11A-1-3

11A-1-4

TORQUE SPECIFICATIONS

Nm M6 M8 Fitting (Rear wheel drive) Water outlet fitting (Rear wheel drive) Thermostat case
Nov. 1995 Dec. 1998 PWEE9520 PWEE9520-A
Alternator and ignition system Water pump pulley bolt Alternator brace (alternator side) Alternator brace (tightened with water pump) Alternator pivot bolt Oil level gauge guide Crankshaft bolt Spark plug Distributor Ignition coil Camshaft position sensor Camshaft position sensor support Camshaft position sensing cylinder Timing belt Timing belt cover Timing belt tensioner Crankshaft angle sensor (Rear wheel drive) Engine support bracket (left) Idler pulley Camshaft sprocket bolt Fuel system Delivery pipe Fuel pressure regulator Throttle body Fuel pump Breather tube Carburetor Air temperature sensor EGR valve Water pump Water inlet fitting Water inlet pipe assembly Water inlet pipe
Item Thermo valve Water temperature gauge unit Water temperature sensor Water pump Exhaust manifold and intake manifold Boost sensor Solenoid valve assembly Intake manifold Intake manifold stay (MPI) Intake manifold stay (carburetor) Exhaust manifold cover Exhaust manifold Oxygen sensor Rocker arms, rocker shafts, and camshaft Fuel pump cover Rocker cover Rocker shaft assembly Adjusting screw Bearing cap Cylinder head and valves Cylinder head bolt Tighten to 49 Nm, then completely loosen and retighten as described. Oil pump and oil pan Transmission stay Oil pan Drain plug Oil screen Front case Relief plug Oil pump cover Pistons and connecting rods Connecting rod nut 17 + 90_ to 100_ + 90_ + 90_ M8 M10 M8 M44 Nm 29 13

11A-1-5

11A-1-5a
Item Crankshaft and cylinder block Flywheel Drive plate Rear plate Bell housing cover Rear oil seal case Bearing cap bolt Oil pressure switch Knock sensor

Nm 18 23

11A-1-5b

11A-1-6

NEW TIGHTENING METHOD USING PLASTIC REGION TIGHTENING BOLTS
Parts of the engine use plastic region tightening bolts. The tightening procedure for these is different from that of conventional bolts and is described in relevant parts of this manual. Note that plastic region tightening bolts have fixed service limits. These limits are indicated in relevant parts of this manual and must be strictly observed. D D Plastic region tightening bolts are used for the following applications: (1) Cylinder head bolts (2) Connecting rod cap bolts The tightening procedure is basically as follows: After tightening a bolt to the specified torque, tighten it by a further 90 _ + 90_ or by a further 90100. The exact tightening procedure differs depending on the bolt and is described in relevant parts of this manual.

SEALANTS

Item Water pump Thermo valve Engine coolant temperature sensor Engine coolant temperature gauge unit Camshaft bearing cap Semi-circular packing Rocker cover Front oil seal case Oil pump Oil pressure switch Specified sealant Mitsubishi Genuine Part No. MD970389 or equivalent Mitsubishi Genuine Part No. MD970389 or equivalent 3M Nut Locking Part No. 4171 or equivalent 3M ATD Part No. 8660 or equivalent 3M ATD Part No. 8660 or equivalent 3M ATD Part No. 8660 or equivalent 3M ATD Part No. 8660 or equivalent Mitsubishi Genuine Part No. MD970389 or equivalent Mitsubishi Genuine Part No. MD970389 or equivalent 3M ATD Part No. 8660 or equivalent Quantity As required As required As required As required As required As required As required As required As required As required
4G1 ENGINE (E - W) - Specifications FORM-IN-PLACE GASKET

11A-1-7

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.

INSPECTION

1. TIMING BELT Check the timing belt closely. Replace the belt with a new one if any of the following defects is evident: (1) Hardened backing rubber (the backing rubber is glossy, non-elastic, and so hard that scratching with fingernails leaves no mark)

Separation

(2) Surface cracks in the backing rubber (3) Splits in the canvas and/or separation of the canvas and rubber (4) Cracks at the bases of teeth (5) Cracks in the side of the belt

Cracked side

Cracked tooth base

Rounded edge

(6) Abnormal wear on the belts sides NOTE The sides of the belt are normal if they are sharp as if cut by a knife.
Abnormal wear (exposed core wire)

11A-4-4

Canvas worn exposing rubber Missing tooth
(7) Abnormal wear on teeth Initial stage: Canvas worn (fluffy canvas fibers, rubbery texture gone, white discoloration, canvas texture indistinct) Final stage: Canvas worn, exposing rubber (tooth width reduced) (8) Missing teeth
2. TENSIONER PULLEY AND IDLER PULLEY (1) Check that the pulleys turn smoothly without play and are not abnormally noisy. Replace either or both of the pulleys if necessary.

MB990767

"AA CAMSHAFT SPROCKET BOLT INSTALLATION (1) Using the special tools shown in the illustration, lock the camshaft sprocket in position. (2) Tighten the camshaft sprocket bolt to the specified torque.

Timing belt tensioner

"BA TIMING BELT TENSIONER / TENSIONER SPRING INSTALLATION (1) Lock the timing belt tensioner in the illustrated position.
(2) Fit one of the tensioner spring projections over the hooked portion of the timing belt tensioner and fit the tensioner onto the oil pump case.

11A-4-5

(3) Grip the other tensioner spring projection and fit it onto the oil pump case lug as shown in the illustration. (4) Move the timing belt tensioner in the direction shown and temporarily tighten the bolt.
"CA TIMING BELT INSTALLATION (1) Align the camshaft timing mark with the timing mark on the cylinder head.
(2) Align the crankshaft timing mark with the timing mark on the front case.

(3) Keeping the tension side of the timing belt tight, fit the timing belt onto the crankshaft sprocket, camshaft sprocket, and tensioner pulley in that order. (4) Loosen the tensioner pulley mounting bolts by 1/4 to 1/2 of a turn and allow the tensioner spring to apply tension to the timing belt. (5) Turn the crankshaft twice in the normal rotating direction (clockwise) and check that the timing marks are correctly aligned. Caution This procedure utilizes the camshafts driving torque to apply tension evenly to the timing belt. Be sure to turn the crankshaft as described above. Do not turn the crankshaft in reverse. (6) Tighten the tensioner pulley mounting bolts.

11A-4-6

"DA TIMING BELT INSTALLATION (1) Place the camshaft sprocket timing marks at the positions shown. NOTE After aligning the sprocket timing marks, let go of the sprockets. The exhaust camshaft sprocket will rotate by one tooth in the direction shown and remain stable in this position.
(3) Turn the exhaust camshaft sprocket in the direction shown and fit the timing belt with the timing marks aligned. (4) Use a bulldog clip to prevent the timing belt teeth from jumping.
(5) Fit the timing belt onto the idler pulley, crankshaft sprocket, and tensioner pulley in that order. NOTE When fitting the belt, keep the camshaft sprocket timing marks correctly aligned and keep the tension side of the belt tight. (6) Loosen the tensioner pulley mounting bolts by 1/4 to 1/2 of a turn and allow the tensioner spring to apply tension to the timing belt. (7) Remove the bulldog clip. (8) Turn the crankshaft twice in the normal rotating direction (clockwise) and check that the timing marks are correctly aligned. Caution This procedure utilizes the camshafts driving torque to apply tension evenly to the timing belt. Be sure to turn the crankshaft as described above. Do not turn the crankshaft in reverse. (9) Tighten the tensioner pulley mounting bolts.
4G1 ENGINE (E - W) - Fuel and Emission Control Systems

11A-5-1

5. FUEL AND EMISSION CONTROL SYSTEMS
REMOVAL AND INSTALLATION <SOHC - CARBURETOR>
Removal steps 1. Breather tube 2. Fuel hose 3. Fuel pump 4. Gasket 5. Insulator 6. Gasket

7. 8. 9. 10. 11.

Carburetor Upper gasket Spacer Lower gasket EGR valve (vehicles with automatic transmission for GCC only) 12. Gasket

11A-5-2

REMOVAL AND INSTALLATION <SOHC - MPI>
Removal steps 1. Throttle body assembly 2. Gasket 3. Fuel return pipe "BA 4. Fuel pressure regulator 5. O-ring 6. Insulator 7. Insulator
"AA 8. 9. 10. 11. 12. 13. 14. 15.
Injector O-ring Grommet Delivery pipe EGR valve Gasket Air temperature sensor Gasket
4G1 ENGINE (E - W) - Fuel and Emission Control Systems REMOVAL AND INSTALLATION <SOHC - REAR WHEEL DRIVE>

11A-5-2a

11 Nm 18 Nm

8. 9. 10. 11. 12.

Gasket Water inlet pipe O-ring O-ring Water pump

11A-6-2a

REMOVAL AND INSTALLATION <SOHC 16-VALVE - MPI - FRONT WHEEL DRIVE>

12 Nm 29 Nm

11 Nm 13 Nm 22 Nm

11A-6-2b

REMOVAL AND INSTALLATION <SOHC 16-VALVE - MPI - REAR WHEEL DRIVE>

23 Nm 13 Nm

Removal steps 1. Water hose 2. Water hose "EA 3. Water temperature sensor "DA 4. Water temperature gauge unit 5. Water outlet fitting 6. Gasket
"CA 7. 8. 9. "BA 10. "BA 11. "AA 12.
Thermostat Fitting Gasket Water inlet pipe O-ring Water pump
4G1 ENGINE (E - W) - Water Pump and Water Hose REMOVAL AND INSTALLATION <DOHC>

11A-6-3

11A-6-4
4G1 ENGINE (E - W) - Water Pump and Water Hose INSTALLATION SERVICE POINTS
"AA WATER PUMP INSTALLATION (1) Apply a 3 mm bead of form-in-place gasket (FIPG) to the mounting surface. Specified sealant: Mitsubishi Genuine equivalent. Part No. MD970389 or
"BA O-RING / WATER PIPE INSTALLATION (1) Replace the water inlet pipe O-rings with new ones, then apply water to the O-rings so that they can be inserted easily into the water pump and thermostat case. Caution 1. Do not apply engine oil or any other oily substance to the O-rings. 2. Secure the water pipe after the thermostat case has been installed. "CA THERMOSTAT INSTALLATION (1) Fit the thermostat such that its jiggle valve is at the top.
"DA WATER TEMPERATURE GAUGE UNIT INSTALLATION (1) If the water temperature gauge unit is to be reused, apply the specified sealant to its thread. Specified sealant: 3M ATD Part No. 8660 or equivalent.
"EA WATER TEMPERATURE SENSOR INSTALLATION (1) If the water temperature sensor is to be reused, apply the specified sealant to its thread. Specified sealant: 3M Nut Locking Part No. 4171 or equivalent.

11A-6-5

"FA THERMO VALVE INSTALLATION (1) If the thermo valve is to be reused, apply the specified sealant to its thread. Specified sealant: Mitsubishi Genuine equivalent. Part No. MD970389 or
4G1 ENGINE (E - W) - Intake and Exhaust Manifolds

11A-7-1

7. INTAKE AND EXHAUST MANIFOLDS
Removal steps 1. Engine hanger 2. Intake manifold stay 3. Intake manifold 4. Intake manifold gasket

5. 6. 7. 8.

Exhaust manifold cover Engine hanger Exhaust manifold Exhaust manifold gasket

11A-7-2

17 Nm 21 Nm
Removal steps 1. Engine hanger 2. Intake manifold stay 3. Intake manifold 4. Intake manifold gasket 5. Oxygen sensor (vehicles for Hong Kong only)

11A-8-1a

REMOVAL AND INSTALLATION <SOHC 16-VALVE>

31 Nm 35 Nm

Removal steps 1. Breather hose 2. P.C.V. hose 3. Oil filler cap 4. P.C.V. valve 5. P.C.V. valve gasket 6. Rocker cover 7. Rocker cover gasket 8. Oil seal "FA 9. Oil seal "EA 10. Rocker arms and rocker arm shaft IN "EA 11. Rocker arms and rocker arm shaft EX
"DA "CA "DA "CA
12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Rocker arm B Rocker arm A Rocker arm shaft Adjusting screw Nut Rocker arm C Rocker arm shaft Adjusting screw Nut Camshaft

11A-8-1b

11A-8-2
Removal steps 1. Breather hose 2. P.C.V. hose 3. P.C.V. valve 4. P.C.V. valve gasket 5. Oil filler cap "HA 6. Rocker cover 7. Rocker cover gasket A 8. Rocker cover gasket B
"GA "FA "BA "AA "AA
9. 10. 11. 12. 13. 14. 15.
Semi-circular packing Camshaft oil seal Bearing cap Camshaft Camshaft Roller rocker arm Lash adjuster
4G1 ENGINE (E - W) - Rocker Arms and Camshafts INSPECTION

11A-8-3

1. CAMSHAFT (1) Measure the cam heights and replace the camshaft if any height exceeds the specified limit.
Standard value mm Intake SOHC 12-VALVE SOHC 16-VALVE DOHC Exhaust SOHC 12-VALVE SOHC 16-VALVE DOHC 38.78 36.99 34.67 39.10 36.85 34.26 Limit mm 38.28 36.49 34.17 38.60 36.35 33.76
2. LASH ADJUSTERS Caution 1. The lash adjusters are precision-engineered mechanisms. Do not allow them to become contaminated 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.

To clean outside

To clean inside

To fill diesel fuel

(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 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

11A-8-4
(3) While gently pushing down the internal steel ball using special tool MD998442, move the plunger through 5 to 10 strokes until it slides smoothly. In addition to eliminating stiffness in the plunger, this operation will remove dirty oil. Caution The steel ball spring is extremely weak, so the lash adjusters 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.
(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 or other people.

4G1 ENGINE (E - W) - Cylinder Head and Valves

11A-9-1

9. CYLINDER HEAD AND VALVES
Removal steps AA" "DA 1. Cylinder head bolt 2. Cylinder head assembly 3. Cylinder head gasket AB" "CA 4. Retainer lock 5. Valve spring retainer "BA 6. Valve spring 7. Intake valve (primary) 8. Intake valve (secondary) AB" "CA 9. Retainer lock 10. Valve spring retainer "BA 11. Valve spring
12. AC" "AA 13. 14. AC" "AA 15. 16. 17. 18. 19. 20. 21. 22.
Exhaust valve Valve stem seal Valve spring seat Valve stem seal Valve spring seat Intake valve guide Exhaust valve guide Intake valve seat (primary) Intake valve seat (secondary) Exhaust valve seat Cylinder head

11A-9-1a

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

11A-9-1b

11A-9-2
AA" "DA AB" "CA "BA AB" "CA "BA
Removal steps 1. Cylinder head bolt 2. Cylinder head assembly 3. Cylinder head gasket 4. Retainer lock 5. Valve spring retainer 6. Valve spring 7. Intake valve 8. Retainer lock 9. Valve spring retainer 10. Valve spring
Exhaust valve Valve stem seal Valve spring seat Valve stem seal Valve spring seat Intake valve guide Exhaust valve guide Intake valve seat Exhaust valve seat Cylinder head

SOHC MB991653

11A-9-3

REMOVAL SERVICE POINTS

AA" CYLINDER HEAD BOLT REMOVAL

DOHC MB991653

AB" RETAINER LOCK REMOVAL (1) Tag removed valves, springs, and other components, noting their cylinder numbers and locations to facilitate reassembly. Store these components safely.

11A-9-4

AC" VALVE STEM SEAL REMOVAL
1. CYLINDER HEAD (1) Before cleaning the cylinder head, check it for water leaks, gas leaks, cracks, and other damage. (2) Remove all oil, water scale, sealant, and carbon. After cleaning the oil passages, blow air through them to verify that they are not blocked. (3) Check for distortion in the cylinder head gasket surface using a straight edge and thickness gauge. If distortion exceeds the specified limit, grind the gasket surface to specification. Gasket surface distortion Standard value: 0.05 mm or less Limit: 0.2 mm Grinding limit: 0.2 mm Cylinder head height (specification when new): SOHC 12-VALVE: 106.9 - 107.1 mm SOHC 16-VALVE: 119.9 - 120.1 mm DOHC: 131.9 - 132.1 mm Caution No more than 0.2 mm of stock may be removed from the cylinder head and cylinder block mating surfaces in total. 2. VALVES (1) Check the valve face for correct contact. If contact is uneven or incomplete, reface the valve seat. (2) If the margin is less than specified, replace the valve. Standard value: Intake: 1.0 mm Exhaust: 1.5 mm Limit: Intake: 0.5 mm Exhaust: 1.0 mm

Contact (must be in center of face)

Margin

6EN0542

11A-9-5

(3) Measure the valves total length. If the measurement is less than specified, replace the valve.
Standard mm Intake SOHC 12-VALVE SOHC 16-VALVE DOHC Exhaust SOHC 12-VALVE SOHC 16-VALVE DOHC 100.75 111.56 106.35 101.05 114.71 106.85 Limit mm 100.25 111.06 105.85 100.55 114.21 106.35

Squareness

3. VALVE SPRINGS (1) Measure the valve springs free height. If the measurement is less than specified, replace the spring.
Standard mm Limit mm 45.6 46.3 50.4 48.6 SOHC 12-VALVE Intake Exhaust 46.1 46.8 50.9 49.1

Free height

SOHC 16-VALVE

1EN0264

(2) Measure the squareness of the spring. If the measurement exceeds the specified limit, replace the spring. Standard value: 2_ or less Limit: 4_

11A-9-6

4. VALVE GUIDES (1) Measure the clearance between the valve guide and valve stem. If the clearance exceeds the specified limit, replace either or both components.

Valve guide

Standard mm Intake

Stem O. D.

1EN0279
Limit mm 0.10 0.10 0.10 0.15 0.15 0.15
0.020 - 0.050 0.020 - 0.047 0.020 - 0.047 0.050 - 0.085 0.030 - 0.062 0.030 - 0.057

Guide I. D.

Exhaust

Valve stem end

Valve projection

Spring seating surface

5. VALVE SEATS (1) Assemble the valve, then measure the valve stem projection between the end of the valve stem and the spring seating surface. If the measurement exceeds the specified limit, replace the valve seat.
Standard mm SOHC 12-VALVE SOHC 16-VALVE DOHC Intake Exhaust Intake Exhaust Intake Exhaust 43.70 43.30 53.21 54.10 48.80 48.70 Limit mm 44.20 43.80 53.71 54.60 49.30 49.20
0.9 - 1.3 mm 65_ 0.9 - 1.3 mm 65_

11A-9-7

VALVE SEAT CORRECTION SERVICE POINTS
(1) Before correcting the valve seat, check the clearance between the valve guide and valve. If necessary, replace the valve guide. (2) Using the appropriate special tool or seat grinder, correct the valve seat to achieve the specified seat width and angle. (3) After correcting the valve seat, lap the valve and valve seat using lapping compound. Then, check the valve stem projection (refer to 5. VALVE SEATS in INSPECTION).

44_ 15_

0.5 - 1.0 mm
VALVE SEAT REPLACEMENT SERVICE POINTS
(1) Cut the valve seat to be replaced from the inside to reduce the wall thickness. Then, remove the valve seat. (2) Rebore the valve seat hole in the cylinder head to match the selected oversize valve seat diameter. Valve seat diameters

Standard mm

1EN0274

Cut away 0.5 - 1.0 mm

Intake

Primary Secondary

0.30 O.S. 0.60 O.S. 0.30 O.S. 0.60 O.S. 0.30 O.S. 0.60 O.S. 0.30 O.S. 0.60 O.S. 0.30 O.S. 0.60 O.S. 0.30 O.S. 0.60 O.S. 0.30 O.S. 0.60 O.S. 0.30 O.S. 0.60 O.S. 0.30 O.S. 0.60 O.S.
27.300 - 27.325 27.000 - 27.625 32.300 - 32.325 32.600 - 32.625 35.300 - 35.325 35.600 - 35.625 28.300 - 28.321 28.600 - 28.621 26.300 - 26.321 26.600 - 26.621 30.300 - 30.321 30.600 - 30.621 28.300 - 28.321 28.600 - 28.621 31.300 - 31.325 31.600 - 31.625 27.800 - 27.825 28.100 - 28.125

Valve seat height

Exhaust SOHC 16-VALVE <4G13>

Oversize hole I. D.

1EN0275
Intake Exhaust Intake Exhaust Intake Exhaust
SOHC 16-VALVE <4G18>
(3) Prevent galling of the cylinder head bore by cooling the valve seat with liquid nitrogen before press-fitting it. (4) Correct the valve seat to achieve the specified width and angle (refer to VALVE SEAT CORRECTION SERVICE POINTS).

11A-9-8

4G1 ENGINE (E - W) - Cylinder Head and Valves VALVE GUIDE REPLACEMENT SERVICE POINTS
(1) Using a press, push the valve guide out toward the cylinder block side. (2) Rebore the valve guide hole in the cylinder head to match the oversize valve guide that is to be fitted. Caution Do not install a valve guide of the same size again. Valve guide hole diameters (SOHC 12-VALVE) 0.05 O.S.: 12.050 - 12.068 mm 0.25 O.S.: 12.250 - 12.268 mm 0.50 O.S.: 12.500 - 12.518 mm Valve guide hole diameters (SOHC 16-VALVE, DOHC) 0.05 O.S.: 10.550 - 10.568 mm 0.25 O.S.: 10.750 - 10.768 mm 0.50 O.S.: 11.000 - 11.018 mm
(3) Press-fit the valve guide until it projects by the specified amount. Standard value: SOHC 12-VALVE: 17 mm SOHC 16-VALVE, DOHC: 23 mm Caution 1. The valve guide must be installed from the upper side of the cylinder head. 2. The valve guides differ in length on the intake and exhaust sides. 3. After press-fitting the valve guide, insert a new valve and check that it slides smoothly.

Projection

SOHC 12-VALVE MD998760
"AA VALVE STEM SEAL INSTALLATION (1) Install the valve spring seat. (2) Install a new valve stem seal using the special tool shown in the illustration. Caution 1. Valve stem seals cannot be reused. 2. The valve stem seal must be installed using the correct special tool. Incorrect installation could result in oil leaking past the valve guide.
SOHC 16-VALVE, DOHC MB991671

Spring retainer

11A-9-9

Painted end

"BA VALVE SPRING INSTALLATION (1) Install the valve spring such that its painted end is on the rocker arm side.

Stem seal Spring seat

"CA RETAINER LOCK INSTALLATION
"DA CYLINDER HEAD BOLT INSTALLATION (1) Before reusing the cylinder head bolt, check that its nominal length does not exceed the specified limit. Replace the bolt if this measurement exceeds the limit. Limit: 103.2 mm (2) Fit the washer as shown. (3) Apply engine oil to the bolts thread and washer.

11A-9-10

(4) Tighten the bolts in the sequence shown until each is torqued to 49 Nm. (5) Completely loosen the bolts. (6) Retighten the bolts in the sequence shown until each is torqued to 20 Nm.

Timing belt side 9

(7) Apply paint marks to the cylinder head bolt heads and cylinder head as shown. (8) In accordance with the tightening sequence, tighten each bolt by 90_. (9) Tighten each bolt by a further 90_ and check that the paint marks on the bolt head and cylinder head are aligned.

Paint mark

Caution If the bolts are tightened by an angle of less than 90_, they may not hold the cylinder head with sufficient strength. If the bolts are tightened by an angle exceeding 90_, completely remove them and carry out the installation procedure again.
4G1 ENGINE (E - W) - Oil Pump and Oil Pan

11A-10-1

10. OIL PUMP AND OIL PAN

REMOVAL AND INSTALLATION

44 Nm 7 Nm
Removal steps "EA 1. Oil filter 2. Drain plug "DA 3. Gasket 4. Transmission stay (Rear wheel drive) AA" "CA 5. Oil pan 6. Oil screen 7. Gasket 8. Relief valve 9. Relief valve spring
10. Relief plunger "BA 11. Front oil seal "AA 12. Front case 13. O-ring 14. Oil pump cover 15. Oil pump outer rotor 16. Oil pump inner rotor

11A-10-2

AA" OIL PAN REMOVAL (1) Remove the oil pan mounting bolts. (2) Knock the special tool between the oil pan and cylinder block as shown in the illustration. (3) Tapping the side of the special tool, slide the tool along the oil pan/cylinder block seal and thus remove the oil pan.

Guide B

Guide A

Nov. 1995 PWEE9520

11A-11-4
Push Rod Piston pin Front mark
(8) Mount the piston and connecting rod on the Piston Pin Setting Base (special tool) with the pistons front mark pointing upward. (9) Install the piston pin using a press. If the press-fitting load is out of specification, replace the piston pin and piston assembly or the connecting rod, or both. Standard value: 4,900 - 14,700 N

Side rail

"BA OIL RING INSTALLATION (1) Fit the oil ring spacer into the piston ring groove. Then, fit the upper and lower side rails. NOTE (1) The spacer and side rails may be fitted in either direction. No distinction is made between top and bottom. (2) Spacer and side rail sizes are color-coded as follows:

Spacer

1EN0277
Size STD 0.50 mm O. S. 1.00 mm O. S.

Color None Blue Yellow

End of side rail
(2) To install a side rail, fit one end of the rail into the groove then press the rest of the rail into position by hand as shown. Caution Do not fit side rails using a piston ring expander since they may break.

7EN0451

(3) After installing the side rails, check that they move smoothly in both directions.

11A-11-5

"CA PISTON RING No. 2 / PISTON RING No. 1 INSTALLATION (1) Using piston ring expander, fit No. 2 and No. 1 piston ring into position.

Piston ring expander

NOTE 1. The ring end is provided with identification mark.
Item Identification mark With catalytic converter Without catalytic converter With catalytic converter Without catalytic converter 1T T 2T T2

7EN0452

No. 1 ring No. 2 ring
Identification mark Identification mark Size mark

No. 1 No. 2

2. Install piston rings with identification mark facing up, to the piston crown side. 3. Size marks on piston rings are as follows.
Size STD 0.25 mm O. S. 0.50 mm O. S. 1.00 mm O. S. Size mark None 100 ALL 4G18 ALL 4G13, 4G15

No. 1 ring

Piston pin
"DA PISTON AND CONNECTING ROD ASSEMBLY INSTALLATION (1) Apply oil to the piston, piston rings, and oil ring. (2) Align the gaps of the piston rings and oil ring (side rails and spacer) as shown. (3) With the piston crowns front arrow mark pointing toward the timing belt side, press the piston and connecting rod assembly into the cylinder from the top of the cylinder.

No. 2 ring and spacer

6EN0549
(4) Compress the piston rings tightly with a suitable ring compression tool, then press the piston and connecting rod fully into the cylinder. Do not strike the piston hard since the piston rings may break and the crank pin may be nicked.

11A-12-4

(4) Using a cylinder gauge, measure each cylinders bore and cylindricity. If any cylinder is severely worn, bore all the cylinders to oversize and replace the piston and piston rings accordingly. Take measurements at the points shown.

6EN0553

Standard value: Cylinder bore: 4G13 engine: 71.0 mm 4G15 engine: 75.5 mm 4G18 engine: 76.0 mm Cylindricity: 0.01 mm or less 3. BORING CYLINDERS (1) Oversize pistons to be used should be determined on the basis of the cylinder with the largest bore. (2) Oversize pistons are available with the following oversize dimensions: 0.25 mm, 0.50 mm, and 1.00 mm. Measure the diameter of the piston to be used. Boring must be carried out such that the piston-to-cylinder clearance complies with the standard value. The pistons diameter should be measured at the points shown. (3) Calculate the boring finish dimension based on the piston diameter dimension. D [Boring finish dimension] = [piston O.D.] + [piston-to-cylinder clearance (0.02 0.04 mm)] [honing margin (0.02 mm)] (4) Bore each cylinder to the calculated boring finish dimension. Caution To prevent distortion caused by heat increases during boring bore the cylinders in the following order: No. 2, No. 4, No. 1, No. 3. (5) Hone the cylinders to the final finish dimension (piston O. D. + piston-to-cylinder clearance). (6) Check the clearance between the pistons and cylinders. Standard value: 0.02 - 0.04 mm

Piston O. D.

Thrust direction

6EN0554

MD9988054
"AA OIL PRESSURE SWITCH INSTALLATION (1) Apply the specified sealant to the thread, then fit the oil pressure switch using the special tool shown in the illustration. Specified sealant: 3M ATD Part No. 8660 or equivalent

Apply sealant

Caution 1. Apply sealant such that none is squeezed out past end of the thread. 2. Do not over-tighten the oil pressure switch.

11A-12-5

"BA CRANKSHAFT BEARING INSTALLATION
4G13, 4G15 Color code positions (type 1) No. 4 No. 3 No. 4 No. 3 4G18

No. 1 No. 5 No. 2 No. 5 No. 2
Color code positions (type 2) No. 3 No. 2 No. 3 No. 2
Identification mark positions No. 2 No. 3

No. 1 No. 3

No. 4 No. 5
(1) Select bearings according to the crankshaft identification marks or color codes, referring to the following table. If they are not identifiable, measure the crankshaft journals and choose bearings to match the measurements.

11A-12-6

Crankshaft journal Range 1
Cylinder block bearing diameter Color code Yellow Identification mark 1 Journal diameter mm 47.995 - 48.000 Identification mark 2 Bearing Identification mark 5

47.985 - 49.995

47.980 - 48.985
Cylinder block journal bore diameter
(2) Identification marks showing the cylinder block bearing bore diameter are stamped in the position shown, with No. 1 at the front of the engine. Bearings must be selected and installed in accordance with these identification marks. (3) Based on the identification markings verified in steps (1) and (2), select bearings from table above. See the following example: 1. If the measured crankshaft journal diameter is 48.000 mm, this corresponds to classification 1 in the above table. 2. If the identification mark on the cylinder block bearing hole is 1, select a bearing with an identification mark of 2.

Grooveless

Grooved
Upper bearing (Nos. Lower bearing (Nos. 1, 2, 4, and 5) 1, 2, 4, and 5) Grooveless
(4) Except for the center bearing, all the upper bearings are grooved. The center bearings are grooveless and have flanges. The center bearings are the same at the top and bottom. (5) The lower bearings are all grooveless.
Upper and lower bearings (center) (No. 3) E Mitsubishi Motors Corporation
Arrow indicating front of engine Cap No.

11A-12-7

"CA BEARING CAP INSTALLATION (1) On the bottom surface of each bearing cap is the caps number and an arrow. Starting at the timing belt side, fit the bearing caps in numerical order. Ensure that the arrows point toward the timing belt side.

Distributor & Support :

Page 1 of 4

Date:20/10/2009
Silicone Radiator Hose Kit for Mitsubishi Colt Z27A 4G15

Newsletter

Product Code : ASHK145

(product pic)

System ID SWB00080 SWR00080 SWL00080 Description:
Product Code ASHK145 ASHK145 ASHK145
Name Silicone Radiator Hose Kit for Mitsubishi Colt Z27A 4G15(Blue) Silicone Radiator Hose Kit for Mitsubishi Colt Z27A 4G15(Red) Silicone Radiator Hose Kit for Mitsubishi Colt Z27A 4G15(Black) Silicone Radiator Hose Mitsubishi Colt Z27A 4G15 Product weight = 1kg 4 Layer Polyester 5mm Wall Thickness Hose Burst Pressure Limit Equal to 5Bar Ensure the hose working properly in extreme racing environment. l Accept higher pressure than the original l The temperature change will not affect the shape and the flow rate. l Not Easy to break down or harden, more durable than the original Page 1 of 4
Item Name: Application: Spec:

Description:

URL:www.autobahn88.com Tel:2151-1351 Fax:3012-1938 E- mail:info@auto88-group.com November 23, 2009

Page 2 of 4

l l l l Included Weight (kg): Dimension: Photo Name: Category: Bin No: Usable with: Remarks: Data Path: File Create Date: 2 x Silicone Hose

100%Brand New

Package Weight = 1.5kg (Recommend to send by RAM/EMS/UPS) Package Size: Product Size: ASHK145-Silicone Radiator Hose Kit for Mitsubishi Colt Z27A 4G15 Silicone Hose Radiator Hose No Bin
Z:\New product(Leo Upload)\Silicone Hose\ASHK145-Silicone Radiator Kit for Mitsubishi Colt Z27A 4G15 20/10/2009