Mitsubishi 4G6 SERIES manual

GENERAL INFORMA TION 1 1A-0-3 ............................................ 1. SPECIFICA TIONS 1 1A-1-1 ................................................ SER VICE SPECIFICA TIONS 1 1A-1-1 .................................... T ORQUE SPECIFICA TIONS 1 1A-1-4 ..................................... NEW TIGHTENING METHOD - BY USE OF BOL TS TO BE TIGHTENED[...]

1 1A-0-2 PWEE9616 E Dec. 1996 Mitsubishi Motors Corporation NOTES[...]

4G6 ENGINE <E - W> - General Information 1 1A-0-3 GENERAL INFORMA TION SOHC-4G63 Descriptions Specifications T ype In-line OHV , SOHC Number of cylinders 4 Combustion chamber Pentroof type T otal displacement dm 3 1,997 Cylinder bore mm 85.0 Piston stroke mm 88.0 Compression ratio 10 V alve timing Intake valve Opens (BTDC) 18 _ Closes (ABDC) [...]

4G6 ENGINE <E - W> - General Information 1 1A-0-4 GDI t Descriptions Specifications T ype In-line OHV , SOHC Number of cylinders 4 Combustion chamber Pentroof + curved top piston type T otal displacement dm 3 2,351 Cylinder bore mm 86.5 Piston stroke mm 100.0 Compression ratio 1 1.5 V alve timing Intake valve Opens (BTDC) 16 _ Closes (ABDC) 6[...]

4G6 ENGINE <E - W> - Specifications 1 1A-1-1 1. SPECIFICA TIONS SERVICE SPECIFICA TIONS Items Standard value Limit Timing belt Auto-tensioner rod projection length mm 12 - Auto-tensioner rod pushed-in amount [when pushed with a force of 98 - 196 N] mm 1.0 or less - Rocker arms and camshaft Camshaft cam height mm 4G63 Intake 37.39 36.89 SOHC E[...]

4G6 ENGINE <E - W> - Specifications 1 1A-1-2 Items Limit Standard value V alve thickness to valve guide clearance SOHC Intake 0.02 - 0.05 0.10 mm Exhaust 0.03 - 0.07 0.15 GDI Intake 0.02 - 0.05 0.10 Exhaust 0.05 - 0.09 0.15 V alve face angle mm 45 _ - 45.5 _ - V alve spring free length mm SOHC 51.0 50.0 GDI 48.3 47.3 V alve spring load/instal[...]

4G6 ENGINE <E - W> - Specifications 1 1A-1-3 Items Limit Standard value Front case, counterbalance shaft and oil pan Oil pump side clearance mm Drive gear 0.08 - 0.14 - Driven gear 0.06 - 0.12 - Oil pressure at curb idle speed kPa [Oil temperature is 75 to 90 _ C] 78 or more - Piston and connecting rod Piston outer diameter mm 4G63 85.0 - 4G6[...]

4G6 ENGINE <E - W> - Specifications 1 1A-1-4 TORQUE SPECIFICA TIONS Items Nm Alternator and ignition system W ater pump pulley 9 Adjusting bolt 10 Lock bolt 22 Alternator brace 23 Alternator pivot nut 44 Crankshaft pulley 25 Ignition coil (Multipoint fuel injection) 10 Spark plug 25 Distributor (Carburetor) 12 Camshaft position sensing cylind[...]

4G6 ENGINE <E - W> - Specifications 1 1A-1-5 Items Nm T iming belt cover washer bolt 9 Power steering bracket 49 Crankshaft angle sensor (Multipoint fuel injection) 9 T ensioner arm 22 T ensioner puller 48 Auto tensioner 23 Idler pulley 35 Engine support bracket 49 Oil pump sprocket 54 Crankshaft bolt 11 8 T ensioner “B” 18 Counterbalance[...]

4G6 ENGINE <E - W> - Specifications 1 1A-1-6 Items Nm Fuel pump 4.9 ® 17 ± 2 Harness bracket 8.8 Fuel return pipe 11 Fuel high pressure regulator 18 Fuel pressure sensor 18 Pump camshaft case 23 Injector holder 22 Delivery pipe and injector assembly 11 Engine hanger 11 W ater pump and intake manifold Engine coolant temperature sensor 29 Eng[...]

4G6 ENGINE <E - W> - Specifications 1 1A-1-7 Items Nm Heat protector 13 Exhaust manifold (M8) 29 Exhaust manifold (M10) 49 W ater outlet fitting 13 Rocker arms and camshaft Rocker cover 3.4 Rocker arm shaft 31 Rocker arms and camshafts (GDI) Camshaft position sensor 8.8 Cover 9.8 Camshaft position sensing cylinder 21 Camshaft position sensing[...]

4G6 ENGINE <E - W> - Specifications 1 1A-1-8 Items Nm Oil pan lower 6.9 Baffle plate 6.9 Oil pan upper 6.9 Piston and connecting rod Connecting rod cap 20 + 90 _ ® 100 _ Crankshaft, flywheel and drive plate Flywheel bolt 132 Drive plate bolt 132 Rear plate 11 Bell housing cover 8.8 Oil seal case bolt 11 Bearing cap bolt 25 + 90 _ ® 100 _ Re[...]

4G6 ENGINE <E - W> - Specifications 1 1A-1-9 NEW TIGHTENING METHOD - BY USE OF BOL TS T O BE TIGHTENED IN PLASTIC AREA A new type of bolts, to be tightened in plastic area, is currently used some parts of the engine. The tightening method for the bolts is dif ferent from the conventional one. Be sure to observe the method described in the tex[...]

4G6 ENGINE <E - W> - Specifications 1 1A-1-10 FORM-IN-PLACE GASKET The engine has several areas where the form-in-place gasket (FIPG) is in use. T o 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. T oo thin a [...]

4G6 ENGINE (E - W) - Special T ools 1 1A-2-1 2. SPECIAL TOOLS T ool Number Name Use MB990767 Crankshaft pulley holder Holding camshaft sprocket Use with MD998719. MD990938 Handle Installation of crankshaft rear oil seal Use with MD998776. MB991603 Silent shaft bearing puller stopper Guide stopper for removal and installation of counterbalance shaft[...]

4G6 ENGINE (E - W) - Special T ools 1 1A-2-2 T ool Use Name Number MD998440 Leak down tester Leak down test of lash adjuster MD998441 Lash adjuster retainer Air bleeding of lash adjuster MD998442 Lash adjuster wire Air bleeding of lash adjuster MD998443 Lash adjuster holder Retainer for holding lash adjuster in rocker arm at time of removal and ins[...]

4G6 ENGINE (E - W) - Special T ools 1 1A-2-3 T ool Use Name Number MD998738 Set screw Adjustment of timing belt tension MD998767 T ensioner puller socket wrench Adjustment of timing belt tension MD998772 V alve spring compressor Removal and installation of valve and related parts MD998774 V alve stem seal installer Installation of valve stem seal M[...]

4G6 ENGINE (E - W) - Special T ools 1 1A-2-4 T ool Use Name Number MD998783 Plug wrench retainer Removal and installation of front case cap plug MD998785 Sprocket stopper Holding silent shaft sprocket Added PWEE9616-A E Aug. 1998 Mitsubishi Motors Corporation[...]

4G6 ENGINE (E - W) - Alternator and Ignition System 1 1A-3-1 3. AL TERNA TOR AND IGNITION SYSTEM REMOV AL AND INST ALLA TION <CARBURETOR> 9 10 4 5 3 1 7 6 12 Nm 25 Nm 24 Nm 10 Nm 9N m 25 Nm 22 Nm 44 Nm 8 2 Removal steps 1. Drive belt 2. W ater pump pulley 3. Alternator brace 4. Alternator 5. Crankshaft pulley 6. Spark plug cable 7. Spark plug[...]

4G6 ENGINE (E - W) - Alternator and Ignition System 1 1A-3-2 REMOV AL AND INST ALLA TION <MUL TIPOINT FUEL INJECTION> 11 10 4 5 2 3 1 7 9 22 Nm 14 Nm 24 Nm 22 Nm 9N m 25 Nm 44 Nm 25 Nm 6 10 Nm 10 Nm r 10 Nm 8 Removal steps 1. Drive belt 2. W ater pump pulley 3. Alternator brace 4. Alternator 5. Crankshaft pulley 6. Spark plug cable 7. Ignitio[...]

4G6 ENGINE (E - W) - Alternator and Ignition System 1 1A-3-3 REMOV AL AND INST ALLA TION (GDI) 11 10 4 5 2 3 1 7 9 22 Nm 13 Nm 25 Nm 22 Nm 49 Nm 23 Nm 49 Nm 25 Nm 6 49 Nm 9.8 Nm 8.8 Nm 8 12 9.8 Nm Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Drive belt 5. W ater pump pulley 6. Alternator 7. Alternator brace 8. Idler pulley[...]

4G6 ENGINE (E - W) - Alternator and Ignition System 1 1A-3-4 INST ALLA TION SERVICE POINTS " A A CAMSHAFT POSITION SENSOR SUPPORT INST ALLA TION (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 " B A DISTRIBUT OR ASSEMBL Y INST ALLA TION (1) T urn[...]

4G6 ENGINE (E - W) - Intake Manifold (GDI) 1 1A-3a-1 3a. INT AKE MANIFOLD (GDI) REMOV AL AND INST ALLA TION (SP ACE W AGON) 3 1 2 8.8 Nm 8.8 Nm 4 5 8.8 Nm 11 N m 11 N m 6 7 8 9 10 11 23 Nm 12 13 14 15 16 17 19 18 19 Nm 8.8 Nm 19 Nm 30 Nm 8.8 Nm 30 Nm 11 N m 23 Nm 11 N m Removal steps 1. V acuum pipe and hose (1999 model vehicles for Hong Kong) 2. S[...]

4G6 ENGINE (E - W) - Intake Manifold (GDI) 1 1A-3a-2 REMOV AL AND INST ALLA TION (GALANT) 23 Nm 8.8 Nm 8.8 Nm 11 N m 2 1 3 19 Nm 4 15 16 19 Nm 5 6 7 8 9 11 10 14 12 13 23 Nm 8.8 Nm 30 Nm 11 N m Removal steps 1. V acuum pipe and hose 2. Solenoid valve 3. Throttle body " D A 4. Throttle body gasket " C A 5. Intake manifold stay " B A 6[...]

4G6 ENGINE (E - W) - Intake Manifold (GDI) 1 1A-3a-3 INST ALLA TION SERVICE POINTS " A A EGR SUPPORT / HOSE CLAMP / GASKET INST ALLA TION (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 attac[...]

4G6 ENGINE (E - W) - Timing Belt 1 1A-4-1 4. TIMING BEL T REMOV AL AND INST ALLA TION (SOHC) 1 2 10 4 23 22 9 11 6 20 14 8 13 15 21 7 17 18 45 Nm 14 Nm 11 N m 22 Nm 9N m 48 Nm 88 Nm 54 Nm 11 8 N m 49 Nm 16 45 Nm 18 Nm 19 35 Nm 23 Nm 5 12 3 49 Nm 9N m Removal steps 1. T iming belt front upper cover 2. T iming belt front lower cover 3. Power steering[...]

4G6 ENGINE (E - W) - Timing Belt 1 1A-4-2 REMOV AL AND INST ALLA TION (GDI) 1 2 11 5 24 23 10 12 7 21 15 9 14 16 22 8 18 19 54 Nm 11 N m 48 Nm 48 Nm 49 Nm 11 N m 23 Nm 8.8 Nm 49 Nm 17 3.4 Nm 88 Nm 20 11 N m 23 Nm 6 13 4 18 Nm 25 26 27 28 29 30 31 32 33 11 8 N m 9N m 45 Nm 3 Removal steps 1. Front upper cover 2. Front lower cover 3. Power steering p[...]

4G6 ENGINE (E - W) - Timing Belt 1 1A-4-3 REMOV AL SER VICE POINTS A A " TIMING BEL T REMOV AL (1) Mark belt running direction for reinstallation. NOTE (1) W ater or oil on the belt shorten 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 part[...]

4G6 ENGINE (E - W) - Timing Belt 1 1A-4-4 A D " CRANKSHAFT BOL T LOOSENING (1) Hold the drive plate with the special tool as shown. (2) Remove the crankshaft bolt. A E " CRANKSHAFT SPROCKET REMOV AL (1) If it is dif ficult to remove the sprocket, use the special tool. A F " TIMING BEL T “B” REMOV AL (1) Make a mark on the back of[...]

4G6 ENGINE (E - W) - Timing Belt 1 1A-4-5 A H " CRANKSHAFT SPROCKET “B” REMOV AL (1) If it is dif ficult to remove the sprocket, use the special tool. A I " CAMSHAFT SPROCKET BOL T LOOSENING (1) Using the special tools shown in the illustration, lock the camshaft sprocket in position. (2) Loosen the camshaft bolt. A J " CAMSHAFT [...]

4G6 ENGINE (E - W) - Timing Belt 1 1A-4-6 " C A ENGINE SUPPORT BRACKET INST ALLA TION (1) Coat the bolts illustrated with sealant before tightening. Specified sealant: 3M A TD Part No. 8660 or equivalent " D A SP ACER INST ALLA TION (1) Install the spacer with the chamfered end toward the oil seal. " E A COUNTERBALANCE SHAFT SPROCKET[...]

4G6 ENGINE (E - W) - Timing Belt 1 1A-4-7 (4) Move t he tensioner “B” in the direction of arrow while lifting with a finger to give a sufficient tension to the tension side of timing belt. In this condition, tighten bolt to secure tensioner “B”. When the bolt is tightened, use care to prevent shaft from turning together . If shaft is turned[...]

4G6 ENGINE (E - W) - Timing Belt 1 1A-4-8 (4) Insert a wire (1.4 mm in diameter) into the set holes. (5) Unclamp the auto tensioner from the vise. (6) Install the auto tensioner to front case and tighten to the specified torque. Caution D Leave the wire installed in the auto tensioner . " J A TENSIONER PULLEY INST ALLA TION (1) Install the ten[...]

4G6 ENGINE (E - W) - Timing Belt 1 1A-4-9 (4) Align the timing mark on oil pump sprocket with its mating mark. (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 [...]

4G6 ENGINE (E - W) - Timing Belt 1 1A-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[...]

4G6 ENGINE (E - W) - Timing Belt 1 1A-4-1 1 (4) Align the timing mark on oil pump sprocket with its mating mark. (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. I[...]

4G6 ENGINE (E - W) - Timing Belt 1 1A-4-12 (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 pull[...]

4G6 ENGINE (E - W) - Timing Belt 1 1A-4-13 (16)Set the special tool as shown and screw it in up to the position where the wire inserted in the auto-tensioner when installing it can be moved lightly . (17)Loosen the retaining bolt of the tensioner pulley . Caution D Loosening the retaining bolt can cause the intake and exhaust camshafts to turn, res[...]

4G6 ENGINE (E - W) - Timing Belt 1 1A-4-14 (2) Cracks on rubber back. (3) Cracks or peeling of canvas. (4) Cracks on rib root. (5) Cracks on belt sides. (6) Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife. (7) Abnormal wear on teeth. (8) Missing tooth. AUT O TENSIONER (1) Check the auto tensioner for possibl[...]

4G6 ENGINE (E - W) - Exhaust Manifold (GDI) 1 1A-4a-1 4a. EXHAUST MANIFOLD (GDI) REMOV AL AND INST ALLA TION 4 5 3 1 13 Nm 49 Nm 2 29 Nm 13 Nm 11 N m 49 Nm 29 Nm Removal steps 1. Exhaust manifold cover (V ehicle for Europe) 2. Exhaust manifold (V ehicle for Europe) 3. Exhaust manifold (V ehicle for Hong Kong) 4. Exhaust manifold gasket 5. Engine ha[...]

4G6 ENGINE (E - W) - Fuel and Emission Control Parts 1 1A-5-1 5. FUEL AND EMISSION CONTROL P ARTS REMOV AL AND INST ALLA TION <CARBURETOR> 1 2 3 4 5 7 8 23 Nm 17 Nm 22 Nm 6 Removal steps 1. Fuel hose 2. Fuel hose 3. Fuel vapor separator 4. W ater hose 5. Carburetor 6. Gasket 7. EGR valve (For GCC) 8. Gasket (For GCC) PWEE9616 E Dec. 1996 Mits[...]

4G6 ENGINE (E - W) - Fuel and Emission Control Parts 1 1A-5-2 REMOV AL AND INST ALLA TION <MUL TIPOINT FUEL INJECTION - GALANT> 1 10 13 12 7 9 18 Nm 2 11 8 12 Nm 6 5 22 Nm 3 4 9N m 14 Removal steps 1. Throttle body " C A 2. Throttle body gasket 3. EGR valve (With EGR valve) 4. Cover (Without EGR valve) 5. EGR valve gasket 6. Injectors an[...]

4G6 ENGINE (E - W) - Fuel and Emission Control Parts 1 1A-5-3 REMOV AL AND INST ALLA TION <MUL TIPOINT FUEL INJECTION - SP ACE W AGON> 1 10 13 12 7 9 18 Nm 2 11 8 9N m 6 5 22 Nm 3 4 12 Nm 14 15 Removal steps 1. Throttle body " C A 2. Throttle body gasket 3. EGR valve 4. EGR valve gasket 5. Fuel hose 6. Fuel return pipe 7. Injectors and d[...]

4G6 ENGINE (E - W) - Fuel and Emission Control Parts 1 1A-5-4 INST ALLA TION SERVICE POINTS " A A INJECT ORS INST ALLA TION (1) Before installing an injector , the rubber O-ring must be lubricated with a drop of clean engine oil to aid in installation. (2) Install injector top end. Be careful not to damage O-ring during installation. " B [...]

4G6 ENGINE (E - W) - Fuel Part (GDI) 1 1A-5a-1 5a. FUEL P ART (GDI) REMOV AL AND INST ALLA TION (1999 MODEL SP ACE W AGON) 9 10 11 N m 11 13 23 Nm 31 27 32 33 35 34 36 37 1 2 3 8.8 Nm 8.8 Nm 8.8 Nm 4 5 6 7 8 12 14 15 16 17 18 19 20 21 22 23 24 25 18 Nm 8.8 Nm 4.9 Nm ® 17 Nm ± 2N m 11 N m 11 N m 11 N m 11 N m 18 Nm 26 28 29 30 22 Nm 38 Revised PWE[...]

4G6 ENGINE (E - W) - Fuel Part (GDI) 1 1A-5a-2 Removal steps 1. Fuel hose 2. Fuel low pressure pipe 3. O-ring 4. Fuel pump return nipple 5. O-ring 6. Clamp A 7. Fuel pipe bracket " F A 8. Fuel feed pipe 9. Backup ring 10. O-ring 1 1. Backup ring " F A 12. Fuel pump 13. O-ring 14. Harness bracket " E A 15. Fuel return pipe 16. Backup [...]

4G6 ENGINE (E - W) - Fuel Part (GDI) 1 1A-5a-2a REMOV AL AND INST ALLA TION (2000 MODEL SP ACE W AGON and GALANT) 9 10 11 N m 11 13 23 Nm 35 31 36 37 39 38 40 41 1 2 3 8.8 Nm 8.8 Nm 8.8 Nm 4 5 6 7 8 12 14 15 16 17 18 19 20 21 22 23 28 29 18 Nm 8.8 Nm 4.9 Nm ® 17 Nm ± 2N m 11 N m 11 N m 11 N m 11 N m 18 Nm 30 32 33 34 22 Nm 42 18 Nm 24 27 25 26 Ad[...]

4G6 ENGINE (E - W) - Fuel Part (GDI) 1 1A-5a-2b Removal steps 1. Fuel hose 2. Fuel low pressure pipe 3. O-ring 4. Fuel pump return nipple 5. O-ring 6. Clamp A 7. Fuel pipe bracket " F A 8. Fuel feed pipe 9. Backup ring 10. O-ring 1 1. Backup ring " F A 12. Fuel pump 13. O-ring 14. Harness bracket " E A 15. Fuel return pipe 16. Backup[...]

4G6 ENGINE (E - W) - Fuel Part (GDI) 1 1A-5a-3 INST ALLA TION SERVICE POINTS " A A BACKUP RING / CORRUGA TED W ASHER INST ALLA TION (1) Attach the backup ring and O-ring to the injector . The thicker backup ring must be so installed that the inside cut surface is directed as shown in the illustration. (2) Coat the corrugated washer with white [...]

4G6 ENGINE (E - W) - Fuel Part (GDI) 1 1A-5a-4 " C A PUMP CAMSHAFT CASE INST ALLA TION (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 aligni[...]

4G6 ENGINE (E - W) - Fuel Part (GDI) 1 1A-5a-5 " F A FUEL PUMP / FUEL FEED PIPE INST ALLA TION (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 t[...]

4G6 ENGINE (E - W) - W ater Pump and Intake Manifold 1 1A-6-1 6. W A TER PUMP AND INT AKE MANIFOLD REMOV AL AND INST ALLA TION <CARBURETOR> 1 2 17 10 12 Nm 11 12 13 14 Nm 14 Nm 8 13 Nm 11 N m 5 16 20 Nm 15 31 Nm 4 6 7 8 9 24 Nm 13 Nm 3 14 Removal steps 1. W ater hose 2. W ater hose " C A 3. Engine coolant temperature gauge unit 4. W ater[...]

4G6 ENGINE (E - W) - W ater Pump and Intake Manifold 1 1A-6-2 REMOV AL AND INST ALLA TION <MUL TIPOINT FUEL INJECTION - GALANT> 1 2 10 11 13 Nm 12 13 14 14 Nm 14 Nm 9 29 Nm 9 3 11 N m 19 Nm 18 31 Nm 5 6 11 N m 19 8 13 Nm 7 24 Nm 4 17 16 23 Nm 15 Removal steps 1. W ater hose 2. W ater hose " D A 3. Engine coolant temperature sensor "[...]

4G6 ENGINE (E - W) - W ater Pump and Intake Manifold 1 1A-6-3 REMOV AL AND INST ALLA TION <MUL TIPOINT FUEL INJECTION - SP ACE W AGON> 1 2 11 12 13 Nm 13 14 15 14 Nm 14 Nm 10 29 Nm 10 4 11 N m 19 Nm 19 31 Nm 6 7 11 N m 9 13 Nm 8 24 Nm 5 18 17 16 3 Removal steps 1. W ater hose 2. W ater hose 3. W ater hose " D A 4. Engine coolant temperat[...]

4G6 ENGINE (E - W) - W ater Pump and Intake Manifold 1 1A-6-4 INST ALLA TION SERVICE POINTS " A A W A TER PIPE / O-RING INST ALLA TION (1) Wet the O-ring (with water) to facilitate assembly . Caution D Keep the O-ring free of oil or grease. " B A SEALANT APPLICA TION TO THERMOST A T HOUSING Specified sealant: Mitsubishi Genuine Part No. M[...]

4G6 ENGINE (E - W) - W ater Pump and W ater Hose (GDI) 1 1A-6a-1 6a. W A TER PUMP AND W A TER HOSE (GDI) REMOV AL AND INST ALLA TION 9 10 4 5 3 1 7 6 11 N m 22 Nm 12 Nm 8 2 11 12 13 12 Nm 9 12 Nm 29 Nm 13 Nm 23 Nm Removal steps 1. W ater hose " E A 2. W ater hose 3. Engine coolant temperature sensor " D A 4. Engine coolant temperature gau[...]

4G6 ENGINE (E - W) - W ater Pump and W ater Hose (GDI) 1 1A-6a-2 INST ALLA TION SERVICE POINTS " A A O-RING / W A TER INLET PIPE INST ALLA TION (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 t[...]

4G6 ENGINE (E - W) - Exhaust Manifold 1 1A-7-1 7. EXHAUST MANIFOLD REMOV AL AND INST ALLA TION (GALANT) 1 2 13 Nm 13 Nm 6 5 49 Nm 13 Nm 29 Nm 4 3 13 Nm 13 Nm Removal steps " A A 1. W ater outlet fitting 2. Heat protector (Multipoint fuel injection) 3. Exhaust manifold cover (Carburetor) 4. Engine hanger 5. Exhaust manifold 6. Exhaust manifold [...]

4G6 ENGINE (E - W) - Exhaust Manifold 6EN1 170 3 mm diameter bead sealant 1 1A-7-2 REMOV AL AND INST ALLA TION (SP ACE W AGON) 1 2 13 Nm 5 4 49 Nm 29 Nm 3 13 Nm Removal steps " A A 1. W ater outlet fitting 2. Exhaust manifold cover 3. Engine hanger 4. Exhaust manifold 5. Exhaust manifold gasket INST ALLA TION SERVICE POINTS " A A SEALANT [...]

4G6 ENGINE (E - W) - Rocker Arms and Camshaft 1 1A-8-1 8. ROCKER ARMS AND CAMSHAFT REMOV AL AND INST ALLA TION 3 2 18 16 31 Nm 3.4 Nm 17 10 7 9 11 12 10 11 12 10 11 10 12 11 14 15 15 15 15 13 6 8 5 4 1 12 Apply engine oil to all moving parts before installation. Removal steps 1. Breather hose 2. P .C.V . hose 3. Oil filler cap 4. Rocker cover 5. Ro[...]

4G6 ENGINE (E - W) - Rocker Arms and Camshaft 1 1A-8-2 REMOV AL SER VICE POINT A A " ROCKER ARMS AND ROCKER ARM SHAFTS REMOV AL Caution D If the lash adjuster is re-used, clean the lash adjuster . (Refer to 1 1A-8-3.) (1) Set special tool MD998443 to prevent the lash adjuster from coming free and falling to the floor . INST ALLA TION SERVICE P[...]

4G6 ENGINE (E - W) - Rocker Arms and Camshaft 1 1A-8-3 INSPECTION CAMSHAFT (1) Measure the cam height. Item Standard value mm Limit mm GALANT Intake 37.39 36.89 Exhaust 37.14 36.64 SP ACE Intake 37.39 36.89 W AGON Exhaust 36.83 36.33 ROCKER ARM (1) Check the roller surface. If any dents, damage or seizure is evident, replace the rocker arm. (2) Che[...]

4G6 ENGINE (E - W) - Rocker Arms and Camshaft 1 1A-8-4 (3) Fit special tool MD998441 onto the lash adjuster . (4) 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 oi[...]

4G6 ENGINE (E - W) - Rocker Arms and Camshaft 1 1A-8-5 (9) Place the lash adjuster in container C. Then, gently push down the internal steel ball using special tool MD998442. Caution D Do not use container C for cleaning. If cleaning is performed in container C, foreign matter could enter the pressure chamber when the chamber is filled with diesel [...]

4G6 ENGINE (E - W) - Rocker Arms and Camshaft 1 1A-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 throu[...]

4G6 ENGINE (E - W) - Rocker Arms and Camshafts (GDI) 1 1A-8a-1 8a. ROCKER ARMS AND CAMSHAFTS (GDI) REMOV AL AND INST ALLA TION 9 10 5 3 1 7 6 8 2 11 12 21 Nm 8.8 Nm 9.8 Nm 20 Nm 13 Nm Apply engine oil to all moving parts before installation. 4 Removal steps 1. Camshaft position sensor 2. Cover 3. Gasket " D A 4. Camshaft position sensing cylin[...]

4G6 ENGINE (E - W) - Rocker Arms and Camshafts (GDI) 1 1A-8a-2 REMOV AL SER VICE POINTS A A " LASH ADJUSTER REMOV AL Caution D If the lash adjuster is re-used, clean the lash adjuster . (Refer to 1 1A-8a-4.) INST ALLA TION SERVICE POINTS " A A LASH ADJUSTER INST ALLA TION Caution D If the lash adjuster is re-used, clean the lash adjuster [...]

4G6 ENGINE (E - W) - Rocker Arms and Camshafts (GDI) 1 1A-8a-3 (5) Install the beam camshaft cap before the sealant applied becomes dry and hard. (6) T ighten 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 o[...]

4G6 ENGINE (E - W) - Rocker Arms and Camshafts (GDI) 1 1A-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. (1) Prepare three c[...]

4G6 ENGINE (E - W) - Rocker Arms and Camshafts (GDI) 1 1A-8a-5 (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 D Make sure the oil hole in the side of the body is pointing toward container A. Do not point the oil hole at yourse[...]

4G6 ENGINE (E - W) - Rocker Arms and Camshafts (GDI) 1 1A-8a-6 (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, per[...]

4G6 ENGINE (E - W) - Rocker Arms and Camshafts (GDI) 1 1A-8a-7 (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 th[...]

4G6 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-1 9. CYLINDER HEAD AND V AL VES REMOV AL AND INST ALLA TION (SOHC) 20 18 13 5 12 16 6 4 7 11 19 17 15 10 8 14 9 3 Apply engine oil to all moving parts before installation. 2 1 Removal steps A A "" E A 1. Cylinder head bolt 2. Cylinder head assembly " D A 3. Cylinder head gasket A [...]

4G6 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-2 REMOV AL AND INST ALLA TION (GDI) 20 18 13 5 12 16 6 4 7 11 19 17 15 10 9 14 8 3 Apply engine oil to all moving parts before installation. 2 1 Removal steps A A "" E A 1. Cylinder head bolt 2. Cylinder head assembly 3. Cylinder head gasket A B "" C A 4. Retainer lock 5. V a[...]

4G6 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-3 REMOV AL SER VICE POINTS PRECAUTION FOR REMOVED P ARTS Keep removed parts in order according to the cylinder number and intake/exhaust. A A " CYLINDER HEAD BOL TS REMOV AL (1) Using the special tool, loosen the cylinder head bolts. Loosen evenly , little by little. A B " RET AINER LO[...]

4G6 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-4 A C " V AL VE STEM SEAL REMOV AL (1) Do not reuse removed stem seal. INST ALLA TION SERVICE POINTS " A A V AL VE STEM SEAL INST ALLA TION (1) Install the valve spring seat. (2) The special tool must be used to install the valve stem seal. Improper installation could result in oil lea[...]

4G6 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-5 " C A RET AINER LOCK INST ALLA TION (1) The valve spring, if excessively compressed, causes the bottom end of the retainer to be in contact with, and damage, the stem seal. " D A CYLINDER HEAD GASKET IDENTIFICA TION Identification mark: 4G63N " E A CYLINDER HEAD BOL T INST ALLA [...]

4G6 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-6 (6) Make paint marks on the cylinder head bolt heads and cylinder head. (7) Give a 90 _ turn to the cylinder head bolts in the specified tightening sequence. (8) 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 [...]

4G6 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-7 VA LV E (1) Check the valve face for correct contact. If incorrect, reface using a valve refacer . V alve seat contact should be maintained uniform at the center of valve face. (2) If the margin exceeds the service limit, replace the valve. Item Standard value mm Limit mm SOHC Intake 1.0 0.5 E[...]

4G6 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-8 V AL VE 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 Standard value mm Limit mm SOHC Intake 0.02 - 0.05 0.10 Exhaust 0.03 - 0.07 0.15 GDI Intake 0.02 - 0.05 0.10 Exhaust 0.05 - 0.09 0.15 V AL V[...]

4G6 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-9 V AL VE SEA T 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 . V alve seat ring hole diameter Item Standard value[...]

4G6 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-10 V AL VE GUIDE REPLACEMENT PROCEDURE (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 D Do not use the valve guide of the same size as the removed one. V[...]

4G6 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan 1 1A-10-1 10. FRONT CASE, COUNTERBALANCE SHAFTS AND OIL P AN REMOV AL AND INST ALLA TION <GDI ENGINE - VEHICLE FOR EUROPE AND SOHC ENGINE> 3 4 5 32 13 28 29 31 33 2 23 Nm 16 Nm 19 Nm 39 Nm 7 21 Nm 8 9.8 Nm 18 Nm 44 Nm 18 19 26 23 Nm 27 1 23 22 24 Apply engine oil to all moving[...]

4G6 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan 1 1A-10-2 REMOV AL AND INST ALLA TION <GDI ENGINE - VEHICLE FOR HONG KONG> 3 4 5 33 22 16 31 30 32 34 2 23 Nm 16 Nm 9.8 Nm 6.9 Nm 12 Nm 7 9.8 Nm 18 Nm 44 Nm 19 20 28 23 Nm 21 1 24 29 26 Apply engine oil to all moving parts before installation. 25 21 Nm 18 17 14 23 Nm 36 Nm 12 [...]

4G6 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan 1 1A-10-3 REMOV AL SER VICE POINTS A A " OIL P AN REMOV AL (1) Remove all oil pan bolts. (2) Drive in the special tool between the cylinder block and oil pan. NOTE Never use a screwdriver or chisel, instead of the service tool, as a deformed oil pan flange will result in oil le[...]

4G6 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan 1 1A-10-4 (3) Loosen the flange bolt. A F " COUNTERBALANCE SHAFT FRONT BEARING REMOV AL (1) Using the special tool, remove the counterbalance shaft front bearing from the cylinder block. NOTE Be sure to remove the front bearing first. If it has not been removed, the Rear Bearin[...]

4G6 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan 1 1A-10-5 " B A LEFT COUNTERBALANCE SHAFT REAR BEARING INST ALLA TION (1) Install the special tool (Guide Plate) to the cylinder block. (2) Apply engine oil to the rear bearing outer circumference and bearing hole in the cylinder block. (3) Using the special tool, install the r[...]

4G6 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan 1 1A-10-6 " E A OIL PUMP OIL SEAL INST ALLA TION " F A CRANKSHAFT FRONT OIL SEAL INST ALLA TION (1) Using the special tool, install the crankshaft front oil seal into the front case. " G A OIL PUMP DRIVEN GEAR / OIL PUMP DRIVE GEAR INST ALLA TION (1) Apply engine oil [...]

4G6 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan 1 1A-10-7 " I A SEALANT APPLICA TION TO OIL PRESSURE SWITCH (1) Coat the threads of switch with sealant and install the switch using the special tool. Specified sealant: 3M A TD Part No. 8660 or equivalent Caution D Keep the end of the thread portion clear or sealant. D A void [...]

4G6 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan 1 1A-10-8 NOTE (1) Be sure to install the oil pan quickly while the sealant is wet (within 15 minutes). (2) After installation, keep the sealed area away from the oil and coolant for approx. one hour . (3) Note the difference in bolt lengths at the location shown. " M A OIL P A[...]

4G6 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan 1 1A-10-9 (4) Clean both mating surfaces of oil pan lower and oil pan upper . (5) Apply a 4 mm wide bead of sealant to the entire circumference of the oil pan lower flange. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent NOTE (1) Be sure to install the oil pan [...]

4G6 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan 1 1A-10-10 INSPECTION FRONT CASE (1) Check oil holes for clogging and clean if necessary . (2) Check the left counterbalance shaft front bearing section for wear , damage and seizure. If there is anything wrong with the section, replace the front case. (3) Check the front case for c[...]

4G6 ENGINE (E - W) - Piston and Connecting Rod 1 1A-1 1-1 1 1. PISTON AND CONNECTING ROD REMOV AL AND INST ALLA TION 10 6 7 8 9 11 4 3 2 1 5 12 Apply engine oil to all moving parts before installation. Removal steps " G A 1. Nut A A "" F A 2. Connecting rod cap " E A 3. Connecting rod bearing " D A 4. Piston and connecting [...]

4G6 ENGINE (E - W) - Piston and Connecting Rod 1 1A-1 1-2 REMOV AL SER VICE POINTS A A " CONNECTING ROD CAP REMOV AL (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 . A B " PIST ON PIN REMOV AL[...]

4G6 ENGINE (E - W) - Piston and Connecting Rod 1 1A-1 1-3 INST ALLA TION SERVICE POINTS " A A PIST ON PIN INST ALLA TION (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 dimen[...]

4G6 ENGINE (E - W) - Piston and Connecting Rod 1 1A-1 1-4 (10)Check that the piston moves smoothly " B A OIL RING INST ALLA TION (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 Ident[...]

4G6 ENGINE (E - W) - Piston and Connecting Rod 1 1A-1 1-5 " C A PIST ON RING NO. 2 / PIST ON RING NO. 1 INST ALLA TION (1) Using piston ring expander , fit No. 2 and then No. 1 piston ring into position. NOTE 1. The ring end is provided with identification mark. Item Identification mark No. 1 ring 4G63 SOHC 1R 4G64 GDI T No. 2 ring 4G63 SOHC 2[...]

4G6 ENGINE (E - W) - Piston and Connecting Rod 1 1A-1 1-6 (2) The connecting rod bearing identification mark is stamped at the position shown in the illustration. Crankshaft pin Connecting rod bearing Classi- fication Identifica- tion mark Identifi- cation color O. D. mm Identi- fication mark Thickness mm Produc- tion part Service part 1 None Y ell[...]

4G6 ENGINE (E - W) - Piston and Connecting Rod 1 1A-1 1-7 " G A CONNECTING ROD CAP NUT INST ALLA TION Caution D 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 [...]

4G6 ENGINE (E - W) - Piston and Connecting Rod 1 1A-1 1-8 (3) Install the piston ring into the cylinder bore. Force it down with a piston, its 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 feeler gauge. If the ring gap is excessive, replace the piston ring. Stan[...]

4G6 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate 1 1A-12-1 12. CRANKSHAFT , FL YWHEEL AND DRIVE PLA TE REMOV AL AND INST ALLA TION 1 2 3 4 5 10 11 13 14 15 16 17 18 12 21 A 11 N m 132 Nm 9N m 132 Nm 6 7 8 9 11 N m Apply engine oil to all moving parts before installation. <GALANT> <SP ACE W AGON> 7 132 Nm 6 8 9 20 19 Removal ste[...]

4G6 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate 1 1A-12-2 REMOV AL SER VICE POINT A A " OIL JET REMOV AL (1) Knock out the oil jets using an appropriate metal rod. Caution D Be careful not to scratch the cylinder wall. D Do not reuse the removed oil jets. INST ALLA TION SERVICE POINTS " A A OIL JET INST ALLA TION (1) Using a 4.5[...]

4G6 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate 1 1A-12-3 Crankshaft journal outside diameter Cylinder block bearing bore Crankshaft bearing Crankshaft bearing for No. 3 Identification color Size mm Identification mark Identification mark or color Identification mark or color Y ellow 56.994 - 57.000 0 1 or Green 0 or Black 1 2 or Y ellow [...]

4G6 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate 1 1A-12-4 (2) Install the bearings having an oil groove to the cylinder block. (3) Install the bearings having no oil groove to the bearing cap. " D A BEARING CAP / BEARING CAP BOL T INST ALLA TION (1) Install the bearing caps so the arrow points to the timing belt side. (2) Before inst[...]

4G6 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate 1 1A-12-5 (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 No. 3 crankshaft bearings. Standard value: 0.05 - 0.18 mm Limit: 0.25 mm " E A OIL SEAL INST ALLA TION " F A SEALANT[...]

4G6 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate 1 1A-12-6 CYLINDER BLOCK (1) Visually check for scratches, rust, and corrosion. Use also a flaw detecting agent for the check. If defects are evident, correct, or replace. (2) Using a straightedge and feeler gauge, check the block top surface for warpage. Make sure that the surface is free f[...]

4G6 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate 1 1A-12-7 (4) Bore all cylinders to the calculated boring finish dimension. Caution D T o prevent distortion that may result from temperature rise during honing, bore cylinders, working from No. 2, No. 4, No. 1 to No. 3. (5) Hone to final finish dimension (piston O.D. + clearance between pis[...]

NOTES[...]