Mitsubishi 4G9 series Instruction manual

11A
MITSUBISHI
ENGINE
4G9 SERIES (E-W)
WORKSHOP MANUAL
Engine ................................
Pub. No. PWEE9502-F
FOREWORD
This Workshop Manual contains procedures for
removal, disassembly, inspection, adjustment,
reassembly and installation, etc. for service
mechanics.
All information, illustrations and product
descriptions contained in this manual are current
as at the time of publication. We, however, reserve
the right to make changes at any time without
prior notice or obligation.
FILING INSTRUCTION
Please keep these manual pages in the binder
No. BN940001.
File these pages according to the signs
“Added”, “Revised” and “Deleted” on the “List
of effective pages” which are interpreted
below.
Added:
File the pages with this sign additionally in
your manual.
Revised, Deleted:
Replace the existing pages with the
corresponding pages with this sign.
Missing sheets will be supplied upon request.
EMitsubishi Motors Corporation July 1999

INTRODUCTION
Maintenance and Servicing Procedures
(1) A diagram of the component parts is
provided near the front of each section in
order to give the reader a better under-
standing of the installed condition of
component parts.
(2) The numbers provided within the diagram
indicate the sequence for maintenance and
servicing procedures.
: Indicates a non-reusable part.
The tightening torque is provided where
applicable.
DRemoval steps:
The part designation number corresponds
to the number in the illustration to indicate
removal steps.
DDisassembly steps:
The part designation number corresponds
to the number in the illustration to indicate
disassembly steps.
DInstallation steps:
Specified in case installation is impossible
in reverse order of removal steps. Omitted
if installation is possible in reverse order
of removal steps.
DReassembly steps:
Specified in case reassembly is impossible
in reverse order of disassembly steps.
Omitted if reassembly is possible in reverse
order of disassembly steps.
Classification of Major Maintenance/Service Points
When there are major points relative to maintenance and servicing procedures
(such as essential maintenance and service points, maintenance and service stan-
dard values, information regarding the use of special tools, etc.), these are ar-
ranged together as major maintenance and service points and explained in detail.
AA": Indicates that there are essential points for removal or disassembly.
"AA: Indicates that there are essential points for installation or reassembly.
Symbols for Lubrication, Sealants and Adhesives
Information concerning the locations for lu-
brication and for application of sealants and
adhesives is provided, by using symbols, in
the diagram of component parts, or on the
page following the component parts page,
and explained.
: Grease (multipurpose grease unless
there is a brand or type specified)
: Sealant or adhesive
: Brake fluid, automatic transmission fluid
or air conditioner compressor oil
: Engine oil or gear oil
EXPLANATION OF MANUAL CONTENTS

Indicates the
group title.
Indicates the
section title.
Indicates the
group number.
Indicates the
page number.
Denotes tightening
torque.
Denotes non-reusable part.
This number corresponds to
the number appearing in
“Removal steps”,
“Disassembly steps”,
“Installation steps” or
“Reassembly steps”.
Issue date Publication number-Revision code
4G9 ENGINE (E-W) - Water Pump and Water Hose 11A-7-1
7. WATER PUMP AND WATER HOSE
REMOVAL AND INSTALLATION <SOHC>
Removal steps
1. Water hose A
2. Water hose B
3. Engine coolant temperature sensor
4. Engine coolant temperature gauge unit
5. Water outlet fitting
6. Water inlet fitting
7. Thermostat
8. Thermostat case
9. O-ring
10.Water inlet pipe
11.O-ring
12.Water pump
INSTALLATION SERVICE POINTS
WATER PUMP INSTALLATION
(1)Apply a 3 mm diameter of Form-In-Place Gasket (FIPG)
to the location shown in the illustration.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or
equivalent.
"GA
"DA
"BA
"BA
"AA
"CA
EMitsubishi Motors Corporation May 1995 PWEE9502
"AA
"BA
29 Nm 10 Nm
24 Nm
14 Nm
14 Nm
14 Nm
14 Nm
12
11
10
9
2
4
3
1
8
76
5
24 Nm
Indicates the
section num-
ber.
Operating procedures, cau-
tions, etc. on removal, installa-
tion, disassembly and reas-
sembly are described.
"FA
"EA
INTRODUCTION

11A-0-1 E Dec. 1998
11A-0-3 and 11A-0-4 C July 1997
11A-1-1 to 11A-1-6 E Dec. 1998
11A-1-6a and 11A-1-6b E Dec. 1998
11A-1-7 E Dec. 1998
11A-1-8 May 1995
11A-2-1 to 11A-2-3 A Nov. 1995
11A-3-1 A Nov. 1995
11A-3-2 E Dec. 1998
11A-3-2a and 11A-3-2b E Dec. 1998
11A-3-3 and 11A-3-4 A Nov. 1995
11A-3-5 to 11A-3-7 E Dec. 1998
11A-4-1 and 11A-4-2 E Dec. 1998
11A-4-2a to 11A-4-2d E Dec. 1998
11A-4-3 A Nov. 1995
11A-4-4 May 1995
11A-4-5 and 11A-4-6 A Nov. 1995
11A-4-7 to 11A-4-9 May 1995
11A-5-1 B Nov. 1996
11A-5-2 F July 1999 Revised
11A-5-3 to 11A-5-6 E Dec. 1998
11A-5a-1 to 11A-5a-3 E Dec. 1998
11A-6-1 to 11A-6-4 B Nov. 1996
11A-6a-1 and 11A-6a-2 D Jun. 1998
11A-6a-3 and 11A-6a-4 E Dec. 1998
11A-6b-1 to 11A-6b-3 E Dec. 1998
11A-6c-1 to 11A-6c-5 E Dec. 1998
11A-7-1 B Nov. 1996
11A-7-2 May 1995
11A-7-3 to 11A-7-5 E Dec. 1998
11A-8-1 May 1995
11A-8-2 to 11A-8-13 E Dec. 1998
11A-8a-1 to 11A-8a-5 A Nov. 1995
11A-8b-1 and 11A-8b-2 A Nov. 1995
11A-9-1 and 11A-9-2 May 1995
11A-9-3 A Nov. 1995
11A-9-3a and 11A-9-3b C July 1997
11A-9-4 to 11A-9-8 A Nov. 1995
11A-9-9 C July 1997
11A-9-10 E Dec. 1998
11A-9-11 C July 1997
11A-9-12 A Nov. 1995
11A-10-1 May 1995
11A-10-2 D Jun. 1998
11A-10-3 to 11A-10-7 E Dec. 1998
11A-11-1 May 1995
11A-11-2 A Nov. 1995
11A-11-3 to 11A-11-8 May 1995
11A-12-1 C July 1997
11A-12-1a and 11A-12-1b E Dec. 1998
11A-12-2 to 11A-12-6 A Nov. 1995
11A-12-7 E Dec. 1998
LIST OF EFFECTIVE PAGES
Page Revision
Code Date Remarks Page Revision Code Date Remarks
Missing sheets will be supplied upon request.
PWEE9502-F
EJuly 1999Mitsubishi Motors Corporation Revised