MITSUBISHI
ENGINE 4G6 SERIES (E - W)

WORKSHOP MANUAL

FOREWORD
This Workshop Manual contains procedures for removal, disassembly, inspection, adjustment, reassembly and installation, etc. for service mechanics. All information, illustrations and product descriptions contained in this manual are current as at the time of publication. We, however, reserve the right to make changes at any time without prior notice or obligation.

Engine

FILING INSTRUCTION Please keep these manual pages in the binder No. BN940001. File these pages according to the signs Added, Revised and Deleted on the List of effective pages which are interpreted below. Added: File the pages with this sign additionally in your manual. Revised, Deleted: Replace the existing pages with corresponding pages with this sign.
Missing sheets will be supplied upon request.

E Mitsubishi

Motors Corporation Aug. 1999

Pub. No. PWEE9616-B

INTRODUCTION
EXPLANATION OF MANUAL CONTENTS
Maintenance and Servicing Procedures (1) A diagram of the component parts is provided near the front of each section in order to give the reader a better understanding of the installed condition of component parts. (2) The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures. : Indicates a non-reusable part. The tightening torque is provided where applicable. D Removal steps: The part designation number corresponds to the number in the illustration to indicate removal steps. D Disassembly steps: The part designation number corresponds to the number in the illustration to indicate disassembly steps. D Installation steps: Specified in case installation is impossible in reverse order of removal steps. Omitted if installation is possible in reverse order of removal steps. D Reassembly steps: Specified in case reassembly is impossible in reverse order of disassembly steps. Omitted if reassembly is possible in reverse order of disassembly steps.
Classification of Major Maintenance/Service Points When there are major points relative to maintenance and servicing procedures (such as essential maintenance and service points, maintenance and service standard values, information regarding the use of special tools, etc.), these are arranged together as major maintenance and service points and explained in detail. AA" : Indicates that there are essential points for removal or disassembly. "AA : Indicates that there are essential points for installation or reassembly.
Symbols for Lubrication, Sealants and Adhesives Information concerning the locations for lubrication and for application of sealants and adhesives is provided, by using symbols, in the diagram of component parts, or on the page following the component parts page, and explained. : Grease (multipurpose grease unless there is a brand or type specified) : Sealant or adhesive : Brake fluid, automatic transmission fluid or air conditioner compressor oil : Engine oil or gear oil
E Mitsubishi Motors Corporation

Dec. 1996

PWEE9616
Indicates the group title. Indicates the section title. Indicates the group number. Indicates the section number. Indicates the page number.
4G6 ENGINE (E- W) - Water Pump and Intake Manifold

11A-6-1

6. WATER PUMP AND INTAKE MANIFOLD
REMOVAL AND INSTALLATION <CARBURETOR>

13 Nm 24 Nm 11 Nm 4 6

Denotes tightening torque.
13 Nm 20 Nm Nm 14 Nm 12 Nm 8 8
Denotes non-reusable part.
This number corresponds to the number appearing in Removal steps, Disassembly steps, Installation steps or Reassembly steps.
Removal steps 1. Water hose 2. Water hose 3. Engine coolant temperature gauge unit 4. Water inlet fitting 5. Thermostat 6. Thermostat housing 7. Water inlet pipe 8. O-ring Water pipe
14 Nm 9. 10. 11. 12. 13. 14. 15. 16. 17. Water pump Water pump gasket Oil level gauge Oil level gauge guide O-ring Intake manifold stay Intake manifold Intake manifold gasket Engine hanger

"CA

"BA "AA "AA
INSTALLATION SERVICE POINTS
"AA WATER PIPE/O-RING INSTALLATION
(1) Wet the O-ring (with water) to facilitate assembly. Caution D Keep the O-ring free of oil or grease.
Operating procedures, cautions, etc. on removal, installation, disassembly and reassembly are described.

O-ring

6EN0594
Mitsubishi Motors Corporation

Issue date

Publication number-Revision code

LIST OF EFFECTIVE PAGES

Page Revision Code A A A A B A A B A B B B A A Date Remarks Page Revision Code A B B A A A A A A A B A A A Date Remarks
11A-0-1 11A-0-2 11A-0-3 11A-0-4 11A-1-1 to 11A-1-3 11A-1-4 to 11A-1-8 11A-1-9 and 11A-1-10 11A-2-1 and 11A-2-2 11A-2-3 and 11A-2-4 11A-3-1 and 11A-3-2 11A-3-3 11A-3-4 11A-3a-1 and 11A-3a-2 11A-3a-3 11A-4-1 and 11A-4-2 11A-4-3 to 11A-4-14 11A-4a-1 11A-5-1
Aug. 1998 Dec. 1996 Aug. 1998 Aug. 1998 Aug. 1998 Aug. 1999 Revised Aug. 1998 Dec. 1996 Aug. 1998 Dec. 1996 Aug. 1999 Revised Aug. 1998 Aug. 1999 Revised Aug. 1999 Added Aug. 1999 Revised Aug. 1998 Aug. 1998 Dec. 1996
11A-5-2 to 11A-5-4 11A-5a-1 and 11A-5a-2 11A-5a-2a and 11A-5a-2b 11A-5a-3 to 11A-5a-5 11A-6-1 11A-6-2 to 11A-6-4 11A-6a-1 and 11A-6a-2 11A-7-1 and 11A-7-2 11A-8-1 to 11A-8-6 11A-8a-1 to 11A-8a-7 11A-9-1 to 11A-9-10 11A-10-1 11A-10-2 to 11A-10-10 11A-11-1 to 11A-11-4 11A-11-5 11A-11-6 to 11A-11-8 11A-12-1 to 11A-12-7
Aug. 1998 Aug. 1999 Revised Aug. 1999 Added Aug. 1998 Dec. 1996 Aug. 1998 Aug. 1998 Aug. 1998 Aug. 1998 Aug. 1998 Aug. 1998 Aug. 1999 Revised Aug. 1998 Dec. 1996 Aug. 1998 Dec. 1996 Aug. 1998
Aug. 1999 PWEE9616-B Revised

11A-0-1

ENGINE

4G6 SERIES

CONTENTS
GENERAL INFORMATION. 11A-0-3 1. SPECIFICATIONS. 11A-1-1 SERVICE SPECIFICATIONS. 11A-1-1 TORQUE SPECIFICATIONS. 11A-1-4 NEW TIGHTENING METHOD BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA. 11A-1-9 SEALANTS. 11A-1-9 FORM-IN-PLACE GASKET. 11A-1-10 2. SPECIAL TOOLS. 11A-2-1 3. ALTERNATOR AND IGNITION SYSTEM. 11A-3-1 3a. INTAKE MANIFOLD (GDI). 11A-3a-1 4. TIMING BELT. 11A-4-1 4a. EXHAUST MANIFOLD (GDI). 11A-4a-1 5. FUEL AND EMISSION CONTROL PARTS. 11A-5-1 5a. FUEL PARTS (GDI). 11A-5a-1 6. WATER PUMP AND INTAKE MANIFOLD. 11A-6-1 6a. WATER PUMP AND WATER HOSE (GDI). 11A-6a-1 7. EXHAUST MANIFOLD. 11A-7-1 8. ROCKER ARMS AND CAMSHAFT. 11A-8-1 8a. ROCKER ARMS AND CAMSHAFTS (GDI). 11A-8a-1 9. CYLINDER HEAD AND VALVES. 11A-9-1 10. FRONT CASE, COUNTERBALANCE SHAFTS AND OIL PAN 11A-10-1 11. PISTON AND CONNECTING ROD. 11A-11-1 12. CRANKSHAFT, FLYWHEEL AND DRIVE PLATE. 11A-12-1
E Mitsubishi Motors Corporation

Aug. 1998

PWEE9616-A

Revised

11A-0-2

Dec. 1996

PWEE9616
4G6 ENGINE <E - W> - General Information

11A-0-3

GENERAL INFORMATION

SOHC-4G63

Descriptions Type Number of cylinders Combustion chamber Total displacement dm3 Cylinder bore mm Piston stroke mm Compression ratio Valve timing Intake valve Opens (BTDC) Closes (ABDC) Exhaust valve Opens (BBDC) Closes (ATDC) Lubrication system Oil pump type Specifications In-line OHV, SOHC 4 Pentroof type 1,997 85.0 88.18_ 58_ 58_ 18_ Pressure feed, full-flow filtration Involute gear type

SOHC-4G64

Descriptions Type Number of cylinders Combustion chamber Total displacement dm3 Cylinder bore mm Piston stroke mm Compression ratio Valve timing Intake valve Opens (BTDC) Closes (ABDC) Exhaust valve Opens (BBDC) Closes (ATDC) Lubrication system Oil pump type Specifications In-line OHV, SOHC 4 Pentroof type 2,351 86.5 100.16_ 53_ 50_ 16_ Pressure feed, full-flow filtration Involute gear type

11A-0-4

Descriptions Type Number of cylinders Combustion chamber Total displacement dm3 Cylinder bore mm Piston stroke mm Compression ratio Valve timing
Specifications In-line OHV, SOHC 4 Pentroof + curved top piston type 2,351 86.5 100.0 11.5 Intake valve Opens (BTDC) Closes (ABDC) Exhaust valve Opens (BBDC) Closes (ATDC) 16_ 60_ 56_ 16_ Pressure feed, full-flow filtration Involute gear type
Lubrication system Oil pump type
NOTE GDI is a trademark of Mitsubishi Motors Corporation.
4G6 ENGINE <E - W> - Specifications

11A-1-1

1. SPECIFICATIONS

SERVICE SPECIFICATIONS

Items Timing belt Auto-tensioner rod projection length mm Auto-tensioner rod pushed-in amount [when pushed with a force of 98 - 196 N] mm Rocker arms and camshaft Camshaft cam height mm 4G63 SOHC 4G64 SOHC Lash adjuster leak down time [diesel fuel at 15 - 20_C] seconds/mm Camshaft journal outer diameter mm Rocker arms and camshaft (GDI) Camshaft cam height mm Intake Exhaust Lash adjuster leak down time [diesel fuel at 15 - 20_C] seconds/mm Camshaft journal outer diameter mm Cylinder head and valves Cylinder head flatness of gasket surface mm Cylinder head grinding limit of gasket surface mm Total resurfacing depth of both cylinder head and cylinder block Cylinder head overall height mm SOHC GDI Cylinder head bolt shank length mm Valve thickness of valve head (margin) mm SOHC Intake Exhaust GDI Intake Exhaust Valve overall height mm SOHC Intake Exhaust GDI Intake Exhaust Valve stem outer diameter mm

4G6 ENGINE (E - W) - Intake Manifold (GDI)

11A-3a-1

3a. INTAKE MANIFOLD (GDI)
REMOVAL AND INSTALLATION (SPACE WAGON)

8.8 Nm 11 Nm

11 Nm 30 Nm

8.8 Nm 30 Nm

Removal steps 1. Vacuum pipe and hose (1999 model vehicles for Hong Kong) 2. Solenoid valve (1999 model vehicles for Hong Kong) 3. Vacuum pipe and hose (Vehicles for Europe and 2000 model vehicles for Hong Kong) 4. Solenoid valve (Vehicles for Europe and 2000 model vehicles for Hong Kong) 5. Vacuum pipe 6. Throttle body
"DA 7. Throttle body gasket "CA 8. Intake manifold stay "BA 9. Air intake plenum resonator 10. Gasket 11. Water hose 12. EGR valve 13. Gasket "AA 14. Hose clamp "AA 15. EGR support "AA 16. Gasket 17. Gasket 18. Intake manifold 19. Gasket

11A-3a-2

REMOVAL AND INSTALLATION (GALANT)

8.8 Nm 8.8 Nm

23 Nm 19 Nm

19 Nm 30 Nm

11 Nm 8.8 Nm
Removal steps 1. Vacuum pipe and hose 2. Solenoid valve 3. Throttle body "DA 4. Throttle body gasket "CA 5. Intake manifold stay "BA 6. Air intake plenum resonator 7. Gasket 8. Water hose
9. 10. "AA 11. "AA 12. "AA 13. 14. 15. 16.
EGR valve Gasket Hose clamp EGR support Gasket Gasket Intake manifold Gasket
Intake manifold side Cylinder head side

11A-3a-3

INSTALLATION SERVICE POINTS
"AA EGR SUPPORT / HOSE CLAMP / GASKET INSTALLATION (1) Install the gasket, EGR support and hose clamp to the cylinder head in that order and tighten the fasteners temporarily. (2) Install the EGR support assembly to the intake manifold with the gasket attached on the mating surface, and tighten the fasteners to the specified torque. (3) Tighten the fasteners on the cylinder head side to the specified torque. "BA AIR INTAKE PLENUM RESONATOR INSTALLATION (1) Install the mounting bolts on the throttle body side without fail.

Hose clamp

Intake manifold stay
"CA INTAKE MANIFOLD STAY INSTALLATION (1) Tighten the fasteners to the specified torque after confirming that the intake manifold stay is in close contact with the air intake plenum resonator and the cylinder block.
Air intake plenum resonator
"DA THROTTLE BODY GASKET INSTALLATION (1) Position the projection as shown in the illustration.

Projection

4G6 ENGINE (E - W) - Timing Belt

11A-4-1

4. TIMING BELT
REMOVAL AND INSTALLATION (SOHC)

48 Nm 49 Nm 49 Nm

54 Nm 118 Nm

11 Nm 9 Nm

AA" "KA "JA "IA AC" "HA AD" "GA
Removal steps 1. Timing belt front upper cover 2. Timing belt front lower cover 3. Power steering bracket 4. Crankshaft position sensor (Multipoint fuel injection) 5. Timing belt 6. Tensioner pulley 7. Tensioner arm 8. Auto tensioner 9. Idler pulley 10. Oil pump sprocket 11. Crankshaft bolt

Timing mark

Caution D The camshaft sprocket on the exhaust side can turn very easily because of the valve spring tension. Use care not to allow your fingers to get caught by the sprocket. (3) Loosen the lock nut of the tensioner pulley, then remove the timing belt.
AC" OIL PUMP SPROCKET REMOVAL (1) Remove the plug on the left side of cylinder block. (2) Insert a screwdriver (shank diameter 8 mm) to block the counterbalance shaft. (3) Remove the nut. (4) Remove the oil pump sprocket.

11A-4-4

AD" CRANKSHAFT BOLT LOOSENING (1) Hold the drive plate with the special tool as shown. (2) Remove the crankshaft bolt.
AE" CRANKSHAFT SPROCKET REMOVAL (1) If it is difficult to remove the sprocket, use the special tool.
AF" TIMING BELT B REMOVAL (1) Make a mark on the back of the timing belt indicating the direction of rotation so it may be reassembled in the same direction if it is to be reused. NOTE (1) Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and water. These parts should not be washed. Replace parts if seriously contaminated. (2) If there is oil or water on each part check front case oil seals, camshaft oil seal and water pump for leaks.

6EN1322

AG" COUNTERBALANCE SHAFT SPROCKET REMOVAL (1) Set the special tool as shown to prevent the counterbalance shaft sprocket from turning together. (2) Loosen the bolt and remove the sprocket.

11A-4-5

AH" CRANKSHAFT SPROCKET B REMOVAL (1) If it is difficult to remove the sprocket, use the special tool.
AI" CAMSHAFT SPROCKET BOLT LOOSENING (1) Using the special tools shown in the illustration, lock the camshaft sprocket in position. (2) Loosen the camshaft bolt.
AJ" CAMSHAFT SPROCKET BOLT LOOSENING (1) Use a wrench to hold the hexagonal part of the camshaft, and then remove the camshaft sprocket mounting bolt.
"AA CAMSHAFT SPROCKET BOLT TIGHTENING (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.
"BA CAMSHAFT SPROCKET BOLT TIGHTENING (1) Using a wrench, hold the camshaft at its hexagon and tighten the bolt to the specification.

11A-4-6

"CA ENGINE SUPPORT BRACKET INSTALLATION (1) Coat the bolts illustrated with sealant before tightening. Specified sealant: 3M ATD Part No. 8660 or equivalent
"DA SPACER INSTALLATION (1) Install the spacer with the chamfered end toward the oil seal.

Sharp edge

Counterbalance shaft
"EA COUNTERBALANCE SHAFT SPROCKET INSTALLATION (1) Install the counterbalance shaft sprocket and screw the bolt. (2) Install special tool MD998785 as shown in the illustration to lock the counterbalance shaft. (3) Tighten the bolt, and then remove the special tool.

Small holes

6EN1323
"KA TIMING BELT INSTALLATION (1) Check that the timing belt tensioner and spring have been installed in position. (See "JA) (2) Align timing mark on camshaft sprocket with timing mark on cylinder head.
(3) Align timing mark on crankshaft sprocket with timing mark on front case.
Oil pump sprocket timing marks

11A-4-9

(4) Align the timing mark on oil pump sprocket with its mating mark.

6EN1327

Screwdriver

6EN1026

(5) Remove the plug on cylinder block and insert a Phillips screwdriver (shank diameter 8 mm) through the hole (Engine with counterbalance shafts). If it can be inserted as deep as 60 mm or more, the timing marks are correctly aligned. If the inserted depth is only 20 - 25 mm, turn the oil pump sprocket one turn and realign timing marks. Then check to ensure that the screwdriver can be inserted 60 mm or more. Keep the screwdriver inserted until installation of timing belt is finished. (6) Install the timing belt on the crankshaft sprocket, idler pulley, camshaft sprocket, and tensioner pulley in that order.
(7) Lift up the tensioner pulley in the direction of arrow and tighten the center bolt. (8) Check that all timing marks are lined up. (9) Remove the screwdriver inserted in step (5) and fit the plug. (10)Give the crankshaft a quarter counterclockwise turn. Then, turn it clockwise until the timing marks are lined up again.

6EN0899

(11)Install the special tools, Socket Wrench and Torque Wrench, on the tensioner pulley, and loosen the tensioner pulley center bolt. NOTE If the special tool is not available, use a commercially available torque wrench that is capable of measuring 0 - 5 Nm. (12)Torque to 3.5 Nm with the torque wrench. (13)Holding the tensioner pulley with the special tool and torque wrench, tighten the center bolt to specification.

PWEE9616-A Revised

6EN0900

11A-4-10

(14)After giving two clockwise turns to the crankshaft, let it alone for approx. 15 minutes. Then, make sure that the auto tensioner setting wire moves freely. NOTE If the wire does not move freely, repeat step (10) above until it moves freely. (15)Remove the auto tensioner setting wire.
(16)Measure the distance A (between the tensioner arm and auto tensioner body). Standard value: 3.8 - 4.5 mm
"LA TIMING BELT INSTALLATION (1) Place the exhaust side camshaft sprocket in a position where its timing mark is one tooth offset from the timing mark on the rocker cover in the counterclockwise direction. NOTE Even if the timing marks on the sprocket and the rocker cover are brought into alignment, the exhaust camshaft is forced back by the valve spring tension. It is stabilized at a position one tooth before the timing mark. (2) Align the timing mark on the intake side camshaft sprocket with that on the rocker cover. NOTE Even if the timing marks on the sprocket and the cover are brought into alignment, the intake camshaft is forced to turn one tooth in the clockwise direction by the valve spring tension and stabilized there.

(3) Place the timing mark on the crankshaft sprocket one tooth this side from the mated timing mark as in the case of the camshaft sprocket.

11A-4-11

(5) Remove the plug on cylinder block and insert a Phillips screwdriver (shank diameter 8 mm) through the hole (Engine with counterbalance shafts). If it can be inserted as deep as 60 mm or more, the timing marks are correctly aligned. If the inserted depth is only 20 - 25 mm, turn the oil pump sprocket one turn and realign timing marks. Then check to ensure that the screwdriver can be inserted 60 mm or more. Keep the screwdriver inserted until installation of timing belt is finished. (6) Remove the Phillips screwdriver. Place the oil pump sprocket in a position where its timing mark is one tooth offset from the mated timing mark in the counterclockwise direction.
(7) Fit the timing belt over the exhaust side camshaft sprocket, and secure it at the illustrated position using a paper clip.
(8) Turn the intake side camshaft sprocket as shown to a position where its timing mark is one tooth offset from the mated timing mark in the counterclockwise direction. Then, fit the timing belt over the sprocket and secure it with a paper clip. NOTE The intake camshaft will be turned a little clockwise by the valve spring tension and stabilized in position even if the belt is clipped at one tooth offset position.
Aug. 1998 PWEE9616-A Added

11A-4-12

17 cogs
(9) Check to ensure that the timing marks on the intake camshaft sprocket side are in alignment when the exhaust camshaft sprocket is turned clockwise to align the timing marks. NOTE The timing belt span between the intake and exhaust sprockets will have 17 cogs.
(10)Fit the timing belt over the idler pulley, oil pump sprocket and crankshaft sprocket in this order. NOTE Be careful that the belt does not become slack.

Crankshaft sprocket

Oil pump sprocket
(11)Fit the timing belt over the tensioner pulley. NOTE When fitting the timing belt over the tensioner pulley, turn the intake side camshaft sprocket a little counterclockwise, as this will facilitate the work.

Corrugated washer

Mating marks

Injector gasket

Insulator
"BA DELIVERY PIPE AND INJECTOR ASSEMBLY INSTALLATION (1) Lubricate O-ring in the injector with spindle oil gasoline. (2) Insert the injector straight into the injector mounting hole in the delivery pipe. (3) Turn the injector clockwise and counterclockwise. If it dose not rotate smoothly, remove it to check for damaged O-ring. Damaged O-ring must be replaced with a new one. Reinstall the injector and check for smooth rotation again. (4) Align the mating mark on the injector with that on the delivery pipe. (5) Install the injector gaskets and insulators on the cylinder head. The insulator can drop off easily. Apply vaseline to it before installation so that it may be held in position. (6) Install the delivery pipe and injector assembly onto the cylinder head, tighten the fasteners temporarily. (7) Install the injector holders and the washers to the assembly and tighten the fasteners to the specified torque. Caution D Strictly observe the specified torque. (8) Tighten the fasteners of the delivery pipe and injector assembly to the specified torque in the order given in the illustration.

11A-5a-4

Grooved

Coupling

"CA PUMP CAMSHAFT CASE INSTALLATION (1) Lubricate the O-ring (smaller one for oil passage) with vaseline and install it in the pump camshaft case. (2) Apply small amount of engine oil to the O-ring (larger one) in the case. (3) Install the pump camshaft case onto the cylinder head while aligning its coupling with the groove in the camshaft end. NOTE The key of the coupling and the groove in the camshaft end are both arranged offset with respect to the camshaft center. (4) Tighten the pump camshaft case mounting bolts to the specified torque.

Camshaft O-ring

"DA FUEL PRESSURE SENSOR INSTALLATION (1) Install the backup ring to the fuel pressure sensor with its inside cut surface in the illustrated direction. (2) Install the fuel pressure sensor straight into the fuel pressure regulator with labeled surface upward. (3) Tighten the fuel pressure sensor mounting bolt to the specified torque.
Backup ring (Mountable in eitherdirection)

O-ring

"EA FUEL HIGH PRESSURE REGULATOR / FUEL RETURN PIPE INSTALLATION (1) Install the fuel high pressure regulator on the pump camshaft case and tighten the 3 bolts lightly (with somewhat larger torque than finger tight). Tightening to the specification is to be carried out in the step described in "FA. (2) Fit the backup rings and the O-ring on both ends of the fuel return pipe. Note that the larger backup ring must be installed with the inside cut surface in the direction shown in the illustration. (3) Lubricate the O-rings on both ends of the pipe with spindle oil or gasoline. (4) Insert the fuel return pipe ends straight in the respective mounting holes of the pressure regulator and the delivery pipe. Be sure to insert the pipe fully to the stop using care not to twist it. (5) Tighten the bolts at both ends of the pipe to the specified torque.

Backup ring (Mountable in either direction)

11A-5a-5

"FA FUEL PUMP / FUEL FEED PIPE INSTALLATION (1) Insert the fuel pump into the mounting hole in the pump camshaft case, and secure it temporarily with 4 bolts (tighten somewhat with a larger torque than finger tight). (2) Fit the backup rings and the O-ring on both ends of the feed pipe. Note that the larger backup ring must be installed with the inside cut surface in the direction shown in the illustration. (3) Lubricate the O-rings on both ends of the pipe with spindle oil or gasoline. (4) Insert the fuel feed pipe ends straight in the respective mounting holes of the fuel and the delivery pipe. Be sure to insert the pipe fully to the stop using care not to twist it. (5) Tighten the bolts at ends of the pipe to the specified torque. (6) Tighten the mounting bolts of the fuel pressure regulator to the specified torque.
(7) Using a torque wrench having the minimum scale of 0.5 Nm, tighten the fuel pump mounting bolts in the following order. 1) Tighten the bolts to 4.9 Nm in the order given in the illustration. 2) Tighten the bolts to 17 Nm in the order given in the illustration. The torque variation among 4 bolts must be within 2 Nm. Caution D Strictly observe the specified tightening torque. Deviation from the specification can cause problems such as leakage or the like. (8) Clamp the fuel return pipe and feed pipe using the fuel pipe bracket and clamp A, and tighten them lightly. (9) Secure the fuel pipe bracket to the cam cap temporarily. (10)Tighten the bolts which are securing the pipes temporarily to the specified torque. (11)Tighten the bolts on the beam cam shaft side which have been temporarily tightened to the specified torque.
4G6 ENGINE (E - W) - Water Pump and Intake Manifold

11A-6-1

6. WATER PUMP AND INTAKE MANIFOLD

13 Nm 24 Nm

14 Nm 12 Nm
"BA "AA "AA
Removal steps 1. Water hose 2. Water hose 3. Engine coolant temperature gauge unit 4. Water inlet fitting 5. Thermostat 6. Thermostat housing 7. Water inlet pipe 8. O-ring

"CA "BA "AA "AA

7. 8. 9. 10. 11. 12. 13.

Water outlet fitting Thermostat housing O-ring Water inlet pipe Water pump Gasket Knock sensor

11A-6a-2

4G6 ENGINE (E - W) - Water Pump and Water Hose (GDI) INSTALLATION SERVICE POINTS
"AA O-RING / WATER INLET PIPE INSTALLATION (1) Replace the O-ring of the water inlet pipe, and then apply water to the O-ring to make installation easy. Caution D Never apply any oil or grease to the O-ring. D Secure the water pipe after the thermostat case has been reinstalled.
"BA THERMOSTAT CASE INSTALLATION (1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG) to the location shown in the illustration. Specified sealant: Mitsubishi Genuine equivalent Part No. MD970389 or
"CA WATER OUTLET FITTING INSTALLATION (1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG) to the location shown in the illustration. Specified sealant: Mitsubishi Genuine equivalent Part No. MD970389 or
"DA ENGINE COOLANT TEMPERATURE GAUGE UNIT INSTALLATION (1) Apply the specified sealant to the threads. Specified sealant: 3M ATD Part No. 8660 or equivalent
"EA 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
4G6 ENGINE (E - W) - Exhaust Manifold

11A-7-1

7. EXHAUST MANIFOLD
Removal steps "AA 1. Water outlet fitting 2. Heat protector (Multipoint fuel injection) 3. Exhaust manifold cover (Carburetor) 4. Engine hanger 5. Exhaust manifold 6. Exhaust manifold gasket

11A-7-2

Removal steps "AA 1. Water outlet fitting 2. Exhaust manifold cover 3. Engine hanger 4. Exhaust manifold 5. Exhaust manifold gasket
"AA SEALANT APPLICATION TO WATER OUTLET FITTING Specified sealant: Mitsubishi Genuine equivalent Part No. MD970389 or

6EN1170

NOTE (1) Be sure to install the water outlet fitting quickly while the sealant is wet (within 15 minutes). (2) After installation, keep the sealed area away from the oil and coolant for approx. 1 hour.
4G6 ENGINE (E - W) - Rocker Arms and Camshaft

11A-8-1

MD998441 Diesel fuel

(12)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 adjusters height matches that of a new lash adjuster. NOTE If lash adjuster contracts, perform the operations (9) through (12) again to fill it with diesel fuel completely. Replace the lash adjuster if it still contracts after performing these steps. (13)Set the lash adjuster on the special tool MD998440 (leak down tester). (14)After the plunger has moved downward slightly (0.2 to 0.5 mm), measure the time taken for it to move downward by a further 1 mm. Standard value: 3 - 20 seconds/1 mm [with diesel fuel at 15 20_C (59 - 68_F)] NOTE Replace the lash adjuster if the time measurement is out of specification.

MD998440

Division = 1 mm

Lash adjuster

11A-8-6
(15)Fit special tool MD998441 onto the lash adjuster. (16)Place the lash adjuster in container C again, then gently push down the internal steel ball using special tool MD998442. (17)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. (18)Remove special tool MD998441. (19)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 adjusters height matches that of a new lash adjuster. NOTE If lash adjuster contracts, perform the operations (15) through (19) again to fill it with diesel fuel completely. Replace the lash adjuster if it still contracts after performing these steps. (20)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.
4G6 ENGINE (E - W) - Rocker Arms and Camshafts (GDI)

11A-8a-1

8a. ROCKER ARMS AND CAMSHAFTS (GDI)

8.8 Nm 13 Nm

Removal steps 1. Camshaft position sensor 2. Cover 3. Gasket "DA 4. Camshaft position sensing cylinder "CA 5. Camshaft position sensing cylinder support "BA 6. Oil seal
7. 8. 9. 10. 11. AA" "AA 12.
"BA "BA "BA "BA
Beam camshaft cap Beam camshaft cap gasket Intake camshaft Exhaust camshaft Rocker arm Lash adjuster

11A-8a-2

4G6 ENGINE (E - W) - Rocker Arms and Camshafts (GDI) REMOVAL SERVICE POINTS
AA" LASH ADJUSTER REMOVAL Caution D If the lash adjuster is re-used, clean the lash adjuster. (Refer to 11A-8a-4.)
"AA LASH ADJUSTER INSTALLATION Caution D If the lash adjuster is re-used, clean the lash adjuster. (Refer to 11A-8a-4.) (1) Fit the lash adjuster onto the rocker arm without allowing diesel fuel to spill out.

Dowel pin Approx. 11_

"BA BEAM CAMSHAFT CAP GASKET / BEAM CAMSHAFT CAP / CAMSHAFT / OIL SEAL INSTALLATION (1) Locate the camshaft dowel pins as illustrated.

Timing belt side

(2) Apply a 3 mm thick continuous bead of sealant to the bottom surface of the beam camshaft cap along the groove. Specified sealant: Mitsubishi genuine equivalent Part No. MD970389 or
Beam camshaft cap Timing belt side
(3) Apply sealant to the illustrated position of the cylinder head upper surface. Specified sealant: Mitsubishi genuine equivalent Part No. MD970389 or
(4) Install the beam camshaft cap gasket.

11A-8a-3

(5) Install the beam camshaft cap before the sealant applied becomes dry and hard. (6) Tighten the bolts to the specified torque in the order shown in the illustration. Specified torque: 20 Nm
(7) Install the camshaft oil seal before the sealant applied becomes dry and hard. (8) Wipe off squeezed out excess sealant from the circumference of the beam camshaft cap.
"CA CAMSHAFT POSITION SENSING CYLINDER SUPPORT INSTALLATION (1) Apply a 3 mm bead of form-in-place gasket (FIPG) to the area shown. Specified sealant: Mitsubishi genuine equivalent Part No. MD970389 or

Paint mark

Camshaft position sensor
"DA CAMSHAFT POSITION SENSING CYLINDER INSTALLATION (1) Set the No. 1 cylinder to the compression top dead center position (so that dowel pin of the exhaust camshaft is at the top). (2) Install the camshaft position sensing cylinder so that the white paint mark is facing in the direction shown in the illustration.
CAMSHAFT (1) Measure the cam height. Standard value: Intake 35.79 mm Exhaust 37.14 mm Limit: Intake Exhaust

35.29 mm 36.64 mm

11A-8a-4
LASH ADJUSTER Caution D The lash adjusters are precision-engineered mechanisms. Do not allow them to become contaminated by dirt or other foreign substances. D Do not attempt to disassemble the lash adjusters. D Use only fresh diesel fuel to clean the lash adjusters.
(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 D 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.

Item SOHC GDI Intake Exhaust Intake Exhaust Standard value mm 1.0 1.2 1.0 1.5 Limit mm 0.5 0.7 0.5 1.0
(3) Measure valves total length. If measurement is less than specified, replace the valve.
Item SOHC GDI Intake Exhaust Intake Exhaust Standard value mm 112.30 114.11 105.5 105.7 Limit mm 111.80 113.61 105.0 105.2

Out of square

VALVE SPRING (1) Measure the free height of spring and, if it is smaller than the limit, replace.

Free height

Standard value mm 51.0 48.3

Limit mm 50.0 47.3

1EN0264
(2) Measure the squareness of the spring and, if the limit is exceeded, replace.
Item SOHC GDI Standard value mm 2_ 1.5_ Limit mm 4_ 4_

11A-9-8

VALVE GUIDE (1) Measure the clearance between the valve guide and valve stem. If the limit is exceeded, replace the valve guide or valve, or both.
Item SOHC GDI Intake Exhaust Intake Exhaust Standard value mm 0.02 - 0.05 0.03 - 0.07 0.02 - 0.05 0.05 - 0.09 Limit mm 0.10 0.15 0.10 0.15

Valve guide

Valve stem end Valve stem projection Spring seating surface
VALVE SEAT (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.
Item SOHC GDI Intake Exhaust Intake Exhaust Standard value mm 49.30 49.30 49.20 48.40 Limit mm 49.80 49.80 49.70 48.90

DEN0212

VALVE SEAT RECONDITIONING PROCEDURE

0.9 - 1.3 mm

43.5_ - 44_

6EN0491

(1) Before correcting the valve seat, check for clearance between the valve guide and valve and, if necessary, replace the valve guide. (2) Using the seat grinder, correct to obtain 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 VALVE SEAT in INSPECTION).

PWEE9616-A Added

0.5 - 1 mm

11A-9-9

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 selected oversize valve seat diameter. Valve seat ring hole diameter

Height of seat ring

Item SOHC Intake Exhaust

1EN0275

Standard value mm 0.30 O.S. 0.60 O.S. 0.30 O.S. 0.60 O.S. 0.30 O.S. 0.60 O.S. Exhaust 0.30 O.S. 0.60 O.S. 34.30 - 34.33 34.60 - 34.63 31.80 - 31.83 32.60 - 32.63 35.30 - 35.33 35.60 - 35.63 33.30 - 33.33 33.60 - 33.63

Oversize I.D.

OIL SEAL (1) Check the oil seal lip for wear and damage. Replace oil seal if necessary. (2) Check the oil seal lip for deterioration. Replace oil seal if necessary.
COUNTERBALANCE SHAFT (1) Check oil holes for clogging. (2) Check journals for seizure, damage and contact with bearing. If there is anything wrong with the journal, replace the counterbalance shaft, bearing or front case assembly.
OIL PUMP (1) Assemble the oil pump gear to the front case and rotate it to ensure smooth rotation with no looseness. (2) Ensure that there is no ridge wear on the contact surface between the front case and the gear surface of the oil pump cover. (3) Check the side clearance. Standard value: Drive gear Driven gear 0.08 - 0.14 mm 0.06 - 0.12 mm
4G6 ENGINE (E - W) - Piston and Connecting Rod

11A-11-1

11. PISTON AND CONNECTING ROD
"GA AA" "FA "EA "DA "EA "CA
Removal steps 1. Nut 2. Connecting rod cap 3. Connecting rod bearing 4. Piston and connecting rod assembly 5. Connecting rod bearing 6. Piston ring No. 1
"CA 7. Piston ring No. 2 "BA 8. Oil ring AB" "AA 9. Piston pin 10. Piston 11. Connecting rod 12. Bolt

11A-11-2

4G6 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 rod big end for correct reassembly. (2) Keep the removed connecting rods, caps, and bearings in order according to the cylinder number.
AB" PISTON PIN REMOVAL
(1) Insert the special tool, Push Rod, into the piston from the side on which the front mark is stamped in the piston head, and attach the guide C to the push rod end. (2) Place the piston and connecting rod assembly on the special tool, Piston Pin Setting Base, with the front mark facing upward. (3) Using a press, remove the piston pin. NOTE Keep the disassembled pistons, piston pins and connecting rods in order according to the cylinder number.
4G6 ENGINE (E - W) - Piston and Connecting Rod INSTALLATION SERVICE POINTS

11A-11-3

"AA PISTON PIN INSTALLATION (1) Measure the following dimensions of the piston, piston pin and connecting rod. A: Piston pin insertion hole length B: Distance between piston bosses C: Piston pin length D: Connecting rod small end width (2) Obtain dimension L (to be used later) from the above measurements by using by following formula. L =

(A - C) - (B - D) 2

(3) Insert the special tool, Push Rod, 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. (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. (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.

3 mm + L

(8) Place the piston and connecting rod assembly onto the piston setting base with the front marks directed upward. (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: 7,350 - 17,200 N

11A-11-4

(10)Check that the piston moves smoothly

Upper side rail

"BA OIL RING INSTALLATION (1) Fit the oil ring spacer into the piston ring groove. NOTE 1. The side rails and spacer may be installed in either direction. 2. New spacers and side rails are colored for identification of their sizes.
Size Standard 0.50 mm oversize 1.00 mm oversize Identification color None Red Yellow

Spacer

Lower side rail

6EN1237

Side rail gap
(2) Install the upper side rail. 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. See illustration. Use of ring expander to expand the side rail end gap can break the side rail, unlike other piston rings. Caution D Do not use piston ring expander when installing side rail.