Proton 4G1x Engine Manual

8/13/2019 Proton 4G1x Engine Manual

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

1. SPECIFICATIONS 11A-1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE SPECIFICATIONS 11A-1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REWORK DIMENSIONS 11A-1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TORQUE SPECIFICATIONS 11A-1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NEW TIGHTENING METHOD-BY USE OF BOLTS TO BETIGHTENED IN PLASTIC AREA 11A-1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SEALANT 11A-1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FORM-IN-PLACE GASKET 11A-1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. SPECIAL TOOLS 11A-2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. ALTERNATOR AND IGNITION SYSTEM 11A-3-1. . . . . . . . . . . . . . . . . . . . . . . .4. TIMING BELT 11A-4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. FUEL AND EMISSION CONTROL SYSTEMS 11A-5-1. . . . . . . . . . . . . . . . . . .

5a. INTAKE MANIFOLD AND THROTTLE BODY (GDI) 11A-5a-1. . . . . . . . .

5b. EXHAUST MANIFOLD (GDI) 11A-5b-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. WATER PUMP AND WATER HOSE 11A-6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. INTAKE AND EXHAUST MANIFOLDS 11A-7-1. . . . . . . . . . . . . . . . . . . . . . . . . .

7a. FUEL SYSTEM (GDI) 11A-7a-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. ROCKER ARMS AND CAMSHAFTS 11A-8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .8a. ROCKER ARMS AND CAMSHAFTS (GDI) 11A-8a-1. . . . . . . . . . . . . . . . . .

9. CYLINDER HEAD AND VALVES 11A-9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10. OIL PUMP AND OIL PAN 11A-10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11. PISTONS AND CONNECTING RODS 11A-11-1. . . . . . . . . . . . . . . . . . . . . . . . . .

12. CRANKSHAFT AND CYLINDER BLOCK 11A-12-1. . . . . . . . . . . . . . . . . . . . .

11A-0-1

PWEE9520E Nov. 1995Mitsubishi Motors Corporation

ENGINE4G1 SERIESCONTENTS

PWEE9520-DE Aug. 2000Mitsubishi Motors Corporation Revised


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11A-0-2


NOTES


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4G1 ENGINE (E-W) - General Information 11A-0-3


GENERAL INFORMATION


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4G1 ENGINE (E-W) - General Information11A-0-4



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4G1 ENGINE (E-W) - General Information 11A-0-5


Descriptions 4G13 12-VALVE-CARBURETOR 4G13 12-VALVE-MPI

Type In-line OHV, SOHC In-line OHV, SOHC

Number of cylinders 4 4

Combustion chamber Pentroof type Pentroof type

Total displacement dm 3 1,299 1,299

Cylinder bore mm 71.0 71.0

Piston stroke mm 82.0 82.0

Compression ratio 9.5 9.5

Number of Intake 8 8valves

Exhaust 4 4

Valve timing Intake opens BTDC 14 _ BTDC 19 _

Intake closes ABDC 48 _ ABDC 43 _

Exhaust opens BBDC 55 _ BBDC 60 _

Exhaust closes ATDC 13 _ ATDC 8 _

Lubrication system Pressure feed, full-flow filtration Pressure feed, full-flow filtration

Oil pump type Trochoid type Trochoid type

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

Water pump type Centrifugal impeller type Centrifugal impeller type

PWEE9520-AE Dec. 1998Mitsubishi Motors Corporation Revised


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4G1 ENGINE (E W) General Information11A-0-6

PWEE9520Nov. 1995Mitsubishi Motors Corporation

Descriptions 4G13 16-VALVE CARBURETOR 4G13 16-VALVE MPI







Compression ratio 9.5 10, 9.5* 1

Number of Intake 8 8va ves

Exhaust 8 8

Valve timing Intake opens BTDC 12 BTDC 17

Intake closes ABDC 48 ABDC 39

Exhaust opens BBDC 48 BBDC 49

Exhaust closes ATDC 12 ATDC 7





*1: LANCER for General Export

PWEE9520-EFeb. 2001Mitsubishi Motors Corporation Revised


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4G1 ENGINE (EW) General Information 11A-0-7


Descriptions 4G15CARBURETTOR

4G15MPI12-VALVE

4G15MPI16-VALVE

4G15GDI

Type In-line OHV, SOHC In-line OHV, SOHC In-line OHV, DOHC In-line OHV, DOHC

Number of cylinders 4 4 4 4

Combustion chamber Semi spherical type Semi spherical type Pentroof type Pentroof + Curvedpiston head

Total displacement dm 3 1,468 1,468 1,468 1,468

Cylinder bore mm 75.5 75.5 75.5 75.5

Piston stroke mm 82.0 82.0 82.0 82.0

Compression ratio 9.0 9.0 9.5 11.0

Numberf

Intake 8 8 8 8o va ves

Exhaust 4 4 8 8

Valve

timing

Intake opens BTDC 14 BTDC 14 ,

BTDC 13 *1

BTDC 16 BTDC 12

Intake closes ABDC 48 ABDC 48 ,ABDC 47 *1

ABDC 40 ABDC 44

Exhaustopens

BBDC 55 BBDC 55 ,BBDC 56 *1

BBDC 45 BBDC 48

Exhaustcloses

ATDC 13 ATDC 13 ,ATDC 8 *1

ATDC 15 ATDC 12

Lubrication system Pressure feed,full-flow filtration

Pressure feed,full-flow filtration



Oil pump type Trochoid type Trochoid type Trochoid type Trochoid type

Cooling system Water-cooled,forced circulation

Water-cooled,forced circulation



Water pump type Centrifugal impellertype

Centrifugal impellertype



*1: Special low-emission engines on vehicles for Australia



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4G1 ENGINE (EW) General Information11A-0-8


Descriptions 4G18 16-VALVECARBURETOR 4G18 16-VALVEMPI







Compression ratio 9.5 9.5, 10* 1*2

Number of Intake 8 8va ves

Exhaust 8 8

Valve timing Intake opens BTDC 12 BTDC 17 , BTDC 9 *1 , BTDC 17 *2

Intake closes ABDC 48 ABDC 39 , ABDC 51 *1 , ABDC 43 *2

Exhaust opens BBDC 48 BBDC 49 , BBDC 49 *1 , BBDC 53 *2

Exhaust closes ATDC 12 ATDC 7 , ATDC 15 *1 , ATDC 7 *2





*1: SPACE STAR for Europe

*2: LANCER for General Export



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4G1 ENGINE (EW) Specifications 11A-1-1


1. SPECIFICATIONSSERVICE SPECIFICATIONS

Item Standard Limit

Rocker arms and camshaft

Camshaft cam SOHC 12-VALVE Intake (primary) 38.78 38.28height mm

Intake (secondary) 38.78 38.28Exhaust* 1 39.01 38.51

Exhaust* 2 38.97 38.47

SOHC 16-VALVE* 3 Intake 36.99 36.49

Exhaust 36.85 36.35


Exhaust 36.68 36.18


Exhaust 37.16 36.66

SOHC 16-VALVE* 6 Intake 37.17 36.67Exhaust 36.99 36.49

DOHC Intake 34.67 34.17

Exhaust 34.26 33.76

DOHC GDI Intake 34.85 34.35

Exhaust 34.59 34.09

Camshaft journal diameter mm SOHC 45.9345.94

SOHC 16-VALVE* 7 44.9344.94

DOHC 25.9525.97

Cylinder head and valves

Flatness of cylinder head gasket surface mm 0.05 or less

Cylinder head gasket surface grinding limit (including grinding ofcylinder block gasket surface) mm

0.2

Cylinder head overall height mm SOHC 12-VALVE 106.9107.1

SOHC 16-VALVE 119.9120.1

DOHC 131.9132.1

Cylinder head bolt nominal length mm 103.2

Valve margin mm Intake 1.0 0.5

Exhaust 1.5 1.0

Valve stem diameter mm SOHC 12-VALVE 6.6

SOHC 16-VALVE 5.5

DOHC 5.5

*1: With low pollution system*2: Without low pollution system*3: Except 2001 model front wheel drive vehicles*4: 2001 model front wheel drive vehicles for Europe*5: 2001 model front wheel drive vehicles for General Export*6: 2002 model front wheel drive vehicles for Europe*7: SOHC 16-VALVE MPI for Europe



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4G1 ENGINE (E-W) - Specifications11A-1-2


Item LimitStandard

Valve stem-to-guide SOHC 12-VALVE Intake 0.020- 0.050 0.10clearance mm

Exhaust 0.035- 0.050 0.15

SOHC 16-VALVE Intake 0.020 - 0.047 0.10

Exhaust 0.030 - 0.057 0.15

DOHC Intake 0.020- 0.047 0.10

Exhaust 0.030- 0.062 0.15

Valve face angle 45 -45.5 -

Valve stem projec- SOHC 12-VALVE Intake 43.70 44.20tion mm

Exhaust 43.30 43.80

SOHC 16-VALVE Intake 53.21 53.71

Exhaust 54.10 54.60


Exhaust 48.70 49.20

Overall valve length SOHC 12-VALVE Intake 100.75 100.25mmExhaust 101.05 105.55

SOHC 16-VALVE Intake 111.56 111.06

Exhaust 114.71 114.21


Exhaust 106.85 106.35

Valve spring free SOHC 12-VALVE Intake 46.1 45.6height mm

Exhaust 46.8 46.3

SOHC 16-VALVE 50.9 50.4

DOHC 49.1 48.6Valve spring load/ SOHC 12-VALVE Intake 226/40.0 -installed height N/ mm Exhaust 284/39.6 -mm

SOHC 16-VALVE 216/44.2 -

DOHC 177/40.0 -

Valve spring squareness 2 4

Valve seat contact width mm 0.9- 1.3 -

Valve guide internal diameter mm SOHC 12-VALVE 6.6 -

SOHC 16-VALVE 5.5 -

DOHC 5.5 -Valve guide projection mm SOHC 12-VALVE 17.0 -

SOHC 16-VALVE 23.0 -

DOHC 23.0 -

Oil pump and oil pan

Oil pump tip clearance mm 0.06- 0.18 -

Oil pump side clearance mm 0.04- 0.10 -

Oil pump body clearance mm 0.10- 0.18 0.35

PWEE9520-CE Apr. 2000Mitsubishi Motors Corporation Revised


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4G1 ENGINE (E- W) - Specifications 11A-1-2a


Item Standard Limit

Pistons and connecting rods

Piston outside diameter mm 4G13 71.0 -

4G15 75.5 -

4G18 76.0 -

Piston ring side clearance mm No. 1 ring 0.03- 0.07 -

No. 2 ring 0.02- 0.06 -

Piston ring end gap No. 1 ring 0.20- 0.35 0.8clearance

No. 2 ring 0.35- 0.50 0.8

Oil ring 4G13, 4G15 0.20- 0.50 1.0

4G18 0.10- 0.40 1.0

Piston pin O. D. mm 18.0 -

Piston pin press-in load (at room temperature) N 4,900 - 14,700 -

Crankshaft pin oil clearance mm 0.02- 0.04 0.1

Connecting rod big end side clearance mm 0.10- 0.25 0.4Crankshaft and cylinder block

Crankshaft end play mm 0.05- 0.18 0.25

Crankshaft journal diameter mm 48.0 -

Crankshaft pin diameter mm 42.0 -

Crankshaft journal oil clearance mm 0.02- 0.04 0.1

Cylinder block gasket surface flatness mm 0.05 or less -

Cylinder block gasket surface grinding limit (including grinding of cylinder head gasket surface) mm

- 0.2

Cylinder block overall height mm 256 -Cylinder bore cylindricity mm 0.01 -

Cylinder bore I. D. mm 4G13 71.0 -

4G15 75.5 -

4G18 76.0 -

Piston-to-cylinder clearance mm 0.02- 0.04 -



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4G1 ENGINE (E- W) - Specifications11A-1-2b


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PWEE9520-AE Dec. 1998Mitsubishi Motors Corporation AddedPWEE9520-AE Dec. 1998Mitsubishi Motors Corporation Added


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4G1 ENGINE (EW) Specifications 11A-1-3


REWORK DIMENSIONS

Item Standard Limit


Cylinder head oversize valve guide SOHC 12-VALVE 0.05 O. S. 12.040 12.058 hole diameter mm

0.25 O. S. 12.24012.258

0.50 O. S. 12.49012.508 SOHC 16-VALVE 0.05 O. S. 10.55010.568

0.25 O. S. 10.75010.768

0.50 O. S. 11.00011.018

DOHC 0.05 O. S. 10.55010.568

0.25 O. S. 10.75010.768

0.50 O. S. 11.00011.018

DOHC GDI 0.05 O. S. 10.61010.620

0.25 O. S. 10.81010.820

0.50 O. S. 11.06011.070

Oversize valve seat SOHC Intake (primary) 0.3 O. S. 27.30027.325 ring hole diametermm

12-VALVE0.6 O. S. 27.60027.625

Intake (secondary) 0.3 O. S. 32.30032.325

0.6 O. S. 32.60032.625

Exhaust 0.3 O. S. 35.30035.325

0.6 O. S. 35.60035.625

SOHC Intake 0.3 O. S. 28.30028.321 16-VALVE

0.6 O. S. 28.60028.621

Exhaust 0.3 O. S. 26.30026.321

0.6 O. S. 26.60026.621

SOHC Intake 0.3 O. S. 30.30030.321 16-VALVE 0.6 O. S. 30.60030.621

Exhaust 0.3 O. S. 28.30028.321

0.6 O. S. 28.60028.621

DOHC Intake 0.3 O. S. 31.30031.325

0.6 O. S. 31.60031.625

Exhaust 0.3 O. S. 27.80027.825 0.6 O. S. 28.10028.125



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4G1 ENGINE (EW) Specifications11A-1-4


TORQUE SPECIFICATIONS

Item Nm

Alternator and ignition system

Water pump pulley bolt 9

Alternator brace bolt (alternator side) 22

Alternator brace bolt (tightened with water pump) 23Alternator pivot bolt 44

Oil level gauge guide bolt (Flange) 23

Oil level gauge guide bolt (Washer) 19

Crankshaft bolt (M12) 125

Crankshaft bolt (M14) 181

Spark plug 25

Distributor bolt 11

Ignition coil bolt 10

Ignition failure sensor bolt 5

Camshaft position sensor bolt 9

Camshaft position sensor support bolt 13

Camshaft position sensing cylinder bolt 21

Timing belt

Timing belt cover bolt 11

Timing belt tensioner bolt 23

Crankshaft angle sensor bolt 9

Bracket bolt 21

Engine support bracket bolt (M8) 21

Engine support bracket bolt, nut (M10) 35

Idler pulley bolt 35

Camshaft sprocket bolt 88

Fuel and emission control system

Vacuum pipe & hose bolt 9

Delivery pipe bolt 11

Fuel pressure regulator bolt 9Throttle body bolt 18

Hose clamp bolt 10

Fuel pump bolt (SOHC 12-VALVECARBURETOR) 12

Fuel pump bolt (SOHC 16-VALVECARBURETOR) 19

Breather tube clamp bolt 22

Carburetor bolt 17

Air temperature sensor 13

Cover bolt (Except M8 16) 12

PWEE9520-GApr. 2003Mitsubishi Motors Corporation Revised


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4G1 ENGINE (EW) Specifications 11A-1-4a


Item Nm

Cover bolt (M8 16) 18

EGR valve bolt 21



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4G1 ENGINE (EW) Specifications11A-1-4b


Intentionally blank

PWEE9520-FAug. 2001Mitsubishi Motors Corporation Added


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4G1 ENGINE (E- W) - Specifications 11A-1-5


Item Nm

Intake manifold and throttle body (GDI)

Accelerator cable bolt 10

Throttle body bolt 19

Air intake plenum resonator bolt 10

Power plant stay right bolt 49Intake manifold stay bolt 30

EGR valve bolt 19

EGR valve support bolt 19

EGR valve support nut 24

Intake manifold bolt, nut 20

Exhaust manifold (GDI)

Oxygen sensor 44

Exhaust manifold cover bolt 30

Exhaust manifold bracket bolt 35

Exhaust manifold nut (M8) 18


Power plant stay left bolt 35

Water pump and water hose

Water inlet fitting bolt 22

Water inlet pipe bolt (M8) 12

Water inlet pipe bolt (M10) 25

Fitting bolt 23Water outlet fitting bolt (Front wheel drive) 23

Water outlet fitting bolt (Rear wheel drive) 18

Thermostat case bolt 23

Thermo valve 27

Engine coolant temperature gauge unit 11

Engine coolant temperature sensor 29

Water pump bolt 13

Exhaust manifold and intake manifold

Boost sensor bolt 5

Solenoid valve assembly bolt 9

Intake manifold bolt, nut 17

Intake manifold stay bolt (M8) 17

Intake manifold stay bolt (M10) 31

Intake manifold stay bolt 30

Engine hanger bolt 19

Exhaust manifold cover bolt 29



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4G1 ENGINE (E- W) - Specifications4G1 ENGINE (E- W) - Specifications4G1 ENGINE (E- W) - Specifications11A-1-5a


Item Nm



Exhaust manifold bracket A bolt 35

Exhaust manifold bracket B bolt 35

Power plant stay right bolt 49Power plant stay left bolt 35

Oxygen sensor 44

Fuel system (GDI)

Fuel pipe bolt 12

Fuel pump bolt 4.9 17 2

Flange bolt 24

Harness bracket bolt 9.8

Injector holder bolt 23

Delivery pipe and injector bolt 12

Rocker arms and camshaft

Fuel pump cover bolt 12

Rocker cover bolt 3.5

Rocker cover bolt 4

Rocker shaft assembly bolt 31

Adjusting screw 15

Bearing cap bolt (M6) 11

Bearing cap bolt (M8) 24Rocker arms and camshaft (GDI)

Engine hanger bolt 19

Rocker cover bolt 3.5

Beam camshaft cap bolt (M6) 11

Beam camshaft cap bolt (M8) 25


Cylinder head bolt 20 + 90 _ + 90 _

Tighten to 49 Nm, then completely loosen and retighten as described.

Oil pump and oil pan

Transmission stay bolt 23

Oil pan bolt (M6) 7

Oil pan bolt (M8) 24

Drain plug 39

Oil screen bolt 19

Front case bolt 14

Relief plug 44



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4G1 ENGINE (E- W) - Specifications 11A-1-5b


Item Nm

Oil pump cover bolt 10

Pistons and connecting rods

Connecting rod nut 17 + 90 _ to 100 _

Crankshaft and cylinder block

Flywheel bolt 132Drive plate bolt 132

Drive plate bolt 98

Rear plate bolt 10

Bell housing cover bolt 10

Rear oil seal case bolt 11

Bearing cap bolt 34 + 30 _ to 34 _

Oil pressure switch 19

Knock sensor 23



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4G1 ENGINE (E- W) - Specifications11A-1-6

PWEE9520E Apr. 2000Mitsubishi Motors Corporation

NEW TIGHTENING METHOD USING PLASTIC REGION TIGHTENING BOLTSParts of the engine use plastic region tightening bolts. The tightening procedure for these is differentfrom that of conventional bolts and is described in relevant parts of this manual. Note that plastic regiontightening bolts have fixed service limits. These limits are indicated in relevant parts of this manual andmust be strictly observed.D Plastic region tightening bolts are used for the following applications:

(1) Cylinder head bolts(2) Connecting rod cap bolts(3) Bearing cap bolt

D The tightening procedure is basically as follows: After tightening a bolt to the specified torque, tighten it by a further 90 _ + 90_, 90 _ 100 _or 30 _ 34 _.The exact tightening procedure differs depending on the bolt and is described in relevant parts of this manual.

SEALANTS

Item Specified sealant Quantity

Cam position sensor support Mitsubishi Genuine PartNo.MD970389or equivalent As required

Water pump Mitsubishi G enuine P art N o. MD970389 o r equivalent As required

Thermo valve Mitsubishi G enuine P art N o. MD970389 o r equivalent As required

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

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

Engine coolant temperature sensor 3M Nut Locking Part No. 4171 or equivalent As required

Engine coolanttemperature gaugeunit 3M ATD Part No. 8660 or equivalent As required

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

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

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

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

Oil pump case Mitsubishi GenuinePart No.MD970389orequivalent As required

Oil pan Mitsubishi Genuine Part No. MD970389 or equivalent As required

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

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

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



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4G1 ENGINE (E- W) - Specifications 11A-1-7


FORM-IN-PLACE GASKETThe engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasketfully serves its purpose, it is necessary to observe some precautions when applying the gasket. Beadsize, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thicka bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of thefluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary toapply 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-gramtube (Part No. MD970389 or MD997110). Since the RTV hardens as it reacts with the moisture in theatomospheric air, it is normally used in the metallic flange areas. The FIPG, Part No. MD970389, canbe used for sealing both engine oil and coolant, while Part No. 997110 can only be used for engineoil sealing.

DisassemblyThe parts assembled with the FIPG can be easily disassembled without use of a special method. Insome cases, however, the sealant between the joined surfaces may have to be broken by lightly strikingwith 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 usethe special tool to remove the oil pan.

Surface PreparationThoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraperor wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make surethat there are no oils, greases and foreign substances deposited on the application surfaces. Do notforget to remove the old sealant remained in the bolt holes.

Form-In-Place Gasket ApplicationWhen assembling parts with the FIPG, you must observe some precautions, but the procedures is verysimple 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 thebolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it ishardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. Whenthe parts are mounted, make sure that the gasket is applied to the required area only. In addition, donot 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 thetext when applying the FIPG.


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NOTES


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4G1 ENGINE (E- W) - Special Tools 11A-2-1


2. SPECIAL TOOLSTool Number Name Use

MB990767 End yoke holder Holding camshaft sprocket when loosening ortightening bolt (used with MD998715)

MB991614 Angle gauge Installation of crankshaft bearing caps

MB991653 Cylinder head boltwrench (10)

Removal and installation of cylinder head bolts

MB991659 Guide-D Guide for removal and press-fitting of pistonpins

MB991671 Valve steminstaller

Press-fitting of valve stem seals(SOHC 16-VALVE, DOHC)

MD998011 Crankshaft rear oilseal installer

Installation of crankshaft rear oil seal

MD998054 Oil pressure switchwrench

Removal and installation of oil pressure switch

MD998304 Crankshaft front oilseal installer

Installation of crankshaft front oil seal

MD998305 Crankshaft front oilseal guide

Guide for installation of crankshaft front oil seal



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4G1 ENGINE (E- W) - Special Tools11A-2-2


Tool UseNameNumber

MD998442 Air bleed wire Testing of automatic lash adjusters(DOHC)

MD998713 Camshaft oil sealinstaller Installation of camshaft oil seal

MD998715 Pin (2-off) Holding camshaft sprocket when loosening ortightening bolt (used with MB990767)

MD998727 Oil pan remover Removal of oil pan

MD998735 Valve spring com-pressor

Compression of valve springs

MD998760 Valve stem sealinstaller

Installation of valve stem seals(SOHC 12-VALVE)

MD998762 Circular packinginstaller

Installing of circular packing

MD998772 Valve spring com-pressor

Compression of valve springs

MD998780 Piston pin settingtool

Removal and press-fitting of piston pins



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4G1 ENGINE (EW) Special Tools 11A-2-3


Tool UseNameNumber

MD998781 Flywheel stopper Locking flywheel in fixed position

MD998306 Crankshaft front oilseal installer

Installation of crankshaft front oil seal

MB991962 Crankshaft front oilseal guide

Guide for installation of crankshaft oil seal



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4G1 ENGINE (EW) Alternator and Ignition System 11A-3-1


3. ALTERNATOR AND IGNITION SYSTEMREMOVAL AND INSTALLATION

22 Nm

6 7 44 Nm

23 Nm

4M12 125 NmM14 181 Nm

8 9

3

2

23 Nm

1

11

25 Nm

10

13

12 12 Nm

9 Nm

5

Removal steps1. Oil level gauge2. Oil level gauge guide3. O-ring4. Drive belt*5. Water pump pulley6. Alternator brace7. Alternator

A B 8. Crankshaft boltB 9. Crankshaft pulley

10. Spark plug cable11. Spark plug

A 12. Distributor13. O-ring

NOTE*: For details of adjustment, refer to the relevant models

chassis workshop manual.



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4G1 ENGINE (EW) Alternator and Ignition System11A-3-1a


REMOVAL AND INSTALLATION

22 Nm

6

7

44 Nm

23 Nm

4

8

9

3

2

23 Nm

1

11

25 Nm 10

13

1212 Nm

9 Nm

5

M12 125 NmM14 181 Nm









28/147

4G1 ENGINE (EW) Alternator and Ignition System 11A-3-1b



22 Nm

6

7

44 Nm

23 Nm

4 8

9

3

2

23 Nm

11

10 Nm

10

13

13 Nm

9 Nm

5

14

21 Nm

12

25 Nm

9 Nm

10

11

5 Nm

1516

1

M12 125 NmM14 181 Nm



10. Spark plug cable11. Ignition coil12. Spark plug13. Ignition failure sensor

(only vehicles for Europe)14. Cam position sensor

C 15. Cam position sensor support16. Cam position sensing cylinder





29/147

4G1 ENGINE (EW) Alternator and Ignition System11A-3-2



22 Nm

6

7

44 Nm

23 Nm

4125 Nm

8 9

32

23 Nm

1

11

10 Nm10

13

13 Nm

9 Nm

5

14

21 Nm

15

1225 Nm

9 Nm



10. Spark plug cable11. Ignition coil12. Spark plug13. Cam position sensor






30/147




22 Nm

6 744 Nm

23 Nm

4125 Nm

8 9

3

2

23 Nm

1

25 Nm

10

13

1211 Nm

9 Nm

5

11









31/147

4G1 ENGINE (EW) Alternator and Ignition System11A-3-4



22 Nm

7

44 Nm

5

125 Nm

910

4

2

19 Nm

1

25 Nm

15

13 Nm

6

12

10 Nm

9 Nm

21 Nm

3

14

1113

9 Nm

8

Removal steps1. Oil level gauge2. Engine hanger3. Oil level gauge guide4. O-ring5. Drive belt6. Water pump pulley7. Alternator brace8. Alternator assembly


11. Ignition coil12. Spark plug13. Cam position sensor




32/147



REMOVAL SERVICE POINTA CRANKSHAFT BOLT REMOVAL

(1) Lock the flywheel or drive plate in position using the specialtool shown in the illustration, then loosen the crankshaftbolts.

INSTALLATION SERVICE POINTSA DISTRIBUTOR INSTALLATION

(1) Turn the crankshaft clockwise until cylinder No. 1 is attop dead center on its compression stroke.

(2) Align the alignment marks on the distributor housing andcoupling.

(3) Fit the distributor onto the engine, aligning the stud boltswith the slots in the distributor mounting flange.

B CRANKSHAFT PULLEY / BOLT INSTALLATION(1) Hold the flywheel or drive plate using the special tool.

(2) Clean the bolt hole in crankshaft, crankshaft bolt andcrankshaft pulleys seating surface.

(3) Degrease the cleaned seating surface of the crankshaftpulley.

(4) Install the crankshaft pulley.(5) Apply oil to the threads of crankshaft bolt and the outer

surface of washer.(6) Tighten the crankshaft bolt to the specified torque of 125

Nm.

C CAM POSITION SENSOR SUPPORTINSTALLATION

(1) Apply a 3 mm bead of form-in-place gasket (FIPG) tothe area shown.

Specified sealant:Mitsubishi Genuine Part No. MD970389 orequivalent

PWEE9520-FAug. 2001Mitsubishi Motors Corporation Revised

MD998781

Alignment mark

Alignment mark

MD998781

Crankshaft pulley

Crankshaftbolt

Washer

DegreaseCrankshaft

CleanShear-drop


33/147

4G1 ENGINE (EW) Timing Belt 11A-4-1


4. TIMING BELTREMOVAL AND INSTALLATION

11 Nm 111

13

35 Nm

4

37

2

523 Nm

88 Nm

12

9 8

9 Nm

14

6

10

Removal steps1. Timing belt upper cover2. Timing belt lower cover

A D 3. Timing beltC 4. Tensioner springC 5. Timing belt tensioner

6. Crankshaft angle sensor

B 7. Crankshaft sprocket

B 8. Spacer B 9. Sensing blade B 10. Flange

B A 11. Camshaft sprocket bolt12. Camshaft sprocket13. Engine support bracket14. Timing belt rear cover



34/147

4G1 ENGINE (EW) Timing Belt11A-4-1a



11 Nm 1

12

21 Nm

43

7

2

5

23 Nm

88 Nm11

98

9 Nm

13

6

10

35 Nm

35 Nm

21 Nm


A D 3. Timing beltC 4. Tensioner springC 5. Timing belt tensioner

6. Crankshaft angle sensor

B 7. Crankshaft sprocketB 8. Spacer B 9. Sensing blade

B A 10. Camshaft sprocket bolt11. Camshaft sprocket12. Bracket13. Engine support bracket



35/147

4G1 ENGINE (EW) Timing Belt 11A-4-1b



11 Nm

1

8

10

11

35 Nm

4

3

6

2

523 Nm

88 Nm

9

35 Nm

11

14

13

11 Nm

11 Nm

12

7


A E 3. Timing beltA C 4. Tensioner springA C 5. Timing belt tensioner

6. Idler pulleyB 7. Crankshaft sprocket

B 8. FlangeB A 9. Camshaft sprocket bolt

10. Camshaft sprocket11. Engine support bracket12. Timing belt rear cover (lower)13. Timing belt rear cover (right)14. Timing belt rear cover (left)



36/147

4G1 ENGINE (EW) Timing Belt11A-4-2



21 Nm

1

7

10

9

21 Nm

4

14

2

5

23 Nm

88 Nm

35 Nm

11

15

12

11 Nm

11 Nm3

9 Nm

35 Nm

6

35 Nm

8

13

Removal steps1. Timing belt front upper cover2. Timing belt front lower cover

C G 3. Timing belt4. Tensioner springF 5. Timing belt tensioner

6. Idler pulley7. Crank angle sensor

B 8. Crankshaft sprocket

B 9. SpacerB 10. Sensing blade

11. Bracket12. Right engine support bracketB A 13. Camshaft sprocket bolt

14. Camshaft sprocket15. Timing belt rear upper cover



37/147

4G1 ENGINE (E- W) - Timing Belt 11A-4-3


REMOVAL SERVICE POINTSA A" TIMING BELT / TENSIONER SPRING / TIMING

BELT TENSIONER REMOVAL(1) Using pliers, grip the tensioner spring projection (marked

A in the diagram)and remove it from the oil pump casestopper. Then, remove the tensioner spring.

(2) Remove the timing belt tensioner.(3) If the timing belt is to be reused, chalk an arrow on the

belt to indicate the direction of rotation before removingit. This will ensure the timing belt is fitted correctly whenreused.

A B" CAMSHAFT SPROCKET BOLT REMOVAL(1) Using the special tools shown in the illustration, lock the

camshaft sprocket in position.(2) Loosen the camshaft sprocket bolt.

A C" TIMING BELT REMOVAL(1) If the timing belt is to be refused, it is necessary to install

it in the same direction as it was before. Mark an arrowthat shows the direction of rotation on the back surfaceof the timing belt with chalk, etc.

(2) Using pliers and the like, hold the tensioner spring atthe illustrated position, and remove the spring.CautionDo not cause the end of the tensioner spring to givedamage to the timing belt.

(3) Loosen the timing belt tensioner securing bolt.(4) Move the timing belt tensioner in the direction shown

to remove the timing belt.


MB990767

MD998715

Securing bolt


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4G1 ENGINE (E- W) - Timing Belt4G1 ENGINE (E- W) - Timing Belt11A-4-4


INSPECTION1. TIMING BELTCheck the timing belt closely. Replace the belt with a newone 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 fingernailsleaves no mark)

(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

(6) Abnormal wear on the belts sidesNOTEThe sides of the belt are normal if they are sharp asif cut by a knife.

(7) Abnormal wear on teethInitial 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 thepulleys if necessary.


Crack Crack

Separation

Cracked tooth base

Cracked side

Rounded edge

Abnormal wear(exposed core wire)

Canvasworn exposingrubber

Missing tooth


39/147



INSTALLATION SERVICE POINTSA CAMSHAFT SPROCKET BOLT INSTALLATION

(1) Using the special tools shown in the illustration, lock thecamshaft sprocket in position.

(2) Tighten the camshaft sprocket bolt to the specified torque.

B SENSING BLADE / SPACER / FLANGE / CRANKSHAFT SPROCKET

Type with crank angle sensor:(1) Clean the hole in the crankshaft sprocket.(2) Clean and degrease the mating surfaces of the crankshaft

sprocket and crankshaft; sensing blade; and spacer.NOTEDegreasing is necessary to prevent decrease in friction

between the mating surfaces due to presence of oil.

Type without crank angle sensor:(1) Clean the hole in the crankshaft sprocket.(2) Clean and degrease the crankshaft sprocket, flange, and

sprocket fitting surface of the crankshaft.NOTEDegreasing is necessary to prevent decrease in frictionbetween the mating surfaces due to presence of oil.

C TIMING BELT TENSIONER / TENSIONER SPRINGINSTALLATION

(1) Lock the timing belt tensioner in the illustrated position.

(2) Fit one of the tensioner spring projections over the hookedportion of the timing belt tensioner and fit the tensioneronto the oil pump case.


MB990767

MD998715

Sensingblade

Crankshaftsprocket

DegreaseClean

Spacer Crankshaft

Crankshaft

Crankshaftsprocket

DegreaseClean

Flange

Timing belttensioner


40/147

4G1 ENGINE (EW) Timing Belt4G1 ENGINE (EW) Timing Belt11A-4-6


(3) Grip the other tensioner spring projection and fit it ontothe oil pump case lug as shown in the illustration.

(4) Move the timing belt tensioner in the direction shownand temporarily tighten the bolt.

D 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 markon the front case.

(3) Keeping the tension side of the timing belt tight, fit thetiming belt onto the crankshaft sprocket, camshaftsprocket, and tensioner pulley in that order.

(4) Loosen the tensioner pulley mounting bolts by 1/4 to1/2 of a turn and allow the tensioner spring to apply tensionto the timing belt.

(5) Turn the crankshaft twice in the normal rotating direction(clockwise) and check that the timing marks are correctlyaligned.

CautionThis procedure utilizes the camshafts driving torqueto apply tension evenly to the timing belt. Be sureto turn the crankshaft as described above. Do notturn the crankshaft in reverse.

(6) Tighten the tensioner pulley mounting bolts.



41/147

4G1 ENGINE (EW) Timing Belt4G1 ENGINE (EW) Timing Belt 11A-4-7


E TIMING BELT INSTALLATION(1) Place the camshaft sprocket timing marks at the positions

shown.NOTEAfter aligning the sprocket timing marks, let go of thesprockets. The exhaust camshaft sprocket will rotate byone tooth in the direction shown and remain stable in

this position.

(2) Align the crankshaft timing mark with the timing markon the front case.

(3) Turn the exhaust camshaft sprocket in the direction shownand 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.NOTEWhen fitting the belt, keep the camshaft sprocket timingmarks correctly aligned and keep the tension side of thebelt tight.

(6) Loosen the tensioner pulley mounting bolts by 1 / 4 to 1 / 2of a turn and allow the tensioner spring to apply tensionto 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 correctlyaligned.

CautionThis procedure utilizes the camshafts driving torqueto apply tension evenly to the timing belt. Be sureto turn the crankshaft as described above. Do notturn the crankshaft in reverse.

(9) Tighten the tensioner pulley mounting bolts.



42/147

4G1 ENGINE (EW) Timing Belt11A-4-8


F TIMING BELT TENSIONER AND TENSIONERSPRING INSTALLATION

(1) Install the timing belt tensioner and the tensioner spring,and temporarily tighten the timing belt tensioner securingbolt.

(2) Using pliers and the like, secure the spring at the illustratedposition of the front case.CautionDo not cause the end of the tensioner spring to givedamage to the crankshaft sprocket.

G TIMING BELT INSTALLATION(1) Align the timing marks on each camshaft sprocket.

NOTEAfter the timing marks on the sprockets are aligned, thesprockets can turn by about one tooth in the directionshown and remain stable in this position.

(2) Align the crankshaft sprocket timing marks.

(3) While paying attention to the direction of rotation markedon the timing belt (if the timing belt is reused), put thetiming belt over the inlet camshaft sprocket. After that,secure the belt at the position shown with a paper clip,etc.

Securing bolt


Timing marks


43/147



(4) Adjust the timing belt so that 23 cogs will fall within therange between the timing marks on the intake and exhaustcamshaft sprockets. Secure the belt at this position witha paper clip, etc.

(5) While aligning the exhaust camshaft sprocket timingmarks, install the timing belt on the idler pulley, crankshaftsprocket, and the timing belt tensioner in that order.

(6) Ensure that the timing marks on the exhaust camshaftsprocket and on the crankshaft sprocket are in alignment.

(7) Loosen the timing belt tensioner securing bolt, which hastemporarily been tightened, a quarter to half turn. Utilizingtensioner spring tension, give tension to the timing belt.

(8) Remove the paper clips, etc.

(9) Make two turns of the crankshaft sprocket in clockwisedirection to ensure that the timing marks on each camshaftsprocket are in alignment.

CautionOperation under item 9 above is performed in orderto give a constant tension to the timing belt by utilizingcamshaft driving torque. Observe the number of turnsof the sprocket mentioned above. Do not turn thecrankshaft sprocket counterclockwise direction.

23 cogs

Timing marks

Securing bolt



44/147

4G1 ENGINE (E- W) - Fuel and Emission Control Systems 11A-5-1


5. FUEL AND EMISSION CONTROL SYSTEMSREMOVAL AND INSTALLATION

17 Nm

12 Nm

31 Nm

21 Nm11

12

10

9

8

7

3

24

56

1

10 Nm

13

12 Nm

14

Removal steps1. Breather tube2. Fuel hose3. Hose clamp4. Fuel pump5. Gasket6. Insulator7. Gasket

8. Carburetor9. Upper gasket

10. Spacer11. Lower gasket12. EGR valve 13. Cover 14. Gasket



45/147

4G1 ENGINE (E- W) - Fuel and Emission Control Systems11A-5-1a



17 Nm

19 Nm

31 Nm

11

12

10

9

8

7

3

24

56

1

10 Nm

13

12 Nm

Removal steps1. Breather tube2. Fuel hose3. Hose clamp4. Fuel pump5. Gasket6. Insulator7. Gasket

8. Carburetor9. Upper gasket

10. Spacer11. Lower gasket12. Cover13. Gasket

PWEE9520-DE Aug. 2000Mitsubishi Motors Corporation Added


46/147

4G1 ENGINE (EW) Fuel and Emission Control Systems 11A-5-1b


Intentionally blank

PWEE9520-DAug. 2000Mitsubishi Motors Corporation Added


47/147

4G1 ENGINE (EW) Fuel and Emission Control Systems11A-5-2



11 Nm

21 Nm

18 Nm

9 Nm

1

3

13

6

2 5

910

8

7

18

14

16M8 16 18 NmExcept M8 16 12 Nm

15

4

18 Nm

17

11

12

9 Nm

Removal steps1. Vacuum pipe and hose assembly2. Vacuum hose assembly3. Throttle body assembly4. Gasket5. Fuel return pipe

B 6. Fuel pressure regulator7. O-ring8. Insulator9. Insulator

A 10. Injector

11. O-ring12. Grommet13. Delivery pipe14. EGR valve (With EGR valve)15. Cover (Without EGR valve)16. Gasket17. Air temperature sensor (Up to

2000 model)18. Gasket (Up to 2000 model)



48/147

4G1 ENGINE (EW) Fuel and Emission Control Systems 11A-5-2a



11 Nm

18 Nm

21 Nm

9 Nm

1

3

11

6

45

910

8

7

1312

9 Nm

2

Removal steps1. Vacuum pipe and hose2. Throttle body assembly3. Gasket


A 8. Injector9. O-ring

10. Grommet11. Delivery pipe12. EGR valve13. Gasket



49/147

4G1 ENGINE (EW) Fuel and Emission Control Systems11A-5-2b



12

11 Nm

18 Nm

21 Nm

9 Nm

12

3

11

6

4

5

9 108

7

13

9 Nm

Removal steps1. Throttle body assembly2. Gasket3. Fuel return pipe


A 8. Injector9. O-ring

10. Grommet11. Delivery pipe12. EGR valve13. Gasket



50/147

4G1 ENGINE (EW) Fuel and Emission Control Systems 11A-5-3


REMOVAL AND INSTALLATION 11 Nm

11

6 21

18 Nm

9 Nm

3

5

4

9

10

87

Removal steps1. Throttle body assembly2. Gasket

3. Fuel return pipeB 4. Fuel pressure regulator5. O-ring6. Insulator

7. InsulatorA 8. Injector

9. O-ring10. Grommet11. Delivery pipe



51/147

4G1 ENGINE (E- W) - Fuel and Emission Control Systems11A-5-4


INSTALLATION SERVICE POINTS" AA INJECTOR INSTALLATION(1) Fit a new O-ring and grommet onto the injector.(2) Apply spindle oil or gasoline to the injector O-ring.

(3) Fit the injector onto the delivery pipe, turning it to theleft and right as it goes in.

(4) Check that the injector rotates smoothly.

CautionIf the injector does not rotate smoothly, its O-ringmay be binding. If this occurs, remove the injectorfrom the delivery pipe, check the O-ring, and re-insertthe injector.

" BA FUEL PRESSURE REGULATOR INSTALLATION(1) Apply a little new engine oil to the O-ring, then insert

the fuel pressure regulator into the delivery pipe, takingcare not to damage the O-ring.CautionEnsure that no engine oil enters the delivery pipe.

(2) Check that the fuel pressure regulator rotates smoothly.If it does not rotate smoothly, the O-ring may be binding.If this occurs, remove the fuel pressure regulator, checkthe O-ring for damage, then re-insert the regulator intothe delivery pipe.


52/147

4G1 ENGINE (E- W) - Intake Manifold and Throttle Body (GDI) 11A-5a-1


INTAKE MANIFOLD AND THROTTLE BODY (GDI)REMOVAL AND INSTALLATION

49 Nm

11

5

12

10

19 Nm

34

1

8

7

20 Nm

10 Nm

15

30 Nm

6

10 Nm

13

24 Nm

14

2

19 Nm

11

9

17

16

19 Nm

14

18

Removal steps

1. Accelerator cable2. Water hose3. Throttle body4. Gasket5. Air intake plenum resonator6. O-ring7. Power plant stay, right

" BA 8. Intake manifold stay9. Water hose

10. Water hose11. EGR valve12. Gasket13. EGR valve support14. Gasket15. P.C.V. hose

A A" " AA 16. Intake manifold17. Gasket18. Insulator



53/147

4G1 ENGINE (E-W) - Intake Manifold and Throttle Body (GDI)11A-5a-2


REMOVAL SERVICE POINTA A" INTAKE MANIFOLD REMOVALDisconnect the fuel pressure sensor connectors.

INSTALLATION SERVICE POINTS" AA INTAKE MANIFOLD INSTALLATION After installing the intake manifold, connect the fuel pressuresensor connectors.

" BA INTAKE MANIFOLD STAY INSTALLATIONEnsure that the intake manifold stay is in close contact withthe intake manifold and the cylinder block boss. After that,tighten the bolts to the specified torque.



54/147

4G1 ENGINE (E-W) - Exhaust Manifold (GDI) 11A-5b-1


EXHAUST MANIFOLD (GDI)REMOVAL AND INSTALLATION

30 Nm

3

18 Nm

7

4

2

6

29 Nm

5

35 Nm

35 Nm

1

44 Nm

Removal steps1. Oxygen sensor2. Exhaust manifold cover3. Exhaust manifold bracket B4. Exhaust manifold5. Exhaust manifold gasket6. Exhaust manifold bracket A7. Power plant stay, left



55/147

4G1 ENGINE (E- W) - Water Pump and Water Hose 11A-6-1


6. WATER PUMP AND WATER HOSEREMOVAL AND INSTALLATION

11 Nm

1

2

3

4

56 78

9

10

11

12

13

14

27 Nm

27 Nm

22 Nm

23 Nm

12 Nm

13 Nm

Removal steps1. Water hose2. Water hose3. Water hose

" FA 4. Thermo valve " FA 5. Thermo valve" DA 6. Engine coolant temperature gauge

unit7. Water inlet fitting

" CA 8. Thermostat9. Thermostat case

10. Gasket" BA 11. Water inlet pipe" BA 12. O-ring" BA 13. O-ring" AA 14. Water pump



56/147

4G1 ENGINE (E-W) - Water Pump and Water Hose11A-6-1a


1

2

3

4

5

6

7

89

10

11

12

13

22 Nm

12 Nm

13 Nm

23 Nm

12 Nm

Removal steps1. Water hose2. Water hose3. Water hose

" FA 4. Thermo valve" DA 5. Engine coolant temperature gauge


" CA 7. Thermostat8. Thermostat case9. Gasket

" BA 10. Water inlet pipe" BA 11. O-ring" BA 12. O-ring" AA 13. Water pump



57/147

4G1 ENGINE (E-W) - Water Pump and Water Hose 11A-6-1b

Intencionalmenteen blanco



58/147

4G1 ENGINE (E- W) - Water Pump and Water Hose11A-6-2


2

13 Nm

12

10

9

11

12 Nm 11 Nm

4

29 Nm

3

8

7

622 Nm

5

23 Nm

1

Removal steps1. Water hose2. Water hose

"E

A 3. Engine coolant temperature sensor" DA 4. Engine coolant temperature gauge



8. Gasket" BA 9. Water inlet pipe"

BA

10. O-ring" BA 11. O-ring" AA 12. Water pump



59/147

4G1 ENGINE (E- W) - Water Pump and Water Hose 11A-6-2a



2

13 Nm

12

10

9

11

12 Nm

11 Nm

4

29 Nm

3

87

6

22 Nm

5

23 Nm

1

12 Nm


" EA 3. Engine coolant temperature sensor" DA 4. Engine coolant temperature gaugeunit

5. Water inlet fitting" CA 6. Thermostat

7. Thermostat case

8. Gasket" BA 9. Water inlet pipe" BA 10. O-ring" BA 11. O-ring" AA 12. Water pump



60/147

4G1 ENGINE (E- W) - Water Pump and Water Hose11A-6-2b



2

13 Nm

12

1110

12Nm

11 Nm

4

1

25 Nm

9

8

23 Nm

18 Nm

5

7

6

29 Nm3

12Nm


" EA 3. Engine coolant temperature sensor" DA 4. Engine coolant temperature gauge

unit5. Water outlet fitting6. Gasket

" CA 7. Thermostat8. Fitting9. Gasket

" BA 10. Water inlet pipe" BA 11. O-ring" AA 12. Water pump



61/147

4G1 ENGINE (EW) Water Pump and Water Hose 11A-6-2c



2

13 Nm

12

10

9

11

12 Nm

11 Nm

4

23 Nm

38

7

6

22 Nm

5

29 Nm

112 Nm

Removal steps

1. Water hose2. Water hoseE 3. Engine coolant temperature sensorD 4. Engine coolant temperature gauge


C 6. Thermostat7. Thermostat case

8. GasketB 9. Water inlet pipeB 10. O-ringB 11. O-ringA 12. Water pump

PWEE9520-GApr. 2003Mitsubishi Motors Corporation Added


62/147

4G1 ENGINE (EW) Water Pump and Water Hose11A-6-2d


Intentionally blank

PWEE9520-GApr. 2003Mitsubishi Motors Corporation Added


63/147




2

13 Nm

12

10 9

11

12 Nm

4

29 Nm

38

7

6

22 Nm

5

23 Nm

112 Nm

11 Nm


"E

A 3. Engine coolant temperature sensor" DA 4. Engine coolant temperature gauge



8. Gasket" BA 9. Water inlet pipe"

BA

10. O-ring" BA 11. O-ring" AA 12. Water pump



64/147




1

2

4

5

6

7

8

3

8

9

22 Nm

12 Nm

13 Nm

29 Nm

12 Nm

22 Nm

23 Nm

11 Nm

Removal steps" HA 1. Water outlet fitting

2. Water inlet fitting" CA 3. Thermostat" DA 4. Engine coolant temperature gauge

unit

" EA 5. Engine coolant temperature sensor" GA 6. Thermostat housing" BA 7. Water inlet pipe" BA 8. O-ring" AA 9. Water pump



65/147



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 Part No. MD970389 orequivalent.

" 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 insertedeasily into the water pump and thermostat case.Caution1. 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 ENGINE COOLANT TEMPERATURE GAUGE UNITINSTALLATION

(1) If the engine coolant temperature gauge unit is to bereused, apply the specified sealant to its thread.Specified sealant:

3M ATD Part No. 8660 or equivalent.

" EA ENGINE COOLANT TEMPERATURE SENSORINSTALLATION

(1) If the engine coolant temperature sensor is to be reused,apply the specified sealant to its thread.Specified sealant:

3M Nut Locking Part No. 4171 or equivalent.



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" FA THERMO VALVE INSTALLATION(1) If the thermo valve is to be reused, apply the specified

sealant to its thread.Specified sealant:


" GA THERMOSTAT HOUSING INSTALLATION(1) Remove the old liquid gasket from the cylinder head

(thermostat housing mounting surface) and the thermostathousing.

(2) Apply liquid gasket to the thermostat housing mountingsurface by squeezing it to a thickness of 3 mm.Specified sealant:

Mitsubishi Genuine Part No. MD970389 or

equivalent.CautionSqueeze the liquid gasket uniformly so that there isno break in the gasket nor is there too much gasket.

" HA WATER OUTLET FITTING INSTALLATION(1) Remove the old liquid gasket from the thermostat housing

(water outlet fitting mounting surface) and the water outletfitting.

(2) Apply liquid gasket to the water outlet fitting mountingsurface by squeezing it to a thickness of 3 mm.Specified sealant:


CautionSqueeze the liquid gasket uniformly so that there isno break in the gasket nor is there too much gasket.


1EN0511


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4G1 ENGINE (E-W) - Intake and Exhaust Manifolds 11A-7-1


7. INTAKE AND EXHAUST MANIFOLDSREMOVAL AND INSTALLATION

17 Nm

1

2

3

4

5

6

7

8

30 Nm

17 Nm

29 Nm

Removal steps1. Engine hanger2. Intake manifold stay3. Intake manifold4. Intake manifold gasket

5. Exhaust manifold cover6. Engine hanger7. Exhaust manifold8. Exhaust manifold gasket



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4G1 ENGINE (E-W) - Intake and Exhaust Manifolds11A-7-2



17 Nm

1

2

3

4

5

6

7

8

30 Nm

17 Nm29 Nm

29 Nm 19 Nm

Removal steps1. Engine hanger2. Intake manifold stay3. Intake manifold4. Intake manifold gasket




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4G1 ENGINE (E-W) - Intake and Exhaust Manifolds 11A-7-2a



2

4

5

17 Nm

11

10 954 Nm

8

30 Nm

17 Nm

11 Nm

29 Nm

6

7

1 13 Nm

83 Nm8

3

12

Removal steps1. Engine hanger2. Intake manifold stay3. Intake manifold4. Intake manifold gasket5. Air hose6. Exhaust manifold cover

" AA 7. Air pipe" AA 8. Reed valve and bracket

9. Reed valve10. Reed valve bracket A11. Reed valve bracket B12. Exhaust manifold



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4G1 ENGINE (E-W) - Intake and Exhaust Manifolds11A-7-2b



13

444 Nm

5

9

8 7

29 Nm

617 Nm2

31 Nm

17 Nm

17 Nm

Removal steps1. Engine hanger2. Intake manifold stay3. Intake manifold4. Intake manifold gasket5. Oxygen sensor

6. Engine hanger7. Exhaust manifold cover8. Exhaust manifold9. Exhaust manifold gasket



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4G1 ENGINE (EW) Intake and Exhaust Manifolds 11A-7-2c



44 Nm

8

14 30 Nm

9

35 Nm

3

31 Nm

17 Nm

49 Nm

2

6

5

1

5 Nm

9 Nm

17 Nm

12

18 Nm

1030 Nm

11

13

9 Nm

35 Nm

35 Nm

30 Nm

19 Nm

7

4

17 Nm

15

16

35 Nm

Removal steps1. Boost sensor2. Engine hanger3. Power plant stay, right

(From 2004 model)4. Intake manifold stay5. Intake manifold6. Intake manifold gasket7. Solenoid valve assembly8. Solenoid valve assembly9. Oxygen sensor

10. Engine hanger11. Exhaust manifold cover12. Exhaust monifold bracket B13. Exhaust manifold14. Exhaust manifold gasket15. Exhaust manifold bracket A

(Up to 2003 model)16. Power plant stay, left

(From 2004 model)



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4G1 ENGINE (E-W) - Intake and Exhaust Manifolds11A-7-2d



2

4

5

17 Nm

11

10

929 Nm

8

3

31 Nm

17 Nm

17 Nm

29 Nm

6

7

1

5 Nm 9 Nm

19 Nm

Removal steps1. Boost sensor2. Engine hanger3. Intake manifold stay

4. Intake manifold5. Intake manifold gasket6. Solenoid valve assembly

7. Solenoid valve assembly

8. Engine hanger

9. Exhaust manifold cover10. Exhaust manifold11. Exhaust manifold gasket



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4G1 ENGINE (E-W) - Intake and Exhaust Manifolds 11A-7-2e



17 Nm

1

3 4

5

6

7

2

31 Nm

5 Nm

17 Nm

9 Nm

49 Nm

17 Nm

11

10

17 Nm 9 29 Nm

19 Nm8

35 Nm

29 Nm

12

Removal steps1. Boost sensor2. Engine hanger3. Power plant stay right 4. Intake manifold stay5. Solenoid valve assembly6. Intake manifold

7. Intake manifold gasket8. Engine hanger9. Exhaust manifold cover

10. Exhaust manifold11. Exhaust manifold gasket12. Power plant stay left



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4G1 ENGINE (E- W) - Intake and Exhaust Manifolds 11A-7-3



1

34

9 8

7

29 Nm

617 Nm

2

21 Nm

17 Nm

17 Nm

5

44 Nm

29 Nm

Removal steps1. Engine hanger2. Intake manifold stay3. Intake manifold4. Intake manifold gasket5. Oxygen sensor



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4G1 ENGINE (E- W) - Intake and Exhaust Manifolds11A-7-4


INSTALLATION SERVICE POINTS" AA REED VALVE, BRACKET AND AIR PIPE

INSTALLATION(1) Insert the lower end of the air pipe into the exhaust

manifold, then tighten the pipe nut temporarily.(2) Fit the upper end of the air pipe to the reed valve and

bracket assembly, then tighten the pipe nut temporarily.(3) Attach the reed valve and bracket assembly to the reed

valve bracket B and tighten the mounting boltstemporarily.

(4) Tightenthe nutson both endsof the air pipe to the specifiedtorque.

CautionThe tightening torque of the reed valve side nut andthat of the exhaust manifold side nut are differentfrom each other.Be sure to tighten each nut correctly to the specifiedtorque.

(5) Tighten the reed valve and bracket mounting bolts tothe specified torque.

(6) Tighten the pipe clamp bolt.

PWEE9520-BE July 1999Mitsubishi Motors Corporation Added

Reed valve and bracket

Pipe nut (reed valve side)

Pipe clamp bolt

Reed valvebracket B

Air pipe

Pipe nut (exhaustmanifold side)


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4G1 ENGINE (E- W) - Fuel System (GDI) 11A-7a-1


FUEL SYSTEM (GDI)REMOVAL AND INSTALLATION

5

12 Nm

9

24 Nm

20

8

1110

43

12

12 Nm

9.8 Nm

2

17 Nm

15

23 Nm

13

1416

17

7

1921 22

18

1

23

6

Removal steps

1. Injector harness" EA 2. Fuel pipe" EA 3. Backup ring" EA 4. O-ring" EA 5. Backup ring" EA 6. Fuel pump

7. O-ring8. Flange

" DA 9. Fuel pressure sensor" DA 10. O-ring" DA 11. Backup ring

12. Harness bracket

13. Washer14. Injector holder" CA 15. Delivery pipe and injector

16. Insulator17. Injector gasket

" BA 18. Corrugate washer" AA 19. Backup ring" AA 20. O-ring" AA 21. Backup ring

22. Injector23. Delivery pipe



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4G1 ENGINE (E- W) - Fuel System (GDI)11A-7a-2


INSTALLATION SERVICE POINTS" AA BACKUP RING / O-RING INSTALLATIONInstall the backup rings and the O-rings on the injector. Installthe backup ring (thicker one) on the injector with the insidecut surface facing the direction shown in the illustration.

" BA CORRUGATE WASHER INSTALLATION Apply white vaseline to the corrugate washer and install thewasher on the injector in the direction shown.

CautionIf the washer that has once been tightened is refused,it will cause fuel leakage or gas leakage. Be sureto use a new washer.

" CA DELIVERY PIPE AND INJECTOR INSTALLATION(1) Apply spindle oil or gasoline to injector O-rings.(2) Insert the injector straight in the injector mounting hole

on the delivery pipe.(3) Try to the turn the injector. If the injector dose not turn

smoothly, remove the injector and check the O-rings fordamage. If damage is evident, replace the O-rings andreinstall the injector.

(4) Align the matchmark on the injector with that on thedelivery pipe.

(5) Install the delivery pipe and injector on the cylinder headand tighten the bolts to the specified torque in the ordershown in the illustration.

" DA BACKUP RING / O-RING / FUEL PRESSURESENSOR INSTALLATION

(1) Install the backup ring on the fuel pressure sensor withthe inside cut surface facing the direction shown in theillustration.


Backup ring

Cut surface

Corrugate washer

Matchmarks

1 23 4

Backup ring

Cut surface


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4G1 ENGINE (E- W) - Fuel System (GDI) 11A-7a-3


(2) Install the fuel pressure sensor in the direction shown,paying attention to the shape of connector.

" EA FUEL PUMP / BACKUP RING / O-RING / FUELPIPE INSTALLATION

(1) Apply engine oil to the roller and the O-ring of the fuelpump.

(2) Insert the fuel pump in the mounting hole on the cylinderhead, and lightly tighten four bolts (a little more stronglythan you tighten them with fingers).

(3) Install the backup rings and the O-rings on both endsof the fuel pipe. Install the backup ring (thicker one) withthe inside cut surface facing the direction shown in theillustration.

(4) Apply spindle oil or gasoline to the O-rings on both endsof the pipe.

(5) Insert the fuel pipe straight in the mounting hole on thefuel pump. When the fuel pipe is inserted, use care notto twist it and insert as far as it goes.

(6) Tighten the bolts on both ends of the pipe to the specifiedtorque.

(7) Using the torque wrench (minimum scale 0.5 Nm), tightenthe fuel pump mounting bolts by the following procedure.1. Tighten the bolts to 4.9 Nm in the order as shown.2. Tighten the bolts to 17 Nm in the order as shown.

The torque variation of the four bolts should be within2 Nm.

CautionObserve the tightening order. Failure to observe thespecified torques and tightening order will causeleakage, etc.


Backup ring

Cut surface

O-ringBackup ring withno directivity


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4G1 ENGINE (E- W) - Rocker Arms and Camshafts 11A-8-1


8. ROCKER ARMS AND CAMSHAFTSREMOVAL AND INSTALLATION

15Nm

1

5

2

36

4 Nm9

14

13

7

1211

1516

17

21

20

19

22

108

31 Nm

18

4

Apply engine oil to allmoving parts beforeinstallation.

Removal steps1. Breather hose2. P.C.V. hose3. P.C.V. valve4. P.C.V. valve gasket5. Oil filler cap6. Rocker cover7. Rocker cover gasket

" FA 8. Camshaft oil seal" EA 9. Rocker arm and shaft assembly" EA 10. Rocker arm and shaft assembly

11. Rocker arm A

12. Rocker arm spring13. Rocker arm B14. Rocker arm shaft15. Rocker arm C16. Wave washer17. Spacer18. Rocker arm D19. Rocker arm shaft

" CA 20. Adjusting screw21. Nut22. Camshaft

PWEE9520-AE Dec. 1998Mitsubishi Motors Corporation Revised


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4G1 ENGINE (E- W) - Rocker Arms and Camshafts11A-8-1a



3.5 Nm

9 Nm

31 Nm

1 2

3

4

5

6

10

11

1213

14

1516

17

1819

20

21

9 Nm


9

8

7

Removal steps1. Breather hose2. P.C.V. hose3. Oil filler cap4. P.C.V. valve5. P.C.V. valve gasket6. Rocker cover7. Rocker cover gasket8. Oil seal

" FA 9. Oil seal" EA 10. Rocker arms and rocker arm shaft,

intake" EA 11. Rocker arms and rocker arm shaft,

exhaust

12. Rocker arm A13. Rocker arm B

" DA 14. Rocker arm shaft" CA 15. Adjusting screw

16. Nut17. Rocker arm C

" DA 18. Rocker arm shaft" CA 19. Adjusting screw

20. Nut21. Camshaft



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4G1 ENGINE (E- W) - Rocker Arms and Camshafts 11A-8-1b



3.5 Nm

31 Nm

1

2

3

4

5

6

10

11

1213

14

15

16


7

9

8

19

18

17

Removal steps1. Breather hose2. P.C.V. hose3. Oil filler cap4. P.C.V. valve5. P.C.V. valve gasket6. Rocker cover7. Rocker cover gasket8. Oil seal

" FA 9. Oil sealA A" " EA 10. Rocker arms and rocker arm shaft,

intake

A A" " EA 11. Rocker arms and rocker arm shaft,exhaust

12. Rocker arm A13. Rocker arm B

" DA 14. Rocker arm shaft" IA 15. Lash adjuster

16. Rocker arm C" DA 17. Rocker arm shaft" IA 18. Lash adjuster

19. Camshaft



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4G1 ENGINE (E- W) - Rocker Arms and Camshafts11A-8-2



24 Nm

12

35 4

6

7 9

11

12

13

14

15

11 Nm

10

8


4 Nm

Removal steps1. Breather hose2. P.C.V. hose3. P.C.V. valve4. P.C.V. valve gasket5. Oil filler cap

" HA 6. Rocker cover7. Rocker cover gasket A8. Rocker cover gasket B

" GA 9. Semi-circular packing" FA 10. Camshaft oil seal" BA 11. Bearing cap" AA 12. Camshaft" AA 13. Camshaft

14. Roller rocker armA B" " J A 15. Lash adjuster



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4G1 ENGINE (E-W) - Rocker Arms and Camshafts 11A-8-2a


REMOVAL SERVICE POINTSA A" ROCKER ARMS AND ROCKER ARM SHAFTS

REMOVAL

CautionIf the lash adjuster is re-used, clean the lash adjuster.(Refer to 11A-8-3.)

Set special tool MD998443 to prevent the lash adjuster fromcoming free and falling to the floor.

A B" LASH ADJUSTER REMOVAL

CautionIf the lash adjuster is re-used, clean the lash adjuster.(Refer to 11A-8-6.)


MD998443


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4G1 ENGINE (E- W) - Rocker Arms and Camshafts11A-8-2b


Intentionallyblank



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4G1 ENGINE (EW) Rocker Arms and Camshafts 11A-8-3


INSPECTION1. CAMSHAFT(1) Measure the cam heights and replace the camshaft if

any height exceeds the specified limit.

Standardvalue mm

Limit mm

Intake SOHC 12-VALVE*1

38.78 38.28SOHC 12-VALVE* 2 38.78 38.28

SOHC 16-VALVE* 3 36.99 36.49

SOHC 16-VALVE* 4 36.86 36.36

SOHC 16-VALVE* 5 37.30 36.80

SOHC 16-VALVE* 6 37.17 36.67

DOHC 34.67 34.17

Exhaust SOHC 12-VALVE* 1 39.01 38.51

SOHC 12-VALVE* 2 38.97 38.47

SOHC 16-VALVE*3

36.85 36.35SOHC 16-VALVE* 4 36.68 36.18

SOHC 16-VALVE* 5 37.16 36.66

SOHC 16-VALVE* 6 36.99 36.49

DOHC 34.26 33.76

*1: With low pollution system*2: Without low pollution system*3: Except 2001 model front wheel drive vehicles*4: 2001 model front wheel drive vehicles for Europe*5: 2001 model front wheel drive vehicles for General

Export*6: 2002 model front wheel drive vehicles for Europe

2. LASH ADJUSTERS(SOHC)

Caution1. The lash adjusters are precision-engineered

mechanisms. Do not allow them to becomecontaminated by dirt or other foreign substances.

2. Do not attempt to disassemble the lash adjusters.3. Use only fresh diesel fuel to clean the lash

adjusters.

(1) Prepare three containers and approximately five litersof diesel fuel. Into each container, pour enough dieselfuel to completely cover a lash adjuster when it is standingupright. Then, perform the following steps with each lashadjuster.


To cleanoutside

To cleaninside

To filldiesel fuel

A B C


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(2) Place the lash adjuster in container A and clean its outsidesurface.NOTEUse a nylon brush if deposits are hard to remove.

(3) While gently pushing down the internal steel ball usingspecial tool MD998442, move the plunger through 5 to10 strokes until it slides smoothly. In addition to eliminatingstiffness in the plunger, this operation will remove dirtyoil.

CautionThe steel ball spring is extremely weak, so the lashadjusters functionality may be lost if the air bleedwire is pushed in hard.NOTEIf the plunger remains stiff or the mechanism appearsotherwise abnormal, replace the lash adjuster.

(4) Remove the lash adjuster from the container. Then, pushdown the steel ball gently andpush theplunger to eliminatediesel fuel from the pressure chamber.

(5) Place the lash adjuster in container B. Then, gently pushdown the internal steel ball using special tool MD998442and move the plunger through 5 to 10 strokes until itslides smoothly. This operation will clean the lashadjusters pressure chamber.

CautionThe steel ball spring is extremely weak, so the lashadjusters functionality may be lost if the air bleedwire is pushed in hard.

Diesel fuel


Wire or MD998442

Diesel fuel

Wire or MD998442Diesel fuel

Wire or MD998442

Diesel fuel


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4G1 ENGINE (E- W) - Rocker Arms and Camshafts 11A-8-5


(6) Remove the lash adjuster from the container. Then, pushdown the steel ball gently andpush theplunger to eliminatediesel fuel from the pressure chamber.

(7) Place the lash adjuster in container C. Then, gently pushdown the internal steel ball using special tool MD998442.CautionDo not use container C for cleaning. If cleaning isperformed in container C, foreign matter could enterthe pressure chamber when chamber is filled withdiesel fuel.

(8) Stand the lash adjuster with its plunger at the top, thenpush the plunger downward firmly until it moves throughits greatest possible stroke. Return the plunger slowly,then release the steel ball and allow the pressure chamberto fill with diesel fuel.

(9) Remove the lash adjuster from the container, then standthe lash adjuster with its plunger at the top. Push theplunger firmly and check that it does not move. Also,check that the lash adjusters height matches that of anew lash adjuster.NOTEIf lash adjuster contracts, perform the operations (7)through (9) again to fill it with diesel fuel completely.Replace the lash adjuster if it still contracts after performingthese steps.

(10)Stand the lash adjuster upright to prevent diesel fuel fromspilling out. Do not allow the lash adjuster to becomecontaminated by dirt or other foreign matter. Fit the lashadjuster onto the engine as soon as possible.

Wire or MD998442Diesel fuel


Wire or MD998442

Diesel fuel

Wire or MD998442

Diesel fuel


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PWEE9520E Nov. 1995Mits

Proton 4G1x Engine Manual

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Transcript of Proton 4G1x Engine Manual