Mitsubishi Engine 4G6

11A-0-1
ENGINE
4G6 SERIES
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-0-3 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-4 NEW TIGHTENING METHOD BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA . . 11A-1-9 SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-9 FORM-IN-PLACE GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-10 2. SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-2-1 3. ALTERNATOR AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 11A-3-1 3a. INTAKE MANIFOLD (GDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-3a-1 4. TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-4-1 4a. EXHAUST MANIFOLD (GDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-4a-1 5. FUEL AND EMISSION CONTROL PARTS . . . . . . . . . . . . . . . . . . . . . . 11A-5-1 5a. FUEL PARTS (GDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-5a-1 6. WATER PUMP AND INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . 11A-6-1 6a. WATER PUMP AND WATER HOSE (GDI) . . . . . . . . . . . . . . . . . . . . . 11A-6a-1 7. EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-7-1 8. ROCKER ARMS AND CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-8-1 8a. ROCKER ARMS AND CAMSHAFTS (GDI) . . . . . . . . . . . . . . . . . . . 11A-8a-1 9. CYLINDER HEAD AND VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-9-1 10. FRONT CASE, COUNTERBALANCE SHAFTS AND OIL PAN 11A-10-1 11. PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-11-1 12. CRANKSHAFT, FLYWHEEL AND DRIVE PLATE . . . . . . . . . . . . . 11A-12-1
E Mitsubishi Motors Corporation
Aug. 1998
PWEE9616-A
Revised
11A-0-2
NOTES
Dec. 1996
PWEE9616
4G6 ENGINE <E - W> - General Information
11A-0-3
GENERAL INFORMATION
SOHC-4G63
Descriptions Type Number of cylinders Combustion chamber Total displacement dm3 Cylinder bore mm Piston stroke mm Compression ratio Valve timing Intake valve Opens (BTDC) Closes (ABDC) Exhaust valve Opens (BBDC) Closes (ATDC) Lubrication system Oil pump type Specifications In-line OHV, SOHC 4 Pentroof type 1,997 85.0 88.0 10 18_ 58_ 58_ 18_ Pressure feed, full-flow filtration Involute gear type
SOHC-4G64
Descriptions Type Number of cylinders Combustion chamber Total displacement dm3 Cylinder bore mm Piston stroke mm Compression ratio Valve timing Intake valve Opens (BTDC) Closes (ABDC) Exhaust valve Opens (BBDC) Closes (ATDC) Lubrication system Oil pump type Specifications In-line OHV, SOHC 4 Pentroof type 2,351 86.5 100.0 10 16_ 53_ 50_ 16_ Pressure feed, full-flow filtration Involute gear type
Aug. 1998
PWEE9616-A
Revised
11A-0-4
GDIt
Descriptions Type Number of cylinders Combustion chamber Total displacement dm3 Cylinder bore mm Piston stroke mm Compression ratio Valve timing
4G6 ENGINE <E - W> - General Information
Specifications In-line OHV, SOHC 4 Pentroof + curved top piston type 2,351 86.5 100.0 11.5 Intake valve Opens (BTDC) Closes (ABDC) Exhaust valve Opens (BBDC) Closes (ATDC) 16_ 60_ 56_ 16_ Pressure feed, full-flow filtration Involute gear type
Lubrication system Oil pump type
NOTE GDI is a trademark of Mitsubishi Motors Corporation.
Aug. 1998
PWEE9616-A
Added
4G6 ENGINE <E - W> - Specifications
11A-1-1
1. SPECIFICATIONS
SERVICE SPECIFICATIONS
Items Timing belt Auto-tensioner rod projection length mm Auto-tensioner rod pushed-in amount [when pushed with a force of 98 - 196 N] mm Rocker arms and camshaft Camshaft cam height mm 4G63 SOHC 4G64 SOHC Lash adjuster leak down time [diesel fuel at 15 - 20_C] seconds/mm Camshaft journal outer diameter mm Rocker arms and camshaft (GDI) Camshaft cam height mm Intake Exhaust Lash adjuster leak down time [diesel fuel at 15 - 20_C] seconds/mm Camshaft journal outer diameter mm Cylinder head and valves Cylinder head flatness of gasket surface mm Cylinder head grinding limit of gasket surface mm Total resurfacing depth of both cylinder head and cylinder block Cylinder head overall height mm SOHC GDI Cylinder head bolt shank length mm Valve thickness of valve head (margin) mm SOHC Intake Exhaust GDI Intake Exhaust Valve overall height mm SOHC Intake Exhaust GDI Intake Exhaust Valve stem outer diameter mm
Aug. 1998 PWEE9616-A
Standard value
Limit
12 1.0 or less
Intake Exhaust Intake Exhaust
37.39 37.14 37.39 36.83 3 - 20/1.0 45
36.89 36.64 36.89 36.33 -
35.79 37.14 3 - 20/1.0 26
35.29 36.64 -
Less than 0.05 120 132 1.0 1.2 1.0 1.5 112.30 114.11 105.5 105.7 6.0
0.2 0.2 Maximum 99.4 0.5 0.7 0.5 1.0 111.80 113.61 105.0 105.2 Revised
11A-1-2
Items

Standard value SOHC Intake Exhaust GDI Intake Exhaust 0.02 - 0.05 0.03 - 0.07 0.02 - 0.05 0.05 - 0.09 45_ - 45.5_ SOHC GDI 51.0 48.3 267/44.2 294/40.0 2_ or less 1.5_ or less 0.9 - 1.3 SOHC GDI 6.0 6.6 14.0 19.5 49.30 Intake Exhaust 49.20 48.40 11.05 - 11.07 11.25 - 11.27 11.50 - 11.52 12.05 - 12.07 12.25 - 12.27 12.50 - 12.52 34.30 - 34.33 34.60 - 34.63 35.30 - 35.33 35.60 - 35.63 34.30 - 34.33 34.60 - 34.63 33.30 - 33.33 33.60 - 33.63 Limit 0.10 0.15 0.10 0.15 50.0 47.3 Maximum 4_ Maximum 4_ 49.80 49.70 48.90 -
Valve thickness to valve guide clearance mm
Valve face angle mm Valve spring free length mm
Valve spring load/installed height N/mm
SOHC GDI
Valve spring out-of-squareness
SOHC GDI
Valve seat valve contact width mm Valve guide inner diameter mm
Valve guide projection from cylinder head upper surface mm Valve stem projection mm
SOHC GDI SOHC GDI
Oversize rework dimensions of valve guide hole (SOHC) mm
0.05 Oversize diameter 0.25 Oversize diameter 0.50 Oversize diameter
Oversize rework dimensions of valve guide hole (GDI) mm
0.05 Oversize diameter 0.25 Oversize diameter 0.50 Oversize diameter
Intake oversize rework dimensions of valve seat hole (SOHC) mm Intake oversize rework dimensions of valve seat hole (GDI) mm Exhaust oversize rework dimensions of valve seat hole (SOHC) mm Exhaust oversize rework dimensions of valve seat hole (GDI) mm
0.3 Oversize diameter 0.6 Oversize diameter 0.3 Oversize diameter 0.6 Oversize diameter 0.3 Oversize diameter 0.6 Oversize diameter 0.3 Oversize diameter 0.6 Oversize diameter
Aug. 1998
PWEE9616-A
Revised

Items Front case, counterbalance shaft and oil pan Oil pump side clearance mm Drive gear Driven gear Oil pressure at curb idle speed kPa [Oil temperature is 75 to 90_C] Piston and connecting rod Piston outer diameter mm 4G63 4G64 Piston ring side clearance mm No. 1 No. 2 Piston ring end gap mm No. 1 No. 2 Oil ring side rail Piston pin outer diameter mm Piston pin press-in load N (Room temperature) Crankshaft pin oil clearance mm Connecting rod big end side clearance mm Crankshaft, flywheel and drive plate Crankshaft end play mm Crankshaft journal outer diameter mm Crankshaft pin outer diameter mm Crankshaft journal oil clearance mm Bearing cap bolt shank length mm Piston to cylinder clearance mm Cylinder block flatness of gasket surface mm Cylinder block grinding limit of gasket surface mm Total resurfacing depth of both cylinder head and cylinder block Cylinder block overall height mm 4G63 4G64 Cylinder block inner diameter mm 4G63 4G64 Cylindricity mm 0.05 - 0.25 57.0 45.0 0.02 - 0.04 0.02 - 0.04 0.05 284 290 85.0 86.5 0.01 0.40 0.1 85.0 86.5 0.02 - 0.06 0.02 - 0.06 0.25 - 0.35 0.40 - 0.55 0.10 - 0.40 22.0 7,350 - 17,200 0.02 - 0.05 0.10 - 0.25 0.1 0.1 0.8 0.8 1.0 0.1 0.4 0.08 - 0.14 0.06 - 0.12 78 or more Standard value Limit
11A-1-3
Maximum 71.1 0.1 0.2 -
Aug. 1998
PWEE9616-A
Revised
11A-1-4
Items
TORQUE SPECIFICATIONS
Nm
Alternator and ignition system Water pump pulley Adjusting bolt Lock bolt Alternator brace Alternator pivot nut Crankshaft pulley Ignition coil (Multipoint fuel injection) Spark plug Distributor (Carburetor) Camshaft position sensing cylinder (Multipoint fuel injection) Camshaft position sensor support (Multipoint fuel injection) Camshaft position sensor (Multipoint fuel injection) Oil level gauge guide Idler pulley bracket (M8) (Vehicle for Hong Kong) Idler pulley bracket (M10) (Vehicle for Hong Kong) Idler pulley (Vehicle for Hong Kong) Intake manifold (GDI) Vacuum pipe and hose (Flange bolt) Vacuum pipe and hose (Bolt, washer assembly) Solenoid valve Vacuum pipe Throttle body Intake manifold stay (M6) Intake manifold stay (M8) Air intake plenum resonator (Flange bolt) Air intake plenum resonator (Bolt, washer assembly) EGR valve EGR valve support Intake manifold Timing belt Timing belt cover flange bolt
Aug. 1999 PWEE9616-B
9 10 22 23 44 25 10 25 12 22 14 10 13 22 49 49
11 8.8 8.8 11 11 8.8 30 11 8.8 23 23 19
11
Revised

Items Timing belt cover washer bolt Power steering bracket Crankshaft angle sensor (Multipoint fuel injection) Tensioner arm Tensioner puller Auto tensioner Idler pulley Engine support bracket Oil pump sprocket Crankshaft bolt Tensioner B Counterbalance shaft sprocket Camshaft sprocket bolt Exhaust manifold (GDI) Exhaust manifold cover Exhaust manifold (M10) Exhaust manifold (M8) Engine hanger Fuel and emission parts Carburetor (Carburetor) Fuel vapor separator (Carburetor) Throttle body (Multipoint fuel injection) EGR valve (Except General Export) Injectors and delivery pipe (Multipoint fuel injection) Fuel pressure regulator (Multipoint fuel injection) Fuel part (GDI) Fuel low pressure pipe (M6) Fuel low pressure pipe (M8) Fuel pump return nipple Clamp A Fuel pipe bracket Fuel feed pipe
11A-1-5
Nm 9 49 9 22 48 23 35 49 54 118 18 45 88
13 49 29 11
17 23 18 22 12 9
8.8 18 8.8 8.8 11 11
Aug. 1999
PWEE9616-B
Revised
11A-1-6
Items Fuel pump Harness bracket Fuel return pipe Fuel high pressure regulator Fuel pressure sensor Pump camshaft case Injector holder

Nm 4.9 17 2 8.8 11 18 18 23 22 11 11
Delivery pipe and injector assembly Engine hanger Water pump and intake manifold Engine coolant temperature sensor Engine coolant temperature gauge unit Water inlet fitting Thermostat housing Water inlet pipe Water pump Oil level gauge guide Intake manifold stay Intake manifold Engine hanger Detonation sensor (Multipoint fuel injection) Water pump and water hose (GDI) Engine coolant temperature sensor Engine coolant temperature gauge unit Water inlet fitting Water outlet fitting Thermostat housing Water inlet pipe Water pump Knock sensor Exhaust manifold Exhaust manifold cover
29 11 13 24 13 14 14 31 19 11 23
29 11 12 12 23 12 13 22
13
Aug. 1999
PWEE9616-B
Revised

Items Heat protector Exhaust manifold (M8) Exhaust manifold (M10) Water outlet fitting Rocker arms and camshaft Rocker cover Rocker arm shaft Rocker arms and camshafts (GDI) Camshaft position sensor Cover Camshaft position sensing cylinder Camshaft position sensing support Beam camshaft cap Cylinder head and valves Cylinder head bolt [Tighten to 78 Nm and then completely loosen before finally tightening with above procedure.] Front case, counterbalance shaft and oil pan Drain plug Oil pan Oil level sensor (For Europe) Stiffener (For Europe) Oil screen Oil pressure switch (4G63) Oil pressure switch (4G64) Relief plug Oil filter bracket Plug Flange bolt Oil pump cover bolt Oil pump cover screw Front case Transmission stay (GDI engine) Oil level gauge guide
11A-1-7
Nm 13 29 49 13
3.4 31
8.8 9.8 21 13 20
20 + 90_ + 90_
39 6.9 8.8 21 18 19 9.8 44 18 23 36 16 9.8 23 21 12

Revised
11A-1-8
Items Oil pan lower Baffle plate Oil pan upper Piston and connecting rod Connecting rod cap

Nm 6.9 6.9 6.9
20 + 90_ 100_
Crankshaft, flywheel and drive plate Flywheel bolt Drive plate bolt Rear plate Bell housing cover Oil seal case bolt Bearing cap bolt 132 132 11 8.8 11 25 + 90_ 100_
Aug. 1999
PWEE9616-B
Revised
11A-1-9
NEW TIGHTENING METHOD - BY USE OF BOLTS TO 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 different from the conventional one. Be sure to observe the method described in the text when tightening the bolts. Service limits are provided for the bolts. Make sure that the service limits described in the text are strictly observed. D Areas where the bolts are in use: (1) Cylinder head bolts (2) Main bearing cap bolts (3) Connecting rod cap bolts Tightening method After tightening the bolts to the specified torque, tighten them another 90_ or 180_ (twice 90_). The tightening method varies on different areas. Observe the tightening method described in the text.
SEALANTS
Item Cam position sensor support Engine coolant temperature sensor Engine coolant temperature gauge unit Thermostat case Water outlet fitting Beam camshaft cap Cylinder head Oil pressure switch Oil pan Oil seal case Specified sealant Mitsubishi Genuine Part No. MD970389 or equivalent 3M Nut Locking Part No. 4171 or equivalent 3M ATD Part No. 8660 or equivalent Mitsubishi Genuine Part No. MD970389 or equivalent Mitsubishi Genuine Part No. MD970389 or equivalent Mitsubishi Genuine Part No. MD970389 or equivalent Mitsubishi Genuine Part No. MD970389 or equivalent 3M ATD Part No. 8660 or equivalent Mitsubishi Genuine Part No. MD970389 or equivalent Mitsubishi Genuine Part No. MD970389 or equivalent Quantity As required As required As required As required As required As required As required As required As required As required
Aug. 1998
PWEE9616-A
Added
11A-1-10
FORM-IN-PLACE GASKET
The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to apply the gasket evenly without a break, while observing the correct bead size. The FIPG used in the engine is a room temperature vulcanisation (RTV) type and is supplied in a 100-gram tube (Part No. MD970389). Since the RTV hardens as it reacts with the moisture in the atmospheric air, it is normally used in the metallic flange areas. The FIPG, Part No. MD970389, can be used for sealing both engine oil and coolant, while Part No. MD997110 can only be used for engine oil sealing. Disassembly The parts assembled with the FIPG can be easily disassembled without use of a special method. In some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces. For removal of the oil pan, the special tool Oil Pan Remover (MD998727) is available. Be sure to use the special tool to remove the oil pan. <Except aluminium die-cast oil pans> Surface Preparation Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure that there are no oils, greases and foreign substances deposited on the application surfaces. Do not forget to remove the old sealant remained in the bolt holes. Form-in-Place Gasket Application When assembling parts with the FIPG, you must observe some precautions, but the procedures is very simple as in the case of a conventional precut gasket. Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time (about one hour) has passed after installation is completed. The FIPG application procedure may vary on different areas. Observe the procedure described in the text when applying the FIPG.
Aug. 1998
PWEE9616-A
Added
4G6 ENGINE (E - W) - Special Tools
11A-2-1
2. SPECIAL TOOLS
Tool Number MB990767 Name Crankshaft pulley holder Use 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 rear bearing Use with MD998372.
MB991654
Cylinder head bolt wrench (12)
Removal and installation of cylinder head bolt
MD998162
Plug wrench
Removal and installation of front case cap plug Use with MD998783.
MD998285
Crankshaft front oil seal guide
Guide for installation of crankshaft front oil seal Use with MD998375.
MD998371
Silent shaft bearing puller
Removal of counterbalance shaft front bearing
MD998372
Silent shaft bearing puller
Removal of counterbalance shaft rear bearing
MD998375
Crankshaft front seal installer
Installation of crankshaft front oil seal
Dec. 1996
PWEE9616
11A-2-2
Tool

Number MD998440 Name Leak down tester Use 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 installation of rocker shaft assembly
MD998705
Silent shaft bearing installer
Installation of counterbalance shaft front and rear bearing
MD998713
Camshaft oil seal installer
Installation of camshaft oil seal
MD998719
Pulley holder pin
Holding camshaft sprocket Use with MB990767.
MD998727
Oil pan remover
Removal of oil pan
MD998735
Valve spring compressor
Removal and installation of valve and related parts
Dec. 1996
PWEE9616

Tool Number MD998738 Name Set screw Use Adjustment of timing belt tension
11A-2-3
MD998767
Tensioner puller socket wrench
Adjustment of timing belt tension
MD998772
Valve spring compressor
Removal and installation of valve and related parts
MD998774
Valve stem seal installer
Installation of valve stem seal
MD998775
Valve stem seal installer
Installation of valve stem seal
MD998776
Crankshaft rear oil seal installer
Installation of crankshaft rear oil seal Use with MB990938.
MD998778
Crankshaft sprocket puller
Removal of crankshaft sprocket
MD998780
Piston setting tool
Removal and installation of piston pin
MD998781
Flywheel stopper
Holding of flywheel and drive plate
Aug. 1998
PWEE9616-A
Revised
11A-2-4
Tool

Number MD998783 Name Plug wrench retainer Use Removal and installation of front case cap plug
MD998785
Sprocket stopper
Holding silent shaft sprocket
Aug. 1998
PWEE9616-A
Added
4G6 ENGINE (E - W) - Alternator and Ignition System
11A-3-1
3. ALTERNATOR AND IGNITION SYSTEM

REMOVAL AND INSTALLATION <CARBURETOR>
6
12 Nm 25 Nm
7 10
10 Nm
3
44 Nm
22 Nm
2
24 Nm 9 Nm
25 Nm
Removal steps 1. Drive belt 2. Water pump pulley 3. Alternator brace 4. Alternator 5. Crankshaft pulley 6. Spark plug cable 7. Spark plug 8. High tension cable "BA 9. Distributor assembly 10. O-ring
Dec. 1996
PWEE9616
11A-3-2
4G6 ENGINE (E - W) - Alternator and Ignition System
REMOVAL AND INSTALLATION <MULTIPOINT FUEL INJECTION>
10 Nm
6 9
25 Nm
10 Nm
10
8 11
4
22 Nm 10 Nm
3
44 Nm 14 Nm
r
22 Nm 24 Nm 9 Nm
2 5
25 Nm
Removal steps 1. Drive belt 2. Water pump pulley 3. Alternator brace 4. Alternator 5. Crankshaft pulley 6. Spark plug cable
7. 8. 9. "AA 10. 11.
Ignition coil assembly Spark plug Camshaft position sensor Camshaft position sensing support Camshaft position sensing cylinder
Dec. 1996
PWEE9616
4G6 ENGINE (E - W) - Alternator and Ignition System REMOVAL AND INSTALLATION (GDI)
11A-3-3
9.8 Nm
11
25 Nm
12
49 Nm
7
9.8 Nm
22 Nm 23 Nm
8.8 Nm
5
13 Nm
8 9
49 Nm 25 Nm
2 3 10
49 Nm 22 Nm
Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Drive belt 5. Water pump pulley 6. Alternator 7. Alternator brace
8. Idler pulley bracket (Vehicle for Hong Kong) 9. Idler pulley (Vehicle for Hong Kong) 10. Crankshaft pulley 11. Ignition coil 12. Spark plug
Aug. 1999
PWEE9616-B
Revised
11A-3-4
4G6 ENGINE (E - W) - Alternator and Ignition System INSTALLATION SERVICE POINTS

"AA CAMSHAFT POSITION SENSOR SUPPORT INSTALLATION (1) Apply a 3 mm bead of form-in-place gasket (FIPG) to the area shown. Specified sealant: Mitsubishi Genuine equivalent Part No. MD970389 or
"BA DISTRIBUTOR ASSEMBLY INSTALLATION (1) Turn the crankshaft to bring No. 1 cylinder to the top dead center on compression stroke. (2) Align the mating marks on the distributor housing with that of the coupling key.
Stud bolt
(3) Install the distributor assembly on the engine while aligning the stud bolt used for securing the distributor with the slot in the mounting flange of the distributor.
Aug. 1998
PWEE9616-A
Added
4G6 ENGINE (E - W) - Intake Manifold (GDI)
11A-3a-1
3a. INTAKE MANIFOLD (GDI)

REMOVAL AND INSTALLATION (SPACE WAGON)
8.8 Nm
3
8.8 Nm
8.8 Nm 11 Nm
11 Nm
16 14
11 Nm
12 5 13 11 1
23 Nm
6
8.8 Nm
23 Nm
17 18 10 19
19 Nm
19 Nm
15
11 Nm 30 Nm
9
8.8 Nm 30 Nm
Removal steps 1. Vacuum pipe and hose (1999 model vehicles for Hong Kong) 2. Solenoid valve (1999 model vehicles for Hong Kong) 3. Vacuum pipe and hose (Vehicles for Europe and 2000 model vehicles for Hong Kong) 4. Solenoid valve (Vehicles for Europe and 2000 model vehicles for Hong Kong) 5. Vacuum pipe 6. Throttle body
"DA 7. Throttle body gasket "CA 8. Intake manifold stay "BA 9. Air intake plenum resonator 10. Gasket 11. Water hose 12. EGR valve 13. Gasket "AA 14. Hose clamp "AA 15. EGR support "AA 16. Gasket 17. Gasket 18. Intake manifold 19. Gasket
Revised
11A-3a-2
REMOVAL AND INSTALLATION (GALANT)
8.8 Nm 8.8 Nm
1 2 8
11 Nm
9 11
23 Nm
3 4
23 Nm 19 Nm
13 10 14 12
15 16
19 Nm 30 Nm
11 Nm 8.8 Nm
Removal steps 1. Vacuum pipe and hose 2. Solenoid valve 3. Throttle body "DA 4. Throttle body gasket "CA 5. Intake manifold stay "BA 6. Air intake plenum resonator 7. Gasket 8. Water hose
9. 10. "AA 11. "AA 12. "AA 13. 14. 15. 16.
EGR valve Gasket Hose clamp EGR support Gasket Gasket Intake manifold Gasket
Revised

Intake manifold side Cylinder head side
11A-3a-3
INSTALLATION SERVICE POINTS

"AA EGR SUPPORT / HOSE CLAMP / GASKET INSTALLATION (1) Install the gasket, EGR support and hose clamp to the cylinder head in that order and tighten the fasteners temporarily. (2) Install the EGR support assembly to the intake manifold with the gasket attached on the mating surface, and tighten the fasteners to the specified torque. (3) Tighten the fasteners on the cylinder head side to the specified torque. "BA AIR INTAKE PLENUM RESONATOR INSTALLATION (1) Install the mounting bolts on the throttle body side without fail.
Hose clamp
Intake manifold stay
"CA INTAKE MANIFOLD STAY INSTALLATION (1) Tighten the fasteners to the specified torque after confirming that the intake manifold stay is in close contact with the air intake plenum resonator and the cylinder block.
Air intake plenum resonator
"DA THROTTLE BODY GASKET INSTALLATION (1) Position the projection as shown in the illustration.
Projection
Aug. 1999
PWEE9616-B
Added
4G6 ENGINE (E - W) - Timing Belt
11A-4-1
4. TIMING BELT
REMOVAL AND INSTALLATION (SOHC)
20
45 Nm
18
45 Nm
17
16 15
18 Nm
14
23
88 Nm
13 19 7
22 21
9 Nm
22 Nm
48 Nm 49 Nm 49 Nm
14 Nm
6 12 8
23 Nm
4 10
54 Nm 118 Nm
11 9
35 Nm
11 Nm 9 Nm
AA" "KA "JA "IA AC" "HA AD" "GA
Removal steps 1. Timing belt front upper cover 2. Timing belt front lower cover 3. Power steering bracket 4. Crankshaft position sensor (Multipoint fuel injection) 5. Timing belt 6. Tensioner pulley 7. Tensioner arm 8. Auto tensioner 9. Idler pulley 10. Oil pump sprocket 11. Crankshaft bolt
AE"
AF" "FA AG" "EA "DA AH" "CA AI" "AA
12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
Crankshaft sprocket Flange (Multipoint fuel injection) Flange (Carburetor) Tensioner B Timing belt B Counterbalance shaft sprocket Spacer Crankshaft sprocket B Engine support bracket Camshaft sprocket bolt Camshaft sprocket Timing belt rear cover
Aug. 1999
PWEE9616-B
Revised
11A-4-2
REMOVAL AND INSTALLATION (GDI)

21 22 6
48 Nm
25
3.4 Nm
7 23 24
23 Nm
26 27
8 2
23 Nm
31
11 Nm
12
13
11 Nm
118 Nm 49 Nm 11 Nm
9 Nm
32
5 30
88 Nm 45 Nm 18 Nm
18 17
4
29
15
28 10 33
48 Nm
20 19
8.8 Nm 49 Nm
14 11
54 Nm
16
AB" "LA "JA "IA AC" "HA AD" "GA AE" AF" "FA AG" "EA
Removal steps 1. Front upper cover 2. Front lower cover 3. Power steering pump bracket stay 4. Power steering bracket 5. Timing belt 6. Tensioner pulley 7. Tensioner arm 8. Auto tensioner 9. Idle pulley 10. Crankshaft position sensor 11. Oil pump sprocket 12. Crankshaft bolt 13. Crankshaft sprocket 14. Flange 15. Tensioner B 16. Timing belt B 17. Counterbalance shaft sprocket
Aug. 1999
AH"
"DA 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. "CA 28. AJ" "BA 29. 30. 31. 32. 33.
Spacer Crankshaft sprocket B Crankshaft key Breather hose PCV hose PCV valve PCV valve gasket Oil filler cap Rocker cover Rocker cover gasket Engine support bracket Camshaft sprocket bolt Camshaft sprocket Timing belt rear right cover Timing belt rear left upper cover Timing belt rear left lower cover
Revised
PWEE9616-B
4G6 ENGINE (E - W) - Timing Belt REMOVAL SERVICE POINTS
11A-4-3
AA" TIMING BELT REMOVAL (1) Mark belt running direction for reinstallation. NOTE (1) Water 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 parts if seriously contaminated. (2) If there is oil or water on each part, check front case oil seals, camshaft oil seal and water pump for leaks.
AB" TIMING BELT REMOVAL (1) If the timing belt is to be reused, chalk an arrow mark on the back surface of the belt so that the belt can be reinstalled in the same direction. (2) Place the exhaust camshaft sprocket in a position where the timing mark for No. 1 cylinder is positioned about one tooth before the top dead center of the compression stroke.
Timing mark
Caution D The camshaft sprocket on the exhaust side can turn very easily because of the valve spring tension. Use care not to allow your fingers to get caught by the sprocket. (3) Loosen the lock nut of the tensioner pulley, then remove the timing belt.
AC" OIL PUMP SPROCKET REMOVAL (1) Remove the plug on the left side of cylinder block. (2) Insert a screwdriver (shank diameter 8 mm) to block the counterbalance shaft. (3) Remove the nut. (4) Remove the oil pump sprocket.
Aug. 1998
PWEE9616-A
Revised
11A-4-4

AD" CRANKSHAFT BOLT LOOSENING (1) Hold the drive plate with the special tool as shown. (2) Remove the crankshaft bolt.
AE" CRANKSHAFT SPROCKET REMOVAL (1) If it is difficult to remove the sprocket, use the special tool.
AF" TIMING BELT B REMOVAL (1) Make a mark on the back of the timing belt indicating the direction of rotation so it may be reassembled in the same direction if it is to be reused. NOTE (1) Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and water. These parts should not be washed. Replace parts if seriously contaminated. (2) If there is oil or water on each part check front case oil seals, camshaft oil seal and water pump for leaks.
6EN1322
MD998785
AG" COUNTERBALANCE SHAFT SPROCKET REMOVAL (1) Set the special tool as shown to prevent the counterbalance shaft sprocket from turning together. (2) Loosen the bolt and remove the sprocket.
Aug. 1998
PWEE9616-A
Revised
11A-4-5
AH" CRANKSHAFT SPROCKET B REMOVAL (1) If it is difficult to remove the sprocket, use the special tool.
AI" CAMSHAFT SPROCKET BOLT LOOSENING (1) Using the special tools shown in the illustration, lock the camshaft sprocket in position. (2) Loosen the camshaft bolt.
AJ" CAMSHAFT SPROCKET BOLT LOOSENING (1) Use a wrench to hold the hexagonal part of the camshaft, and then remove the camshaft sprocket mounting bolt.

"AA CAMSHAFT SPROCKET BOLT TIGHTENING (1) Using the special tools shown in the illustration, lock the camshaft sprocket in position. (2) Tighten the camshaft sprocket bolt to the specified torque.
"BA CAMSHAFT SPROCKET BOLT TIGHTENING (1) Using a wrench, hold the camshaft at its hexagon and tighten the bolt to the specification.
Aug. 1998
PWEE9616-A
Revised
11A-4-6

"CA ENGINE SUPPORT BRACKET INSTALLATION (1) Coat the bolts illustrated with sealant before tightening. Specified sealant: 3M ATD Part No. 8660 or equivalent
"DA SPACER INSTALLATION (1) Install the spacer with the chamfered end toward the oil seal.
Sharp edge
Counterbalance shaft
MD998785
"EA COUNTERBALANCE SHAFT SPROCKET INSTALLATION (1) Install the counterbalance shaft sprocket and screw the bolt. (2) Install special tool MD998785 as shown in the illustration to lock the counterbalance shaft. (3) Tighten the bolt, and then remove the special tool.
Timing marks (on front case)
Timing marks
"FA TIMING BELT B INSTALLATION (1) Align timing marks on the crankshaft sprocket B and counterbalance shaft sprocket with the marks on the front case respectively. (2) Install the timing belt B on the crankshaft sprocket B and counterbalance shaft sprocket. There should be no slack on the tension side.
(3) Make sure that the relationship between the tensioner pulley center and the bolt center is as shown in the illustration.
Aug. 1998
PWEE9616-A
Revised
11A-4-7
(4) Move the 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 together, belt will be overtensioned.
(5) Check to ensure that timing marks on sprockets and front case are in alignment. (6) Press with index finger the center of span on the tension side of timing belt B. The bolt must deflect 5 - 7 mm.
"GA CRANKSHAFT BOLT TIGHTENING (1) Using the special tool, hold the flywheel or drive plate. (2) Install the crankshaft pulley in position.
"HA OIL PUMP SPROCKET INSTALLATION (1) Insert a Phillips screwdriver (shank diameter 8 mm shaft) through the plug hole on the left side of the cylinder block to block the left counterbalance shaft. (2) Install the oil pump sprocket. (3) Apply a proper amount of engine oil to the bearing surfaces of the nuts. (4) Tighten the nuts to the specified torque.
6EN0564
"IA AUTO TENSIONER INSTALLATION (1) If the auto tensioner rod is in its fully extended position, reset it as follows. (2) Clamp the auto-tensioner in the vise with soft jaws. (3) Push in the rod little by little with the vise until the set hole A in the rod is aligned with the hole B in the cylinder.
6AE0049
Aug. 1998
PWEE9616-A
Revised
11A-4-8

(4) Insert a wire (1.4 mm in diameter) into the set holes. (5) Unclamp the auto tensioner from the vise.
6AE0050
(6) Install the auto tensioner to front case and tighten to the specified torque. Caution D Leave the wire installed in the auto tensioner.
6EN0350
"JA TENSIONER PULLEY INSTALLATION (1) Install the tensioner pulley in such direction that its two small holes are arranged vertically.
Small holes
6EN1323
"KA TIMING BELT INSTALLATION (1) Check that the timing belt tensioner and spring have been installed in position. (See "JA) (2) Align timing mark on camshaft sprocket with timing mark on cylinder head.
(3) Align timing mark on crankshaft sprocket with timing mark on front case.
Aug. 1998
PWEE9616-A
Revised

Oil pump sprocket timing marks
11A-4-9
(4) Align the timing mark on oil pump sprocket with its mating mark.
6EN1327
Plug
Screwdriver
6EN1026
(5) Remove the plug on cylinder block and insert a Phillips screwdriver (shank diameter 8 mm) through the hole (Engine with counterbalance shafts). If it can be inserted as deep as 60 mm or more, the timing marks are correctly aligned. If the inserted depth is only 20 - 25 mm, turn the oil pump sprocket one turn and realign timing marks. Then check to ensure that the screwdriver can be inserted 60 mm or more. Keep the screwdriver inserted until installation of timing belt is finished. (6) Install the timing belt on the crankshaft sprocket, idler pulley, camshaft sprocket, and tensioner pulley in that order.
(7) Lift up the tensioner pulley in the direction of arrow and tighten the center bolt. (8) Check that all timing marks are lined up. (9) Remove the screwdriver inserted in step (5) and fit the plug. (10)Give the crankshaft a quarter counterclockwise turn. Then, turn it clockwise until the timing marks are lined up again.
6EN0899
MD998767
(11)Install the special tools, Socket Wrench and Torque Wrench, on the tensioner pulley, and loosen the tensioner pulley center bolt. NOTE If the special tool is not available, use a commercially available torque wrench that is capable of measuring 0 - 5 Nm. (12)Torque to 3.5 Nm with the torque wrench. (13)Holding the tensioner pulley with the special tool and torque wrench, tighten the center bolt to specification.
PWEE9616-A Revised
6EN0900
Aug. 1998
11A-4-10

(14)After giving two clockwise turns to the crankshaft, let it alone for approx. 15 minutes. Then, make sure that the auto tensioner setting wire moves freely. NOTE If the wire does not move freely, repeat step (10) above until it moves freely. (15)Remove the auto tensioner setting wire.
(16)Measure the distance A (between the tensioner arm and auto tensioner body). Standard value: 3.8 - 4.5 mm
Timing mark
"LA TIMING BELT INSTALLATION (1) Place the exhaust side camshaft sprocket in a position where its timing mark is one tooth offset from the timing mark on the rocker cover in the counterclockwise direction. NOTE Even if the timing marks on the sprocket and the rocker cover are brought into alignment, the exhaust camshaft is forced back by the valve spring tension. It is stabilized at a position one tooth before the timing mark. (2) Align the timing mark on the intake side camshaft sprocket with that on the rocker cover. NOTE Even if the timing marks on the sprocket and the cover are brought into alignment, the intake camshaft is forced to turn one tooth in the clockwise direction by the valve spring tension and stabilized there.
Timing mark
(3) Place the timing mark on the crankshaft sprocket one tooth this side from the mated timing mark as in the case of the camshaft sprocket.
Aug. 1998
PWEE9616-A
Added

Oil pump sprocket timing marks
11A-4-11
(4) Align the timing mark on oil pump sprocket with its mating mark.
6EN1327
Plug
Screwdriver
6EN1026
(5) Remove the plug on cylinder block and insert a Phillips screwdriver (shank diameter 8 mm) through the hole (Engine with counterbalance shafts). If it can be inserted as deep as 60 mm or more, the timing marks are correctly aligned. If the inserted depth is only 20 - 25 mm, turn the oil pump sprocket one turn and realign timing marks. Then check to ensure that the screwdriver can be inserted 60 mm or more. Keep the screwdriver inserted until installation of timing belt is finished. (6) Remove the Phillips screwdriver. Place the oil pump sprocket in a position where its timing mark is one tooth offset from the mated timing mark in the counterclockwise direction.
Timing mark
6EN1327
(7) Fit the timing belt over the exhaust side camshaft sprocket, and secure it at the illustrated position using a paper clip.
(8) Turn the intake side camshaft sprocket as shown to a position where its timing mark is one tooth offset from the mated timing mark in the counterclockwise direction. Then, fit the timing belt over the sprocket and secure it with a paper clip. NOTE The intake camshaft will be turned a little clockwise by the valve spring tension and stabilized in position even if the belt is clipped at one tooth offset position.
Aug. 1998 PWEE9616-A Added
11A-4-12
17 cogs

(9) Check to ensure that the timing marks on the intake camshaft sprocket side are in alignment when the exhaust camshaft sprocket is turned clockwise to align the timing marks. NOTE The timing belt span between the intake and exhaust sprockets will have 17 cogs.
Timing mark
(10)Fit the timing belt over the idler pulley, oil pump sprocket and crankshaft sprocket in this order. NOTE Be careful that the belt does not become slack.
Crankshaft sprocket
Oil pump sprocket
(11)Fit the timing belt over the tensioner pulley. NOTE When fitting the timing belt over the tensioner pulley, turn the intake side camshaft sprocket a little counterclockwise, as this will facilitate the work.
Crankshaft sprocket
(12)Turn the crankshaft pulley a little in the illustrated direction to pull up the timing belt at the idler pulley side. (13)Check to ensure that the timing marks on the crankshaft sprocket, oil pump sprocket and exhaust camshaft sprocket are all offset one tooth from the corresponding timing marks in the counterclockwise direction.
MD998767
(14)Using the special tool, turn the tensioner pulley in the illustrated direction to strain the timing belt. Then, secure the tensioner temporarily by tightening the retaining bolt lightly. NOTE There must be no slack in the timing belt between the intake and exhaust camshafts. (15)Turn the crankshaft to align the timing mark with the mark for No. 1 cylinder top dead center in the compression stroke.
Aug. 1998
PWEE9616-A
Added
11A-4-13
MD998738
(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, resulting in slackened timing belt. Use care that the timing belt does not come off the sprockets at this time. (18)Pull up the slack of the timing belt by turning the tensioner in illustrated direction using the special tool and a torque wrench (0 - 5 Nm). (19)From this position, turn back the tensioner until the torque wrench reading becomes 3.5 Nm, then secure it by tightening the retaining bolt. (20)Remove the special tool attached in step (16). (21)Rotate the crankshaft clockwise 2 turns. Then, leave it intact 15 minutes. (22)Check to see that the wire inserted when installing the auto-tensioner can be pulled out lightly. If it can be pulled out lightly, the timing belt is being tensioned properly. If so, remove the wire. In addition, check that the rod protrusion from the auto-tensioner meets the standard value, which is also an indication of properly tensioned timing belt. Standard value: 3.8 - 4.5 mm (23)If the wire cannot be removed with a light force, repeat steps (16) through (21) until the proper belt tensioner is obtained.
MD998767
INSPECTION
TIMING BELT Replace belt if any of the following conditions exist. (1) Hardening of back rubber. Back side is glossy without resilience and leaves no indent when pressed with fingernail.
Aug. 1998
PWEE9616-A
Added
11A-4-14

(2) (3) (4) (5) Cracks Cracks Cracks Cracks on rubber back. or peeling of canvas. on rib root. 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.
12 mm
AUTO TENSIONER (1) Check the auto tensioner for possible leaks and replace as necessary. (2) Check the rod end for wear or damage and replace as necessary. (3) Measure the rod protrusion. If it is out of specification, replace the auto tensioner. Standard value: 12 mm
6EN0161
98 to 196 N Movement
(4) Press the rod with a force of 98 to 196 N and measure its protrusion. (5) If the measured value is 1 mm or more shorter than the value obtained in step (3), replace the auto tensioner.
6EN1033
Aug. 1998
PWEE9616-A
Added
4G6 ENGINE (E - W) - Exhaust Manifold (GDI)
11A-4a-1
4a. EXHAUST MANIFOLD (GDI)

REMOVAL AND INSTALLATION
11 Nm
29 Nm
5 4
49 Nm
29 Nm
13 Nm
49 Nm 13 Nm
Removal steps 1. Exhaust manifold 2. Exhaust manifold 3. Exhaust manifold 4. Exhaust manifold 5. Engine hanger
cover (Vehicle for Europe) (Vehicle for Europe) (Vehicle for Hong Kong) gasket
Aug. 1998
PWEE9616-A
Added
4G6 ENGINE (E - W) - Fuel and Emission Control Parts
11A-5-1
5. FUEL AND EMISSION CONTROL PARTS

17 Nm
2 6 4
23 Nm
22 Nm
7 1 3 8
Removal steps 1. Fuel hose 2. Fuel hose 3. Fuel vapor separator 4. Water hose 5. Carburetor 6. Gasket 7. EGR valve (For GCC) 8. Gasket (For GCC)
Dec. 1996 PWEE9616
11A-5-2
4G6 ENGINE (E - W) - Fuel and Emission Control Parts
REMOVAL AND INSTALLATION <MULTIPOINT FUEL INJECTION - GALANT>

3 5
12 Nm 22 Nm
9
9 Nm
4 8 12 13
18 Nm
1 2
14
11 10
Removal steps 1. Throttle body "CA 2. Throttle body gasket 3. EGR valve (With EGR valve) 4. Cover (Without EGR valve) 5. EGR valve gasket 6. Injectors and delivery pipe 7. Insulator
"BA 8. 9. 10. "AA 11. 12. 13. 14.
Fuel pressure regulator O-ring Insulator Injectors O-ring Grommet Delivery pipe
Aug. 1998
PWEE9616-A
Revised
4G6 ENGINE (E - W) - Fuel and Emission Control Parts REMOVAL AND INSTALLATION <MULTIPOINT FUEL INJECTION - SPACE WAGON>
11A-5-3
6
12 Nm
22 Nm
4 15 13 14 10 9 12 11 3 1 2
18 Nm
9 Nm
8 7
Removal steps 1. Throttle body "CA 2. Throttle body gasket 3. EGR valve 4. EGR valve gasket 5. Fuel hose 6. Fuel return pipe 7. Injectors and delivery pipe 8. Insulator
"BA 9. 10. 11. "AA 12. 13. 14. 15.
Fuel pressure regulator O-ring Insulator Injectors O-ring Grommet Delivery pipe
Aug. 1998
PWEE9616-A
Revised
11A-5-4
4G6 ENGINE (E - W) - Fuel and Emission Control Parts INSTALLATION SERVICE POINTS
"AA INJECTORS INSTALLATION (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.
Grommet O-ring
1EN0388
"BA FUEL PRESSURE REGULATOR INSTALLATION (1) Apply a small amount of new engine oil to the O-ring. Insert the fuel pressure regulator into the delivery pipe being careful not to damage the O-ring. Caution D Be sure not to let engine oil get into the delivery pipe. (2) Check that the fuel pressure regulator turns smoothly. If it does not turn smoothly, the O-ring may be trapped. Remove the fuel pressure regulator and check the O-ring for damage, and then re-insert it into the delivery pipe and check once again.
GALANT
Projection
SPACE WAGON
Projection
"CA GASKET INSTALLATION (1) Position the projection as shown in the illustration.
Aug. 1998
PWEE9616-A
Added
4G6 ENGINE (E - W) - Fuel Part (GDI)
11A-5a-1
5a. FUEL PART (GDI)

REMOVAL AND INSTALLATION (1999 MODEL SPACE WAGON)
26
8.8 Nm 11 Nm 8.8 Nm
18 Nm 8.8 Nm
6 8
11 Nm 11 Nm
15
14 17
3 18 7 16
4.9 Nm 17 Nm 2 Nm
11 10 9 19 22 21 12
11 Nm 8.8 Nm
20
18 Nm
4 5 37 34 35 36 32 33 29 31 30
22 Nm
13 23
24 27 28 25
23 Nm
11 Nm
38
Aug. 1999
PWEE9616-B
Revised
11A-5a-2

"DA 20. 21. 22. "CA 23. 24. 25. 26. 27. 28. "BA 29. 30. 31. 32. "AA 33. "AA 34. "AA 35. "AA 36. 37. 38. Fuel pressure sensor Backup ring O-ring Pump camshaft case O-ring O-ring Injector harness Washer Injector holder Delivery pipe and injector assembly Insulator Injector washer Injector Corrugated washer Backup ring O-ring Backup ring Delivery pipe Engine hanger
"FA
"FA "EA
"EA
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 8. Fuel feed pipe 9. Backup ring 10. O-ring 11. Backup ring 12. Fuel pump 13. O-ring 14. Harness bracket 15. Fuel return pipe 16. Backup ring 17. O-ring 18. Backup ring 19. Fuel high pressure regulator
Aug. 1999
PWEE9616-B
Revised
11A-5a-2a
REMOVAL AND INSTALLATION (2000 MODEL SPACE WAGON and GALANT)
30
8.8 Nm
11 Nm
8.8 Nm
18 Nm 8.8 Nm
15
14 17
8
11 Nm
3 18 16 19 26 25 24 23 12
18 Nm
11 Nm
7 11 10 9
8.8 Nm
4.9 Nm 17 Nm 2 Nm
11 Nm
4 5 41 38 39 40 36 37 33 35 34
22 Nm
22 13 21 20 27
18 Nm
28 31 32 29
23 Nm
11 Nm
42
Aug. 1999
PWEE9616-B
Added
11A-5a-2b

23. Flange (SPACE WAGON for Europe) 24. Fuel pressure sensor (SPACE WAGON for Europe) 25. Backup ring (SPACE WAGON for Europe) 26. O-ring (SPACE WAGON for Europe) 27. Pump camshaft case 28. O-ring 29. O-ring 30. Injector harness 31. Washer 32. Injector holder 33. Delivery pipe and injector assembly 34. Insulator 35. Injector washer 36. Injector 37. Corrugated washer 38. Backup ring 39. O-ring 40. Backup ring 41. Delivery pipe 42. Engine hanger
"FA
"FA "EA
"EA "DA
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 8. Fuel feed pipe 9. Backup ring 10. O-ring 11. Backup ring 12. Fuel pump 13. O-ring 14. Harness bracket 15. Fuel return pipe 16. Backup ring 17. O-ring 18. Backup ring 19. Fuel high pressure regulator 20. Fuel pressure sensor (GALANT and SPACE WAGON for Hong Kong) 21. Backup ring (GALANT and SPACE WAGON for Hong Kong) 22. O-ring (GALANT and SPACE WAGON for Hong Kong)
"DA
"CA
"BA
"AA "AA "AA "AA
Aug. 1999
PWEE9616-B
Added
4G6 ENGINE (E - W) - Fuel Part (GDI) INSTALLATION SERVICE POINTS
11A-5a-3
"AA BACKUP RING / CORRUGATED WASHER INSTALLATION (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.
Cut surface Backup ring
(2) Coat the corrugated washer with white vaseline and install it to the injector as shown. Caution D Always replace the corrugated washer with new one. Reused corrugated washer can cause fuel or gas leaks.
Corrugated washer
Mating marks
Injector gasket
Insulator
"BA DELIVERY PIPE AND INJECTOR ASSEMBLY INSTALLATION (1) Lubricate O-ring in the injector with spindle oil gasoline. (2) Insert the injector straight into the injector mounting hole in the delivery pipe. (3) Turn the injector clockwise and counterclockwise. If it dose not rotate smoothly, remove it to check for damaged O-ring. Damaged O-ring must be replaced with a new one. Reinstall the injector and check for smooth rotation again. (4) Align the mating mark on the injector with that on the delivery pipe. (5) Install the injector gaskets and insulators on the cylinder head. The insulator can drop off easily. Apply vaseline to it before installation so that it may be held in position. (6) Install the delivery pipe and injector assembly onto the cylinder head, tighten the fasteners temporarily. (7) Install the injector holders and the washers to the assembly and tighten the fasteners to the specified torque. Caution D Strictly observe the specified torque. (8) Tighten the fasteners of the delivery pipe and injector assembly to the specified torque in the order given in the illustration.
Aug. 1998
PWEE9616-A
Added
11A-5a-4
Grooved

Coupling
"CA PUMP CAMSHAFT CASE INSTALLATION (1) Lubricate the O-ring (smaller one for oil passage) with vaseline and install it in the pump camshaft case. (2) Apply small amount of engine oil to the O-ring (larger one) in the case. (3) Install the pump camshaft case onto the cylinder head while aligning its coupling with the groove in the camshaft end. NOTE The key of the coupling and the groove in the camshaft end are both arranged offset with respect to the camshaft center. (4) Tighten the pump camshaft case mounting bolts to the specified torque.
Camshaft O-ring
"DA FUEL PRESSURE SENSOR INSTALLATION (1) Install the backup ring to the fuel pressure sensor with its inside cut surface in the illustrated direction. (2) Install the fuel pressure sensor straight into the fuel pressure regulator with labeled surface upward. (3) Tighten the fuel pressure sensor mounting bolt to the specified torque.
Backup ring (Mountable in eitherdirection)
O-ring
"EA FUEL HIGH PRESSURE REGULATOR / FUEL RETURN PIPE INSTALLATION (1) Install the fuel high pressure regulator on the pump camshaft case and tighten the 3 bolts lightly (with somewhat larger torque than finger tight). Tightening to the specification is to be carried out in the step described in "FA. (2) Fit the backup rings and the O-ring on both ends of the fuel return pipe. Note that the larger backup ring must be installed with the inside cut surface in the direction shown in the illustration. (3) Lubricate the O-rings on both ends of the pipe with spindle oil or gasoline. (4) Insert the fuel return pipe ends straight in the respective mounting holes of the pressure regulator and the delivery pipe. Be sure to insert the pipe fully to the stop using care not to twist it. (5) Tighten the bolts at both ends of the pipe to the specified torque.
Aug. 1998
PWEE9616-A
Added

Backup ring (Mountable in either direction)
11A-5a-5
O-ring
"FA FUEL PUMP / FUEL FEED PIPE INSTALLATION (1) Insert the fuel pump into the mounting hole in the pump camshaft case, and secure it temporarily with 4 bolts (tighten somewhat with a larger torque than finger tight). (2) Fit the backup rings and the O-ring on both ends of the feed pipe. Note that the larger backup ring must be installed with the inside cut surface in the direction shown in the illustration. (3) Lubricate the O-rings on both ends of the pipe with spindle oil or gasoline. (4) Insert the fuel feed pipe ends straight in the respective mounting holes of the fuel and the delivery pipe. Be sure to insert the pipe fully to the stop using care not to twist it. (5) Tighten the bolts at ends of the pipe to the specified torque. (6) Tighten the mounting bolts of the fuel pressure regulator to the specified torque.
(7) Using a torque wrench having the minimum scale of 0.5 Nm, tighten the fuel pump mounting bolts in the following order. 1) Tighten the bolts to 4.9 Nm in the order given in the illustration. 2) Tighten the bolts to 17 Nm in the order given in the illustration. The torque variation among 4 bolts must be within 2 Nm. Caution D Strictly observe the specified tightening torque. Deviation from the specification can cause problems such as leakage or the like. (8) Clamp the fuel return pipe and feed pipe using the fuel pipe bracket and clamp A, and tighten them lightly. (9) Secure the fuel pipe bracket to the cam cap temporarily. (10)Tighten the bolts which are securing the pipes temporarily to the specified torque. (11)Tighten the bolts on the beam cam shaft side which have been temporarily tightened to the specified torque.
Aug. 1998
PWEE9616-A
Added
4G6 ENGINE (E - W) - Water Pump and Intake Manifold
11A-6-1
6. WATER PUMP AND INTAKE MANIFOLD

13 Nm 24 Nm
1 15
11 Nm
3 5
13 Nm
20 Nm
14
2 7 16 8
31 Nm
11 17
14 Nm 12 Nm
12 9 13
10
14 Nm
"CA
"BA "AA "AA
Removal steps 1. Water hose 2. Water hose 3. Engine coolant temperature gauge unit 4. Water inlet fitting 5. Thermostat 6. Thermostat housing 7. Water inlet pipe 8. O-ring
9. 10. 11. 12. 13. 14. 15. 16. 17.
Water pump Water pump gasket Oil level gauge Oil level gauge guide O-ring Intake manifold stay Intake manifold Intake manifold gasket Engine hanger
Dec. 1996
PWEE9616
11A-6-2
REMOVAL AND INSTALLATION <MULTIPOINT FUEL INJECTION - GALANT>

13 Nm 24 Nm
16
11 Nm
1 4
5 6
17
19 Nm 13 Nm
2 15 8
31 Nm
9 9 19
29 Nm
3
23 Nm
12 18
14 Nm 11 Nm
13 10 14
11
14 Nm
"DA "CA
"BA "AA "AA
Removal steps 1. Water hose 2. Water hose 3. Engine coolant temperature sensor 4. Engine coolant temperature gauge unit 5. Water inlet fitting 6. Thermostat 7. Thermostat housing 8. Water inlet pipe 9. O-ring
10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
Water pump Water pump gasket Oil level gauge Oil level gauge guide O-ring Intake manifold stay Intake manifold Intake manifold gasket Engine hanger Detonation sensor
Aug. 1998
PWEE9616-A
Revised
4G6 ENGINE (E - W) - Water Pump and Intake Manifold REMOVAL AND INSTALLATION <MULTIPOINT FUEL INJECTION - SPACE WAGON>
3
13 Nm 24 Nm
11A-6-3
8 1 17
11 Nm
5 7
18 2
19 Nm 13 Nm
10 9 10
29 Nm
16
31 Nm
19 13
11 Nm
11
14 Nm
14 12
14 Nm
15
"DA "CA
"BA "AA
Removal steps 1. Water hose 2. Water hose 3. Water hose 4. Engine coolant temperature sensor 5. Engine coolant temperature gauge unit 6. Water inlet fitting 7. Thermostat 8. Thermostat housing 9. Water inlet pipe
"AA 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
O-ring Water pump Water pump gasket Oil level gauge Oil level gauge guide O-ring Intake manifold stay Intake manifold Intake manifold gasket Engine hanger
Aug. 1998
PWEE9616-A
Revised
11A-6-4

Water pipe

"AA WATER PIPE / O-RING INSTALLATION (1) Wet the O-ring (with water) to facilitate assembly. Caution D Keep the O-ring free of oil or grease.
O-ring
6EN0594
"BA SEALANT APPLICATION TO THERMOSTAT HOUSING Specified sealant: Mitsubishi Genuine equivalent Part No. MD970389 or
3 mm diameter bead sealant
6EN1168
NOTE (1) Be sure to install the housing quickly while the sealant is wet (within 15 minutes). (2) After installation, keep the sealed area away from the oil and coolant for approx. 1 hour. "CA SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE GAUGE UNIT Specified sealant: 3M ATD Part No. 8660 or equivalent
9EN0092
"DA SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE SENSOR Specified sealant: 3M Nut Locking Part No. 4171 or equivalent
9EN0091
Aug. 1998
PWEE9616-A
Added
4G6 ENGINE (E - W) - Water Pump and Water Hose (GDI)
11A-6a-1
6a. WATER PUMP AND WATER HOSE (GDI)

12 Nm 11 Nm
7 4
23 Nm
29 Nm
1 9
12 Nm
3 6
8 5 13
22 Nm
10
12 Nm
11
12
13 Nm
Removal steps 1. Water hose "EA 2. Water hose 3. Engine coolant temperature sensor "DA 4. Engine coolant temperature gauge unit 5. Water inlet fitting 6. Thermostat
"CA "BA "AA "AA
7. 8. 9. 10. 11. 12. 13.
Water outlet fitting Thermostat housing O-ring Water inlet pipe Water pump Gasket Knock sensor
Aug. 1998
PWEE9616-A
Added
11A-6a-2
4G6 ENGINE (E - W) - Water Pump and Water Hose (GDI) INSTALLATION SERVICE POINTS
"AA O-RING / WATER INLET PIPE INSTALLATION (1) Replace the O-ring of the water inlet pipe, and then apply water to the O-ring to make installation easy. Caution D Never apply any oil or grease to the O-ring. D Secure the water pipe after the thermostat case has been reinstalled.
"BA THERMOSTAT CASE INSTALLATION (1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG) to the location shown in the illustration. Specified sealant: Mitsubishi Genuine equivalent Part No. MD970389 or
"CA WATER OUTLET FITTING INSTALLATION (1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG) to the location shown in the illustration. Specified sealant: Mitsubishi Genuine equivalent Part No. MD970389 or
"DA ENGINE COOLANT TEMPERATURE GAUGE UNIT INSTALLATION (1) Apply the specified sealant to the threads. Specified sealant: 3M ATD Part No. 8660 or equivalent
9EN0092
"EA ENGINE COOLANT TEMPERATURE SENSOR INSTALLATION (1) When reusing the sensor, apply the specified sealant to the threads. Specified sealant: 3M Nut Locking Part No. 4171 or equivalent
9EN0091
Aug. 1998
PWEE9616-A
Added
4G6 ENGINE (E - W) - Exhaust Manifold
11A-7-1
7. EXHAUST MANIFOLD
REMOVAL AND INSTALLATION (GALANT)
1
13 Nm
6
29 Nm
4
13 Nm
49 Nm
2 5
13 Nm
13 Nm
3
13 Nm
Removal steps "AA 1. Water outlet fitting 2. Heat protector (Multipoint fuel injection) 3. Exhaust manifold cover (Carburetor) 4. Engine hanger 5. Exhaust manifold 6. Exhaust manifold gasket
Aug. 1998
PWEE9616-A
Revised
11A-7-2
4G6 ENGINE (E - W) - Exhaust Manifold
REMOVAL AND INSTALLATION (SPACE WAGON)
1
13 Nm
5
29 Nm
49 Nm
2 4
13 Nm
Removal steps "AA 1. Water outlet fitting 2. Exhaust manifold cover 3. Engine hanger 4. Exhaust manifold 5. Exhaust manifold gasket

3 mm diameter bead sealant
"AA SEALANT APPLICATION TO WATER OUTLET FITTING Specified sealant: Mitsubishi Genuine equivalent Part No. MD970389 or
6EN1170
NOTE (1) Be sure to install the water outlet fitting quickly while the sealant is wet (within 15 minutes). (2) After installation, keep the sealed area away from the oil and coolant for approx. 1 hour.
Aug. 1998
PWEE9616-A
Revised
4G6 ENGINE (E - W) - Rocker Arms and Camshaft
11A-8-1
8. ROCKER ARMS AND CAMSHAFT

Apply engine oil to all moving parts before installation.
2 3
3.4 Nm
5 6
13 8 12 12 12 11 12 11 10 14 17 15 9 15 10 15 10 15 11 11 10 16
31 Nm
18
Removal steps 1. Breather hose 2. P.C.V. hose 3. Oil filler cap 4. Rocker cover 5. Rocker cover gasket 6. Oil seal "CA 7. Oil seal AA" "BA 8. Rocker arms and rocker arm shaft AA" "BA 9. Rocker arms and rocker arm shaft
"BA 10. 11. 12. 13. "AA 14. 15. 16. "AA 17. 18.
Rocker shaft spring Rocker arm A Rocker arm B Rocker arm shaft (Intake side) Lash adjuster Rocker arm C Rocker arm shaft (Exhaust side) Lash adjuster Camshaft
Revised
11A-8-2
4G6 ENGINE (E - W) - Rocker Arms and Camshaft REMOVAL SERVICE POINT

AA" ROCKER ARMS AND ROCKER ARM SHAFTS REMOVAL Caution D If the lash adjuster is re-used, clean the lash adjuster. (Refer to 11A-8-3.) (1) Set special tool MD998443 to prevent the lash adjuster from coming free and falling to the floor.

"AA LASH ADJUSTER INSTALLATION (1) Insert the lash adjuster to rocker arm, being careful not to spill the diesel fuel. Then use the special tool to prevent adjuster from falling while installing it. Caution D If the lash adjuster is re-used, clean the lash adjuster. (Refer to 11A-8-3.)
"BA ROCKER SHAFT SPRING / ROCKER ARMS AND ROCKER ARM SHAFT INSTALLATION (1) Temporarily tighten the rocker shaft with the bolt so that all rocker arms on the inlet valve side do not push the valves. (2) Fit the rocker shaft spring from the above and position it so that it is right angles to the plug guide. NOTE Install the rocker shaft spring before installing the exhaust side rocker arms and rocker arm shaft. (3) Remove the special tool for securing the lash adjuster. (4) Make sure that the notch in the rocker arm shaft is in the direction as illustrated.
"CA CAMSHAFT OIL SEAL INSTALLATION

MD998713
Aug. 1998
PWEE9616-A
Revised
4G6 ENGINE (E - W) - Rocker Arms and Camshaft INSPECTION

CAMSHAFT (1) Measure the cam height.
Item GALANT SPACE WAGON Intake Exhaust Intake Exhaust Standard value mm 37.39 37.14 37.39 36.83
11A-8-3
Limit mm 36.89 36.64 36.89 36.33
ROCKER ARM (1) Check the roller surface. If any dents, damage or seizure is evident, replace the rocker arm. (2) Check rotation of the roller. If it does not rotate smoothly or if looseness is evident, replace the rocker arm. (3) Check the inside diameter. If damage or seizure is evident, replace the rocker arm.
Roller tip
LASH ADJUSTERS
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.
Outside cleaning
Inside cleaning
Filling with diesel fuel
(1) Prepare three containers and approximately five liters of diesel fuel. Into each container, pour enough diesel fuel to completely cover a lash adjuster when it is standing upright. Then, perform the following steps with each lash adjuster.
(2) Place the lash adjuster in container A and clean its outside surface. NOTE Use a nylon brush if deposits are hard to remove.
Aug. 1998
PWEE9616-A
Revised
11A-8-4
MD998441

(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 oil. Caution D The steel ball spring is extremely weak, so the lash adjusters functionality may be lost if the air bleed wire is pushed in hard. NOTE If the plunger remains stiff or the mechanism appears otherwise abnormal, replace the lash adjuster.
MD998442
Diesel fuel
(5) Remove 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.
MD998442 Diesel fuel MD998441
(6) Fit special tool MD998441 onto the lash adjuster. (7) Place the lash adjuster in container B. Then, gently push down the internal steel ball using special tool MD998442 and move the plunger through 5 to 10 strokes until it slides smoothly. This operation will clean the lash adjusters pressure chamber. Caution D The steel ball spring is extremely weak, so the lash adjusters functionality may be lost if the air bleed wire is pushed in hard. (8) Remove 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.
MD998442
Diesel fuel
MD998442 Diesel fuel E Mitsubishi Motors Corporation

Aug. 1998 PWEE9616-A Revised

MD998442
11A-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 fuel.
MD998441
Diesel fuel
MD998442
(10)Stand the lash adjuster with its plunger at the top, then push the plunger downward firmly until it moves through its greatest possible stroke. Return the plunger slowly, then release the steel ball and allow the pressure chamber to fill diesel fuel. (11)Remove special tool MD998441.
MD998441 Diesel fuel
(12)Remove the lash adjuster from the container, then stand the lash adjuster with its plunger at the top. Push the plunger firmly and check that it does not move. Also, check that the lash adjusters height matches that of a new lash adjuster. NOTE If lash adjuster contracts, perform the operations (9) through (12) again to fill it with diesel fuel completely. Replace the lash adjuster if it still contracts after performing these steps. (13)Set the lash adjuster on the special tool MD998440 (leak down tester). (14)After the plunger has moved downward slightly (0.2 to 0.5 mm), measure the time taken for it to move downward by a further 1 mm. Standard value: 3 - 20 seconds/1 mm [with diesel fuel at 15 20_C (59 - 68_F)] NOTE Replace the lash adjuster if the time measurement is out of specification.
MD998440
Division = 1 mm
Lash adjuster
Aug. 1998
PWEE9616-A
Added
11A-8-6
MD998442

(15)Fit special tool MD998441 onto the lash adjuster. (16)Place the lash adjuster in container C again, then gently push down the internal steel ball using special tool MD998442. (17)Stand the lash adjuster with its plunger at the top, then push the plunger downward firmly until it moves through its greatest possible stroke. Return the plunger slowly, then release the steel ball and allow the pressure chamber to fill with diesel fuel. (18)Remove special tool MD998441. (19)Remove the lash adjuster from the container, then stand the lash adjuster with its plunger at the top. Push the plunger firmly and check that it does not move. Also, check that the lash adjusters height matches that of a new lash adjuster. NOTE If lash adjuster contracts, perform the operations (15) through (19) again to fill it with diesel fuel completely. Replace the lash adjuster if it still contracts after performing these steps. (20)Stand the lash adjuster upright to prevent diesel fuel spilling out. Do not allow the lash adjuster to become contaminated by dirt or other foreign matter. Fit the lash adjuster onto the engine as soon as possible.
Aug. 1998
PWEE9616-A
Added
4G6 ENGINE (E - W) - Rocker Arms and Camshafts (GDI)
11A-8a-1
8a. ROCKER ARMS AND CAMSHAFTS (GDI)

20 Nm
7
8 9 10
9.8 Nm
2 3 5
11
21 Nm
12
1
8.8 Nm 13 Nm
Removal steps 1. Camshaft position sensor 2. Cover 3. Gasket "DA 4. Camshaft position sensing cylinder "CA 5. Camshaft position sensing cylinder support "BA 6. Oil seal
7. 8. 9. 10. 11. AA" "AA 12.
"BA "BA "BA "BA
Beam camshaft cap Beam camshaft cap gasket Intake camshaft Exhaust camshaft Rocker arm Lash adjuster
Aug. 1998
PWEE9616-A
Added
11A-8a-2
4G6 ENGINE (E - W) - Rocker Arms and Camshafts (GDI) REMOVAL SERVICE POINTS
AA" LASH ADJUSTER REMOVAL Caution D If the lash adjuster is re-used, clean the lash adjuster. (Refer to 11A-8a-4.)

"AA LASH ADJUSTER INSTALLATION Caution D If the lash adjuster is re-used, clean the lash adjuster. (Refer to 11A-8a-4.) (1) Fit the lash adjuster onto the rocker arm without allowing diesel fuel to spill out.
Dowel pin Approx. 11_
"BA BEAM CAMSHAFT CAP GASKET / BEAM CAMSHAFT CAP / CAMSHAFT / OIL SEAL INSTALLATION (1) Locate the camshaft dowel pins as illustrated.
Timing belt side
3 mm
(2) Apply a 3 mm thick continuous bead of sealant to the bottom surface of the beam camshaft cap along the groove. Specified sealant: Mitsubishi genuine equivalent Part No. MD970389 or
Beam camshaft cap Timing belt side
(3) Apply sealant to the illustrated position of the cylinder head upper surface. Specified sealant: Mitsubishi genuine equivalent Part No. MD970389 or
(4) Install the beam camshaft cap gasket.
Aug. 1998
PWEE9616-A
Added
11A-8a-3
(5) Install the beam camshaft cap before the sealant applied becomes dry and hard. (6) Tighten the bolts to the specified torque in the order shown in the illustration. Specified torque: 20 Nm
Timing belt side
MD998713
(7) Install the camshaft oil seal before the sealant applied becomes dry and hard. (8) Wipe off squeezed out excess sealant from the circumference of the beam camshaft cap.
"CA CAMSHAFT POSITION SENSING CYLINDER SUPPORT INSTALLATION (1) Apply a 3 mm bead of form-in-place gasket (FIPG) to the area shown. Specified sealant: Mitsubishi genuine equivalent Part No. MD970389 or
Paint mark
Camshaft position sensor
"DA CAMSHAFT POSITION SENSING CYLINDER INSTALLATION (1) Set the No. 1 cylinder to the compression top dead center position (so that dowel pin of the exhaust camshaft is at the top). (2) Install the camshaft position sensing cylinder so that the white paint mark is facing in the direction shown in the illustration.
INSPECTION
CAMSHAFT (1) Measure the cam height. Standard value: Intake 35.79 mm Exhaust 37.14 mm Limit: Intake Exhaust
35.29 mm 36.64 mm
Added
11A-8a-4

LASH ADJUSTER Caution D The lash adjusters are precision-engineered mechanisms. Do not allow them to become contaminated by dirt or other foreign substances. D Do not attempt to disassemble the lash adjusters. D Use only fresh diesel fuel to clean the lash adjusters.
Outside cleaning
Inside cleaning
Filling with diesel fuel
(1) Prepare three containers and approximately five liters of diesel fuel. Into each container, pour enough diesel fuel to completely cover a lash adjuster when it is standing upright. Then, perform the following steps with each lash adjuster.
(2) Place the lash adjuster in container A and clean its outside surface. NOTE Use a nylon brush if deposits are hard to remove.
Diesel fuel
(3) While gently pushing down the internal steel ball using special tool MD998442, move the plunger through 5 to 10 strokes until it slides smoothly. In addition to eliminating stiffness in the plunger, this operation will remove dirty oil. Caution D The steel ball spring is extremely weak, so the lash adjusters functionality may be lost if the air bleed wire is pushed in hard. NOTE If the plunger remains stiff or the mechanism appears otherwise abnormal, replace the lash adjuster.
MD998442
Diesel fuel
Aug. 1998
PWEE9616-A
Added
11A-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 yourself or other people.
(5) Place the lash adjuster in container B. Then, gently push down the internal steel ball using special tool MD998442 and move the plunger through 5 to 10 strokes until it slides smoothly. This operation will clean the lash adjusters pressure chamber. Caution D The steel ball spring is extremely weak, so the lash adjusters functionality may be lost if the air bleed wire is pushed in hard.
MD998442
Diesel fuel
(6) Remove 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 yourself or other people.
(7) 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 chamber is filled with diesel fuel.
(8) Stand the lash adjuster with its plunger at the top, then push the plunger downward firmly until it moves through its greatest possible stroke. Return the plunger slowly, then release the steel ball and allow the pressure chamber to fill with diesel fuel.
MD998442
Diesel fuel
Aug. 1998
PWEE9616-A
Added
11A-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 adjusters height matches that of a new lash adjuster. NOTE If 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 performing these steps. (10)Set the lash adjuster on the special tool MD998440 (leak down tester).
MD998440
Division = 1 mm
Lash adjuster
Lash adjuster
Nut
(11)Remove the bolt from the tester, then adjust the height as illustrated. (12)After the plunger has moved downward slightly measure the time taken for it to move downward by a further 1 mm. Standard value: 3 - 20 second/1 mm [with diesel fuel at 15 - 20_C (59 - 68_F)] NOTE Replace the lash adjuster if the time measurement is out of specification. (13)Place the lash adjuster in container C again, then gently push down the internal steel ball using special tool MD998442. (14)Stand the lash adjuster with its plunger at the top, then push the plunger downward firmly until it moves through its greatest possible stroke. Return the plunger slowly, then release the steel ball and allow the pressure chamber to fill with diesel fuel.
MD998442
Diesel fuel
Aug. 1998
PWEE9616-A
Added
11A-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 adjusters height matches that of a new lash adjuster. NOTE If lash adjuster contracts, perform the operations (13) through (15) again to fill it with diesel fuel completely. Replace the lash adjuster if it still contracts after performing these steps. (16)Stand the lash adjuster upright to prevent diesel fuel from spilling out. Do not allow the lash adjuster to become contaminated by dirt or other foreign matter. Fit the lash adjuster onto the engine as soon as possible.
MD998442
Diesel fuel
Aug. 1998
PWEE9616-A
Added
4G6 ENGINE (E - W) - Cylinder Head and Valves
11A-9-1
9. CYLINDER HEAD AND VALVES

REMOVAL AND INSTALLATION (SOHC)
1 20 10 4 8 9 14 6 12 15 17
13 16 11 19
18 7 3
AA" "EA "DA AB" "CA "BA AB" "CA "BA
Removal steps 1. Cylinder head bolt 2. Cylinder head assembly 3. Cylinder head gasket 4. Retainer lock 5. Valve spring retainer 6. Valve spring 7. Intake valve 8. Retainer lock 9. Valve spring retainer 10. Valve spring
11. AC" "AA 12. 13. AC" "AA 14. 15. 16. 17. 18. 19. 20.
Exhaust valve Valve stem seal Valve spring seat Valve stem seal Valve spring seat Intake valve guide Exhaust valve guide Intake valve seat Exhaust valve seat Cylinder head
Aug. 1998
PWEE9616-A
Revised
11A-9-2
REMOVAL AND INSTALLATION (GDI)

8 9 10 4 5 6 12 13 19 16 18 7 3 11 20 14 15 17
AA" "EA AB" "CA "BA AB" "CA "BA
Removal steps 1. Cylinder head bolt 2. Cylinder head assembly 3. Cylinder head gasket 4. Retainer lock 5. Valve spring retainer 6. Valve spring 7. Intake valve 8. Retainer lock 9. Valve spring retainer 10. Valve spring
11. AC" "AA 12. 13. AC" "AA 14. 15. 16. 17. 18. 19. 20.
Exhaust valve Valve stem seal Valve spring seat Valve stem seal Valve spring seat Intake valve guide Exhaust valve guide Intake valve seat Exhaust valve seat Cylinder head
Aug. 1998
PWEE9616-A
Revised
4G6 ENGINE (E - W) - Cylinder Head and Valves REMOVAL SERVICE POINTS

MB991654
11A-9-3
PRECAUTION FOR REMOVED PARTS Keep removed parts in order according to the cylinder number and intake/exhaust. AA" CYLINDER HEAD BOLTS REMOVAL (1) Using the special tool, loosen the cylinder head bolts. Loosen evenly, little by little.
9EN0061
MB991654
MD998772
AB" RETAINER LOCK REMOVAL (1) Store removed valves, springs and other parts, tagged to indicate their cylinder No. and location for reassembly.
9EN0062
MD998772
Aug. 1998
PWEE9616-A
Revised
11A-9-4

AC" VALVE STEM SEAL REMOVAL (1) Do not reuse removed stem seal.

"AA VALVE STEM SEAL INSTALLATION (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 leaks past the valve guide.
MD998774
Caution D Do not reuse removed valve stem seals.
9EN0065
MD998737
"BA VALVE SPRING INSTALLATION (1) Direct the valve spring end with identification color toward the spring retainer.
Aug. 1998
PWEE9616-A
Revised

MD998772
11A-9-5
"CA RETAINER LOCK INSTALLATION (1) The valve spring, if excessively compressed, causes the bottom end of the retainer to be in contact with, and damage, the stem seal.
9EN0062
MD998772
"DA CYLINDER HEAD GASKET IDENTIFICATION Identification mark: 4G63N
"EA CYLINDER HEAD BOLT INSTALLATION (1) When installing the cylinder head bolts, check that the shank length of each bolt meets the limit. If the limit is exceeded, replace the bolt. Limit: Max. 99.4 mm (2) Apply engine oil to the bolt threads and to the washers.
Shank length
6EN0782
Timing belt side
(3) Using the special tool (MB991654) and according to the tightening sequence, tighten the bolts to the specified torque. Tightening torque: 78 Nm (4) Loosen all bolts fully. (5) Retighten the loosened bolts to a torque of 20 Nm in the specified tightening sequence.
Aug. 1998
PWEE9616-A
Revised
11A-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 on the cylinder head are on the same straight line.
Paint mark
6AE0297
90_
90_
Caution D If the bolt is turned less than 90_, proper fastening performance may not be expected. When tightening the bolt, therefore, be careful to give a sufficient turn to it. D If the bolt is overtightened, loosen the bolt completely and then retighten it by repeating the tightening procedure from step (1).
INSPECTION
CYLINDER HEAD (1) Check the cylinder head gasket surface for flatness by using a straightedge and thickness gauge. Standard value: 0.05 mm Limit: 0.2 mm (2) If the service limit is exceeded, correct to meet specification.
9EN0064
Grinding limit: *0.2 mm * Includes combined with cylinder block grinding. Cylinder head height (Specification when new): SOHC 119.9 - 120.1 mm GDI 131.9 - 132.1 mm
Aug. 1998
PWEE9616-A
Revised
11A-9-7
VALVE (1) Check the valve face for correct contact. If incorrect, reface using a valve refacer. Valve seat contact should be maintained uniform at the center of valve face. (2) If the margin exceeds the service limit, replace the valve.
Item SOHC GDI Intake Exhaust Intake Exhaust Standard value mm 1.0 1.2 1.0 1.5 Limit mm 0.5 0.7 0.5 1.0
(3) Measure valves total length. If measurement is less than specified, replace the valve.
Out of square
VALVE SPRING (1) Measure the free height of spring and, if it is smaller than the limit, replace.
Item
Free height
Standard value mm 51.0 48.3
Limit mm 50.0 47.3
SOHC GDI
1EN0264
(2) Measure the squareness of the spring and, if the limit is exceeded, replace.
Item SOHC GDI Standard value mm 2_ 1.5_ Limit mm 4_ 4_
Aug. 1998
PWEE9616-A
Added
11A-9-8

VALVE GUIDE (1) Measure the clearance between the valve guide and valve stem. If the limit is exceeded, replace the valve guide or valve, or both.
Item SOHC GDI Intake Exhaust Intake Exhaust Standard value mm 0.02 - 0.05 0.03 - 0.07 0.02 - 0.05 0.05 - 0.09 Limit mm 0.10 0.15 0.10 0.15
Valve guide
Valve stem end Valve stem projection Spring seating surface
VALVE SEAT (1) Assemble the valve, then measure the valve stem projection between the end of the valve stem and the spring seating surface. If the measurement exceeds the specified limit, replace the valve seat.
DEN0212
VALVE SEAT RECONDITIONING PROCEDURE

0.9 - 1.3 mm
43.5_ - 44_
6EN0491
(1) Before correcting the valve seat, check for clearance between the valve guide and valve and, if necessary, replace the valve guide. (2) Using the seat grinder, correct to obtain the specified seat width and angle. (3) After correcting the valve seat, lap the valve and valve seat using lapping compound. Then, check the valve stem projection (refer to VALVE SEAT in INSPECTION).
PWEE9616-A Added
Aug. 1998

0.5 - 1 mm
11A-9-9
VALVE SEAT REPLACEMENT PROCEDURE

(1) Cut the valve seat to be replaced from the inside to thin the wall thickness. Then, remove the valve seat.
0.5 - 1 mm
(2) Rebore the valve seat hole in the cylinder head to a selected oversize valve seat diameter. Valve seat ring hole diameter
Height of seat ring
Item SOHC Intake Exhaust

1EN0275
Standard value mm 0.30 O.S. 0.60 O.S. 0.30 O.S. 0.60 O.S. 0.30 O.S. 0.60 O.S. Exhaust 0.30 O.S. 0.60 O.S. 34.30 - 34.33 34.60 - 34.63 31.80 - 31.83 32.60 - 32.63 35.30 - 35.33 35.60 - 35.63 33.30 - 33.33 33.60 - 33.63
Oversize I.D.
GDI
Intake
(3) Before fitting the valve seat, either heat the cylinder head up to approximately 250_C (482_F) or cool the valve seat in liquid nitrogen, to prevent the cylinder head bore from galling. (4) Using a valve seat cutter, correct the valve seat to the specified width and angle. See VALVE SEAT RECONDITIONING PROCEDURE.
Aug. 1998
PWEE9616-A
Added
11A-9-10
4G6 ENGINE (E - W) - Cylinder Head and Valves VALVE 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. Valve gauge hole diameters in cylinder head
Item SOHC 0.05 O.S. 0.25 O.S. 0.50 O.S. GDI 0.05 O.S. 0.25 O.S. 0.50 O.S. Standard value mm 11.05 - 11.07 11.25 - 11.27 11.50 - 11.52 12.05 - 12.07 12.25 - 12.27 12.50 - 12.52
(3) Press-fit the valve guide until it protrude specified value (SOHC 14 mm, GDI 19.5 mm) as shown in the illustration. Caution D Press the valve guide from the cylinder head top surface. D Valve guide for intake valve and that for exhaust valve are different in length. (45.5 mm for intake valve; 50.5 mm for exhaust valve)
Protrusion
1EN0106
(4) After the valve guide has been installed, insert a new valve to check for smooth sliding motion.
Aug. 1998
PWEE9616-A
Added
4G6 ENGINE (E - W) -
Front Case, Counterbalance Shafts and Oil Pan
11A-10-1
10. FRONT CASE, COUNTERBALANCE SHAFTS AND OIL PAN

REMOVAL AND INSTALLATION <GDI ENGINE - VEHICLE FOR EUROPE AND SOHC ENGINE>
19 Nm
33 31 30 32
13
(4G63)
21 18 (SOHC)
23 Nm 9.8 Nm
20
28
23 Nm
22 23 24 8
16 Nm
29
21 Nm
18 (GDI) 19
18 Nm
27 7
18 Nm 39 Nm 23 Nm 36 Nm
25 17 16 12 10 11 15 14 1
9.8 Nm 44 Nm 23 Nm
26
(4G64)
2 4 5
6.9 Nm
13
8.8 Nm
21 Nm
"OA "NA
AA" "LA
AD" "KA AE" "JA "IA
Removal steps 1. Oil filter 2. Drain plug 3. Drain plug gasket 4. Oil level sensor (Vehicle for Europe) 5. Transmission stay (GDI engine) 6. Oil pan 7. Oil screen 8. Oil screen gasket 9. Stiffener (SOHC engine - vehicle for Europe) 10. Plug 11. O-ring 12. Flange bolt 13. Oil pressure switch 14. Relief plug 15. Relief plug gasket 16. Relief spring 17. Relief plunger
Aug. 1999
"HA "GA "GA "FA "EA "DA
AF" "CA AG" "BA AG" "AA
18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.
Oil filter bracket Oil filter bracket gasket Front case assembly Front case gasket Oil pump cover Oil pump driven gear Oil pump drive gear Crankshaft front oil seal Oil pump oil seal Counterbalance shaft oil seal Front case Counterbalance shaft, left Counterbalance shaft, right Counterbalance shaft front bearing Counterbalance shaft rear bearing, left 33. Counterbalance shaft rear bearing, right
Revised
PWEE9616-B
11A-10-2
REMOVAL AND INSTALLATION <GDI ENGINE - VEHICLE FOR HONG KONG>

34 32
31
33
22
23 Nm
21
9.8 Nm
29
23 Nm 18 Nm
23 24 25 7
30
6.9 Nm
20 19
28
16 Nm
10 9
18 Nm
26 13 18 17 14 11 12 16 15 1
9.8 Nm 44 Nm
27
23 Nm 6.9 Nm
36 Nm 23 Nm
3
39 Nm
5
12 Nm
2
6.9 Nm
4 8
21 Nm
"OA "NA AB" "MA AC" "MA AD" "KA AE" "JA "IA
Removal steps 1. Oil filter 2. Drain plug 3. Drain plug gasket 4. Transmission stay 5. Oil level gauge guide 6. Oil pan lower 7. Baffle plate 8. Oil pan upper 9. Oil screen 10. Gasket 11. Plug 12. O-ring 13. Flange bolt 14. Oil pressure switch 15. Relief plug 16. Gasket 17. Relief spring 18. Relief plunger
"HA "GA "GA "FA "EA "DA
AF" "CA AG" "BA AG" "AA
19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33.
Oil filter bracket Oil filter bracket gasket Front case assembly Gasket Oil pump cover Oil pump driven gear Oil pump drive gear Crankshaft front oil seal Oil pump oil seal Counterbalance shaft oil seal Front case Counterbalance shaft, left Counterbalance shaft, right Counterbalance shaft front bearing Counterbalance shaft rear bearing, left 34. Counterbalance shaft rear bearing, right
Aug. 1998
PWEE9616-A
Revised
4G6 ENGINE (E - W) MD998727
11A-10-3
REMOVAL SERVICE POINTS

AA" OIL PAN REMOVAL (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 leakage.
6EN0698
AB" OIL PAN LOWER REMOVAL (1) Apply a wood block to the oil pan side and remove the oil pan lower by tapping lightly on it with a plastic hammer. Caution D Do not use a scraper or special tool to remove the oil pan.
AC" OIL PAN UPPER REMOVAL (1) Remove all bolts. (2) Screw a bolt into bolt hole A shown to remove the oil pan. Caution D Do not use a scraper or special tool to remove the oil pan.
MD998162
AD" PLUG REMOVAL (1) If the plug is too tight, hit the plug head with a hammer two to three times, and the plug will be easily loosened.
MD998783
AE" FLANGE BOLT REMOVAL (1) Remove the plug on the side of cylinder block. (2) Insert a Phillips screwdriver (shank diameter 8 mm) into the plug hole to lock the counterbalance shaft.
Plug
Screwdriver
6EN1026
Aug. 1998
PWEE9616-A
Revised
11A-10-4
(3) Loosen the flange bolt.
6EN0565
AF" COUNTERBALANCE SHAFT FRONT BEARING REMOVAL (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 Bearing Puller cannot be used.
MB991603
AG" COUNTERBALANCE SHAFT REAR BEARING REMOVAL (1) Using the special tool, remove the left counterbalance shaft rear bearing from the cylinder block. NOTE When removing the left counterbalance shaft rear bearing, install the special tool (MB991603) in front of the cylinder block.

"AA RIGHT COUNTERBALANCE SHAFT REAR BEARING INSTALLATION (1) Apply engine oil to the outer surface of bearing. (2) Using special tools, install right rear bearing. Make sure that oil hole of bearing is aligned with oil hole of cylinder block.
MD998705
6EN1034
Aug. 1998
PWEE9616-A
Revised
11A-10-5
MB991603
"BA LEFT COUNTERBALANCE SHAFT REAR BEARING INSTALLATION (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 rear bearing.

MB991603 Rear bearing
NOTE The left rear bearing has no oil holes.
MD998705
6EN0557
"CA COUNTERBALANCE SHAFT FRONT BEARING INSTALLATION (1) Using special tools, install front bearing.
MD998705
MD998705 Bearing
Cylinder block
6EN1035
"DA COUNTERBALANCE SHAFT OIL SEAL INSTALLATION
Aug. 1998
PWEE9616-A
Revised
11A-10-6
"EA OIL PUMP OIL SEAL INSTALLATION
"FA CRANKSHAFT FRONT OIL SEAL INSTALLATION (1) Using the special tool, install the crankshaft front oil seal into the front case.
"GA OIL PUMP DRIVEN GEAR / OIL PUMP DRIVE GEAR INSTALLATION (1) Apply engine oil amply to the gears and line up the alignment marks.
"HA FRONT CASE ASSEMBLY INSTALLATION (1) Set the special tool on the front end of crankshaft and apply a thin coat of engine oil to the outer circumference of the special tool to install the front case.
(2) Install the front case assembly through a new front case gasket and temporarily tighten the flange bolts (other than those for tightening the filter bracket).
Aug. 1998
PWEE9616-A
Revised
11A-10-7
"IA SEALANT APPLICATION TO OIL PRESSURE SWITCH (1) Coat the threads of switch with sealant and install the switch using the special tool. Specified sealant: 3M ATD Part No. 8660 or equivalent Caution D Keep the end of the thread portion clear or sealant. D Avoid an overtightening.
"JA FLANGE BOLT INSTALLATION (1) Insert a Phillips screwdriver into a hole in the left side of the cylinder block to lock the silent shaft.
6EN0564
(2) Secure the oil pump driven gear onto the left counterbalance shaft by tightening the flange bolt to specified torque.
MD998162
"KA PLUG INSTALLATION (1) Install a new O-ring to the groove of front case. (2) Using the special tool, install the plug and tighten to specified torque.
MD998783
"LA OIL PAN INSTALLATION (1) Clean both mating surfaces of oil pan and cylinder block. (2) Apply a 4 mm wide bead of sealant to the entire circumference of the oil pan flange. Specified sealant: Mitsubishi Genuine equivalent
Bolt hole portion E Mitsubishi Motors Corporation Groove portion
6EN0213 Aug. 1998 PWEE9616-A Revised
Part
No.
MD970389
or
11A-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.
Oil pan upper
"MAOIL PAN UPPER / OIL PAN LOWER INSTALLATION (1) Clean both mating surfaces of oil pan and cylinder block. (2) Apply a 4 mm wide bead of sealant to the entire circumference of the oil pan upper flange. Specified sealant: Mitsubishi Genuine equivalent Part No. MD970389 or
Groove portion
Bolt hole portion
NOTE (1) Be sure to install the oil pan quickly while the sealant is wet (within 15 minutes). (2) After installation, keep the sealant area away from the oil and coolant for approx. one hour.
Timing belt side
(3) Note the difference in bolt lengths at the location shown.
M6 16 mm
Aug. 1998
PWEE9616-A
Revised
4G6 ENGINE (E - W) Oil pan lower
11A-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 equivalent Part No. MD970389 or
Groove portion
Bolt hole portion
NOTE (1) Be sure to install the oil pan quickly while the sealant is wet (within 15 minutes). (2) After installation, keep the sealant area away from the oil and coolant for approx. one hour.
8 1
(6) Tighten the oil pan lower mounting bolts in the sequence shown in the illustration.
4 2 7 5
Oil pan side Drain plug gasket
"NA DRAIN PLUG GASKET INSTALLATION (1) Install the drain plug gasket in the shown direction.
7EN0307
Bracket side
"OA OIL FILTER INSTALLATION (1) Clean the installation surface of the filter bracket. (2) Apply engine oil to the O-ring of the oil filter. (3) Screw the oil filter in until the O-ring contacts the bracket. Then tighten 3/4 turn (tightening torque: 16 Nm). NOTE For the oil filter MD135737, tighten one turn (Tightening torque: 14 Nm) after the O-ring contacts the bracket.
6EN0591
Aug. 1998
PWEE9616-A
Added
11A-10-10 4G6 ENGINE (E - W) -
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 cracks and other damage. Replace cracked or damaged front case.
OIL SEAL (1) Check the oil seal lip for wear and damage. Replace oil seal if necessary. (2) Check the oil seal lip for deterioration. Replace oil seal if necessary.
COUNTERBALANCE SHAFT (1) Check oil holes for clogging. (2) Check journals for seizure, damage and contact with bearing. If there is anything wrong with the journal, replace the counterbalance shaft, bearing or front case assembly.
OIL PUMP (1) Assemble the oil pump gear to the front case and rotate it to ensure smooth rotation with no looseness. (2) Ensure that there is no ridge wear on the contact surface between the front case and the gear surface of the oil pump cover. (3) Check the side clearance. Standard value: Drive gear Driven gear 0.08 - 0.14 mm 0.06 - 0.12 mm
Aug. 1998
PWEE9616-A
Added
4G6 ENGINE (E - W) - Piston and Connecting Rod
11A-11-1
11. PISTON AND CONNECTING ROD

6 7 8
4 10
9 11
12
3 2 1
"GA AA" "FA "EA "DA "EA "CA
Removal steps 1. Nut 2. Connecting rod cap 3. Connecting rod bearing 4. Piston and connecting rod assembly 5. Connecting rod bearing 6. Piston ring No. 1
Dec. 1996
"CA 7. Piston ring No. 2 "BA 8. Oil ring AB" "AA 9. Piston pin 10. Piston 11. Connecting rod 12. Bolt
PWEE9616
11A-11-2
4G6 ENGINE (E - W) - Piston and Connecting Rod REMOVAL SERVICE POINTS

AA" CONNECTING ROD CAP REMOVAL (1) Mark the cylinder number on the side of the connecting rod big end for correct reassembly. (2) Keep the removed connecting rods, caps, and bearings in order according to the cylinder number.
AB" PISTON PIN REMOVAL
(1) Insert the special tool, Push Rod, into the piston from the side on which the front mark is stamped in the piston head, and attach the guide C to the push rod end. (2) Place the piston and connecting rod assembly on the special tool, Piston Pin Setting Base, with the front mark facing upward. (3) Using a press, remove the piston pin. NOTE Keep the disassembled pistons, piston pins and connecting rods in order according to the cylinder number.
Dec. 1996
PWEE9616
4G6 ENGINE (E - W) - Piston and Connecting Rod INSTALLATION SERVICE POINTS
11A-11-3
"AA PISTON PIN INSTALLATION (1) Measure the following dimensions of the piston, piston pin and connecting rod. A: Piston pin insertion hole length B: Distance between piston bosses C: Piston pin length D: Connecting rod small end width (2) Obtain dimension L (to be used later) from the above measurements by using by following formula. L =
(A - C) - (B - D) 2
(3) Insert the special tool, Push Rod, into the piston pin and attach the guide A to the push rod end. (4) Assemble the connecting rod in the piston with their front marks facing the same direction. (5) Apply engine oil to the entire periphery of the piston pin. (6) Insert the piston pin, push rod and guide A assembly having assembled in step (3) from the guide A side into the piston pin hole on the front marked side. (7) Screw the guide B into the guide A until the gap between both guides amounts to the value L obtained in step (2) plus 3 mm.
3 mm + L
(8) Place the piston and connecting rod assembly onto the piston setting base with the front marks directed upward. (9) Press-fit the piston pin using a press. If the press-fitting force required is less than the standard value, replace the piston and piston pin set or/and the connecting rod. Standard value: 7,350 - 17,200 N
Dec. 1996
PWEE9616
11A-11-4

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

6EN1237
Side rail gap
(2) Install the upper side rail. To install the side rail, first fit one end of the rail into the piston groove, then press the remaining portion into position by finger. See illustration. Use of ring expander to expand the side rail end gap can break the side rail, unlike other piston rings. Caution D Do not use piston ring expander when installing side rail.
1EN0269
(3) Install the lower side rail in the same procedure as described in step (2). (4) Make sure that the side rails move smoothly in either direction.
Dec. 1996
PWEE9616
11A-11-5
"CA PISTON RING NO. 2 / PISTON RING NO. 1 INSTALLATION (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 No. 1 ring No. 2 ring 4G63 SOHC 4G64 GDI
Identification mark Identification mark Side mark
Identification mark 1R T 2R 2T
4G63 SOHC 4G64 GDI
2. Install piston rings with identification mark facing up, to the piston crown side. 3. Size marks on position rings are as follows.
Size Standard 0.50 mm oversize 1.00 mm oversize Size mark None 50 100
No. 1 No. 2
9EN0524
"DA PISTON AND CONNECTING ROD ASSEMBLY INSTALLATION (1) Liberally coat engine oil on the circumference of the piston, piston ring, and oil ring. (2) Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in the figure. (3) Rotate the crankshaft so that crank pin is on the center of cylinder bore.
Timing belt side
(4) Use suitable thread protectors on the connecting rod bolts before inserting piston and connecting rod assembly into the cylinder block. Care must be taken not to nick the crank pin. (5) Using a suitable piston ring compressor tool, install the piston and connecting rod assembly into the cylinder block.
"EA CONNECTING ROD BEARINGS INSTALLATION When the bearing needs replacing, select and install a proper bearing by the following procedure. (1) Measure the crankshaft pin diameter and confirm its classification from the following table. In the case of a crankshaft supplied as a service part, identification colors of its pins are painted at the positions shown in the illustration.
Aug. 1998
PWEE9616-A
Revised
11A-11-6

(2) The connecting rod bearing identification mark is stamped at the position shown in the illustration.
Crankshaft pin Classification Identification mark Production part Identification color Service part Yellow None White 44.995 - 45.000 44.985 - 44.995 44.980 - 44.985 1 2 3 1.478 - 1.491 1.491 - 1.495 1.495 - 1.499 O. D. mm Connecting rod bearing Identification mark Thickness mm
Identification mark
1 2 3
None None None
Connecting rod I.D.: 48.000 - 48.015 mm (3) Select a proper bearing from the above table on the basic of the identification data confirmed under items (1) and (2). [Example] If the measured value of a crankshaft pin outer diameter is 44.996 mm, the pin is classified as 1 in the table. In case the crankshaft is also replaced by a spare part, check the identification colors of the pins painted on the new crankshaft. If the color is yellow, for example, the pin is classified as 1. In the above cases, select the connection rod bearing having identification mark 1.
"FA CONNECTING ROD CAP NUT INSTALLATION (1) Verifying the mark made during disassembly, install the bearing cap to the connecting rod. If the connecting rod is new with no index mark, make sure that the bearing locking notches come on the same side as shown.
(2) Make sure that the connecting rod big end side clearance meets the specification. Standard value: 0.10 - 0.25 mm Limit: 0.4 mm
Dec. 1996
PWEE9616
11A-11-7
"GA CONNECTING ROD CAP NUT INSTALLATION 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 should be examined BEFORE reuse. If the bolt threads are necked down, the bolt should be replaced. Necking can be checked by running a nut with fingers to the full length of the bolt threads. If the nut does not run down smoothly, the bolt should be replaced. (2) Before installation of each nut, apply engine oil to the thread portion and bearing surface of the nut. (3) Install each nut to the bolt and tighten it with fingers. Then tighten the nuts alternately to install the cap properly. (4) Tighten the nuts to a torque of 20 Nm. (5) Make a paint mark on the head of each nut. (6) Make a paint mark on the bolt end at the position 90_ to 100_ from the paint mark made on the nut in the direction of tightening the nut. (7) Give a 90_ to 100_ turn to the nut and make sure that the paint mark on the nut and that on the bolt are in alignment. Caution D If the nut is turned less than 90_, proper fastening performance may not be expected. When tightening the nut, therefore, be careful to give a sufficient turn to it. D If the nut is overtightened (exceeding 100_), loosen the nut completely and then retighten it by repeating the tightening procedure from step (1).
Paint mark
90_ - 100_
Paint mark
Nut
Bolt
6AE0298
INSPECTION
PISTON RING (1) Check the piston ring for damage, excessive wear, and breakage and replace if defects are evident. If the piston has been replaced with a new one, the piston rings must also be replaced with new ones. (2) Check for the clearance between the piston ring and ring groove. If the limit is exceeded, replace the ring or piston, or both. Standard value: 0.02 - 0.06 mm Limit: 0.1 mm
Dec. 1996
PWEE9616
11A-11-8

(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. Standard value: No. 1 ring 0.25 - 0.35 mm No. 2 ring 0.40 - 0.55 mm Oil ring 0.10 - 0.40 mm Limit: No. 1, No. 2 ring 0.8 mm Oil ring 1.0 mm
CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE METHOD) (1) Remove oil from the crankshaft pin and connecting rod bearing. (2) Cut the Plastigage to the same length as the width of the bearing and place it on the crankshaft pin in parallel with its axis.
Plastigage
(3) Install the connecting rod cap carefully and tighten the nuts to specified torque. (4) Carefully remove the connecting rod cap. (5) Measure the width of the Plastigage at its widest part by using a scale printed on the Plastigage package. Standard value: 0.02 - 0.05 mm Limit: 0.1 mm
Dec. 1996
PWEE9616
4G6 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate
11A-12-1
12. CRANKSHAFT, FLYWHEEL AND DRIVE PLATE

3
2
11 Nm
1
132 Nm
10
13 21 12 5
<GALANT>
11 Nm
11
9 Nm
7 8 9
132 Nm
20
19 18
<SPACE WAGON>
132 Nm
17 9
7 6
16 15
14
Removal steps 1. Flywheel bolt <M/T> 2. Adapter plate <M/T> 3. Flexible flywheel <M/T> 4. Adapter plate <M/T> 5. Crankshaft bushing <M/T> 6. Drive plate bolt <A/T> 7. Adapter plate <A/T> 8. Drive plate <A/T> 9. Crankshaft bushing <A/T> 10. Rear plate 11. Bell housing cover 12. Oil seal case 13. Oil seal 14. Bearing cap bolt 15. Bearing cap 16. Crankshaft bearing, lower
Aug. 1998
17. Crankshaft "CA 18. Crankshaft bearing, upper "BA 19. Crankshaft thrust bearing <GDI engine> AA" "AA 20. Oil jet <GDI engine> 21. Cylinder block Caution On the flexible wheel equipped engines, do not remove any of the bolts A of the flywheel shown in the illustration. The balance of the flexible flywheel is adjusted in an assembled condition. Removing the bolt, therefore, can cause the flexible flywheel to be out of balance, giving damage to the flywheel.
PWEE9616-A Revised
"FA "EA "DA "DA "CA
11A-12-2
4G6 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate REMOVAL SERVICE POINT
AA" OIL JET REMOVAL (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.

"AA OIL JET INSTALLATION (1) Using a 4.5 mm diameter pin punch, drive in the oil jet to the crankshaft journal until it seats to the bottom.
"BA CRANKSHAFT THRUST BEARING INSTALLATION (1) Install the two thrust bearing in the number 3 bearing bore in the cylinder block. For easier installation, apply engine oil to the bearings; this will help hold them in position. (2) The thrust bearings must be installed with their groove side toward the crankshaft web.
Groove
Identification color of crankshaft journal
"CA CRANKSHAFT BEARING INSTALLATION (1) From the following table, select a bearing whose size is appropriate for the crankshaft journal outside diameter.
Aug. 1998
PWEE9616-A
Revised

Bearing bore size identification mark No. 1 No. 2 No. 3 No. 4 No. 5 Bearing bore identification mark
11A-12-3
Cylinder inner diameter size mark
Bottom of cylinder block
Rear face of cylinder block
Crankshaft journal outside diameter Identification color Yellow Size mm 56.994 - 57.000
Cylinder block bearing bore Identification mark 0 1 2
Crankshaft bearing Identification mark or color 1 or Green 2 or Yellow 1 or Green 2 or Yellow 3 or None 2 or Yellow 3 or None 4 or Blue 5 or Red
Crankshaft for No. 3
bearing
Identification mark or color 0 or Black 1 or Green 2 or Yellow 1 or Green 2 or Yellow 3 or None 2 or Yellow 3 or None 4 or Blue
None
56.988 - 56.994
0 1 2
White
56.982 - 56.988
0 1 2
Crankshaft bearing size identification mark or color
Identification mark or color E Mitsubishi Motors Corporation

Aug. 1998
For example, if the crankshaft journal outside diameter ID color is yellow and cylinder block bearing bore ID mark is 1, select a bearing whose ID mark is 2 or ID color is yellow for number 1, 2, 4 and 5, and a bearing whose ID mark is 1 or ID color is green for number 3. If there is no ID color paint on the crankshaft, measure the journal outside diameter and select a bearing appropriate for the measured value.
PWEE9616-A
Revised
11A-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.
Groove
Upper Lower
"DA BEARING CAP / BEARING CAP BOLT INSTALLATION (1) Install the bearing caps so the arrow points to the timing belt side. (2) Before installing the bearing cap bolts, check that the shank length of each bolt meets the limit. If the limit is exceeded, replace the bolt.
Shank length
9EN0477
Limit: Max. 71.1 mm (3) Apply engine oil to the threaded portion and bearing surface of the bolt. (4) Tighten the bolts to 25 Nm in the specified tightening sequence.
Arrow mark
Paint mark
Paint mark
(5) Make a paint mark on the head of each bolt. (6) Make a paint mark on the bearing cap at the position 90_ to 100_ from the paint mark made on the bolt in the direction of tightening the bolt. (7) According to the specified tightening sequence, give a 90_ to 100_ turn to each bolt and make sure that the paint mark on the bolt and that on the cap are in alignment. Caution D If the bolt is turned less than 90_, proper fastening performance may not be expected. When tightening the bolt, therefore, be careful to give a sufficient turn to it. D If the bolt is overtightened (exceeding 100_), loosen the bolt completely and then retighten it by repeating the tightening procedure from step (1).
90_ - 100_
6AE0299
Aug. 1998
PWEE9616-A
Revised
11A-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
"EA OIL SEAL INSTALLATION
"FA SEALANT APPLICATION TO OIL SEAL CASE Specified sealant: Mitsubishi Genuine equivalent Part No. MD970389 or
NOTE (1) Be sure to install the case 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.
Plastigage
INSPECTION
CRANKSHAFT OIL CLEARANCE (PLASTIGAGE METHOD) (1) Remove oil from the crankshaft journal and the crankshaft bearing. (2) Install the crankshaft. (3) Cut the Plastigage to the same length as the width of the bearing and place it on the journal in parallel with its axis. (4) Install the crankshaft bearing cap carefully and tighten the bolts to the specified torque. (5) Carefully remove the crankshaft bearing cap. (6) Measure the width of the Plastigage at its widest part by using a scale printed on the Plastigage package. Standard value: 0.02 - 0.04 mm Limit: 0.1 mm
Plastigage
Aug. 1998
PWEE9616-A
Revised
11A-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 from gasket chips and other foreign matter. Standard value: 0.05 mm Limit: 0.1 mm (3) If the distortion is excessive, correct within the allowable limit or replace. Grinding limit: 0.2 mm Includes/combined with cylinder head grinding Cylinder block height (when new): 4G63 284 mm 4G64 290 mm (4) Check cylinder walls for scratches and seizure. If defects are evident, correct (bored to oversize) or replace.
(5) Using cylinder gauge, measure the cylinder bore and cylindricity. If worn badly, correct cylinder to an oversize and replace piston and piston rings. Measure at the points shown in illustration. Standard value: Cylinder I.D. 4G63 85.00 - 85.03 mm 4G64 86.50 - 86.53 mm Cylindricity 0.01 mm or less
BORING CYLINDER (1) Oversize pistons to be used should be determined on the basis of the largest bore cylinder. Piston size identification
Size 0.50 O.S. 1.00 O.S. Identification mark 0.50 1.00
NOTE Size mark is stamped on the piston top. (2) Measure outside diameter of piston to be used. Measure it in thrust direction as shown. (3) Based on the measured piston O.D. calculate boring finish dimension. Boring finish dimension = Piston O.D. + (clearance between piston O.D. and cylinder) - 0.02 mm (honing margin)
Aug. 1998
PWEE9616-A
Revised
11A-12-7
(4) Bore all cylinders to the calculated boring finish dimension. Caution D To 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 piston O.D. and cylinder). (6) Check clearance between piston and cylinder. Clearance between piston and cylinder: 0.02 - 0.04 mm NOTE When boring cylinders, finish all of four cylinders to same oversize. Do not bore only one cylinder to an oversize.
Aug. 1998
PWEE9616-A
Added
NOTES

Mitsubishi Engine 4G6

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11A-0-1

E Mitsubishi Motors Corporation

E Mitsubishi Motors Corporation

4G6 ENGINE <E - W> - General Information

E Mitsubishi Motors Corporation

4G6 ENGINE <E - W> - General Information

Lubrication system Oil pump type

NOTE GDI is a trademark of Mitsubishi Motors Corporation.

E Mitsubishi Motors Corporation

4G6 ENGINE <E - W> - Specifications

Intake Exhaust Intake Exhaust

37.39 37.14 37.39 36.83 3 - 20/1.0 45

36.89 36.64 36.89 36.33 -

35.79 37.14 3 - 20/1.0 26

4G6 ENGINE <E - W> - Specifications

Valve thickness to valve guide clearance mm

Valve face angle mm Valve spring free length mm

Valve spring load/installed height N/mm

Valve spring out-of-squareness

Valve seat valve contact width mm Valve guide inner diameter mm

SOHC GDI SOHC GDI

Oversize rework dimensions of valve guide hole (SOHC) mm

0.05 Oversize diameter 0.25 Oversize diameter 0.50 Oversize diameter

Oversize rework dimensions of valve guide hole (GDI) mm

0.05 Oversize diameter 0.25 Oversize diameter 0.50 Oversize diameter

E Mitsubishi Motors Corporation

4G6 ENGINE <E - W> - Specifications

Maximum 71.1 0.1 0.2 -

E Mitsubishi Motors Corporation

4G6 ENGINE <E - W> - Specifications

11 8.8 8.8 11 11 8.8 30 11 8.8 23 23 19

4G6 ENGINE <E - W> - Specifications

8.8 18 8.8 8.8 11 11

4G6 ENGINE <E - W> - Specifications

4G6 ENGINE <E - W> - Specifications

39 6.9 8.8 21 18 19 9.8 44 18 23 36 16 9.8 23 21 12

4G6 ENGINE <E - W> - Specifications

E Mitsubishi Motors Corporation

4G6 ENGINE <E - W> - Specifications

NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA

E Mitsubishi Motors Corporation

4G6 ENGINE <E - W> - Specifications

E Mitsubishi Motors Corporation

4G6 ENGINE (E - W) - Special Tools

Installation of crankshaft rear oil seal Use with MD998776.

Silent shaft bearing puller stopper

Cylinder head bolt wrench (12)

Removal and installation of cylinder head bolt

Crankshaft front oil seal guide

Silent shaft bearing puller

Removal of counterbalance shaft front bearing

Silent shaft bearing puller

Removal of counterbalance shaft rear bearing

Crankshaft front seal installer

Installation of crankshaft front oil seal

E Mitsubishi Motors Corporation

4G6 ENGINE (E - W) - Special Tools

Lash adjuster retainer

Air bleeding of lash adjuster

Lash adjuster wire