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Mitsubishi 4G9 4G9 ENGINE (E - W)

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11A-3-2b4G9 ENGINE (E - W) - Alternator and Ignition System

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E Mitsubishi Motors Corporation

Dec. 1998

PWEE9502-E

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Contents

CONTENTS Page GENERAL INFORMATION 4G9 ENGINE (E-W)- General Information 4G93 4G9 ENGINE (E–W)– General Information 4G94 1. SPECIFICATIONS Page Page REWORK DIMENSIONS TORQUE SPECIFICATIONS Page Page Page Page Page 4G9 ENGINE (E-W)- Specifications NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA SEALANT 4G9 ENGINE (E - W) - Specifications FORM-IN-PLACEGASKET 2. SPECIAL TOOLS Page Page 3. ALTERNATOR AND IGNITION SYSTEM Page REMOVAL AND INSTALLATION <SOHC for PAJERO io> (Engines without distributor) 4G9 ENGINE (E - W) REMOVAL AND INSTALLATION <DOHC –MIVEC <DOHC–GDIfor CARISMA, SPACE STAR, SPACE RUNNER, GALANT –GDI for PAJERO io REMOVAL SERVICE POINT INSTALLATION SERVICE POINTS 4. TIMING BELT 11A-4-1a4G9 ENGINE (E–W)– Timing Belt REMOVAL AND INSTALLATION 4G9 ENGINE (E-W)- Timing Belt REMOVAL AND INSTALLATION <SOHC for PAJERO io Page 11A-4-2b4G9 ENGINE (E–W)– Timing Belt REMOVAL AND INSTALLATION <DOHC–MIVEC <DOHC–GDIfor CARISMA, SPACE STAR, SPACE RUNNER REMOVAL AND INSTALLATION <DOHC–GDIfor GALANT REMOVAL AND INSTALLATION <DOHC–GDIfor PAJERO io Page 4G9 ENGINE (E - W) - Timing Belt REMOVAL SERVICE POINTS 4G9 ENGINE (E - W) - Timing belt Page Page Page 11A-4-84G9 ENGINE (E–W)– Timing Belt INSPECTION Page 5. FUEL AND EMISSION CONTROL SYSTEM REMOVAL AND INSTALLATION <SOHC–MPIfor other than PAJERO io REMOVAL AND INSTALLATION <SOHC–MPIfor PAJERO io Page Page Page 5a. THROTTLE BODY AND EGR SYSTEM (GDI) <From 2001 model for CARISMA, SPACE STAR and GALANT REMOVAL AND INSTALLATION <For PAJERO io - 4G93 REMOVAL AND INSTALLATION <For PAJERO io - 4G94 Page 6. INTAKE AND EXHAUST MANIFOLD REMOVAL AND <SOHC Page –MPI–FRONT WHEEL DRIVE (4G94) <SOHC–MPI– REAR WHEEL DRIVE (4G93 – Except from 2002 model for Europe) <SOHC–MPI– REAR WHEEL DRIVE (4G93 – from 2002 model for Europe) REMOVAL AND INSTALLATION–MPI– REAR<SOHCWHEEL DRIVE (4G94) Page Page INSTALLATION SERVICE POINT 6a. INTAKE MANIFOLD (GDI) Page Page 11A-6a-2 4G9 ENGINE (E - W) - Intake Manifold (GDI) REMOVAL AND INSTALLATION <For SPACE RUNNER 4G9 ENGINE (E - W) - Intake Manifold (GDI) REMOVAL AND INSTALLATION <For PAJERO io 11A-6a-4 4G9 ENGINE (E - W) - Intake Manifold (GDI) INSTALLATION SERVICE POINT 6b. EXHAUST MANIFOLD (GDI) REMOVAL AND INSTALLATION <For GALANT Page Page Page 6c. INJECTOR AND FUEL PUMP ASSEMBLY (GDI) Page Page Page Page Page Page Page Page 6d. INTAKE AND EXHAUST MANIFOLD <4G94-GDIfor PAJERO io Page 7. WATER PUMP AND WATER HOSE – REAR WHEEL DRIVE – FRONT REMOVAL AND INSTALLATION– REAR<DOHCWHEEL DRIVE Page Page 8. ROCKER ARMS AND CAMSHAFTS REMOVAL AND INSTALLATION <SOHC (with Lash adjuster) Page Page 11A-8-2a1 REMOVAL AND INSTALLATION <DOHC - GDI Page Page Page REMOVAL AND INSTALLATION <DOHC-GDIfor PAJERO io - 4G94 REMOVAL AND INSTALLATION <DOHC-GDIfor PAJERO io - 4G93 Page Page Page Page Page Page Page Page Page Page Page Page Page 8a. ROCKER COVER AND CAMSHAFTS (MIVEC) Page Page Page VALVE CLEARANCE ADJUSTMENT ROCKER ARM PISTON INSPECTION 8b. ROCKER ARMS AND ROCKER SHAFT CAPS (MIVEC) Page 9. CYLINDER HEAD AND VALVES Page REMOVAL AND INSTALLATION <DOHC - MIVEC Page 11A-9-3b5 Page Page Page Page Page Page Page Page Page 10. FRONT CASE AND OIL PUMP REMOVAL AND INSTALLATION <SOHC (4G94 Except for PAJERO io) REMOVAL AND INSTALLATION <SOHC (4G94 for PAJER REMOVAL AND INSTALLATION <DOHC (Except GDI for PAJERO io) Page Page Page Page Page 11. PISTON AND CONNECTING ROD Page Page Page Page Page Page INSPECTION11300850074 12. CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE PLATE REMOVAL AND INSTALLATION (AUTOMATIC TRANSMISSION) REMOVAL AND INSTALLATION <PAJERO io REMOVAL SERVICE POINT