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Mitsubishi 4g64 PDF
Mitsubishi 4g64 PDF
ENGINE
4G6 SERIES
CONTENTS
Number of cylinders 4
Compression ratio 10
SOHC-4G64
Descriptions Specifications
Number of cylinders 4
Compression ratio 10
GDIt
Descriptions Specifications
Number of cylinders 4
NOTE
GDI is a trademark of Mitsubishi Motors Corporation.
Timing belt
Auto-tensioner rod pushed-in amount [when pushed with a force of 98 1.0 or less -
- 196 N] mm
Rocker arms and camshaft
GDI 132 -
Valve thickness to valve guide clearance SOHC Intake 0.02 - 0.05 0.10
mm
Exhaust 0.03 - 0.07 0.15
GDI 294/40.0 -
GDI 6.6 -
Oversize rework dimensions of valve guide 0.05 Oversize diameter 11.05 - 11.07 -
hole (SOHC) mm
0.25 Oversize diameter 11.25 - 11.27 -
Oversize rework dimensions of valve guide 0.05 Oversize diameter 12.05 - 12.07 -
hole (GDI) mm
0.25 Oversize diameter 12.25 - 12.27 -
Intake oversize rework dimensions of valve 0.3 Oversize diameter 34.30 - 34.33 -
seat hole (SOHC) mm
0.6 Oversize diameter 34.60 - 34.63 -
Intake oversize rework dimensions of valve 0.3 Oversize diameter 35.30 - 35.33 -
seat hole (GDI) mm
0.6 Oversize diameter 35.60 - 35.63 -
Oil pressure at curb idle speed kPa [Oil temperature is 75 to 90_C] 78 or more -
4G64 86.5 -
4G64 290 -
4G64 86.5 -
Cylindricity mm 0.01 -
TORQUE SPECIFICATIONS
Items Nm
Adjusting bolt 10
Lock bolt 22
Alternator brace 23
Crankshaft pulley 25
Spark plug 25
Distributor (Carburetor) 12
Vacuum pipe 11
Throttle body 11
EGR valve 23
Intake manifold 19
Timing belt
Items Nm
Tensioner arm 22
Tensioner puller 48
Auto tensioner 23
Idler pulley 35
Tensioner “B” 18
Engine hanger 11
Carburetor (Carburetor) 17
Clamp A 8.8
Items Nm
Injector holder 22
Engine hanger 11
Thermostat housing 24
Water pump 14
Intake manifold 19
Engine hanger 11
Thermostat housing 23
Water pump 13
Knock sensor 22
Exhaust manifold
Items Nm
Heat protector 13
Cover 9.8
Drain plug 39
Oil screen 18
Relief plug 44
Plug 23
Flange bolt 36
Front case 23
Items Nm
Rear plate 11
SEALANTS
Item Specified sealant Quantity
Cam position sensor support Mitsubishi Genuine Part No. MD970389 or As required
equivalent
Engine coolant temperature sensor 3M Nut Locking Part No. 4171 or equivalent As required
Engine coolant temperature gauge unit 3M ATD Part No. 8660 or equivalent As required
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.
MB991603 Silent shaft bearing Guide stopper for removal and installation of
puller stopper counterbalance shaft rear bearing
Use with MD998372.
MB991654 Cylinder head bolt Removal and installation of cylinder head bolt
wrench (12)
MD998162 Plug wrench Removal and installation of front case cap plug
Use with MD998783.
MD998285 Crankshaft front oil Guide for installation of crankshaft front oil seal
seal guide Use with MD998375.
MD998443 Lash adjuster Retainer for holding lash adjuster in rocker arm
holder at time of removal and installation of rocker
shaft assembly
6
12 Nm
25 Nm 7
10
4
10 Nm 9
3
44 Nm
22 Nm 2
24 Nm
9 Nm 5
25 Nm
1
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
10 Nm
10 Nm
6
9
10
25 Nm 8
11
4
22 Nm
10 Nm
3
14 Nm
44 Nm
22 Nm 2
24 Nm
9 Nm 5
25 Nm
1
Removal steps
1. Drive belt 7. Ignition coil assembly
2. Water pump pulley 8. Spark plug
3. Alternator brace 9. Camshaft position sensor
4. Alternator "AA 10. Camshaft position sensing support
5. Crankshaft pulley 11. Camshaft position sensing cylinder
6. Spark plug cable
9.8 Nm
11
25 Nm
12
49 Nm
7
9.8 Nm
1
22 Nm 8.8 Nm
4 5
23 Nm
13 Nm
8
9 2
49 Nm
3
25 Nm
10
49 Nm
22 Nm
Removal steps
1. Oil level gauge 8. Idler pulley bracket
2. Oil level gauge guide (Vehicle for Hong Kong)
3. O-ring 9. Idler pulley
4. Drive belt (Vehicle for Hong Kong)
5. Water pump pulley 10. Crankshaft pulley
6. Alternator 11. Ignition coil
7. Alternator brace 12. Spark plug
8.8 Nm 8.8 Nm 2 11 Nm
3
11 Nm
8.8 Nm 4 11 Nm
16
12
5
14
13 11
7
6
1 8.8 Nm
23 Nm
23 Nm 17 19 Nm
15 18
11 Nm
10
30 Nm 19
19 Nm
8.8 Nm
30 Nm
8
Removal steps
1. Vacuum pipe and hose "DA 7. Throttle body gasket
(1999 model vehicles for Hong "CA 8. Intake manifold stay
Kong) "BA 9. Air intake plenum resonator
2. Solenoid valve (1999 model ve- 10. Gasket
hicles for Hong Kong) 11. Water hose
3. Vacuum pipe and hose 12. EGR valve
(Vehicles for Europe and 2000 13. Gasket
model vehicles for Hong Kong) "AA 14. Hose clamp
4. Solenoid valve "AA 15. EGR support
(Vehicles for Europe and 2000 "AA 16. Gasket
model vehicles for Hong Kong) 17. Gasket
5. Vacuum pipe 18. Intake manifold
6. Throttle body 19. Gasket
8.8 Nm
8.8 Nm
2
8
11 Nm
9
11 3
23 Nm 4 19 Nm
13
23 Nm
5
10
14 15
12
16
7
19 Nm
30 Nm
11 Nm
8.8 Nm
Removal steps
1. Vacuum pipe and hose 9. EGR valve
2. Solenoid valve 10. Gasket
3. Throttle body "AA 11. Hose clamp
"DA 4. Throttle body gasket "AA 12. EGR support
"CA 5. Intake manifold stay "AA 13. Gasket
"BA 6. Air intake plenum resonator 14. Gasket
7. Gasket 15. Intake manifold
8. Water hose 16. Gasket
Air intake
plenum
resonator
Projection
20
45 Nm
18
45 Nm
17
16
15 23
14 18 Nm
13 88 Nm 5
19 22
7 21
22 Nm 9 Nm
1 48 Nm
49 Nm 49 Nm
3
6 4
14 Nm
12
10
11
8 9 54 Nm
23 Nm
35 Nm
118 Nm
11 Nm
9 Nm 2
Removal steps
1. Timing belt front upper cover AE" 12. Crankshaft sprocket
2. Timing belt front lower cover 13. Flange (Multipoint fuel injection)
3. Power steering bracket 14. Flange (Carburetor)
4. Crankshaft position sensor 15. Tensioner “B”
(Multipoint fuel injection) AF" "FA 16. Timing belt “B”
AA" "KA 5. Timing belt AG" "EA 17. Counterbalance shaft sprocket
"JA 6. Tensioner pulley "DA 18. Spacer
7. Tensioner arm AH" 19. Crankshaft sprocket “B”
"IA 8. Auto tensioner "CA 20. Engine support bracket
9. Idler pulley AI" "AA 21. Camshaft sprocket bolt
AC" "HA 10. Oil pump sprocket 22. Camshaft sprocket
AD" "GA 11. Crankshaft bolt 23. Timing belt rear cover
21
25
1 22 3.4 Nm
6
48 Nm 7
23 26
24
27
23 Nm
8
2 23 Nm
31
13 11 Nm
12
11 Nm
118 Nm
49 Nm 11 Nm
9 Nm 32
5
30 18 3
45 Nm
17 4
88 Nm 18 Nm
28
29 15
10
33
48 Nm 20
19 8.8 Nm
16 49 Nm
14
9
11
54 Nm
Removal steps
1. Front upper cover "DA 18. Spacer
2. Front lower cover AH" 19. Crankshaft sprocket B
3. Power steering pump bracket stay 20. Crankshaft key
4. Power steering bracket 21. Breather hose
AB" "LA 5. Timing belt 22. PCV hose
"JA 6. Tensioner pulley 23. PCV valve
7. Tensioner arm 24. PCV valve gasket
"IA 8. Auto tensioner 25. Oil filler cap
9. Idle pulley 26. Rocker cover
10. Crankshaft position sensor 27. Rocker cover gasket
AC" "HA 11. Oil pump sprocket "CA 28. Engine support bracket
AD" "GA 12. Crankshaft bolt AJ" "BA 29. Camshaft sprocket bolt
AE" 13. Crankshaft sprocket 30. Camshaft sprocket
14. Flange 31. Timing belt rear right cover
15. Tensioner B 32. Timing belt rear left upper cover
AF" "FA 16. Timing belt B 33. Timing belt rear left lower cover
AG" "EA 17. Counterbalance shaft sprocket
E Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised
4G6 ENGINE (E - W) - Timing Belt 11A-4-3
REMOVAL SERVICE POINTS
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.
Counter-
Sharp balance
edge shaft
6EN0564
6AE0049
6AE0050
6EN0350
Small holes
6EN1323
6EN1327
6EN0899
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.
6EN1327
6EN1327
(7) Fit the timing belt over the exhaust side camshaft sprocket,
and secure it at the illustrated position using a paper
clip.
(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.
Oil pump
sprocket
Crankshaft
sprocket
Crankshaft
(12)Turn the crankshaft pulley a little in the illustrated direction
sprocket 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.
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.
AUTO TENSIONER
12 mm (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 (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
Movement value obtained in step (3), replace the auto tensioner.
6EN1033
11 Nm
29 Nm
5
4
49 Nm
29 Nm
3
13 Nm
49 Nm
13 Nm
2 1
Removal steps
1. Exhaust manifold cover (Vehicle for Europe)
2. Exhaust manifold (Vehicle for Europe)
3. Exhaust manifold (Vehicle for Hong Kong)
4. Exhaust manifold gasket
5. Engine hanger
17 Nm
2 22 Nm
6 23 Nm
4
1 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)
E Mitsubishi Motors Corporation Dec. 1996 PWEE9616
11A-5-2 4G6 ENGINE (E - W) - Fuel and Emission Control Parts
3
5 22 Nm
12 Nm
9
18 Nm
9 Nm 4
8
12
13
1
14 11
10 2
7
6
Removal steps
1. Throttle body "BA 8. Fuel pressure regulator
"CA 2. Throttle body gasket 9. O-ring
3. EGR valve (With EGR valve) 10. Insulator
4. Cover (Without EGR valve) "AA 11. Injectors
5. EGR valve gasket 12. O-ring
6. Injectors and delivery pipe 13. Grommet
7. Insulator 14. Delivery pipe
22 Nm
6
12 Nm 4
5 15 18 Nm
13 3
14
1
12
10 2
9 11
9 Nm
8
7
Removal steps
1. Throttle body "BA 9. Fuel pressure regulator
"CA 2. Throttle body gasket 10. O-ring
3. EGR valve 11. Insulator
4. EGR valve gasket "AA 12. Injectors
5. Fuel hose 13. O-ring
6. Fuel return pipe 14. Grommet
7. Injectors and delivery pipe 15. Delivery pipe
8. Insulator
O-ring
1EN0388
26
18 Nm
11 Nm 8.8 Nm 8.8 Nm
8.8 Nm
15 14 2
6
17
8
3
11 Nm
18
11 Nm 1
7 16
11
10 4.9 Nm ®
17 Nm ± 2 Nm 19 22
9 8.8 Nm
21
20
12
11 Nm 18 Nm
4
13
5
37 30 23
34
22 Nm
35
24
36
32 27
33 28 23 Nm
29 31 25
11 Nm
38
Removal steps
1. Fuel hose "DA 20. Fuel pressure sensor
2. Fuel low pressure pipe 21. Backup ring
3. O-ring 22. O-ring
4. Fuel pump return nipple "CA 23. Pump camshaft case
5. O-ring 24. O-ring
6. Clamp A 25. O-ring
7. Fuel pipe bracket 26. Injector harness
"FA 8. Fuel feed pipe 27. Washer
9. Backup ring 28. Injector holder
10. O-ring "BA 29. Delivery pipe and injector assembly
11. Backup ring 30. Insulator
"FA 12. Fuel pump 31. Injector washer
13. O-ring 32. Injector
14. Harness bracket "AA 33. Corrugated washer
"EA 15. Fuel return pipe "AA 34. Backup ring
16. Backup ring "AA 35. O-ring
17. O-ring "AA 36. Backup ring
18. Backup ring 37. Delivery pipe
"EA 19. Fuel high pressure regulator 38. Engine hanger
18 Nm
11 Nm 8.8 Nm
30 8.8 Nm
8.8 Nm 15 2
6 14
17
8 3
11 Nm
18
1
16
7
11 Nm
11 19 26
10 4.9 Nm ®
17 Nm ± 2 Nm 25
9 8.8 Nm
24
23
18 Nm
12
11 Nm 22
4
13 21
5 20
27 18 Nm
41 34
38
22 Nm
39
28
40
36 31
37 32 23 Nm
33 35 29
11 Nm
42
Removal steps
1. Fuel hose 23. Flange
2. Fuel low pressure pipe (SPACE WAGON for Europe)
3. O-ring "DA 24. Fuel pressure sensor
4. Fuel pump return nipple (SPACE WAGON for Europe)
5. O-ring 25. Backup ring
6. Clamp A (SPACE WAGON for Europe)
7. Fuel pipe bracket 26. O-ring
"FA 8. Fuel feed pipe (SPACE WAGON for Europe)
9. Backup ring "CA 27. Pump camshaft case
10. O-ring 28. O-ring
11. Backup ring 29. O-ring
"FA 12. Fuel pump 30. Injector harness
13. O-ring 31. Washer
14. Harness bracket 32. Injector holder
"EA 15. Fuel return pipe "BA 33. Delivery pipe and injector assembly
16. Backup ring 34. Insulator
17. O-ring 35. Injector washer
18. Backup ring 36. Injector
"EA 19. Fuel high pressure regulator "AA 37. Corrugated washer
"DA 20. Fuel pressure sensor "AA 38. Backup ring
(GALANT and SPACE WAGON for "AA 39. O-ring
Hong Kong) "AA 40. Backup ring
21. Backup ring (GALANT and SPACE 41. Delivery pipe
WAGON for Hong Kong) 42. Engine hanger
22. O-ring (GALANT and SPACE
WAGON for Hong Kong)
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
3 1 2 4
Backup ring
15
3 4
11 Nm
5
13 Nm
14
20 Nm 2 8
7
16 8
31 Nm
11
17
12 Nm
14 Nm
12 10
13
14 Nm
Removal steps
1. Water hose 9. Water pump
2. Water hose 10. Water pump gasket
"CA 3. Engine coolant temperature gauge 11. Oil level gauge
unit 12. Oil level gauge guide
4. Water inlet fitting 13. O-ring
5. Thermostat 14. Intake manifold stay
"BA 6. Thermostat housing 15. Intake manifold
"AA 7. Water inlet pipe 16. Intake manifold gasket
"AA 8. O-ring 17. Engine hanger
11 Nm 4
5
17 6
19 Nm
13 Nm
2
9 29 Nm
15
8
31 Nm 9 3
23 Nm
19
12
18
11 Nm
14 Nm
13 11
10
14
14 Nm
Removal steps
1. Water hose 10. Water pump
2. Water hose 11. Water pump gasket
"DA 3. Engine coolant temperature sensor 12. Oil level gauge
"CA 4. Engine coolant temperature gauge 13. Oil level gauge guide
unit 14. O-ring
5. Water inlet fitting 15. Intake manifold stay
6. Thermostat 16. Intake manifold
"BA 7. Thermostat housing 17. Intake manifold gasket
"AA 8. Water inlet pipe 18. Engine hanger
"AA 9. O-ring 19. Detonation sensor
13 Nm
24 Nm
8
1
11 Nm
17 5
6
7
18
13 Nm
2
19 Nm 29 Nm
10
9
4
16 10
31 Nm
19
13
11 Nm
11
14 Nm
14
12
14 Nm 15
Removal steps
1. Water hose "AA 10. O-ring
2. Water hose 11. Water pump
3. Water hose 12. Water pump gasket
"DA 4. Engine coolant temperature sensor 13. Oil level gauge
"CA 5. Engine coolant temperature gauge 14. Oil level gauge guide
unit 15. O-ring
6. Water inlet fitting 16. Intake manifold stay
7. Thermostat 17. Intake manifold
"BA 8. Thermostat housing 18. Intake manifold gasket
"AA 9. Water inlet pipe 19. Engine hanger
O-ring 6EN0594
9EN0092
9EN0091
12 Nm
11 Nm
7
2 29 Nm
4
23 Nm
1 3
9
6
12 Nm
5
13 10
12 Nm
22 Nm
9
11 12
13 Nm
Removal steps
1. Water hose "CA 7. Water outlet fitting
"EA 2. Water hose "BA 8. Thermostat housing
3. Engine coolant temperature sensor "AA 9. O-ring
"DA 4. Engine coolant temperature gauge "AA 10. Water inlet pipe
unit 11. Water pump
5. Water inlet fitting 12. Gasket
6. Thermostat 13. Knock sensor
9EN0092
9EN0091
1
13 Nm
29 Nm
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
1
13 Nm
5
29 Nm
49 Nm
2
13 Nm
4
Removal steps
"AA 1. Water outlet fitting
2. Exhaust manifold cover
3. Engine hanger
4. Exhaust manifold
5. Exhaust manifold gasket
3.4 Nm
31 Nm
13
8
12
11
12
11
12 10
11 16
12 10
11
10
15
10 15
14 15 18
17
15
(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.
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.
A B C
(2) Place the lash adjuster in container A and clean its outside
surface.
NOTE
Use a nylon brush if deposits are hard to remove.
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
MD998442 Diesel fuel lash adjuster’s 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.
(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
adjuster’s pressure chamber.
Caution
D The steel ball spring is extremely weak, so the
MD998442 Diesel fuel lash adjuster’s 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
(10)Stand the lash adjuster with its plunger at the top, then
MD998442
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
20 Nm
10
9.8 Nm
2
3
6 5
21 Nm
11 12
4
1
8.8 Nm
13 Nm
Removal steps
1. Camshaft position sensor 7. "BA Beam camshaft cap
2. Cover 8. "BA Beam camshaft cap gasket
3. Gasket 9. "BA Intake camshaft
"DA 4. Camshaft position sensing cylinder 10. "BA Exhaust camshaft
"CA 5. Camshaft position sensing cylinder 11. Rocker arm
support AA" "AA 12. Lash adjuster
"BA 6. Oil seal
3 mm
(2) Apply a 3 mm thick continuous bead of sealant to the
Timing belt bottom surface of the beam camshaft cap along the
side
groove.
Specified sealant:
Mitsubishi genuine Part No. MD970389 or
equivalent
(7) Install the camshaft oil seal before the sealant applied
becomes dry and hard.
MD998713 (8) Wipe off squeezed out excess sealant from the
circumference of the beam camshaft cap.
INSPECTION
CAMSHAFT
(1) Measure the cam height.
Standard value:
Intake 35.79 mm
Exhaust 37.14 mm
Limit:
Intake 35.29 mm
Exhaust 36.64 mm
E Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added
11A-8a-4 4G6 ENGINE (E - W) - Rocker Arms and Camshafts (GDI)
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.
A B C
(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 adjuster’s functionality may be lost if the
Diesel fuel air bleed wire is pushed in hard.
MD998442
NOTE
If the plunger remains stiff or the mechanism appears
otherwise abnormal, replace the lash adjuster.
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
MD998442 oil hole at yourself or other people.
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.
Diesel fuel
MD998442
(9) Remove the lash adjuster from the container, then stand
the lash adjuster with its plunger at the top. Push the
plunger firmly and check that it does not move. Also,
check that the lash adjuster’s height matches that of a
new lash adjuster.
NOTE
If lash adjuster contracts, 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.
Lash adjuster
(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
Nut mm.
Lash
adjuster 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
Diesel fuel to fill with diesel fuel.
MD998442
2 1
8
20 9
10
4
14
5 15
6 17
12
13
16 19
11
18
Removal steps
AA" "EA 1. Cylinder head bolt 11. Exhaust valve
2. Cylinder head assembly AC" "AA 12. Valve stem seal
"DA 3. Cylinder head gasket 13. Valve spring seat
AB" "CA 4. Retainer lock AC" "AA 14. Valve stem seal
5. Valve spring retainer 15. Valve spring seat
"BA 6. Valve spring 16. Intake valve guide
7. Intake valve 17. Exhaust valve guide
AB" "CA 8. Retainer lock 18. Intake valve seat
9. Valve spring retainer 19. Exhaust valve seat
"BA 10. Valve spring 20. Cylinder head
1 8
9
10
14
4 20
5 15
6
17
12
13
19
16 11
18
Removal steps
AA" "EA 1. Cylinder head bolt 11. Exhaust valve
2. Cylinder head assembly AC" "AA 12. Valve stem seal
3. Cylinder head gasket 13. Valve spring seat
AB" "CA 4. Retainer lock AC" "AA 14. Valve stem seal
5. Valve spring retainer 15. Valve spring seat
"BA 6. Valve spring 16. Intake valve guide
7. Intake valve 17. Exhaust valve guide
AB" "CA 8. Retainer lock 18. Intake valve seat
9. Valve spring retainer 19. Exhaust valve seat
"BA 10. Valve spring 20. Cylinder head
9EN0061
MB991654
9EN0062
MD998772
MD998737
9EN0062
MD998772
6EN0782
(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
90_ 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.
90_
Paint mark
Caution
D If the bolt is turned less than 90_, proper fastening
6AE0297
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
VALVE SPRING
Out of (1) Measure the free height of spring and, if it is smaller
square
than the limit, replace.
Item Standard value mm Limit mm
Free SOHC 51.0 50.0
height
GDI 48.3 47.3
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.
Valve
guide Item Standard value mm Limit mm
SOHC Intake 0.02 - 0.05 0.10
Exhaust 0.03 - 0.07 0.15
GDI Intake 0.02 - 0.05 0.10
Exhaust 0.05 - 0.09 0.15
VALVE SEAT
Valve stem end
(1) Assemble the valve, then measure the valve stem
projection between the end of the valve stem and the
Valve stem
projection spring seating surface. If the measurement exceeds the
specified limit, replace the valve seat.
Spring seating Item Standard value mm Limit mm
surface
SOHC Intake 49.30 49.80
Exhaust 49.30 49.80
DEN0212 GDI Intake 49.20 49.70
Exhaust 48.40 48.90
0.5 - 1 mm
(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”.
21
18 (SOHC) 20
23 Nm
9.8 Nm 29
9
28 22
23 Nm
23 21 Nm
24
18 (GDI)
19 27 8
18 Nm 16 Nm 7
6
25 26
18 Nm
12 39 Nm
17 3
10 11
(4G64) 16 23 Nm 2
15 36 Nm
13
14 4 5
23 Nm
8.8 Nm
1 6.9 Nm
9.8 Nm 44 Nm
21 Nm
Removal steps
"OA 1. Oil filter 18. Oil filter bracket
2. Drain plug 19. Oil filter bracket gasket
"NA 3. Drain plug gasket "HA 20. Front case assembly
4. Oil level sensor 21. Front case gasket
(Vehicle for Europe) 22. Oil pump cover
5. Transmission stay (GDI engine) "GA 23. Oil pump driven gear
AA" "LA 6. Oil pan "GA 24. Oil pump drive gear
7. Oil screen "FA 25. Crankshaft front oil seal
8. Oil screen gasket "EA 26. Oil pump oil seal
9. Stiffener (SOHC engine - vehicle "DA 27. Counterbalance shaft oil seal
for Europe) 28. Front case
AD" "KA 10. Plug 29. Counterbalance shaft, left
11. O-ring 30. Counterbalance shaft, right
AE" "JA 12. Flange bolt AF" "CA 31. Counterbalance shaft front bearing
"IA 13. Oil pressure switch AG" "BA 32. Counterbalance shaft rear bearing,
14. Relief plug left
15. Relief plug gasket AG" "AA 33. Counterbalance shaft rear bearing,
16. Relief spring right
17. Relief plunger
E Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised
11A-10-2 4G6 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan
34
32
31
Apply engine oil to all 33
moving parts before
installation.
22
21
23 Nm
9.8 Nm
30
29 23
6.9 Nm
23 Nm
24 25
7
10 6
18 Nm
20 9
28
19 16 Nm
26 18 Nm
27
13
18
11 12 23 Nm 6.9 Nm
17
14 36 Nm 3 5
16 12 Nm
15
23 Nm 2
39 Nm 4
1 6.9 Nm
9.8 Nm 44 Nm
8
21 Nm
Removal steps
"OA 1. Oil filter 19. Oil filter bracket
2. Drain plug 20. Oil filter bracket gasket
"NA 3. Drain plug gasket "HA 21. Front case assembly
4. Transmission stay 22. Gasket
5. Oil level gauge guide 23. Oil pump cover
AB" "MA 6. Oil pan lower "GA 24. Oil pump driven gear
7. Baffle plate "GA 25. Oil pump drive gear
AC" "MA 8. Oil pan upper "FA 26. Crankshaft front oil seal
9. Oil screen "EA 27. Oil pump oil seal
10. Gasket "DA 28. Counterbalance shaft oil seal
AD" "KA 11. Plug 29. Front case
12. O-ring 30. Counterbalance shaft, left
AE" "JA 13. Flange bolt 31. Counterbalance shaft, right
"IA 14. Oil pressure switch AF" "CA 32. Counterbalance shaft front bearing
15. Relief plug AG" "BA 33. Counterbalance shaft rear bearing,
16. Gasket left
17. Relief spring AG" "AA 34. Counterbalance shaft rear bearing,
18. Relief plunger right
MD998783
Plug
Screwdriver
6EN1026
6EN0565
MD998705
6EN1034
MD998705
6EN0557
MD998705
MD998705
Bearing
Cylinder block
6EN1035
(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).
6EN0564
(2) Secure the oil pump driven gear onto the left
counterbalance shaft by tightening the flange bolt to
specified torque.
MD998783
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.
M6 ´ 16
mm
8 (6) Tighten the oil pan lower mounting bolts in the sequence
6 shown in the illustration.
1
4
3
2 5
9 7
Drain plug
gasket
7EN0307
6EN0591
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 0.08 - 0.14 mm
Driven gear 0.06 - 0.12 mm
4
10
12
9
11
2
1
Removal steps
"GA 1. Nut "CA 7. Piston ring No. 2
AA" "FA 2. Connecting rod cap "BA 8. Oil ring
"EA 3. Connecting rod bearing AB" "AA 9. Piston pin
"DA 4. Piston and connecting rod assem- 10. Piston
bly 11. Connecting rod
"EA 5. Connecting rod bearing 12. Bolt
"CA 6. Piston ring No. 1
E Mitsubishi Motors Corporation Dec. 1996 PWEE9616
11A-11-2 4G6 ENGINE (E - W) - Piston and Connecting Rod
(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.
3 mm + L (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.
(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
(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
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
(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
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
13 4
12 A
21 5
<GALANT>
9 Nm
11 Nm 11 7
8 132 Nm
9 6
19
20 18
15
14
Removal steps
1. Flywheel bolt <M/T> 17. Crankshaft
2. Adapter plate <M/T> "CA 18. Crankshaft bearing, upper
3. Flexible flywheel <M/T> "BA 19. Crankshaft thrust bearing <GDI en-
4. Adapter plate <M/T> gine>
5. Crankshaft bushing <M/T> AA" "AA 20. Oil jet <GDI engine>
6. Drive plate bolt <A/T> 21. Cylinder block
7. Adapter plate <A/T>
8. Drive plate <A/T> Caution
9. Crankshaft bushing <A/T> On the flexible wheel equipped engines, do not
10. Rear plate remove any of the bolts “A” of the flywheel shown
11. Bell housing cover in the illustration.
"FA 12. Oil seal case The balance of the flexible flywheel is adjusted in
"EA 13. Oil seal an assembled condition. Removing the bolt,
"DA 14. Bearing cap bolt therefore, can cause the flexible flywheel to be out
"DA 15. Bearing cap
"CA 16. Crankshaft bearing, lower of balance, giving damage to the flywheel.
Bearing bore
identification
mark
Cylinder inner
diameter size
mark
Crankshaft journal outside diameter Cylinder block Crankshaft bearing Crankshaft bearing
bearing bore for No. 3
1 2 or Yellow 1 or Green
2 1 or Green 2 or Yellow
1 3 or None 2 or Yellow
2 2 or Yellow 3 or None
1 4 or Blue 3 or None
2 5 or Red 4 or Blue
Crankshaft bearing size For example, if the crankshaft journal outside diameter
identification mark or color 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
Identification appropriate for the measured value.
mark or color
Upper
Lower
Arrow mark
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.
Plastigage
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
BORING CYLINDER
(1) Oversize pistons to be used should be determined on
the basis of the largest bore cylinder.
Piston size identification
Size Identification mark
0.50 O.S. 0.50
1.00 O.S. 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)