CONTENTS

Maintenance Manual
Overview . . . . . . . . . . . . . . . . . . . . . . . . 4
Maintenance Standards . . . . . . . . . . . . 4
DOHC
4G6 ENGINE
Tightening Torques . . . . . . . . . . . . . . . 4
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . 6
Alternator,
FOREWORD Ignition System. . . . . . . . . . . . . . . . . . . 7
This manual describes the 4G6DOHC engine, but Timing Belt . . . . . . . . . . . . . . . . . . . . . . 8
explains only points which differ from those in the
following maintenance manual:
Fuel System . . . . . . . . . . . . . . . . . . . . 10
● 4G6 DOHC Engine Maintenance Manual (No.
Secondary Air System,
1039G46)
The content of this manual is based on the engine as it
Intake Manifold . . . . . . . . . . . . . . . . . . 12
was in January 2003. Some points may have changed Exhaust Manifold . . . . . . . . . . . . . . . . 14
due to subsequent engine specification changes.
International SI standard units are used in this manual. Water Pump,
(However, old units are used for some figures we have Water Hoses . . . . . . . . . . . . . . . . . . . . 15
taken from existing documents).
Cylinder Head, Valves . . . . . . . . . . . . 17
Any opinions, requests, or questions concerning this
manual, should be written on the ‘Servicing
Pistons, Connecting Rods. . . . . . . . . 18
Comment Form’ at the end, and sent to us by fax. Starter Motor . . . . . . . . . . . . . . . . . . . . 20
January 2003

MITSUBISHI MOTOR CORPORATION

This manual uses recycled paper.

2 HOW TO FOLLOW THIS MANUAL

How to Follow this Manual

Extent of maintenance operation covered in this manual

This manual explains maintenance procedures carried out after the engine has been removed from the vehicle.
Please consult the relevant vehicle maintenance manual if you need to remove the engine from the vehicle or
carry out checks / maintenance without removing it.

How to follow the explanations

Maintenance Procedures
(1) At the beginning of each section there are component drawings to enable you to understand how
they are fitted.
(2) Numbers on these drawings denote the order for maintenance procedures, The drawings also
show parts that cannot be re-used, and tightening torques.
Removal order: The numbers before the part names given in the removal order correspond to the
numbers in the component drawings, and denote the order in which they are removed.
Fitting order: If the order in which they are fitted is simply the reverse of the order in which they
were removed, the fitting order is omitted.
Dismantling order: The numbers before the part names given in the dismantling order
correspond to the numbers in the component drawings, and denote the order in which they are
dismantled.
Assembly order: If the order in which they are assembled is simply the reverse of the dismantling
order, the assembly order is omitted.

Categorisation of Key Maintenance Points

Key points for maintenance/maintenance A
= key point concerning removing/dismantling
standards / use of special tools are
A== key point concerning fitting/assembling
explained in detail as key maintenance *
in key points concerning removing / dismantling are
’01-14G6DOHC Engine Maintenance Manual’.

*= ’01-14G6DOHC
key points concerning fitting / removing are in
Engine Maintenance Manual’

Symbols for Lubricants and Sealants

.............. Grease
Lubricant/sealant application/topping-up
locations are shown on the component
drawing or the following page, by these symbols. .............. Sealant, liquid gasket (FIPG)

.............. Brake fluid

.............. Engine oil

Checks
The only checks explained in this manual are those for which special tools or measuring instruments are used.
General visual checks and cleaning of components are not explained, but this constitutes essential maintenance
and must be carried out.
 HOW TO FOLLOW THIS MANUAL 3

Page number Engine type Title

4G6 – TIMING BELT

Denotes tightening torque

Denotes part that cannot be re-used

1. Timing belt front upper
* 7.

Auto-tensioner
cover 8.
Idler pulley
2. Timing belt front lower 9. Crank angle sensor
cover *

* 10. Oil pump sprocket
3. Power steering pump bracket *

* 11. Crankshaft bolt
*

* 4. Timing belt 

 12. Crankshaft sprocket
* *
Key Point for
Removing
A
Removing crankshaft bolt
Using the flywheel stopper (Special tool No.MD998781),
secure drive plate, and remove crankshaft bolt.

This letter corresponds to the These points explain maintenance

letter in the Removal / Fitting / procedures / precautions required for
Dismantling / Assembly order. removal / fitting / dismantling /
assembly.
4 4G6 – OVERVIEW, MAINTENANCE STANDARDS, TIGHTENING TORQUES
 4G6 – TIGHTENING TORQUES 5

Item Tightening Torque (N •m)

Spark plugs 25 ± 5
Timing Belt
Timing belt cover bolts (flange) 11 ± 1
Timing belt cover bolts (washer) 9.0 ± 1.0
Power steering pump bracket bolts 49 ± 9
Tensioner pulley bolts 48 ± 5
Tensioner arm bolts 21 ± 4
Auto-tensioner bolts 23 ± 3
Idler pulley bolts 35 ± 6
Crank angle sensor bolts 8.8 ± 1.0
Oil pump sprocket nuts 54 ± 5
Crankshaft bolts 167
Tensioner B bolts 19 ± 3
Counterbalance shaft sprocket bolts 45 ± 3
Connector bracket bolts 10 ± 1
Rocker cover bolts 3.5 ± 0.5
Engine support bracket bolts 49 ± 5
Camshaft sprocket bolts 88 ± 10
Fuel System
Throttle body bolts 19 ± 3
Cover bolts 11 ±1
Fuel pressure regulator bolts 8.8 ± 2.0
Delivery pipe and injector bolts 11 ± 1
Vacuum hose and pipe bolts 11 ± 1
Solenoid assembly bolts 9.0 ± 1.0
Vacuum tank bracket bolts 9.0 ± 1.0
Secondary Air System / Intake Manifold
Exhaust manifold heat protector bolts 14 ± 1
Vacuum hose and pipe bolts 11 ± 1
Air pipe assembly bolts (eye bolts) 49 ± 5
Air pipe assembly bolts (M6 flange) 11 ± 1
Air pipe assembly bolts (M8 flange) 24 ± 3
Air pipe assembly bolts (M8 washer) 14 ± 1
Air control valve assembly bolts 22 ± 4
Air control valve bracket bolts 22 ± 4
Intake manifold stay bolts 31 ± 3
Intake manifold bolts (M8) 20 ± 2
Intake manifold bolts / nuts (M10) 36 ± 6
Exhaust Manifold
Engine hanger bolts 19 ± 3
Turbocharger heat protector bolts 14 ± 1
O2 sensor 44 ± 5
Exhaust fitting bracket bolts 35 ± 6
Exhaust fitting bolts / nuts 59 ± 5
6

Item Tightening Torque (N •m)

Air outlet fitting bolts 19 ± 1
Oil return pipe bolts (flange) 14 ± 1
Oil return pipe bolts (washer) 9.0 ± 1.0
Turbocharger assembly and pipe assembly bolts / nuts 64 ± 5
Oil pipe bolts (M10 eye bolts) 17 ± 2
Oil pipe bolts (M12 eye bolts) 31 ± 2
Oil pipe bolts (M12 flange) 11 ± 1
Water pipe bolts (flange) 10 ± 1
Water pipe bolts (eye bolts) 42 ± 7
Exhaust manifold nuts (M8) 29 ± 3
Exhaust manifold nuts (M10) 49 ± 5
Water Pump / Water Pipe
Water temperature sensor 29 ± 10
Water temperature gauge unit 10.8 ± 1.0
Water outlet fitting bolts 10 ± 1
Thermostat case bolts 23 ± 4
Water inlet pipe bolts (M6) 5.0 ± 1.0
Water inlet pipe bolts (M8) 13 ± 2
Water pump bolts 14 ± 1
Knock sensor 23 ± 2

Sealants

Where used Brand used

Water outlet fitting* MZ100191 or equivalent
Thermostat housing* MZ100191 or equivalent
* = Where liquid gasket (FIPG) is used.
 4G6 – ALTERNATOR, IGNITION SYSTEM 7

Alternator, Ignition System

Removal / Fitting

Removal Order

1. Oil level gauge 8. Alternator brace

2. O ring 9. Alternator
3. Oil level gauge guide 10. Crankshaft pulley
4. O ring 11. Centre cover
5. Water pump pulley 12. Spark plug cable
6. Cap 13. Ignition coil
7. Auto-tensioner assembly 14. Spark plug
8 4G6 – TIMING BELT

Timing Belt

Removal / Fitting

1. Timing belt front upper cover
* 7. Auto-tensioner

2. Timing belt front lower cover 8. Idler pulley
3. Power steering pump bracket 9. Crank angle sensor
*

* 4. Timing belt *

* 10. Oil pump sprocket

* 5. Tensioner pulley *

* 11. Crankshaft bolt
6. Tensioner arm *

* 12. Crankshaft sprocket

* 13. Crankshaft sensing blade
14. Tensioner B
 4G6 – TIMING BELT 9
*

* 15. Timing belt B
* 26. Rocker cover
*

* 16. Counterbalance shaft
* 27. Rocker cover gasket A
sprocket 28. Rocker cover gasket B

* 17. Spacer
* 29. Semicircular washer
*

* 18. Crankshaft sprocket B
* 30. Engine support bracket
19. Crankshaft key *

* 31. Camshaft sprocket bolt
20. Breather hose 32. Camshaft sprocket
21. PVC hose 33. Timing belt rear right cover
22. PVC valve 34. Timing belt rear left upper
23. PVC valve gasket cover
24. Oil filler cap 35. Timing belt rear left lower
25. Connector bracket cover
10 4G6 – FUEL SYSTEM

Fuel System

Removal / Fitting
 4G6 – FUEL SYSTEM 11
Removal Order
1. Throttle body assembly 15. Delivery pipe

* 2. Throttle body gasket 16. Vacuum hose
3. Cover 17. Vacuum hose
4. Gasket 18. Vacuum hose
5. Fuel hose 19. Solenoid valve assembly

* 6. Fuel pressure regulator 20. Solenoid valve assembly
7. O ring 21. Vacuum hose and pipe
8. Delivery pipe and injector 22. Solenoid valve assembly
9. Insulator 23. Vacuum tank bracket
10. Fuel return pipe 24. Vacuum tank
11. Insulator 25. Vacuum hose assembly

* 12. Injector 26. Vacuum hose and pipe
13. O ring 27. Vacuum hose and pipe
14. Grommet
12 4G6 – SECONDARY AIR SYSTEM, INTAKE MANIFOLD

Secondary Air System, Intake Manifold

Removal / Fitting

Removal Order
1. Exhaust manifold heat
A 6. Air control valve bracket
protector
* 7. Intake manifold stay

* 2. Air pipe assembly 8. Alternator brace stay
3. Air control valve gasket 9. Intake manifold
4. Air control valve assembly 10. Intake manifold gasket
5. Engine hanger
4G6 – SECONDARY AIR SYSTEM, INTAKE MANIFOLD 13
Key Points for Fitting

AFitting air control valve bracket
1. Temporarily tighten bolts which secure air control valve
bracket and engine hanger to intake manifold.
2. Tighten Bolt No. 1 in drawing, which also secures
thermostat housing, to specified torque, 23 ± 4 N•m.
3. Tighten Nut No. 2 to specified torque, 36 ± 6 N•m.
4. Tighten Bolt No. 3 in drawing, which also secures engine
hanger, to specified torque, 22 ± 4 N•m.
14 4G6 – EXHAUST MANIFOLD

Exhaust Manifold

Removal / Fitting

Removal Order
1. Engine hanger 10. Oil return pipe gasket
2. Turbocharger heat protector
* Oil return pipe gasket
11.
3. O2 sensor 12. Turbocharger assembly and
4. Exhaust fitting bracket pipe assembly
5. Exhaust fitting 13. Turbocharger gasket
6. Exhaust fitting gasket 14. Oil pipe
7. Air outlet fitting 15. Water pipe B

* 8. Air outlet fitting gasket 16. Water pipe A
9. Oil return pipe 17. Turbocharger assembly

* 18. Exhaust manifold
19. Exhaust manifold gasket
 4G6 – WATER PUMP, WATER HOSES 15

Water Pump, Water Hoses

Removal / Fitting

Removal Order
1. Water hose
A9. Thermostat housing
2. Water hose 10. Gasket
3. Water hose
* 11. Water inlet pipe
4. Water hose
* 12. O ring

* 5. Water temperature sensor 13. Water pump

* 6. Water temperature gauge unit 14. Water pump gasket

B 7. Water outlet fitting 15. Knock sensor
8. Thermostat
16 4G6 – WATER PUMP, WATER PIPES

Key Points for Fitting

A Fitting thermostat housing

(1) Squeeze liquid gasket (thickness 3mm) into area indicated
in drawing.
Liquid gasket brand:
MZ100191 or equivalent
(2) Tighten bolts indicated by j on drawing, to specified torque,
23 ± 4 N•m.
(3) Tighten water inlet pipe bolt (k), using fixing on pipe, to
specified torque, 5.0 ± 1.0 N•m.
(4) Bolt l was tightened when fitting air control valve bracket
was fitted (See Page 13).

B Fitting water outlet fitting

Squeeze liquid gasket (thickness 3 mm) into area shown in
drawing.
Liquid gasket brand:
MZ100191 or equivalent
 4G6 – CYLINDER HEAD / VALVES 17

Cylinder Head / Valves

Perpendicularity

Checks

Valve springs
Free height (1) Measure free height of spring. If it is above limit, replace
valve spring.
Standard height: 50.4 mm
Limit: 49.4 mm
(2) Measure perpendicularity of spring. If it is ‘leaning’ by more
than the permitted limit, replace the valve spring.
Standard variance from perpendicular:
Within 2.0˚
Limit: 4˚
18 4G6 – PISTONS, CONNECTING RODS

Pistons, Connecting Rods

Removal / Fitting

Smear engine oil on

all sliding sections
when fitting

Removal Order

* 1. Connecting rod cap nut
* 7. Piston ring No. 2
*

* 2. Connecting rod cap
A 8. Oil ring

* 3. Connecting rod bearing *

* 9. Piston pin

* 4. Piston connecting rod 10. Piston

* 5. Connecting rod bearing 11. Connecting rod

* 6. Piston ring No. 1 12. Bolt
 4G6 – PISTONS, CONNECTING RODS 19

A Fitting oil ring

1. Fit oil ring spacer into piston ring groove, then ft upper side
rail, and finally fit lower side rail.
Upper Lower
side side NB:
rail rail (1) Fit them so that the side rail / spacer gaps are in the
gap gap positions shown in the drawing.
(2) Mark (new) spacers and side rails with distinguishing
colour (shown in chart below) to denote their sizes.
Spacer gap Size Colour
S.T.D. None
0.50 mm O.S. Red
1.00 mm O.S. Yellow

End of side rail

2. Tip for fitting side rails: First insert one end of rail into piston
groove. Then, holding this end with your thumb, as shown in
the drawing, push the rest of it in.

Warning
Like the other piston rings, opening the side rails out
with ring expanders may cause them to break.

3. After fitting the side rail on the piston, check that it rotates
smoothly in both directions.
20 4G6 – STARTER MOTOR

Starter Motor

Removal / Fitting

Dismantling Order
1. Screw 8. Armature
*
2. Magnetic switch 9. Yoke assembly
3. Screw 10. Packing A
4. Bolt 11. Packing B
5. Cover assembly 12. Plate
6. Brush holder 13. Planetary gear
7. Rear bearing 14. Lever
 4G6 – STARTER MOTOR 21
Dismantling Order
*

* 15. Snap ring 18. Internal gear
*

* 16. Snap ring 19. Planetary gear shaft
17. Over-running clutch 20. Front bracket

RJDB301023-26
22
Memo: