03en Volume 1 - Engine & EL - p475

11A-0-1
ENGINE
4G9 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-1-4
NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE
TIGHTENED IN PLASTIC AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-7
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-7
FORM-IN-PLACE GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-8
2. SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-2-1
3. ALTERNATOR AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 11A-3-1
4. TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-4-1
5. FUEL AND EMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . 11A-5-1
6. INTAKE AND EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-6-1
7. WATER PUMP AND WATER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-7-1
8. ROCKER ARMS AND CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-8-1
9. CYLINDER HEAD AND VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-9-1
10. FRONT CASE AND OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-10-1
11. PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-11-1
12. CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE
PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-12-1
E Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised

11A-0-2
NOTES
E Mitsubishi Motors Corporation May 1995 PWEE9502

4G9 ENGINE (E - W) - General Information 11A-0-3
GENERAL INFORMATION
4G9 series
Descriptions 4G92- SOHC 4G93- DOHC
Type In-line OHV, SOHC In-line OHV, DOHC
Number of cylinders 4 4
Combustion chamber Pentroof type Pentroof type
Total displacement dm3 1,597 1,834
Cylinder bore mm 81.0 81.0
Piston stroke mm 77.5 89.0
Compression ratio 10.0 10.5
Valve timing Intake Opens 20_, 14_* 20_
valve (BTDC)
Closes 42_, 58_* 60_

(ABDC)
Exhaust Opens 54_, 52_* 61_

valve (BBDC)
Closes 2_, 16_* 15_

(ATDC)
Lubrication system Pressure feed, full-flow filtration Pressure feed, full-flow filtration
Oil pump type Trochoid type Trochoid type
Cooling system Water-cooled forced circulation Water-cooled forced circulation
Water pump type Centrifugal impeller type Centrifugal impeller type
*: LANCER for general export and CARISMA for 6B model
E Mitsubishi Motors Corporation July 1997 PWEE9502-C Revised

4G9 ENGINE (E - W) - Specifications 11A-1-1
1. SPECIFICATIONS
SERVICE SPECIFICATIONS
Items Standard value Limit
Timing belt
Auto-tensioner rod protrusion amount (When removed from engine) 11 -
mm
Auto-tensioner rod stroke mm Within 1 -
Auto-tensioner rod protrusion amount (When checking with installed 3.8 - 4.5 -
on engine) mm
Rocker arms and camshaft
Camshaft cam 4G92-SOHC*1 Intake 37.34 36.84
height mm
Exhaust 36.79 36.29
4G92-SOHC*2 Intake 37.78 37.28

Exhaust 37.83 37.33
4G93-SOHC Intake 37.53 37.03
Exhaust 37.64 37.14
4G93-DOHC Intake 35.31 34.81
Exhaust 35.20 34.70
Valve clearance mm Intake 0.09 -
Exhaust 0.20 -
Camshaft journal O.D. mm SOHC 26.0 -
DOHC 45.0 -
Cylinder head and valve

Cylinder head gasket surface flatness mm Less than 0.03 0.2
Grinding limit of cylinder head gasket surface mm - 0.2*
*Total resurfacing depth of both cylinder head and cylinder block
Cylinder head overall height mm SOHC 119.9 - 120.1 -
DOHC 131.9 - 132.1 -
Thickness of valve SOHC Intake 1.0 0.5
head (margin) mm
Exhaust 1.3 0.8
DOHC Intake 1.0 0.5
Exhaust 1.2 0.7
Valve overall height SOHC Intake 110.15 109.65
mm
Exhaust 113.70 113.20
DOHC Intake 104.19 103.69
Exhaust 103.87 103.37
*1: LANCER for Europe and CARISMA for Europe

*2: LANCER for general export and CARISMA for 6B model
*3: For CARISMA
*4: For PAJERO io

11A-1-2 4G9 ENGINE (E - W) - Specifications

Valve spring free length mm SOHC 50.9 49.9
DOHC 45.0 44.0
Valve spring out-of-squareness Max. 2_ 4_
Valve stem to valve Intake 0.02 - 0.05 0.10
guide clearance mm
Exhaust 0.05 - 0.09 0.15
Valve seat valve contact width mm 0.9 - 1.3 -
Valve guide projection from cylinder head SOHC 14.0 -
upper surface mm
DOHC 19.0 -
Valve stem projec- SOHC Intake 49.30 49.80
tion mm
Exhaust 49.35 49.85
DOHC Intake 46.70 47.20
Exhaust 46.65 47.15
Cylinder head bolt shank length mm - 96.4
Valve stem O.D. mm 6.0 -
Valve face angle 45_ - 45.5_ -
Valve spring load/installed height N/mm SOHC 216/44.2 -
DOHC 255/44.5 -
Valve guide I.D. mm 6.0 -
Font case, oil pump and oil pan
Oil pump tip clearance mm 0.06 - 0.18 -
Oil pump side clearance mm 0.04 - 0.10 -
Oil pump body clearance mm 0.10 - 0.18 0.35
Piston and connecting rod
Piston ring to piston ring groove clearance No. 1 0.03 - 0.07 0.1
mm
No. 2 0.02 - 0.06 0.1
Piston ring end gap No. 1 0.25 - 0.40 0.8
mm
No. 2 0.40 - 0.55 0.8
SOHC 0.20 - 0.60 1.0
DOHC 0.10 - 0.35 1.0
Crankshaft pin oil clearance mm 0.02 - 0.05 0.1
Piston pin press-in load N [Room temperature] 4,500 - 14,700 -
Connecting rod big end side clearance mm 0.10 - 0.25 0.4
Piston pin O.D. mm 19.0 -
Piston O.D. mm 81.0 -


Crankshaft, cylinder block, flywheel and drive plate
Crankshaft journal oil clearance mm 0.02 - 0.04 0.1
Cylinder block gasket surface flatness mm 0.05 0.1
Grinding limit of cylinder block gasket surface mm - 0.2*
*Total resurfacing depth of both cylinder head and cylinder block
Cylinder block overall height mm 4G92 243.5 -
4G93 263.5 -
Cylinder block I.D. mm 81.0 -
Piston to cylinder clearance mm 0.02 - 0.04 -
Bearing cap bolt shank length mm - 71.1
Crankshaft end play mm 0.05 - 0.25 0.4
Crankshaft journal O.D. mm 50 -
Crankshaft pin O.D. mm 45 -
REWORK DIMENSIONS
Items Standard value
Cylinder head and valve
Oversize rework dimensions of valve guide hole (both intake and 0.05 O.S. 11.05 - 11.07
exhaust) mm
0.25 O.S. 11.25 - 11.27
0.50 O.S. 11.50 - 11.52
Oversize rework dimensions of intake valve SOHC 0.30 O.S. 31.80 - 31.83
seat hole mm
0.60 O.S. 32.10 - 32.13
DOHC 0.30 O.S. 34.30 - 34.32
0.60 O.S. 34.60 - 34.62
Oversize rework dimensions of exhaust valve SOHC 0.30 O.S. 29.30 - 29.32
seat hole mm
0.60 O.S. 29.60 - 29.62
DOHC 0.30 O.S. 30.80 - 30.82
0.60 O.S. 31.10 - 31.13
Crankshaft, flywheel and drive plate
Crankshaft out of roundness and taper of journal and pin mm 0.005
NOTE
O.D.: Outer diameter
I.D.: Inner diameter
O.S.: Oversize diameter
Items

TORQUE SPECIFICATIONS
Items Nm
Alternator and ignition system
Oil level gauge 13
Distributor 12
Ignition coil 10
Spark plug 25
Crankshaft bolt 181
Alternator brace (M10) 49
Alternator brace (M8) 23
Lock bolt 23
Adjusting bolt <Except SOHC for PAJERO io and DOHC- GDI for PAJERO io> 10
Power steering pump pulley 25
Power steering pump bracket stay 49
Power steering pump bracket (M8) 21
Power steering pump bracket (M10) 44
Alternator pivot bolt 44
Center cover 3
Cam position sensor 9
Cam position sensor support 13
Cam position sensing cylinder 21
Engine cover 2.9
Timing belt
Camshaft sprocket bolt 88
Cam position sensor <DOHC> 9.8
Crank angle sensor 9.8
Timing belt rear cover 11
Timing belt tensioner 24
Engine support bracket, right 49
Accessory mount 49
Timing belt cover 11
Tensioner pulley bolt 49
Tensioner arm bolt 44
Auto-tensioner bolt 13
Idler pulley bolt 36
Items Nm
Fuel system and emission system
Breather tube 21
Fuel pump 18
Carburetor 17
EGR valve 21
Fuel return pipe 9
Delivery pipe 12
Fuel pressure regulator 9
Throttle body stay 23
Throttle body 19
Vacuum hose and pipe assembly <SOHC- MPI for other than PAJERO io> 10
Solenoid valve assembly <SOHC- MPI for other than PAJERO io> 11
Intake manifold and exhaust manifold
Exhaust manifold (M10) 29
Exhaust manifold (M8) 18
Exhaust manifold bracket 19
Engine hanger 12
Oil level gauge guide 14
Boost sensor 5
Intake air temperature sensor 13
Heat protector 13
Intake manifold 20
Intake manifold stay 30
Water pump and water hose
Water pump 24
Water inlet pipe 14
Thermostat case 24
Water inlet fitting <Except DOHC- GDI for PAJERO io> 19
Water by-pass fitting 23
Water pipe 13
Water outlet fitting <Except DOHC- GDI for PAJERO io> 14
Engine coolant temperature gauge unit 10
Engine coolant temperature sensor 29
Water fitting 23
Rocker arms and camshaft
Lock nut 9
Rocker arm shaft 31
Rocker cover 3.5
Items Nm
Bearing cap bolt (M6) 11

Bearing cap bolt (M8) 24
Beam camshaft cap (M8) 21
Beam camshaft cap (M6) 11
Cylinder head and valves
CylInder head bolt 74 Nm and then completely loosen,
finally tighten 20 Nm + 90_ + 90_
Oil pressure switch 10
Front case and oil pump
Oil pump cover 10
Oil pump case 14
Relief plug 44
Oil screen 19
Oil pan 7
Upper oil pan <Only M6 ´ 121> 7
Upper oil pan <Except M6 ´ 121> 11
Upper oil pan <M8> 24
Lower oil pan 7
Cover 7
Baffle plate <For CARISMA, SPACE STAR only> 7
Drain plug 39
Oil pressure switch 10
Baffle plate mounting bolt 7
Piston and connecting rod
Connecting rod cap nut 20 + 90_ to 100_
Crankshaft, cylinder block, flywheel and drive plate
Bearing cap bolt 25 + 90_ to 100_
Oil seal case 11
Bell housing cover 9
Rear plate 11
Drive plate bolt 98
Flywheel bolt 98
Baffle plate 9
Knock sensor 22

NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC
AREA
A new type of bolts, to be tightened in plastic area, is currently used for some parts of the engine.
The tightening method for bolts of this type is different from the conventional one. Be sure to observe
the method described in the text when tightening the bolts.
Service limits are provided for the bolts. Make sure that the service limits described in the text are strictly
observed.
D Areas where the bolts are in use:
(1) Cylinder head bolts
(2) Main bearing cap bolts
(3) Connecting rod cap bolts
D Tightening method
After tightening the bolts to the specified torque, tighten them another 90_ or 180_ (twice 90_). The
tightening method varies on different areas. Observe the tightening method described in the text.
SEALANT
Items Specified sealant Quantity
Water pump Mitsubishi Genuine Part No.MD970389 or equivalent As required
Thermostat case Mitsubishi Genuine Part No.MD970389 or equivalent As required
Water by-pass fitting Mitsubishi Genuine Part No.MD970389 or equivalent As required
Water fitting Mitsubishi Genuine Part No.MD970389 or equivalent As required
Engine coolant temperature sensor 3M Nut Locking Part No.4171 or equivalent As required
Engine coolant temperature gauge unit 3M ATD Part No.8660 or equivalent As required
Camshaft bearing cap 3M ATD Part No.8660 or equivalent As required
Semi-circular packing 3M ATD Part No.8660 or equivalent As required
Rocker cover 3M ATD Part No.8660 or equivalent As required
Beam camshaft cap Mitsubishi Genuine Part No.MD970389 or equivalent As required
Cylinder head Mitsubishi Genuine Part No.MD970389 or equivalent As required
Oil pressure switch 3M ATD Part No.8660 or equivalent As required
Water outlet fitting Mitsubishi Genuine Part No.MD970389 or equivalent As required
Oil pump case Mitsubishi Genuine Part No.MD970389 or equivalent As required
Oil pan/Upper oil pan/Lower oil pan Mitsubishi Genuine Part No.MD970389 or equivalent As required
Oil seal case Mitsubishi Genuine Part No.MD970389 or equivalent As required
Drive plate bolt 3M Nut Locking Part No.4171 or equivalent As required
Flywheel bolt 3M Nut Locking Part No.4171 or equivalent As required
Cam position sensor support Mitsubishi Genuine Part No.MD970389 or equivalent As required
Oil control valve 3M ATD Part No.8660 or equivalent As required
Camshaft holder 3M ATD Part No.8660 or equivalent As required

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. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to
apply the gasket evenly without a break, while observing the correct bead size.
The FIPG used in the engine is a room temperature vulcanization (RTV) type and is supplied in a 100-gram
tube (Part No. MD970389 or MD997110). Since the RTV hardens as it reacts with the moisture in the
atomospheric air, it is normally used in the metallic flange areas. The FIPG, Part No. MD970389, can
be used for sealing both engine oil and coolant, while Part No. 997110 can only be used for engine
oil sealing.
Disassembly
The parts assembled with the FIPG can be easily disassembled without use of a special method. In
some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking
with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the
joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.
For removal of the oil pan, the special tool “Oil Pan Remover” (MD998727) is available. Be sure to use
the special tool to remove the oil pan. <Except aluminium die-cast oil pans>
Surface Preparation
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure
that there are no oils, greases and foreign substances deposited on the application surfaces. Do not
forget to remove the old sealant remained in the bolt holes.
Form-In-Place Gasket Application

When assembling parts with the FIPG, you must observe some precautions, but the procedures is very
simple as in the case of a conventional precut gasket.
Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the
bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is
hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When
the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do
not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time
(about one hour) has passed after installation is completed.
The FIPG application procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.

4G9 ENGINE (E - W) - Special Tools 11A-2-1
2. SPECIAL TOOLS
Tool Number Name Use
MB990938 Handle Use with MD998776
MB990767 Crankshaft pulley Holding camshaft sprocket when loosening

holder and tightening of bolt.
Use with MD998719
MD998440 Leak-down tester Leak-down test of lash adjuster
MD998442 Air bleed wire Air bleeding of lash adjuster
MD998713 Camshaft oil seal Installation of camshaft oil seal

installer
MD998716 Crankshaft wrench Rotation of crankshaft when installing piston

and timing belt.
MD998717 Crankshaft front oil Installation of crankshaft front oil seal

seal installer
MB991653 Cylinder head bolt Tightening and loosening of cylinder head bolt
wrench
MB991659 Guide D Removal of piston pin (Use with MD998780)
E Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Revised

11A-2-2 4G9 ENGINE (E - W) - Special Tools

MD998719 Pulley holder pin Use with MB990767
(2)
MD998727 Oil pan remover Removal of the oil pan
MD998754 Pin Use with MB990767
MD998767 Tensioner pulley Adjustment of timing belt tension

socket wrench
MD998772 Valve spring Removal and installation of valve and related

compressor parts
MD998774 Valve stem seal Installation of valve stem seal

installer
MD998775 Valve stem seal Installation of valve stem seal

installer
MD998776 Crankshaft rear oil Installation of crankshaft rear oil seal

seal installer Use with MB990938

4G9 ENGINE (E - W) - Special Tools 11A-2-3

MD998780 SETTING TOOL Removal and installation of piston pin
Piston pin
MD998735 Valve spring Compression of valve spring

compressor
MD998781 Flywheel stopper Holding flywheel and drive plate
MB991477 Valve adjusting Adjustment of valve clearance (MIVEC)

wrench
MB991478 Valve adjusting Adjustment of valve clearance (MIVEC)

wrench feeler
gauge set
MB991479 Rocker arm Adjustment of valve clearance (MIVEC)

piston checker
MD998784 Valve spring Compression of valve spring (MIVEC)

compressor (Use with MD998772)
adapter

4G9 ENGINE (E - W) - Alternator and Ignition System 11A-3-1
3. ALTERNATOR AND IGNITION SYSTEM
REMOVAL AND INSTALLATION <SOHC>
10 Nm
10
11
9 Nm
13 Nm
8
25 Nm 9
21 Nm
2 12
10 Nm
23 Nm
3
44 Nm
23 Nm
49 Nm
5
4
181 Nm
Removal steps
1. Drive belt* 7. Spark plug cable
2. Alternator 8. Ignition coil
3. Alternator brace 9. Spark plug
AA" "BA 4. Crankshaft bolt 10. Cam position sensor
5. Crankshaft pulley "AA 11. Cam position sensor support
6. Front flange 12. Cam position sensing cylinder
NOTE:
*: For details of adjustment, refer to the relevant model’s
chassis workshop manual.

11A-3-2 4G9 ENGINE (E - W) - Alternator and Ignition System
REMOVAL AND INSTALLATION <DOHC>
3 Nm
10 Nm
8
10 25 Nm
11
23 Nm
10 Nm
2
23 Nm
3
44 Nm
23 Nm
5 6
29 Nm
181 Nm
1
Removal steps
1. Drive belt* 7. Center cover
2. Alternator 8. Ignition coil
3. Alternator brace 9. Spark plug cable
AA" "BA 4. Crankshaft bolt 10. Spark plug
5. Crankshaft pulley 11. Ignition failure sensor
6. Flange NOTE:
*: For details of adjustment, refer to the relevant model’s
chassis workshop manual.

4G9 ENGINE (E - W) - Alternator and Ignition System 11A-3-3
REMOVAL SERVICE POINT
AA" CRANKSHAFT BOLT REMOVAL
MD998781
(1) Use the special tool to hold the flywheel or the drive
plate, and then loosen the crankshaft mounting bolts.
INSTALLATION SERVICE POINTS

"AA CAM POSITION SENSOR SUPPORT
INSTALLATION
(1) Apply a 3 mm bead of form-in-place gasket (FIPG) to
the area shown.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or
equivalent.
"BA CRANKSHAFT BOLT INSTALLATION

(1) Use the special tool to hold the flywheel or the drive
MD998781 plate, and then tighten the crankshaft mounting bolts.
E Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Added

4G9 ENGINE (E - W) - Timing Belt 11A-4-1
4. TIMING BELT
14
88 Nm
13
11 Nm
1 7
4 5 6
11 Nm 8
11 Nm 10 9.8 Nm
11 12
9
23 Nm
3
2
49 Nm
Removal steps
1. Timing belt front upper cover 8. Crankshaft angle sensor
2. Timing belt front lower cover (Engines without distributor)
3. Engine support bracket, right 9. Crankshaft sprocket
AA" "DA 4. Timing belt 10. Crankshaft spacer
"CA 5. Tensioner spring (Engines without distributor)
"BA 6. Timing belt tensioner 11. Crankshaft sensing plate
7. Timing belt rear cover (Engines without distributor)
12. Crankshaft key
AB" "AA 13. Camshaft sprocket bolt
14. Camshaft sprocket

11A-4-2 4G9 ENGINE (E - W) - Timing Belt
19
11 Nm
88 Nm 4
18
17
5
24 Nm
11 Nm 1
6
10
36 Nm
7 11
1516
44 Nm 14
11 Nm
13
20
9
11 Nm
8 9.8 Nm
12
13 Nm
3
2
49 Nm
Removal steps
1. Timing belt upper cover 11. Cam position sensor
2. Timing belt lower cover 12. Crank angle sensor
3. Engine support bracket 13. Crankshaft sprocket
AA" "FA 4. Timing belt 14. Sensing plate
5. Tensioner pulley 15. Crankshaft spacer
6. Tensioner arm 16. Crankshaft sprocket key
7. Shaft AB" "AA 17. Camshaft sprocket bolt
"EA 8. Auto-tensioner 18. Camshaft sprocket
9. Timing belt rear cover 19. Timing belt rear cover
10. Idler pulley 20. Timing belt rear cover

REMOVAL SERVICE POINTS
AA" TIMING BELT REMOVAL
(1) Mark belt running direction for reinstallation.
AB" CAMSHAFT SPROCKET BOLT REMOVAL
MB990767
MD998719
or
MD998754
<With rocker cover removed> (Except SOHC)

(1) Use a wrench to hold the hexagonal part of the camshaft,
and then remove the camshaft sprocket mounting bolt.

MB990767 "AA CAMSHAFT SPROCKET BOLT INSTALLATION
MD998719
or
MD998754

11A-4-4 4G9 ENGINE (E - W) - Timing belt
"BA TIMING BELT TENSIONER INSTALLATION

(1) Let the pulley of the timing belt tensioner comr closest
to the exhaust side. Temporarily tighten the tensioner
Exhaust pulley fixing bolt.
side
Tensioner
pulley fixing
bolt
"CA TENSIONER SPRING INSTALLATION

Tensioner
(1) Insert the tip A (shorter one) of the tensioner spring into
“A” “B” the oil pump case.
(2) Use pliers or similar tool to pinch the tip B (longer one),
and then hook it to the tensioner bracket arm.
Pliers
"DA TIMING BELT INSTALLATION

(1) Turn the crankshaft sprocket by three teeth from the timing
mark.
Caution
Aligning the timing marks positions the piston to the
top dead centre. Then, if the 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
Timing mark 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.
Timing marks (5) Place the timing belt over the sprocket according in the
following order.
1. Crankshaft sprocket
2. Water pump sprocket
3. Camshaft sprocket
4. Tension pulley

(6) Slightly loosen the tensioner pulley fixing bolt which is
tightened temporarily to tighten the belt by a force of
the tensioner spring.
(7) Turn the crankshaft clockwise by two turns.

(8) Check that the timing marks are aligned.
MD998716 (9) Tighten the fixing bolt of the tensioner pulley.
"EA AUTO-TENSIONER INSTALLATION

Set hole (A)
Set hole (B)
(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 tilt it.
2) Slowly close the vice to force the rod in to align hole
(A) of the rod with the set hole (B).
3) Insert a 2.0-mm-Allen key in diameter or similar into
the set holes.
4) Remove the auto-tensioner from the vice.
(2) Install the auto-tensioner

Leave the align key until installation of the timing belt
is completed.

"FA 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.
Timing mark
(4) Fit the timing belt to the intake camshaft sprocket and
Paper clip secure with a paper clip at the illustrated position.
Timing mark (5) Use two wrenches to fit the timing belt to the exhaust
sprocket while aligning the timing marks.
Timing mark

(6) 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.
Idler pulley
Water
pump
sprocket
Tensioner
pulley
Crankshaft sprocket
(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 all timing marks are in alignment.
(11)Give a 1/4 counterclockwise turn to the crankshaft. Then
turn the crankshaft clockwise to align the timing marks
again.

(12)Install the special tool and a torque wrench to the tensioner

pulley.
(13)Using torque wrench, torque to 2.6 Nm.
MD998767
(14)While holding the tensioner pulley to prevent it from
turning, tighten the center bolt to the specified torque.
(15)Give two clockwise turns 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.
INSPECTION 11300200077
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.
(2) Cracks on rubber back.

Cracks (3) Cracks or peeling of canvas.
(4) Cracks on tooth bottom.
(5) Cracks on belt sides.
Peeling
Cracks
Cracks

(6) Abnormal wear of belt sides. The sides are normal if
they are sharp as if cut by a knife.
Rounded edge
Abnormal wear
(Fluffy strand)
(7) Abnormal wear on teeth.

(8) Missing tooth.
Rubber exposed
Tooth missing
and canvas
fiber exposed
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.
(3) Measure the rod projection length. If not within the
standard value, replace the tensioner.
Standard value: 11 mm
11 mm
(4) Press the rod by a force of 98 to 196 N and measure

98 to 196 N the rod stroke. If not within the standard value, replace
the tensioner.
Stroke
Standard value: 1 mm or less

4G9 ENGINE (E - W) - Fuel and Emission Control System 11A-5-1
5. FUEL AND EMISSION CONTROL SYSTEM
REMOVAL AND INSTALLATION <SOHC - MPI>
12 Nm
2
19 Nm
14
13 8
11
10
10 Nm
12 3
21 Nm
1 15 17
18
5 9 9 Nm
16
7
16
6
9 Nm 11 Nm
Removal steps
1. Vacuum hose and pipe assembly 10. Insulator
2. Throttle body "AA 11. Injector
"CA 3. Gasket 12. O-ring
4. Vacuum hose 13. Grommet
5. Fuel hose 14. Delivery pipe
"BA 6. Fuel pressure regulator 15. Fuel return pipe
7. O-ring 16. Solenoid valve assembly
8. Delivery pipe and injector 17. EGR valve
9. Insulator 18. Gasket
E Mitsubishi Motors Corporation July 1999 PWEE9502-F Revised

11A-5-2 4G9 ENGINE (E - W) - Fuel and Emission Control System
11 Nm
4 18 Nm
15 4
14 23 Nm
2
9
12
10 Nm
11 3
13
1 23 Nm
10
9 Nm
16
6
5
8
9 Nm
Removal steps
1. Vacuum pipe assembly 10. Insulator
2. Throttle body assembly 11. Insulator
"CA 3. Gasket "AA 12. Injector
4. Throttle body stay (MIVEC) 13. O-ring
5. Vacuum hose 14. Grommet
6. Fuel hose 15. Delivery pipe
"BA 7. Fuel pressure regulator 16. Fuel return pipe
8. O-ring
9. Delivery pipe and injector

4G9 ENGINE (E - W) - Fuel and Emission Control System 11A-5-3
"AA 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 delivery
pipe.
(2) While turning 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
Injector connector
and check the O-ring for damage, and then re-insert it
into the delivery pipe and check once again.
A B (4) Check that the clearance between the injector connector
and the delivery pipe is uniform (A = B).
Delivery pipe
"BA 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.
<SOHC - MPI> "CA GASKET INSTALLATION

Projection (1) Position the projection as shown in the illustration.

4G9 ENGINE (E - W) - Intake and Exhaust Manifold 11A-6-1
6. INTAKE AND EXHAUST MANIFOLD
REMOVAL AND INSTALLATION <SOHC-MPI>
20 Nm
12 Nm
3 5
20 Nm 1
4 6
7 14 Nm
2 13
29 Nm
18 Nm
12
30 Nm
11
10
9 8
12 13 Nm
19 Nm
Removal steps
1. Engine hanger 7. O-ring
2. Intake manifold stay 8. Exhaust manifold cover
3. Intake manifold 9. Engine hanger
4. Intake manifold gasket "AA 10. Exhaust manifold bracket A
5. Oil level gauge "AA 11. Exhaust manifold bracket B
6. Oil level gauge guide 12. Exhaust manifold
13. Exhaust manifold gasket
E Mitsubishi Motors Corporation Nov. 1996 PWEE9502-B Revised

11A-6-2 4G9 ENGINE (E - W) - Intake and Exhaust Manifold
20 Nm
12 Nm
3
1
20 Nm
4
12
11
2
29 Nm
18 Nm
30 Nm 8 12 Nm
10
6
9
7 14 Nm
19 Nm
Removal steps
1. Engine hanger 7. O-ring
2. Intake manifold stay 8. Engine hanger
3. Intake manifold "AA 9. Exhaust manifold bracket A
4. Intake manifold gasket "AA 10. Exhaust manifold bracket B
5. Oil level gauge 11. Exhaust manifold
6. Oil level gauge guide 12. Exhaust manifold gasket

4G9 ENGINE (E - W) - Intake and Exhaust Manifold 11A-6-3
INSTALLATION SERVICE POINT
Bracket A "AA EXHAUST MANIFOLD INSTALLATION
Bracket B
(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.
Exhaust
manifold
"BA INTAKE MANIFOLD STAY INSTALLATION

(1) Install the intake manifold stay with its “UP” mark directed
toward the intake manifold.
“UP” mark
E Mitsubishi Motors Corporation Nov. 1996 PWEE9502-B Added

4G9 ENGINE (E - W) - Water Pump and Water Hose 11A-7-1
7. WATER PUMP AND WATER HOSE 11301790016
10 Nm
29 Nm
1
3
4
24 Nm
8
2
7
6
14 Nm
14 Nm
24 Nm
5
14 Nm
10 14 Nm
11
12
Removal steps
1. Water hose "DA 7. Thermostat
(Except carburetor engines) "CA 8. Thermostat case
2. Water hose "BA 9. O-ring
"GA 3. Engine coolant temperature sensor "BA 10. Water inlet pipe
"FA 4. Engine coolant temperature gauge "BA 11. O-ring
unit "AA 12. Water pump
"EA 5. Water outlet fitting
6. Water inlet fitting

11A-7-2 4G9 ENGINE (E - W) - Water Pump and Water Hose
REMOVAL AND INSTALLATION<DOHC>
10 Nm
1 29 Nm
3
4
24 Nm
8
2
7
6
14 Nm
24 Nm 14 Nm
5
14 Nm
10
14 Nm
11
12
Removal steps
1. Water hose A "DA 7. Thermostat
2. Water hose B "CA 8. Thermostat case
"GA 3. Engine coolant temperature sensor "BA 9. O-ring
"FA 4. Engine coolant temperature gauge "BA 10. Water inlet pipe
unit "BA 11. O-ring
"EA 5. Water outlet fitting "AA 12. Water pump
6. Water inlet fitting

4G9 ENGINE (E - W) - Water Pump and Water Hose 11A-7-3
"AA WATER PUMP 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
"BA WATER INLET PIPE <SOHC, DOHC> / WATER

PIPE <DOHC - GDI for PAJERO io> / O-RING
INSTALLATION
(1) Replace the O-ring of the water inlet pipe <SOHC, DOHC>
or water pipe <DOHC - GDI for PAJERO io>, and then
apply water to the O-ring to make installation easy.
Caution
1. Never apply any oil or grease to the O-ring.
2. Secure the water pipe after the thermostat case
has been installed.
"CA THERMOSTAT CASE INSTALLATION

Specified sealant:
equivalent
"DA THERMOSTAT INSTALLATION

(1) Install the thermostat so that the jiggle valve is facing
straight up.
Jiggle valve
<SOHC, DOHC> "EA WATER OUTLET FITTING INSTALLATION

Specified sealant:
equivalent

11A-7-4 4G9 ENGINE (E - W) - Water Pump and Water Hose
"FA ENGINE COOLANT TEMPERATURE GAUGE UNIT

INSTALLATION
(1) Apply the specified sealant to the threads.
Specified sealant:
3M ATD Part No.8660 or equivalent
"GA ENGINE 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
"HA WATER BY-PASS FITTING INSTALLATION

Specified sealant:
equivalent.
"IA WATER FITTING INSTALLATION

Specified sealant:
equivalent.

4G9 ENGINE (E - W) - Rocker Arms and Camshafts 11A-8-1
8. ROCKER ARMS AND CAMSHAFTS 11300540070
3
2
1
4 31 Nm
35 Nm
5 9
13
10
8 17
18
11 12 19 9 Nm
14
15
9 Nm
16
6
20
Apply engine oil to

all moving parts
before installation.
7
Removal steps
1. Breather hose 11. Rocker arm B
2. P.C.V. hose 12. Rocker arm A
3. Oil filler cap "BA 13. Rocker arm shaft
4. Rocker cover "AA 14. Adjusting screw
5. Rocker cover gasket 15. Nut
6. Oil seal 16. Rocker arm C
"EA 7. Oil seal "BA 17. Rocker arm shaft
"DA 8. Rocker arm spring "AA 18. Adjusting screw
"CA 9. Rocker arms and rocker arm shaft 19. Nut
IN 20. Camshaft
10. Rocker arms and rocker arm shaft
EX
11A-8-2 4G9 ENGINE (E - W) - Rocker Arms and Camshafts

9
5
3 1
2
4
3.5 Nm 6
8
11 Nm
24 Nm
11
13
12
10
14
Apply engine oil to
15 all moving parts
Removal steps
1. Breather hose 10. Oil seal
2. P.C.V. hose "HA 11. Bearing cap
3. P.C.V. valve "GA 12. Intake camshaft
4. P.C.V. valve gasket "GA 13. Exhaust camshaft
5. Oil filler cap 14. Rocker arm
"JA 6. Rocker cover AA" "FA 15. Lash adjuster
7. Rocker cover gasket A
8. Rocker cover gasket B
"IA 9. Semi-circular packing

AA" LASH ADJUSTER REMOVAL
Caution
D If the lash adjuster is re-used, clean the lash
adjuster. (Refer to 11A-8-6.)

1 mm or less
"AA ADJUSTING SCREW INSTALLATION
(1) Install provisionally the screw to the rocker arm. Insert
it so that the end of the screw is flush with the edge
of the rocker arm or projects slightly (1 mm or less).
"BA ROCKER ARM SHAFT INSTALLATION

Timing belt side
(1) Place the end with the larger chamfered side toward the
timing belt side.
Chamfered 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.
Oil holes
"CA ROCKER 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.
"DA ROCKER ARM SPRING INSTALLATION

(1) Insert the rocker arm spring at an angle to the spark
plug guide and then install it so that it is at a right angle
to the guide.

"EA OIL SEAL INSTALLATION

MD998713
"FA LASH ADJUSTER INSTALLATION

Caution
D If the lash adjuster is re-used, clean the lash
adjuster. (Refer to 11A-8-6.)
(1) Fit the lash adjuster onto the cylinder head using care
not to allow diesel fuel to spill out.
"GA CAMSHAFT INSTALLATION

(1) Apply engine oil to the camshaft journals and cam before
installing the camshaft. Use care not to confuse the intake
Slit camshaft with the exhaust camshaft.
NOTE
The rear end of the intake camshaft is provided with
a 4 mm-wide slit.
Journal
"HA BEARING CAP INSTALLATION

(1) Locate the camshaft dowel pins as illustrated.
Dowel
pins
(2) Apply sealant to the locations shown in the illustration.

Specified sealant:
3M ATD Part No. 8660 or equivalent

(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.
Cap No.
Identification mark (stamped on front and No. 2
IN or EX side through No. 5 bearing caps)
identification L: Intake side
R: Exhaust side
(4) Make sure that the rocker arms are installed in the
specified locations.
►I◄ SEALANT APPLICATION ON SEMI-CIRCULAR

PACKING
Specified sealant: 3M ATD Part No.8660 or equivalent
►J◄ SEALANT APPLICATION ON ROCKER COVER

(1) Apply sealant to the areas indicated in the illustration.
Specified sealant: 3M ATD Part No.8660 or equivalent
Timing mark
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.
When No.1 cylinder is at compression top (2) The valve clearances at the places indicated by arrows in the
dead centre
illustration can be adjusted.
(3) 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 turn, and then tighten the lock nuts.
(5) Turn the crankshaft once in the clockwise direction to set
the No.4
E Mitsubishi Motors Corporation Dec. 1998

PWEE9502-E Added
When No.4 cylinder is at compression top (6) Adjust the valve clearances indicated by arrows in the
dead centre illustration by the same procedure as in steps (3) and (4)
above.
INSPECTION
CAMSHAFT
(1) Measure the cam height.
Intake SOHC 37.78 37.28

side DOHC 35.49 34.99
Exhaust SOHC 37.83 37.33
side DOHC 35.20 34.70
LASH ADJUSTER
Caution
Outside Inside Filling with 1. The lash adjusters are precision-engineered
cleaning cleaning diesel fuel 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
A
diesel fuel. Into each container, pour enough diesel fuel
B C
to completely cover a lash adjuster when it is standing
upright. Then, perform the following steps with each lash
adjuster.
(2) Place the lash adjuster in container A and clean its
outside surface.
NOTE
Use a nylon brush if deposits are hard to remove.
Diesel fuel

(3) While gently pushing down the internal steel ball using
special tool, move the plunger through five to ten strokes
until it slides smoothly. In addition to eliminating stiffness
in the plunger, this operation will remove dirty oil.
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.
MD998442
Diesel fuel NOTE
If the plunger remains stiff or the mechanism appears
otherwise abnormal, replace the lash adjuster.
(4) Removal 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.
Caution
Make sure the oil hole in the side of the body is pointing
toward container A. Do not point the oil hole at yourself
MD998442 or other people.
Diesel fuel
(5) Place the lash adjuster in container B. Then, gently push

down the internal steel ball using special tool and move
the plunger through five to ten 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
Diesel fuel wire is pushed in hard.
MD998442
(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.
Caution
Make sure the oil hole in the side of the body is pointing
toward container A. Do not point the oil hole at yourself
MD998442 or other people.
Diesel fuel
(7) Place the lash adjuster in container C. Then, gently push

down the internal steel ball using special tool.
Caution
Do not use container C for cleaning. If cleaning is
performed in container C, foreign matter could enter
the pressure chamber when chamber is filled with
diesel fuel.
MD998442 Diesel fuel

(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.
Diesel fuel
MD998442
(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 operation (7) through
(9) again to fill it with diesel fuel completely. Replace
the lash adjuster if it still contracts after performing these
steps.
(10)Set the lash adjuster on the special tool.

Division = 1 mm
MD998440
Lash adjuster
(11)Remove the bolt from the tester, then adjust the height
as illustrated.
(12)After the plunger has moved downward slightly (0.2 to
0.5 mm), measure the time taken for it to move downward
Nut by a further 1 mm.
Lash
adjuster Standard value:
3 - 20 second/1 mm (with diesel fuel at 15 to 20_C)
NOTE
Replace the lash adjuster if the time measurement is
out of specification.
(13)Place the lash adjuster in container C again, then gently

push down the internal steel ball using special tool.
(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. Return the plunger slowly,
then release the steel ball and allow the pressure chamber
to fill with diesel fuel.
Diesel fuel
MD998442

(15)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 the lash adjuster’s height matches that of a new
lash adjuster.
NOTE
If lash adjuster contracts, perform the operations (13)
through (15) again to fill it with diesel fuel completely.
Replace the lash adjuster if it still contracts after performing
these steps.
(16)Stand the lash adjuster upright to prevent diesel fuel
spilling out. Do not allow the lash adjuster to become
contaminated by dirt or other foreign matter. Fit the lash
adjuster onto the engine as soon as possible.

4G9 ENGINE (E - W) - Cylinder Head and Valves 11A-9-1
9. CYLINDER HEAD AND VALVES 11300690072
8
9
1
4 10
5 14
6 15
12 17 2
13
16
20
19
18 11
Lubricate all internal

parts with engine oil
during reassembly.
Removal steps
AA" "DA 1. Cylinder head bolt 11. Intake valve
2. Cylinder head assembly AC" "AA 12. Valve stem seal
3. Cylinder head gasket 13. Valve spring seat
AB" "CA 4. Retainer lock AC" "AA 14. Valve stem seal
5. Valve spring retainer 15. Valve spring seat
"BA 6. Valve spring 16. Exhaust valve guide
7. Exhaust valve 17. Intake valve guide
AB" "CA 8. Retainer lock 18. Exhaust valve seat
9. Valve spring retainer 19. Intake valve seat
"BA 10. Valve spring 20. Cylinder head
2 3
1 10 Nm
5
21 6
7
9 13
10 14
11 17
15
16
18
19
8
20
12
4
Lubricate all internal

parts with engine oil
during assembly.
Removal steps
"EA 1. Oil pressure switch 12. Intake valve
AA" "DA 2. Cylinder head bolt AC" "AA 13. Valve stem seal
3. Cylinder head assembly 14. Valve spring seat
4. Cylinder head gasket AC" "AA 15. Valve stem seal
AB" "CA 5. Retainer lock 16. Valve spring seat
6. Valve spring retainer 17. Exhaust valve guide
"BA 7. Valve spring 18. Intake valve guide
8. Exhaust valve 19. Exhaust valve seat
AB" "CA 9. Retainer lock 20. Intake valve seat
10. Valve spring retainer 21. Cylinder head
"BA 11. Valve spring

SOHC REMOVAL SERVICE POINTS
MB991653 AA" CYLINDER HEAD BOLT REMOVAL
(1) Loosen the cylinder head bolts using the special tool.
DOHC, MIVEC
MB991653
AB" RETAINER LOCK REMOVAL

(1) Store the removed valves, springs and other parts, tagged
MD998772 to indicate their cylinder No. and location to aid
reassembly.
MD998735
◄C► VALVE STEM SEAL REMOVAL

11A-9-4 4G9 ENGINE (E - W) - Cylinder Head and Valves
◄D► VALVE HANDLING PRECAUTIONS
(1) Sodium reacts violently with water or moisture generation
heat and liberating hydrogen. It must be handled with
utmost care because otherwise the following dangerous
conditions may result:
Loss of eyesight if sodium gets in eyes.
Burns if sodium contact skin.
Fire hazard.
(2) Handling of Sodium-filled Exhaust Valves
Sodium-filled exhaust valves are not dangerous and may be
handled in the same way as ordinary valves unless they are
broken.
Never try to break the valves and expose sodium to the air.
When worn exhaust valves are to be discarded,
have them disposed of by a salvage company equipped with
special disposal system, notifying them that the valves
contain sodium.
Should the exhaust valves be broken, neutralize sodium
using the method described below, and discard the valves
in the same way as ordinary valves.
(3) How to Neutralize Sodium
Place a container filled with more than 10 liters of water in a
well ventilated large space.
Wear rubber gloves and goggles, and carefully take out
broken valves from the cylinder head.
Put a broken valve in the water-filled container and quickly
get away from the container at least 2 or 3 m (6.6 or 10 ft.)

Caution
z Valves must be neutralized one at a time.
z Put a valve in the container only after sodium in the
preceding one has completely reacted with water.
Keep fire away from the container during the neutralization.
The resulting hydrogen gas is highly explosive.
When the reaction has finished (there is no more generation
of hydrogen gas), take the valves out of the container with
large tweezers or the like.
NOTE
The reaction occurs when water enters the cavity in the
valve. Hydrogen gas may be trapped inside the valve,
temporarily blocking the water passage. In such a case, wait
until hydrogen gas in released and remaining sodium reacts
with water.
After the neutralization of sodium, water in the container
contains sodium hydroxide and is highly alkaline. The water
solution should be disposed of according to local
regulations.
Caution
z Do not let the solution contact the eyes or the skin.
z Should it get in the eyes, immediately flush them with
clean water thoroughly, and receive medical attention.
When it contacts the skin, wash with ample amounts of
clean water.

SOHC INSTALLATION SERVICE POINTS

►A◄ VALVE STEM SEAL INSTALLATION
(1) Install the vale spring seat.
(2) Use the special tool to install the valve stem seal. Improper
installation could result oil leaking past the valve guide.
MD998774 Caution
Do not reuse removed valve stem seals.
DOHC
MD998775
►B◄ VALVE SPRING INSTALLATION

Spring
retainer (1) Install the valve spring with the painted end on the rocker
Painted
end arm side.
Stem seal
Spring seat
►C◄ RETAINER LOCK INSTALLATION

MD998772
(1) The valve spring, if excessively compressed, causes the
bottom end of retainer to be in contact with the stem seal,
and damage it.
MD998735
►D◄ CYLINDER HEAD BOLT INSTALLATION

(1) When installing the cylinder head bolts, check that the
shank length of each bolt meets the limit. If the limit is
exceeded, replace the bolts.
Limit: Max. 96.4 mm
(2) Install the washers as illustrated.
(3) Apply engine oil to the bolt threads and washers.
Shank length
(4) According to the tightening sequence, tighten the bolts to

Timing belt side the specified torque 74 Nm.
(5) Loosen all bolts fully.
(6) Retighten the loosened bolts to a torque of 20 Nm in the
specified tightening sequence.
8 6 1 3 9 (7) Make paint marks on the cylinder head bolt heads and
cylinder head.
10 4 2 5 7 (8) Give a 90_ turn to the cylinder head bolts in the specified
tightening sequence.
(9) Give another 90_ turn to the cylinder head bolts and make
sure that the paint mark on the head of each cylinder head
bolt and that on the cylinder head are on the same straight
line.
Caution
1. If the bolt is turned less than 90°, proper fastening
performance may not be expected. When tightening the bolt,
90_ therefore, be careful to give a sufficient turn to it.
2. If the bolt is overtightened, loosen the bolt completely and
then retighten it by repeating the tightening procedure from
step (1).
90_
Pain mark
►E◄ SEALANT APPLICATION TO OIL PRESSURE

SWITCH
(1) Apply sealant to the threads of the switch.
Specified sealant:
Caution
Use care not to allow the sealant to plug the oil passage.
INSPECTION
CYLINDER HEAD
(1) Check the cylinder head gasket surface for flatness by
using a straightedge and thickness gauge.
Standard value: 0.03 mm
Limit: 0.2 mm
(2) If the service limit is exceeded, correct to meet the
specification.
Grinding limit:*0.2 mm
*Includes/combined with cylinder block grinding
Cylinder head height (Specification when new):
119.9 - 120.1 mm <SOHC>
131.9 - 132.1 mm <DOHC>
1
VALVE
(1) Check the valve face for correct contact. If incorrect,
reface using a valve refacer. Valve should make a uniform
contact with the seat at the centre of valve face.
(2) If the margin is smaller than the service limit, replace
Valve seat contact the valve.
Margin
Standard value Limit mm

mm
Intake 1.0 0.5
DOHC 1.2 0.7
(3) Measure the overall height of the valve. If the specified

limit is exceeded, replace the valve.
mm
DOHC 104.19 103.69
DOHC 103.87 103.37

VALVE SPRING
Out of square
(1) Measure the valve spring’s free height. If the measurement
is less than specified, replace the spring.
Free height mm
SOHC 50.9 49.9
DOHC 45.0 44.0
(2) Measure the squareness of the spring. If the measurement

exceeds the specified limit, replace the spring.
Standard value: 2_ or less
Limit: 4_
Valve stem end VALVE SEAT

(1) Assemble the valve, then measure the valve stem
Valve stem projection between the end of the valve stem and the
projection spring seating surface. If the measurement exceeds the
specified limit, replace the valve seat.
Spring seating
surface Standard value Limit mm
mm
DOHC 46.70 47.20
DOHC 46.65 47.15
VALVE GUIDE
(1) Measure the clearnace between the valve guide and valve
stem. If the limit is exceeded, replace the valve guide
or valve, or both.
Valve
guide Standard value:
Intake: 0.02 - 0.05 mm
Exhaust: 0.05 - 0.09 mm
Limit:
Intake: 0.10 mm
Exhaust: 0.15 mm
0.9 - 1.3 mm VALVE SEAT RECONDITIONING PROCEDURE
0.9 - 1.3 mm (1) Before correcting the valve seat, check the clearance
65_ between the valve guide and valve. If necessary, replace
65_ the valve and/or valve guide.
(2) Using the appropriate special tool or seat grinder, correct
the valve seat to achieve the specified seat width and
15_
15_ angle.
(3) After correcting the valve seat, lap the valve and valve
44_ 44_ seat using lapping compound. Then, check the valve
stem projection (refer to VALVE SEAT in INSPECTION).
0.5 - 1.0 mm VALVE SEAT REPLACEMENT PROCEDURE

(1) Cut the valve seat to be replaced from the inside to thin
the wall thickness. Then, remove the valve seat.
(2) Rebore the valve seat hole in the cylinder head to a
Cut away selected oversize valve seat diameter.
Intake valve seat hole diameter
0.5 - 1.0 mm 0.3 O.S. <SOHC>: 31.80 - 31.83 mm
<DOHC>: 34.30 - 34.33 mm
0.6 O.S. <SOHC>: 32.10 - 32.13 mm
<DOHC>: 34.60 - 34.63 mm
Exhaust valve seat hole diameter
0.3 O.S. <SOHC>: 29.30 - 29.32 mm
<DOHC>: 30.80 - 30.83 mm
0.6 O.S. <SOHC>: 29.60 - 29.62 mm
Valve seat
<DOHC>: 31.10 - 31.13 mm
height
Oversize valve seat

hole diameter
(3) Before fitting the valve seat, either heat the cylinder head
up to approximately 250_C or cool the valve seat in liquid
nitrogen, to prevent the cylinder head bore from galling.
(4) Correct the valve seat to the specified width and angle.
VALVE GUIDE REPLACEMENT

(1) Force the valve guide out toward the cylinder block using
a press.
(2) Machine the valve guide hole in the cylinder head to
the size of the oversize valve guide to be installed.
Caution
Do not use the valve guide of the same size as the
removed one.
Valve guide hole diameters in cylinder head
0.05 O.S.: 11.05 - 11.07 mm
0.25 O.S.: 11.25 - 11.27 mm
0.50 O.S.: 11.50 - 11.52 mm

(3) Press-fit the valve guide until it protrude specified value

(SOHC: 14 mm, DOHC: 19 mm) as shown in the
illustration.
Caution
1. Press the valve guide from the cylinder head top
surface.
2. Valve guide for intake valve and that for exhaust
valve are different in length. (45.5 mm for intake
Protrusion
valve; 50.5 mm for exhaust valve)
(4) After the valve guide has been installed, insert a new
valve to check for smooth sliding motion.
E Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Added

4G9 ENGINE (E - W) - Front Case and Oil Pump 11A-10-1
10. FRONT CASE AND OIL PUMP
10 Nm
12 14
13
15
1
16
10 Nm
7
6
19 Nm
10
9
11 8 44 Nm
14 Nm
2 3
7 Nm
39 Nm
4
Apply engine oil to all

moving parts before
installation.
Removal steps
"FA 1. Oil pressure switch 9. Relief spring
"EA 2. Oil filter 10. Relief plunger
3. Drain plug "CA 11. Oil seal
4. Drain plug gasket "BA 12. Oil pump case
AA" "DA 5. Oil pan 13. O-ring
6. Oil screen 14. Oil pump case cover
7. Oil screen gasket AC" "AA 15. Outer rotor
8. Relief plug AC" "AA 16. Inner rotor

11A-10-2 4G9 ENGINE (E - W) - Front Case and Oil pump
10 Nm
10 Nm
14
15 16
17
1 18 6
9
8
19 Nm
7 Nm
5
12
11
7 Nm
13 10 44 Nm
14 Nm
3 4
2
39 Nm
24 Nm
7 Nm
Apply engine oil to all

moving parts before
installation.
Removal steps
"FA 1. Oil pressure switch 10. Relief plug
"EA 2. Oil filter 11. Relief spring
3. Drain plug 12. Relief plunger
4. Drain plug gasket "CA 13. Oil seal
5. Baffle plate <For CARISMA, "BA 14. Oil pump case
SPACE STAR only> 15. O-ring
AB" "DA 6. Upper oil pan 16. Oil pump case cover
"DA 7. Lower oil pan AC" "AA 17. Outer rotor
8. Oil screen AC" "AA 18. Inner rotor
9. Oil screen gasket
E Mitsubishi Motors Corporation Jun. 1998 PWEE9502-D Revised

MD998727 MD998727 REMOVAL SERVICE POINTS
AA" OIL PAN REMOVAL
(1) Knock in the special tool deeply between the oil pan
and the cylinder block.
(2) Hitting the side of the special tool, slide the special tool
along the oil pan to remove the oil pan.
AB" REMOVAL OF UPPER OIL PAN

(1) At first remove the bolt (Length: 121 mm <DOHC,
DOHC- GDI for CARISMA>, 116 mm <DOHC - GDI for
PAJERO io>) which is nearest to flywheel, and the remove
the other bolts.
Caution
Never use the special tool (oil pan remover), etc.
AC" OUTER ROTOR/INNER ROTOR REMOVAL

(1) Make alignment dots on the outer and inner rotors for
Alignment dots reference in reassembly.

"AA INNER ROTOR/OUTER ROTOR INSTALLATION
Alignment dots
(1) Apply engine oil to the rotors. Then, install the rotors
ensuring that the alignment dots made at disassembly
are properly aligned.
"BA SEALANT APPLICATION TO OIL PUMP CASE

3 mm diameter
bead sealant
Specified sealant:
equivalent

11A-10-4 4G9 ENGINE (E - W) - Front Case and Oil pump
"CA CRANKSHAFT FRONT OIL SEAL INSTALLATION

MD998717 Using the special tool, knock the oil seal into the oil pump
case.
Oil pump case
MD998717 Crankshaft
Guide
Oil seal
OIL PAN, UPPER OIL PAN "DA OIL PAN/UPPER OIL PAN/LOWER OIL PAN
INSTALLATION
(1) Remove all the remaining gasket from the mating surfaces
using a scraper or a wire brush.
(2) Apply a 4 mm diameter bead of sealant to the oil pan
flange.
See “Form-In-Place Gasket” in “SPECIFICATIONS”.
Specified sealant:
Bolt hole
Groove portion Mitsubishi Genuine Part No. MD970389 or
portion equivalent
(3) Install the oil pan within 15 minutes after applying the
LOWER OIL PAN <SOHC, DOHC> sealant.
4 mm
diameter
bead
sealant Bolt hole
portion
Groove portion
<SOHC, DOHC> (4) Tighten the lower oil pan mounting bolts in the sequence
shown in the illustration.

◄E► OIL FILTER INSTALLATION

(1) Clean the filter installation surface of the cylinder block.
(2) Apply engine oil to the O-ring of the oil filter.
(3) Screw in the oil filter until its O-ring comes in contact
with the base. Then tighten one more turn.
◄F►SEALANT APPLICATION TO OIL PRESSURE

SWITCH
(1) Apply sealant to the threads of the switch.
Specified sealant:
Caution
Use care not to allow the sealant to plug the oil
Oil passage passage.
INSPECTION
OIL PUMP
(1) Check the tip clearance.
(2) Check the side clearance.

(3) Check the body clearance.

Limit: 0.35 mm

4G9 ENGINE (E - W) - Piston and Connecting Rod 11A-11-1
11. PISTON AND CONNECTING ROD
REMOVAL AND INSTALLATION
Lubricate all inter-

nal parts with en-
gine oil during re- 6
assembly.
7
8
9 4
10
12
11
2
1
Removal steps
"GA 1. Nut "CA 7. Piston ring No. 2
AA" "FA 2. Connecting rod cap "BA 8. Oil ring
"EA 3. Connecting rod bearing AB" "AA 9. Piston pin
"DA 4. Piston and connecting rod 10. Piston
"EA 5. Connecting rod bearing 11. Connecting rod
"CA 6. Piston ring No. 1 12. Bolt

11A-11-2 4G9 ENGINE (E - W) - Piston and Connecting Rod
REMOVAL SERVICE POINTS

AA" CONNECTING ROD CAP REMOVAL
(1) Mark the cylinder number on the side of the connecting
Cylinder number rod big end for correct reassembly.
Piston pin setting tool: MD998780 AB" PISTON PIN REMOVAL

Guide A: Piston pin setting tool (MD998780) consists of the parts shown
Push rod 17.9 mm in the illustration at left.
To remove the piston pin, Guide D (MB991659) is also used
in combination with the Piston pin setting tool.
Guide B
Guide A:
18.9 mm
Guide C Guide A:
20.9 mm
Base
Guide A:
21.9 mm
(1) Insert the Push Rod (special tool) into the piston from
the side on which the front mark is stamped in the piston
Push rod head, and attach the guide D to the push rod end.
(2) Place the piston and connecting rod assembly on the
Piston Pin Setting Base (special tool) with the front mark
facing upward.
Front mark
(3) Using a press, remove the piston pin.
Front NOTE
mark
Keep the disassembled pistons, piston pins and
connecting rods in order according to the cylinder number.
Guide D
Base

"AA PISTON PIN INSTALLATION
(1) Measure the following dimensions of the piston, piston
pin and connecting rod.
C A: Piston pin insertion hole length
D
B: Distance between piston bosses
C: Piston pin length
D: Connecting rod small end width
Connecting rod (2) Calculate the following formula by substituting the
Piston pin measured value.
Piston
L = ((A - C) - (B - D))/2
(3) Insert the Push Rod (special tool) into the piston pin and
attach the guide A to the push rod end.
(4) Assemble the connecting rod in the piston with their front
marks facing the same direction.
B A (5) Apply engine oil to the entire periphery of the piston pin.
(6) Insert the piston pin, push rod and guide A assembly
having assembled in step (3) from the guide A side into
the piston pin hole on the front marked side.
3 mm + L (7) Screw the guide B into the guide A until the gap between
both guides amounts to the value L obtained in step
(2) plus 3 mm.
Guide B Guide A
(8) Place the piston and connecting rod assembly onto the
piston setting base with the front marks directed upward.
Push rod
(9) Press-fit the piston pin using a press. If the press-fitting
force required is less than the standard value, replace
the piston and piston pin set or/and the connecting rod.
Standard value: 4,500 - 14,700 N
Piston pin
Front mark
Front
mark
Guide A
Base
Guide B

"BA OIL RING INSTALLATION

Side rail
(1) Fit the oil ring spacer into the piston ring groove. Install
the upper side rail, and then install the lower side rail.
NOTE
Spacer 1. The side rails and spacer may be installed in either
direction.
2. New spacer and side rail are painted with the following
identification colour according to the size.
Size Identification colour
Standard size None
Side rail end 0.50 mm O.S. Blue
1.00 mm O.S. Yellow
3. To install the side rail, first fit one end of the rail
into the piston groove, then press the remaining
portion into position by finger as shown in the
illustration.
Caution
Do not use piston ring expander when installing side
rail. Use of piston ring expander to expand the side
rail end gap can break the side rail, unlike other piston
rings.
(3) Make sure that the side rails move smoothly in either
direction.
"CA PISTON RING NO.2/PISTON RING NO.1

INSTALLATION
(1) Using piston ring expander, install the piston rings with
their side having identification marks facing up.
Identification mark:
No.1 ring: T
No.2 ring: 2T
Identification mark “T” NOTE

Identification mark “2T” The piston ring is stamped with the following size mark.
Size mark
Size Size mark
Standard size None
No.1 0.50 mm O.S. 50
No.2 1.00 mm O.S. 100

Upper side rail No.1 ring "DA PISTON AND CONNECTING ROD INSTALLATION
(1) Liberally coat engine oil on the circumference of the piston,
piston ring and oil ring.
(2) Arrange the piston ring and oil ring gaps (side rail and
Piston pin spacer) as shown in the illustration.
(3) Face the front mark (arrow) on the top of the piston toward
the camshaft sprocket.
No.2 ring and Lower side rail
spacer
(4) Using a suitable piston ring compressor tool, insert the

piston and connecting rod assembly into the cylinder block.
Caution
Do not strike the piston into the cylinder block because
the piston ring or crank pin will be damaged.
"EA CONNECTING ROD BEARING INSTALLATION

(1) When the bearings are to be replaced, select correct
Check digit
ones according to the identification marks stamped in
No.4 the crankshaft.
No.3
No.2 Crank pin O.D.
identification Crankshaft Connecting rod bearing
No.1
mark Pin O.D. Identification Identification colour (Line
identification mark (service production part)
Crankshaft journal mark part)
O.D. identification
mark 1 S1 Brown
2 S2 Black
3 S3 Green
Identification
mark
Identification
colour

"FA CONNECTING ROD CAP INSTALLATION

(1) Mate the correct bearing cap with the correct connecting
rod by checking with the alignment marks marked during
disassembly. If a new connecting rod has no alignment
Cylinder No. mark, position the notches for locking the bearing on
the same side.
Notches
(2) Check if the thrust clearance in the connecting rod big

end is correct.
Limit: 0.4 mm
"GA CONNECTING ROD CAP NUT INSTALLATION

Caution
If the cylinder head has been installed before installing
the connecting rod cap nut, be sure to remove the spark
plugs.
(1) Since the connecting rod cap bolts and nuts are torqued
using the plastic area tightening method, the bolts should
be examined BEFORE reuse. If the bolt threads are
“necked down”, the bolt should be replaced.
Necking can be checked by running a nut with fingers
to the full length of the bolt threads. If the nut does not
run down smoothly, the bolt should be replaced.
(2) Before installation of each nut, apply engine oil to the
thread portion and bearing surface of the nut.
(3) Install each nut to the bolt and tighten it with fingers.
Then tighten the nuts alternately to install the cap properly.
(4) Tighten the nuts to a torque of 20 Nm.

(5) Make a paint mark on the head of each nut.
Paint mark (6) Make a paint mark on the bolt end at the position 90_
Paint to 100_ from the paint mark made on the nut in the direction
mark 90_ - 100_ of tightening the nut.
(7) Give a 90_ to 100_ turn to the nut and make sure that
the paint mark on the nut and that on the bolt are in
alignment.
Nut Bolt Caution
1. If the nut is turned less than 90_, proper fastening
performance may not be expected. When
tightening the nut, therefore, be careful to give
a sufficient turn to it.
2. If the nut is overtightened (exceeding 100_), loosen
the nut completely and then retighten it by
repeating the tightening procedure from step (1).
INSPECTION 11300850074
PISTON RING
(1) Check the clearance between the piston ring and ring
groove. If the limit is exceeded, replace the ring or piston,
or both.
Standard value:
No.1: 0.03 - 0.07 mm
No.2: 0.02 - 0.06 mm
Limit:
No.1: 0.1 mm
No.2: 0.1 mm
Push in by Install the piston ring into the cylinder bore. Force the
the piston ring down with a piston, the piston crown being in contact
with the ring, to correctly position it at right angles to
the cylinder wall. Then, measure the end gap with a
thickness gauge.
If the ring gap is excessive, replace the piston ring.
Standard value:
Piston No.1: 0.25 - 0.40 mm
Piston ring ring gap No.2: 0.40 - 0.55 mm
Oil:
SOHC: 0.20 - 0.60 mm
DOHC: 0.10 - 0.35 mm
Limit:
No.1, No.2: 0.8 mm
Oil: 1.0 mm

CRANKSHAFT PIN OIL CLEARANCE (PLASTIGAGE

METHOD)
(1) Remove oil from crankshaft pin and connecting rod
bearing.
(2) Cut the Plastigage to the same length as the width of
bearing and place it on crankshaft pin in parallel with
its axis.
(3) Install the connecting rod cap carefully and tighten the
bolts to specified torque.
Plastigage (4) Carefully remove the connecting rod cap.
(5) Measure the width of the Plastigage at its widest part
by using a scale printed on the Plastigage package.
Limit: 0.1 mm

4G9 ENGINE (E - W) - Crankshaft, Cylinder Block, Flywheel and Drive Plate 11A-12-1
12. CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE
PLATE
REMOVAL AND INSTALLATION
22 Nm M/T <engines with conven-

11 tional flywheel>
11 Nm
22
14
24 1
13
2 98 Nm
M/T <engines with

flexible flywheel>
21 11 Nm
12 3
23
20 5 4
19 7 98 Nm
6 A
18
9 Nm A/T
17
8
9
16 10 98 Nm
15 Apply engine oil to

9 Nm all moving parts
Removal steps
"FA 1. Flywheel bolt 15. Baffle plate
2. Flywheel <DOHC- MIVEC and DOHC - GDI>
"FA 3. Flywheel bolt "CA 16. Bearing cap bolt
4. Plate "CA 17. Bearing cap
5. Adapter plate "BA 18. Crankshaft bearing, lower
6. Flywheel 19. Crankshaft
7. Adapter plate "BA 20. Thrust plate
"FA 8. Drive plate bolt "BA 21. Crankshaft bearing, upper
9. Adapter plate 22. Knock sensor
10. Drive plate <DOHC- MIVEC and DOHC - GDI>
11. Rear plate AA" "AA 23. Oil jet
12. Bell housing cover <SOHC> <DOHC- MIVEC and DOHC - GDI>
"EA 13. Rear oil seal case 24. Cylinder block
"DA 14. Oil seal
Caution
On the flexible wheel equipped engines, do not remove any of the bolts “A” of the flywheel shown
in the illustration.
The balance of the flexible flywheel is adjusted in an assembled condition. Removing the bolt,
therefore, can cause the flexible flywheel to be out of balance, giving damage to the flywheel.
11A-12-2 4G9 ENGINE (E - W) - Crankshaft, Cylinder Block, Flywheel and Drive Plate

AA" OIL JET REMOVAL
(1) Knock out the oil jets using an appropriate metal rod.
Caution
1. Be careful not to scratch the cylinder wall.
2. Do not reuse the removed oil jets.

"AA OIL JET INSTALLATION
(1) Using a 4.5 mm diameter pin punch, drive in the oil jet
to the crankshaft journal until it seats to the bottom.
"BA CRANKSHAFT BEARING INSTALLATION

(1) When the bearings are to be replaced, select correct
Check digit ones and install them in the correct positions according
to the identification marks stamped on the crankshaft
Crank pin and the top surface of the cylinder block.
O.D. identifi-
cation mark Crankshaft Cylinder Crankshaft bearing
No. 5
No. 4 journal block bearing
No. 3 Journal bore
No. 2 O.D. identifi-
No. 1 cation mark Identification Identification Identification Identification
mark mark mark (service colour (Line
parts) production parts)
1 0 1 Brown
1 2 Black
2 3 Green
2 0 2 Black
1 3 Green
2 4 Yellow
3 0 3 Green
1 4 Yellow
2 5 Pink*
*: Older bearings may be marked in red.

No. 3 No. 2
No. 4 No. 1 Identifica-
No. 5 tion mark
for cylin-
der block
bearing
Cylinder I.D. support
identification section
mark I.D.
Serial No.
Front
(2) Install the bearings having an oil groove to the cylinder

block.
(3) Install the bearings having no oil groove on the bearing
Oil groove caps.
Grooves (4) Install the thrust bearings at the No. 3 upper bearing
Identification with the grooved side towards the crank web.
mark
Identification Identifica-
colour tion colour Identification
colour
"CA BEARING CAP/BEARING CAP BOLT INSTALLATION

(1) Install the bearing caps so that their arrows are positioned
on the time belt side.
(2) When installing the bearing cap bolts, check that the
shank length of each bolt meets the limit. If the limit is
exceeded, replace the bolt.
Limit: max. 71.1 mm
Length of shank
(3) Apply engine oil to the threaded portion and bearing
surface of the bolt.
(4) Tighten the bearing cap bolts to 25 Nm torque in the

tightening sequence.
(8) (4) (1) (5) (9)
(7) (3) (2) (6) (10)
Arrow

(5) Make a paint mark on the head of each bolt.

Paint (6) Make a paint mark on the area around the bolt bearing
Paint marks marks
surface at location 90_ to 100_ in the direction of tightening
the bolt, as referenced from the paint mark on the bolt
head.
(7) Give a 90_ to 100_ turn to the bolts in the tightening
sequence. Make sure that the paint mark on the bolt
and that on the area around the bolt bearing surface
90_ - 100_ are in alignment.
Caution
1. If the nut is turned less than 90_, proper fastening
performance may not be expected. When
tightening the nut, therefore, be careful to give
a sufficient turn to it.
2. If the nut is overtightened (exceeding 100_), loosen
the nut completely and then retighten it by
repeating the tightening procedure from step (1).
(8) After installing the bearing caps, make sure that the
crankshaft turns smoothly and the end play is correct.
If the end play exceeds the limit, replace crankshaft
bearings.
Limit: 0.4 mm
"DA OIL SEAL INSTALLATION
MB990938
MD998776
"EA SEALANT APPLICATION TO OIL SEAL CASE

Specified sealant:
equivalent

"FA DRIVE PLATE BOLT/FLYWHEEL BOLT
INSTALLATION
(1) Remove all the ramaining sealant from bolts and thread
holes of crankshaft.
(2) Apply engine oil to the flange of bolt.
(3) Apply engine oil into the thread holes of crankshaft.
(4) Apply specified sealant to the thread of bolts.
Specified sealant:
3M Nut Locking Part No. 4171 or equivalent
(5) Tighten the bolts to specified torque.
INSPECTION
CRANKSHAFT JOURNAL OIL CLEARANCE
(PLASTIGAUGE METHOD)
(1) Remove oil from the crankshaft journal and he crankshaft
bearing.
(2) Install the crankshaft.
(3) Cut the Plastigauge to the same length as the width of
bearing and place it on the journal in parallel with its
Plastigauge
axis.
(4) Install the crankshaft bearing cap carefully and tighten

the bolts to the specified torque.
(5) Carefully remove the crankshaft bearing cap.
(6) Measure the width of the Plastigauge at its widest part
by using a scale printed on the Plastigauge package.
Limit: 0.1 mm
Plastigauge
CYLINDER BLOCK
(1) Using a straightedge and thickness gauge, check the
block top surface for warpage. Make sure that the surface
is free from gasket chips and other foreign matter.
Standard value: 0.05 mm or less
Limit: 0.1 mm
(2) If the distortion is excessive, correct within the allowable
limit or replace.
Grinding limit: 0.2 mm
The total thickness of the stock allowed to be
removed from cylinder block and mating cylinder
head 0.2 mm at maximum.
Cylinder block height (when new):
243.5 mm <4G92>
263.5 mm <4G93>
(3) Check the cylinder walls for scratches and seizure. If
defects are evident, correct (bored to oversize) or replace.

(4) Using a cylinder gauge, measure the cylinder bore and

cylindricity. If worn badly, correct the cylinder to an
A oversize and replace the piston and piston rings. Measure
B at the points shown in illustration.
Standard value:
12 mm
Cylinder inner diameter: 81.00 - 81.03 mm
Out-of-roundness and taper of cylinder bore: 0.01
Centre mm or less
Bottom
BORING CYLINDER
(1) Oversize pistons to be used should be determined on
the basis of the largest bore cylinder.
Piston size identification
Size Identification mark
Thrust
direction 0.50 mm O.S. 0.50
Piston O.D.
1.00 mm O.S. 1.00
NOTE
Size mark is stamped on the piston top.
(2) Measure outside diameter of piston to be used. Measure
it in thrust direction as shown.
(3) Based on the measured piston O.D., calculate the boring
finish dimension.
Boring finish dimension = Piston O.D. + (Clearance
between piston O.D. and cylinder) - 0.02 mm
(honing margin)
(4) Bore all cylinders to the calculated boring finish dimension.
Caution
To prevent distortion that may result from temperature
rise during honing, bore cylinders, in the order of
No. 2, No. 4, No.1 and No. 3.
(5) Hone to the final finish dimension (Piston O.D. + clearance
between piston O.D. and cylinder.)
(6) Check the clearance between piston and cylinder.
Clearance between piston and cylinder:
0.02 - 0.04 mm
NOTE
When boring cylinders, finish all of four cylinders to the
same oversize. Do not bore only one cylinder to an
oversize.

11B-1
11B-2
11B-3
11B-4
11B-5
11B-6
11B-7
11B-8
11B-9
11B-10
11B-11
11B-12
11B-13
11B-14
11B-15
11B-16
11B-17
11B-18
11B-19
11B-20
11B-22
11B-23
11B-24
13A-1
13A-2
13A-3
13A-4
13A-5
13A-6
13A-7
13A-8
13A-9
13A-10
13A-11
13A-12
13A-13
13A-14
13A-15
13A-16
13A-17
13A-18
13A-19
13A-20
13A-21
13A-22
13A-23
13A-24
13A-25
13A-26
13A-27
13A-28
13A-29
13A-30
13A-31
13A-32
13A-33
13A-34
13A-35
13A-36
13A-37
13A-38
13A-39
13A-40
13A-41
13A-42
13A-43
13A-44
13A-45
13A-46
13A-47
13A-48
13A-49
13A-50
13A-51
13A-52
13A-53
13A-54
13A-55
13A-56
13A-57
13A-58
13A-59
13A-60
13A-61
13A-62
13A-63
13A-64
13A-65
13A-66
13A-67
13A-68
13A-69
13A-70
13A-71
13A-72
13A-73
13A-74
13A-75
13A-76
13A-77
13A-78
13A-79
13A-80
13A-81
13A-82
13A-83
13A-84
13A-85
13A-86
13A-87
13A-88
13A-89
13A-90
13A-91
13A-92
13A-93
13A-94
13A-95
13A-96

03en Volume 1 - Engine & EL - p475

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11A-0-1

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-0-3

E Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised

E Mitsubishi Motors Corporation May 1995 PWEE9502

Closes 42_, 58_* 60_

Exhaust Opens 54_, 52_* 61_

Closes 2_, 16_* 15_

Oil pump type Trochoid type Trochoid type

Cooling system Water-cooled forced circulation Water-cooled forced circulation

Water pump type Centrifugal impeller type Centrifugal impeller type

*: LANCER for general export and CARISMA for 6B model

E Mitsubishi Motors Corporation July 1997 PWEE9502-C Revised

4G92-SOHC*2 Intake 37.78 37.28

Cylinder head and valve

*1: LANCER for Europe and CARISMA for Europe

E Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised

Items Standard value Limit

E Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised

Items Standard value Limit

E Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised

Bearing cap bolt (M6) 11

E Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised

Water pump Mitsubishi Genuine Part No.MD970389 or equivalent As required

Thermostat case Mitsubishi Genuine Part No.MD970389 or equivalent As required

Water by-pass fitting Mitsubishi Genuine Part No.MD970389 or equivalent As required

Water fitting Mitsubishi Genuine Part No.MD970389 or equivalent As required

Camshaft bearing cap 3M ATD Part No.8660 or equivalent As required

Semi-circular packing 3M ATD Part No.8660 or equivalent As required

Rocker cover 3M ATD Part No.8660 or equivalent As required

Beam camshaft cap Mitsubishi Genuine Part No.MD970389 or equivalent As required

Cylinder head Mitsubishi Genuine Part No.MD970389 or equivalent As required

Oil pressure switch 3M ATD Part No.8660 or equivalent As required

Water outlet fitting Mitsubishi Genuine Part No.MD970389 or equivalent As required

Oil pump case Mitsubishi Genuine Part No.MD970389 or equivalent As required

Oil seal case Mitsubishi Genuine Part No.MD970389 or equivalent As required

Drive plate bolt 3M Nut Locking Part No.4171 or equivalent As required

Flywheel bolt 3M Nut Locking Part No.4171 or equivalent As required

Oil control valve 3M ATD Part No.8660 or equivalent As required

Camshaft holder 3M ATD Part No.8660 or equivalent As required

E Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Revised

Form-In-Place Gasket Application

E Mitsubishi Motors Corporation May 1995 PWEE9502

MB990767 Crankshaft pulley Holding camshaft sprocket when loosening

MD998440 Leak-down tester Leak-down test of lash adjuster

MD998442 Air bleed wire Air bleeding of lash adjuster

MD998713 Camshaft oil seal Installation of camshaft oil seal

MD998716 Crankshaft wrench Rotation of crankshaft when installing piston

MD998717 Crankshaft front oil Installation of crankshaft front oil seal

MB991659 Guide D Removal of piston pin (Use with MD998780)

E Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Revised

Tool Number Name Use

MD998727 Oil pan remover Removal of the oil pan

MD998754 Pin Use with MB990767

MD998767 Tensioner pulley Adjustment of timing belt tension

MD998772 Valve spring Removal and installation of valve and related

MD998774 Valve stem seal Installation of valve stem seal

MD998775 Valve stem seal Installation of valve stem seal

MD998776 Crankshaft rear oil Installation of crankshaft rear oil seal

E Mitsubishi Motors Corporation Nov. 1995 PWEE9502-A Revised