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Mitsubishi Engine 4G9 Series Workshop Manual

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General Mitsubishi Workshop Manual of 4G9 engine (4G92, 4G93, 4G94), that are mounted on Lancer, Carisma, Pajero, Galant, Space Star, Space Runner either with MIVEC, GDI, SOHC or DOHC. 4G92 SOHC and 4G92 DOHC MIVEC engine also are used on Mitsubishi Colt sixth generation (19922000), a super mini car built by Mitsubishi. This document mostly gives information on general maintenance on overhaul of Mitsubishi engine type above, inspecting and adjusting also given, with pictures and words work together explains things quickly.

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REWORK DIMENSIONS 11A-1-4 TORQUE SPECIFICATIONS 11A-1-5 NEW TIGHTENING METHOD–BY USE OF BOLTS TO BE

TIGHTENED IN PLASTIC AREA 11A-1-7 SEALANT 11A-1-7 FORM-IN-PLACE GASKET 11A-1-8

2 SPECIAL TOOLS 11A-2-1

3 ALTERNATOR AND IGNITION SYSTEM 11A-3-1

4 TIMING BELT 11A-4-1

5 FUEL AND EMISSION CONTROL SYSTEM 11A-5-1 5a THROTTLE BODY AND EGR SYSTEM (GDI) 11A-5a-1

6 INTAKE AND EXHAUST MANIFOLD 11A-6-1 6a INTAKE MANIFOLD (GDI) 11A-6a-1 6b EXHAUST MANIFOLD (GDI) 11A-6b-1 6c INJECTOR AND FUEL PUMP ASSEMBLY (GDI) 11A-6c-1 6d INTAKE AND EXHAUST MANIFOLD

<4G94–GDI for PAJERO io> 11A-6d-1

7 WATER PUMP AND WATER HOSE 11A-7-1

8 ROCKER ARMS AND CAMSHAFTS 11A-8-1 8a ROCKER COVER AND CAMSHAFTS (MIVEC) 11A-8a-1 8b ROCKER ARMS AND ROCKER SHAFT CAPS (MIVEC) 11A-8b-1

9 CYLINDER HEAD AND VALVES 11A-9-1

10 FRONT CASE AND OIL PUMP 11A-10-1

11 PISTON AND CONNECTING ROD 11A-11-1

12 CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE PLATE 11A-12-1

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47.5_ (Ηιγη−σπεεδ χαm)Χλοσεσ

(ΑΒDΧ)

72.5_ (Ηιγη−σπεεδ χαm)Εξηαυστ

ϖαλϖε

Οπενσ(ΒΒDΧ)

70_ (Ηιγη−σπεεδ χαm)Χλοσεσ

(ΑΤDΧ)

35_ (Ηιγη−σπεεδ χαm)Λυβριχατιον σψστεm Πρεσσυρε φεεδ, φυλλ−φλοω φιλτρατιον Πρεσσυρε φεεδ, φυλλ−φλοω φιλτρατιον

∗: ΛΑΝΧΕΡ φορ γενεραλ εξπορτ ανδ ΧΑΡΙΣΜΑ φορ 6Β mοδελ

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Χλοσεσ (ΑΒDΧ)

Εξηαυστ ϖαλϖε

Οπενσ (ΒΒDΧ)

Χλοσεσ (ΑΤDΧ)

Wατερ−χοολεδ φορχεδ χιρχυλατιον

τψπε

Χεντριφυγαλ ιmπελλερ τψπε

Χεντριφυγαλ ιmπελλερ τψπε

∗1: Υπ το 1999 mοδελ

∗ 2 : Φροm 2000 mοδελ

ΠWΕΕ9502−Γ

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Descriptions 4G94–SOHC 4G94–DOHC–GDI

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

Closes(ABDC)

Exhaustvalve

Opens(BBDC)

Closes(ATDC)

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

Oil pump type Trochoid type Trochoid type

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

Water pump type Centrifugal impeller type Centrifugal impeller type

PWEE9502-I

EMitsubishi Motors Corporation Mar 2001 Revised

Trang 6

Auto-tensioner rod stroke mm Within 1 –

Auto-tensioner rod protrusion amount (When checking with installed

Exhaust 37.83 37.334G92–SOHC*G S C 3 Intake 36.92 36.42

Exhaust 36.70 36.654G93–SOHC*G S C 4 Intake 37.53 37.03

Exhaust 37.64 37.144G93–SOHC*G S C 5 Intake 37.11 36.61

Exhaust 37.15 36.654G94–SOHCS C Intake 37.91 37.41

Exhaust 37.70 37.204G93–DOHCG C Intake 35.31 34.81

Exhaust 35.20 34.704G93–DOHC–GDI Intake 35.49 34.994G93 DOHC GDI

Exhaust 34.73 34.234G94–DOHC–GDI Intake 35.49 34.994G94 DOHC GDI

Exhaust 34.91 34.41Valve clearance mm Intake 0.09 –

Camshaft journal O.D mm SOHC 26.0 –

Rocker cover and camshaft (MIVEC)

Camshaft height mm Intake A 36.41 36.91

Intake B 33.58 33.08Exhaust A 35.83 35.33Exhaust B 34.24 33.74Valve clearance (cold engine) mm Intake 0.1 –

*1: LANCER for Europe and CARISMA for Europe

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

*3: LANCER for Europe (from 2001 model) and CARISMA for Europe (from 2001 model)

*4: Except for Europe

*5: For Europe

PWEE9502-K

EMitsubishi Motors Corporation Jun 2002 Revised

Trang 7

Cylinder head and valve

Cylinder head gasket surface flatness mm Less than 0.03 0.2

Grinding limit of cylinder head gasket surface mm

*Total resurfacing depth of both cylinder head and cylinder block

Cylinder head overall height mm SOHC 119.9 – 120.1 –

DOHC 131.9 – 132.1 –DOHC–MIVEC 119.8 – 120.0 –DOHC–GDI 131.9 – 132.1 –Thickness of valve

Exhaust 115.63 115.13DOHC–GDI Intake 104.19 103.69

Exhaust 103.87 103.37Valve spring free length mm SOHC (with lash ad-

Valve stem to valve

guide clearance mm

Except DOHC–GDIfor PAJERO io

Intake 0.02 – 0.05 0.10guide clearance mm for PAJERO io

Exhaust 0.05 – 0.09 0.15DOHC–GDI

for PAJERO io

Intake 0.02 – 0.05 0.10for PAJERO io

Exhaust 0.04– 0.06 0.15Valve seat valve contact width mm 0.9 – 1.3 –

Valve guide projection from cylinder head

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Valve stem

Exhaust 57.85 58.35DOHC–GDI Intake 46.70 47.20

Exhaust 46.65 47.15Cylinder head bolt shank length mm – 96.4

Valve face angle 45_ – 45.5_ –

Valve spring load/installed height N/mm SOHC 216/44.2 –

DOHC–MIVEC 255/44.5 –DOHC–GDI 196/37.5 –

Font case, oil pump and oil pan

Oil pump tip clearance mm 0.06 – 0.18 –

Oil pump side clearance mm 0.04 – 0.10 –

Oil pump body clearance mm 0.10 – 0.18 0.35

Piston and connecting rod

Piston ring to piston ring groove clearance

mm

No 1 0.03 – 0.07 0.1mm

No 2 0.02 – 0.06 0.1Piston ring end gap

mm

No 1 4G92, 4G93 0.25 – 0.40 0.8mm

4G94 0.15 – 0.30 0.8

Oil ring SOHC (4G92, 4G93) 0.20 – 0.60 1.0

SOHC (4G94), DOHC

0.10 – 0.35 1.0Crankshaft pin oil clearance mm 0.02 – 0.05 0.1

Piston pin press-in load N [Room temperature] 4,500 – 14,700 –

Connecting rod big end side clearance mm 0.10 – 0.25 0.4

Piston O.D mm 4G92, 4G93 81.0 –

Crankshaft, cylinder block, flywheel and drive plate

Crankshaft journal oil clearance mm 0.02 – 0.04 0.1

Cylinder block gasket surface flatness mm 0.05 0.1

Grinding limit of cylinder block gasket surface mm

*Total resurfacing depth of both cylinder head and cylinder block

PWEE9502-I

EMitsubishi Motors Corporation Mar 2001 Revised

Trang 9

Cylinder block overall height mm 4G92 243.5 –

Cylinder block I.D mm 4G92, 4G93 81.0 –

Piston to cylinder clearance mm 0.02 – 0.04 –

Bearing cap bolt shank length mm – 71.1

Crankshaft end play mm 0.05 – 0.25 0.4

REWORK DIMENSIONS

Cylinder head and valve

Oversize rework dimensions of valve guide hole (both intake and

exhaust) mm

0.05 O.S 11.05 – 11.07exhaust) mm

0.25 O.S 11.25 – 11.270.50 O.S 11.50 – 11.52Oversize rework dimensions of intake valve

seat hole mm

SOHC 0.30 O.S 31.80 – 31.83seat hole mm

0.60 O.S 32.10 – 32.13DOHC 0.30 O.S 34.30 – 34.32

0.60 O.S 34.60 – 34.62Oversize rework dimensions of exhaust valve

seat hole mm

SOHC 0.30 O.S 29.30 – 29.32seat hole mm

0.60 O.S 29.60 – 29.62DOHC 0.30 O.S 30.80 – 30.82

0.60 O.S 31.10 – 31.13

Crankshaft, flywheel and drive plate

Crankshaft out of roundness and taper of journal and pin mm 0.005

NOTE

O.D.: Outer diameter

I.D.: Inner diameter

O.S.: Oversize diameter

PWEE9502-I

EMitsubishi Motors Corporation Mar 2001 Revised

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Alternator and ignition system

Power steering pump pulley 25

Power steering pump bracket stay 49

Power steering pump bracket (M8) 21

Power steering pump bracket (M10) 44

Ignition failure sensor (M6) 5

Ignition failure sensor (M8) 23

Ignition failure sensor bracket 10

Cam position sensor support 13

Cam position sensing cylinder 21

Timing belt

Timing belt rear upper cover 11

Engine support bracket, right 49

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Cover <Without EGR valve> 12

Throttle body stay <MIVEC> 23

Throttle body stay <4G94> 24

Vacuum hose and pipe assembly <Engine with solenoid valve> (Flange bolt) 11

Vacuum hose and pipe assembly <Engine with solenoid valve> (Bolt and

washer assembly)

9Vacuum hose and pipe assembly <Engine without solenoid valve> 10

Throttle body and EGR system (GDI)

Intake manifold stay (M8) 20

Intake manifold stay (M10) 30

Throttle body stay

<CARISMA from 2001 model, SPACE STAR from 2001 model, GALANT>

24Throttle body stay <For PAJERO io – 4G94> 18

EGR valve (Bolt and washer assembly) 18

PWEE9502-I

EMitsubishi Motors Corporation Mar 2001 PWEE9502-K Revised

EMitsubishi Motors Corporation Jun 2002 Revised

Trang 12

Exhaust manifold bracket (M8) 19

Exhaust manifold bracket (M10 Bolt and washer assembly) 35

Exhaust manifold bracket (M10 Flange bolt) 98

Engine hanger (Bolt with head mark “4”) 12

Engine hanger (Bolt with head mark “7”) 19

Intake manifold (GDI)

Vacuum pipe and hose <Except for PAJERO io> 11

Vacuum pipe and hose <For PAJERO io> 9

Accelerator cable bracket 9

Exhaust manifold (GDI)

Exhaust manifold bracket (M8 × 20) 18

Exhaust manifold bracket (M8 × 22) 35

Exhaust manifold bracket (M8 × 25) 19

Exhaust manifold bracket (M10) 35

Exhaust manifold bracket <For PAJERO io> 98

PWEE9502-K

EMitsubishi Motors Corporation Jun 2002 Revised

Trang 13

Injector and fuel pump assembly (GDI)

Fuel low pressure pipe (M6) 18

Fuel low pressure pipe (M8) 9

Fuel high pressure regulator 18

Fuel pressure sensor <Except for PAJERO io> 23

Fuel pressure sensor <For PAJERO io> 18

Delivery pipe and injector 11

Intake and exhaust manifold <4G94–GDI for PAJERO io>

Intake manifold stay nut 29

Intake manifold stay bolt 31

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Water inlet fitting <Except PAJERO io> 19

Water inlet fitting <PAJERO io> 24

Water outlet fitting <Except PAJERO io> 19

Water outlet fitting <PAJERO io> 24

Engine coolant temperature gauge unit 10

Engine coolant temperature sensor 29

Rocker cover and camshafts (MIVEC)

Camshaft bearing cap (M6) 11

Camshaft bearing cap (M8) 23

Rocker arms and rocker shaft caps (MIVEC)

Cylinder head and valves

CylInder head bolt 74 Nm and then completely loosen,

finally tighten 20 Nm + 90_ + 90_

Front case and oil pump

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Baffle plate <DOHC–MPI> 7

Baffle plate <Except DOHC–MPI> 11

Piston and connecting rod

Connecting rod cap nut 20 + 90_ to 100_

Crankshaft, cylinder block, flywheel and drive plate

Bearing cap bolt 25 + 90_ to 100_

Bell housing cover (Flange bolt) 10

Bell housing cover (Bolt and washer assembly) 9

Rear plate <SPACE STAR> 10

Rear plate <Except SPACE STAR> 11

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Α νεω τψπε οφ βολτσ, το βε τιγητενεδ ιν πλαστιχ αρεα, ισ χυρρεντλψ υσεδ φορ σοmε παρτσ οφ τηε ενγινε.Τηε τιγητενινγ mετηοδ φορ βολτσ οφ τηισ τψπε ισ διφφερεντ φροm τηε χονϖεντιοναλ ονε Βε συρε το οβσερϖετηε mετηοδ δεσχριβεδ ιν τηε τεξτ ωηεν τιγητενινγ τηε βολτσ.

Σερϖιχε λιmιτσ αρε προϖιδεδ φορ τηε βολτσ Μακε συρε τηατ τηε σερϖιχε λιmιτσ δεσχριβεδ ιν τηε τεξτ αρε στριχτλψοβσερϖεδ

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α βεαδ, ον τηε οτηερ ηανδ, χουλδ βε σθυεεζεδ ουτ οφ λοχατιον, χαυσινγ βλοχκινγ ορ ναρροωινγ οφ τηεφλυιδ φεεδ λινε Το ελιmινατε τηε ποσσιβιλιτψ οφ λεακσ φροm α ϕοιντ, τηερεφορε, ιτ ισ αβσολυτελψ νεχεσσαρψ τοαππλψ τηε γασκετ εϖενλψ ωιτηουτ α βρεακ, ωηιλε οβσερϖινγ τηε χορρεχτ βεαδ σιζε.

Τηε ΦΙΠΓ υσεδ ιν τηε ενγινε ισ α ροοm τεmπερατυρε ϖυλχανιζατιον (ΡΤς) τψπε ανδ ισ συππλιεδ ιν α 100−γραmτυβε (Παρτ Νο ΜD970389 ορ ΜD997110) Σινχε τηε ΡΤς ηαρδενσ ασ ιτ ρεαχτσ ωιτη τηε mοιστυρε ιν τηεατοmοσπηεριχ αιρ, ιτ ισ νορmαλλψ υσεδ ιν τηε mεταλλιχ φλανγε αρεασ Τηε ΦΙΠΓ, Παρτ Νο ΜD970389, χαν

βε υσεδ φορ σεαλινγ βοτη ενγινε οιλ ανδ χοολαντ, ωηιλε Παρτ Νο 997110 χαν ονλψ βε υσεδ φορ ενγινεοιλ σεαλινγ

Disassembly

Τηε παρτσ ασσεmβλεδ ωιτη τηε ΦΙΠΓ χαν βε εασιλψ δισασσεmβλεδ ωιτηουτ υσε οφ α σπεχιαλ mετηοδ Ινσοmε χασεσ, ηοωεϖερ, τηε σεαλαντ βετωεεν τηε ϕοινεδ συρφαχεσ mαψ ηαϖε το βε βροκεν βψ λιγητλψ στρικινγωιτη α mαλλετ ορ σιmιλαρ τοολ Α φλατ ανδ τηιν γασκετ σχραπερ mαψ βε λιγητλψ ηαmmερεδ ιν βετωεεν τηεϕοινεδ συρφαχεσ Ιν τηισ χασε, ηοωεϖερ, χαρε mυστ βε τακεν το πρεϖεντ δαmαγε το τηε ϕοινεδ συρφαχεσ.Φορ ρεmοϖαλ οφ τηε οιλ παν, τηε σπεχιαλ τοολ “Οιλ Παν Ρεmοϖερ” (ΜD998727) ισ αϖαιλαβλε Βε συρε το υσετηε σπεχιαλ τοολ το ρεmοϖε τηε οιλ παν <Εξχεπτ αλυmινιυm διε−χαστ οιλ πανσ>

Surface Preparation

Τηορουγηλψ ρεmοϖε αλλ συβστανχεσ δεποσιτεδ ον τηε γασκετ αππλιχατιον συρφαχεσ, υσινγ α γασκετ σχραπερ

ορ ωιρε βρυση Χηεχκ το ενσυρε τηατ τηε συρφαχεσ το ωηιχη τηε ΦΙΠΓ ισ το βε αππλιεδ ισ φλατ Μακε συρετηατ τηερε αρε νο οιλσ, γρεασεσ ανδ φορειγν συβστανχεσ δεποσιτεδ ον τηε αππλιχατιον συρφαχεσ Dο νοτφοργετ το ρεmοϖε τηε ολδ σεαλαντ ρεmαινεδ ιν τηε βολτ ηολεσ

Form-In-Place Gasket Application

Wηεν ασσεmβλινγ παρτσ ωιτη τηε ΦΙΠΓ, ψου mυστ οβσερϖε σοmε πρεχαυτιονσ, βυτ τηε προχεδυρεσ ισ ϖερψσιmπλε ασ ιν τηε χασε οφ α χονϖεντιοναλ πρεχυτ γασκετ

Αππλιεδ ΦΙΠΓ βεαδ σηουλδ βε οφ τηε σπεχιφιεδ σιζε ανδ ωιτηουτ βρεακσ Αλσο βε συρε το ενχιρχλε τηεβολτ ηολε χιρχυmφερενχε ωιτη α χοmπλετελψ χοντινυουσ βεαδ Τηε ΦΙΠΓ χαν βε ωιπεδ αωαψ υνλεσσ ιτ ισηαρδενεδ Wηιλε τηε ΦΙΠΓ ισ στιλλ mοιστ (ιν λεσσ τηαν 15 mινυτεσ), mουντ τηε παρτσ ιν ποσιτιον Wηεντηε παρτσ αρε mουντεδ, mακε συρε τηατ τηε γασκετ ισ αππλιεδ το τηε ρεθυιρεδ αρεα ονλψ Ιν αδδιτιον, δονοτ αππλψ ανψ οιλ ορ ωατερ το τηε σεαλινγ λοχατιονσ ορ σταρτ τηε ενγινε υντιλ α συφφιχιεντ αmουντ οφ τιmε(αβουτ ονε ηουρ) ηασ πασσεδ αφτερ ινσταλλατιον ισ χοmπλετεδ

Τηε ΦΙΠΓ αππλιχατιον προχεδυρε mαψ ϖαρψ ον διφφερεντ αρεασ Οβσερϖε τηε προχεδυρε δεσχριβεδ ιν τηετεξτ ωηεν αππλψινγ τηε ΦΙΠΓ

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Χοmπρεσσιον οφ ϖαλϖε σπρινγ (ΜΙςΕΧ)(Υσε ωιτη ΜD998772)

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4G9 ENGINE (E–W) – Alternator and Ignition System 11A-3-1

3 ALTERNATOR AND IGNITION SYSTEM

REMOVAL AND INSTALLATION <SOHC> (Engines with distributor)

21 Nm

44 Nm 11

AA" "BA 4 Crankshaft bolt

"BA 5 Crankshaft pulley

"BA 6 Front flange

7 Spark plug cable

8 Spark plug

9 O-ring

10 Distributor

11 Power steering pump pulley

12 Power steering pump bracket stay

13 Power steering pump bracketNOTE:

*: For details of adjustment, refer to the relevant model’schassis workshop manual

PWEE9502-J

EMitsubishi Motors Corporation Apr 2002 Revised

Trang 22

REMOVAL AND INSTALLATION <SOHC for other than PAJERO io>

(Engines without distributor)

2

8

7

9 Nm 11

4

1

5 6

182 ± 4 Nm

21 Nm

44 Nm 14

AA" "BA 4 Crankshaft bolt

"BA 5 Crankshaft pulley

"BA 6 Front flange

7 Spark plug cable

8 Ignition coil

9 Spark plug

10 Ignition failure sensor (From 2001

model vehicles for Europe)

11 Cam position sensor

"AA 12 Cam position sensor support

13 Cam position sensing cylinder

14 Power steering pump pulley

15 Power steering pump bracket stay

16 Power steering pump bracketNOTE:

*: For details of adjustment, refer to the relevant model’schassis workshop manual

PWEE9502-J

EMitsubishi Motors Corporation Apr 2002 Revised

Trang 23

4G9 ENGINE (E–W) – Alternator and Ignition System 11A-3-2a

REMOVAL AND INSTALLATION <SOHC for PAJERO io>

(Engines without distributor)

9 Nm 12

4 1

5 6

10 Nm

21 Nm 9

14

13 8

25 Nm

44 Nm

49 Nm

10 11

AA" "BA 4 Crankshaft bolt

"BA 5 Crankshaft pulley

"BA 6 Front flange

7 Spark plug cable

8 Ignition coil

9 Spark plug

10 Ignition failure sensor (For Europe)

11 Ignition failure sensor bracket (For Europe)

12 Cam position sensor

"AA 13 Cam position sensor support

14 Cam position sensing cylinder

15 Power steering pump pulley

16 Power steering pump bracket stay

17 Power steering pump bracketNOTE

*: For details of adjustment, refer to the relevant model’schassis workshop manual

PWEE9502-K

EMitsubishi Motors Corporation Jun 2002 Revised

Trang 25

EMitsubishi Motors Corporation Nov 1995

REMOVAL AND INSTALLATION <DOHC>

AA" "BA 4 Crankshaft bolt

"BA 5 Crankshaft pulley

"BA 6 Front flange

7 Center cover

8 Ignition coil

9 Spark plug cable

10 Spark plug

11 Ignition failure sensor

12 Power steering pump pulley

13 Power steering pump bracket stay

14 Power steering pump bracketNOTE:

*: For details of adjustment, refer to the relevant model’schassis workshop manual

PWEE9502-J

EMitsubishi Motors Corporation Apr 2002 Revised

Trang 26

EMitsubishi Motors Corporation Nov 1995 Added

REMOVAL AND INSTALLATION <DOHC–MIVEC>

4 1

AA" "BA 4 Crankshaft bolt

"BA 5 Crankshaft pulley

"BA 6 Front flange

7 Center cover

8 Spark plug cable

9 Ignition coil

10 Spark plug

11 Cam position sensor

"AA 12 Cam position sensor support

13 Cam position sensing cylinder

14 Power steering pump pulley

15 Power steering pump bracket stay

16 Power steering pump bracketNOTE:

*: For details of adjustment, refer to the relevant model’schassis workshop manual

PWEE9502-J

EMitsubishi Motors Corporation Apr 2002 Revised

Trang 27

EMitsubishi Motors Corporation Nov 1995

REMOVAL AND INSTALLATION

<DOHC–GDI for CARISMA, SPACE STAR, SPACE RUNNER, GALANT>

13 Nm 10

14 5 Nm

8

21 Nm 17

44 Nm 15

AA" "BA 4 Crankshaft bolt

"BA 5 Crankshaft pulley

"BA 6 Front flange

7 Engine cover

8 Earth strap (From 2001 model forCARISMA, From 2001 model forSPACE STAR)

9 Ignition coil

10 Spark plug

11 Cam position sensor

"AA 12 Cam position sensor support

13 Cam position sensing cylinder

14 Ignition failure sensor (From 2001model for CARISMA, From 2001model for SPACE STAR)

15 Power steering pump pulley

16 Power steering pump bracket stay

17 Power steering pump bracketNOTE:

*: For details of adjustment, refer to the relevant model’schassis workshop manual

PWEE9502-J

EMitsubishi Motors Corporation Apr 2002 Revised

Trang 28

EMitsubishi Motors Corporation Nov 1995 Added

REMOVAL AND INSTALLATION <DOHC–GDI for PAJERO io>

1 5

Removal steps

1 Oil level gauge

2 Oil level gauge guide

3 O-ring

4 Drive belt*

5 Alternator

6 Alternator brace

AA" "BA 7 Crankshaft bolt

"BA 8 Crankshaft pulley

"BA 9 Front flange

10 Power steering pump pulley

11 Power steering pump bracket stay

12 Power steering pump bracket

13 Ignition coil

14 Spark plug

15 Cam position sensor

"AA 16 Cam position sensor support

17 Cam position sensing cylinderNOTE:

*: For details of adjustment, refer to the relevant model’schassis workshop manual

PWEE9502-I

EMitsubishi Motors Corporation Mar 2001 Revised

Trang 29

EMitsubishi Motors Corporation Nov 1995

REMOVAL SERVICE POINT

AA"CRANKSHAFT BOLT REMOVAL

(1) Use the special tool to hold the flywheel or the driveplate, and then loosen the crankshaft mounting bolts

INSTALLATION SERVICE POINTS

"AACAM POSITION SENSOR SUPPORT INSTALLATION

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

(3) Clean the bolt hole in the crankshaft, the crankshaftcontacting surface and washer contacting surface of thecrankshaft pulley, and the washer

(4) Apply an appropriately small amount of oil to the threadsand seating surface of the crankshaft bolt

(5) Tighten the crankshaft bolt to the specified torque of 182

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REMOVAL AND INSTALLATION <SOHC for CARISMA (Up to 1999 model),

LANCER (Except from 2001 model for Europe), GALANT>

14

13

Removal steps

1 Timing belt front upper cover

2 Timing belt front lower cover

3 Engine support bracket, right

AA" "DA 4 Timing belt

"CA 5 Tensioner spring

"BA 6 Timing belt tensioner

7 Timing belt rear cover

8 Crankshaft angle sensor (Engines without distributor)

"GA 9 Crankshaft sprocket

"GA10 Crankshaft spacer

(Engines without distributor)

"GA 11 Crankshaft sensing blade

(Engines without distributor)

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REMOVAL AND INSTALLATION

<SOHC for CARISMA (From 2000 model), LANCER (From 2001 model for

Europe), SPACE STAR>

1 Timing belt front upper cover

2 Timing belt front lower cover

3 Engine support bracket, right

AA" "DA 4 Timing belt

"CA 5 Tensioner spring

"BA 6 Timing belt tensioner

7 Timing belt rear cover

8 Crankshaft angle sensor (Engines without distributor)

"GA 9 Crankshaft sprocket

"GA10 Crankshaft spacer

(Engines without distributor)

"GA 11 Crankshaft sensing blade

(Engines without distributor)

Trang 33

1 Timing belt front upper cover

2 Timing belt front lower cover

3 Accessory mount

AA" "DA 4 Timing belt

"CA 5 Tensioner spring

"BA 6 Timing belt tensioner

7 Timing belt rear cover

8 Crankshaft angle sensor

"GA 9 Crankshaft sprocket

"GA10 Crankshaft spacer

"GA 11 Crankshaft sensing blade

Trang 34

24 Nm

Removal steps

1 Timing belt upper cover

2 Timing belt lower cover

3 Engine support bracket

AA" "FA 4 Timing belt

11 Cam position sensor

12 Crankshaft angle sensor

"GA13 Crankshaft sprocket

"GA14 Crankshaft spacer

"GA15 Crankshaft sensing blade

16 Crankshaft sprocket key

AB" "AA 17 Camshaft sprocket bolt

18 Camshaft sprocket

19 Timing belt rear cover

20 Timing belt rear cover

PWEE9502-I

EMitsubishi Motors Corporation Mar 2001 Revised

Trang 35

1 Timing belt front upper cover

2 Timing belt front lower cover

3 Engine support bracket, right

AA" "FA 4 Timing belt

5 Tensioner pulley

6 Tensioner arm

7 Shaft

"EA 8 Auto tensioner

9 Timing belt rear cover

10 Idler pulley

11 Crankshaft angle sensor

"GA12 Crankshaft sprocket

"GA13 Crankshaft spacer

"GA14 Crankshaft sensing blade

15 Crankshaft key

AB" "AA 16 Camshaft sprocket bolt

17 Camshaft sprocket

18 Timing belt rear cover

19 Timing belt rear cover

PWEE9502-I

EMitsubishi Motors Corporation Mar 2001 Revised

Trang 36

REMOVAL AND INSTALLATION

<DOHC–GDI for CARISMA, SPACE STAR, SPACE RUNNER>

14 16

Removal steps

1 Timing belt front upper cover

2 Timing belt front lower cover

3 Engine support bracket, right

AA" "FA 4 Timing belt

5 Tensioner pulley

6 Tensioner arm

7 Shaft

"EA 8 Auto tensioner

9 Timing belt rear cover

"GA13 Crankshaft sprocket

"GA14 Crankshaft spacer

"GA15 Crankshaft sensing blade

Trang 37

13 15

48 Nm

16

Removal steps

1 Timing belt front upper cover

2 Timing belt front lower cover

3 Engine support bracket, right

AA" "FA 4 Timing belt

5 Tensioner pulley

6 Tensioner arm

7 Shaft

"EA 8 Auto tensioner

9 Timing belt rear cover

10 Idler pulley

11 Crankshaft angle sensor

"GA12 Crankshaft sprocket

"GA13 Crankshaft spacer

"GA14 Crankshaft sensing blade

Trang 38

1 Timing belt front upper cover

2 Timing belt front lower cover

"EA 8 Auto tensioner

9 Timing belt rear cover

10 Idler pulley

11 Bracket

12 Crankshaft angle sensor

"GA13 Crankshaft sprocket

"GA14 Crankshaft spacer

"GA15 Crankshaft sensing blade

16 Crankshaft key

AB" "AA 17 Camshaft sprocket bolt

18 Camshaft sprocket

19 Timing belt rear cover <4G93>

20 Timing belt rear cover <4G93>

21 Timing belt rear upper cover

<4G94>

PWEE9502-I

EMitsubishi Motors Corporation Mar 2001 Revised

Trang 40

ΕMitsubishi Motors Corporation Nov 1995 Revised

REMOVAL SERVICE POINTS

ΑATIMING BELT REMOVAL

(1) Μαρκ βελτ ρυννινγ διρεχτιον φορ ρεινσταλλατιον

ΑBCAMSHAFT SPROCKET BOLT REMOVAL

<With rocker cover removed> (Except SOHC)

(1) Υσε α ωρενχη το ηολδ τηε ηεξαγοναλ παρτ οφ τηε χαmσηαφτ,ανδ τηεν ρεmοϖε τηε χαmσηαφτ σπροχκετ mουντινγ βολτ

INSTALLATION SERVICE POINTS

AΑCAMSHAFT SPROCKET BOLT INSTALLATION

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