Mitsubishi 4G9 User Manual

GENERAL INFORMATION 11A-0-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. SPECIFICATIONS 11A-1-1. . . . .

4G9 ENGINE (E–W) – Specifications11A-1-5TORQUE SPECIFICATIONSItems NmAlternator and ignition systemOil level gauge 13Distributor 12Ignition coil 10Spa

4G9 ENGINE (E-W) -Rocker Arms and Camshafts11A-8-12aPWEE9502-CEJuly 1997Mitsubishi Motors Corporation AddedREMOVAL AND INSTALLATION <DOHC-GDI>3.

4G9 ENGINE (E-W) -Rocker Arms and Camshafts11A-8-22bPWEE9502-CEJuly 1997Mitsubishi Motors Corporation AddedIntentionally blank

4G9 ENGINE (E-W) -Rocker Arms and Camshafts11A-8-3PWEE9502EMay 1995Mitsubishi Motors CorporationREMOVAL AND INSTALLATION <DOHC-GDI for CARISMA (Up

4G9 ENGINE (E–W) – Rocker Arms and Camshafts11A-8-3aPWEE9502EMay 1995Mitsubishi Motors CorporationREMOVAL AND INSTALLATION <DOHC–GDI for CARISMA, S

4G9 ENGINE (E-W) -Rocker Arms and Camshafts11A-8-3bPWEE9502EMay 1995Mitsubishi Motors CorporationREMOVAL AND INSTALLATION <DOHC-GDI for PAJERO io -

4G9 ENGINE (E-W) -Rocker Arms and Camshafts11A-8-4PWEE9502EMay 1995Mitsubishi Motors CorporationREMOVAL AND INSTALLATION <DOHC-GDI for PAJERO io -

4G9 ENGINE (E-W) -Rocker Arms and Camshafts11A-8-5REMOVAL SERVICE POINTAA"LASH ADJUSTER REMOVALCautionDIf the lash adjuster is re-used, clean the

4G9 ENGINE (E-W) -Rocker Arms and Camshafts11A-8-6"EAOIL SEAL INSTALLATION"FALASH ADJUSTER INSTALLATIONCautionDIf the lash adjuster is re-us

4G9 ENGINE (E-W) -Rocker Arms and Camshafts11A-8-7PWEE9502EMay 1995Mitsubishi Motors Corporation(3) The bearing caps No. 2 through No. 5 are of the sa

4G9 ENGINE (E-W) -Rocker Arms and Camshafts11A-8-8PWEE9502EMay 1995Mitsubishi Motors Corporation(4) Apply sealant to the illustrated position of the c

4G9 ENGINE (E–W) – Specifications11A-1-6Items NmFuel system and emission systemBreather tube 21Fuel pump 18Carburetor 17EGR valve 21Cover <Withou

4G9 ENGINE (E-W) -Rocker Arms and Camshafts11A-8-9PWEE9502EMay 1995Mitsubishi Motors Corporation"JASEALANT APPLICATION ON SEMI-CIRCULARPACKINGSpe

4G9 ENGINE (E-W) -Rocker Arms and Camshafts11A-8-9aPWEE9502EMay 1995Mitsubishi Motors Corporation(6) Adjust the valve clearances indicated by arrows i

4G9 ENGINE (E-W) -Rocker Arms and Camshafts11A-8-9bPWEE9502EMay 1995Mitsubishi Motors CorporationIntentionallyblankPWEE9502-HEJuly 2000Mitsubishi Moto

4G9 ENGINE (E–W) – Rocker Arms and Camshafts11A-8-10PWEE9502EMay 1995Mitsubishi Motors CorporationINSPECTIONCAMSHAFT(1) Measure the cam height.Standar

4G9 ENGINE (E-W) -Rocker Arms and Camshafts11A-8-11PWEE9502EMay 1995Mitsubishi Motors Corporation(2) Place the lash adjuster in container A and clean

4G9 ENGINE (E-W) -Rocker Arms and Camshafts11A-8-12PWEE9502EMay 1995Mitsubishi Motors Corporation(6) Remove the lash adjuster from the container. Then

4G9 ENGINE (E-W) -Rocker Arms and Camshafts11A-8-13PWEE9502EMay 1995Mitsubishi Motors Corporation(DOHC)Caution1. The lash adjusters are precision-engi

4G9 ENGINE (E-W) -Rocker Arms and Camshafts11A-8-14PWEE9502EMay 1995Mitsubishi Motors Corporation(4) Remove the lash adjuster from the container. Then

4G9 ENGINE (E-W) -Rocker Arms and Camshafts11A-8-15PWEE9502EMay 1995Mitsubishi Motors Corporation(9) Remove the lash adjuster from the container, then

4G9 ENGINE (E-W) -Rocker Cover and Camshafts (MIVEC)11A-8a-1PWEE9502-AENov. 1995Mitsubishi Motors CorporationAdded8a. ROCKER COVER AND CAMSHAFTS (MIVE

4G9 ENGINE (E–W) – Specifications11A-1-6aItems NmIntake manifold and exhaust manifoldExhaust manifold (M8) 18Exhaust manifold (M10) 29Exhaust manifold

4G9 ENGINE (E-W) -Rocker Cover and Camshafts (MIVEC)11A-8a-2PWEE9502-AENov. 1995Mitsubishi Motors Corporation AddedINSPECTION1. OIL CONTROL VALVE(1) C

4G9 ENGINE (E-W) -Rocker Cover and Camshafts (MIVEC)11A-8a-3PWEE9502-AENov. 1995Mitsubishi Motors CorporationAddedINSTALLATION SERVICE POINTS"AAS

4G9 ENGINE (E-W) -Rocker Cover and Camshafts (MIVEC)11A-8a-4PWEE9502-AENov. 1995Mitsubishi Motors Corporation Added(2) Apply the specified sealant to

4G9 ENGINE (E-W) -Rocker Cover and Camshafts (MIVEC)11A-8a-5PWEE9502-AENov. 1995Mitsubishi Motors CorporationAdded"GAROCKER COVER INSTALLATIONApp

4G9 ENGINE (E-W) -Rocker Arms and Rocker Shaft Caps (MIVEC)11A-8b-1PWEE9502-AENov. 1995Mitsubishi Motors CorporationAdded8b. ROCKER ARMS AND ROCKER SH

4G9 ENGINE (E-W) -Rocker Arms and Rocker Shaft Caps (MIVEC)11A-8b-2PWEE9502-AENov. 1995Mitsubishi Motors Corporation AddedINSTALLATION SERVICE POINT&q

4G9 ENGINE (E-W) -Cylinder Head and Valves11A-9-1PWEE9502EMay 1995Mitsubishi Motors Corporation9. CYLINDER HEAD AND VALVES11300690072REMOVAL AND INSTA

4G9 ENGINE (E-W) -Cylinder Head and Valves11A-9-2PWEE9502EMay 1995Mitsubishi Motors CorporationREMOVAL AND INSTALLATION <DOHC>Lubricate all inte

4G9 ENGINE (E-W) -Cylinder Head and Valves11A-9-3PWEE9502-AENov. 1995Mitsubishi Motors CorporationRevisedREMOVAL AND INSTALLATION <DOHC-MIVEC>Ap

4G9 ENGINE (E-W) -Cylinder Head and Valves11A-9-43aPWEE9502-CEJuly 1997Mitsubishi Motors Corporation AddedREMOVAL AND INSTALLATION <DOHC-GDI>App

4G9 ENGINE (E–W) – Specifications11A-1-6bItems NmExhaust manifold (M8) 17Exhaust manifold (M10) 29Injector and fuel pump assembly (GDI)Fuel low pres

4G9 ENGINE (E-W) -Cylinder Head and Valves11A-9-53bPWEE9502-CEJuly 1997Mitsubishi Motors CorporationAddedIntentionally blank

4G9 ENGINE (E-W) -Cylinder Head and Valves11A-9-4PWEE9502-AENov. 1995Mitsubishi Motors Corporation RevisedREMOVAL SERVICE POINTSAA"CYLINDER HEAD

4G9 ENGINE (E-W) -Cylinder Head and Valves11A-9-5PWEE9502-AENov. 1995Mitsubishi Motors CorporationRevisedAC"VALVE STEM SEAL REMOVALAD"VALVE

4G9 ENGINE (E-W) -Cylinder Head and Valves11A-9-6PWEE9502-AENov. 1995Mitsubishi Motors Corporation RevisedCautionDValves must be neutralized one at a

4G9 ENGINE (E-W) -Cylinder Head and Valves11A-9-7PWEE9502-AENov. 1995Mitsubishi Motors CorporationRevised"BAVALVE SPRING INSTALLATION(1) Install

4G9 ENGINE (E-W) -Cylinder Head and Valves11A-9-8PWEE9502-AENov. 1995Mitsubishi Motors Corporation Revised(4) According to the tightening sequence, ti

4G9 ENGINE (E-W) -Cylinder Head and Valves11A-9-9PWEE9502-CEJuly 1997Mitsubishi Motors CorporationRevisedINSPECTIONCYLINDER HEAD(1) Check the cylinder

4G9 ENGINE (E–W) – Cylinder Head and Valves11A-9-10PWEE9502-AENov. 1995Mitsubishi Motors CorporationRevisedVALVE SPRING(1) Measure the valve spring’s

4G9 ENGINE (E-W) -Cylinder Head and Valves11A-9-11PWEE9502-CEJuly 1997Mitsubishi Motors CorporationRevisedVALVE SEAT RECONDITIONING PROCEDURE(1) Befor

4G9 ENGINE (E-W) -Cylinder Head and Valves11A-9-12PWEE9502-AENov. 1995Mitsubishi Motors Corporation Added(3) Press-fit the valve guide until it protru

4G9 ENGINE (E–W) – Specifications11A-1-6cItems NmWater inlet fitting <Except PAJERO io> 19Water inlet fitting <PAJERO io> 24Water by-pas

4G9 ENGINE (E–W) – Front Case and Oil Pump11A-10-1PWEE9502EMay 1995Mitsubishi Motors Corporation10. FRONT CASE AND OIL PUMPREMOVAL AND INSTALLATION &l

4G9 ENGINE (E–W) – Front Case and Oil pump11A-10-1aPWEE9502EMay 1995Mitsubishi Motors CorporationREMOVAL AND INSTALLATION <SOHC (4G94 Except for PA

4G9 ENGINE (E–W) – Front Case and Oil pump11A-10-1bPWEE9502EMay 1995Mitsubishi Motors CorporationREMOVAL AND INSTALLATION <SOHC (4G94 for PAJERO

4G9 ENGINE (E–W) – Front Case and Oil pump11A-10-2PWEE9502EMay 1995Mitsubishi Motors CorporationREMOVAL AND INSTALLATION <DOHC (Except GDI for PAJE

4G9 ENGINE (E–W) – Front Case and Oil pump11A-10-3PWEE9502EMay 1995Mitsubishi Motors CorporationREMOVAL AND INSTALLATION <DOHC–GDI for PAJERO io>

4G9 ENGINE (E-W) -Front Case and Oil Pump11A-10-4REMOVAL SERVICE POINTSAA"OIL PAN REMOVAL(1) Knock in the special tool deeply between the oil pan

4G9 ENGINE (E–W) – Front Case and Oil Pump11A-10-5PWEE9502EMay 1995Mitsubishi Motors Corporation"CA CRANKSHAFT FRONT OIL SEAL INSTALLATIONUsing t

4G9 ENGINE (E–W) – Front Case and Oil Pump11A-10-6PWEE9502EMay 1995Mitsubishi Motors Corporation(4) Tighten the lower oil pan mounting bolts in the

4G9 ENGINE (E-W) -Front Case and Oil Pump11A-10-7(2) Check the side clearance.Standard value: 0.04 - 0.10 mm(3) Check the body clearance.Standard valu

4G9 ENGINE (E-W) -Piston and Connecting Rod11A-11-1PWEE9502EMay 1995Mitsubishi Motors Corporation11. PISTON AND CONNECTING RODREMOVAL AND INSTALLATION

4G9 ENGINE (E–W) – Specifications11A-1-6dItems NmUpper oil pan (M8) 24Lower oil pan 11Cover 7Baffle plate <DOHC–MPI> 7Baffle plate <Except

4G9 ENGINE (E-W) -Piston and Connecting Rod11A-11-2PWEE9502-AENov. 1995Mitsubishi Motors CorporationRevisedREMOVAL SERVICE POINTSAA"CONNECTING RO

4G9 ENGINE (E–W) – Piston and Connecting Rod11A-11-3PWEE9502EMay 1995Mitsubishi Motors CorporationINSTALLATION SERVICE POINTS"AA PISTON PIN INSTA

4G9 ENGINE (E–W) – Piston and Connecting Rod11A-11-4PWEE9502EMay 1995Mitsubishi Motors Corporation(9) Place the piston and connecting rod assembly o

4G9 ENGINE (E–W) – Piston and Connecting Rod11A-11-5PWEE9502EMay 1995Mitsubishi Motors Corporation"CA PISTON RING NO.2/PISTON RING NO.1INSTALLATI

11A-11-6PWEE9502EMay 1995Mitsubishi Motors Corporation"EA CONNECTING ROD BEARING INSTALLATION(1) When the bearings are to be replaced, select cor

4G9 ENGINE (E–W) – Piston and Connecting Rod4G9 ENGINE (E–W) – Piston and Connecting Rod11A-11-7PWEE9502EMay 1995Mitsubishi Motors Corporation&quo

4G9 ENGINE (E–W) – Piston and Connecting Rod11A-11-8PWEE9502EMay 1995Mitsubishi Motors CorporationINSPECTION 11300850074PISTON RING(1) Check the cle

4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate11A-12-1PWEE9502-CEJuly 1997Mitsubishi Motors Corporation Revised12. CRANKSHAFT

4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate11A-12-1aREMOVAL AND INSTALLATION (AUTOMATIC TRANSMISSION)11 Nm1213141516172071

4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate11A-12-1bREMOVAL AND INSTALLATION <PAJERO io>11 Nm98 Nm11 NmApply engine

4G9 ENGINE (E-W) -Specifications11A-1-7NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED IN PLASTICAREAA new type of bolts, to be tightened in p

4G9 ENGINE (E -W)-Crankshaft, Cylinder Block, Flywheel and Drive Plate11A-12-2PWEE9502-AENov. 1995Mitsubishi Motors Corporation RevisedREMOVAL SERVICE

4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate11A-12-3PWEE9502-AENov. 1995Mitsubishi Motors Corporation RevisedOil pan viewNo

4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate11A-12-4PWEE9502-AENov. 1995Mitsubishi Motors Corporation Revised"CA BEA

4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate11A-12-5PWEE9502-AENov. 1995Mitsubishi Motors Corporation Revised"DA OIL

4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate11A-12-6PWEE9502-AENov. 1995Mitsubishi Motors Corporation RevisedCYLINDER BLO

4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate11A-12-7PWEE9502-AENov. 1995Mitsubishi Motors Corporation RevisedCautionTo pr

NOTES

Service BulletinsClick on the applicable bookmark to select the Service Bulletin.

SERVICE BULLETINQUALITY INFORMATION ANALYSISOVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATIONSERVICE BULLETINNo.: MSB-99E11-001Date: 1999-12-15<

2• Crankshaft weightFrontJournal O.D.identificationmarkJournal O.D.identificationmarkPin O.D.identificationmarkPin O.D.identificationmarkNewOld

4G9 ENGINE (E-W) -Specifications11A-1-8PWEE9502EMay 1995Mitsubishi Motors CorporationFORM-IN-PLACE GASKETThe engine has several areas where the form-i

SERVICE PUBLICATION & TRAININGINTERNATIONAL AFTER-SALES DEPARTMENT. MITSUBISHI MOTORS CORPORATION1MSB–03E11–001SERVICE BULLETINNO. : MSB–03E11–00

2MSB–03E11–001AttachmentApplicable Manuals:ManualPub. No. PageENGINE 4G6 (E–W) Wkh M lPWEE9616 (English) 11A-5a-1, 11A 5 2Workshop ManualPWES9617 (Spa

4G9 ENGINE (E-W) -Special Tools11A-2-1PWEE9502-AENov. 1995Mitsubishi Motors Corporation Revised2. SPECIAL TOOLSTool Number Name UseMB990938 Handle Use

4G9 ENGINE (E-W) -Special Tools11A-2-2PWEE9502-AENov. 1995Mitsubishi Motors CorporationRevisedTool UseNameNumberMD998719 Pulley holder pin(2)Use with

11A-0-2PWEE9502EMay 1995Mitsubishi Motors CorporationNOTES

4G9 ENGINE (E-W) -Special Tools11A-2-3PWEE9502-AENov. 1995Mitsubishi Motors Corporation RevisedTool UseNameNumberMD998780 SETTING TOOLPiston pinRemova

4G9 ENGINE (E–W) – Alternator and Ignition System11A-3-13. ALTERNATOR AND IGNITION SYSTEMREMOVAL AND INSTALLATION <SOHC> (Engines with distribut

4G9 ENGINE (E–W) – Alternator and Ignition System11A-3-2REMOVAL AND INSTALLATION <SOHC for other than PAJERO io> (Engines without distributor)

4G9 ENGINE (E–W) – Alternator and Ignition System11A-3-2aREMOVAL AND INSTALLATION <SOHC for PAJERO io> (Engines without distributor)5 Nm23 Nm25

4G9 ENGINE (E-W) -Alternator and Ignition System11A-3-2bIntentionally blankPWEE9502-EEDec. 1998Mitsubishi Motors Corporation Added

4G9 ENGINE (E–W) – Alternator and Ignition System11A-3-3PWEE9502-AENov. 1995Mitsubishi Motors CorporationREMOVAL AND INSTALLATION <DOHC>10 Nm25

4G9 ENGINE (E–W) – Alternator and Ignition System11A-3-4PWEE9502-AENov. 1995Mitsubishi Motors Corporation AddedREMOVAL AND INSTALLATION <DOHC–MIV

4G9 ENGINE (E–W) – Alternator and Ignition System11A-3-5PWEE9502-AENov. 1995Mitsubishi Motors CorporationREMOVAL AND INSTALLATION <DOHC–GDI for C

4G9 ENGINE (E–W) – Alternator and Ignition System11A-3-6PWEE9502-AENov. 1995Mitsubishi Motors Corporation AddedREMOVAL AND INSTALLATION <DOHC–GDI

4G9 ENGINE (E–W) – Alternator and Ignition System11A-3-7PWEE9502-AENov. 1995Mitsubishi Motors CorporationREMOVAL SERVICE POINTAA" CRANKSHAFT BOLT

4G9 ENGINE (E-W) -General Information11A-0-3PWEE9502-CEJuly 1997Mitsubishi Motors Corporation RevisedGENERAL INFORMATION4G92Descriptions 4G92-SOHC 4G9

4G9 ENGINE (E–W) – Timing Belt11A-4-14. TIMING BELTREMOVAL AND INSTALLATION <SOHC for CARISMA (Up to 1999 model),LANCER (Except from 2001 model for

4G9 ENGINE (E–W) – Timing Belt11A-4-1aREMOVAL AND INSTALLATION <SOHC for CARISMA (From 2000 model), LANCER (From 2001 model forEurope), SPACE STAR&

4G9 ENGINE (E-W) -Timing Belt11A-4-1bIntentionallyblankPWEE9502-GEMay 2000Mitsubishi Motors Corporation Added

4G9 ENGINE (E–W) – Timing Belt11A-4-2REMOVAL AND INSTALLATION <SOHC for PAJERO io>11 Nm88 Nm11 Nm23 Nm49 Nm1110145326789129.8 Nm1413Removal step

4G9 ENGINE (E–W) – Timing Belt11A-4-2aREMOVAL AND INSTALLATION <DOHC>88 Nm11 Nm11 Nm36 Nm44 Nm11 Nm49 Nm13 Nm11 Nm9.8 Nm201298321517184196107131

4G9 ENGINE (E–W) – Timing Belt11A-4-2bREMOVAL AND INSTALLATION <DOHC–MIVEC>11 Nm88 Nm11 Nm35 Nm11 Nm49 Nm111014532678911 Nm18171648 Nm12141315

4G9 ENGINE (E–W) – Timing Belt11A-4-2cREMOVAL AND INSTALLATION <DOHC–GDI for CARISMA, SPACE STAR, SPACE RUNNER>2111 Nm88 Nm11 Nm35 Nm11 Nm49 N

4G9 ENGINE (E–W) – Timing Belt11A-4-2dREMOVAL AND INSTALLATION <DOHC–GDI for GALANT>11 Nm88 Nm11 Nm35 Nm11 Nm49 Nm1110145326789181748 Nm121413

4G9 ENGINE (E–W) – Timing Belt11A-4-2eREMOVAL AND INSTALLATION <DOHC–GDI for PAJERO io>11 Nm88 Nm11 Nm35 Nm11 Nm49 Nm111014532678911 Nm191848

4G9 ENGINE (E-W) -Timing Belt11A-4-2fIntentionallyblankPWEE9502-GEMay 2000Mitsubishi Motors Corporation Added

4G9 ENGINE (E-W) -General Information11A-0-44G93Descriptions 4G93- SOHC 4G93-DOHC 4G93-DOHC-GDIType In-line OHV, SOHC In-line OHV, DOHC In-line OHV, D

4G9 ENGINE (E-W) -Timing Belt11A-4-3PWEE9502-AENov. 1995Mitsubishi Motors Corporation RevisedREMOVAL SERVICE POINTSAA"TIMING BELT REMOVAL(1) Mark

4G9 ENGINE (E-W) -Timing belt11A-4-4PWEE9502EMay 1995Mitsubishi Motors Corporation"BATIMING BELT TENSIONER INSTALLATION(1) Le t the pulley of the

4G9 ENGINE (E-W) -Timing Belt11A-4-5PWEE9502-AENov. 1995Mitsubishi Motors Corporation Revised(6) Slightly loosen the tensioner pulley fixing bolt whic

4G9 ENGINE (E-W) -Timing Belt11A-4-6PWEE9502-AENov. 1995Mitsubishi Motors Corporation Revised"FATIMING BELT INSTALLATION(1) Make sure that the au

4G9 ENGINE (E-W) -Timing Belt11A-4-7PWEE9502EMay 1995Mitsubishi Motors Corporation(6) Secure the timing belt with a paper clip at the illustratedposit

4G9 ENGINE (E–W) – Timing Belt11A-4-8PWEE9502EMay 1995Mitsubishi Motors Corporation(12)Install the special tool and a torque wrench to the tensionerpu

4G9 ENGINE (E-W) -Timing Belt11A-4-9PWEE9502EMay 1995Mitsubishi Motors Corporation(6) Abnormal wear of belt sides. The sides are normal ifthey are sha

4G9 ENGINE (E-W) -Fuel and Emission Control System11A-5-1PWEE9502-BENov. 1996Mitsubishi Motors CorporationRevised5. FUEL AND EMISSION CONTROL SYSTEMRE

4G9 ENGINE (E–W) – Fuel and Emission Control System11A-5-2PWEE9502-BENov. 1996Mitsubishi Motors Corporation RevisedREMOVAL AND INSTALLATION <SOHC–M

4G9 ENGINE (E–W) – Fuel and Emission Control System11A-5-3PWEE9502-BENov. 1996Mitsubishi Motors CorporationRevisedREMOVAL AND INSTALLATION <SOHC–MP

4G9 ENGINE (E–W) – General Information11A-0-5PWEE9502-CEJuly 1997Mitsubishi Motors Corporation Revised4G94Descriptions 4G94–SOHC 4G94–DOHC–GDIType In-

4G9 ENGINE (E–W) – Fuel and Emission Control System11A-5-4PWEE9502-BENov. 1996Mitsubishi Motors CorporationRevisedREMOVAL AND INSTALLATION <DOHC&

4G9 ENGINE (E-W) -Fuel and Emission Control System11A-5-5INSTALLATION SERVICE POINTS"AAINJECTORS INSTALLATION(1) Apply a small amount of new engi

4G9 ENGINE (E-W) -Fuel and Emission Control System11A-5-6PWEE9502-EEDec. 1998Mitsubishi Motors Corporation Added<SOHC-MPIforPAJERO io>Projection

4G9 ENGINE (E-W) -Throttle Body and EGR System (GDI)11A-5a-15a. THROTTLE BODY AND EGR SYSTEM (GDI)REMOVAL AND INSTALLATION <Up to 2000 model for CA

4G9 ENGINE (E–W) – Throttle Body and EGR System (GDI)11A-5a-2REMOVAL AND INSTALLATION <From 2001 model for CARISMA, SPACE STAR and GALANT>18 Nm3

4G9 ENGINE (E-W) -Throttle Body and EGR System (GDI)11A-5a-3REMOVAL AND INSTALLATION <For PAJERO io - 4G93>13 Nm23 Nm18 Nm146101928471331611 Nm1

4G9 ENGINE (E-W) -Throttle Body and EGR System (GDI)11A-5a-4REMOVAL AND INSTALLATION <For PAJERO io - 4G94>13 Nm23 Nm18 Nm156111928471431611 Nm1

4G9 ENGINE (E-W) -Throttle Body and EGR System (GDI)11A-5a-5INSTALLATION SERVICE POINTS"AATHROTTLE BODY GASKET"BAINTAKE MANIFOLD STAY INSTAL

4G9 ENGINE (E–W) – Intake and Exhaust Manifold11A-6-1PWEE9502-BENov. 1996Mitsubishi Motors CorporationRevised6. INTAKE AND EXHAUST MANIFOLDREMOVAL AND

4G9 ENGINE (E–W) – Intake and Exhaust Manifold11A-6-2PWEE9502-BENov. 1996Mitsubishi Motors Corporation RevisedREMOVAL AND INSTALLATION <SOHC–MPI–

4G9 ENGINE (E–W) – Specifications11A-1-11. SPECIFICATIONSSERVICE SPECIFICATIONSItems Standard value LimitTiming beltAuto-tensioner rod protrusion amou

4G9 ENGINE (E–W) – Intake and Exhaust Manifold11A-6-2aPWEE9502-BENov. 1996Mitsubishi Motors CorporationRevisedREMOVAL AND INSTALLATION <SOHC–MPI–FR

4G9 ENGINE (E–W) – Intake and Exhaust Manifold11A-6-2bPWEE9502-BENov. 1996Mitsubishi Motors Corporation RevisedREMOVAL AND INSTALLATION <SOHC–MPI

4G9 ENGINE (E–W) – Intake and Exhaust Manifold11A-6-2cPWEE9502-BENov. 1996Mitsubishi Motors CorporationRevisedREMOVAL AND INSTALLATION <SOHC–MPI –

4G9 ENGINE (E–W) – Intake and Exhaust Manifold11A-6-2dPWEE9502-BENov. 1996Mitsubishi Motors CorporationRevisedREMOVAL AND INSTALLATION <SOHC–MPI

4G9 ENGINE (E–W) – Intake and Exhaust Manifold11A-6-2ePWEE9502-BENov. 1996Mitsubishi Motors CorporationRevisedREMOVAL AND INSTALLATION <SOHC–MPI

4G9 ENGINE (E–W) – Intake and Exhaust Manifold11A-6-2fPWEE9502-BENov. 1996Mitsubishi Motors CorporationRevisedIntentionally blankPWEE9502-KEJun. 200

4G9 ENGINE (E–W) – Intake and Exhaust Manifold11A-6-3PWEE9502-BENov. 1996Mitsubishi Motors CorporationRevisedREMOVAL AND INSTALLATION <DOHC>20 N

4G9 ENGINE (E–W) – Intake and Exhaust Manifold11A-6-4PWEE9502-BENov. 1996Mitsubishi Motors CorporationAddedINSTALLATION SERVICE POINT"AA EXHAUS

4G9 ENGINE (E-W) -Intake Manifold (GDI)11A-6a-1PWEE9502-DEJun. 1998Mitsubishi Motors CorporationRevised6a. INTAKE MANIFOLD (GDI)REMOVAL AND INSTALLATI

4G9 ENGINE (E–W) – Intake Manifold (GDI)11A-6a-1aPWEE9502-DEJun. 1998Mitsubishi Motors Corporation AddedREMOVAL AND INSTALLATION <From 2001 model f

4G9 ENGINE (E–W) – Specifications11A-1-2Items Standard value LimitCylinder head and valveCylinder head gasket surface flatness mm Less than 0.03 0.2

4G9 ENGINE (E-W) -Intake Manifold (GDI)11A-6a-1bPWEE9502-DEJun. 1998Mitsubishi Motors CorporationRevisedIntentionallyblankPWEE9502-GEMay 2000Mitsubish

4G9 ENGINE (E-W) -Intake Manifold (GDI)11A-6a-2PWEE9502-DEJun. 1998Mitsubishi Motors Corporation AddedREMOVAL AND INSTALLATION <For SPACE RUNNER>

4G9 ENGINE (E-W) -Intake Manifold (GDI)11A-6a-3REMOVAL AND INSTALLATION <For PAJERO io>9Nm19 Nm23 Nm810195632411 Nm11 Nm9Nm30 Nm79Nm9NmRemoval s

4G9 ENGINE (E-W) -Intake Manifold (GDI)11A-6a-4INSTALLATION SERVICE POINT"AAINTAKE MANIFOLD STAY INSTALLATION(1) Check to ensure that the intake

4G9 ENGINE (E-W) -Exhaust Manifold (GDI)11A-6b-16b. EXHAUST MANIFOLD (GDI)REMOVAL AND INSTALLATION <For CARISMA, SPACE STAR, SPACE RUNNER>17 Nm3

11A-6b-1aREMOVAL AND INSTALLATION <For GALANT>17 Nm19 Nm35 Nm 13 Nm911054732629 Nm13 Nm13 Nm44 Nm24 Nm35 Nm118Removal steps1. Oil level gauge2.

4G9 ENGINE (E-W) -Exhaust Manifold (GDI)11A-6b-1bIntentionallyblankPWEE9502-GEMay 2000Mitsubishi Motors Corporation Added

4G9 ENGINE (E-W) -Exhaust Manifold (GDI)11A-6b-2REMOVAL AND INSTALLATION <For PAJERO io>17 Nm13 Nm1352429 Nm18 Nm98 Nm29 NmRemoval steps1. Exhau

4G9 ENGINE (E-W) -Exhaust Manifold (GDI)11A-6b-3INSTALLATION SERVICE POINTS"AAEXHAUST MANIFOLD BRACKET INSTALLATION(1) Slide the washers over the

4G9 ENGINE (E-W) -Injector and Fuel Pump Assembly (GDI)11A-6c-16c. INJECTOR AND FUEL PUMP ASSEMBLY (GDI)REMOVAL AND INSTALLATION <Up to 2000 model

4G9 ENGINE (E–W) – Specifications11A-1-3Items LimitStandard valueValve stem projec-tion mmSOHC Intake 49.30 49.80tion mmExhaust 49.35 49.85DOHC Inta

4G9 ENGINE (E–W) – Injector and Fuel Pump Assembly (GDI)11A-6c-1aREMOVAL AND INSTALLATION <From 2001 model for CARISMA, SPACE STAR and GALANT>14

4G9 ENGINE (E-W) -Injector and Fuel Pump Assembly (GDI)11A-6c-1bREMOVAL AND INSTALLATION <For PAJERO io - 4G94>1413101219114321551819232211 Nm22

4G9 ENGINE (E-W) -Injector and Fuel Pump Assembly (GDI)11A-6c-2REMOVAL AND INSTALLATION <For PAJERO io - 4G93>2818 Nm17±2Nm9Nm141087196521541617

4G9 ENGINE (E-W) -Injector and Fuel Pump Assembly (GDI)11A-6c-3INSTALLATION SERVICE POINTS"AABACKUP RING / O-RING / CORRUGATEDWASHER INSTALLATION

4G9 ENGINE (E-W) -Injector and Fuel Pump Assembly (GDI)11A-6c-4(8) Tighten the fasteners of the delivery pipe a n d injectorassembly to the specified

4G9 ENGINE (E-W) -Injector and Fuel Pump Assembly (GDI)11A-6c-5(2) Fit the backup rings and the O-ring on both ends of thefuel return pipe. Note that

4G9 ENGINE (E-W) -Injector and Fuel Pump Assembly (GDI)11A-6c-6"GAO-RING / FUEL PUMP INSTALLATION(1) Apply engine oil to the roller of the fuel p

4G9 ENGINE (E-W) -Injector and Fuel Pump Assembly (GDI)11A-6c-7"IAO-RING / BACKUP RING / FUEL PRESSURESENSOR INSTALLATION(1) Fit the backup ring

4G9 ENGINE (E-W) -Intake and Exhaust Manifold <4G94- GDI for PAJERO io>11A-6d-16d. INTAKE AND EXHAUST MANIFOLD<4G94-GDI for PAJERO io>REMO

4G9 ENGINE (E-W) -Intake and Exhaust Manifold <4G94- GDI for PAJERO io>11A-6d-2INSTALLATION SERVICE POINTS"AAEXHAUST MANIFOLD BRACKET INSTA

4G9 ENGINE (E–W) – Specifications11A-1-4Items LimitStandard valueCylinder block overall height mm 4G92 243.5 –4G93 263.5 –4G94 286.7 –Cylinder block

4G9 ENGINE (E–W) – Water Pump and Water Hose11A-7-1PWEE9502-BENov. 1996Mitsubishi Motors CorporationRevised7. WATER PUMP AND WATER HOSE 11301790016REM

4G9 ENGINE (E–W) – Water Pump and Water Hose11A-7-2PWEE9502EMay 1995Mitsubishi Motors CorporationREMOVAL AND INSTALLATION <SOHC – REAR WHEEL DRIV

4G9 ENGINE (E–W) – Water Pump and Water Hose11A-7-3PWEE9502-BENov. 1996Mitsubishi Motors CorporationRevisedREMOVAL AND INSTALLATION <DOHC – FRONT

4G9 ENGINE (E–W) – Water Pump and Water Hose11A-7-4PWEE9502EMay 1995Mitsubishi Motors CorporationREMOVAL AND INSTALLATION <DOHC – REAR WHEEL DRIV

4G9 ENGINE (E–W) – Water Pump and Water Hose11A-7-5PWEE9502-BENov. 1996Mitsubishi Motors CorporationRevisedINSTALLATION SERVICE POINTS"AA WATER

4G9 ENGINE (E–W) – Water Pump and Water Hose11A-7-6PWEE9502EMay 1995Mitsubishi Motors Corporation"FA ENGINE COOLANT TEMPERATURE GAUGE UNITINSTA

4G9 ENGINE (E–W) – Rocker Arms and Camshafts11A-8-1PWEE9502EMay 1995Mitsubishi Motors Corporation8. ROCKER ARMS AND CAMSHAFTS 11300540070REMOVAL AND I

4G9 ENGINE (E–W) – Rocker Arms and Camshafts11A-8-1aPWEE9502EMay 1995Mitsubishi Motors CorporationREMOVAL AND INSTALLATION <SOHC (with Lash adjuste

4G9 ENGINE (E-W) -Rocker Arms and Camshafts11A-8-1bPWEE9502EMay 1995Mitsubishi Motors CorporationIntentionallyblankPWEE9502-GEMay 2000Mitsubishi Motor

4G9 ENGINE (E-W) -Rocker Arms and Camshafts11A-8-2PWEE9502EMay 1995Mitsubishi Motors CorporationREMOVAL AND INSTALLATION <DOHC>3723.5 Nm415611 N