that the rocker arms are installed in the specified locations. Dl BEAM CAMSHAFT CAP INSTALLATION (1) Locate the camshaft dowel pin as illustrated. (2) Tur the crankshaft anticlockwise a quarter tur (90°), (8) Apply a 3 mm thick continuous bead of sealant to the bottom surface of the beam camshaft cap along the groove. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent Preess02-< Revised11A-8-8 4G9 ENGINE (E-W) - Rocker Arms and Camshafts “®DORG-GDI for CARISMA (Up fe 2000 mode, ‘SPACE STAR (1999 model), SPACE FUNNER> F ae =DOHO-GDI for GARISMA (From 2001 moda) ‘SPAGE STAR (erom 2001 mode), GALANT PAJERO lor Engine tront side 9ENoo72 “ 3022 14 senoae? “=EOHS-GDI for CARISIA (From 2001 mosh, SBACE SAR (room 2001 mode), GALANT, PALERO loo “d= Engine font side {© mteubie Motor Corporation sty 2000 (4) Apply sealant to the illustrated position of the cylinder head upper surface Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivale! (6) Install the beam camshaft cap before the sealant applied becomes dry and hard. (6) Tighten the bolts to the specified torque in the order shown in the illustration. Mé bolt 11Nm. M8 bolt 21Nm Caution The M8 bolts plated green cannot be reused. Always replace such bolts with M8 bolts finished by glossy plating which are available eeparately. The MB bolt finished by glosey plating ie reusable; if the caps have already been assembled with such bolts, then reassemble the caps using them. (2) Install the camshaft oil seal (use the special tool) and the thrust case before the sealant applied becomes dry and hard, (8) Wipe off squeezed out excess sealant from the circumference of the beam camshaft cap. Pweese024 Revised4G9 ENGINE (E-W) - Rocker Arms and Camshafts DENO0S3 senai7s| xing eenioe) "Ting rar eNo5i4 ‘When No.1 cylinder Is at compression top dead centre € iteubie Motor Corporation 11A-8-9 D> J-q SEALANT APPLICATION ON SEMI-CIRCULAR PACKING. Specified sealant: 3M ATD Part No.8660 or equivalent > K(SEALANT APPLICATION ON ROCKER COVER (1) Apply sealant to the areas indicated in the illustration. Specified sealant: 3M ATD Part No.8660 or equivalent DL O-RING / COVER INSTALLATION (1) Apply liquid gasket on the illustrated position of the cover. Specified sealant: 3M ATD Part No.8660 or equivalent (2) Lubricate the O-ring in the cover with engine oil. Install the cover in place on the cylinder head and the beam camshaft cap. VALVE CLEARANCE ADJUSTMENT Adjust the valve clearance by the following procedure. Adjustment values (when engine is cold): Intake valve: 0.09 mm. Exhaust valve: 0.20 mm (1) Turn the crankshaft in the clockwise direction to align the camshaft sprocket timing marks and to set the No.1 cylinder to the compression top dead centre position (2) The valve clearances at the places indicated by arrows in the illustration can be adjusted. (8) Use a thickness gauge to adjust the clearance between the ends of the valve stems and the adjusting screws, (4) Hold the adjusting screws with a screwdriver so that they do not tum, and then tighten the lock nuts, (©) Tur the crankshaft once in the clockwise direction to set the No.4 cylinder to the compression top dead centre position. Revised11A-8-9a 4G9 ENGINE (E-W) - Rocker Arms and Camshafts When No. oylinder ie at compression top | (6) Adjust the valve clearances indicated by arrows in the oad contre illustration by the same procedure as in steps (3) and (4) above. PENOSIS {@ mteubien motor Corporation sty 2000 Pweese024 ded4G9 ENGINE (E-W) - Rocker Arms and Camshafts 11A-8-9b Intentionally blank {2 mteubien Motore Corporation sty 2000 Pweese024 ded11A-8-10 4G9 ENGINE (E-W) — Rocker Arms and Camshafts Outside Inside Filling with cleaning cleaning ——_lgsel fuel 6EN1698 (© mitsubishi Motors Corporation Jun. 2002 INSPECTION CAMSHAFT (1) Measure the cam height ‘Standard | _Limit mm value mm Intake | 4G92-SOHC? 37.34 36.84 side ['4e92-soHe? 37.78 37.28 4G92-SOHC? 36.92 36.42 4G93-SOHCt 37.53 37.08 4G93-SOHC 37.1 36.61 4G94-SOHC 37.91 37.41 4G93-DOHC 35.49 34.99 4G93-DOHC-GDI_| 35.49 34.99 4G94-DOHC-GDI_| 35.49 34.99 Exhaust | 4G92-SOHC* 37.83 37.33 side 4G92-SOHC? 37.83 37.33 4G92-SOHC"? 36.70 36.65 4G93-SOHC™* 37.64 37.14 4G93-SOHC 37.15 36.65 4G94-SOHC 37.70 37.20 4G93-DOHC 35.20 34.70 4G93-DOHC-GOI_| 34.73 34.23 4G94-DOHC-GDI__| 34.91 34.41 2 2 “4 “5 LANCER for Europe and CARISMA for Europe. LANCER for general export and CARISMA for 6B model LANCER for Europe (from 2001 model) and CARISMA for Europe (from 2001 model) Except for Europe For Europe LASH ADJUSTER (SOHC) Caution 1. The lash adjusters are procision-ongineered mechanisms. Do not allow them to become contained by dirt or other foreign substances. 2. Do not attempt to disassemble the lash adjusters. 3. Use only fresh diesel fuel to clean the lash adjusters. (1) Prepare three containers and approximately five liters of diesel fuel. Into each container, pour enough diesel fuel to completely cover a lash adjuster when its standing upright. Then, perform the following steps with each lash adjuster. PwEES602K Revised4G9 ENGINE (E-W) - Rocker Arms and Camshafts 11A-8-11 Diesel tuel GENL699 Dieseltue! Wire’or mD9eea42 GEN1 808 Wire or mDeesaa2 Biosolfuat BEN1B09 Diesel uct Wire or Moge8442 EN 008 {© teubie motor Corporation nay 2000, (2) Place the lash adjuster in container A and clean its outside surface, NOTE Use a nylon brush if deposits are hard to remove. (3) While gently pushing down the intemal 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 all Caution The steel ball spring is extremely weak, 80 the lash adjuster’s functionality may be lost if the air bleed wire Is pushed in hard. NOTE If the plunger remains stif or the mechanism appears otherwise abnormal, replace the lash adjuster. (4) Remove the lash adjuster from the container, Then, push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber. (6) Place the lash adjuster in container B. Then, gently push down the internal steel ball using special tool MD998442 and move the plunger through 5 to 10 strokes until it slides smoothly. This operation will clean the lash adjuster's pressure chamber. 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. Preess02-< Revised11A-8-12 4G9 ENGINE (E-W) - Rocker Arms and Camshafts Wire or mDeesas2 == dieseruer BENIB08 Wire ormpege442 Diesel fuel BENt0 Wire or Moee8442 i Dieseltue! BENest BENI70¢ {@ uteubien motor Corporation Atay 2000, (6) Remove the lash adjuster from the container. Then, push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber. (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. (8) Stand the lash adjuster with its plunger at the top, then push the plunger downward firmly until it moves through its greatest possible stroke, Return the plunger slowly, then release the steel ball and allow the pressure chamber to fill with diesel fuel (9) Remove the lash adjuster from the container, then stand the lash adjuster with its plunger at the top. Push the plunger firmly and check that it does not move. Also, check that the lash adjuster’s height matches that of a new lash adjuster. NOTE If lash adjuster contracts, perform the operations (7) through (9) again to fill it with diesel fuel completely. Replace the lash adjuster ifit still contracts after performing these steps. (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. Preess02-< Revised4G9 ENGINE (E-W) - Rocker Arms and Camshafts 11A-8-13 Outside Inside ing wth cleaning cleaning giosel fuel A 8 c GEN1698 Diesol fuol GENL699 Diesel fuel BEM1207 Mpee8442 {@ uteubien motor Corporation Atay 2000, (DOHC) Caution 1. The lash adjusters are precision-engineered mechanisms. Do not allow them to become contained by dirt or other foreign substances. 2. Do not attempt to dieassemble the lach adjusters. 3. Use only frech diesel fuel to clean the lach adjusters. (1) Prepare three containers and approximately five liters of diesel fuel. Into each container, pour enough diesel fuel to completely cover a lash adjuster when itis standin upright. Then, perform the following steps with each las! adjuster, (2) Place the lash adjuster in container A and clean its outside surface. NOTE Use a nylon brush if deposits are hard to remove. (3) While gently pushing down the intemal steel ball using special tool MD998442, move the plunger through 5 to 40 strokes untilit slides smoothly. In addition to eliminating stiffness in the plunger, this operation will remove dirty oll. Caution T ball spring is extremely weak, so the lash adjuster’s functionality may be lost if the air bleed wire is pushed in hard. NOTE If the plunger remains stiff or the mechanism appears otherwise abnormal, replace the lash adjuster, Preess02-< Revised