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Manual Mitsubishi 4G1

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  • Mitsubishi 4G1 - page 1

    GENERAL INFORMA TION 1 1A-0-3 ........................................... 1. SPECIFICA TIONS 1 1A-1-1 ................................................. SERVICE SPECIFICA TIONS 1 1A-1-1 .................................... REWORK DIMENSIONS 1 1A-1-3 ........................................ T ORQUE SPECIFICA TIONS 1 1A-1-4 ........................... ...

  • Mitsubishi 4G1 - page 2

    1 1A-0-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation NOTES ...

  • Mitsubishi 4G1 - page 3

    4G1 ENGINE (E - W) - General Information 1 1A-0-3 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation GENERAL INFORMA TION ...

  • Mitsubishi 4G1 - page 4

    4G1 ENGINE (E - W) - General Information 1 1A-0-4 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation ...

  • Mitsubishi 4G1 - page 5

    4G1 ENGINE (E - W) - General Information 1 1A-0-5 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Descriptions 4G13 12-V AL VE - CARBURET OR 4G13 12-V AL VE - MPI T ype In-line OHV , SOHC In-line OHV , SOHC Number of cylinders 4 4 Combustion chamber Pentroof type Pentroof type T otal displacement dm 3 1,299 1,299 Cylinder bore mm 71.0 71.0 Pist ...

  • Mitsubishi 4G1 - page 6

    4G1 ENGINE (E - W) - General Information 1 1A-0-6 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Descriptions 4G13 16-V AL VE - MPI 4G18 16-V AL VE - MPI T ype In-line OHV , SOHC In-line OHV , SOHC Number of cylinders 4 4 Combustion chamber Pentroof type Pentroof type T otal displacement dm 3 1,299 1,584 Cylinder bore mm 71.0 76.0 Piston strok ...

  • Mitsubishi 4G1 - page 7

    4G1 ENGINE (E - W) - General Information 1 1A-0-7 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Descriptions 4G15 - CARBURETT OR 4G15 - MPI T ype In-line OHV , SOHC In-line OHV , DOHC Number of cylinders 4 4 Combustion chamber Semi spherical type Pentroof type T otal displacement dm 3 1,468 1,468 Cylinder bore mm 75.5 75.5 Piston stroke mm 82 ...

  • Mitsubishi 4G1 - page 8

    NOTES ...

  • Mitsubishi 4G1 - page 9

    4G1 ENGINE (E - W) - Specifications 1 1A-1-1 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 1. SPECIFICA TIONS SERVICE SPECIFICA TIONS Item Standard Limit Rocker arms, rocker shafts, and camshaft Camshaft cam SOHC 12-V AL VE Intake (primary) 38.78 38.28 height mm Intake (secondary) 38.78 38.28 Exhaust 39.10 38.60 SOHC 16-V AL VE Intake 36.99 3 ...

  • Mitsubishi 4G1 - page 10

    4G1 ENGINE (E - W) - Specifications 1 1A-1-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Item Limit Standard Overall valve length SOHC 12-V AL VE Intake 100.75 100.25 mm Exhaust 101.05 105.55 SOHC 16-V AL VE Intake 1 1 1.56 1 1 1.06 Exhaust 1 14.71 1 14.21 DOHC Intake 106.35 105.85 Exhaust 106.85 106.35 V alve spring free SOHC 12-V AL VE In ...

  • Mitsubishi 4G1 - page 11

    4G1 ENGINE (E - W) - Specifications 1 1A-1-2a PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Item Standard Limit Crankshaft and cylinder block Crankshaft end play mm 0.05 - 0.18 0.25 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 ...

  • Mitsubishi 4G1 - page 12

    4G1 ENGINE (E - W) - Specifications 1 1A-1-2b PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Intentionally blank PWEE9520-A E Dec. 1998 Mitsubishi Motors Corporation Added PWEE9520-A E Dec. 1998 Mitsubishi Motors Corporation Added ...

  • Mitsubishi 4G1 - page 13

    4G1 ENGINE (E - W) - Specifications 1 1A-1-3 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REWORK DIMENSIONS Item Standard Limit Cylinder head and valves Cylinder head oversize valve guide SOHC 12-V AL VE 0.05 O. S. 12.050 - 12.068 - hole diameter mm 0.25 O. S. 12.250 - 12.268 - 0.50 O. S. 12.500 - 12.518 - SOHC 16-V AL VE 0.05 O. S. 10.550 - ...

  • Mitsubishi 4G1 - page 14

    4G1 ENGINE (E - W) - Specifications 1 1A-1-4 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation TORQUE SPECIFICA TIONS Item Nm Alternator and ignition system W ater pump pulley bolt 9 Alternator brace (alternator side) 22 Alternator brace (tightened with water pump) 23 Alternator pivot bolt 44 Oil level gauge guide 23 Crankshaft bolt 125 Spark plu ...

  • Mitsubishi 4G1 - page 15

    4G1 ENGINE (E - W) - Specifications 1 1A-1-5 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Item Nm Thermo valve 27 W ater temperature gauge unit 11 W ater temperature sensor 29 W ater pump 13 Exhaust manifold and intake manifold Boost sensor 5 Solenoid valve assembly 9 Intake manifold 17 Intake manifold stay (MPI) M8 17 M10 21 Intake manifold ...

  • Mitsubishi 4G1 - page 16

    4G1 ENGINE (E - W) - Specifications 1 1A-1-5a PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Item Nm Crankshaft and cylinder block Flywheel 132 Drive plate 132 Rear plate 10 Bell housing cover 10 Rear oil seal case 11 Bearing cap bolt 51 Oil pressure switch 18 Knock sensor 23 PWEE9520-A E Dec. 1998 Mitsubishi Motors Corporation Added ...

  • Mitsubishi 4G1 - page 17

    4G1 ENGINE (E - W) - Specifications 1 1A-1-5b PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Intentionally blank PWEE9520-A E Dec. 1998 Mitsubishi Motors Corporation Added PWEE9520-A E Dec. 1998 Mitsubishi Motors Corporation Added ...

  • Mitsubishi 4G1 - page 18

    4G1 ENGINE (E - W) - Specifications 1 1A-1-6 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation NEW TIGHTENING METHOD USING PLASTIC REGION TIGHTENING BOL TS Parts of the engine use plastic region tightening bolts. The tightening procedure for these is different from that of conventional bolts a nd is described in relevant parts of this manual. Not ...

  • Mitsubishi 4G1 - page 19

    4G1 ENGINE (E - W) - Specifications 1 1A-1-7 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation FORM-IN-PLACE GASKET The engine has several areas where the form-in-place gasket (FIPG) is in use. T o ensure that the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size, continuity and locat ...

  • Mitsubishi 4G1 - page 20

    NOTES ...

  • Mitsubishi 4G1 - page 21

    4G1 ENGINE (E - W) - Special T ools 1 1A-2-1 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 2. SPECIAL TOOLS T ool Number Name Use MB990767 End yoke holder Holding camshaft sprocket when loosening or tightening bolt (used with MD998715) MD99801 1 Crankshaft rear oil seal installer Installation of crankshaft rear oil seal MD998054 Oil pressure ...

  • Mitsubishi 4G1 - page 22

    4G1 ENGINE (E - W) - Special T ools 1 1A-2-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation T ool Use Name Number MD998760 V alve stem seal installer Installation of valve stem seals (SOHC 12-V AL VE) MD998780 Piston pin setting tool Removal and press-fitting of piston pins MB991659 Guide-D Guide for removal and press-fitting of piston pins MD ...

  • Mitsubishi 4G1 - page 23

    4G1 ENGINE (E - W) - Alternator and Ignition System 1 1A-3-1 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 3. AL TERNA TOR AN D IGNITION SYSTEM REMOV AL AND INST ALLA TION <SOHC 12-V AL VE> 22 Nm 6 7 44 Nm 23 Nm 4 123 Nm 8 9 3 2 23 Nm 1 11 25 Nm 10 13 12 12 Nm 9N m 5 Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. ...

  • Mitsubishi 4G1 - page 24

    4G1 ENGINE (E - W) - Alternator and Ignition System 1 1A-3-1a PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC 16-V AL VE - FRONT WHEEL DRIVE> 22 Nm 6 7 44 Nm 23 Nm 4 125 Nm 8 9 3 2 23 Nm 1 11 25 Nm 10 13 12 12 Nm 9N m 5 Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Drive belt* 5. ...

  • Mitsubishi 4G1 - page 25

    4G1 ENGINE (E - W) - Alternator and Ignition System 1 1A-3-1b PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC 16-V AL VE - REAR WHEEL DRIVE> 22 Nm 6 7 44 Nm 23 Nm 4 125 Nm 8 9 3 2 23 Nm 1 11 10 Nm 10 13 13 Nm 9N m 5 14 21 Nm 15 12 25 Nm 9N m Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-r ...

  • Mitsubishi 4G1 - page 26

    4G1 ENGINE (E - W) - Alternator and Ignition System 1 1A-3-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC> 22 Nm 6 7 44 Nm 23 Nm 4 103 Nm 8 9 3 2 23 Nm 1 25 Nm 10 13 12 11 N m 9N m 5 11 Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Drive belt* 5. W ater pump pulley 6. Alternato ...

  • Mitsubishi 4G1 - page 27

    4G1 ENGINE (E - W) - Alternator and Ignition System 1 1A-3-3 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL SER VICE POINT A A " CRANKSHAFT BOL T REMOV AL (1) Lock t he flywheel or drive plate in position using t he special tool shown in the illustration, then loosen the crankshaft bolts. INST ALLA TION SER VICE POINTS " A A ...

  • Mitsubishi 4G1 - page 28

    NOTES ...

  • Mitsubishi 4G1 - page 29

    4G1 ENGINE (E - W) - T iming Belt 1 1A-4-1 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 4. TIMING BEL T REMOV AL AND INST ALLA TION <SOHC> 11 N m 1 10 12 35 Nm 4 3 7 2 5 23 Nm 88 Nm 11 9 8 9N m 13 6 Removal steps 1. T iming belt upper cover 2. T iming belt lower cover A A "" C A 3. T iming belt " B A 4. T ensioner spring ...

  • Mitsubishi 4G1 - page 30

    4G1 ENGINE (E - W) - T iming Belt 1 1A-4-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC> 11 N m 1 7 9 10 35 Nm 4 3 6 2 5 23 Nm 88 Nm 8 35 Nm 11 13 12 11 N m 11 N m Removal steps 1. T iming belt upper cover 2. T iming belt lower cover A A "" D A 3. T iming belt A A "" B A 4. T ension ...

  • Mitsubishi 4G1 - page 31

    4G1 ENGINE (E - W) - T iming Belt 1 1A-4-3 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL SER VICE POINTS A A " TIMING BEL T / TENSIONER SPRING / TIMING BEL T TENSIONER REMOV AL (1) Using pliers, grip the tensioner spring projection (marked “A” in the diagram)and remove it from the oil pump case stopper . Then, remove the ten ...

  • Mitsubishi 4G1 - page 32

    4G1 ENGINE (E - W) - T iming Belt 1 1A-4-4 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation (7) Abnormal wear on teeth Initial stage: Canvas worn (fluffy canvas fibers, rubbery texture gone, white discoloration, canvas texture indistinct) Final stage: Canvas worn, exposing rubber (tooth width reduced) (8) Missing teeth 2. TENSIONER PULLEY AND ID ...

  • Mitsubishi 4G1 - page 33

    4G1 ENGINE (E - W) - T iming Belt 1 1A-4-5 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation (3) Grip the other tensioner spring projection and fit it onto the oil pump case lug as shown in th e illustration. (4) Move th e timing belt tensioner in th e direction shown and temporarily tighten the bolt. " C A TIMING BEL T INST ALLA TION (1) Al ...

  • Mitsubishi 4G1 - page 34

    4G1 ENGINE (E - W) - T iming Belt 1 1A-4-6 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation " D A TIMING BEL T INST ALLA TION (1) Place t he camshaft sprocket timing marks at the positions shown. NOTE After aligning t he sprocket timing marks, let go of the sprockets. The exhaust camshaft sprocket will rotate by one tooth in the direction s ...

  • Mitsubishi 4G1 - page 35

    4G1 ENGINE (E - W) - Fuel and Emission Control Systems 1 1A-5-1 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 5. FUEL AND EMISSION CONTROL SYSTEMS REMOV AL AND INST ALLA TION <SOHC - CARBURETOR> 17 Nm 11 N m 22 Nm 21 Nm 11 12 10 9 8 7 3 2 4 5 6 1 Removal steps 1. Breather tube 2. Fuel hose 3. Fuel pump 4. Gasket 5. Insulator 6. Gasket 7 ...

  • Mitsubishi 4G1 - page 36

    4G1 ENGINE (E - W) - Fuel and Emission Control Systems 1 1A-5-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC - MPI> 11 N m 18 Nm 21 Nm 18 Nm 9N m 1 2 3 11 6 4 5 9 10 8 7 15 14 13 12 Removal steps 1. Throttle body assembly 2. Gasket 3. Fuel return pipe " B A 4. Fuel pressure regulator 5. O-ring 6. ...

  • Mitsubishi 4G1 - page 37

    4G1 ENGINE (E - W) - Fuel and Emission Control Systems 1 1A-5-2a PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC - REAR WHEEL DRIVE> 11 N m 18 Nm 21 Nm 9N m 1 2 3 11 6 4 5 9 10 8 7 13 12 9N m Removal steps 1. Throttle body assembly 2. Gasket 3. Fuel return pipe " B A 4. Fuel pressure regulator 5. O-r ...

  • Mitsubishi 4G1 - page 38

    4G1 ENGINE (E - W) - Fuel and Emission Control Systems 1 1A-5-2b PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Intentionally blank PWEE9520-A E Dec. 1998 Mitsubishi Motors Corporation Added ...

  • Mitsubishi 4G1 - page 39

    4G1 ENGINE (E - W) - Fuel and Emission Control Systems 1 1A-5-3 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC> 11 N m 11 6 2 1 18 Nm 9N m 3 5 4 9 10 8 7 Removal steps 1. Throttle body assembly 2. Gasket 3. Fuel return pipe " B A 4. Fuel pressure regulator 5. O-ring 6. Insulator 7. Insulator " ...

  • Mitsubishi 4G1 - page 40

    4G1 ENGINE (E - W) - Fuel and Emission Control Systems 1 1A-5-4 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation INST ALLA TION SER VICE POINTS " A A INJECT OR INST ALLA TION (1) Fit a new O-ring and grommet onto the injector . (2) Apply spindle oil or gasoline to th e injector O-ring. (3) Fit the injector onto the delivery pipe, turning it ...

  • Mitsubishi 4G1 - page 41

    4G1 ENGINE (E - W) - W ater Pump an d W ater Hose 1 1A-6-1 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 6. W A TER PUMP AND W A TER HOSE REMOV AL AND INST ALLA TION <SOHC - CARBURETOR> 11 N m 1 2 3 4 5 6 7 8 9 10 11 12 13 14 27 Nm 27 Nm 22 Nm 23 Nm 12 Nm 13 Nm Removal steps 1. W ater hose 2. W ater hose 3. W ater hose " F A 4. The ...

  • Mitsubishi 4G1 - page 42

    4G1 ENGINE (E - W) - W ater Pump an d W ater Hose 1 1A-6-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC - MPI> 2 13 Nm 12 10 9 11 12 Nm 11 N m 4 29 Nm 3 8 7 6 22 Nm 5 23 Nm 1 Removal steps 1. W ater hose 2. W ater hose " E A 3. W ater temperature sensor " D A 4. W ater temperature gauge unit ...

  • Mitsubishi 4G1 - page 43

    4G1 ENGINE (E - W) - W ater Pump an d W ater Hose 1 1A-6-2a PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC 16-V AL VE - MPI - FRONT WHEEL DRIVE> 2 13 Nm 12 10 9 11 12 Nm 11 N m 4 29 Nm 3 8 7 6 22 Nm 5 23 Nm 1 12 Nm Removal steps 1. W ater hose 2. W ater hose " E A 3. W ater temperature sensor " ...

  • Mitsubishi 4G1 - page 44

    4G1 ENGINE (E - W) - W ater Pump an d W ater Hose 1 1A-6-2b PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC 16-V AL VE - MPI - REAR WHEEL DRIVE> 2 13 Nm 12 11 10 12 Nm 11 N m 4 1 25 Nm 9 8 23 Nm 23 Nm 5 7 6 29 Nm 3 12 Nm Removal steps 1. W ater hose 2. W ater hose " E A 3. W ater temperature sensor & ...

  • Mitsubishi 4G1 - page 45

    4G1 ENGINE (E - W) - W ater Pump an d W ater Hose 1 1A-6-3 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC> 2 13 Nm 12 10 9 11 12 Nm 11 N m 4 29 Nm 3 8 7 6 22 Nm 5 23 Nm 1 12 Nm Removal steps 1. W ater hose 2. W ater hose " E A 3. W ater temperature sensor " D A 4. W ater temperature gauge unit ...

  • Mitsubishi 4G1 - page 46

    4G1 ENGINE (E - W) - W ater Pump an d W ater Hose 1 1A-6-4 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation INST ALLA TION SER VICE POINTS " A A W A TER PUMP INST ALLA TION (1) Apply a 3 mm bead of form-in-place gasket (FIPG) to the mounting surface. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent. " B A O-RING / ...

  • Mitsubishi 4G1 - page 47

    4G1 ENGINE (E - W) - W ater Pump an d W ater Hose 1 1A-6-5 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation " F A THERMO V AL VE INST ALLA TION (1) If the thermo valve is to be reused, apply the specified sealant to its thread. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent. ...

  • Mitsubishi 4G1 - page 48

    NOTES ...

  • Mitsubishi 4G1 - page 49

    4G1 ENGINE (E - W) - Intake and Exhaust Manifolds 1 1A-7-1 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 7. INT AKE A ND EXHAUST MANIFOLDS REMOV AL AND INST ALLA TION <SOHC - CARBURETOR> 17 Nm 1 2 3 4 5 6 7 8 30 Nm 17 Nm 29 Nm Removal steps 1. Engine hanger 2. Intake manifold stay 3. Intake manifold 4. Intake manifold gasket 5. Exhaust ...

  • Mitsubishi 4G1 - page 50

    4G1 ENGINE (E - W) - Intake and Exhaust Manifolds 1 1A-7-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC - MPI> 1 3 4 44 Nm 5 9 8 7 29 Nm 6 17 Nm 2 21 Nm 17 Nm 17 Nm Removal steps 1. Engine hanger 2. Intake manifold stay 3. Intake manifold 4. Intake manifold gasket 5. Oxygen sensor (vehicles for Hong Ko ...

  • Mitsubishi 4G1 - page 51

    4G1 ENGINE (E - W) - Intake and Exhaust Manifolds 1 1A-7-2a PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC 16-V AL VE - MPI - REAR WHEEL DRIVE> 2 4 5 17 Nm 11 10 9 29 Nm 8 3 21 Nm 17 Nm 17 Nm 29 Nm 6 7 1 5N m 9N m 19 Nm Removal steps 1. Boost sensor 2. Engine hanger 3. Intake manifold stay 4. Intake mani ...

  • Mitsubishi 4G1 - page 52

    4G1 ENGINE (E - W) - Intake and Exhaust Manifolds 1 1A-7-2b PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC - CARBURETOR FOR CENTRAL AMERICA> 2 4 5 17 Nm 11 10 9 54 Nm 8 30 Nm 17 Nm 11 N m 29 Nm 6 7 1 13 Nm 83 Nm 8 3 12 Removal steps 1. Engine hanger 2. Intake manifold stay 3. Intake manifold 4. Intake ma ...

  • Mitsubishi 4G1 - page 53

    4G1 ENGINE (E - W) - Intake and Exhaust Manifolds 1 1A-7-3 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC> 1 3 4 9 8 7 29 Nm 6 17 Nm 2 21 Nm 17 Nm 17 Nm 5 44 Nm 29 Nm Removal steps 1. Engine hanger 2. Intake manifold stay 3. Intake manifold 4. Intake manifold gasket 5. Oxygen sensor 6. Exhaust manifold c ...

  • Mitsubishi 4G1 - page 54

    4G1 ENGINE (E - W) - Intake and Exhaust Manifolds 1 1A-7-4 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation INST ALLA TION SER VICE POINTS " A A REED V AL VE, BRACKET AND AIR PIPE INST ALLA TION (1) Insert the lower en d of the air pipe into the exhaust manifold, then tighten the pipe nut temporarily . (2) Fit the upper end of the air pipe ...

  • Mitsubishi 4G1 - page 55

    NOTES ...

  • Mitsubishi 4G1 - page 56

    4G1 ENGINE (E - W) - Rocker Arms an d Camshafts 1 1A-8-1 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 8. ROCKER ARMS AND CAMSHAFTS REMOV AL AND INST ALLA TION <SOHC 12-V AL VE> 15 Nm 1 5 2 3 6 4N m 9 14 13 7 12 11 15 16 17 21 20 19 22 10 8 31 Nm 18 4 Apply engine oil to all moving parts before installation. Removal steps 1. Breather ho ...

  • Mitsubishi 4G1 - page 57

    4G1 ENGINE (E - W) - Rocker Arms an d Camshafts 1 1A-8-1a PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC 16-V AL VE> 35 Nm 9N m 31 Nm 1 2 3 4 5 6 10 11 12 13 14 15 16 17 18 19 20 21 9N m Apply engine oil to all moving parts before installation. 9 8 7 Removal steps 1. Breather hose 2. P .C.V . hose 3. Oil ...

  • Mitsubishi 4G1 - page 58

    4G1 ENGINE (E - W) - Rocker Arms an d Camshafts 1 1A-8-1b PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Intentionally blank PWEE9520-A E Dec. 1998 Mitsubishi Motors Corporation Added ...

  • Mitsubishi 4G1 - page 59

    4G1 ENGINE (E - W) - Rocker Arms an d Camshafts 1 1A-8-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC> 24 Nm 1 2 3 5 4 6 7 9 11 12 13 14 15 11 N m 10 8 Apply engine oil to all moving parts before installation. 4N m Removal steps 1. Breather hose 2. P .C.V . hose 3. P .C.V . valve 4. P .C.V . valve gask ...

  • Mitsubishi 4G1 - page 60

    4G1 ENGINE (E - W) - Rocker Arms an d Camshafts 1 1A-8-3 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation INSPECTION 1. CAMSHAFT (1) Measure the cam heights and replace the camshaft if any height exceeds the specified limit. Standard value mm Limit mm Intake SOHC 12-V AL VE 38.78 38.28 SOHC 16-V AL VE 36.99 36.49 DOHC 34.67 34.17 Exhaust SOHC 12 ...

  • Mitsubishi 4G1 - page 61

    4G1 ENGINE (E - W) - Rocker Arms an d Camshafts 1 1A-8-4 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation (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 ...

  • Mitsubishi 4G1 - page 62

    4G1 ENGINE (E - W) - Rocker Arms an d Camshafts 1 1A-8-5 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation (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 pres ...

  • Mitsubishi 4G1 - page 63

    4G1 ENGINE (E - W) - Rocker Arms an d Camshafts 1 1A-8-6 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation NOTE Replace the lash adjuster if the time measurement is out of specification. (13)Place the lash adjuster in container C again, then gently push down the internal steel ball using special tool MD998442. (14)Stand the lash adjuster with its ...

  • Mitsubishi 4G1 - page 64

    4G1 ENGINE (E - W) - Rocker Arms an d Camshafts 1 1A-8-7 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation " B A BEARING CAP INST ALLA TION (1) Position the camshaft dowel pins as shown. NOTE With the camshaft dowel pins in this position, t he camshaft notches for tightening cylinder head bolt are correctly positioned. (2) Bearing caps Nos. ...

  • Mitsubishi 4G1 - page 65

    4G1 ENGINE (E - W) - Rocker Arms an d Camshafts 1 1A-8-8 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation " E A ROCKER ARM / ROCKER SHAFT ASSEMBL Y INST ALLA TION (1) Assemble the rocker arms and rocker shaft, paying attention to the identification marks. Then mount the assembly on the cylinder head. " F A CAMSHAFT OIL SEAL INST ALLA T ...

  • Mitsubishi 4G1 - page 66

    4G1 ENGINE (E - W) - Rocker Arms an d Camshafts 1 1A-8-9 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation " H A ROCKER COVER INST ALLA TION (1) Apply the specified sealant to the area shown, then fit the rocker cover . Specified sealant: 3M A TD part No. 8660 or equivalent V AL VE CLEARANCE ADJUSTMENT <SOHC 12-V AL VE> (1) Position th ...

  • Mitsubishi 4G1 - page 67

    4G1 ENGINE (E - W) - Rocker Arms an d Camshafts 1 1A-8-10 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation <SOHC 16-V AL VE> (1) Position the No. 1 cylinder at top dead center on the compression stroke. (2) Adjust the valve clearance at the points shown in t he illustration. (3) Loosen the adjusting screw locknut. (4) Using a feeler gauge, ...

  • Mitsubishi 4G1 - page 68

    4G1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-1 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 9. CYLINDER HEAD AND V AL VES REMOV AL AND INST ALLA TION <SOHC 12-V AL VE> Apply engine oil to all moving parts before installation. 1 2 22 4 5 6 14 13 17 19 7 20 8 12 21 18 16 15 11 10 9 3 Removal steps A A "" D A 1. Cylinde ...

  • Mitsubishi 4G1 - page 69

    4G1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-1a PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC 16-V AL VE> Apply engine oil to all moving parts before installation. 1 2 4 5 6 14 13 17 19 7 8 12 18 16 15 11 10 9 3 20 Removal steps A A "" D A 1. Cylinder head bolt 2. Cylinder head assemb ...

  • Mitsubishi 4G1 - page 70

    4G1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-1b PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Intentionally blank PWEE9520-A E Dec. 1998 Mitsubishi Motors Corporation Added ...

  • Mitsubishi 4G1 - page 71

    4G1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC> Apply engine oil to all moving parts before installation. 1 2 4 5 6 14 13 17 19 7 8 12 18 16 15 11 10 9 3 20 Removal steps A A "" D A 1. Cylinder head bolt 2. Cylinder head assembly 3. Cylind ...

  • Mitsubishi 4G1 - page 72

    4G1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-3 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL SER VICE POINTS A A " CYLINDER HEAD BOL T REMOV AL A B " RET AINER LOCK REMOV AL (1) T ag removed valves, springs, and other components, noting their cylinder numbers an d locations to facilitate reassembly . Store these co ...

  • Mitsubishi 4G1 - page 73

    4G1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-4 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation A C " V AL VE STEM SEAL REMOV AL INSPECTION 1. CYLINDER HEAD (1) Before cleaning the cylinder head, check it for water leaks, gas leaks, cracks, and other damage. (2) Remove all oil, water scale, sealant, a nd carbon. After cleaning the ...

  • Mitsubishi 4G1 - page 74

    4G1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-5 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation (3) Measure the valve’s total length. If the measurement is less than specified, replace the valve. Standard mm Limit mm Intake SOHC 12-V AL VE 100.75 100.25 SOHC 16-V AL VE 1 1 1.56 1 1 1.06 DOHC 106.35 105.85 Exhaust SOHC 12-V AL VE 101.0 ...

  • Mitsubishi 4G1 - page 75

    4G1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-6 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 4. V AL VE GUIDES (1) Measure the clearance between the valve guide and valve stem. If the clearance exceeds the specified limit, replace either or both components. Standard mm Limit mm Intake SOHC 12-V AL VE 0.020 - 0.050 0.10 SOHC 16-V AL V ...

  • Mitsubishi 4G1 - page 76

    4G1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-7 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation V AL VE SEA T CORRECTION SERVICE POINTS (1) Before correcting the valve seat, check the clearance between the valve guide a nd valve. If necessary , replace the valve guide. (2) Using the appropriate special tool or seat grinder , correct the ...

  • Mitsubishi 4G1 - page 77

    4G1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-8 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation V AL VE GUIDE REPLACEMENT SER VICE 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. Caution Do not ...

  • Mitsubishi 4G1 - page 78

    4G1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-9 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation " B A V AL VE SPRING INST ALLA TION (1) Install the valve spring such that its painted end is on the rocker arm side. " C A RET AINER LOCK INST ALLA TION " D A CYLINDER HEAD BOL T INST ALLA TION (1) Before reusing the cylinder ...

  • Mitsubishi 4G1 - page 79

    4G1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-10 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation (4) T ighten the bolts in the sequence shown until each is torqued to 49 Nm. (5) Completely loosen t he bolts. (6) Retighten the bolts in the sequence shown until each is torqued to 20 Nm. (7) Apply paint marks to the cylinder head bolt head ...

  • Mitsubishi 4G1 - page 80

    4G1 ENGINE (E - W) - Oil Pump an d Oil Pan 1 1A-10-1 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 10. OIL PUMP AN D OIL P AN REMOV AL AND INST ALLA TION 11 1 12 14 13 16 15 10 9 8 6 5 7 2 3 10 Nm 13 Nm 44 Nm 18 Nm 7N m 4 39 Nm 23 Nm Apply engine oil to all moving parts before installation. Removal steps " E A 1. Oil filter 2. Drain plug ...

  • Mitsubishi 4G1 - page 81

    4G1 ENGINE (E - W) - Oil Pump an d Oil Pan 1 1A-10-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL SER VICE POINTS A A " OIL P AN REMOV AL (1) Remove t he oil pa n mounting bolts. (2) Knock the special tool between the oil pan and cylinder block as shown in th e illustration. (3) T apping the side of the special tool, slide the ...

  • Mitsubishi 4G1 - page 82

    4G1 ENGINE (E - W) - Oil Pump an d Oil Pan 1 1A-10-3 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation INST ALLA TION SER VICE POINTS " A A FRONT OIL SEAL CASE INST ALLA TION (1) Clean the sealant application surfaces on the cylinder block and front oil seal case. (2) Apply a 3 mm bead of form-in-place gasket to the entire circumference of t ...

  • Mitsubishi 4G1 - page 83

    4G1 ENGINE (E - W) - Oil Pump an d Oil Pan 1 1A-10-4 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation " E A OIL FIL TER INST ALLA TION (1) Clean th e filter mounting surface on the front case. (2) Apply engine oil to the oil filter ’ s O-ring. (3) Screw on the oil filter until the O-ring is seated on the mounting surface. Then, give the o ...

  • Mitsubishi 4G1 - page 84

    4G1 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-1 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 1 1. PIST ONS AND CONNECTING RODS REMOV AL AND INST ALLA TION 6 7 8 10 12 4 9 11 5 1 2 3 Apply engine oil to all moving parts before installation. Removal steps " G A 1. Connecting rod nu t A A "" F A 2. Connecting ro d cap ...

  • Mitsubishi 4G1 - page 85

    4G1 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL SER VICE POINTS A A " CONNECTING ROD CAP REMOV AL (1) Mark the cylinder number on th e side of th e connecting rod big end to facilitate reassembly . A B " PISTON PIN REMOV AL (1) Insert the Push Rod (special tool) from ...

  • Mitsubishi 4G1 - page 86

    4G1 ENGINE (E - W) - Pistons and Connecting Rods (A - C) - (B - D) L= 2 1 1A-1 1-3 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 2. CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE METHOD) (1) Wipe all oil off the crankshaft pin an d connecting rod bearing. (2) On the pin, place a plastic gauge that is cut to the same length as the bearing’ s wi ...

  • Mitsubishi 4G1 - page 87

    4G1 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-4 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation (8) Mount the piston and connecting rod on the Piston Pin Setting Base (special tool) with the piston’s front mark pointing upward. (9) Install the piston pin using a press. If the press-fitting load is out of specification, replace the ...

  • Mitsubishi 4G1 - page 88

    4G1 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-5 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation " C A PISTON RING No. 2 / PISTON RING No. 1 INST ALLA TION (1) Using piston ring expander , fit No. 2 and No. 1 piston ring into position. NOTE 1. The ring en d is provided with identification mark. Item Identifica- tion mark No. 1 r ...

  • Mitsubishi 4G1 - page 89

    4G1 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-6 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation " E A CONNECTING ROD BEARING INST ALLA TION Identification mark positions No. 4 No. 1 No. 3 No. 2 B A 4G13, 4G15 4G18 Color code positions No. 4 No. 1 No. 3 No. 2 No. 4 No. 1 No. 3 No. 2 No. 2 No. 1 A B No. 3 No. 4 P P (1) Select bea ...

  • Mitsubishi 4G1 - page 90

    4G1 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-7 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation " F A CONNECTING ROD CAP INST ALLA TION (1) Aligning the marks made during disassembly , fit t he bearing cap onto the connecting rod. If the connecting rod is new and has no index mark, ensure that the bearing locking notches are bo ...

  • Mitsubishi 4G1 - page 91

    4G1 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-8 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Caution 1. If the nuts are turned by less than 90 _ , the cap may not be held on with sufficient strength. 2. If the nuts are turned by more than 100 _ , loosen them completely and carry out the tightening procedure again. PWEE9520-A E De ...

  • Mitsubishi 4G1 - page 92

    4G1 ENGINE (E - W) - Crankshaft and Cylinder Block 1 1A-12-1 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 12. CRANKSHAFT AND CYLINDER BLOCK REMOV AL AND INST ALLA TION Apply engine oil to all moving parts before installation. 18 Nm 11 11 N m 10 Nm 132 Nm 16 12 51 Nm 132 Nm 10 Nm 14 22 24 1 2 3 4 5 6 7 8 9 10 17 18 19 20 21 132 Nm 13 15 22 Nm ...

  • Mitsubishi 4G1 - page 93

    4G1 ENGINE (E - W) - Crankshaft and Cylinder Block 1 1A-12-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Removal steps 1. Flywheel bolt 2. Flywheel 3. Flywheel bolt 4. Adapter plate 5. Flywheel 6. Adapter plate 7. Crankshaft bushing 8. Drive plate bolt 9. Adapter plate 10. Drive plate 1 1. Crankshaft bushing 12. Rear plate 13. Bell housing ...

  • Mitsubishi 4G1 - page 94

    4G1 ENGINE (E - W) - Crankshaft and Cylinder Block 1 1A-12-3 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL SER VICE POINTS A A " OIL PRESSURE SWITCH REMOV AL (1) Disconnect the oil pressure switch terminals. (2) Using the special tool, remove the oil pressure switch. Caution The thread is coated with sealant. T ake care not to b ...

  • Mitsubishi 4G1 - page 95

    4G1 ENGINE (E - W) - Crankshaft and Cylinder Block 1 1A-12-4 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation (4) Using a cylinder gauge, measure each cylinder ’ s bore and cylindricity . If any cylinder is severely worn, bore all the cylinders to oversize and replace the piston and piston rings accordingly . T ake measurements at th e points ...

  • Mitsubishi 4G1 - page 96

    4G1 ENGINE (E - W) - Crankshaft and Cylinder Block 1 1A-12-5 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation " B A CRANKSHAFT BEARING INST ALLA TION 4G13, 4G15 Color code positions (type 1) No. 5 No. 2 Color code positions (type 2) No. 4 No. 3 No. 5 No. 2 No. 1 Identification mark positions No. 4 No. 3 No. 5 No. 2 No. 1 4G18 No. 4 No. 3 No ...

  • Mitsubishi 4G1 - page 97

    4G1 ENGINE (E - W) - Crankshaft and Cylinder Block 1 1A-12-6 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Crankshaft journal Cylinder block bearing diameter Bearing Range Color code Identification mark Journal diameter mm Identification mark Identification mark 1 Y ellow 1 47.995 - 48.000 0 1 1 2 2 3 2 None 2 47.985 - 49.995 0 2 1 3 2 4 3 Wh ...

  • Mitsubishi 4G1 - page 98

    4G1 ENGINE (E - W) - Crankshaft and Cylinder Block 1 1A-12-7 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation " C A BEARING CAP INST ALLA TION (1) On the bottom surface of each bearing cap is the cap’s number and an arrow . Starting at t he timing belt side, fit the bearing caps in numerical order . Ensure that the arrows point toward th ...

  • Mitsubishi 4G1 - page 99

    NOTES ...

Manufacturer Mitsubishi Category Automobile Parts

Documents that we receive from a manufacturer of a Mitsubishi 4G1 can be divided into several groups. They are, among others:
- Mitsubishi technical drawings
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- Mitsubishi product data sheets
- information booklets
- or energy labels Mitsubishi 4G1
All of them are important, but the most important information from the point of view of use of the device are in the user manual Mitsubishi 4G1.

A group of documents referred to as user manuals is also divided into more specific types, such as: Installation manuals Mitsubishi 4G1, service manual, brief instructions and user manuals Mitsubishi 4G1. Depending on your needs, you should look for the document you need. In our website you can view the most popular manual of the product Mitsubishi 4G1.

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A complete manual for the device Mitsubishi 4G1, how should it look like?
A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use Mitsubishi 4G1 by users. Manuals are usually written by a technical writer, but in a language understandable to all users of Mitsubishi 4G1.

A complete Mitsubishi manual, should contain several basic components. Some of them are less important, such as: cover / title page or copyright page. However, the remaining part should provide us with information that is important from the point of view of the user.

1. Preface and tips on how to use the manual Mitsubishi 4G1 - At the beginning of each manual we should find clues about how to use the guidelines. It should include information about the location of the Contents of the Mitsubishi 4G1, FAQ or common problems, i.e. places that are most often searched by users in each manual
2. Contents - index of all tips concerning the Mitsubishi 4G1, that we can find in the current document
3. Tips how to use the basic functions of the device Mitsubishi 4G1 - which should help us in our first steps of using Mitsubishi 4G1
4. Troubleshooting - systematic sequence of activities that will help us diagnose and subsequently solve the most important problems with Mitsubishi 4G1
5. FAQ - Frequently Asked Questions
6. Contact detailsInformation about where to look for contact to the manufacturer/service of Mitsubishi 4G1 in a specific country, if it was not possible to solve the problem on our own.

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