Engine 4g1

11A-0-1
M14 CRANKSHAFT BOLT

<Tightening torque>
ENGINE
The specified tightening torque for the crankshaft bolt is 181 N!m.
<Tightening procedure>
1. Prevent the flywheel or drive plate from rotating
using the special tool.
4G1 SERIES
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-0-3
MD998781 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1
2. Clean the crankshaft bolt hole.
Crankshaft pulley 3. Clean and degrease the crankshaft pulley. REWORK DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-3
Crankshaft bolt Degrease NOTE
Crankshaft Degreasing is necessary to prevent lack of frictional TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-4
Washer
coefficient on the mating surfaces due to presence NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE
of oil or grease. TIGHTENED IN PLASTIC AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-6
4. Install the crankshaft pulley.
5. Apply necessary minimum amount of engine oil to SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-6
the threads and bearing surface of the crankshaft FORM-IN-PLACE GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-7
Clean bolt flange.
6. Clean the washer. 2. SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-2-1
7. Install the washer with the grooved side toward the 3. ALTERNATOR AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 11A-3-1
bolt head.
8. Tighten the crankshaft bolt to 181 N!m. 4. TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-4-1
5. FUEL AND EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . 11A-5-1
5a. INTAKE MANIFOLD AND THROTTLE BODY (GDI) . . . . . . . . . 11A-5a-1
5b. EXHAUST MANIFOLD (GDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-5b-1
Groove 6. WATER PUMP AND WATER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-6-1
7. INTAKE AND EXHAUST MANIFOLDS . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-7-1
7a. FUEL SYSTEM (GDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-7a-1
8. ROCKER ARMS AND CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-8-1
8a. ROCKER ARMS AND CAMSHAFTS (GDI) . . . . . . . . . . . . . . . . . . 11A-8a-1
9. CYLINDER HEAD AND VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-9-1
10. OIL PUMP AND OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-10-1
11. PISTONS AND CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-11-1
12. CRANKSHAFT AND CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . 11A-12-1
MSB–02E11–505 4 Nov. 1995 PWEE9520

E Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised
11A-0-2
NOTES
<Tightening procedure>
1. Prevent the flywheel or drive plate from rotating
using the special tool.
MD998781
Crankshaft pulley
2. Clean the crankshaft bolt hole.
3. Clean and degrease the crankshaft pulley.
Crankshaft bolt Degrease
Crankshaft NOTE
Washer
Degreasing is necessary to prevent lack of frictional
coefficient on the mating surfaces due to presence
of oil or grease.
4. Install the crankshaft pulley.
5. Apply necessary minimum amount of engine oil to
Clean
Shear droop the threads and bearing surface of the crankshaft
bolt flange.
6. Clean the washer.
7. Install the washer with the shear droop side toward
the bolt head.
8. Tighten the crankshaft bolt in the following proce-
dure.
<Crankshaft with steel plate pulley>
1. Tighten the crankshaft bolt to 132 N!m.
Caution
35 – 55° MB991614 Never exceed a torque of 206 N!m during
additional tightening to an angle within the
specified range.
2. Using the special tool, Angle gauge
(MB991614), turn the bolt in the tightening direc-
tion to an angle within the 35 – 55° range.
<Crankshaft with casting pulley>
Tighten the crankshaft bolt to 132 N!m.
MSB–02E11–505 3
E Mitsubishi Motors Corporation Nov. 1995 PWEE9520
4G1 ENGINE (E - W) - General Information 11A-0-3
GENERAL INFORMATION
3. Details:
M12 CRANKSHAFT BOLT

In order to prevent the crankshaft bolt from loosening and thereby improve reliability, an increased
tightening torque has been established as follows:
<Tightening torque>
Tightening torque
Current torque New torque Type
125 N!m 132 N!m 3
132 N!m + (35 to 55°)
Caution: Stop tightening and never tighten the bolt any more
4
if a torque of 206 N!m is reached during additional tightening
to an angle within the specified range.
Applicable vehicle models

Vehicle model (code) Type Remarks
LANCER (CJ1A, CJ2A) 3 Crankshaft with casting pulley
4 Crankshaft with steel plate pulley
LANCER (CS1A, CS2A, CS3A) 4 Crankshaft with steel plate pulley
SPACE STAR (DG1A, DG3A) 3 Crankshaft with casting pulley
4 Crankshaft with steel plate pulley
MSB–02E11–505 2
11A-0-4 4G1 ENGINE (E - W) - General Information
SERVICE PUBLICATION & TRAINING

INTERNATIONAL AFTER-SALES DEPARTMENT. MITSUBISHI MOTORS CORPORATION
!"#$%&" '())"*%+ +,- . MSB–02E11–505
/0*" . 2002–09–20 12,/")3 12453

(EC)LANCER(CK0A) 95 05
95–05
4G1 ENGINE CRANKSHAFT BOLT – CHANGE TO
!('6"&* . (EC)SPACE 95–05
TORQUE AND TIGHTENING PROCEDURE STAR(DG0A)
7#,(8 . ENGINE /#09*+,- . 02EN510
&,##"&*%,+ %+*"#+0*%,+0)
09*"#:!0)"!
/"80#*2"+*
T. Kobayashi
T K b hi – M
Manager SERVICE
PUBLICATION & TRAINING
1. Description:
This Service Bulletin informs you of the change that has been made to the tightening torque
for the 4G1 engine’s M12 crankshaft bolt. The tightening procedure for the upsized M14 crankshaft
bolt is also contained here in addition to the new tightening torque and procedure for the existing
M12 crankshaft bolt.
2. Applicable Manuals:
Manual Pub. No. Page

ENGINE 4G1 (E–W) PWEE9520-F (English) 11A-1-4
Workshop Manual PWES9521-F (Spanish) 11A-3-1, 1a, 1b, 3, 4
PWEF9522-F (French)
PWEG9523-F (German)
PWED9524-F (Dutch)
PWEW9525-F (Swedish)
ENGINE PWEH9903R-E (English, 11A-1-4
Workshop Manual Spanish, Swedish) 11A-3-1, 1a, 1b, 3, 4
PWEK9904R-E (French,
German, Dutch)
MSB–02E11–505 1
4G1 ENGINE (E - W) - General Information 11A-0-5
11A-12-6 4G1 ENGINE (E-W) – Crankshaft and Cylinder Block
Crankshaft journal Cylinder block Bearing Descriptions 4G13 12-VALVE- CARBURETOR 4G13 12-VALVE- MPI
bearing diameter
Type In-line OHV, SOHC In-line OHV, SOHC
Range Color code Identification mark Journal diameter mm Identification Identification
mark mark or color Number of cylinders 4 4
1 Yellow 1 47.995 – 48.000 0 1 or Brown
1 2 or None Combustion chamber Pentroof type Pentroof type
2 3 or Blue
2 None 2 47.985 – 49.995 0 2 or None Total displacement dm3 1,299 1,299
1 3 or Blue
2 4 or Yellow Cylinder bore mm 71.0 71.0
3 White 3 47.980 – 48.985 0 3 or Blue
1 4 or Yellow Piston stroke mm 82.0 82.0
2 5 or Green
Compression ratio 9.5 9.5
<Added>
Number of Intake 8 8
valves
Timing belt side (2) Identification marks showing the cylinder block bearing bore Exhaust 4 4
diameter are stamped in the position shown, with No. 1 at the
front of the engine. Bearings must be selected and installed in Valve timing Intake opens BTDC 14_ BTDC 19_
accordance with these identification marks.
Intake closes ABDC 48_ ABDC 43_
(3) Based on the identification markings verified in steps (1) and
(2), select bearings from table above. See the following Exhaust opens BBDC 55_ BBDC 60_
example:
Cylinder block journal bore 1. If the measured crankshaft journal diameter 48.000 mm, Exhaust closes ATDC 13_ ATDC 8_
diameter
this corresponds to classification 1 in the above table.
1EN0505
Lubrication system Pressure feed, full-flow filtration Pressure feed, full-flow filtration
2. If the identification mark on the cylinder block bearing hole
is “1”, select a bearing with an identification mark of “2”. Oil pump type Trochoid type Trochoid type
Cooling system Water-cooled, forced circulation Water-cooled, forced circulation
Water pump type Centrifugal impeller type Centrifugal impeller type

<Correct>
Identification color
1EN0402 <Incorrect> Identification mark
1EN0920
(4) Except for the center bearing, all the upper bearings are
Grooved
Grooveless grooved. The center bearings are grooveless and have flanges.
The center bearings are the same at the top and bottom.
(5) The lower bearings are all grooveless.
Upper bearing (Nos.
Lower bearing (Nos. 1, 1, 2, 4, and 5)
2, 4, and 5) Grooveless
Upper and lower

bearings (center) (No.3) 1EN0317
4
E Mitsubishi Motors Corporation Nov. 1998
Dec. 1995 PWEE9520
PWEE9520-A Revised
11A-0-6 4G1 ENGINE (E–W) – General Information
Descriptions 4G13 16-VALVE–CARBURETOR 4G13 16-VALVE–MPI
Type In-line OHV, SOHC In-line OHV, SOHC

<Correct>
Number of cylinders 4 4 To replace the one on previous page.
Combustion chamber Pentroof type Pentroof type
Total displacement dm3 1,299 1,299 Identification mark Identification color

1EN0920
Cylinder bore mm 71.0 71.0
Piston stroke mm 82.0 82.0
Compression ratio 9.5 10, 9.5*1
Number of Intake 8 8
valves
Exhaust 8 8
Valve timing Intake opens BTDC 12" BTDC 17"
Intake closes ABDC 48" ABDC 39"
Exhaust opens BBDC 48" BBDC 49"
Exhaust closes ATDC 12" ATDC 7"
Lubrication system Pressure feed, full-flow filtration Pressure feed, full-flow filtration
Oil pump type Trochoid type Trochoid type
Cooling system Water-cooled, forced circulation Water-cooled, forced circulation
Water pump type Centrifugal impeller type Centrifugal impeller type
*1: LANCER for General Export
3
! Mitsubishi Motors Corporation Nov. 2001
Feb. 1995 PWEE9520
PWEE9520-E Revised
3.Details:
11A-11-6 4G1 ENGINE (E-W) – Pistons and Connecting Rods 4G1 ENGINE (E–W) – General Information 11A-0-7
!E" CONNECTING ROD BEARING INSTALLATION Descriptions 4G15– 4G15–MPI 4G15–MPI 4G15–GDI
CARBURETTOR 12-VALVE 16-VALVE
4G13, 4G15 4G18
Color code positions Type In-line OHV, SOHC In-line OHV, SOHC In-line OHV, DOHC In-line OHV, DOHC
No.4 No.1 No.1
No.4
Number of cylinders 4 4 4 4
Combustion chamber Semi spherical type Semi spherical type Pentroof type Pentroof + Curved
piston head
Total displacement dm3 1,468 1,468 1,468 1,468
Cylinder bore mm 75.5 75.5 75.5 75.5
Piston stroke mm 82.0 82.0 82.0 82.0

No.3 No.3
No.2 No.2 Compression ratio 9.0 9.0 9.5 11.0
Identification mark positions Number Intake 8 8 8 8

No.2 No.4 of valves
Exhaust 4 4 8 8
No.1 No.3 Valve Intake opens BTDC 14" BTDC 14" , BTDC 16" BTDC 12"
timing BTDC 13"*1
Intake closes ABDC 48" ABDC 48" , ABDC 40" ABDC 44"
ABDC 47"*1
Exhaust BBDC 55" BBDC 55" , BBDC 45" BBDC 48"

P opens BBDC 56"*1
P
Exhaust ATDC 13" ATDC 13" , ATDC 15" ATDC 12"
No.1 No.4 closes ATDC 8"*1
1EN0619
No.2 No.3
Lubrication system Pressure feed, Pressure feed, Pressure feed, Pressure feed,
full-flow filtration full-flow filtration full-flow filtration full-flow filtration
Identification color (1) Select bearings according to crankshaft and connecting rod
identification marks or color codes, referring to the following Oil pump type Trochoid type Trochoid type Trochoid type Trochoid type
table.
Cooling system Water-cooled, Water-cooled, Water-cooled, Water-cooled,
Crankshaft Connecting rod Bearing identification forced circulation forced circulation forced circulation forced circulation
identification mark identification color mark or color
I, Yellow White 1 or Yellow Water pump type Centrifugal impeller Centrifugal impeller Centrifugal impeller Centrifugal impeller
<Incorrect> None 1 or Yellow
type type type type
or <Correct> Yellow 2 or None
1EN0525 II, None White 1 or Yellow *1: Special low-emission engines on vehicles for Australia
<Incorrect> None 2 or None
or <Correct> Yellow 3 or Blue
III, White White 2 or None
<Incorrect> None 3 or Blue
or <Correct> Yellow 3 or Blue
<Added>
To be replaced by the one on following page.
1EN0402 <Incorrect>
2
Feb. 1995 PWEE9520
PWEE9520-E Revised
11A-0-8 4G1 ENGINE (E–W) – General Information
Descriptions
Type
4G18 16-VALVE–CARBURETOR
In-line OHV, SOHC

4G18 16-VALVE–MPI
In-line OHV, SOHC

SERVICE BULLETIN
QUALITY INFORMATION ANALYSIS
Number of cylinders 4 4 OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION
Combustion chamber Pentroof type Pentroof type
Total displacement dm3 1,584 1,584

SERVICE BULLETIN No.: MSB-01E11-502
Cylinder bore mm 76.0 76.0

Date: 2002-02-26 <Model> <M/Y>
Subject: CORRECTION TO 4G1 ENGINE BEARING (EC)COLT/LANCER 95-10
Piston stroke mm 87.3 87.3 IDENTIFICATION MARKS (EC)SPACE STAR 95-10
Compression ratio 9.5 9.5, 10*1*2 Group: ENGINE Draft No.: 01EN502 (EC)PAJERO iO 95-10
Number of Intake 8 8 CORRECTION INTERNATIONAL

valves CAR
Exhaust 8 8 ADMINISTRATION T.Inoue - Manager
OFFICE SERVICE PUBLICATION
Valve timing Intake opens BTDC 12" BTDC 17" , BTDC 9"*1 , BTDC 17"*2 1. Description:
Intake closes ABDC 48" ABDC 39" , ABDC 51"*1 , ABDC 43"*2 In the 4G1 engine Workshop Manuals shown below, omission of descriptions from the
identification marks for the connecting rod bearing and the crankshaft bearing, has been rectified.
Exhaust opens BBDC 48" BBDC 49" , BBDC 49"*1 , BBDC 53"*2
Exhaust closes ATDC 12" ATDC 7" , ATDC 15"*1 , ATDC 7"*2 2. Applicable Manuals:
Lubrication system Pressure feed, full-flow filtration Pressure feed, full-flow filtration Manual Pub. No. Language Page(s)
Oil pump type Trochoid type Trochoid type ENGINE 4G1 (E-W) PWEE9520 (English) 11A-11-6,
Workshop Manual PWES9521 (Spanish) 11A-12-6
Cooling system Water-cooled, forced circulation Water-cooled, forced circulation PWEF9522 (French)
Water pump type Centrifugal impeller type Centrifugal impeller type PWEG9523 (German)
PWED9524 (Dutch)
*1: SPACE STAR for Europe PWEW9525 (Swedish)
*2: LANCER for General Export

Feb. 1995 PWEE9520
PWEE9520-E Revised
4G1 ENGINE (E–W) – Specifications 11A-1-1
1. SPECIFICATIONS
SERVICE SPECIFICATIONS
Item Standard Limit
Service Bulletins Rocker arms and camshaft

Camshaft cam
height mm
SOHC 12-VALVE Intake (primary)
Intake (secondary)
38.78
38.78
38.28
38.28
Exhaust*1 39.01 38.51
Exhaust*2 38.97 38.47
SOHC 16-VALVE*3 Intake 36.99 36.49
Click on the applicable bookmark to select the Service Bulletin.
Exhaust 36.85 36.35
Exhaust 36.68 36.18
Exhaust 37.16 36.66
Exhaust 36.99 36.49
DOHC Intake 34.67 34.17
Exhaust 34.26 33.76
DOHC GDI Intake 34.85 34.35
Exhaust 34.59 34.09
Camshaft journal diameter mm SOHC 45.93–45.94 –
SOHC 16-VALVE*7 44.93–44.94 –
DOHC 25.95–25.97 –
Cylinder head and valves
Flatness of cylinder head gasket surface mm 0.05 or less –
Cylinder head gasket surface grinding limit (including grinding of – 0.2
cylinder block gasket surface) mm
Cylinder head overall height mm SOHC 12-VALVE 106.9–107.1 –
SOHC 16-VALVE 119.9–120.1 –
DOHC 131.9–132.1 –
Cylinder head bolt nominal length mm – 103.2
Valve margin mm Intake 1.0 0.5
Exhaust 1.5 1.0
Valve stem diameter mm SOHC 12-VALVE 6.6 –
SOHC 16-VALVE 5.5 –
DOHC 5.5 –
*1: With low pollution system
*2: Without low pollution system
*3: Except 2001 model front wheel drive vehicles
*4: 2001 model front wheel drive vehicles for Europe
*5: 2001 model front wheel drive vehicles for General Export
*6: 2002 model front wheel drive vehicles for Europe
*7: SOHC 16-VALVE MPI for Europe
Feb. 1995 PWEE9520
PWEE9520-E Revised
11A-1-2 4G1 ENGINE (E–W) – Specifications 11A-12-8 4G1 ENGINE (E - W) - Crankshaft and Cylinder Block
"EA REAR OIL SEAL CASE INSTALLATION

Item Standard Limit
(1) Apply liquid gasket to the rear oil seal case at the illustrated
Valve stem-to-guide SOHC 12-VALVE Intake 0.020–0.050 0.10 position if it has no pre-formed gasket attached.
clearance mm
Exhaust 0.035–0.050 0.15 Specified sealant:
Mitsubishi Genuine Part No. MD970389 or
SOHC 16-VALVE Intake 0.020 – 0.047 0.10 equivalent
Exhaust 0.030 – 0.057 0.15 Caution
DOHC Intake 0.020–0.047 0.10 Squeeze the liruid gasket uniformly so that there is
no break in the gasket nor is there too much gasket.
Exhaust 0.030–0.062 0.15
(2) Apply a suitable amount of engine to the entire periphery
Valve face angle 45° –45.5° – of the oil seal lip and install the oil seal on the cylinder
Valve stem projec- SOHC 12-VALVE Intake 43.70 44.20 block.
tion mm
Exhaust 43.30 43.80
SOHC 16-VALVE Intake 53.21 53.71
Exhaust 54.10 54.60
DOHC Intake 48.80 49.30
Exhaust 48.70 49.20
Overall valve length SOHC 12-VALVE Intake 100.75 100.25
mm
Exhaust 101.05 105.55
SOHC 16-VALVE Intake 111.56 111.06 "FA FLYWHEEL BOLT / DRIVE PLATE BOLT
INSTALLATION
Exhaust 114.71 114.21
(1) Clean off sealant, oil and deposits from the threaded
DOHC Intake 106.35 105.85 portion of the drive plate/adapter plate tightening bolts
Exhaust 106.85 106.35 and from the threaded holes on the crankshaft.
(2) Apply engine oil to the bolt flange and to the threaded
Valve spring free SOHC 12-VALVE Intake 46.1 45.6 holes on the crankshaft.
height mm (3) Apply sealant to the threaded portion of the bolt (if the
Exhaust 46.8 46.3
bolt is reused).
SOHC 16-VALVE 50.9 50.4
Specified sealant:
DOHC 49.1 48.6 3M Nut Locking Part No. 4171 or equivalent
Valve spring load/ SOHC 12-VALVE Intake 226/40.0 – (4) Using the special tool, secure the drive plate and tighten
installed height N/ the bolts to the specified torque.
mm Exhaust 284/39.6 –
SOHC 16-VALVE 216/44.2 –
DOHC 177/40.0 –
Valve spring squareness 2° 4°
Valve seat contact width mm 0.9–1.3 –
Valve guide internal diameter mm SOHC 12-VALVE 6.6 – MD998781
DOHC 5.5 –
Valve guide projection mm SOHC 12-VALVE 17.0 –
DOHC 23.0 –
Oil pump and oil pan
Oil pump tip clearance mm 0.03–0.08 –
Oil pump side clearance mm 0.04–0.10 –
Oil pump body clearance mm 0.10–0.18 0.35
Aug. 2000 PWEE9520
PWEE9520-D Added
!
! Mitsubishi
Mitsubishi Motors
Motors Corporation
Corporation Nov. 1995
Feb. 2004 PWEE9520
PWEE9520-H Revised
4G1 ENGINE (E - W) - Crankshaft and Cylinder Block 11A-12-7 4G1 ENGINE (E–W) – Specifications 11A-1-2a
Arrow indicating front Cap No. "CA BEARING CAP INSTALLATION
of engine Item Standard Limit
(1) On the bottom surface of each bearing cap is the capís
number and an arrow. Starting at the timing belt side, Pistons and connecting rods
fit the bearing caps in numerical order. Ensure that the
Piston outside diameter mm 4G13 71.0 –
arrows point toward the timing belt side.
4G15 75.5 –
4G18 76.0 –
Piston ring side clearance mm No. 1 ring 0.03–0.07 –
3EN0174 No. 2 ring 0.02–0.06 –
Piston ring end gap No. 1 ring 4G13, 4G18 0.20–0.35 0.8
(2) Apply engine oil to the threaded portion and bearing clearance
4G15 0.15–0.35 0.8
surface of the bolt. Tighten the bolts to 34 Nm.
(3) Using the special tool, tighten the bolts to a further 30 No. 2 ring 4G13, 4G18 0.35–0.50 0.8
to 34 degrees.
4G15 0.35–0.55 0.8
Oil ring 4G13, 4G15 0.20–0.50 1.0
4G18 0.10–0.40 1.0
Piston pin O. D. mm 18.0 –
Piston pin press-in load (at room temperature) N 4,900–14,700 –
Crankshaft pin oil clearance mm 0.02–0.04 0.1
(4) After fitting the bearing caps, measure the end play in Connecting rod big end side clearance mm 0.10–0.25 0.4
the crankshaft. If the measurement exceeds the specified
limit, replace the crankshaft bearings. Crankshaft and cylinder block
Standard value: 0.05 - 0.18 mm Crankshaft end play mm 0.05–0.18 0.25
Limit: 0.25 mm Crankshaft journal diameter mm 48.0 –
Crankshaft pin diameter mm 42.0 –
Crankshaft journal oil clearance mm 0.02–0.04 0.1
Cylinder block gasket surface flatness mm 0.05 or less –
Cylinder block gasket surface grinding limit (including grinding of – 0.2
cylinder head gasket surface) mm
"DA REAR OIL SEAL INSTALLATION
Oil seal MD998011 Cylinder block overall height mm 256 –
Press-fit the rear oil seal using the special tool shown
in the illustration. Cylinder bore cylindricity mm 0.01 –
Cylinder bore I. D. mm 4G13 71.0 –
4G15 75.5 –
4G18 76.0 –
Piston-to-cylinder clearance mm 0.02–0.04 –
Oil seal case

Aug. 2000 PWEE9520
PWEE9520-D Revised
! Mitsubishi Motors Corporation Feb. 2004 PWEE9520-H Revised
11A-1-2b 4G1 ENGINE (E - W) - Specifications 11A-12-6 4G1 ENGINE (E–W) – Crankshaft and Cylinder Block
Crankshaft journal Cylinder block Bearing

bearing diameter
Range Color code Identification Journal diameter Identification Identification

mark mm mark mark
1 Yellow 1 47.994 – 48.000 0 1
1 2
2 3
2 None 2 47.988 – 47.994 0 2
1 3
2 4
3 White 3 47.982 – 47.988 0 3
1 4
2 5
Timing belt side (2) Identification marks showing the cylinder block bearing
bore diameter are stamped in the position shown, with
No. 1 at the front of the engine. Bearings must be selected
Intentionally blank and installed in accordance with these identification marks.
(3) Based on the identification markings verified in steps (1)
and (2), select bearings from table above. See the
following example:
1. If the measured crankshaft journal diameter is 48.000
mm, this corresponds to classification 1 in the above
Cylinder block journal table.
bore diameter
2. If the identification mark on the cylinder block bearing
hole is “1”, select a bearing with an identification mark
of “2”.
Grooved (4) Except for the center bearing, all the upper bearings are
Grooveless grooved. The center bearings are grooveless and have
flanges. The center bearings are the same at the top
and bottom.
Upper bearing (Nos.
Lower bearing (Nos. 1, 2, 4, and 5) (5) The lower bearings are all grooveless.
1, 2, 4, and 5) Grooveless
Upper and lower

bearings (center) (No. 3)
Dec. 1998 PWEE9520
PWEE9520-A Added
Feb. 1995 PWEE9520
PWEE9520-E Revised
4G1 ENGINE (E–W) – Crankshaft and Cylinder Block 11A-12-5 4G1 ENGINE (E–W) – Specifications 11A-1-3
"B# CRANKSHAFT BEARING INSTALLATION REWORK DIMENSIONS
Item Standard Limit
Cylinder head oversize valve guide SOHC 12-VALVE 0.05 O. S. 12.040–12.058 –
hole diameter mm
0.25 O. S. 12.240–12.258 –
0.50 O. S. 12.490–12.508 –
SOHC 16-VALVE 0.05 O. S. 10.550–10.568 –
0.25 O. S. 10.750–10.768 –
0.50 O. S. 11.000–11.018 –
DOHC 0.05 O. S. 10.550–10.568 –
0.25 O. S. 10.750–10.768 –
0.50 O. S. 11.000–11.018 –
DOHC GDI 0.05 O. S. 10.610–10.620 –
0.25 O. S. 10.810–10.820 –
0.50 O. S. 11.060–11.070 –
Oversize valve seat SOHC Intake (primary) 0.3 O. S. 27.300–27.325 –
ring hole diameter 12 VALVE
12-VALVE
mm 0.6 O. S. 27.600–27.625 –
Intake (secondary) 0.3 O. S. 32.300–32.325 –
0.6 O. S. 32.600–32.625 –
Exhaust 0.3 O. S. 35.300–35.325 –
0.6 O. S. 35.600–35.625 –
SOHC Intake 0.3 O. S. 28.300–28.321 –
16 VALVE
16-VALVE
<4G13> 0.6 O. S. 28.600–28.621 –
Exhaust 0.3 O. S. 26.300–26.321 –
0.6 O. S. 26.600–26.621 –
SOHC Intake 0.3 O. S. 30.300–30.321 –
16 VALVE
16-VALVE
<4G18> 0.6 O. S. 30.600–30.621 –
Exhaust 0.3 O. S. 28.300–28.321 –
0.6 O. S. 28.600–28.621 –
(1) Select bearings according to the crankshaft identification
DOHC Intake 0.3 O. S. 31.300–31.325 –
marks or color codes, referring to the following table.
If they are not identifiable, measure the crankshaft journals 0.6 O. S. 31.600–31.625 –
and choose bearings to match the measurements.
Exhaust 0.3 O. S. 27.800–27.825 –
0.6 O. S. 28.100–28.125 –
!
! Mitsubishi
Mitsubishi Motors
Motors Corporation
Feb. 2004 PWEE9520
PWEE9520-H Revised ! Mitsubishi Motors Corporation Nov. 2001
Feb. 1995 PWEE9520
PWEE9520-E Revised
11A-1-4 4G1 ENGINE (E–W) – Specifications 11A-12-4 4G1 ENGINE (E - W) - Crankshaft and Cylinder Block
TORQUE SPECIFICATIONS (4) Using a cylinder gauge, measure each cylinderís bore
and cylindricity. If any cylinder is severely worn, bore
Item Nm all the cylinders to oversize and replace the piston and
piston rings accordingly. Take measurements at the points
Alternator and ignition system shown.
Water pump pulley bolt 9 12 Standard value:
mm Cylinder bore:
Alternator brace bolt (alternator side) 22
4G13 engine: 71.0 mm
Alternator brace bolt (tightened with water pump) 23 4G15 engine: 75.5 mm
4G18 engine: 76.0 mm
Alternator pivot bolt 44 6EN0553
Cylindricity: 0.01 mm or less
Oil level gauge guide bolt (Flange) 23
3. BORING CYLINDERS
Oil level gauge guide bolt (Washer) 19
(1) Oversize pistons to be used should be determined on
Crankshaft bolt (M12) 125 the basis of the cylinder with the largest bore.
(2) Oversize pistons are available with the following oversize
Crankshaft bolt (M14) 181 dimensions: 0.25 mm, 0.50 mm, and 1.00 mm. Measure
Spark plug 25 the diameter of the piston to be used. Boring must be
Thrust carried out such that the piston-to-cylinder clearance
Distributor bolt 11 complies with the standard value. The pistonís diameter
direction
Ignition coil bolt 10 Piston O. D. should be measured at the points shown.
(3) Calculate the boring finish dimension based on the piston
Ignition failure sensor bolt 5 6EN0554 diameter dimension.
Camshaft position sensor bolt 9 D [Boring finish dimension] = [piston O.D.] +
[piston-to-cylinder clearance (0.02 ñ 0.04 mm)] -
Camshaft position sensor support bolt 13 [honing margin (0.02 mm)]
Camshaft position sensing cylinder bolt 21 (4) Bore each cylinder to the calculated boring finish
dimension.
Timing belt
Caution
Timing belt cover bolt 11 To prevent distortion caused by heat increases during
Timing belt tensioner bolt 23 boring bore the cylinders in the following order: No.
2, No. 4, No. 1, No. 3.
Crankshaft angle sensor bolt 9
(5) Hone the cylinders to the final finish dimension (piston
Bracket bolt 21 O. D. + piston-to-cylinder clearance).
(6) Check the clearance between the pistons and cylinders.
Engine support bracket bolt (M8) 21
Standard value: 0.02 - 0.04 mm
Engine support bracket bolt, nut (M10) 35
Idler pulley bolt 35
Camshaft sprocket bolt 88
Fuel and emission control system
Vacuum pipe & hose bolt 9
Delivery pipe bolt 11
Fuel pressure regulator bolt 9 INSTALLATION SERVICE POINTS
Throttle body bolt 18 "AA OIL PRESSURE SWITCH INSTALLATION
MD9988054
Hose clamp bolt 10 (1) Apply the specified sealant to the thread, then fit the
oil pressure switch using the special tool shown in the
Fuel pump bolt (SOHC 12-VALVE–CARBURETOR) 12
illustration.
Fuel pump bolt (SOHC 16-VALVE–CARBURETOR) 19 Specified sealant:
Breather tube clamp bolt 22 3M ATD Part No. 8660 or equivalent
Carburetor bolt 17 Caution
Apply sealant 1. Apply sealant such that none is squeezed out
Air temperature sensor 13 past end of the thread.
Cover bolt (Except M8 × 16) 12 2. Do not over-tighten the oil pressure switch.
Dec. 1995 PWEE9520
PWEE9520-A Revised
Apr. 1995 PWEE9520
PWEE9520-G Revised
4G1 ENGINE (E - W) - Crankshaft and Cylinder Block 11A-12-3 4G1 ENGINE (E–W) – Specifications 11A-1-4a
MD998054 REMOVAL SERVICE POINTS
Item Nm
AA" OIL PRESSURE SWITCH REMOVAL
Cover bolt (M8 × 16) 18
(1) Disconnect the oil pressure switch terminals.
(2) Using the special tool, remove the oil pressure switch. EGR valve bolt 21
Caution
The thread is coated with sealant. Take care not to
bend it when removing the oil pressure switch.
INSPECTION
Plastic
gauge 1. CRANKSHAFT OIL CLEARANCE
The crankshaft oil clearance can be measured easily
using a plastic gauge.
To check the crankshaft oil clearance with a plastic gauge,
carry out the following procedure:
(1) Wipe all oil off the crankshaft journal and the bearingís
inside surface.
(2) Install the crankshaft.
6EN0550 (3) Cut the plastic gauge such that its length matches the
width of the bearing, then place it on the journal along
the journalís axis.
(4) Gently fit the crankshaft bearing cap and tighten the bolts
to the specified torque.
(5) Remove the bolts and gently remove the crankshaft
bearing cap.
(6) Using the scale printed on the plastic gauge bag, measure
the plastic gaugeís crushed section at its widest point.
Standard value: 0.02 - 0.04 mm
Limit: 0.1 mm
1EN0271
Fillet-rolled section NOTE

The crankshaft pins and journals are fillet-rolled and must
not be machined to undersize dimensions.
2. CYLINDER BLOCK
(1) Visually check for cracks, rust, and corrosion, and inspect
the cylinder block using a flaw detecting agent. Rectify
defects where possible or replace the cylinder block.
(2) Ensure that the top surface is free of gasket chips and
other foreign material. Check the cylinder blockís top
surface for distortion using a straight edge and thickness
gauge.
Standard value: 0.05 mm
Limit: 0.1 mm
(3) Check the cylinder walls for cracks and seizure marks.
If defects are evident, bore all the cylinders to oversize
or replace the cylinder block.
Dec. 1998 PWEE9520
PWEE9520-A Revised
Apr. 1995 PWEE9520
PWEE9520-G Revised
11A-1-4b 4G1 ENGINE (E–W) – Specifications 11A-12-2b 4G1 ENGINE (E - W) - Crankshaft and Cylinder Block
Intentionallyblank
Intentionally blank

Aug. 2000 PWEE9520
PWEE9520-D Added
Aug. 2001 PWEE9520
PWEE9520-F Added
4G1 ENGINE (E - W) - Crankshaft and Cylinder Block 11A-12-2a 4G1 ENGINE (E - W) - Specifications 11A-1-5
REMOVAL AND INSTALLATION <GDI> Item Nm
Intake manifold and throttle body (GDI)
2 Accelerator cable bolt 10
23 Nm
Throttle body bolt 19
5 10 Nm
Air intake plenum resonator bolt 10
18
Power plant stay right bolt 49
1
19 Nm Intake manifold stay bolt 30
98 Nm EGR valve bolt 19
17 11 Nm
4 EGR valve support bolt 19
3
EGR valve support nut 24
Intake manifold bolt, nut 20
Exhaust manifold (GDI)
8 Oxygen sensor 44
Exhaust manifold cover bolt 30
7
Exhaust manifold bracket bolt 35
19 6 Exhaust manifold nut (M8) 18
15 Exhaust manifold nut (M10) 29
10 Nm
16 Power plant stay left bolt 35
Water pump and water hose
14
Water inlet fitting bolt 22
Water inlet pipe bolt (M8) 12
Apply engine oil to all Water inlet pipe bolt (M10) 25

13 moving parts before Fitting bolt 23
installation.
Water outlet fitting bolt (Front wheel drive) 23
Water outlet fitting bolt (Rear wheel drive) 18
10 Thermostat case bolt 23
12 Thermo valve 27
10
11
Engine coolant temperature gauge unit 11
9 Engine coolant temperature sensor 29
34 Nm + 30_ to 34_
Water pump bolt 13
Exhaust manifold and intake manifold
Removal steps
"FA 1. Drive plate bolt "CA 11. Bearing cap No. 4 Boost sensor bolt 5
2. Adapter plate "CA 12. Bearing cap center Solenoid valve assembly bolt 9
3. Drive plate "BA 13. Crankshaft bearing, lower
4. Crankshaft bushing 14. Crankshaft Intake manifold bolt, nut 17
5. Rear plate "BA 15. Crankshaft bearing, upper
6. Bell housing cover "BA 16. Crankshaft bearing, center Intake manifold stay bolt <MPI> (M8) 17
"EA 7. Rear oil seal case AA" "AA 17. Oil pressure switch
"DA 8. Rear oil seal 18. Knock sensor Intake manifold stay bolt <MPI> (M10) 31
9. Bearing cap bolt 19. Cylinder block
"CA 10. Bearing cap Intake manifold stay bolt <carburetor> 30
Engine hanger bolt 19
Exhaust manifold cover bolt 29
Aug. 2000 PWEE9520
PWEE9520-D Added E Mitsubishi Motors Corporation Nov. 1995
Aug. 2000 PWEE9520
PWEE9520-D Revised
11A-1-5a 4G1 ENGINE (E - W) - Specifications 11A-12-2 4G1 ENGINE (E–W) – Crankshaft and Cylinder Block
Item Nm Removal steps

"F# 1. Flywheel bolt "E# 15. Rear oil seal case
Exhaust manifold nut (M8) 17 2. Flywheel 16. Rear oil seal case gasket
3. Flywheel bolt "C# 17. Bearing cap bolt
Exhaust manifold nut (M10) 29
4. Adapter plate "C# 18. Bearing cap
Exhaust manifold bracket A bolt 35 5. Flywheel "B# 19. Crankshaft bearing (lower)
6. Adapter plate 20. Crankshaft
Exhaust manifold bracket B bolt 35 7. Crankshaft bushing "B# 21. Crankshaft bearing (upper)
8. Drive plate bolt #A" "A# 22. Oil pressure switch
Power plant stay right bolt 49 9. Adapter plate 23. Knock sensor
10. Drive plate <4G13 (SOHC 16-VALVE) for
Power plant stay left bolt 35 11. Crankshaft bushing Europe, 4G18 for GCC and 4G18
Oxygen sensor 44 12. Rear plate for Europe (From 2004 model)>
13. Bell housing cover 24. Cylinder block
Fuel system (GDI) "D# 14. Rear oil seal
Fuel pipe bolt 12

Caution
Fuel pump bolt 4.9 Æ 17 ± 2 On the flexible flywheel equipped engines, do not remove any of the bolts “A” of the flywheel
Flange bolt 24
shown in the illustration.
The balance of the flexible flywheel is adjusted in the assembled condition. Removing the bolt,
Harness bracket bolt 9.8 therefore, can cause the flexible flywheel to be out of balance, giving damage to the flywheel.
Injector holder bolt 23
Delivery pipe and injector bolt 12
Rocker arms and camshaft
Fuel pump cover bolt 12
Rocker cover bolt <SOHC> 3.5
Rocker cover bolt <DOHC> 4
Rocker shaft assembly bolt 31
Adjusting screw 15
Bearing cap bolt (M6) 11
Bearing cap bolt (M8) 24
Rocker arms and camshaft (GDI)
Engine hanger bolt 19
Rocker cover bolt 3.5
Beam camshaft cap bolt (M6) 11
Beam camshaft cap bolt (M8) 25
Cylinder head bolt 20 + 90_ + 90_
Tighten to 49 Nm, then completely loosen and retighten as described.
Oil pump and oil pan
Transmission stay bolt 23
Oil pan bolt (M6) 7
Oil pan bolt (M8) 24
Drain plug 39
Oil screen bolt 19
Front case bolt 14
Relief plug 44
Aug. 2000 PWEE9520
PWEE9520-D Revised
Apr. 1995 PWEE9520
PWEE9520-G Revised
4G1 ENGINE (E - W) - Crankshaft and Cylinder Block 11A-12-1 4G1 ENGINE (E–W) – Specifications 11A-1-5b
12. CRANKSHAFT AND CYLINDER BLOCK Item Nm
REMOVAL AND INSTALLATION <EXCEPT GDI> Oil pump cover bolt 10
23 Nm Pistons and connecting rods
Apply engine oil to all 132 Nm
Connecting rod nut 17 → + 90" to 94"
moving parts before 23 10 Nm
installation. Crankshaft and cylinder block
1
12 Flywheel bolt 132
Drive plate bolt <Except GDI> 132
Drive plate bolt <GDI> 98
19 Nm
11 Nm Rear plate bolt 10
16 Bell housing cover bolt 10
22
24 14 Rear oil seal case bolt 11
2 Bearing cap bolt 34 → + 30" to 34"
13 Oil pressure switch 19
Knock sensor 23
132 Nm
15 5
4 3
10 Nm
6
21
7
132 Nm
20
A 9 8
19
18
34 Nm + 30_ to 34_
11 10
17

Aug. 2000 PWEE9520
PWEE9520-D Revised
!
! Mitsubishi
Mitsubishi Motors
Motors Corporation
Feb. 2004 PWEE9520
PWEE9520-H Revised
11A-1-6 4G1 ENGINE (E - W) - Specifications 11A-11-8 4G1 ENGINE (E–W) – Pistons and Connecting Rods
NEW TIGHTENING METHOD USING PLASTIC REGION TIGHTENING BOLTS Caution
Parts of the engine use plastic region tightening bolts. The tightening procedure for these is different 1. If the nuts are turned by less than 90°, the cap
from that of conventional bolts and is described in relevant parts of this manual. Note that plastic region may not be held on with sufficient strength.
tightening bolts have fixed service limits. These limits are indicated in relevant parts of this manual and 2. If the nuts are turned by more than 94°, loosen
must be strictly observed. them completely and carry out the tightening
procedure again.
D Plastic region tightening bolts are used for the following applications:
(1) Cylinder head bolts
(2) Connecting rod cap bolts
(3) Bearing cap bolt
D The tightening procedure is basically as follows:
After tightening a bolt to the specified torque, tighten it by a further 90_ + 90_, 90_ñ100_or 30_ñ34_.
The exact tightening procedure differs depending on the bolt and is described in relevant parts of
this manual.
SEALANTS
Item Specified sealant Quantity
Cam position sensor support Mitsubishi Genuine Part No. MD970389 or equivalent As required
Water pump Mitsubishi Genuine Part No. MD970389 or equivalent As required
Thermo valve Mitsubishi Genuine Part No. MD970389 or equivalent As required
Thermostat housing Mitsubishi Genuine Part No. MD970389 or equivalent As required
Water outlet fitting Mitsubishi Genuine Part No. MD970389 or equivalent As required
Engine coolant temperature sensor 3M Nut Locking Part No. 4171 or equivalent As required
Engine coolant temperature gauge unit 3M ATD Part No. 8660 or equivalent As required
Camshaft bearing cap 3M ATD Part No. 8660 or equivalent As required
Semi-circular packing 3M ATD Part No. 8660 or equivalent As required
Rocker cover 3M ATD Part No. 8660 or equivalent As required
Beam camshaft cap Mitsubishi Genuine Part No. MD970389 or equivalent As required
Oil pump case Mitsubishi Genuine Part No. MD970389 or equivalent As required
Oil pan Mitsubishi Genuine Part No. MD970389 or equivalent As required
Oil pressure switch 3M ATD Part No. 8660 or equivalent As required
Rear oil seal case Mitsubishi Genuine Part No. MD970389 or equivalent As required
Drive plate bolt 3M Nut Locking Part No. 4171 or equivalent As required
E Mitsubishi Motors Corporation Apr. 2000

Aug. 2000 PWEE9520
PWEE9520-D Revised
!
! Mitsubishi
Mitsubishi Motors
Motors Corporation
Feb. 2004 PWEE9520
PWEE9520-H Revised
4G1 ENGINE (E–W) – Pistons and Connecting Rods 11A-11-7 4G1 ENGINE (E - W) - Specifications 11A-1-7
"F# CONNECTING ROD CAP INSTALLATION FORM-IN-PLACE GASKET
(1) Aligning the marks made during disassembly, fit the The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket
bearing cap onto the connecting rod. If the connecting fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead
rod is new and has no index mark, ensure that the bearing size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick
Cylinder No. locking notches are both on the same side. 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 vulcanization (RTV) type and is supplied in a 100-gram
tube (Part No. MD970389 or MD997110). Since the RTV hardens as it reacts with the moisture in the
Locking notch
atomospheric air, it is normally used in the metallic flange areas. The FIPG, Part No. MD970389, can
DEN0051 be used for sealing both engine oil and coolant, while Part No. 997110 can only be used for engine
oil sealing.
(2) Check that the connecting rod big end side clearance
confirms with specifications. Disassembly
Standard value: 0.10 – 0.25 mm The parts assembled with the FIPG can be easily disassembled without use of a special method. In
Limit: 0.4 mm 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 ìOil Pan Removerî (MD998727) is available. Be sure to use
the special tool to remove the oil pan. <Except aluminium die-cast oil pans>
Surface Preparation
1EN0276
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
"G# CONNECTING ROD CAP NUT INSTALLATION 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
Caution forget to remove the old sealant remained in the bolt holes.
To fit the connecting rod cap nuts with the cylinder
head in place, the spark plugs must be removed Form-In-Place Gasket Application
beforehand.
When assembling parts with the FIPG, you must observe some precautions, but the procedures is very
(1) The connecting rod bolts and nuts utilize the plastic region simple as in the case of a conventional precut gasket.
tightening method. The bolts must therefore be checked Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the
for stretching before reuse. To check a bolt for stretching, bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is
screw the nut down the entire length of the thread by hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When
hand. Unless the nut turns smoothly all the way, the bolt’s the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do
threaded section is stretched and the bolt must be not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time
replaced. (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.
90° to 94° Paint mark (2) Before fitting the nuts, apply engine oil to their threads
Paint and seating surfaces.
mark (3) Fit the nuts onto the bolts and turn them until they are
finger-tight. After this, the nuts must be tightened
alternately to ensure correct fitting of the cap.
(4) Tighten the nuts to a torque of 17 Nm.
(5) Make a paint mark on the top of each nut as shown.
Nut
Bolt (6) Make paint marks on the bolts 90 to 94° clockwise from
the paint marks on the nuts.
(7) Turn the nuts until their paint marks are aligned with the
paint marks on the bolts.
11A-11-6 4G1 ENGINE (E–W) – Pistons and Connecting Rods
NOTES "E# CONNECTING ROD BEARING INSTALLATION
(1) Select bearings according to crankshaft and connecting

Identification color rod identification marks or color codes, referring to the
following table.
Crankshaft Connecting rod identification Bearing
identification color identification
mark mark
I, Yellow White 1
None 1
Yellow 2
II, None White 1
None 2
Yellow 3
III, White White 2
None 3
Yellow 3
!
! Mitsubishi
Mitsubishi Motors
Motors Corporation
Feb. 2004 PWEE9520
PWEE9520-H Revised
4G1 ENGINE (E–W) – Pistons and Connecting Rods 11A-11-5 4G1 ENGINE (E - W) - Special Tools 11A-2-1
"C# PISTON RING No. 2 / PISTON RING No. 1 2. SPECIAL TOOLS
INSTALLATION
(1) Using piston ring expander, fit No. 2 and No. 1 piston Tool Number Name Use
ring into position. MB990767 End yoke holder Holding camshaft sprocket when loosening or
NOTE tightening bolt (used with MD998715)
Piston ring expander
1. The ring end is provided with identification mark.
Item Identification mark
No. 1 ring 1R or 1T or T
7EN0452
MB991614 Angle gauge Installation of crankshaft bearing caps
No. 2 ring 2R or 2T or T2
Identification mark 2. Install piston rings with identification mark facing up,
to the piston crown side.
Identification mark Size mark 3. Size marks on piston rings are as follows.
Size Size mark MB991653 Cylinder head bolt Removal and installation of cylinder head bolts
STD None ALL wrench (10)
No. 1
0.25 mm O. S. 25 4G18
No. 2
0.50 mm O. S. 50 ALL
1.00 mm O. S. 100 4G13, 4G15
MB991659 Guide-D Guide for removal and press-fitting of piston
pins
"D# PISTON AND CONNECTING ROD ASSEMBLY
Side rail No. 1 ring INSTALLATION
(1) Apply oil to the piston, piston rings, and oil ring.
(2) Align the gaps of the piston rings and oil ring (side rails
MB991671 Valve stem Press-fitting of valve stem seals
and spacer) as shown. installer (SOHC 16-VALVE, DOHC)
Piston pin
(3) With the piston crown’s front arrow mark pointing toward
the timing belt side, press the piston and connecting rod
assembly into the cylinder from the top of the cylinder.
No. 2 ring and Side rail
spacer 6EN0549 MD998011 Crankshaft rear oil Installation of crankshaft rear oil seal
seal installer
(4) Compress the piston rings tightly with a suitable ring
compression tool, then press the piston and connecting
rod fully into the cylinder. Do not strike the piston hard
since the piston rings may break and the crank pin may
be nicked. MD998054 Oil pressure switch Removal and installation of oil pressure switch
wrench
MD998304 Crankshaft front oil Installation of crankshaft front oil seal

seal installer
MD998305 Crankshaft front oil Guide for installation of crankshaft front oil seal
seal guide

Aug. 2000 PWEE9520
PWEE9520-D Revised
11A-2-2 4G1 ENGINE (E - W) - Special Tools 11A-11-4 4G1 ENGINE (E–W) – Pistons and Connecting Rods
Tool Number Name Use 3 mm + L (8) Screw guide B into guide A. Leave a gap between the
two guides of 3 mm plus the value (L) calculated in step
MD998442 Air bleed wire Testing of automatic lash adjusters (3).
(DOHC)
MD998713 Camshaft oil seal Installation of camshaft oil seal

installer Guide B Guide A
(9) Mount the piston and connecting rod on the Piston Pin
Push Rod Setting Base (special tool) with the piston’s front mark
MD998715 Pin (2-off) Holding camshaft sprocket when loosening or pointing upward.
tightening bolt (used with MB990767) (10)Install the piston pin using a press. If the press-fitting
Piston pin load is out of specification, replace the piston pin and
piston assembly or the connecting rod, or both.
Front mark Standard value: 4,900 – 14,700 N
Front
MD998727 Oil pan remover Removal of oil pan mark
Guide A
MD998735 Valve spring com- Compression of valve springs Base

pressor
Guide B
MD998760 Valve stem seal Installation of valve stem seals

installer (SOHC 12-VALVE) "B# OIL RING INSTALLATION
(1) Fit the oil ring spacer into the piston ring groove. Then,
fit the upper and lower side rails.
Side rail NOTE
MD998762 Circular packing Installing of circular packing (1) The spacer and side rails may be fitted in either
installer direction. No distinction is made between top and
bottom.
(2) Spacer and side rail sizes are color-coded as follows:
Size Color
MD998772 Valve spring com- Compression of valve springs STD None ALL
pressor 0.25 mm O. S. White 4G18
Spacer
1EN0277
0.50 mm O. S. Blue ALL
End of side rail 1.00 mm O. S. Yellow 4G13, 4G15
MD998780 Piston pin setting Removal and press-fitting of piston pins (2) To install a side rail, fit one end of the rail into the groove
tool then press the rest of the rail into position by hand as
shown.
Caution
Do not fit side rails using a piston ring expander since
they may break.
(3) After installing the side rails, check that they move
7EN0451
smoothly in both directions.
Aug. 2000 PWEE9520
PWEE9520-D Revised
Apr. 1995 PWEE9520
PWEE9520-G Revised
4G1 ENGINE (E–W) – Pistons and Connecting Rods 11A-11-3 4G1 ENGINE (E–W) – Special Tools 11A-2-3
2. CRANKSHAFT PIN OIL CLEARANCE (PLASTIC Tool Number Name Use
GAUGE METHOD)
(1) Wipe all oil off the crankshaft pin and connecting rod MD998781 Flywheel stopper Locking flywheel in fixed position
bearing.
(2) On the pin, place a plastic gauge that is cut to the same
length as the bearing’s width. The plastic gauge must
be centered on the pin in parallel with the pin’s axis.
(3) Gently place the connecting rod cap in position and tighten
the bolts to the specified torque. MD998306 Crankshaft front oil Installation of crankshaft front oil seal
(4) Remove the bolts and gently remove the connecting rod seal installer
cap.
(5) Measure the compressed part of the plastic gauge at
its widest point using the scale printed on the plastic
gauge bag.
MB991962 Crankshaft front oil Guide for installation of crankshaft oil seal
Standard value: 0.02 – 0.04 mm seal guide
Limit: 0.1 mm
Timing belt side INSTALLATION SERVICE POINTS

Production date No. 1 "A# PISTON PIN INSTALLATION
(1) When replacing the piston, read off the cylinder bore
No. 2
size mark on the cylinder block as illustrated, and select
No. 3 a piston according to the flowing table.
No. 4
CYLINDER BORE SIZE PISTON SIZE MARK
MARK
A A
B None
C C
NOTE:
The piston size mark shows on the top of the piston.
D C (2) Measure the following lengths (as shown):
A: Piston boss-to-piston boss outside dimension
B: Piston boss-to-piston boss inside dimension
Connecting rod
C: Piston pin length
D: Connecting rod small end eye thickness
(3) Enter the measured values into the following formula:
Piston Piston pin
L= (A–C) – (B–D)
2
(4) Insert the Push Rod (special tool) into the piston pin,
then fit Guide A (special tool).
(5) Fit the piston and connecting rod together such that their
B A front marks are on the same side.
(6) Apply engine oil to the outside of the piston pin.
(7) Into the front-mark side of the piston, insert the Guide
A, piston pin, and Push Rod, starting with guide A.

Apr. 1995 PWEE9520
PWEE9520-G Revised ! Mitsubishi Motors Corporation Nov. 2003
Apr. 1995 PWEE9520
PWEE9520-G Revised
4G1 ENGINE (E–W) – Alternator and Ignition System 11A-3-1 11A-11-2 4G1 ENGINE (E–W) – Pistons and Connecting Rods
3. ALTERNATOR AND IGNITION SYSTEM REMOVAL SERVICE POINTS

"A# CONNECTING ROD CAP REMOVAL
REMOVAL AND INSTALLATION <SOHC 12-VALVE>
(1) Mark the cylinder number on the side of the connecting
Cylinder No. rod big end to facilitate reassembly.
12 12 Nm DEN0050
"B# PISTON PIN REMOVAL

13 Push rod
(1) Insert the Push Rod (special tool) from the front arrow
mark side, then fit guide D.
(2) Mount the piston and connecting rod assembly on the
Piston Pin Setting Base (special tool) with the piston’s
6 7 44 Nm front mark pointing upward.
Front mark (3) Remove the piston pin using a press.
10
22 Nm Front NOTE
25 Nm mark
After removing the piston pin, keep the piston, piston
pin, and connecting rod together. Do not allow pistons,
piston pins, and connecting rods from different cylinders
Guide D to become mixed up.
11
1
5 Base INSPECTION
23 Nm
1. PISTON RINGS
9 Nm 23 Nm
(1) Check the piston ring side clearance. If the clearance
exceeds the specified limit, replace the ring or piston,
or both.
2 Standard values:
No. 1 ring: 0.03 – 0.07 mm
No. 2 ring: 0.02 – 0.06 mm
3
Limits:
8 9 No. 1 ring: 0.1 mm
No. 2 ring: 0.1 mm
4
M12 125 Nm (2) Insert the piston ring into the cylinder bore and push
M14 181 Nm it down with a piston. Ensure that the piston’s crown
is in contact with the ring such that the ring is at 90$
to the cylinder wall. Then, measure the end gap with
a thickness gauge. If the gap is too large, replace the
piston ring.
7EN0475
Standard values Limits mm
mm
Removal steps Push in with piston No. 1 ring 4G13, 4G18 0.20 – 0.35 0.8
1. Oil level gauge 10. Spark plug cable
2. Oil level gauge guide 11. Spark plug 4G15 0.15 – 0.35 0.8
3. O-ring #A" 12. Distributor No. 2 ring 4G13, 4G18 0.35 – 0.50 0.8
4. Drive belt* 13. O-ring
5. Water pump pulley NOTE 4G15 0.35 – 0.55 0.8
6. Alternator brace *: For details of adjustment, refer to the relevant model’s
7. Alternator Oil ring 4G13 0.20 – 0.50 1.0
chassis workshop manual.
"A# #B" 8. Crankshaft bolt 4G15
#B" 9. Crankshaft pulley 4G18 0.10 – 0.40 1.0
Piston ring End gap

Apr. 1995 PWEE9520
PWEE9520-G Revised !
! Mitsubishi
Mitsubishi Motors
Motors Corporation
Corporation Nov.
Feb. 1995
2004 PWEE9520
PWEE9520-H Revised
4G1 ENGINE (E–W) – Pistons and Connecting Rods 11A-11-1 11A-3-1a 4G1 ENGINE (E–W) – Alternator and Ignition System
11. PISTONS AND CONNECTING RODS REMOVAL AND INSTALLATION <SOHC 16-VALVE – FRONT WHEEL DRIVE (WITH
DISTRIBUTOR)>
REMOVAL AND INSTALLATION
6
7
8
9 25 Nm
10 10
4
12 Nm
11 12
12
13
11 44 Nm
22 Nm
5
6
7 23 Nm
5
23 Nm 1
9
9 Nm
Apply engine oil to all 8

moving parts before 3
installation. M12 125 Nm
4 M14 181 Nm
2
17 Nm → + 90$ to 94$
1
Removal steps Removal steps

#G" 1. Connecting rod nut #C" 7. Piston ring No. 2 1. Oil level gauge 10. Spark plug cable
"A# #F" 2. Connecting rod cap #B" 8. Oil ring 2. Oil level gauge guide 11. Spark plug
#E" 3. Connecting rod bearing "B# #A" 9. Piston pin 3. O-ring #A" 12. Distributor
#D" 4. Piston and connecting rod assem- 10. Piston 4. Drive belt* 13. O-ring
bly 11. Connecting rod 5. Water pump pulley NOTE
5. Connecting rod bearing 12. Bolt 6. Alternator brace *: For details of adjustment, refer to the relevant model’s
#C" 6. Piston ring No. 1 7. Alternator chassis workshop manual.
"A# #B" 8. Crankshaft bolt
#B" 9. Crankshaft pulley
! Mitsubishi Motors Corporation Feb. 2004 PWEE9520-H Revised ! Mitsubishi Motors Corporation Nov. 2003
Apr. 1995 PWEE9520
PWEE9520-G Revised
4G1 ENGINE (E–W) – Alternator and Ignition System 11A-3-1b 11A-10-4 4G1 ENGINE (E - W) - Oil Pump and Oil Pan
"EA OIL FILTER INSTALLATION

REMOVAL AND INSTALLATION <SOHC 16-VALVE – FRONT WHEEL DRIVE (WITH
CAM POSITION SENSOR)> (1) Clean the filter mounting surface on the front case.
(2) Apply engine oil to the oil filterís O-ring.
(3) Screw on the oil filter until the O-ring is seated on the
mounting surface. Then, give the oil filter one further
10 Nm turn such that it is torqued to approximately 14 Nm.
10 Caution
The oil filter must be tightened using a commercially
11 available filter wrench. If the filter is tightened by hand
only, it will be insufficiently torqued, resulting in oil
leaks.
9 Nm
25 Nm 14
10
12 5 Nm
15
16
11
44 Nm 13
22 Nm 21 Nm "FA OIL FILTER INSTALLATION

6 (1) Clean the filter mounting surface on the front case.
13 Nm (2) Apply engine oil to the O-ring of the oil filter.
(3) Screw the oil filter in and tighten the oil filter approximately
3/4 of a turn (approx. 16 ± 4 Nm) from where the O-ring
has come into contact with the oil filter mounting surface.
Bracket side Caution
7 23 Nm
1 The oil filter must be tightened using a commercially
23 Nm 5 available filter wrench. If the filter is tightened by hand
only, it will be insufficiently torqued, resulting in oil
9 leaks.
9 Nm
4
8
M12 125 Nm
M14 181 Nm
Removal steps
1. Oil level gauge 10.
Spark plug cable
2. Oil level gauge guide 11.
Ignition coil
3. O-ring 12.
Spark plug
4. Drive belt* 13.
Ignition failure sensor
5. Water pump pulley (only vehicles for Europe)
6. Alternator brace 14. Cam position sensor
7. Alternator #C" 15. Cam position sensor support
"A# #B" 8. Crankshaft bolt 16. Cam position sensing cylinder
#B" 9. Crankshaft pulley NOTE
*: For details of adjustment, refer to the relevant model’s
chassis workshop manual.
Aug. 2000 PWEE9520
PWEE9520-D Revised
Apr. 1995 PWEE9520
PWEE9520-G Revised
4G1 ENGINE (E–W) – Oil Pump and Oil Pan 11A-10-3 11A-3-2 4G1 ENGINE (E–W) – Alternator and Ignition System
INSTALLATION SERVICE POINTS REMOVAL AND INSTALLATION <SOHC 16-VALVE – REAR WHEEL DRIVE>
"A# FRONT OIL SEAL CASE INSTALLATION
(1) Clean the sealant application surfaces on the cylinder
block and front oil seal case. 10
(2) Apply a 3 mm bead of form-in-place gasket to the entire
10 Nm
circumference of the oil pan flange.
Specified sealant:
equivalent.
"B# FRONT OIL SEAL INSTALLATION 9 Nm

MD998305 (M12) (1) Place the special tool on the crankshaft’s front end and 13
MB991962 (M14) apply engine oil to the its outer circumference. 25 Nm
12
6 11 14
7 15
44 Nm 13 Nm
(2) Apply engine oil to the oil seal lip, then push the oil seal 22 Nm 21 Nm
MD998304 (M12) along the guide by hand until it touches the front case.
MD998306 (M14)
Tap the oil seal into place using the special tool.
23 Nm 5 1
9 Nm
23 Nm
"C# OIL PAN INSTALLATION

(1) Clean the mating surfaces of the cylinder block and oil 2
pan.
(2) Apply a 4 mm bead of form-in-place gasket to the outer 3
circumference of the oil pan flange. 8 9
Specified sealant:
M12 125 Nm
Mitsubishi Genuine Part No. MD970389 or 4 M14 181 Nm
equivalent.
Removal steps
"D# DRAIN PLUG GASKET INSTALLATION 1. Oil level gauge 10. Spark plug cable
(1) Replace the drain plug gasket with a new one. Fit the 2. Oil level gauge guide 11. Ignition coil
Oil pan side 3. O-ring 12. Spark plug
new gasket as shown. 4. Drive belt* 13. Cam position sensor
5. Water pump pulley #C" 14. Cam position sensor support
6. Alternator brace 15. Cam position sensing cylinder
7. Alternator NOTE
"A# #B" 8. Crankshaft bolt *: For details of adjustment, refer to the relevant model’s
#B" 9. Crankshaft pulley chassis workshop manual.

Apr. 1995 PWEE9520
PWEE9520-G Revised !
! Mitsubishi
Mitsubishi Motors
Motors Corporation
Feb. 2004 PWEE9520
PWEE9520-H Revised
4G1 ENGINE (E–W) – Alternator and Ignition System 11A-3-3 11A-10-2 4G1 ENGINE (E–W) – Oil Pump and Oil Pan
REMOVAL AND INSTALLATION <DOHC> MD998727 MD998727 REMOVAL SERVICE POINT

"A# OIL PAN REMOVAL
(1) Remove the oil pan mounting bolts.
(2) Knock the special tool between the oil pan and cylinder
block as shown in the illustration.
10 (3) Tapping the side of the special tool, slide the tool along
the oil pan/cylinder block seal and thus remove the oil
pan.
25 Nm
12 INSPECTION
11
11 Nm 1. OIL PUMP
(1) Fit the rotor into the front case.
13 (2) Check the tip clearance using a thickness gauge.
Standard value: 0.03 – 0.08 mm
6 7 44 Nm
22 Nm
(3) Check the side clearance using a straight edge and
thickness gauge.
Standard value: 0.04 – 0.10 mm
5 1
23 Nm
9 Nm 23 Nm
(4) Check the body clearance using a thickness gauge.

2 Standard value: 0.10 – 0.18 mm
Limit: 0.35 mm
3
8 9
4
M12 125 Nm
M14 181 Nm
Removal steps
1. Oil level gauge 10. Spark plug cable
2. Oil level gauge guide 11. Spark plug
3. O-ring #A" 12. Distributor
4. Drive belt* 13. O-ring
5. Water pump pulley NOTE
6. Alternator brace *: For details of adjustment, refer to the relevant model’s
7. Alternator chassis workshop manual.
!
! Mitsubishi
Mitsubishi Motors
Motors Corporation
Feb. 2004 PWEE9520
PWEE9520-H Revised !
! Mitsubishi
Mitsubishi Motors
Motors Corporation
Feb. 2004 PWEE9520
PWEE9520-H Revised
4G1 ENGINE (E - W) - Oil Pump and Oil Pan 11A-10-1b 11A-3-4 4G1 ENGINE (E–W) – Alternator and Ignition System
REMOVAL AND INSTALLATION <GDI> REMOVAL AND INSTALLATION <DOHC–GDI>
10 Nm
Apply engine oil to all
moving parts before
installation. 9 Nm
11
25 Nm 13
7 12
10 Nm 15
11 12 44 Nm 14
14 13 Nm
15 21 Nm
14 Nm
13
6 22 Nm
1
1 5
19 Nm 8
6
2
9
10 9 Nm
8 4
19 Nm
7 7 Nm
3
44 Nm 2 3
4
39 Nm
5
10
9
M12 125 Nm
M14 181 Nm
Removal steps
1. Oil filter
"FA 9. Relief plunger Removal steps
2. Drain plug "BA 10. Oil seal
"DA 3. Gasket "AA 11. Front case 1. Oil level gauge 11. Ignition coil
AA" "CA 4. Oil pan 12. O-ring 2. Engine hanger 12. Spark plug
5. Oil screen 13. Oil pump cover 3. Oil level gauge guide 13. Cam position sensor
6. Gasket 14. Outer rotor 4. O-ring #C" 14. Cam position sensor support
7. Relief valve 15. Inner rotor 5. Drive belt 15. Cam position sensing cylinder
8. Relief valve spring 6. Water pump pulley
7. Alternator brace
8. Alternator assembly

Aug. 2000 PWEE9520
PWEE9520-D Added
!
! Mitsubishi
Mitsubishi Motors
Motors Corporation
Feb. 2004 PWEE9520
PWEE9520-H Revised
4G1 ENGINE (E–W) – Alternator and Ignition System 11A-3-5 11A-10-1a 4G1 ENGINE (E - W) - Oil Pump and Oil Pan
REMOVAL SERVICE POINT REMOVAL AND INSTALLATION <EXCEPT GDI (REAR WHEEL DRIVE)>
"A# CRANKSHAFT BOLT REMOVAL
MD998781
(1) Lock the flywheel or drive plate in position using the special
tool shown in the illustration, then loosen the crankshaft Apply engine oil to all
bolts. moving parts before
installation.
INSTALLATION SERVICE POINTS

10 Nm
#A" DISTRIBUTOR INSTALLATION 12
(1) Turn the crankshaft clockwise until cylinder No. 1 is at
13 14
Alignment mark top dead center on its compression stroke.
(2) Align the alignment marks on the distributor housing and 14 Nm
coupling.
(3) Fit the distributor onto the engine, aligning the stud bolts 7
with the slots in the distributor mounting flange. 5
Alignment mark 6
15
16
#B" CRANKSHAFT PULLEY / BOLT INSTALLATION
19 Nm
(1) Hold the flywheel or drive plate using the special tool.
MD998781
24 Nm
10
11 9
8 7 Nm
44 Nm
4
Crankshaft pulley (2) Clean the bolt hole in crankshaft, crankshaft bolt and
crankshaft pulley’s seating surface. 1
Crankshaft Degrease 3
bolt (3) Degrease the cleaned seating surface of the crankshaft
Crankshaft 2
pulley.
(4) Install the crankshaft pulley.
39 Nm 23 Nm
(5) Apply oil to the threads of crankshaft bolt and the outer
surface of washer.
(6) Tighten the crankshaft bolt to the specified torque of 125
Washer
Nm.
Clean
Shear-drop
Removal steps
1. Oil filter
"EA 10. Relief plunger
2. Drain plug "BA 11. Front oil seal
#C" CAM POSITION SENSOR SUPPORT "DA 3. Gasket "AA 12. Front case
INSTALLATION 4. Transmission stay 13. O-ring
(1) Apply a 3 mm bead of form-in-place gasket (FIPG) to AA" "CA 5. Oil pan 14. Oil pump cover
the area shown. 6. Oil screen 15. Oil pump outer rotor
7. Gasket 16. Oil pump inner rotor
Specified sealant: 8. Relief valve
Mitsubishi Genuine Part No. MD970389 or 9. Relief valve spring
equivalent

Aug. 2000 PWEE9520
PWEE9520-D Added
Aug. 2001 PWEE9520
PWEE9520-F Revised
4G1 ENGINE (E - W) - Oil Pump and Oil Pan 11A-10-1 4G1 ENGINE (E–W) – Timing Belt 11A-4-1
10. OIL PUMP AND OIL PAN 4. TIMING BELT
REMOVAL AND INSTALLATION <EXCEPT GDI (FRONT WHEEL DRIVE)> REMOVAL AND INSTALLATION <SOHC – With timing belt rear cover>

moving parts before
installation.
13
14
10 Nm 12
13
88 Nm
15
14
14 Nm
11 Nm 1
11
8 6
7
16
17 5
23 Nm
19 Nm 35 Nm
39 Nm
11
3 8
2 9
10 7 Nm
12 24 Nm
6
9 3
44 Nm
7
5 4
4 9 Nm
10
1 2
23 Nm
23 Nm
Removal steps
1. Timing belt upper cover $B# 8. Spacer <Without Distributor>
2. Timing belt lower cover $B# 9. Sensing blade <Without Distributor>
Removal steps #A$ $D# 3. Timing belt $B# 10. Flange <With Distributor>
$C# 4. Tensioner spring #B$ $A# 11. Camshaft sprocket bolt
"EA 1. Oil filter 10. Relief valve spring $C# 5. Timing belt tensioner 12. Camshaft sprocket
2. Drain plug 11. Relief plunger 6. Crankshaft angle sensor 13. Engine support bracket
"DA 3. Gasket "BA 12. Front oil seal <Without Distributor> 14. Timing belt rear cover
4. Transmission stay (cast metal) "AA 13. Front case $B# 7. Crankshaft sprocket
5. Transmission stay (sheet metal) 14. O-ring
AA" "CA 6. Oil pan 15. Oil pump cover
7. Oil screen 16. Oil pump outer rotor
8. Gasket 17. Oil pump inner rotor
9. Relief valve

Aug. 2000 PWEE9520
PWEE9520-D Revised
Feb. 1995 PWEE9520
PWEE9520-E Revised
11A-4-1a 4G1 ENGINE (E–W) – Timing Belt 4G1 ENGINE (E - W) - Cylinder Head and Valves 11A-9-11
"DA CYLINDER HEAD BOLT INSTALLATION
REMOVAL AND INSTALLATION <SOHC – Without timing belt rear cover>
(1) Before reusing the cylinder head bolt, check that its nominal
length does not exceed the specified limit. Replace the
bolt if this measurement exceeds the limit.
Limit: 103.2 mm
(2) Apply engine oil to the boltís thread and washer.
Shank length
Timing belt side

(3) Tighten the bolts in the sequence shown until each is
torqued to 49 Nm.
(4) Completely loosen the bolts.
11 13 8 6 1 3 9 (5) Retighten the bolts in the sequence shown until each is
88 Nm torqued to 20 Nm.
35 Nm
11 Nm 1
10 4 2 5 7
10 12
5 (6) Apply paint marks to the cylinder head bolt heads and
21 Nm
21 Nm cylinder head as shown.
23 Nm
35 Nm
90_ (7) In accordance with the tightening sequence, tighten each
bolt by 90_.
(8) Tighten each bolt by a further 90_ and check that the
paint marks on the bolt head and cylinder head are aligned.
Caution
8 6 If the bolts are tightened by an angle of less than
90_ Paint mark
9 90_, they may not hold the cylinder head with sufficient
3 strength.
7 If the bolts are tightened by an angle exceeding 90_,
4 9 Nm completely remove them and carry out the installation
procedure again.
2 MD998601
"EA VALVE STEM SEAL INSTALLATION
Valve
Valve stem seal (1) Install the valve spring seat.
(2) Install the valve.
(3) Apply a small amount of engine oil to the valve stem
seal.
Valve guide (4) Using the valve stem as a guide, install the valve stem
Removal steps seal to the valve guide with the special tool.
1. Timing belt upper cover $B# 7. Crankshaft sprocket Valve spring seat
Caution
2. Timing belt lower cover $B# 8. Spacer <Without Distributor>
#A$ $D# 3. Timing belt $B# 9. Sensing blade <Without Distributor> Improper installation of the valve stem seal will cause
$C# 4. Tensioner spring #B$ $A# 10. Camshaft sprocket bolt oil to work down. Use the special tool to install the
$C# 5. Timing belt tensioner 11. Camshaft sprocket Intake side Exhaust side valve stem seal.
Body color: Gray Body color: Grayish green
6. Crankshaft angle sensor 12. Bracket Embossed identification
<Without Distributor> 13. Engine support bracket
Embossed identification
symbol: None symbol: SD NOTE
The valve stem seal differs between the intake and exhaust
sides.

Aug. 2000 PWEE9520
PWEE9520-D Added
Feb. 1995 PWEE9520
PWEE9520-E Revised
11A-9-10 4G1 ENGINE (E - W) - Cylinder Head and Valves 4G1 ENGINE (E–W) – Timing Belt 11A-4-1b
SOHC 16-VALVE, DOHC REMOVAL AND INSTALLATION <DOHC>
MB991671
"BA VALVE SPRING INSTALLATION

Spring (1) Install the valve spring such that its painted end is on
Painted retainer
end
the rocker arm side.
13
Stem seal 11 Nm
11 Nm
11 Nm 3 14
Spring seat
10
1
88 Nm
SOHC MD998772 "CA RETAINER LOCK INSTALLATION
(1) The valve spring, if excessively compressed, causes the 9
bottom end of retainer to be in contact with the stem seal,
and damage it.
11
23 Nm
5
12
11
6
35 Nm
DOHC
35 Nm
7
4
MD998772
2
Removal steps
MD998735 1. Timing belt upper cover $B# 8. Flange
2. Timing belt lower cover #B$ $A# 9. Camshaft sprocket bolt
#A$ $E# 3. Timing belt 10. Camshaft sprocket
#A$ $C# 4. Tensioner spring 11. Engine support bracket
#A$ $C# 5. Timing belt tensioner 12. Timing belt rear cover (lower)
6. Idler pulley 13. Timing belt rear cover (right)
$B# 7. Crankshaft sprocket 14. Timing belt rear cover (left)

Aug. 2000 PWEE9520
PWEE9520-D Revised
Feb. 1995 PWEE9520
PWEE9520-E Revised
11A-4-2 4G1 ENGINE (E–W) – Timing Belt 4G1 ENGINE (E - W) - Cylinder Head and Valves 11A-9-9
REMOVAL AND INSTALLATION <GDI> VALVE GUIDE REPLACEMENT SERVICE

POINTS
(1) Using a press, push the valve guide out toward the cylinder
block side.
(2) Rebore the valve guide hole in the cylinder head to match
the oversize valve guide that is to be fitted.
11 Nm
Caution
Do not install a valve guide of the same size again.
15 Valve guide hole diameters (SOHC 12-VALVE)
0.05 O.S.: 12.040 - 12.058 mm
0.25 O.S.: 12.240 - 12.258 mm
0.50 O.S.: 12.490 - 12.508 mm
14 Valve guide hole diameters (SOHC 16-VALVE, DOHC)
88 Nm 0.05 O.S.: 10.550 - 10.568 mm
0.25 O.S.: 10.750 - 10.768 mm
11 Nm 13 0.50 O.S.: 11.000 - 11.018 mm
1 3 35 Nm Valve guide hole diameters (DOHC - GDI)
0.05 O.S.: 10.61 - 10.62 mm
5 9 0.25 O.S.: 10.81 - 10.82 mm
23 Nm
0.50 O.S.: 11.06 - 11.07 mm
6
(3) Press-fit the valve guide until it projects by the specified
amount.
Standard value:
10 SOHC 12-VALVE: 17 mm
SOHC 16-VALVE, DOHC: 23 mm
8 35 Nm
4 Caution
1. The valve guide must be installed from the upper
11
side of the cylinder head.
Projec- 2. The valve guides differ in length on the intake
tion
7 and exhaust sides. (48 mm for intake valve; 55
21 Nm 21 Nm mm for exhaust valve)
2 9 Nm
35 Nm 12 3. After press-fitting the valve guide, insert a new
valve and check that it slides smoothly.
Removal steps
1. Timing belt front upper cover $B# 9. Spacer
2. Timing belt front lower cover $B# 10. Sensing blade
#C$ $G# 3. Timing belt 11. Bracket
4. Tensioner spring 12. Right engine support bracket
$F# 5. Timing belt tensioner #B$ $A# 13. Camshaft sprocket bolt SOHC 12-VALVE INSTALLATION SERVICE POINTS
6. Idler pulley 14. Camshaft sprocket
7. Crank angle sensor 15. Timing belt rear upper cover "AA VALVE STEM SEAL INSTALLATION
$B# 8. Crankshaft sprocket (1) Install the valve spring seat.
MD998760
(2) Install a new valve stem seal using the special tool shown
in the illustration.
Caution
1. Valve stem seals cannot be reused.
2. The valve stem seal must be installed using the
correct special tool. Incorrect installation could
result in oil leaking past the valve guide.
Aug. 2000 PWEE9520
PWEE9520-D Revised
Feb. 1995 PWEE9520
PWEE9520-E Revised
11A-9-8 4G1 ENGINE (E - W) - Cylinder Head and Valves 4G1 ENGINE (E - W) - Timing Belt 11A-4-3
0.5 - 1.0 mm VALVE SEAT REPLACEMENT SERVICE REMOVAL SERVICE POINTS
POINTS AA" TIMING BELT / TENSIONER SPRING / TIMING
(1) Cut the valve seat to be replaced from the inside to reduce BELT TENSIONER REMOVAL
the wall thickness. Then, remove the valve seat. (1) Using pliers, grip the tensioner spring projection (marked
Cut away (2) Rebore the valve seat hole in the cylinder head to match ìAî in the diagram)and remove it from the oil pump case
the selected oversize valve seat diameter. stopper. Then, remove the tensioner spring.
0.5 - 1.0 mm (2) Remove the timing belt tensioner.
Valve seat hole diameters
(3) If the timing belt is to be reused, chalk an arrow on the
Standard mm belt to indicate the direction of rotation before removing
1EN0274 it. This will ensure the timing belt is fitted correctly when
SOHC In- Primary 0.30 O.S. 27.300 - 27.325 reused.
12-VALVE take
0.60 O.S. 27.600 - 27.625 AB" CAMSHAFT SPROCKET BOLT REMOVAL
Secondary 0.30 O.S. 32.300 - 32.325 MD998715
(1) Using the special tools shown in the illustration, lock the
0.60 O.S. 32.600 - 32.625 MB990767 camshaft sprocket in position.
(2) Loosen the camshaft sprocket bolt.
Valve seat
Exhaust 0.30 O.S. 35.300 - 35.325
height 0.60 O.S. 35.600 - 35.625
SOHC Intake 0.30 O.S. 28.300 - 28.321
16-VALVE
0.60 O.S. 28.600 - 28.621
<4G13>
Exhaust 0.30 O.S. 26.300 - 26.321
Oversize hole I. D. 1EN0275
0.60 O.S. 26.600 - 26.621
SOHC Intake 0.30 O.S. 30.300 - 30.321 AC" TIMING BELT REMOVAL
16-VALVE
<4G18>
0.60 O.S. 30.600 - 30.621 (1) If the timing belt is to be refused, it is necessary to install
Exhaust 0.30 O.S. 28.300 - 28.321 it in the same direction as it was before. Mark an arrow
that shows the direction of rotation on the back surface
0.60 O.S. 28.600 - 28.621 of the timing belt with chalk, etc.
DOHC Intake 0.30 O.S. 31.300 - 31.325
0.60 O.S. 31.600 - 31.625
Exhaust 0.30 O.S. 27.800 - 27.825
0.60 O.S. 28.100 - 28.125
(3) Prevent galling of the cylinder head bore by cooling the

valve seat with liquid nitrogen before press-fitting it. (2) Using pliers and the like, hold the tensioner spring at
(4) Correct the valve seat to achieve the specified width and the illustrated position, and remove the spring.
angle (refer to VALVE SEAT CORRECTION SERVICE Caution
POINTS). Do not cause the end of the tensioner spring to give
damage to the timing belt.
(3) Loosen the timing belt tensioner securing bolt.

(4) Move the timing belt tensioner in the direction shown
Securing bolt to remove the timing belt.

Aug. 2000 PWEE9520
PWEE9520-D Revised E Mitsubishi Motors Corporation Nov. 1995
Aug. 2000 PWEE9520
PWEE9520-D Revised
11A-4-4 4G1 ENGINE (E - W) - Timing Belt 4G1 ENGINE (E - W) - Cylinder Head and Valves 11A-9-7
INSPECTION <except GDI> VALVE SEAT CORRECTION SERVICE POINTS
1. TIMING BELT 0.9 - 1.3 mm (1) Before correcting the valve seat, check for clearance
Check the timing belt closely. Replace the belt with a new 65 between the valve guide and valve and, if necessary,
one if any of the following defects is evident: replace the valve guide.
(1) Hardened backing rubber (the backing rubber is glossy, (2) Correct to obtain the specified seat width and angle.
non-elastic, and so hard that scratching with fingernails (3) After correction, the valve and valve seat should be lapped
leaves no mark) with a lapping compound.
46 - 46.5 15
(2) Surface cracks in the backing rubber <GDI - Intake side>

Crack Crack
(3) Splits in the canvas and/or separation of the canvas and
rubber 0.9 - 1.3 mm
(4) Cracks at the bases of teeth 65
Separation (5) Cracks in the side of the belt
44
Cracked side
20
Cracked tooth base
(6) Abnormal wear on the beltís sides <GDI - Exhaust side>

Rounded edge NOTE
0.9 - 1.3 mm
The sides of the belt are normal if they are sharp as 65
if cut by a knife.
44
Abnormal wear
(exposed core wire)
15
(7) Abnormal wear on teeth

Canvas worn exposing Initial stage:
rubber Canvas worn (fluffy canvas fibers, rubbery texture gone,
white discoloration, canvas texture indistinct)
Missing tooth Final stage:
Canvas worn, exposing rubber (tooth width reduced)
(8) Missing teeth
2. TENSIONER PULLEY AND IDLER PULLEY

(1) Check that the pulleys turn smoothly without play and
are not abnormally noisy. Replace either or both of the
pulleys if necessary.

Aug. 2000 PWEE9520
Aug. 2000 PWEE9520
PWEE9520-D Revised
11A-9-6 4G1 ENGINE (E - W) - Cylinder Head and Valves 4G1 ENGINE (E–W) – Timing Belt 11A-4-5
4. VALVE GUIDES
(1) Measure the clearance between the valve guide and valve
$A# CAMSHAFT SPROCKET BOLT INSTALLATION
stem. If the clearance exceeds the specified limit, replace
either or both components. MB990767 (1) Using the special tools shown in the illustration, lock the
Valve camshaft sprocket in position.
guide Standard mm Limit mm (2) Tighten the camshaft sprocket bolt to the specified torque.
Intake SOHC 12-VALVE 0.020 - 0.050 0.10
SOHC 16-VALVE 0.020 - 0.047 0.10
Stem O. D. DOHC 0.020 - 0.047 0.10
Guide I. D. 1EN0279 MD998715
Exhaust SOHC 12-VALVE 0.035 - 0.050 0.15
Valve stem end SOHC 16-VALVE 0.030 - 0.057 0.15
Crankshaft Sensing $B# SENSING BLADE / SPACER / FLANGE /
DOHC 0.030 - 0.062 0.15 sprocket blade CRANKSHAFT SPROCKET
Valve projection
Spacer Crankshaft Type with crank angle sensor:
5. VALVE SEATS (1) Clean the hole in the crankshaft sprocket.
(1) Assemble the valve, then measure the valve stem (2) Clean and degrease the mating surfaces of the crankshaft
Spring seating projection between the end of the valve stem and the sprocket and crankshaft; sensing blade; and spacer.
surface spring seating surface. If the measurement exceeds the NOTE
specified limit, replace the valve seat. Degrease
Degreasing is necessary to prevent decrease in friction
Clean between the mating surfaces due to presence of oil.
Standard mm Limit mm
SOHC Intake 43.70 44.20
12-VALVE Type without crank angle sensor:
Exhaust 43.30 43.80
Crankshaft Flange (1) Clean the hole in the crankshaft sprocket.
SOHC Intake 53.21 53.71 sprocket
16-VALVE Crankshaft (2) Clean and degrease the crankshaft sprocket, flange, and
Exhaust 54.10 54.60 sprocket fitting surface of the crankshaft.
DOHC Intake 48.80 49.30 NOTE
Exhaust 48.70 49.20 Degreasing is necessary to prevent decrease in friction
between the mating surfaces due to presence of oil.
Clean Degrease
$C# TIMING BELT TENSIONER / TENSIONER SPRING

INSTALLATION
Timing belt (1) Lock the timing belt tensioner in the illustrated position.
tensioner
(2) Fit one of the tensioner spring projections over the hooked
portion of the timing belt tensioner and fit the tensioner
onto the oil pump case.

Apr. 1995 PWEE9520
PWEE9520-C Revised
Feb. 1995 PWEE9520
PWEE9520-E Revised
(3) Grip the other tensioner spring projection and fit it onto (3) Measure the valveís total length. If the measurement is
the oil pump case lug as shown in the illustration. less than specified, replace the valve.
(4) Move the timing belt tensioner in the direction shown Standard mm Limit mm
and temporarily tighten the bolt.
Intake SOHC 12-VALVE 100.75 100.25
SOHC 16-VALVE 111.56 111.06
DOHC 106.35 105.85
Exhaust SOHC 12-VALVE 101.05 100.55
SOHC 16-VALVE 114.71 114.21
DOHC 106.85 106.35
$D# TIMING BELT INSTALLATION
(1) Align the camshaft timing mark with the timing mark on
the cylinder head.
3. VALVE SPRINGS
(2) Align the crankshaft timing mark with the timing mark Squareness
on the front case. (1) Measure the valve springís free height. If the measurement
is less than specified, replace the spring.
Standard mm Limit mm
Free height SOHC Intake 46.1 45.6
12-VALVE
Exhaust 46.8 46.3
SOHC 16-VALVE 50.9 50.4
DOHC 49.1 48.6
1EN0264
(2) Measure the squareness of the spring. If the measurement

(3) Keeping the tension side of the timing belt tight, fit the exceeds the specified limit, replace the spring.
timing belt onto the crankshaft sprocket, camshaft Standard value: 2_ or less
sprocket, and tensioner pulley in that order. Limit: 4_
(4) Loosen the tensioner pulley mounting bolts by 1/4 to
1/2 of a turn and allow the tensioner spring to apply tension
to the timing belt.
(5) Turn the crankshaft twice in the normal rotating direction
(clockwise) and check that the timing marks are correctly
aligned.
Caution
This procedure utilizes the camshaft’s driving torque
to apply tension evenly to the timing belt. Be sure
to turn the crankshaft as described above. Do not
turn the crankshaft in reverse.
(6) Tighten the tensioner pulley mounting bolts.

Dec. 1995 PWEE9520
PWEE9520-A Revised
Feb. 1995 PWEE9520
PWEE9520-E Revised
AC" VALVE STEM SEAL REMOVAL $E# TIMING BELT INSTALLATION
(1) Place the camshaft sprocket timing marks at the positions
shown.
NOTE
After aligning the sprocket timing marks, let go of the
sprockets. The exhaust camshaft sprocket will rotate by
one tooth in the direction shown and remain stable in
this position.
INSPECTION (2) Align the crankshaft timing mark with the timing mark
1. CYLINDER HEAD on the front case.
(1) Before cleaning the cylinder head, check it for water leaks,
gas leaks, cracks, and other damage.
(2) Remove all oil, water scale, sealant, and carbon. After
cleaning the oil passages, blow air through them to verify
that they are not blocked.
(3) Check for distortion in the cylinder head gasket surface
using a straight edge and thickness gauge. If distortion
exceeds the specified limit, grind the gasket surface to
specification.
Gasket surface distortion (3) Turn the exhaust camshaft sprocket in the direction shown
Standard value: 0.05 mm or less and fit the timing belt with the timing marks aligned.
Limit: 0.2 mm (4) Use a bulldog clip to prevent the timing belt teeth from
Grinding limit: 0.2 mm jumping.
Cylinder head height (specification when new):
SOHC 12-VALVE: 106.9 - 107.1 mm
SOHC 16-VALVE: 119.9 - 120.1 mm
DOHC: 131.9 - 132.1 mm
Caution
No more than 0.2 mm of stock may be removed from
the cylinder head and cylinder block mating surfaces
in total.
2. VALVES (5) Fit the timing belt onto the idler pulley, crankshaft sprocket,
and tensioner pulley in that order.
(1) Check the valve face for correct contact. If contact is
uneven or incomplete, reface the valve seat. NOTE
Contact (must (2) If the margin is less than specified, replace the valve. When fitting the belt, keep the camshaft sprocket timing
be in center of marks correctly aligned and keep the tension side of the
Standard value:
face) Margin belt tight.
Intake: 1.0 mm
Exhaust: 1.5 mm (6) Loosen the tensioner pulley mounting bolts by 1/4 to 1/2
Limit: of a turn and allow the tensioner spring to apply tension
Intake: 0.5 mm to the timing belt.
6EN0542 Exhaust: 1.0 mm (7) Remove the bulldog clip.
(8) Turn the crankshaft twice in the normal rotating direction
(clockwise) and check that the timing marks are correctly
aligned.
Caution
This procedure utilizes the camshaft’s driving torque
to apply tension evenly to the timing belt. Be sure
to turn the crankshaft as described above. Do not
turn the crankshaft in reverse.
(9) Tighten the tensioner pulley mounting bolts.

Dec. 1998 PWEE9520
PWEE9520-A Revised
Feb. 1995 PWEE9520
PWEE9520-E Revised
$F# TIMING BELT TENSIONER AND TENSIONER SOHC REMOVAL SERVICE POINTS
Securing bolt SPRING INSTALLATION AA" CYLINDER HEAD BOLT REMOVAL
MB991653
(1) Install the timing belt tensioner and the tensioner spring,
and temporarily tighten the timing belt tensioner securing
bolt.
(2) Using pliers and the like, secure the spring at the illustrated DOHC
position of the front case.
MB991653
Caution
Do not cause the end of the tensioner spring to give
damage to the crankshaft sprocket.
$G# TIMING BELT INSTALLATION SOHC MD998772

AB" RETAINER LOCK REMOVAL
(1) Align the timing marks on each camshaft sprocket. (1) Tag removed valves, springs, and other components,
noting their cylinder numbers and locations to facilitate
NOTE reassembly. Store these components safely.
After the timing marks on the sprockets are aligned, the
sprockets can turn by about one tooth in the direction
shown and remain stable in this position.
(2) Align the crankshaft sprocket timing marks. DOHC

Timing marks
MD998772
(3) While paying attention to the direction of rotation marked MD998735

on the timing belt (if the timing belt is reused), put the
timing belt over the inlet camshaft sprocket. After that,
secure the belt at the position shown with a paper clip,
etc.

Feb. 1995 PWEE9520
PWEE9520-E Revised
REMOVAL AND INSTALLATION <DOHC - GDI> (4) Adjust the timing belt so that 23 cogs will fall within the
23 cogs
range between the timing marks on the intake and exhaust
camshaft sprockets. Secure the belt at this position with
49 Nm
Æ Fully loosen. a paper clip, etc.
20 Nm 1
Æ 90 + 90 9 8
10
4 5 14
20 15
6
12 17
13
(5) While aligning the exhaust camshaft sprocket timing
16 Timing marks
marks, install the timing belt on the idler pulley, crankshaft
19 sprocket, and the timing belt tensioner in that order.
11 (6) Ensure that the timing marks on the exhaust camshaft
18 sprocket and on the crankshaft sprocket are in alignment.
7
3
(7) Loosen the timing belt tensioner securing bolt, which has
temporarily been tightened, a quarter to half turn. Utilizing
Apply engine oil to all Securing bolt tensioner spring tension, give tension to the timing belt.
moving parts before
installation. (8) Remove the paper clips, etc.
(9) Make two turns of the crankshaft sprocket in clockwise

direction to ensure that the timing marks on each camshaft
sprocket are in alignment.
Caution
Operation under item 9 above is performed in order
to give a constant tension to the timing belt by utilizing
Removal steps
camshaft driving torque. Observe the number of turns
of the sprocket mentioned above. Do not turn the
AA" "DA 1. Cylinder head bolt 11. Exhaust valve
2. Cylinder head assembly AC" "EA 12. Valve stem seal
crankshaft sprocket counterclockwise direction.
3. Gasket 13. Valve spring seat
AB" "CA 4. Retainer lock AC" "EA 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

Aug. 2000 PWEE9520
PWEE9520-D Revised
Feb. 1995 PWEE9520
PWEE9520-E Revised
4G1 ENGINE (E - W) - Fuel and Emission Control Systems 11A-5-1 4G1 ENGINE (E - W) - Cylinder Head and Valves 11A-9-1b
5. FUEL AND EMISSION CONTROL SYSTEMS REMOVAL AND INSTALLATION <DOHC>
REMOVAL AND INSTALLATION <SOHC 12-VALVE - CARBURETOR>
2
17 Nm 49 Nm
Æ Fully loosen. 1 8
20 Nm
Æ 90 + 90 9
10 Nm 10
4 14
5 20 15
3 8 12 Nm
17
6
12
13
9 16
13 19
10
18 11
7
2
4 11 21 Nm
3
12
14
5
6
7
12 Nm
31 Nm
1
Apply engine oil to

all moving parts
before installation.
Removal steps
AA" "DA 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
"BA 6. Valve spring 16. Intake valve guide
7. Intake valve 17. Exhaust valve guide
AB" "CA 8. Retainer lock 18. Intake valve seat
Removal steps 9. Valve spring retainer 19. Exhaust valve seat
1. Breather tube 8. Carburetor "BA 10. Valve spring 20. Cylinder head
2. Fuel hose 9. Upper gasket
3. Hose clamp 10. Spacer
4. Fuel pump 11. Lower gasket
5. Gasket 12. EGR valve <engine with EGR>
6. Insulator 13. Cover <engine without EGR>
7. Gasket 14. Gasket

Aug. 2000 PWEE9520
Aug. 2000 PWEE9520
PWEE9520-D Revised
11A-9-1a 4G1 ENGINE (E–W) – Cylinder Head and Valves 11A-5-1a 4G1 ENGINE (E - W) - Fuel and Emission Control Systems
REMOVAL AND INSTALLATION <SOHC 16-VALVE> REMOVAL AND INSTALLATION <SOHC 16-VALVE - CARBURETOR>
17 Nm
49 Nm → Fully loosen.
→ 20 Nm → 90° + 90°
10 Nm
1 9 8
4 3 8
5 10
14
6 9
12 15
13 17 2 10 12 Nm
16 2
4 11
20
12
5 13
19 6
11 7
18
3 19 Nm
7
31 Nm
1
moving parts before
installation.
Removal steps
"A# #D" 1. Cylinder head bolt 11. Intake valve
2. Cylinder head assembly "C# #A" 12. Valve stem seal
"B# #C" 4. Retainer lock "C# #A" 14. Valve stem seal
#B" 6. Valve spring 16. Exhaust valve guide
7. Exhaust valve 17. Intake valve guide Removal steps
"B# #C" 8. Retainer lock 18. Exhaust valve seat
9. Valve spring retainer 19. Intake valve seat 1. Breather tube 8. Carburetor
#B" 10. Valve spring 20. Cylinder head 2. Fuel hose 9. Upper gasket
3. Hose clamp 10. Spacer
4. Fuel pump 11. Lower gasket
5. Gasket 12. Cover
6. Insulator 13. Gasket
7. Gasket

Aug. 2000 PWEE9520
PWEE9520-D Added
! Mitsubishi
! Mitsubishi Motors
Motors Corporation
Feb. 1995 PWEE9520
PWEE9520-H Revised
4G1 ENGINE (E–W) – Fuel and Emission Control Systems 11A-5-1b 4G1 ENGINE (E–W) – Cylinder Head and Valves 11A-9-1
9. CYLINDER HEAD AND VALVES
49 Nm → Fully loosen.
→ 20 Nm → 90° + 90°
1 2
9
10
11
4 22
5 15
6 16
13 18
14
21
17
12
19 20
7 8
3
Intentionally blank

moving parts before
installation.
Removal steps
"A# #D" 1. Cylinder head bolt 12. Exhaust valve
2. Cylinder head assembly "C# #A" 13. Valve stem seal
"B# #C" 4. Retainer lock "C# #A" 15. Valve stem seal
#B" 6. Valve spring 17. Intake valve guide
7. Intake valve (primary) 18. Exhaust valve guide
8. Intake valve (secondary) 19. Intake valve seat (primary)
"B# #C" 9. Retainer lock 20. Intake valve seat (secondary)
10. Valve spring retainer 21. Exhaust valve seat
#B" 11. Valve spring 22. Cylinder head

Aug. 2000 PWEE9520
PWEE9520-D Added ! Mitsubishi
! Mitsubishi Motors
Motors Corporation
Feb. 1995 PWEE9520
PWEE9520-H Revised
11A-8a-6 4G1 ENGINE (E - W) - Rocker Arms and Camshafts 11A-5-2 4G1 ENGINE (E–W) – Fuel and Emission Control Systems
(9) Remove the lash adjuster from the container, then stand
the lash adjuster with its plunger at the top. Push the
REMOVAL AND INSTALLATION <SOHC–MPI – FRONT WHEEL DRIVE (EXCEPT
plunger firmly and check that it does not move. Also, FROM 2001 model FOR EUROPE)>
check that the lash adjusterís height matches that of a
new lash adjuster.
11 Nm 9 Nm
NOTE
If lash adjuster contracts, perform the operations (7)
through (9) again to fill it with diesel fuel completely. 13 1
Replace the lash adjuster if it still contracts after performing
these steps. 5
2
(10)Stand the lash adjuster upright to prevent diesel fuel from

spilling out. Do not allow the lash adjuster to become 8
contaminated by dirt or other foreign matter. Fit the lash
adjuster onto the engine as soon as possible. 11
18 Nm
12
7
10 3
6
9 21 Nm
9 Nm
16
4 M8 × 16 18 Nm
Except M8 × 16 12 Nm
14
15
18 17
18 Nm
Removal steps
1. Vacuum pipe and hose assembly 11. O-ring
2. Vacuum hose assembly 12. Grommet
3. Throttle body assembly 13. Delivery pipe
4. Gasket 14. EGR valve (With EGR valve)
5. Fuel return pipe 15. Cover (Without EGR valve)
"B# 6. Fuel pressure regulator 16. Gasket
7. O-ring 17. Air temperature sensor (Up to
8. Insulator 2000 model)
9. Insulator 18. Gasket (Up to 2000 model)
"A# 10. Injector

Aug. 2000 PWEE9520
PWEE9520-D Added
Apr. 1995 PWEE9520
PWEE9520-G Revised
4G1 ENGINE (E–W) – Fuel and Emission Control Systems 11A-5-2a 4G1 ENGINE (E - W) - Rocker Arms and Camshafts 11A-8a-5
(4) Remove the lash adjuster from the container. Then, push
REMOVAL AND INSTALLATION <SOHC–MPI – FRONT WHEEL DRIVE (FROM down the steel ball gently and push the plunger to eliminate
2001 model FOR EUROPE)> diesel fuel from the pressure chamber.
Caution
Make sure the oil hole in the side of the body is pointing
9 Nm
9 Nm toward container A. Do not point the oil hole at yourself
4 or other people.
MD998442
11 Nm 5
Diesel fuel
(5) Place the lash adjuster in container B. Then, gently push

down the internal steel ball using special tool MD998442
11 1 and move the plunger through 5 to 10 strokes until it
9 slide smoothly. This operation will clean the lash adjusterís
pressure chamber.
6 10 3
18 Nm Caution
7 The steel ball spring is extremely weak, so the lash
adjusterís functionality may be lost if the air bleed
8 Diesel fuel wire is pushed in hard.
MD998442
2 (6) Remove the lash adjuster from the container. Then, push
21 Nm down the steel ball gently and push the plunger to eliminate
diesel fuel from the pressure chamber.
13 Caution
12
toward container A. Do not point the oil hole at yourself
MD998442
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
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
Removal steps (8) Stand the lash adjuster with its plunger at the top, then
1. Vacuum pipe and hose "A# 8. Injector push the plunger downward firmly until it moves through
2. Throttle body assembly 9. O-ring its greatest possible stroke. Return the plunger slowly,
3. Gasket 10. Grommet then release the steel ball and allow the pressure chamber
"B# 4. Fuel pressure regulator 11. Delivery pipe to fill with diesel fuel.
5. O-ring 12. EGR valve
6. Insulator 13. Gasket
7. Insulator
Diesel fuel
MD998442

Aug. 2000 PWEE9520
PWEE9520-D Added
Apr. 1995 PWEE9520
PWEE9520-G Revised
11A-8a-4 4G1 ENGINE (E - W) - Rocker Arms and Camshafts 11A-5-2b 4G1 ENGINE (E–W) – Fuel and Emission Control Systems
INSPECTION REMOVAL AND INSTALLATION <SOHC–MPI – REAR WHEEL DRIVE>

CAMSHAFT
(1) Measure the cam height. 9 Nm
Standard value:
Intake: 34.85 mm 11 Nm
3
Exhaust: 34.59 mm
18 Nm
Limit:
Intake: 34.35 mm 11
Exhaust: 34.09 mm 2
1
LASH ADJUSTER
6
5
Caution
1. The lash adjusters are precision-engineered 4
mechanisms. Do not allow them to become
contaminated by dirt or other foreigní substances.
2. Do not attempt to disassemble the lash adjusters. 21 Nm
9 10
3. Use only fresh diesel fuel to clean the lash 8
adjusters.
9 Nm 7
(1) Prepare three containers and approximately five liters

of diesel fuel. Into each container, pour enough diesel 12
Outside Inside Filling with
cleaning cleaning diesel fuel fuel to completely cover a lash adjuster when it is standing 13
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.
Removal steps
Diesel
fuel 1. Throttle body assembly "A# 8. Injector
2. Gasket 9. O-ring
3. Fuel return pipe 10. Grommet
(3) While gently pushing down the internal steel ball using "B# 4. Fuel pressure regulator 11. Delivery pipe
special tool MD998442, move the plunger through 5 to 5. O-ring 12. EGR valve
10 strokes until it slides smoothly. In addition to eliminating 6. Insulator 13. Gasket
stiffness in the plunger, this operation will remove dirty 7. Insulator
oil.
Caution
The steel ball spring is extremely weak, so the lash
wire is pushed in hard.
MD998442
Diesel fuel NOTE
If the plunger remains stiff or the mechanism appears
otherwise abnormal, replace the lash adjuster.
Aug. 2000 PWEE9520
PWEE9520-D Added
Apr. 1995 PWEE9520
PWEE9520-G Revised
4G1 ENGINE (E–W) – Fuel and Emission Control Systems 11A-5-3 4G1 ENGINE (E - W) - Rocker Arms and Camshafts 11A-8a-3
(4) Install the beam camshaft and tighten the bolts to the
REMOVAL AND INSTALLATION <DOHC> Front of engine
specified torque in the order shown in the illustration.
11 Nm Tightening torque
11 Nm (M6)
25 Nm (M8)
(5) After tightening the bolts, completely wipe out the liquid
3 11 gasket that has overflowed the intake part before the
gasket is hardened (within 15 minutes after application
of liquid gasket).
18 Nm
1 "DA SEMI-CIRCULAR PACKING INSTALLATION

6 2 Using the special tool, install the semi-circular packing.
MD998762
9
5 10
4 8 "EA OIL SEAL INSTALLATION

7 MD998713 Using the special tool, install the oil seal.
9 Nm
"FA P.C.V. VALVE INSTALLATION

Install the P.C.V. valve with its nipple directed as shown.
Removal steps
1. Throttle body assembly 7. Insulator
2. Gasket "A# 8. Injector
3. Fuel return pipe 9. O-ring
"B# 4. Fuel pressure regulator 10. Grommet
5. O-ring 11. Delivery pipe
6. Insulator

Aug. 2000 PWEE9520
PWEE9520-D Added
Apr. 1995 PWEE9520
PWEE9520-G Revised
11A-8a-2 4G1 ENGINE (E - W) - Rocker Arms and Camshafts 11A-5-4 4G1 ENGINE (E - W) - Fuel and Emission Control Systems
REMOVAL SERVICE POINT INSTALLATION SERVICE POINTS

AA" LASH ADJUSTER REMOVAL "AA INJECTOR INSTALLATION
Caution (1) Fit a new O-ring and grommet onto the injector.
If the lash adjuster is to be reused, be sure to clean (2) Apply spindle oil or gasoline to the injector O-ring.
and inspect it before installation. (Refer to 11A-8a-4.)
INSTALLATION SERVICE POINTS (3) Fit the injector onto the delivery pipe, turning it to the
"AA LASH ADJUSTER INSTALLATION left and right as it goes in.
(4) Check that the injector rotates smoothly.
Caution
Caution
If the lash adjuster is to be reused, be sure to clean
If the injector does not rotate smoothly, its O-ring
and inspect it before installation. (Refer to 11A-8a-4.) may be binding. If this occurs, remove the injector
While using care not to spill diesel fuel in the lash adjuster, from the delivery pipe, check the O-ring, and re-insert
install the lash adjuster on the rocker arm. the injector.
"BA EXHAUST CAMSHAFT / INTAKE CAMSHAFT

Approx.
INSTALLATION
"BA FUEL PRESSURE REGULATOR INSTALLATION
30_ (1) Turn the crankshaft to place the No. 1 cylinder at top
dead center. (1) Apply a little new engine oil to the O-ring, then insert
Approx.
17_ (2) Place dowel pins of the camshafts in the positions shown the fuel pressure regulator into the delivery pipe, taking
in the illustration. care not to damage the O-ring.
Caution
Ensure that no engine oil enters the delivery pipe.
(2) Check that the fuel pressure regulator rotates smoothly.
If it does not rotate smoothly, the O-ring may be binding.
If this occurs, remove the fuel pressure regulator, check
"CA BEAM CAMSHAFT CAP INSTALLATION the O-ring for damage, then re-insert the regulator into
the delivery pipe.
(1) Remove deposits from the liquid gasket coating surfaces
of the beam camshaft cap and the cylinder head.
(2) Apply liquid gasket to the five grooves on the bottom
surface of the beam camshaft cap by squeezing it to
a thickness of 3 mm.
Specified sealant:
equivalent.
NOTE
Install the beam camshaft cap within 15 minutes of
application of liquid gasket.
(3) Apply a suitable amount of liquid gasket to the ten positions
as shown on the top surface of the cylinder head.
Specified sealant:
equivalent.
NOTE
Install the beam camshaft cap within 15 minutes after
application of liquid gasket.

Aug. 2000 PWEE9520
PWEE9520-D Added E Mitsubishi Motors Corporation Nov. 1995 PWEE9520
4G1 ENGINE (E - W) - Intake Manifold and Throttle Body (GDI) 11A-5a-1 4G1 ENGINE (E - W) - Rocker Arms and Camshafts 11A-8a-1
INTAKE MANIFOLD AND THROTTLE BODY (GDI) ROCKER ARMS AND CAMSHAFTS (GDI)
REMOVAL AND INSTALLATION REMOVAL AND INSTALLATION
19 Nm
6
10 Nm 3
4 3 3.5 Nm
2
2
1 4
20 Nm
5 8
49 Nm 14
7 9
8 13 3.5 Nm
16 14
25 Nm
19 Nm
11 Nm
24 Nm
12
7 17
12
11
15 9
30 Nm
11
6
10
13
15
18
5 11 14
19 Nm
10 Nm
19 Nm
10
16
17
1
moving parts before
installation.
Removal steps
1. Accelerator cable 10. Water hose
2. Water hose 11. EGR valve Removal steps
3. Throttle body 12. Gasket
4. Gasket 13. EGR valve support 1. Engine hanger "EA 10. Oil seal
5. Air intake plenum resonator 14. Gasket 2. Breather hose "DA 11. Semi-circular packing
6. O-ring 15. P.C.V. hose "FA 3. P.C.V. valve "CA 12. Beam camshaft cap
7. Power plant stay, right AA" "AA 16. Intake manifold 4. Gasket 13. Gasket
"BA 8. Intake manifold stay 17. Gasket 5. Oil filler cap "BA 14. Intake camshaft
9. Water hose 18. Insulator 6. Inlet rocker cover "BA 15. Exhaust camshaft
7. Gasket 16. Roller rocker arm
8. Exhaust rocker cover AA" "AA 17. Lash adjuster
9. Gasket

Aug. 2000 PWEE9520
Aug. 2000 PWEE9520
PWEE9520-D Added
4G1 ENGINE (E–W) – Rocker Arms and Camshafts 11A-8-11 11A-5a-2 4G1 ENGINE (E - W) - Intake Manifold and Throttle Body (GDI)
(6) Rotate clockwise the crankshaft one complete turn (360" REMOVAL SERVICE POINT
Timing belt side
degree). AA" INTAKE MANIFOLD REMOVAL
(7) Adjust the valve clearance at points as shown in the
Disconnect the fuel pressure sensor connectors.
illustration.
(8) Repeat steps (3) to (5) to adjust the valve clearance
of remaining valves.
(9) With the engine mounted on vehicle, warm up the engine.
Then, check for valve clearance on hot engine and adjust
if necessary.
Standard value: on hot engine
Intake 0.25 mm
Exhaust 0.30 mm
"AA INTAKE MANIFOLD INSTALLATION
After installing the intake manifold, connect the fuel pressure
sensor connectors.
"BA INTAKE MANIFOLD STAY INSTALLATION

Ensure that the intake manifold stay is in close contact with
the intake manifold and the cylinder block boss. After that,
tighten the bolts to the specified torque.

Aug. 2000 PWEE9520
PWEE9520-D Added
!
! Mitsubishi
Mitsubishi Motors
Motors Corporation
Feb. 2004 PWEE9520
PWEE9520-H Revised
4G1 ENGINE (E - W) - Exhaust Manifold (GDI) 11A-5b-1 11A-8-10 4G1 ENGINE (E–W) – Rocker Arms and Camshafts
EXHAUST MANIFOLD (GDI) Timing belt side

(6) Rotate clockwise the crankshaft one complete turn (360"
degree).
REMOVAL AND INSTALLATION (7) Adjust the valve clearance at points as shown in the
illustration.
(8) Repeat steps (3) to (5) to adjust the valve clearance
of remaining valves.
(9) With the engine mounted on vehicle, warm up the engine.
30 Nm
Then, check for valve clearance on hot engine and adjust
if necessary.
2 Standard value: on hot engine
Intake 0.20 mm
Exhaust 0.25 mm
18 Nm
Timing belt side

<SOHC 16-VALVE>
(1) Position the No. 1 cylinder at top dead center on the
29 Nm
4 compression stroke.
(2) Adjust the valve clearance at the points shown in the
illustration.
6
7
1
44 Nm
35 Nm
(3) Loosen the adjusting screw locknut.
(4) Using a feeler gauge, adjust the valve clearance by turning
3 35 Nm the adjusting screw.
Standard value: on cold engine
Intake 0.14 mm
Exhaust 0.19 mm
(5) While holding the adjusting screw with a screwdriver,
Removal steps tighten the lock nut.
Thickness gauge
1. Oxygen sensor
2. Exhaust manifold cover
3. Exhaust manifold bracket B
4. Exhaust manifold
5. Exhaust manifold gasket
6. Exhaust manifold bracket A
7. Power plant stay, left

Aug. 2000 PWEE9520
PWEE9520-D Added
! Mitsubishi Motors Corporation Feb. 2004 PWEE9520-H Added
Revised
4G1 ENGINE (E - W) - Rocker Arms and Camshafts 11A-8-9 4G1 ENGINE (E - W) - Water Pump and Water Hose 11A-6-1
"HA ROCKER COVER INSTALLATION 6. WATER PUMP AND WATER HOSE
(1) Apply the specified sealant to the area shown, then fit
the rocker cover. REMOVAL AND INSTALLATION <SOHC 12-VALVE - CARBURETOR>
Specified sealant:
3M ATD part No. 8660 or equivalent
1 22 Nm
2 27 Nm
27 Nm
"IA LASH ADJUSTER INSTALLATION
4 11 Nm
(1) Insert the lash adjuster to rocker arm, being careful not 12
to spill diesel fuel. Use the special tool to prevent adjuster
MD998443 from falling while installing it. 3 5
11 6 8 7
Caution
Lash adjuster If the lash adjuster is re-used, clean the lash adjuster.
(Refer to 11A-8-3.) 9
23 Nm
10
12 Nm
"JA LASH ADJUSTER INSTALLATION

Caution
If the lash adjuster is re-used, clean the lash adjuster.
(Refer to 11A-8-6.)
Fit the lash adjuster onto the rocker arm without allowing
diesel fuel to spill out. 14
13
Timing belt side VALVE CLEARANCE ADJUSTMENT

<SOHC 12-VALVE>
(1) Position the No. 1 cylinder at top dead center on the
compression stroke.
(2) Adjust the valve clearance at the points shown in the 13 Nm
illustration.
(3) Loosen the adjusting screw locknut. Removal steps

(4) Using a feeler gauge, adjust the valve clearance by turning 1. Water hose "CA 8. Thermostat
the adjusting screw. 2. Water hose 9. Thermostat case
3. Water hose 10. Gasket
Standard value: on cold engine "FA 4. Thermo valve <engines with EGR> "BA 11. Water inlet pipe
Intake 0.09 mm "FA 5. Thermo valve "BA 12. O-ring
Exhaust 0.17 mm "DA 6. Engine coolant temperature gauge "BA 13. O-ring
unit "AA 14. Water pump
(5) While holding the adjusting screw with a screwdriver, 7. Water inlet fitting
tighten the lock nut.
Thickness gauge

Aug. 2000 PWEE9520
Aug. 2000 PWEE9520
PWEE9520-D Revised
11A-6-1a 4G1 ENGINE (E - W) - Water Pump and Water Hose 11A-8-8 4G1 ENGINE (E - W) - Rocker Arms and Camshafts
REMOVAL AND INSTALLATION <SOHC 16-VALVE - CARBURETOR> SOHC 12-VALVE "EA ROCKER ARM / ROCKER SHAFT ASSEMBLY
Timing belt side INSTALLATION
(1) Assemble the rocker arms and rocker shaft, paying
attention to the identification marks. Then mount the
assembly on the cylinder head.
1 12 Nm
2
3
10 Identification mark
11 SOHC 16-VALVE
Timing belt side
12 Nm
4
9
8 Identification
12 22 Nm mark
7
SOHC "FA CAMSHAFT OIL SEAL INSTALLATION
MD998713
13
5
23 Nm
DOHC
MD998713
13 Nm
Removal steps
1. Water hose "CA 7. Thermostat
2. Water hose 8. Thermostat case "GA SEMI-CIRCULAR PACKING INSTALLATION
"FA 4. Thermo valve "BA 10. Water inlet pipe Sealant (1) Apply the specified sealant to the area shown.
"DA 5. Engine coolant temperature gauge "BA 11. O-ring Specified sealant:
unit "BA 12. O-ring
6. Water inlet fitting "AA 13. Water pump 3M ATD Part No. 8660 or equivalent
DEN0053
E Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Added E Mitsubishi Motors Corporation Nov. 1998
Dec. 1995 PWEE9520
PWEE9520-A Added
4G1 ENGINE (E - W) - Rocker Arms and Camshafts 11A-8-7 4G1 ENGINE (E - W) - Water Pump and Water Hose 11A-6-1b
"BA BEARING CAP INSTALLATION
(1) Position the camshaft dowel pins as shown.
NOTE
With the camshaft dowel pins in this position, the camshaft
notches for tightening cylinder head bolt are correctly
positioned.
(2) Bearing caps Nos. 2 to 5 are the same shape. Be sure

to install them in order of their cap numbers and check
the identification marks to ensure that the intake and
exhaust sides are not reversed.
Identification marks:
I: Intake
E: Exhaust
(3) Apply the specified sealant to the surfaces that are to

mate with the cylinder head. Then, tighten the bearing
cap bolts - for the middle caps first, then for the outer
caps, and soon. Tighten the bolts a little at a time such
that each bolt is tightened to the specified torque in the Intencionalmente en blanco
final sequence.
Specified sealant:
3M ATD Part No. 8660 or equivalent
(4) Check that the rocker arms are installed correctly.
"CA ADJUSTING SCREW INSTALLATION

1 mm or less (1) Install provisionally the screw to the rocker arm. Insert
it so that the end of the screw is flush with the edge
of the rocker arm or projects slightly (1 mm or less).
"DA ROCKER ARM SHAFT INSTALLATION

(1) Place the end with the larger chamfered side toward the
flywheel side. <SOHC 12-VALVE>
Place the end with the larger chamfered side toward the
Chamfer timing belt side. <SOHC 16-VALVE>
NOTE
The rocker arm shaft for intake valves have eight oil holes.
Oil holes (2) Place the section of the shaft with the oil holes toward
the cylinder head.

Dec. 1998 PWEE9520
PWEE9520-A Added E Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Added
11A-6-2 4G1 ENGINE (E - W) - Water Pump and Water Hose 11A-8-6b 4G1 ENGINE (E - W) - Rocker Arms and Camshafts
REMOVAL AND INSTALLATION <SOHC - MPI> (7) Place the lash adjuster in container C. Then, gently push
down the internal steel ball using special tool MD998442.
11 22 Nm Caution
2 6 Do not use container C for cleaning. If cleaning is
29 Nm 7 the pressure chamber when chamber is filled with
diesel fuel.
3 MD998442 Diesel fuel
11 Nm
12 Nm
4 8
9 (8) Stand the lash adjuster with its plunger at the top, then
push the plunger downward firmly until it moves through
5
its greatest possible stroke. Return the plunger slowly,
then release the steel ball and allow the pressure chamber
23 Nm
to fill with diesel fuel.
10
Diesel fuel
MD998442
1
(9) Remove the lash adjuster from the container, then stand
the lash adjuster with its plunger at the top. Push the
12 plunger firmly and check that it does not move. Also,
new lash adjuster.
NOTE
through (9) again to fill it with diesel fuel completely.
these steps.
(10)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
13 Nm adjuster onto the engine as soon as possible.
Removal steps
2. Water hose "BA 9. Water inlet pipe
"EA 3. Engine coolant temperature sensor "BA 10. O-ring
"DA 4. Engine coolant temperature gauge "BA 11. O-ring
5. Water inlet fitting INSTALLATION SERVICE POINTS
"CA 6. Thermostat "AA CAMSHAFT INSTALLATION
7. Thermostat case
(1) Apply engine oil to the camshaft journals and cams before
Slit
installation. Ensure that the intake-side and exhaust-side
camshafts are not reversed.
NOTE
There is a 4 mm-wide slot in the rear end of the
exhaust-side camshaft.
E Mitsubishi Motors Corporation Aug. 2000 PWEE9520-D Revised E Mitsubishi Motors Corporation Nov. 2000
Apr. 1995 PWEE9520
PWEE9520-C Added
4G1 ENGINE (E - W) - Rocker Arms and Camshafts 11A-8-6a 4G1 ENGINE (E - W) - Water Pump and Water Hose 11A-6-2a
(3) While gently pushing down the internal steel ball using REMOVAL AND INSTALLATION <SOHC 16-VALVE - MPI - FRONT WHEEL DRIVE>
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 2
oil.
Caution 12 Nm
Diesel fuel wire is pushed in hard.
MD998442 1
NOTE 9
otherwise abnormal, replace the lash adjuster. 12 Nm
29 Nm
11
23 Nm
10
3
down the steel ball gently and push the plunger to eliminate
Caution 12
Make sure the oil hole in the side of the body is pointing 8
toward container A. Do not point the oil hole at yourself 7
MD998442 or other people.
Diesel fuel
4 6
5
11 Nm
13 Nm 22 Nm
and move the plunger through 5 to 10 strokes until it
slides smoothly. This operation will clean the lash
adjusterís pressure chamber.
Caution
adjusterís functionality may be lost if the air bleed Removal steps
Diesel fuel wire is pushed in hard.
MD998442 1. Water hose 8. Gasket
2. Water hose "BA 9. Water inlet pipe
(6) Remove the lash adjuster from the container. Then, push unit "AA 12. Water pump
down the steel ball gently and push the plunger to eliminate 5. Water inlet fitting
diesel fuel from the pressure chamber. "CA 6. Thermostat
7. Thermostat case
Caution
toward container B. Do not point the oil hole at yourself
MD998442 or other people.
Diesel fuel

Apr. 1995 PWEE9520
PWEE9520-C Added E Mitsubishi Motors Corporation Nov. 1995
Aug. 2000 PWEE9520
PWEE9520-D Revised
11A-6-2b 4G1 ENGINE (E - W) - Water Pump and Water Hose 11A-8-6 4G1 ENGINE (E - W) - Rocker Arms and Camshafts
REMOVAL AND INSTALLATION <SOHC 16-VALVE - MPI - REAR WHEEL DRIVE> (DOHC)
Caution
1. The lash adjusters are precision-engineered
12 Nm contaminated by dirt or other foreign substances.
2 18 Nm
2. Do not attempt to disassemble the lash adjusters.
1 5 3. Use only fresh diesel fuel to clean the lash
adjusters.
6
12 Nm
10
11 7 (1) Prepare three containers and approximately five liters
To clean To clean To fill of diesel fuel. Into each container, pour enough diesel
outside inside diesel fuel fuel to completely cover a lash adjuster when it is standing
adjuster.
25 Nm
A B C
9
29 Nm
3 8
surface.
4 NOTE
11 Nm
12
Diesel fuel
23 Nm
13 Nm
Removal steps
1. Water hose "CA 7. Thermostat
2. Water hose 8. Fitting
"EA 3. Engine coolant temperature sensor 9. Gasket
"DA 4. Engine coolant temperature gauge "BA 10. Water inlet pipe
unit "BA 11. O-ring
5. Water outlet fitting "AA 12. Water pump
6. Gasket

Aug. 2000 PWEE9520
Apr. 1995 PWEE9520
PWEE9520-C Revised
4G1 ENGINE (E - W) - Rocker Arms and Camshafts 11A-8-5 4G1 ENGINE (E–W) – Water Pump and Water Hose 11A-6-2c
(6) Remove the lash adjuster from the container. Then, push REMOVAL AND INSTALLATION <SOHC 16-VALVE–MPI – FRONT WHEEL DRIVE
diesel fuel from the pressure chamber. (FROM 2004 model FOR EUROPE)>
2
12 Nm
1
Wire or MD998442
Diesel fuel
9
12 Nm
(7) Place the lash adjuster in container C. Then, gently push
Wire or MD998442 down the internal steel ball using special tool MD998442.
Caution
Do not use container C for cleaning. If cleaning is
the pressure chamber when chamber is filled with 11
diesel fuel.
23 Nm
Diesel fuel 29 Nm
10
8 3
(8) Stand the lash adjuster with its plunger at the top, then
Wire or 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 6
to fill with diesel fuel. 13 Nm
12
Diesel fuel
7
4
(9) Remove the lash adjuster from the container, then stand 5
the lash adjuster with its plunger at the top. Push the 11 Nm
22 Nm
plunger firmly and check that it does not move. Also,
new lash adjuster.
NOTE
through (9) again to fill it with diesel fuel completely.
these steps. Removal steps
(10)Stand the lash adjuster upright to prevent diesel fuel from 2. Water hose "B# 9. Water inlet pipe
spilling out. Do not allow the lash adjuster to become "E# 3. Engine coolant temperature sensor "B# 10. O-ring
contaminated by dirt or other foreign matter. Fit the lash "D# 4. Engine coolant temperature gauge "B# 11. O-ring
adjuster onto the engine as soon as possible. unit "A# 12. Water pump
5. Water inlet fitting
"C# 6. Thermostat
7. Thermostat case

Apr. 1995 PWEE9520
PWEE9520-C Revised
Apr. 1995 PWEE9520
PWEE9520-G Added
11A-6-2d 4G1 ENGINE (E–W) – Water Pump and Water Hose 11A-8-4 4G1 ENGINE (E - W) - Rocker Arms and Camshafts
surface.
NOTE
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
Diesel fuel adjusterís functionality may be lost if the air bleed
Wire or MD998442 wire is pushed in hard.
NOTE
otherwise abnormal, replace the lash adjuster.
Intentionally blank
Wire or MD998442
Diesel fuel

and move the plunger through 5 to 10 strokes until it
slides smoothly. This operation will clean the lash
adjusterís pressure chamber.
Caution
Diesel fuel adjusterís functionality may be lost if the air bleed
Wire or MD998442 wire is pushed in hard.

Apr. 1995 PWEE9520
PWEE9520-C Revised
Apr. 1995 PWEE9520
PWEE9520-G Added
4G1 ENGINE (E–W) – Rocker Arms and Camshafts 11A-8-3 4G1 ENGINE (E - W) - Water Pump and Water Hose 11A-6-3
INSPECTION REMOVAL AND INSTALLATION <DOHC>

1. CAMSHAFT
(1) Measure the cam heights and replace the camshaft if
any height exceeds the specified limit. 12 Nm
Standard Limit mm
value mm 11
Intake SOHC 12-VALVE*1 38.78 38.28 2
1
SOHC 12-VALVE*2 38.78 38.28 12 Nm
SOHC 16-VALVE*3 36.99 36.49
SOHC 16-VALVE*4 36.86 36.36
SOHC 16-VALVE*5 37.30 36.80
SOHC 16-VALVE*6 37.17 36.67
DOHC 34.67 34.17 29 Nm
8
Exhaust SOHC 12-VALVE*1 39.01 38.51 3
7 22 Nm
SOHC 12-VALVE*2 38.97 38.47
9
SOHC 16-VALVE*3 36.85 36.35 10 6
SOHC 16-VALVE*4 36.68 36.18
SOHC 16-VALVE*5 37.16 36.66
SOHC 16-VALVE*6 36.99 36.49
DOHC 34.26 33.76 12
*1: With low pollution system
*2: Without low pollution system 23 Nm 4
*3: Except 2001 model front wheel drive vehicles
*4: 2001 model front wheel drive vehicles for Europe 5
*5: 2001 model front wheel drive vehicles for General 11 Nm
Export
6
* : 2002 model front wheel drive vehicles for Europe
2. LASH ADJUSTERS
13 Nm
(SOHC)
Caution
1. The lash adjusters are precision-engineered
contaminated by dirt or other foreign substances.
2. Do not attempt to disassemble the lash adjusters. Removal steps
3. Use only fresh diesel fuel to clean the lash 1. Water hose 8. Gasket
adjusters. 2. Water hose "BA 9. Water inlet pipe
(1) Prepare three containers and approximately five liters 5. Water inlet fitting
To clean To clean To fill of diesel fuel. Into each container, pour enough diesel "CA 6. Thermostat
outside inside diesel fuel fuel to completely cover a lash adjuster when it is standing 7. Thermostat case
adjuster.
A B C

Aug. 2000 PWEE9520
PWEE9520-D Revised
Feb. 1995 PWEE9520
PWEE9520-E Revised
11A-6-4 4G1 ENGINE (E - W) - Water Pump and Water Hose 11A-8-2b 4G1 ENGINE (E - W) - Rocker Arms and Camshafts
REMOVAL AND INSTALLATION <DOHC - GDI>
22 Nm
29 Nm 1
5
23 Nm
11 Nm
12 Nm 4
6
3
12 Nm
2
22 Nm
8 Intentionallyblank
13 Nm
Removal steps
"HA 1. Water outlet fitting "EA 5. Engine coolant temperature sensor
2. Water inlet fitting "GA 6. Thermostat housing
"CA 3. Thermostat "BA 7. Water inlet pipe

Aug. 2000 PWEE9520
Aug. 2000 PWEE9520
PWEE9520-D Added
4G1 ENGINE (E - W) - Rocker Arms and Camshafts 11A-8-2a 4G1 ENGINE (E - W) - Water Pump and Water Hose 11A-6-5
REMOVAL SERVICE POINTS INSTALLATION SERVICE POINTS
AA" ROCKER ARMS AND ROCKER ARM SHAFTS "AA WATER PUMP INSTALLATION
REMOVAL (1) Apply a 3 mm bead of form-in-place gasket (FIPG) to
Caution the mounting surface.
If the lash adjuster is re-used, clean the lash adjuster. Specified sealant:
(Refer to 11A-8-3.) Mitsubishi Genuine Part No. MD970389 or
Set special tool MD998443 to prevent the lash adjuster from equivalent.
coming free and falling to the floor.
MD998443
AB" LASH ADJUSTER REMOVAL "BA O-RING / WATER PIPE INSTALLATION

Caution (1) Replace the water inlet pipe O-rings with new ones, then
If the lash adjuster is re-used, clean the lash adjuster. apply water to the O-rings so that they can be inserted
(Refer to 11A-8-6.) easily into the water pump and thermostat case.
Caution
1. Do not apply engine oil or any other oily substance
to the O-rings.
2. Secure the water pipe after the thermostat case
has been installed.
"CA THERMOSTAT INSTALLATION

(1) Fit the thermostat such that its jiggle valve is at the top.
"DA ENGINE COOLANT TEMPERATURE GAUGE UNIT

INSTALLATION
(1) If the engine coolant temperature gauge unit is to be
reused, apply the specified sealant to its thread.
Specified sealant:
3M ATD Part No. 8660 or equivalent.
"EA ENGINE COOLANT TEMPERATURE SENSOR

INSTALLATION
(1) If the engine coolant temperature sensor is to be reused,
apply the specified sealant to its thread.
Specified sealant:
3M Nut Locking Part No. 4171 or equivalent.

Aug. 2000 PWEE9520
Aug. 2000 PWEE9520
PWEE9520-D Revised
11A-6-6 4G1 ENGINE (E - W) - Water Pump and Water Hose 11A-8-2 4G1 ENGINE (E - W) - Rocker Arms and Camshafts
"FA THERMO VALVE INSTALLATION REMOVAL AND INSTALLATION <DOHC>

(1) If the thermo valve is to be reused, apply the specified
sealant to its thread. Apply engine oil to all
moving parts before 2
Specified sealant: installation. 1
equivalent.
3
5 4
6
1EN0511
4 Nm
"GA THERMOSTAT HOUSING INSTALLATION

(1) Remove the old liquid gasket from the cylinder head
(thermostat housing mounting surface) and the thermostat
housing.
(2) Apply liquid gasket to the thermostat housing mounting 7 9
surface by squeezing it to a thickness of 3 mm.
Specified sealant: 24 Nm
equivalent. 8
Caution 11 Nm
Squeeze the liquid gasket uniformly so that there is
no break in the gasket nor is there too much gasket.
11
13
12
10
"HA WATER OUTLET FITTING INSTALLATION

(1) Remove the old liquid gasket from the thermostat housing 14
(water outlet fitting mounting surface) and the water outlet
fitting. 15
(2) Apply liquid gasket to the water outlet fitting mounting
surface by squeezing it to a thickness of 3 mm.
Specified sealant:
equivalent.
Caution
Squeeze the liquid gasket uniformly so that there is
no break in the gasket nor is there too much gasket. Removal steps
1. Breather hose "GA9. Semi-circular packing
2. P.C.V. hose 10.
"FA Camshaft oil seal
3. P.C.V. valve 11.
"BA Bearing cap
4. P.C.V. valve gasket 12.
"AA Camshaft
5. Oil filler cap 13.
"AA Camshaft
"HA 6. Rocker cover 14. Roller rocker arm
7. Rocker cover gasket A AB" "JA 15. Lash adjuster
8. Rocker cover gasket B

Aug. 2000 PWEE9520
Aug. 2000 PWEE9520
PWEE9520-D Revised
4G1 ENGINE (E - W) - Rocker Arms and Camshafts 11A-8-1b 4G1 ENGINE (E - W) - Intake and Exhaust Manifolds 11A-7-1
REMOVAL AND INSTALLATION <SOHC 16-VALVE (With Lash adjuster)> 7. INTAKE AND EXHAUST MANIFOLDS
REMOVAL AND INSTALLATION <SOHC 12-VALVE - CARBURETOR>
2
4 1
1
5
3
31 Nm
3 4
3.5 Nm
10
6 14
11
8
7
17 17 Nm 7
13 5
12
2 29 Nm
15
16
18 30 Nm

moving parts before
8 installation.
19
9
17 Nm
Removal steps
1. Breather hose AA" "EA 11. Rocker arms and rocker arm shaft,
2. P.C.V. hose exhaust Removal steps
3. Oil filler cap 12. Rocker arm A
4. P.C.V. valve 13. Rocker arm B 1. Engine hanger 5. Exhaust manifold cover
5. P.C.V. valve gasket "DA 14. Rocker arm shaft 2. Intake manifold stay 6. Engine hanger
6. Rocker cover "IA 15. Lash adjuster 3. Intake manifold 7. Exhaust manifold
7. Rocker cover gasket 16. Rocker arm C 4. Intake manifold gasket 8. Exhaust manifold gasket
8. Oil seal "DA 17. Rocker arm shaft
"FA 9. Oil seal "IA 18. Lash adjuster
AA" "EA 10. Rocker arms and rocker arm shaft, 19. Camshaft
intake

Aug. 2000 PWEE9520
Aug. 2000 PWEE9520
PWEE9520-D Revised
11A-7-2 4G1 ENGINE (E - W) - Intake and Exhaust Manifolds 11A-8-1a 4G1 ENGINE (E - W) - Rocker Arms and Camshafts
REMOVAL AND INSTALLATION <SOHC 16-VALVE - CARBURETOR> REMOVAL AND INSTALLATION <SOHC 16-VALVE (With Adjusting screw)>
1 4
2
1 5
3
4 31 Nm
3.5 Nm
3
10
14
6
8
11
17 Nm
7
17 Nm 5 7
29 Nm
18
2
13
12 19
20
9 Nm
15
30 Nm 16
9 Nm 17
29 Nm 19 Nm 8
moving parts before
6 21 installation.
9
Removal steps
1. Engine hanger 5. Exhaust manifold cover Removal steps
2. Intake manifold stay 6. Engine hanger 1. Breather hose 12. Rocker arm A
3. Intake manifold 7. Exhaust manifold 2. P.C.V. hose 13. Rocker arm B
4. Intake manifold gasket 8. Exhaust manifold gasket 3. Oil filler cap "DA 14. Rocker arm shaft
4. P.C.V. valve "CA 15. Adjusting screw
5. P.C.V. valve gasket 16. Nut
6. Rocker cover 17. Rocker arm C
7. Rocker cover gasket "DA 18. Rocker arm shaft
8. Oil seal "CA 19. Adjusting screw
"FA 9. Oil seal 20. Nut
"EA 10. Rocker arms and rocker arm shaft, 21. Camshaft
intake
"EA 11. Rocker arms and rocker arm shaft,
exhaust

Aug. 2000 PWEE9520
PWEE9520-D Revised E Mitsubishi Motors
E Mitsubishi Motors Corporation
Aug. 2000 PWEE9520
PWEE9520-D Revised
4G1 ENGINE (E - W) - Rocker Arms and Camshafts 11A-8-1 4G1 ENGINE (E - W) - Intake and Exhaust Manifolds 11A-7-2a
8. ROCKER ARMS AND CAMSHAFTS REMOVAL AND INSTALLATION <SOHC - CARBURETOR FOR CENTRAL AMERICA>
5
1
3
4 6
4 Nm
9
2 11
8
31 Nm 13 Nm
1
5
14 3 54 Nm
7 4 10 9
11 Nm 7
12 13
11 19
8
20 83 Nm
21 17 Nm 12
6
15 Nm
18 2 29 Nm
17
16 22
15
30 Nm

moving parts before
10 installation.
8
17 Nm
Removal steps
1. Breather hose 12. Rocker arm spring Removal steps
2. P.C.V. hose 13. Rocker arm B
3. P.C.V. valve 14. Rocker arm shaft 1. Engine hanger "AA 7. Air pipe
4. P.C.V. valve gasket 15. Rocker arm C 2. Intake manifold stay "AA 8. Reed valve and bracket
5. Oil filler cap 16. Wave washer 3. Intake manifold 9. Reed valve
6. Rocker cover 17. Spacer 4. Intake manifold gasket 10. Reed valve bracket ìAî
7. Rocker cover gasket 18. Rocker arm D 5. Air hose 11. Reed valve bracket ìBî
"FA 8. Camshaft oil seal 19. Rocker arm shaft 6. Exhaust manifold cover 12. Exhaust manifold
"EA 9. Rocker arm and shaft assembly "CA 20. Adjusting screw
"EA 10. Rocker arm and shaft assembly 21. Nut
11. Rocker arm A 22. Camshaft

Dec. 1998 PWEE9520
PWEE9520-A Revised E Mitsubishi Motors Corporation Nov. 1995
Aug. 2000 PWEE9520
PWEE9520-D Revised
11A-7-2b 4G1 ENGINE (E - W) - Intake and Exhaust Manifolds 11A-7a-4 4G1 ENGINE (E–W) – Fuel System (GDI)
REMOVAL AND INSTALLATION <SOHC 12-VALVE - MPI> "F# INJECTOR INSTALLATION
When replacing injectors, confirm the identification on
Identification replacement injectors and use the injectors with the same
mark mark for all cylinders of the engine.
Identification marks
A
1 B
3 44 Nm C
4
5 Caution
Be aware that the fuel injectors are identified by colors,
not by alphabet marks, in a vehicle produced up to
Injector the beginning of December 1998. The color marks
9 correspond to the alphabet marks as follows:
A = Yellow
Identification B = Pink
17 Nm
7 color
C = Light blue
8
29 Nm
17 Nm
31 Nm
2 17 Nm
6
Removal steps
1. Engine hanger 6. Engine hanger
2. Intake manifold stay 7. Exhaust manifold cover
3. Intake manifold 8. Exhaust manifold
4. Intake manifold gasket 9. Exhaust manifold gasket
5. Oxygen sensor <vehicles for Hong
Kong only>

Aug. 2000 PWEE9520
PWEE9520-D Revised
! Mitsubishi Motors Corporation Feb. 2004 PWEE9520-H Added
4G1 ENGINE (E - W) - Fuel System (GDI) 11A-7a-3 4G1 ENGINE (E–W) – Intake and Exhaust Manifolds 11A-7-2c
(2) Install the fuel pressure sensor in the direction shown,
paying attention to the shape of connector.
REMOVAL AND INSTALLATION <SOHC 16-VALVE–MPI – FRONT WHEEL DRIVE
(FROM 2001 model for Europe)>
9 Nm
9 Nm
1 7
8
5 Nm 30 Nm 11
17 Nm
2
"EA FUEL PUMP / BACKUP RING / O-RING / FUEL
PIPE INSTALLATION
6
(1) Apply engine oil to the roller and the O-ring of the fuel
pump.
14 30 Nm
17 Nm
13
3 5
18 Nm
(2) Insert the fuel pump in the mounting hole on the cylinder 49 Nm
head, and lightly tighten four bolts (a little more strongly
than you tighten them with fingers). 17 Nm 9
44 Nm
31 Nm 10
30 Nm
4
19 Nm
35 Nm
(3) Install the backup rings and the O-rings on both ends
of the fuel pipe. Install the backup ring (thicker one) with 35 Nm
Backup ring with O-ring the inside cut surface facing the direction shown in the 16
no directivity illustration.
(4) Apply spindle oil or gasoline to the O-rings on both ends 12
of the pipe. 15 35 Nm
(5) Insert the fuel pipe straight in the mounting hole on the
fuel pump. When the fuel pipe is inserted, use care not
Cut surface
to twist it and insert as far as it goes. 35 Nm
Backup ring (6) Tighten the bolts on both ends of the pipe to the specified
torque.
(7) Using the torque wrench (minimum scale 0.5 Nm), tighten
Removal steps
the fuel pump mounting bolts by the following procedure.
1. Tighten the bolts to 4.9 Nm in the order as shown. 1. Boost sensor 10. Engine hanger
2. Engine hanger 11. Exhaust manifold cover
2. Tighten the bolts to 17 Nm in the order as shown. 3. Power plant stay, right 12. Exhaust monifold bracket B
The torque variation of the four bolts should be within (From 2004 model) 13. Exhaust manifold
2 Nm. 4. Intake manifold stay 14. Exhaust manifold gasket
5. Intake manifold 15. Exhaust manifold bracket A
Caution 6. Intake manifold gasket (Up to 2003 model)
Observe the tightening order. Failure to observe the 7. Solenoid valve assembly 16. Power plant stay, left
specified torques and tightening order will cause 8. Solenoid valve assembly (From 2004 model)
leakage, etc. 9. Oxygen sensor

Aug. 2000 PWEE9520
PWEE9520-D Added
Apr. 1995 PWEE9520
PWEE9520-G Revised
11A-7-2d 4G1 ENGINE (E - W) - Intake and Exhaust Manifolds 11A-7a-2 4G1 ENGINE (E - W) - Fuel System (GDI)
REMOVAL AND INSTALLATION <SOHC 16-VALVE - MPI - REAR WHEEL DRIVE> INSTALLATION SERVICE POINTS
"AA BACKUP RING / O-RING INSTALLATION
Install the backup rings and the O-rings on the injector. Install
the backup ring (thicker one) on the injector with the inside
6 cut surface facing the direction shown in the illustration.
5 Nm 9 Nm
7 Cut surface
1
Backup ring
2
4 "BA CORRUGATE WASHER INSTALLATION
17 Nm 5 Apply white vaseline to the corrugate washer and install the
washer on the injector in the direction shown.
29 Nm Caution
11 9 If the washer that has once been tightened is refused,
it will cause fuel leakage or gas leakage. Be sure
to use a new washer.
10
Corrugate washer
3 "CA DELIVERY PIPE AND INJECTOR INSTALLATION

(1) Apply spindle oil or gasoline to injector O-rings.
17 Nm (2) Insert the injector straight in the injector mounting hole
on the delivery pipe.
19 Nm
31 Nm
(3) Try to the turn the injector. If the injector dose not turn
smoothly, remove the injector and check the O-rings for
damage. If damage is evident, replace the O-rings and
Matchmarks reinstall the injector.
17 Nm 8 (4) Align the matchmark on the injector with that on the
29 Nm delivery pipe.
(5) Install the delivery pipe and injector on the cylinder head
and tighten the bolts to the specified torque in the order
shown in the illustration.
3 1 2 4
Removal steps
1. Boost sensor 7. Solenoid valve assembly <With
2. Engine hanger catalytic converter>
3. Intake manifold stay 8. Engine hanger
4. Intake manifold 9. Exhaust manifold cover
5. Intake manifold gasket 10. Exhaust manifold
6. Solenoid valve assembly <Without 11. Exhaust manifold gasket "DA BACKUP RING / O-RING / FUEL PRESSURE
catalytic converter> SENSOR INSTALLATION
(1) Install the backup ring on the fuel pressure sensor with
the inside cut surface facing the direction shown in the
illustration.
Cut surface
Backup ring

Aug. 2000 PWEE9520
Aug. 2000 PWEE9520
PWEE9520-D Added
4G1 ENGINE (E–W) – Fuel System (GDI) 11A-7a-1 4G1 ENGINE (E - W) - Intake and Exhaust Manifolds 11A-7-2e
7a. FUEL SYSTEM (GDI) REMOVAL AND INSTALLATION <SOHC 16-VALVE - MPI - FRONT WHEEL DRIVE
(EXCEPT FROM 2001 model FOR EUROPE)>
REMOVAL AND INSTALLATION
12 Nm 5 Nm
1
2
24 Nm
5 5 9 Nm
12 Nm
8 17 Nm
4
17 Nm
3 2
9.8 Nm
6
9 12 6 1
11
10
7 11
17 Nm
4 10
15 3 17 Nm 9
23 29 Nm
7
20
19
21 22
23 Nm 49 Nm
18 17 Nm
17
13 31 Nm
29 Nm 8
14 19 Nm
16
35 Nm
12
Removal steps Removal steps

1. Injector harness 13. Washer 1. Boost sensor 7. Intake manifold gasket
"E# 2. Fuel pipe 14. Injector holder 2. Engine hanger 8. Engine hanger
"E# 3. Backup ring "C# 15. Delivery pipe and injector 3. Power plant stay right <CVT> 9. Exhaust manifold cover
"E# 4. O-ring 16. Insulator 4. Intake manifold stay 10. Exhaust manifold
"E# 5. Backup ring 17. Injector gasket 5. Solenoid valve assembly 11. Exhaust manifold gasket
"E# 6. Fuel pump "B# 18. Corrugate washer 6. Intake manifold 12. Power plant stay left <CVT>
7. O-ring "A# 19. Backup ring
8. Flange "A# 20. O-ring
"D# 9. Fuel pressure sensor "A# 21. Backup ring
"D# 10. O-ring "F# 22. Injector
"D# 11. Backup ring 23. Delivery pipe
12. Harness bracket

Aug. 2000 PWEE9520
PWEE9520-D Added
!
! Mitsubishi
Mitsubishi Motors
Motors Corporation
Feb. 2004 PWEE9520
PWEE9520-H Revised
4G1 ENGINE (E - W) - Intake and Exhaust Manifolds 11A-7-3 11A-7-4 4G1 ENGINE (E - W) - Intake and Exhaust Manifolds
REMOVAL AND INSTALLATION <DOHC> INSTALLATION SERVICE POINTS

Reed valve and bracket
"AA REED VALVE, BRACKET AND AIR PIPE
Pipe nut (reed valve side) INSTALLATION
(1) Insert the lower end of the air pipe into the exhaust
manifold, then tighten the pipe nut temporarily.
(2) Fit the upper end of the air pipe to the reed valve and
Pipe clamp bolt bracket assembly, then tighten the pipe nut temporarily.
(3) Attach the reed valve and bracket assembly to the reed
valve bracket ìBî and tighten the mounting bolts
temporarily.
(4) Tighten the nuts on both ends of the air pipe to the specified
1 torque.
Air pipe
Caution
3 Reed valve The tightening torque of the reed valve side nut and
4 bracket ìBî
that of the exhaust manifold side nut are different
from each other.
Be sure to tighten each nut correctly to the specified
Pipe nut (exhaust torque.
manifold side)
17 Nm (5) Tighten the reed valve and bracket mounting bolts to
the specified torque.
9 8 (6) Tighten the pipe clamp bolt.
6 44 Nm
17 Nm
5
29 Nm
17 Nm
21 Nm
29 Nm
7
Removal steps
1. Engine hanger 6. Exhaust manifold cover
2. Intake manifold stay 7. Engine hanger
3. Intake manifold 8. Exhaust manifold
4. Intake manifold gasket 9. Exhaust manifold gasket
5. Oxygen sensor
E Mitsubishi Motors Corporation Nov. 1995 PWEE9520 E Mitsubishi Motors Corporation Nov. 1999
July 1995 PWEE9520
PWEE9520-B Added

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11A-0-1

M14 CRANKSHAFT BOLT

MSB–02E11–505 4 Nov. 1995 PWEE9520

M12 CRANKSHAFT BOLT

Applicable vehicle models

SERVICE PUBLICATION & TRAINING

!"#$%&" '())"*%+ +,- . MSB–02E11–505

/0*" . 2002–09–20 12,/")3 12453

7#,(8 . ENGINE /#09*+,- . 02EN510

Manual Pub. No. Page

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

Water pump type Centrifugal impeller type Centrifugal impeller type

Upper and lower

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

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

Total displacement dm3 1,299 1,299 Identification mark Identification color

Piston stroke mm 82.0 82.0

Compression ratio 9.5 10, 9.5*1

Valve timing Intake opens BTDC 12" BTDC 17"

Intake closes ABDC 48" ABDC 39"

Exhaust opens BBDC 48" BBDC 49"

Exhaust closes ATDC 12" ATDC 7"

Oil pump type Trochoid type Trochoid type

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

Water pump type Centrifugal impeller type Centrifugal impeller type

*1: LANCER for General Export

Total displacement dm3 1,468 1,468 1,468 1,468

Cylinder bore mm 75.5 75.5 75.5 75.5

Piston stroke mm 82.0 82.0 82.0 82.0

Identification mark positions Number Intake 8 8 8 8

Exhaust BBDC 55" BBDC 55" , BBDC 45" BBDC 48"

To be replaced by the one on following page.

In-line OHV, SOHC

In-line OHV, SOHC

Total displacement dm3 1,584 1,584

Cylinder bore mm 76.0 76.0

Number of Intake 8 8 CORRECTION INTERNATIONAL

! Mitsubishi Motors Corporation Nov. 2001

Service Bulletins Rocker arms and camshaft

"EA REAR OIL SEAL CASE INSTALLATION

E Mitsubishi Motors Corporation Nov. 1995

Crankshaft journal Cylinder block Bearing

Range Color code Identification Journal diameter Identification Identification

1 Yellow 1 47.994 – 48.000 0 1

2 None 2 47.988 – 47.994 0 2

3 White 3 47.982 – 47.988 0 3

Upper and lower

Fillet-rolled section NOTE

E Mitsubishi Motors Corporation Nov. 1995

Apply engine oil to all Water inlet pipe bolt (M10) 25

Item Nm Removal steps

Fuel pipe bolt 12

E Mitsubishi Motors Corporation Nov. 1995

Water pump Mitsubishi Genuine Part No. MD970389 or equivalent As required

Thermo valve Mitsubishi Genuine Part No. MD970389 or equivalent As required

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

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

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

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