Service Manual Gdi Pump Mitsubishi

. ENGINE 4G9 SERIES GENERAL INFORMATION 1. SPECIFICATIONS SERVICE SPECIFICATIONS REWORK DIMENSIONS TORQUE SPECIFICATIONS NEW TIGHTENING METHOD–BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA SEALANT. 11A-0-2 NOTES Mitsubishi Motors Corporation May 1995 PWEE9502. 4G9 ENGINE (E - W) - GENERAL INFORMATION 4G92 Descriptions Type Number of cylinders Combustion chamber Total displacement dm Cylinder bore mm Piston stroke mm Compression ratio Valve timing Intake Opens valve (BTDC) Closes (ABDC) Exhaust Opens valve (BBDC) Closes.

1. Service Manual Gdi Pump Mitsubishi 1.8

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11A-0-4 4G9 ENGINE (E - W) - 4G93 Descriptions Type Number of cylinders Combustion chamber Total displacement dm Cylinder bore mm Piston stroke mm Compression ratio Valve timing Intake Opens valve (BTDC) Closes (ABDC) Exhaust Opens valve (BBDC) Closes (ATDC). 4G9 ENGINE (E–W) – 4G94 Descriptions Type Number of cylinders Combustion chamber Total displacement dm Cylinder bore mm Piston stroke mm Compression ratio Valve timing Intake Opens valve (BTDC) Closes (ABDC) Exhaust Opens valve (BBDC) Closes (ATDC) Lubrication system Oil pump type. 4G9 ENGINE (E–W) – 1. SPECIFICATIONS SERVICE SPECIFICATIONS Items Timing belt Auto-tensioner rod protrusion amount (When removed from engine) Auto-tensioner rod stroke mm Auto-tensioner rod protrusion amount (When checking with installed on engine) mm Rocker arms and camshaft Camshaft cam 4G92–SOHC. 11A-1-2 4G9 ENGINE (E–W) – Items Cylinder head and valve Cylinder head gasket surface flatness mm Grinding limit of cylinder head gasket surface mm.Total resurfacing depth of both cylinder head and cylinder block Cylinder head overall height mm Thickness of valve.

4G9 ENGINE (E–W) – Items Valve stem projec- SOHC tion mm tion mm DOHC DOHC–MIVEC DOHC–GDI Cylinder head bolt shank length mm Valve stem O.D. Mm Valve face angle Valve spring load/installed height N/mm Valve guide I.D. Mm Font case, oil pump and oil pan. 11A-1-4 4G9 ENGINE (E–W) – Items Cylinder block overall height mm Cylinder block I.D. Mm Piston to cylinder clearance mm Bearing cap bolt shank length mm Crankshaft end play mm Crankshaft journal O.D. Mm Crankshaft pin O.D. Mm REWORK DIMENSIONS.

4G9 ENGINE (E–W) – TORQUE SPECIFICATIONS Items Alternator and ignition system Oil level gauge Distributor Ignition coil Spark plug Crankshaft bolt Alternator brace (M8) Alternator brace (M10) Lock bolt Adjusting bolt Power steering pump pulley Power steering pump bracket stay. 11A-1-6 4G9 ENGINE (E–W) – Items Fuel system and emission system Breather tube Fuel pump Carburetor EGR valve Cover Fuel return pipe Delivery pipe Fuel pressure regulator Throttle body stay Throttle body stay Throttle body.

4G9 ENGINE (E–W) – Items Intake manifold and exhaust manifold Exhaust manifold (M8) Exhaust manifold (M10) Exhaust manifold bracket (M8) Exhaust manifold bracket (M10 Bolt and washer assembly) Exhaust manifold bracket (M10 Flange bolt) Engine hanger (Bolt with head mark “4”) Engine hanger (Bolt with head mark “7”). 11A-1-6b 4G9 ENGINE (E–W) – Items Exhaust manifold (M8) Exhaust manifold (M10) Injector and fuel pump assembly (GDI) Fuel low pressure pipe (M6) Fuel low pressure pipe (M8) Fuel nipple Clamp Fuel feed pipe Fuel pump Harness bracket Fuel pipe. 4G9 ENGINE (E–W) – Items Water inlet fitting Water inlet fitting Water by-pass fitting Water pipe Water outlet fitting Water outlet fitting Engine coolant temperature gauge unit Engine coolant temperature sensor. 11A-1-6d 4G9 ENGINE (E–W) – Items Upper oil pan (M8) Lower oil pan Cover Baffle plate Baffle plate Drain plug Oil pressure switch Transmission stay Piston and connecting rod Connecting rod cap nut Crankshaft, cylinder block, flywheel and drive plate. 4G9 ENGINE (E - W) - NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA A new type of bolts, to be tightened in plastic area, is currently used for some parts of the engine. 11A-1-8 4G9 ENGINE (E - W) - Specifications FORM-IN-PLACE GASKET The engine has several areas where the form-in-place gasket (FIPG) is in use.

To ensure that the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size, continuity and location are of paramount importance.

4G9 ENGINE (E - W) - 2. SPECIAL TOOLS Tool Number MB990938 MB990767 MD998440 MD998442 MD998713 MD998716 MD998717 MB991653 MB991659 Mitsubishi Motors Corporation Nov. 1995 Special Tools Name Handle Use with MD998776 Crankshaft pulley Holding camshaft sprocket when loosening holder and tightening of bolt. 11A-2-2 4G9 ENGINE (E - W) - Tool Number MD998719 MD998727 MD998754 MD998767 MD998772 MD998774 MD998775 MD998776 Mitsubishi Motors Corporation Nov. 1995 Special Tools Name Pulley holder pin Use with MB990767 Oil pan remover Removal of the oil pan Use with MB990767. 4G9 ENGINE (E - W) - Tool Number MD998780 MD998735 MD998781 MB991477 MB991478 MB991479 MD998784 Mitsubishi Motors Corporation Nov. 1995 Special Tools Name SETTING TOOL Removal and installation of piston pin Piston pin Valve spring Compression of valve spring compressor.

4G9 ENGINE (E–W) – 3. ALTERNATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION (Engines with distributor) 25 Nm 5 Nm 23 Nm 23 Nm 49 Nm 4 Nm Removal steps 1. Drive belt. 2. Alternator 3.

Alternator brace AA' 'BA 4. Crankshaft bolt 'BA 5.

11A-3-2 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION (Engines without distributor) 25 Nm 5 Nm 23 Nm 23 Nm 49 Nm 4 Nm Removal steps 1. Drive belt.

2. Alternator 3. Alternator brace AA' 'BA 4. Crankshaft bolt 'BA 5.

4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION (Engines without distributor) 25 Nm 5 Nm 23 Nm 23 Nm 49 Nm Removal steps 1. Drive belt. 2. Alternator 3. Alternator brace AA' 'BA 4. Crankshaft bolt 'BA 5.

Crankshaft pulley 'BA 6. 11A-3-2b 4G9 ENGINE (E - W) - Alternator and Ignition System Intentionally blank Mitsubishi Motors Corporation Dec. 1998 PWEE9502-E Added. 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION 5 Nm 23 Nm 23 Nm 29 Nm 4 Nm Removal steps 1. Drive belt.

2. Alternator 3. Alternator brace AA' 'BA 4. Crankshaft bolt 'BA 5.

Crankshaft pulley 'BA 6. Front flange 7. 11A-3-4 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION 5 Nm 23 Nm 23 Nm 49 Nm 4 Nm Removal steps 1. Drive belt.

2. Alternator 3. Alternator brace AA' 'BA 4. Crankshaft bolt 'BA 5. Crankshaft pulley 'BA 6. Front flange 7. 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION 2.9 Nm 5 Nm 23 Nm 23 Nm 49 Nm Removal steps 1.

Drive belt. 2. Alternator 3. Alternator brace AA' 'BA 4. Crankshaft bolt 'BA 5.

11A-3-6 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION 5 Nm 23 Nm 23 Nm 44 Nm 4 Nm Removal steps 1. Oil level gauge 2. Oil level gauge guide 3.

Drive belt. 5. Alternator 6.

4G9 ENGINE (E–W) – MD998781 MD998781 Crankshaft pulley Front flange Crankshaft bolt Crankshaft Clean Washer Degrease Big chamfered side Mitsubishi Motors Corporation Nov. 1995 Mitsubishi Motors Corporation Jun. 2002 Alternator and Ignition System REMOVAL SERVICE POINT AA' CRANKSHAFT BOLT REMOVAL (1) Use the special tool to hold the flywheel or the drive plate, and then loosen the crankshaft mounting bolts. Timing belt 'CA 5. Tensioner spring 'BA 6. Timing belt tensioner 7.

Timing belt rear cover Mitsubishi Motors Corporation Mar. 2001 4G9 ENGINE (E–W) – Timing Belt 88 Nm 11 Nm 23 Nm 'GA 9.

Crankshaft sprocket 'GA 10. Timing belt tensioner 7.

Timing belt rear cover 8. Crankshaft angle sensor (Engines without distributor) Mitsubishi Motors Corporation Apr. 2002 4G9 ENGINE (E–W) – Timing Belt 88 Nm 11 Nm 23 Nm 'GA 9. Crankshaft sprocket 'GA 10. Crankshaft spacer 'GA 11. 11A-4-1b 4G9 ENGINE (E - W) - Timing Belt Intentionallyblank Mitsubishi Motors Corporation May 2000 PWEE9502-G Added.

Timing belt 'CA 5. Tensioner spring 'BA 6. Timing belt tensioner 7. Timing belt rear cover Mitsubishi Motors Corporation Mar. 2001 4G9 ENGINE (E–W) – Timing Belt 88 Nm 11 Nm 23 Nm 'GA 9. Crankshaft sprocket 'GA 10. Tensioner pulley 6.

Tensioner arm 7. Auto-tensioner 9. Timing belt rear cover 10. Idler pulley Mitsubishi Motors Corporation Mar. 2001 4G9 ENGINE (E–W) – Timing Belt 88 Nm 24 Nm 36 Nm 44 Nm 11 Nm 9.8 Nm 13 Nm 'GA 13.

Tensioner arm 7. Auto tensioner 9. Timing belt rear cover 10. Idler pulley Mitsubishi Motors Corporation Mar. 2001 4G9 ENGINE (E–W) – Timing Belt 88 Nm 35 Nm 48 Nm 12 14 13 11 Nm 'GA 12. Crankshaft sprocket 'GA 13. Idler pulley 11.

Crankshaft angle sensor (Up to 1999 model) 12. Crankshaft angle sensor (From 2000 model) Mitsubishi Motors Corporation Mar.

2001 4G9 ENGINE (E–W) – Timing Belt 11 Nm 88 Nm 35 Nm 48 Nm 11 Nm 13 Nm 9.8 Nm. Tensioner pulley 6. Tensioner arm 7. Auto tensioner 9. Timing belt rear cover Mitsubishi Motors Corporation Mar.

2001 4G9 ENGINE (E–W) – Timing Belt 88 Nm 35 Nm 48 Nm 11 Nm 13 Nm 'GA 12. Crankshaft sprocket 'GA 13. Tensioner arm 7. Auto tensioner 9. Timing belt rear cover 10. Idler pulley Mitsubishi Motors Corporation Mar. 2001 4G9 ENGINE (E–W) – Timing Belt 11 Nm 88 Nm 48 Nm 35 Nm 48 Nm 11 Nm.

11A-4-2f 4G9 ENGINE (E - W) - Timing Belt Intentionallyblank Mitsubishi Motors Corporation May 2000 PWEE9502-G Added. MD998754 MB990767 MD998719 MD998754 Mitsubishi Motors Corporation Nov. 1995 4G9 ENGINE (E - W) - Timing Belt REMOVAL SERVICE POINTS AA' TIMING BELT REMOVAL (1) Mark belt running direction for reinstallation. AB' CAMSHAFT SPROCKET BOLT REMOVAL (Except SOHC) (1) Use a wrench to hold the hexagonal part of the camshaft, and then remove the camshaft sprocket mounting bolt. Timing mark Timing marks Mitsubishi Motors Corporation May 1995 4G9 ENGINE (E - W) - Timing belt 'BA TIMING BELT TENSIONER INSTALLATION (1) Let the pulley of the timing belt tensioner comr closest to the exhaust side. Temporarily tighten the tensioner pulley fixing bolt. Set hole (A) Set hole (B) Mitsubishi Motors Corporation Nov.

1995 4G9 ENGINE (E - W) - Timing Belt (6) Slightly loosen the tensioner pulley fixing bolt which is tightened temporarily to tighten the belt by a force of the tensioner spring. Paper clip Timing mark Timing mark Mitsubishi Motors Corporation Nov. 1995 4G9 ENGINE (E - W) - Timing Belt 'FA TIMING BELT INSTALLATION (1) Make sure that the auto-tensioner is installed properly.

(Refer to service point F.) (2) Align the timing mark on each sprocket with the corresponding mark on the timing belt. Crankshaft sprocket Mitsubishi Motors Corporation May 1995 4G9 ENGINE (E - W) - Timing Belt (6) Secure the timing belt with a paper clip at the illustrated position. (7) Fit the belt to the idler pulley water pump sprocket, crankshaft sprocket and tensioner pulley in that order. Cracks Mitsubishi Motors Corporation May 1995 Mitsubishi Motors Corporation Mar.

2001 4G9 ENGINE (E–W) – Timing Belt (12)Install the special tool and a torque wrench to the tensioner pulley. (13)Using torque wrench, torque to 2.6 Nm. (14)While holding the tensioner pulley to prevent it from turning, tighten the center bolt to the specified torque. 98 to 196 N Stroke Mitsubishi Motors Corporation May 1995 4G9 ENGINE (E - W) - Timing Belt (6) Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife. (7) Abnormal wear on teeth.

4G9 ENGINE (E - W) - 5. FUEL AND EMISSION CONTROL SYSTEM REMOVAL AND INSTALLATION 18 Nm 21 Nm Removal steps 1. Breather tube 2.

11A-5-2 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION 12 Nm 9 Nm Removal steps 1. Vacuum hose and pipe assembly 2. Throttle body 'CA 3. Engine hanger (4G94) 5. Throttle body stay (4G94) 6. 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION 12 Nm 9 Nm 9 Nm Removal steps 1. Stay (From 2002 model) 2.

Harness bracket 3. Throttle cable bracket 4. Vacuum hose and pipe assembly 5. Throttle body 'CA 6. 11A-5-4 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION 11 Nm 9 Nm Removal steps 1. Vacuum pipe assembly 2. Throttle body assembly 'CA 3.

Throttle body stay (MIVEC) 5. Vacuum hose 6. Fuel hose 'BA 7. Fuel pressure regulator 8. 4G9 ENGINE (E - W) - Injector connector Delivery pipe Projection Mitsubishi Motors Corporation Dec. 1998 Fuel and Emission Control System INSTALLATION SERVICE POINTS 'AA INJECTORS INSTALLATION (1) Apply a small amount of new engine oil to the O-ring. 11A-5-6 4G9 ENGINE (E - W) - Projection Mitsubishi Motors Corporation Dec.

1998 Fuel and Emission Control System PWEE9502-E Added. 4G9 ENGINE (E - W) - 5a. THROTTLE BODY AND EGR SYSTEM (GDI) REMOVAL AND INSTALLATION 9 Nm 30 Nm Removal steps 1. Air intake plenum resonator 2. 11A-5a-2 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION 20 Nm 24 Nm 30 Nm Removal steps 'BA 1. Intake manifold stay (For GALANT) 2.

Water hose 3. Water hose 4. Water hose 5. 4G9 ENGINE (E - W) - REMOVAL AND INSTALLATION 18 Nm 18 Nm 11 Nm Removal steps 1. Water hose 2. Water hose 3.

Water hose 4. Water hose 5.

Water hose 6. Water hose clamp 7. 11A-5a-4 4G9 ENGINE (E - W) - REMOVAL AND INSTALLATION 18 Nm 18 Nm 18 Nm 11 Nm Removal steps 1. Water hose 2. Water hose 3. Water hose 4. Water hose 5.

Water hose 6. 4G9 ENGINE (E - W) - Intake manifold Bolt. 4G9 ENGINE (E–W) – 6. INTAKE AND EXHAUST MANIFOLD REMOVAL AND INSTALLATION 20 Nm 20 Nm 31 Nm Bolt with head mark “4” 12 Nm Bolt with head mark “7” 19 Nm Removal steps 1. Engine hanger 'BA 2. Intake manifold stay 3. 11A-6-2 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION 20 Nm 20 Nm 31 Nm Removal steps 1.

Engine hanger 2. Intake manifold stay 3. Intake manifold 4. Intake manifold gasket 5. 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION 20 Nm 20 Nm 31 Nm Removal steps 1.

Engine hanger 2. Intake manifold stay 3. Intake manifold 4.

Intake manifold gasket 5. Oil level gauge 6.

11A-6-2b 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION 20 Nm 20 Nm 31 Nm Removal steps 1. Intake manifold stay 2. Intake manifold 3. Intake manifold gasket 4. Oil level gauge 5. Oil level gauge guide 6. 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION 19 Nm 31 Nm Removal steps 1.

Oil level gauge 2. Oil level gauge guide 3. Engine hanger 5. 11A-6-2d 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION 19 Nm 31 Nm Removal steps 1.

Oil level gauge 2. Oil level gauge guide 3.

Engine hanger 5. 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION 19 Nm 31 Nm Removal steps 1. Oil level gauge 2. Oil level gauge guide 3.

Engine hanger 5. Intake manifold stay 6. Intake manifold Mitsubishi Motors Corporation Nov. 11A-6-2f 4G9 ENGINE (E–W) – Mitsubishi Motors Corporation Nov. 1996 Mitsubishi Motors Corporation Jun.

2002 Intake and Exhaust Manifold Intentionally blank PWEE9502-B PWEE9502-K Revised Added. 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION 20 Nm 20 Nm 31 Nm Removal steps 1. Engine hanger 2. Intake manifold stay 3.

Intake manifold 4. Intake manifold gasket 5. Oil level gauge 6. Oil level gauge guide Mitsubishi Motors Corporation Mar. 11A-6-4 4G9 ENGINE (E–W) – Bracket A Bracket B Exhaust manifold Exhaust manifold Bracket Intake manifold Intake manifold stay Cylinder block “UP” mark Mitsubishi Motors Corporation Nov. 1996 Mitsubishi Motors Corporation Mar. 2001 Intake and Exhaust Manifold INSTALLATION SERVICE POINT 'AA EXHAUST MANIFOLD BRACKET INSTALLATION.

4G9 ENGINE (E - W) - 6a. INTAKE MANIFOLD (GDI) REMOVAL AND INSTALLATION 9 Nm 11 Nm 19 Nm Removal steps 1. Air by-pass hose (Up to 1998 model for CARISMA, SPACE RUNNER) 2. 11A-6a-1a 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION 11 Nm Removal steps 1. Vacuum pipe and hose 2. Purge hose 3. Solenoid valve Mitsubishi Motors Corporation Jun.

1998 Mitsubishi Motors Corporation Apr. 4G9 ENGINE (E - W) - Mitsubishi Motors Corporation Jun.

1998 Mitsubishi Motors Corporation May 2000 Intake Manifold (GDI) Intentionallyblank PWEE9502-D PWEE9502-G 11A-6a-1b Revised Added. 11A-6a-2 4G9 ENGINE (E - W) - REMOVAL AND INSTALLATION 9 Nm 19 Nm Removal steps 1. Air by-pass hose 2.

Vacuum pipe and hose 3. Solenoid valve 5. Connector bracket Mitsubishi Motors Corporation Jun. 4G9 ENGINE (E - W) - REMOVAL AND INSTALLATION 9 Nm 11 Nm 9 Nm 9 Nm 11 Nm 30 Nm Removal steps 1.

Vacuum pipe and hose 3. Solenoid valve 4. Fuel pump protector 5. 11A-6a-4 4G9 ENGINE (E - W) - Intake manifold Intake manifold stay Cylinder block Mitsubishi Motors Corporation Dec. 1998 Intake Manifold (GDI) INSTALLATION SERVICE POINT 'AA INTAKE MANIFOLD STAY INSTALLATION (1) Check to ensure that the intake manifold stay is in close. 4G9 ENGINE (E - W) - 6b.

EXHAUST MANIFOLD (GDI) REMOVAL AND INSTALLATION Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. Exhaust manifold cover 5. Engine hanger 'AA 6. Exhaust manifold bracket A 'AA 7. Engine hanger 6.

Exhaust manifold cover 7. Exhaust manifold bracket B 8. Heat protector 9. Exhaust manifold 10.

Exhaust manifold gasket 11. Exhaust manifold bracket A Mitsubishi Motors Corporation May 2000 29 Nm 19 Nm 24 Nm 35 Nm 35 Nm. 11A-6b-1b 4G9 ENGINE (E - W) - Exhaust Manifold (GDI) Intentionallyblank Mitsubishi Motors Corporation May 2000 PWEE9502-G Added. 11A-6b-2 4G9 ENGINE (E - W) - REMOVAL AND INSTALLATION Removal steps 1. Exhaust manifold cover 2. Engine hanger 'BA 3.

Exhaust manifold bracket 4. Exhaust manifold 5.

Exhaust manifold gasket Mitsubishi Motors Corporation Dec. 1998 Exhaust Manifold (GDI). 4G9 ENGINE (E - W) - Bracket A Bracket B Shear-droop Exhaust manifold Bracket Mitsubishi Motors Corporation Dec. 1998 Exhaust Manifold (GDI) INSTALLATION SERVICE POINTS 'AA EXHAUST MANIFOLD BRACKET INSTALLATION (1) Slide the washers over the bolts with the chamfered side toward the bolt.

4G9 ENGINE (E - W) - 6c. INJECTOR AND FUEL PUMP ASSEMBLY (GDI) REMOVAL AND INSTALLATION 11 Nm 11 Nm 11 Nm 22 Nm Removal steps 1. 11A-6c-1a 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION 23 Nm 11 Nm 11 Nm 22 Nm Removal steps 1. Injector harness 2. Flange 'IA 3. Fuel pressure sensor 'IA 4.

Backup ring 'IA. 4G9 ENGINE (E - W) - REMOVAL AND INSTALLATION 23 Nm 11 Nm 11 Nm 22 Nm Removal steps 1.

Injector harness 4. Flange 'IA 5. Fuel pressure sensor 'IA. 11A-6c-2 4G9 ENGINE (E - W) - REMOVAL AND INSTALLATION 9 Nm 11 Nm 18 Nm 9 Nm 22 Nm Removal steps 1. Injector harness 2. 4G9 ENGINE (E - W) - Cut surface Backup ring Corrugated washer Mating marks Mating marks Injector gasket Mitsubishi Motors Corporation Dec.

1998 Injector and Fuel Pump Assembly (GDI) INSTALLATION SERVICE POINTS 'AA BACKUP RING / O-RING / CORRUGATED WASHER INSTALLATION (1) Attach the backup rings and O-ring to the injector. 11A-6c-4 4G9 ENGINE (E - W) - Coupling Groove O-ring Camshaft Cut surface Backup ring Cut surface Backup ring Mitsubishi Motors Corporation Dec. 1998 Injector and Fuel Pump Assembly (GDI) (8) Tighten the fasteners of the delivery pipe and injector assembly to the specified torque in the order given in the illustration. 4G9 ENGINE (E - W) - Cut surface Backup ring Mitsubishi Motors Corporation Dec. 1998 Injector and Fuel Pump Assembly (GDI) (2) Fit the backup rings and the O-ring on both ends of the fuel return pipe. Note that the larger backup ring must be installed with the inside cut surface in the direction shown in the illustration. 11A-6c-6 4G9 ENGINE (E - W) - Backup ring (no special orientation) Cut surface Backup ring (thicker one) Mitsubishi Motors Corporation May 2000 Injector and Fuel Pump Assembly (GDI) 'GA O-RING / FUEL PUMP INSTALLATION (1) Apply engine oil to the roller of the fuel pump and O-ring.

4G9 ENGINE (E - W) - Cut surface Backup ring Fuel pressure sensor Label surface Delivery pipe Mitsubishi Motors Corporation July 2000 Injector and Fuel Pump Assembly (GDI) 'IA O-RING / BACKUP RING / FUEL PRESSURE SENSOR INSTALLATION (1) Fit the backup ring to the fuel pressure sensor so that its inner cut surface faces in the direction shown. 4G9 ENGINE (E - W) - 6d.

INTAKE AND EXHAUST MANIFOLD REMOVAL AND INSTALLATION 9 Nm 9 Nm 11 Nm 29 Nm 31 Nm Removal steps 1. Purge hose 3. Vacuum pipe and hose 4.

11A-6d-2 4G9 ENGINE (E - W) - Shear-droop Exhaust manifold Bracket Intake manifold Intake manifold stay Cylinder block Mitsubishi Motors Corporation July 2000 Intake and Exhaust Manifold INSTALLATION SERVICE POINTS 'AA EXHAUST MANIFOLD BRACKET INSTALLATION (1) The washers must be installed with the shear-drooped side toward the bolts. 4G9 ENGINE (E–W) – 7. WATER PUMP AND WATER HOSE REMOVAL AND INSTALLATION 24 Nm Removal steps 1. Water hose (Except carburetor engines) 2. Water hose 'GA 3.

Engine coolant temperature sensor 'FA 4. Engine coolant temperature gauge unit 'EA 5. 11A-7-2 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION 24 Nm 24 Nm Removal steps 1. Water hose 2.

Water hose 3. Water hose 4. Water pipe 'GA 5. Engine coolant temperature sensor 'FA 6. Engine coolant temperature gauge unit 'IA. 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION 24 Nm Removal steps 1. Water hose A (Except GDI engine) 2.

Water hose B (Except GDI engine) 'GA 3. Engine coolant temperature sensor 'FA 4. Engine coolant temperature gauge unit 'EA 5. 11A-7-4 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION 24 Nm 24 Nm Removal steps 'GA 1. Engine coolant temperature sensor 'FA 2. Engine coolant temperature gauge unit 'IA 3.

Water fitting 'EA 4. Water outlet fitting 5. 4G9 ENGINE (E–W) – Jiggle valve Mitsubishi Motors Corporation Nov. 1996 Mitsubishi Motors Corporation Jun. 2002 Water Pump and Water Hose INSTALLATION SERVICE POINTS 'AA WATER PUMP INSTALLATION (1) Apply 3 mm diameter of Form-In-Place Gasket (FIPG) to the location shown in the illustration.

11A-7-6 4G9 ENGINE (E–W) – Mitsubishi Motors Corporation May 1995 Mitsubishi Motors Corporation Jun. 2002 Water Pump and Water Hose 'FA ENGINE COOLANT TEMPERATURE GAUGE UNIT INSTALLATION (1) Apply the specified sealant to the threads. Specified sealant: 3M ATD Part No.8660 or equivalent.

4G9 ENGINE (E–W) – 8. ROCKER ARMS AND CAMSHAFTS REMOVAL AND INSTALLATION 35 Nm 11 12 9 Nm Removal steps 1. Breather hose 2. Oil filler cap 4. Rocker cover 5. Rocker cover gasket 6. 11A-8-1a 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION 35 Nm Removal steps 1.

Breather hose 2. Oil filler cap 4.

Rocker cover 5. Rocker cover gasket 6. Oil seal 'EA 7. Oil seal 'DA 8.

4G9 ENGINE (E - W) - Mitsubishi Motors Corporation May 1995 Mitsubishi Motors Corporation May 2000 Rocker Arms and Camshafts Intentionallyblank PWEE9502 PWEE9502-G 11A-8-1b Added. 11A-8-2 4G9 ENGINE (E - W) - REMOVAL AND INSTALLATION 3.5 Nm 11 Nm 24 Nm Removal steps 1. Breather hose 2. Valve gasket 5. Oil filler cap 'KA 6.

Rocker cover 7. 4G9 ENGINE (E - W) - REMOVAL AND INSTALLATION 3.5 Nm Apply engine oil to all moving parts before installation. Removal steps 1. Breather hose 2. P.C.V hose 3. P.C.V valve 4. P.C.V valve gasket 5.

Oil filler cap 6. 11A-8-2 2 b 4G9 ENGINE (E - W) - Rocker Arms and Camshafts Intentionally blank Mitsubishi Motors Corporation July 1997 PWEE9502-C Added. 4G9 ENGINE (E - W) - REMOVAL AND INSTALLATION 3.5 Nm Apply engine oil to all moving parts before installation. Removal steps 1. Breather hose 2. 11A-8-3a 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION Removal steps 1.

Valve gasket 4. Breather hose 5. Oil filler cap 6. Rocker cover, intake 7. 4G9 ENGINE (E - W) - REMOVAL AND INSTALLATION Apply engine oil to all moving parts before installation.

Removal steps 1. Valve gasket 3. Breather hose 4. Oil filler cap 5. 11A-8-4 4G9 ENGINE (E - W) - REMOVAL AND INSTALLATION 3.5 Nm Apply engine oil to all moving parts before installation. Removal steps 1. Breather hose 2.

Valve gasket 4. 4G9 ENGINE (E - W) - 1 mm or less Timing belt side Chamfered side Oil holes Mitsubishi Motors Corporation Dec.

1998 Rocker Arms and Camshafts REMOVAL SERVICE POINT AA' LASH ADJUSTER REMOVAL Caution If the lash adjuster is re-used, clean the lash adjuster. 11A-8-6 4G9 ENGINE (E - W) - MD998713 Journal Dowel pins Mitsubishi Motors Corporation Dec. 1998 Rocker Arms and Camshafts 'EA OIL SEAL INSTALLATION 'FA LASH ADJUSTER INSTALLATION Caution If the lash adjuster is re-used, clean the lash adjuster.

(Refer to 11A-8-10.) (1) Fit the lash adjuster onto the cylinder head using care not to allow diesel fuel to spill out. 4G9 ENGINE (E - W) - Cap No. IN or EX side identification Dowel pin. 11A-8-8 4G9 ENGINE (E - W) - Engine front side Removal steps AA' 'DA 1. Cylinder head bolt 2.

Cylinder head assembly 3. Cylinder head gasket AB' 'CA 4. Retainer lock 5.

Valve spring retainer 'BA 6. 11A-9-2 4G9 ENGINE (E - W) - REMOVAL AND INSTALLATION Removal steps 'EA 1. Oil pressure switch AA' 'DA 2. Cylinder head bolt 3.

Cylinder head assembly 4. Cylinder head gasket AB' 'CA 5. Retainer lock 6. Valve spring retainer 'BA 7. 4G9 ENGINE (E - W) - REMOVAL AND INSTALLATION Removal steps 'EA 1. Oil pressure switch AA' 'DA 2.

Cylinder head bolt 3. Cylinder head assembly 4.

Cylinder head gasket AB' 'CA 5. Retainer lock 6. Valve spring retainer 'BA 7. 11A-9-4 3 a 4G9 ENGINE (E - W) - REMOVAL AND INSTALLATION Removal steps AA' 'DA 1.

Cylinder head bolt 2. Cylinder head assembly 3.

Cylinder head gasket AB' 'CA 4. Retainer lock 5.

Valve spring retainer 'BA 6. 11A-9-5 3 b 4G9 ENGINE (E - W) - Cylinder Head and Valves Intentionally blank Added Mitsubishi Motors Corporation July 1997 PWEE9502-C. 11A-9-4 4G9 ENGINE (E - W) - SOHC MB991653 DOHC, MIVEC MB991653 Except MIVEC MD998772 MIVEC MD998772 MD998784 MD998735 Mitsubishi Motors Corporation Nov. 1995 Cylinder Head and Valves REMOVAL SERVICE POINTS AA' CYLINDER HEAD BOLT REMOVAL (1) Loosen the cylinder head bolts using the special tool.

4G9 ENGINE (E - W) - Mitsubishi Motors Corporation Nov. 1995 Cylinder Head and Valves AC' VALVE STEM SEAL REMOVAL AD' VALVE HANDLING PRECAUTIONS (1) Sodium reacts violently with water or moisture generation heat and liberating hydrogen. It must be handled with. 11A-9-6 4G9 ENGINE (E - W) - SOHC MD998774 DOHC MD998775 Mitsubishi Motors Corporation Nov. 1995 Cylinder Head and Valves Caution Valves must be neutralized one at a time. Put a valve in the container only after sodium in the preceding one has completely reacted with water. 4G9 ENGINE (E - W) - Spring retainer Painted Stem seal Spring seat Except MIVEC MD998772 MIVEC MD998772 MD998784 MD998735 Shank length Mitsubishi Motors Corporation Nov.

1995 Cylinder Head and Valves 'BA VALVE SPRING INSTALLATION (1) Install the valve spring with the painted end on the rocker arm side. 11A-9-8 4G9 ENGINE (E - W) - Timing belt side Pain mark Oil passage Mitsubishi Motors Corporation Nov. 1995 Cylinder Head and Valves (4) According to the tightening sequence, tighten the bolts to the specified torque 74 Nm. (5) Loosen all bolts fully. 4G9 ENGINE (E - W) - Valve seat contact Margin Mitsubishi Motors Corporation July 1997 Cylinder Head and Valves INSPECTION CYLINDER HEAD (1) Check the cylinder head gasket surface for flatness by using a straightedge and thickness gauge. Standard value: 0.03 mm Limit: 0.2 mm. 11A-9-10 4G9 ENGINE (E–W) – Out of square Free height Valve stem end Valve stem projection Spring seating surface Valve guide Mitsubishi Motors Corporation Nov.

1995 Mitsubishi Motors Corporation Jun. 2002 Cylinder Head and Valves VALVE SPRING (1) Measure the valve spring’s free height. If the measurement is less than specified, replace the spring. 4G9 ENGINE (E - W) - 0.9 - 1.3 mm 0.9 - 1.3 mm 0.5 - 1.0 mm Cut away 0.5 - 1.0 mm Valve seat height Oversize valve seat hole diameter Mitsubishi Motors Corporation July 1997 Cylinder Head and Valves.

11A-9-12 4G9 ENGINE (E - W) - Protrusion Mitsubishi Motors Corporation Nov. 1995 Cylinder Head and Valves (3) Press-fit the valve guide until it protrude specified value (SOHC: 14 mm, DOHC: 19 mm) as shown in the illustration. Press the valve guide from the cylinder head top surface.

4G9 ENGINE (E–W) – 10. FRONT CASE AND OIL PUMP REMOVAL AND INSTALLATION 10 Nm 14 Nm Apply engine oil to all moving parts before installation. Removal steps 'FA 1. Oil pressure switch 'EA 2. Oil filter 3.

11A-10-1a 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION 10 Nm 14 Nm Apply engine oil to all moving parts before installation. Removal steps 'FA 1. Oil pressure switch 'EA 2. Oil filter 3.

Drain plug 4. 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION Apply engine oil to all moving parts before installation.

10 Nm 14 Nm Removal steps 'FA 1. Oil pressure switch 'EA 2. Oil filter 3. Drain plug 4. Drain plug gasket 5. 11A-10-2 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION 10 Nm 14 Nm Apply engine oil to all moving parts before installation. Removal steps 'FA 1.

Oil pressure switch 'EA 2. Oil filter 3.

Drain plug 4. 4G9 ENGINE (E–W) – REMOVAL AND INSTALLATION Apply engine oil to all moving parts before installation. 10 Nm 14 Nm Removal steps 'FA 1. Oil pressure switch 'EA 2. Oil filter 3.

Service Manual Gdi Pump Mitsubishi 1.8

Drain plug 4. Drain plug gasket 5. 11A-10-4 4G9 ENGINE (E - W) - MD998727 MD998727 Alignment dots Alignment dots 3 mm diameter bead sealant Mitsubishi Motors Corporation Dec. 1998 Front Case and Oil Pump REMOVAL SERVICE POINTS AA' OIL PAN REMOVAL (1) Knock in the special tool deeply between the oil pan and the cylinder block. 4G9 ENGINE (E–W) – MD998717 Oil pump case MD998717 Crankshaft Guide Oil seal OIL PAN, UPPER OIL PAN Bolt hole Groove portion portion LOWER OIL PAN 4 mm diameter bead sealant Bolt hole portion Groove portion LOWER OIL PAN. 11A-10-6 4G9 ENGINE (E–W) – Oil passage Mitsubishi Motors Corporation May 1995 Mitsubishi Motors Corporation Jun. 2002 Front Case and Oil Pump (4) Tighten the lower oil pan mounting bolts in the sequence shown in the illustration.

4G9 ENGINE (E - W) - Mitsubishi Motors Corporation Dec. 1998 Front Case and Oil Pump (2) Check the side clearance. Standard value: 0.04 - 0.10 mm (3) Check the body clearance. Standard value: 0.10 - 0.18 mm Limit: 0.35 mm. 4G9 ENGINE (E - W) - 11. PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION Lubricate all inter- nal parts with en- gine oil during re- assembly.

Removal steps 'GA 1. Nut AA' 'FA 2. Connecting rod cap 'EA 3. Connecting rod bearing 'DA 4. 11A-11-2 4G9 ENGINE (E - W) - Cylinder number Piston pin setting tool: MD998780 Guide A: Push rod 17.9 mm Guide B Guide A: 18.9 mm Guide C Guide A: 20.9 mm Base Guide A: 21.9 mm Push rod Front mark.

4G9 ENGINE (E–W) – Timing belt side Manufacturing date Check digit No. 4 Cylinder bore size mark Connecting rod Piston pin Piston 3 mm + L Guide B Guide A Mitsubishi Motors Corporation May 1995 Mitsubishi Motors Corporation Apr. 11A-11-4 4G9 ENGINE (E–W) – Push rod Piston pin Front mark Front mark Guide A Base Guide B Side rail Spacer Side rail end Mitsubishi Motors Corporation May 1995 Mitsubishi Motors Corporation Jun. 2002 Piston and Connecting Rod (9) Place the piston and connecting rod assembly onto the piston setting base with the front marks directed upward.

4G9 ENGINE (E–W) – Identification mark “T” Identification mark Size mark “2T” or ”T2” Upper side rail No.1 ring Piston pin Lower side rail No.2 ring and spacer Mitsubishi Motors Corporation May 1995 Mitsubishi Motors Corporation Apr. 2003 Piston and Connecting Rod 'CA PISTON RING NO.2/PISTON RING NO.1. 11A-11-6 4G9 ENGINE (E–W) – 4G9 ENGINE (E–W) – Check digit No.4 No.3 Crank pin O.D. No.2 identification No.1 mark Crankshaft journal O.D. Identification mark P view Check digit No.4 No.3 No.2 No.1 Identification mark Identification colour Mitsubishi Motors Corporation.

4G9 ENGINE (E–W) – 4G9 ENGINE (E–W) – Cylinder No. Notches Paint mark Paint mark 90 – 100 Mitsubishi Motors Corporation May 1995 Mitsubishi Motors Corporation Jun. 2002 Piston and Connecting Rod Piston and Connecting Rod 'FA CONNECTING ROD CAP INSTALLATION.

11A-11-8 4G9 ENGINE (E–W) – Push in by the piston Piston ring gap Piston ring Plastigauge Mitsubishi Motors Corporation May 1995 Mitsubishi Motors Corporation Mar. 2001 Piston and Connecting Rod INSPECTION PISTON RING (1) Check the clearance between the piston ring and ring groove.

4G9 ENGINE (E–W) 12. CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE PLATE REMOVAL AND INSTALLATION (MANUAL TRANSMISSION) 23 Nm Removal steps 'FA 1. Flywheel bolt 2. Flywheel 'FA 3. Flywheel bolt 4. Adapter plate 6. Adapter plate 8.

11A-12-1a 4G9 ENGINE (E–W) REMOVAL AND INSTALLATION (AUTOMATIC TRANSMISSION) 23 Nm Removal steps 'FA 1. Flywheel bolt 2. Adapter plate 3.

Drive plate 'FA 4. Drive plate bolt 5.

Adapter plate 6. Drive plate 7. Rear plate 8. Bell housing cover. 4G9 ENGINE (E–W) REMOVAL AND INSTALLATION Apply engine oil to all moving parts before installation. 23 Nm Removal steps 'FA 1.

Flywheel bolt 2. Flywheel 'FA 3. Flywheel bolt 4.

Adapter plate. 11A-12-2 4G9 ENGINE (E - W) Check digit Crank O.D.

Identifi- cation mark No. 3 Journal No. Identifi- No. 1 cation mark Mitsubishi Motors Corporation Nov.

1995 Mitsubishi Motors Corporation May 2000 Crankshaft, Cylinder Block, Flywheel and Drive Plate REMOVAL SERVICE POINT AA'. 4G9 ENGINE (E–W) P view No.5 No.4 No.3 No.2 No.1 Oil pan view Timing belt side No. 1 Oil groove Grooves Identification mark Identifica- Identification Identification tion colour colour colour Mitsubishi Motors Corporation Nov. 1995 Mitsubishi Motors Corporation Mar.

11A-12-4 4G9 ENGINE (E–W) Length of shank Arrow Paint marks 90 – 100 Mitsubishi Motors Corporation Nov. 1995 Mitsubishi Motors Corporation Mar. 2001 – Crankshaft, Cylinder Block, Flywheel and Drive Plate 'CA BEARING CAP/BEARING CAP BOLT INSTALLATION (1) Install the bearing caps so that their arrows are positioned on the time belt side. 4G9 ENGINE (E–W) MB990938 MD998776 Plastigauge Plastigauge Mitsubishi Motors Corporation Nov.

1995 Mitsubishi Motors Corporation Mar. 2001 – Crankshaft, Cylinder Block, Flywheel and Drive Plate 'DA OIL SEAL INSTALLATION 'EA SEALANT APPLICATION TO OIL SEAL CASE Specified sealant: Mitsubishi Genuine equivalent 'FA DRIVE PLATE BOLT/FLYWHEEL BOLT. 11A-12-6 4G9 ENGINE (E–W) 12 mm Centre Bottom Thrust direction Piston O.D. Mitsubishi Motors Corporation Nov.

1995 Mitsubishi Motors Corporation Mar. 2001 – Crankshaft, Cylinder Block, Flywheel and Drive Plate CYLINDER BLOCK (1) Using a straightedge and thickness gauge, check the block top surface for warpage. 4G9 ENGINE (E–W) Flywheel Distance moved Dowel pin Runout Dowel pin Flywheel Mitsubishi Motors Corporation Nov. 1995 Mitsubishi Motors Corporation Mar. 2001 – Crankshaft, Cylinder Block, Flywheel and Drive Plate Caution To prevent distortion that may result from temperature rise during honing, bore cylinders, in the order of No.

Service Bulletins Click on the applicable bookmark to select the Service Bulletin. SERVICE BULLETIN OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION SERVICE BULLETIN Subject: CHANGE IN POSITIONS OF CRANKSHAFT IDENTIFICATION MARKS Group: ENGINE INFORMATION INTERNATIONAL ADMINISTRATION OFFICE 1. Description: This Service Bulletin informs you that the journal O.D.

Identification marks and the pin O.D. Crankshaft weight Front Journal O.D.

Identification mark Journal O.D. Identification mark Pin O.D. Identification mark Pin O.D.

Identification mark. INTERNATIONAL AFTER-SALES DEPARTMENT. MITSUBISHI MOTORS CORPORATION SERVICE BULLETIN DISUSE OF INJECTOR BACKUP RINGS IN GDI SUBJECT: ENGINES ENGINES GROUP: ENGINE INTERNATIONAL INFORMATION AFTER SALES AFTER SALES DEPARTMENT Description: This service bulletin informs you of disuse of one of the backup rings that has been used in each fuel injector on GDI engines. Attachment Applicable Manuals: Manual ENGINE 4G6 (E–W) W k h Workshop Manual ENGINE 4G9 (E–W) W k h Workshop Manual ENGINE 6G7 (E–W) W k h Workshop Manual ’98 CARISMA GDI W k h Workshop Manual chassis 2001 CARISMA W k h Workshop Manual chassis MSB–03E11–001.