Mitsubishi 4G Engine

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
E Mitsubishi Motors Corporation Dec. 1996 PWEE9616

4G6 ENGINE <E - W> - General Information 11A-0-3
GENERAL INFORMATION
SOHC-4G63
SOHC-4G64
Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised

11A-0-4 4G6 ENGINE <E - W> - General Information
GDI
Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added

4G6 ENGINE <E - W> - Specifications 11A-1-1
1. SPECIFICATIONS
SERVICE SPECIFICATIONS
Timing belt
Rocker arms and camshaft
Rocker arms and camshaft (GDI)
Cylinder head and valves

11A-1-2 4G6 ENGINE <E - W> - Specifications

Front case, counterbalance shaft and oil pan
Piston and connecting rod
Crankshaft, flywheel and drive plate

TORQUE SPECIFICATIONS
Alternator and ignition system
Intake manifold (GDI)
Timing belt
Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised

Exhaust manifold (GDI)
Fuel and emission parts
Fuel part (GDI)

Water pump and intake manifold
Water pump and water hose (GDI)
Exhaust manifold

Rocker arms and camshaft
Rocker arms and camshafts (GDI)
Cylinder head and valves
Front case, counterbalance shaft and oil pan

Piston and connecting rod
Crankshaft, flywheel and drive plate

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

FORM-IN-PLACE GASKET
Disassembly
Surface Preparation
Form-in-Place Gasket Application

4G6 ENGINE (E - W) - Special Tools 11A-2-1
2. SPECIAL TOOLS
Mitsubishi Motors Corporation Dec. 1996 PWEE9616

11A-2-2 4G6 ENGINE (E - W) - Special Tools

4G6 ENGINE (E - W) - Special Tools 11A-2-3

11A-2-4 4G6 ENGINE (E - W) - Special Tools

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
4
10 Nm 9
3
44 Nm
22 Nm 2
24 Nm
9 Nm 5
25 Nm
1
Removal steps

11A-3-2 4G6 ENGINE (E - W) - Alternator and Ignition System
REMOVAL AND INSTALLATION <MULTIPOINT FUEL INJECTION>
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

4G6 ENGINE (E - W) - Alternator and Ignition System 11A-3-3
REMOVAL AND INSTALLATION (GDI)
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

11A-3-4 4G6 ENGINE (E - W) - Alternator and Ignition System
INSTALLATION SERVICE POINTS

A CAMSHAFT POSITION SENSOR SUPPORT
INSTALLATION
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or
equivalent
B DISTRIBUTOR ASSEMBLY INSTALLATION

4G6 ENGINE (E - W) - Intake Manifold (GDI) 11A-3a-1
3a. INTAKE MANIFOLD (GDI)
REMOVAL AND INSTALLATION (SPACE WAGON)
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
D
C
B
A
A
A

11A-3a-2 4G6 ENGINE (E - W) - Intake Manifold (GDI)
REMOVAL AND INSTALLATION (GALANT)
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
A
D A
C A
B

4G6 ENGINE (E - W) - Intake Manifold (GDI) 11A-3a-3
A EGR SUPPORT / HOSE CLAMP / GASKET
INSTALLATION
B AIR INTAKE PLENUM RESONATOR

INSTALLATION
C INTAKE MANIFOLD STAY INSTALLATION
D THROTTLE BODY GASKET INSTALLATION
Mitsubishi Motors Corporation 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 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
E
F F
A K G E
J D
H
I C
I A
C H
D G

11A-4-2 4G6 ENGINE (E - W) - Timing Belt
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
D
H
B L
J
C H C
D G J B
E
F F
G E
REMOVAL SERVICE POINTS
A TIMING BELT REMOVAL
B TIMING BELT REMOVAL
Caution
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.
C OIL PUMP SPROCKET REMOVAL

D CRANKSHAFT BOLT LOOSENING
E CRANKSHAFT SPROCKET REMOVAL
F TIMING BELT “B” REMOVAL
G COUNTERBALANCE SHAFT SPROCKET

REMOVAL

H CRANKSHAFT SPROCKET “B” REMOVAL
I CAMSHAFT SPROCKET BOLT LOOSENING
J CAMSHAFT SPROCKET BOLT LOOSENING

A CAMSHAFT SPROCKET BOLT TIGHTENING
B CAMSHAFT SPROCKET BOLT TIGHTENING

C ENGINE SUPPORT BRACKET INSTALLATION
Specified sealant: 3M ATD Part No. 8660 or equivalent
D SPACER INSTALLATION
E COUNTERBALANCE SHAFT SPROCKET

INSTALLATION
F TIMING BELT “B” INSTALLATION

(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.
B A (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

Caution
Leave the wire installed in the auto tensioner.
J TENSIONER PULLEY INSTALLATION
K TIMING BELT INSTALLATION


Standard value: 3.8 - 4.5 mm
L TIMING BELT INSTALLATION



Caution
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.
Standard value: 3.8 - 4.5 mm
INSPECTION
TIMING BELT

AUTO TENSIONER
Standard value: 12 mm

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
3
13 Nm
49 Nm
13 Nm
2 1
Removal steps

4G6 ENGINE (E - W) - Fuel and Emission Control Parts 11A-5-1
5. FUEL AND EMISSION CONTROL PARTS
17 Nm
2 22 Nm
6 23 Nm
4
1 8
Removal steps

11A-5-2 4G6 ENGINE (E - W) - Fuel and Emission Control Parts
REMOVAL AND INSTALLATION <MULTIPOINT FUEL INJECTION - GALANT>
3
5 22 Nm
12 Nm
9
18 Nm
9 Nm 4
8
12
13
1
14 11
10 2
7
6
Removal steps
B
C

4G6 ENGINE (E - W) - Fuel and Emission Control Parts 11A-5-3
<MULTIPOINT FUEL INJECTION - SPACE WAGON>
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
B
C

11A-5-4 4G6 ENGINE (E - W) - Fuel and Emission Control Parts

A INJECTORS INSTALLATION
B FUEL PRESSURE REGULATOR INSTALLATION
Caution
Be sure not to let engine oil get into the delivery
pipe.
GALANT SPACE WAGON

C GASKET INSTALLATION

4G6 ENGINE (E - W) - Fuel Part (GDI) 11A-5a-1
5a. FUEL PART (GDI)
REMOVAL AND INSTALLATION (1999 MODEL SPACE WAGON)
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
19
17 Nm 2 Nm 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

11A-5a-2 4G6 ENGINE (E - W) - Fuel Part (GDI)
Removal steps
D
A
E A
A
A

4G6 ENGINE (E - W) - Fuel Part (GDI) 11A-5a-2a
REMOVAL AND INSTALLATION (2000 MODEL SPACE WAGON and GALANT)
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

11A-5a-2b 4G6 ENGINE (E - W) - Fuel Part (GDI)
Removal steps
F
C
E B
E A
D A
A
A

A BACKUP RING / CORRUGATED WASHER
INSTALLATION
Caution
Always replace the corrugated washer with new
one. Reused corrugated washer can cause fuel
or gas leaks.
B DELIVERY PIPE AND INJECTOR ASSEMBLY

INSTALLATION
Caution
Strictly observe the specified torque.
3 1 2 4

11A-5a-4 4G6 ENGINE (E - W) - Fuel Part (GDI)
C PUMP CAMSHAFT CASE INSTALLATION
D FUEL PRESSURE SENSOR INSTALLATION
E FUEL HIGH PRESSURE REGULATOR / FUEL

RETURN PIPE INSTALLATION

F FUEL PUMP / FUEL FEED PIPE INSTALLATION
1 3
4 Caution
2
Strictly observe the specified tightening torque.
Deviation from the specification can cause
problems such as leakage or the like.

4G6 ENGINE (E - W) - Water Pump and Intake Manifold 11A-6-1
6. WATER PUMP AND INTAKE MANIFOLD
13 Nm
24 Nm
1 6
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
B
A
A

11A-6-2 4G6 ENGINE (E - W) - Water Pump and Intake Manifold
REMOVAL AND INSTALLATION <MULTIPOINT FUEL INJECTION - GALANT>

13 Nm
24 Nm
7
16 1
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
D
C
B
A
A

4G6 ENGINE (E - W) - Water Pump and Intake Manifold 11A-6-3
<MULTIPOINT FUEL INJECTION - SPACE WAGON>
3
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
A
D
C
B
A

11A-6-4 4G6 ENGINE (E - W) - Water Pump and Intake Manifold

A WATER PIPE / O-RING INSTALLATION
Caution
Keep the O-ring free of oil or grease.
B SEALANT APPLICATION TO THERMOSTAT

HOUSING
Specified sealant:
equivalent
C SEALANT APPLICATION TO ENGINE COOLANT

TEMPERATURE GAUGE UNIT
Specified sealant: 3M ATD Part No. 8660 or equivalent
D SEALANT APPLICATION TO ENGINE COOLANT

TEMPERATURE SENSOR
Specified sealant:
3M Nut Locking Part No. 4171 or equivalent

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
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
E Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added

11A-6a-2 4G6 ENGINE (E - W) - Water Pump and Water Hose (GDI)

"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:
equivalent
"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:
equivalent
"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

4G6 ENGINE (E - W) - Exhaust Manifold 11A-7-1
7. EXHAUST MANIFOLD
REMOVAL AND INSTALLATION (GALANT)
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

11A-7-2 4G6 ENGINE (E - W) - Exhaust Manifold
REMOVAL AND INSTALLATION (SPACE WAGON)
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 mm diameter "AA SEALANT APPLICATION TO WATER OUTLET
bead sealant FITTING
Specified sealant:
equivalent
NOTE
(1) Be sure to install the water outlet fitting quickly while
6EN1170
the sealant is wet (within 15 minutes).
(2) After installation, keep the sealed area away from
the oil and coolant for approx. 1 hour.

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 1
3
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
Removal steps "BA 10. Rocker shaft spring

1. Breather hose 11. Rocker arm A
2. P.C.V. hose 12. Rocker arm B
3. Oil filler cap 13. Rocker arm shaft (Intake side)
4. Rocker cover "AA 14. Lash adjuster
5. Rocker cover gasket 15. Rocker arm C
6. Oil seal 16. Rocker arm shaft (Exhaust side)
"CA 7. Oil seal "AA 17. Lash adjuster
AA" "BA 8. Rocker arms and rocker arm shaft 18. Camshaft
AA" "BA 9. Rocker arms and rocker arm shaft

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
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

INSPECTION
CAMSHAFT
(1) Measure the cam height.
Item Standard value mm Limit mm
GALANT Intake 37.39 36.89
Exhaust 37.14 36.64
SPACE Intake 37.39 36.89
WAGON
Exhaust 36.83 36.33
ROCKER ARM
(1) Check the roller surface. If any dents, damage or seizure
is evident, replace the rocker arm.
(2) 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.
(1) Prepare three containers and approximately five liters

Outside Inside Filling with of diesel fuel. Into each container, pour enough diesel
cleaning cleaning diesel fuel fuel to completely cover a lash adjuster when it is standing
upright. Then, perform the following steps with each lash
adjuster.
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
MD998442 Diesel fuel lash adjuster’s functionality may be lost if the
air bleed wire is pushed in hard.
MD998442
Diesel fuel

(9) Place the lash adjuster in container C. Then, gently push
MD998442 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
Diesel
fuel is filled with diesel fuel.
MD998441
(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
(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 adjuster’s 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

Division = 1 mm down tester).
MD998440 (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:
Lash adjuster 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.

(15)Fit special tool MD998441 onto the lash adjuster.

MD998442
(16)Place the lash adjuster in container C again, then gently
push down the internal steel ball using special tool
MD998442.
MD998441
to fill with diesel fuel.
Diesel fuel (18)Remove special tool MD998441.

new lash adjuster.
NOTE
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.

4G6 ENGINE (E - W) - Rocker Arms and Camshafts (GDI) 11A-8a-1
8a. ROCKER ARMS AND CAMSHAFTS (GDI)
20 Nm

8 moving parts before
installation.
9
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

11A-8a-2 4G6 ENGINE (E - W) - Rocker Arms and Camshafts (GDI)

AA" LASH ADJUSTER REMOVAL
Caution
adjuster. (Refer to 11A-8a-4.)

"AA LASH ADJUSTER INSTALLATION
Caution
adjuster. (Refer to 11A-8a-4.)
(1) Fit the lash adjuster onto the rocker arm without allowing
diesel fuel to spill out.
"BA BEAM CAMSHAFT CAP GASKET / BEAM

CAMSHAFT CAP / CAMSHAFT / OIL SEAL
Dowel pin
INSTALLATION
Approx.
(1) Locate the camshaft dowel pins as illustrated.
11_
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
Beam camshaft cap
(3) Apply sealant to the illustrated position of the cylinder

Timing belt side
head upper surface.
Specified sealant:
equivalent
(4) Install the beam camshaft cap gasket.

(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
(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.
"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:
equivalent
Paint mark "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.
Camshaft
position
sensor
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
LASH ADJUSTER
Caution
D The lash adjusters are precision-engineered
mechanisms. Do not allow them to become
contaminated by dirt or other foreign substances.
D Do not attempt to disassemble the lash adjusters.
D Use only fresh diesel fuel to clean the lash
adjusters.
(1) Prepare three containers and approximately five liters

Outside Inside Filling with of diesel fuel. Into each container, pour enough diesel
cleaning cleaning diesel fuel fuel to completely cover a lash adjuster when it is standing
upright. Then, perform the following steps with each lash
adjuster.
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
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.

(4) Removal the lash adjuster from the container. Then, push
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
(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
adjuster’s pressure chamber.
Caution
lash adjuster’s functionality may be lost if the
Diesel fuel air bleed wire is pushed in hard.
MD998442
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
(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.
MD998442 Diesel fuel
(8) Stand the lash adjuster with its plunger at the top, then
to fill with diesel fuel.
Diesel fuel
MD998442

(9) Remove the lash adjuster from the container, then stand
new lash adjuster.
NOTE
these steps.
(10)Set the lash adjuster on the special tool MD998440 (leak

Division = 1 mm down tester).
MD998440
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.
Diesel fuel to fill with diesel fuel.
MD998442

check the lash adjuster’s height matches that of a new
lash adjuster.
NOTE
Diesel fuel through (15) again to fill it with diesel fuel completely.
MD998442 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.

4G6 ENGINE (E - W) - Cylinder Head and Valves 11A-9-1
9. CYLINDER HEAD AND VALVES
REMOVAL AND INSTALLATION (SOHC)
2 1
8
20 9
10
4
14
5 15
6 17
12
13
16 19
11
18

moving parts before
installation.
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

11A-9-2 4G6 ENGINE (E - W) - Cylinder Head and Valves
1 8
9
10
14
4 20
5 15
6
17
12
13
19
16 11
18

moving parts before
installation.
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

MB991654 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
AB" RETAINER LOCK REMOVAL

MD998772
(1) Store removed valves, springs and other parts, tagged
to indicate their cylinder No. and location for reassembly.
9EN0062
MD998772

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.

"CA RETAINER LOCK INSTALLATION
MD998772
(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
(3) Using the special tool (MB991654) and according to the

Timing belt side 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.

(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
(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.
SOHC Intake 1.0 0.5
Exhaust 1.2 0.7
GDI Intake 1.0 0.5
Exhaust 1.5 1.0
(3) Measure valve’s total length. If measurement is less than

specified, replace the valve.
SOHC Intake 112.30 111.80
Exhaust 114.11 113.61
GDI Intake 105.5 105.0
Exhaust 105.7 105.2
VALVE SPRING
Out of (1) Measure the free height of spring and, if it is smaller
square
than the limit, replace.
Free SOHC 51.0 50.0
height
GDI 48.3 47.3
(2) Measure the squareness of the spring and, if the limit

1EN0264 is exceeded, replace.
SOHC 2_ 4_
GDI 1.5_ 4_

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
VALVE SEAT RECONDITIONING PROCEDURE

(1) Before correcting the valve seat, check for clearance
0.9 - 1.3 mm
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).
43.5_ - 44_
6EN0491

0.5 - 1 mm 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 Item Standard value mm
seat ring
SOHC Intake 0.30 O.S. 34.30 - 34.33
0.60 O.S. 34.60 - 34.63
Exhaust 0.30 O.S. 31.80 - 31.83
Oversize I.D.
0.60 O.S. 32.60 - 32.63
1EN0275
GDI Intake 0.30 O.S. 35.30 - 35.33
0.60 O.S. 35.60 - 35.63
Exhaust 0.30 O.S. 33.30 - 33.33
0.60 O.S. 33.60 - 33.63
(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”.

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 Standard value mm
SOHC 0.05 O.S. 11.05 - 11.07
0.25 O.S. 11.25 - 11.27
0.50 O.S. 11.50 - 11.52
GDI 0.05 O.S. 12.05 - 12.07
0.25 O.S. 12.25 - 12.27
0.50 O.S. 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 (4) After the valve guide has been installed, insert a new
1EN0106 valve to check for smooth sliding motion.

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
13
Apply engine oil to all (4G63) 30
moving parts before
32
installation.
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
REMOVAL AND INSTALLATION <GDI ENGINE - VEHICLE FOR HONG KONG>
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

MD998727
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

A
(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.
AD" PLUG REMOVAL

MD998162 (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

11A-10-4 4G6 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan
(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.
AG" COUNTERBALANCE SHAFT REAR BEARING

REMOVAL
MB991603
(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

"BA LEFT COUNTERBALANCE SHAFT REAR
BEARING INSTALLATION
MB991603 (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.

NOTE
Rear bearing
MB991603 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

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11A-0-1

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

E Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised

E Mitsubishi Motors Corporation Dec. 1996 PWEE9616

Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised

Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added

Rocker arms and camshaft

Rocker arms and camshaft (GDI)

Cylinder head and valves

Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised

Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised

Front case, counterbalance shaft and oil pan

Piston and connecting rod

Crankshaft, flywheel and drive plate

Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised

Alternator and ignition system

Intake manifold (GDI)

Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised

Exhaust manifold (GDI)

Fuel and emission parts

Fuel part (GDI)

Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised

Water pump and intake manifold

Water pump and water hose (GDI)

Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised

Rocker arms and camshaft

Rocker arms and camshafts (GDI)

Cylinder head and valves

Front case, counterbalance shaft and oil pan

Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised

Piston and connecting rod

Crankshaft, flywheel and drive plate

Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised

Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added

Form-in-Place Gasket Application

Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added

Mitsubishi Motors Corporation Dec. 1996 PWEE9616

Mitsubishi Motors Corporation Dec. 1996 PWEE9616

Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Revised

Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added

Mitsubishi Motors Corporation Dec. 1996 PWEE9616

REMOVAL AND INSTALLATION <MULTIPOINT FUEL INJECTION>

Mitsubishi Motors Corporation Dec. 1996 PWEE9616

Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised

INSTALLATION SERVICE POINTS

B DISTRIBUTOR ASSEMBLY INSTALLATION

Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added

Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised

REMOVAL AND INSTALLATION (GALANT)

Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised

B AIR INTAKE PLENUM RESONATOR

C INTAKE MANIFOLD STAY INSTALLATION

D THROTTLE BODY GASKET INSTALLATION

Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Added

Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised

REMOVAL AND INSTALLATION (GDI)

B TIMING BELT REMOVAL

C OIL PUMP SPROCKET REMOVAL