COOLING

CONTENTS

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GENERAL INFORMATION 2 RADIATOR 9

SPECIFICATIONS 3 COOLING FAN 12

General Specifications
Service Specifications
Torque Specifications
Lubricants
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3
3
4
5
THERMOSTAT

WATER PUMP (PETROL-POWERED

VEHICLES 4G32, 4G33)
14

17
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Sealant and Adhesive 5 WATER PUMP (4G92) 18-1
TROUBLESHOOTING 6 WATER PUMP (PETROL-POWERED
VEHICLES 4G63 - 8 VALVE,
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SERVICE ADJUSTMENT PROCEDURES 7 4G64 - 8 VALVE, G63B, G64B) 19

Checking for Coolant Leaks 7 WATER PUMP (4G63, 4G64 - 16 VALVE) . 20-1
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Checking of the Radiator Cap Valve-opening

WATER PUMP (DIESEL-POWERED
Pressure 7 VEHICLES) 21
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Replacement of the Coolant 7

Measurement of Concentration 8 WATER HOSE AND WATER PIPE 24

WATER TEMPERATURE GAUGE UNIT,

THERMO SWITCH AND WATER
TEMPERATURE SENSOR 26

if) Mitsubishi Motors Corporation Jun. 1994 PWWE8608O REVISED

14-2 COOLING - General Information

GENERAL INFORMATION
The cooling system is a water cooling type and the coolant is forcibly circulated by the water pump. The temper-
ature control of the coolant is conducted by the thermostat installed in the intake manifold.
Immediately after engine starting, the coolant does not flow into the radiator until the coolant temperature reaches
the thermostat valve opening temperature. The coolant circulates in the engine and it is prompty warmed up to the
proper temperature, and at the same time, the temperature of the coolant in the cylinder block and cylinder head
is made uniform. When the coolant temperature rises and the thermostat valve opens, the coolant flows into the
radiator. The coolant cooled by the radiator is pumped up and pressurized by the water pump and delivered to the
cylinders and cools the engine. Also, the cooling fan is installed at the water pump pulley and reduces the coolant
temperature in proportion to the engine revolution. Furthermore, between the fan and pulley, the fan clutch is
installed, which reduces the engine output loss and noise.
An automatic transmission oil cooler is installed in the radiator of automatic transmission models.

At cold

f^A Water pump

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.Heater

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"-,
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Radiator
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04GOO35
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Rx>
rr •
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•=A

0
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04G0036

© Mitsubishi Motors Corporation NOV. 86 PWWE8608

 COOLING - Specifications 14-3

SPECIFICATIONS
GENERAL SPECIFICATIONS
Items Petrol-powered vehicles Diesel-powered vehicles
Cooling method Water-cooling, forced circulation type Water-cooling, forced circulation type
Radiator
Type Pressurized corrugated fin type Pressurized corrugated fin type
Performance J/h (kcal/h, BTU/h) * 1 118.465x10 3 (28,300, 112,294) * 4 155,721 x 1 0 3 (37,200, 147,610)
* 2 146,512x10 3 (35,000, 138,888) * fa 214,744x10 3 (51,300, 203.571)
* 3 1 55,721 x 1 0 3 (37.200, 147.610) *6212,651 x10 3 (50,800, 201,587)
Radiator cap
High pressure valve opening 75-105 (0.75-1.05, 11-15) 75-105 (0.75-1.05, 11-15)
pressure kPa (kg/cm 2 , psi)
Vacuum valve opening pressure - 5 or less (-0.05, - 0 . 7 or less) - 5 or less (-0.05, 0.7 or less)
kPa (kg/cm 2 , psi)
Automatic transmission oil cooler

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(With automatic transmission)
Performance J/h (kcal/h, BTU/h) 4.186x10 3 (1.000, 3,968) *4,186x10 3 (1,000, 3,968)
Thermostat
Type
Fan clutch
Type
Water pump
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Wax type with jiggle valve

Thermo type with spiral type bimetal

Wax type

Thermo type with plate type bimetal

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Type Centrifugal impeller Centrifugal impeller
NOTE
(1) * 1 indicates 4G32.4G33.
(2) * 2 indicates 4G63, G63B.
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(3) * 3 indicates 4G64, G64B

(4) *4 indicates vehicles without a turbocharger. (Except L.H. drive vehicles for Europe built from June 1994)
(5) * 5 indicates vehicles with a turbocharger. (Except L.H. drive vehicles for Europe built from June 1994)
rd

(6) * 6 indicates L.H. drive vehicles for Europe built from June 1994.

SERVICE SPECIFICATIONS
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Items Specifications

Standard value
Range of coolant antifreeze concentration % 30-60
Thermostat
76.5°C (170 Q F)Type
C
Valve opening temperature of thermostat C( C F) 76.5(170)
Full-opening temperature of thermostat A (A) 90 (194) or more
82 t , C(180 n F)Type
Valve opening temperature of thermostat °C{°F) 82 (180)
Full-opening temperature of thermostat °C( U F) 95(203) or more
88 C C (190°F)Type
Valve opening temperature of thermostat A (°F) 88(190)
Full-opening temperature of thermostat A(3F) 100 (212) or more
Engine coolant temperature gauge unit
Petrol-powered vehicles
Resistance Q°C(°F] 104±13.5 70(158)
Diesel-powered vehicles
Resistance
Terminal A Q°C(°F) 104±13.5 70(158)
Terminal B kQ DC (DF) 3.25±0.33 20(68)
Q °C (°F) 300 80(176)

X Mitsubishi M o t o r s Corporation Jun. 1994 PWWE8608-O REVISED

14-4 COOLING - Specifications

Items Specifications

Engine coolant temperature sensor

Resistance
<Vehicles built up to May 1994>
kQ °C (°F) 2.45 ± 0 . 2 4 20(68)
Q A (A) 296 ± 3 2 80(176)
<Vehicles built from June 1994>
kQcC(°F) 2.37 ±0.24 20(68)
Q °C(°F) 290 ± 3 2 80(176)
Thermo switch
For Europe 4G63
Continuity temperature °C ( A ) Within 65 (149)
With automatic transmission
Continuity temperature °C (°F) More than 50 (122)
Diesel powered vehicles
=
Continuity temperature C( C F) More than 115(239)

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TORQUE SPECIFICATIONS
Items

Radiator attaching bolt

Reserve tank attaching bolt
Shroud attaching nut
. co Nm

9-14
4-6
4-6
kgm

0.9-1.4
0.4-0.6
0.4-0.6
ft.lbs.

7-10
3-4
3-4
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Plate attaching nut 4-6 0.4-0.6 3-4
Radiator hose lower bracket attaching bolt <4G92> 9-14 0.9-1.4 7-10
Shroud (upper) attaching nut <4G92> 10-15 1.0-1.5 7-10
Cooling fan attaching bolt
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Except 4G92 10-12 1.0-1.2 7.2-9.0

4G92 8-10 0.8-1.0 6-7
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Fan clutch attaching bolt 10-12 1.0-1.2 7.2-9.0

Fan clutch attaching nut 8-10 0.8-1.0 6.0-7.2
Cooling fan bracket attaching bolt 30-42 3.0-4.2 22-30
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8-10 0.8-1.0 6-7

Water outlet fitting attaching bolt
Petrol-powered vehicles 17-20 1.7-2.0 12-14
Diesel-powered vehicles 10-13 1.0-1.3 7.2-9.4
Water inlet fitting attaching bolt
4G92 17-20 1.7-2.0 12-14
4G63, 4G64 10-15 1.0-1.5 7-11
Timing belt cover attaching bolt 10-12 1.0-1.2 7.2-9.0
Water pump attaching bolt
Bolt head mark " 4 T " 12-15 1.2-1.5 9-11
Bolt head mark "7T" 20-17 2.0-2.7 14-19
Timing belt rear cover attaching bolt 8-12 0.8-1.2 6-9
Alternator brace attaching bolt 35-55 3.5-5.5 25-40

S) Mitsubishi Motors Corporation Jun. 1994 PWWE8608-O REVISED

 COOLING - Specifications 14-4-1

Items Nm kgm ft.lbs.

Crankshaft pulley attaching bolt

Petrol-powered vehicles
4G32 and 4G33 engines 15-18 1.5-1.8 11-13
Except 4G32 and 4G33 engines 20-30 2.0-3.0 14-22
Diesel-powered vehicles 170-190 17-19 123-137
Power steering oil pump and bracket attaching bolt 14-21 1.4-2.1 10-15
Power steering oil pump to bracket 25-33 2.5-3.3 18-24
Water pipe attaching bolt
:
bolt size (M6) 10-12 1.0-1.2 7.2-8.6
bolt size (M8) 12-15 1.2-1.5 8.6-11
Thermostat case attaching bolt ,
4G92 22-25,43-55 2.2-2.5,4.3-5.5 16-18, 3 1 - 4 0
4G63, 4 G 6 4 - 1 6 valve 19-28 1.9-2.8 14-20
Water pipe attaching bolt <4G63, 4G64 - 16 valve> 10-15,43-55 1.0-1.5,4.3-5.5 7-11, 31-40

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Water by-pass fitting attaching bolt 19-28 1.9-2.8 14-20
Water pipe to turbocharger 35-50 3.5-5.0 25-36
Engine coolant temperature gauge unit
Vehicles built up to September 1987
Vehicles built from October 1987
Thermo switch
For Europe 4G63
.
4G92, 4G63, 4G64 - 16 valve
co 8-10
10-12

20-40
20-40
0.8-1.0
1.0-1.2

2.0-4.0
2.0-4.0
5.8-7.2
7.2-8.6

14-29
14-29
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With automatic transmission ; 6-9 0.6-0.9 4.3-6.5
Diesel powered vehicles <4WD> : 7-9 0.7-0.9 5.1-6.5
Engine coolant temperature sensor 20-40 2.0-4.0 14-29
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© Mitsubishi Motors Corporation Jun. 1994 PWWE8608-O ADDED

14-5 COOLING - Specifications

LUBRICANTS
Quantity*
Items Recommended antifreeze Engine
lit. U.S.qts. Imp.qts.

Engine HIGH QUALITY ETHYLENE GLYCOL 4G33 7.7 (8.2) 8.14(8.66) 6.78(7.22)
coolant ANTIFREEZE COOLANT 4G32 7.5 (8.0) 7.92 (8.45) 6.60 (7.04)
4G63 - 8 valve
(Excluding vehicles for
Europe)
2WD 7.35 (7.85) 7.77 (8.29) 6.47 (6.91)
4WD 7.5 (8.0) 7.92 (8.45) 6.60(7.04)
4 G 6 3 - 8 v a l v e , G63B
(Vehicles for Europe)
2WD 7.3 (7.8) 7.71 (8.24) 6.42 (6.86)
4WD 7.4(7.9) 7.82 (8.35) 6 51 (6.95)
G64B 7.4(7.9) 7.82 (8.35) 6.51 (6.95)
4G64 - 8 valve

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2WD 8.15(8.65) 8.61 (9.14) 7.17 (7.61)
4WD 8.3 (8.8) 8.77 (9.30) 7.30 (7.74)
4D56

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Without turbocharger
With turbocharger
<Vehicles built up to
May1994>
<Vehicles built from
8.7 (9.2)

10.0(10.6)
9.19(9.72)

10.57(11.10)
7.66(8.10)

8.80 (9.24)
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9.0(9.5) 9.51 (10.03) 7.92 (8.36)
June 1994>
4G92 6.0 6.34 5.28
4G63, 4 G 6 4 - 16 valve 8.0 (8.5) 8.45 (8.98) 7.04(7.48)
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NOTE
(1) 'Quantity includes 0.9 liters (0.95 U.S. qts., 0.79 imp.qts.) reserve tank capacity.
(2) ( ) indicates figure with rear heater.
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SEALANT AND ADHESIVE

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Items Specified sealant and adhesive Remarks

Engine coolant temperature 3M ATD Part No. 8660 or equivalent Semi drying sealant
gauge unit (Petrol-powered
vehicles)

Engine coolant temperature 3M Nut Locking Part No. 4171 or equivalent Drying sealant
gauge unit
(Diesel-powered vehicles)
Engine coolant temperature
sensor
Thermo switch

Water pump (4G92) MITSUBISHI GENUINE Part No. 9703S9 or Semi drying sealant
Water by-pass fitting (4G63, 4G64) equivalent

X Mitsubishi Motors Corporation Jun. 1994 PWWE8608-O REVISED

 COOLING - Troubleshooting 14-6

TROUBLESHOOTING
Symptom Probable cause Remedy Reference
page

Overheat Insufficient coolant Replenish 14-7

Antifreeze concentration too great Correct 14-8

Loose or broken drive belt Replace 14-13

Inoperative fan clutch Replace 14-13

Damaged or blocked (insufficiently Correct -

ventilated) radiator fins

Water leaks

Damaged radiator core joint Replace 14-9

Corroded or cracked hoses Replace 14-9

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(radiator hose, heater hose, etc.)

Loose bolt or defective gasket in Correct or replace 14-14

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water outlet fitting (thermostat)

Loose water pump mounting bolt or Correct or replace 14-17, 19, 21

defective gasket
. Faulty radiator cap valve or setting Replace 14-7
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of spring

Loose cylinder head bolt Correct

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Damaged cylinder head gasket Replace

Refer to GROUP 11
ENGINE
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Cracked cylinder block Replace

Cracked cylinder head Replace

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Faulty thermostat operation Replace 14-16

Faulty water pump operation Replace 14-18, 20, 22

Water passage clogged with slime or Clean -

rust deposit or foreign substance

No rise in Faulty thermostat Replace 14-16

temperature

© Mitsubishi M o t o r s Corporation Jun. 1994 PWWE8608O REVISED

14-7 C O O L I N G - Service A d j u s t m e n t Procedures

SERVICE ADJUSTMENT PROCEDURES

E14FAAA

CHECKING FOR COOLANT LEAKS

1. Confirm that the coolant level is up to the filler neck. Install a
radiator cap tester and apply 160 kPa (1.6 kg/cm 2 , 23 psi)
pressure, and then check for leakage from the radiator hose or
connections.
Caution
1. Be sure to completely clean away any moisture from
the places checked.
04R0016
2. When the tester is taken out, be careful not to spill any
coolant from it.
3. Be careful, when installing and removing the tester
and when testing, not to deform the filler neck of the
radiator.
2. If there is leakage, rapair or replace the appropriate part.

CHECKING OF THE RADIATOR CAP VALVE-

OPENING PRESSURE E1 4FBAB

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Refer to GROUP 11 ENGINE-Service adjustment procedures

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REPLACEMENT OF THE COOLANT EUFCAF
1. For vehicles with a heater, set the warm water flow control
lever to the hot position.
2. Remove the radiator cap.
. 3. Remove the drain plug and drain out the coolant.
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4. Drain the coolant out of the reserve tank.
5. After draining out the coolant, securely close the drain plug.
6. Pour the specified coolant into the radiator until it is com-
pletely full, and then attach the radiator cap.
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Recommended antifreeze:
HIGH QUALITY ETHYLENE GLYCOL ANTIFREEZE
COOLANT
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Quantity lit. (U.S.qts., Imp.qts.)

4G33 7.7 (8.14, 6.78)
*8.2 (8.66, 7.22)
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4G32 7.5 (7.92, 6.60)

*8.0 (8.45, 7.04)
4G63 - 8 valve (excluding vehicles for Europe)
2WD 7.35 (7.77, 6.47)
»7.85 (8.29, 6.91)
4WD 7.5 (7.92, 6.60)
*8.0 (8.45, 7.04)
4G63 - 8 valve, G63B (vehicles for Europe)
2WD 7.3 (7.71, 6.42)
*7.8 (8.24, 6.86)
4WD 7.4 (7.82, 6.51)
*7.9 (8.35, 6.95)
G64B 7.4 (7.82, 6.51)
*7.9 (8.35, 6.95)
4G64 - 8 valve
2WD 8.15 (8.61, 7.17)
*8.65 (9.14, 7.61)
4WD 8.3 (8.77, 7.30)
*8.8 (9.30, 7.74)
4D56 Without turbocharger 8.7 (9.19, 7.66)
*9.2 (9.72, 8.10)
With turbocharger
<Vehicles built up to May 1994>
10.0 (10.57, 8.80)
*10.5 (11.10, 9.24)
%) Mitsubishi Motors Corporation Jun. 1994 PWWE8608O REVISED
 C O O L I N G - Service A d j u s t m e n t Procedures 14-8
<Vehicles built from June 1994>
9.0 (9.51, 7.92)
*9.5 (10.03, 8.36)
4G92 6.0 (6.34, 5.28)
4G63, 4G64 - 16 valve 8.0 (8.45, 7.04)
*8.5 (8.98, 7.48)
NOTE
1. (*) indicates vehicles with rear heater.
2. For Norway, the non-amine type of antifreeze should be
used.
7. Pour coolant into the reserve tank.
8. After warming up the engine until the thermostat opens, re-
move the radiator cap and check the amount of coolant.
Pour coolant into the radiator until it is completely full, and
then attach the radiator cap securely.
10. Pour coolant into the reserve tank until it reaches the FULL
line.
NOTE

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For vehicles equipped with rear heater (under seat type), refer
to GROUP 55 HEATER, AIR CONDITIONER AND
VENTILATION-Service Adjustment Procedures.

. 1.
2.
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MEASUREMENT OF CONCENTRATION E^DAA
Measure the specific gravity of the coolant with a hydrometer.
Measure the coolant temperature, and calculate the concen-
tration from the relation between the specific gravity and tem-
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perature, using the following table for reference.

04R0017
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RELATIONSHIP BETWEEN ANTIFREEZE CONCENTRATION AND SPECIFIC GRAVITY

Freezing Safe operating Coolant
Coolant temperature °C (T) and specific gravity temperature temperature concentration
rd

10(50) 20 (68) . 30 (86) 40(104) 50 (122) °C (°F) °C (°F) (Specific volume)

1.054 1.050 1.046 1.042 1.036 -16(3.2) - 1 1 (12.2) 30 %
1.063 I 1.058 I 1.054 1.049 1.044 - 2 0 (-4) -15(5) 35 %
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1.071 1.067 1.062 1.057 1.052 - 2 5 (-13) - 2 0 (-4) 40%

1.079 1.074 1.069 1.064 1.058 - 3 0 (-22) - 2 5 (-13) 45%
1.087 1.082 1.076 1.070 1.064 - 3 6 (-32.8) - 3 1 (-23.8) 50 %
1.095 1.090 1.084 1.077 1.070 - 4 2 (-44) - 3 7 (-35) 55%
1.103 1.098 1.092 1.084 1.076 - 5 0 (-58) - 4 5 (-49) 60 %

Example:
How to obtain safe operating temperature of coolant-antifreeze mixture
The safe operating temperature is down to -15°C (5°F) when the measured specific gravity is 1.058 at the coolant
temperature of 20°C (68°F).

RECOMMENDED ANTIFREEZE

Antifreeze Allowable concentration

HIGH QUALITY ETHYLENE GLYCOL ANTIFREEZE COOLANT 30-60 %

Caution
If the concentration of the antifreeze is below 30 %, the anti-corrosion property will be adversely affected.
In addition, if the concentration is above 60 %, both the anti-freezing and engine cooling properties will
decrease, affecting the engine adversely. For these reaso.ts, be sure to maintain the concentration level
within the specified range.

REVISED
© Mitsubishi Motors Corporation Jun. 1994 PWWE8608O
 COOLING - Radiator 14-10
SERVICE POINTS OF REMOVAL E14ÜBAB

2. REMOVAL OF COVER
-——tt . ^ J -
Turn cover about 30 mm (1.2 in.) clockwise towards front of
vehicles and remove cover towards engine.
'At
^ y

04G0014

INSPECTION E14QCAA
• Check for foreign material between radiator fins.
• Check the radiator fins for bend or damage.
• Check the radiator for corrosion, damage, rust or scale.
• Check the radiator hoses for cracks, damage or deterioration.
• Check the reserve tank for damage.

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• Check the spring of radiator cap for deterioration.
• Check the packing of radiator cap for damage or cracks.

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SERVICE POINTS OF INSTALLATION
2. INSTALLATION OF COVER
EI^DAC
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(1) Match the retainer on cover left end to shroud.
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rd

04G0015
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~;r- (2) Turn cover counterclockwise towards vehicle front to the

•*• shroud stopper position.
'• Irt|
•""• Vr a

d K
Stopper x 3
A ^-"--
:^yyA
y —KJ.- 04G0016

(3) Engage other cover retainers to shroud.

.y\'.'A\
•yAmAAA'y *f\
y'y

- -Hfcü
+%-\
Ak
AAA'

04G0017
Zl Mitsubishi M o t o r s Corporation Jun. 1994 PWWE8608-O REVISED
14-11 COOLING - Radiator

(4) Turn cover clockwise until the arrow (or solid line) reaches
shroud clip position.

^••--typ- -- — - f
.f
% y""'
Att
..---^yA" z
_.$--^- - • ••-

04G0018

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i Mitsubishi Motors Corporation Jun. 1994 PWWE8608-O REVISED

 COOLING - Radiator 14-11-1
REMOVAL AND INSTALLATION [Vehicles built from June 1994]

Pre-removal Operation Post-installation Operation

• Removal of driving seat • Installation of automatic transmission oil hose
• Removal of seat underframe and checking of oil volume.
(Refer to GROUP 01 GENERAL - (Refer to GROUP 23 AUTOMATIC TRANSMISSION
Engine Compartment Work) - Service Adjustment Procedures)
• Drainage of coolant • Supplying of coolant
• Removal of automatic transmission oil hose (Refer to P.14-7.)
(Vehicles with automatic transmission) • Installation of seat underframe
• Installation of driving seat

4D56

9-14 Nm
0.9-1.4 kgm <2WD>
4-6 Nm
0.4-0.6 kgm 7-10 ft.lbs.
4-6 Nm
3-4 ft.lbs. 7 0.4-0.6 kgm
3-4 ft.lbs.

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^ ' # Q \ > 4-6 Nm
•fi* 0.4-0.6 kgm
^ ^ 3 - 4 ft.lbs
<4WD>
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4-6 Nm
0.4-0.6 kgm
3-4 ftlbs.
rd

(?)
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Removal steps
1. Radiator cap
2. Drain plug
3. Clip 04G0123
«• M 4. Cover
5. Shroud 4-6 Nm
6. Plate <L.H. drive vehicles for Europe> 0.4-0.6 kgm
7. Overflow tube 3-4 ftlbs.
8. Reserve tank
H U 9. Radiator hose upper
«• M 13. Radiator hose lower
14. Radiator

NOTE
(1) Reverse the removal procedures to reinstall.
(2) « t : Refer to "Service Points of Removal".
(3) M : Referto "Service Points of Installation".

c Mitsubishi Motors Corporation Jun. 1994 PWWE8608-D ADDED

14-11-2 COOLING - Radiator

4G92 9-14 Nm
0.9-1.4 kgm
7-10 ft.lbs.

4-6 Nm
0.4-0.6 kgm 4-6 Nm
3-4 ft.lbs. 0.4-0.6 kgm
3-4 ft.lbs.

9-14 Nm
0.9-1.4 kgm
7-10 ftlbs.
<M
10-15 Nm
1.0-1.5 kgm

m
7-11 ft.lbs.
10-15 Nm
1.0-1.5 kgm
7-11 ft.lbs.
04G0098

4G63, 4G64

4-6 Nm
0.4-0.6 kgm
. co
9-14 Nm
0.9-1.4 kgm
7-10 ft.lbs.
<2WD>
4-6 Nm
0.4-0.6 kgm
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3-4 ft.lbs.
3-4 ft.lbs.
ia
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4-6 Nm
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0.4-0.6 kgm
^ 3-4 ft.lbs.
<4WD>

Removal steps
1. Radiator cap
2. Dram plug
7. Overflow tube
8. Reserve tank
4» M 9. Radiator hose upper
10. Shroud (upper)
11. Shroud (lower) 4-6 Nm
12 Shroud mounting nut 0.4-0.6 kgm
4* M 13. Radiator hose lower 3-4 ft.lbs.
14. Radiator 04G0122
15. Shroud
16. Plate <L.H. drive vehicles for Europe>

NOTE
(1) Reverse the removal procedures to reinstall.
(2) | > : Referto "Service Points of Removal".
(3) M : Refer to "Service Points of Installation"

Mitsubishi Motors Corporation Jun. 1994 PWWE8608-O ADDED

 COOLING - Radiator 14-11-3
SERVICE POINTS OF R E M O V A L EUQBAB
4. REMOVAL OF COVER
Turn cover about 30 mm (1.2 in.) clockwise towards front of
vehicles and remove cover towards engine.

04G0014

DISCONNECTION OF RADIATOR HOSE UPPER/13. RA-

DIATOR HOSE LOWER
After making mating marks on the radiator hose and the hose
clamp, disconnect the radiator hose.

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Mating marks

. 04W0044

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INSPECTION E14QCAA
gn
Check for foreign material between radiator fins.
Check the radiator fins for bend or damage.
Check the radiator for corrosion, damage, rust or scale.
Check the radiator hoses for cracks, damage or deterioration.
Check the reserve tank for damage
ia

Check the spring of radiator cap for deterioration.

Check the packing of radiator cap for damage or cracks.
rd
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SERVICE POINTS OF INSTALLATION

Projection 13. CONNECTION OF RADIATOR HOSE LOWER/9. RADIA-
TOR HOSE UPPER
X (1) Insert each hose as far as the projection of the water out-
let fitting or water inlet fitting.
i L .

Water outlet fitting or

water inlet fitting 04S0033

(2) Align the mating marks on the radiator hose and hose
clamp, and then connect the radiator hose.

Mating marks

04W0044

© Mitsubishi Motors Corporation Jun. 1994 PWWE8608O ADDED

14-11-4 COOLING - Radiator

4. INSTALLATION OF COVER
rrKr / (1) Match the retainer on cover left end to shroud.

04G0015

(2) Turn cover counterclockwise towards vehicle front to the

shroud stopper position.
Ü
«H I
^

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Stopper

A^A
. 04G0016

co
(3) Engage other cover retainers to shroud.
gn
r^3*V-J
ia
rd

04G0017

(4) Turn cover clockwise until the arrow (or solid line) reach-
ca

es shroud clip position.

04G0018

: Mitsubishi Motors Corporation Jun. 1394 PWWE8608O ADDED

 COOLING - Cooling Fan 14-12
COOLING FAN
REMOVAL AND INSTALLATION

Pre-removal Operation Post-installation Operation

• Removal of radiator cover and shroud • Installation of radiator cover and shrould
<Except 4G92> (Refer to P. 14-9.) <Except 4G92> (Refer to P. 14-9.)

Petrol-powered vehicles (Except 4G92)

8 - 1 0 Nm
0.8-1.0 kgm
6.0-7.2 ft.lbs

*i 10-12 Nm

m
1.0-1.2 kgm
7.2-9.0 ft.lbs

10-12 Nm
1.0-1.2 kgm
7.2-9.0 ft.lbs
. co
gn

04G0054
ia
rd

Diesel-powered vehicles
ca

10-12 Nm
1.0-1.2 kgm
7.2-9.0 ftlbs

fcj
Removal steps
M 3. Power steering oil pump drive b
(vehicles with a power steering) 10-12 Nm 04G0053
Air conditioner compressor drive 1.0-1.2 kgm
M (vehicles with an air conditioner) 7.2-9.0 ft.lbs.
5. Alternator drive belt
6. Fan clutch
7. Water pump pulley
Cooling fan

NOTE
(1) Reverse the removal procedures to reinstall.
( 2 ) ^ ^ : Refer to "Service Points of Installation"
(3) *' indicates 4G32, 4G33.
(4) * 2 indicates 4G63, 4G64, G63B, G64B.

Mitsubishi Motors Corporation Jun. 1994 PWWE8608-O REVISED

14-12-1 COOLING-Cooling Fan

4G92

30-42 Nm
3.0-4.2 kgm
22-30 ft.lbs.

10-12 Nm
4-6 Nm 1.0-1.2 kgm
0.4-0.6 kgm 7-9 ft.lbs.
3-4 ft.lbs.
8-10 Nm
0.8-1.0 kgm
10-15 Nm 6-7 ft.lbs.
1,0-1.5 kgm
7-11 ft.lbs. 8-10 Nm

m
0.8-1.0 kgm
6-7 ft.lbs.
30-42 Nm

co
3.0-4.2 kgm
22-30 ft.lbs.
. 4-6 Nm
gn
10-15 Nm 0.4-0.6 kgm
04G0OB4
1.0-1.5 kgm 3-4 ft.lbs.
7-11 ft.lbs.
Removal steps
ia

1. Shroud (upper)
M 2. Drive belt
(Vehicles with power steering or air conditioner)
rd

M 5. Alternator drive belt

6. Fan clutch
7. Water pump pulley
8. Cooling fan
ca

9. Cooling fan bracket assembly

NOTE
(1) Reverse the removal procedures to reinstall
(2) M : Refer to "Service Points of Installation'

© Mitsubishi Motors Corporation Jun. 1994 PWWE8608-O ADDED

 COOLING - Cooling Fan 14-13
INSPECTION E14JCAB
Cooling fan COOLING FAN
• Check the blades for damage and cracks.
Fan clutch • Check for cracks and damage around bolt holes in fan hub.
• If any portion of fan is damaged or cracked, replace cooling
fan.

5C0O07

FAN CLUTCH
• Check to ensure that fluid in fan clutch is not leaking at case
joint and seals. If fluid quantity decreases due to leakage, fan
speed will decrease and engine overheating might result.
• When fan attached to engine is turned by hand, it should give
a sense of some resistance. If fan turns lightly, it is defective.

m
• In case of thermostatic control type, check for a broken bi-
Bimetal metal.

. 3C0002
co
BELT
A belt which has following defects should be replaced.
gn
• Damaged, peeled or cracked surface
• Oil or greasy surface
99® • A belt worn to such an extent that it is in contact with bottom
of V groove in pulley
ia

• Worn or hardened rubber

rd

1C0004
ca

SERVICE POINT OF INSTALLATION E,4JDAC

5. INSTALLATION OF ALTERNATOR DRIVE BELT/4. AIR
CONDITIONER COMPRESSOR DRIVE BELT/3. POWER
STEERING OIL PUMP DRIVE BELT/2. DRIVE BELT
Install drive belts. Check belt tension.
(Refer to GROUP 11 ENGINE - Service Adjustment Proce-
dures.)

© Mitsubishi Motors Corporation Jun. 1994 PWWE8608-O REVISED

14-14 COOLING - Thermostat

THERMOSTAT
REMOVAL AND INSTALLATION E14GA

PETROL-POWERED VEHICLES (Vehicles built up to May 1994]

Pre-removal Operation Post-installation Operation

Drainage of coolant Installation of seat underframe {L.H.D.j
Removal of driving sea (L.H.D 1 installation of driving seat (I H.D.)
Removal of seat underframe {L H.D. Supplying of coolant
(Refer to GROUP 0 1 - Engine L.orr pa rtrnent (Referto P. 14-7.)
Work.)

Petrol-powered vehicles without M.P.I

17-20 Nm
'1.7-2.0 kgm
12-14 ftlbs.

m
. co
gn
Petrol-powered vehicles with M.P.I
ia
rd
ca

17-20 Nm
/y^y
1.7-2.0 kgm
12-14 ft.lbs.

04G0055

Removal steps
1. Radiator hose upper
2. Water outlet fitting
6. Gasket
M 7 Thermostat
NOTE
(1) Reverse the removal procedures to reinstall.
(2) * • • : Refer to "Service Points of Installation'
(3) E l : Non-reusable parts

© Mitsubishi M o t o r s Corporation Jun. 1994 PWWE8608-O REVISED

 COOLING - Thermostat 14-14-1

PETROL-POWERED VEHICLES [Vehicles built from June 1994]

Pre-remova 1 Operation Post-installation Operation

• Drainage of coolant • installatior of seat underframe (L.H.D.) <4G92>
• Removal of seat undc rframe (L.H.D.) <4G92> • Installation of seat underframe (R.H.D.) <4G63>
• Removal of seat underframe (R.H.D.) <4G63> • Supplying of coolant
(Refer to GROUP 01 - Engine Compartment (Refer to P.14 -7.)
Work.)

4G92 4G63, 4G64

10-15 Nm
1.0-1.5 kgm

m
7-11 ft.lbs.

. co
gn

17-20 Nm
ia

1.7-2.0 kgm
12-14 ft.lbs.
rd

04G0090

04GO092
ca

Removal steps
4t •• 1. Radiator hose lower
4. Water inlet fitting
M 7. Thermostat

NOTE
(1) Reverse the removal procedures to reinstall.
(2) 4 t : Referto "Service Points of Removal".
(3) M : Refer to "Service Points of Installation".

© Mitsubishi Motors Corporation Jun. 1994 PWWE8608O ADDED

14-15 COOLING - Thermostat

DIESEL-POWERED VEHICLES

Pre-removal Operation Post-installation Operation

Removal of driving seat (R.H.D.) • Supplying of coolant
Removal of seat underframe (R.H.D.) (Referto P.14-7.)
(Refer to GROUP 01 GENERAL-Engine • Installation of power steering oil pump
Compartment Work.) (Refer to GRDUP 37 STEERING-Oi! Pump.;
Removal of power steering oil pump • Installation of seat underframe (R.H.D.)
Drainage of coolant • Installation of driving seat (R.H.D.)

m
.1 0 - 1 3 Nm
1 . 0 - 1 . 3 kgm
7 . 2 - 9 . 4 ft.lbs
/ co
gn
ia
rd
ca

Removal steps
ff ^f 3. Radiator h o s e l o w e r
5. W a t e r p u m p fitting
6. Gasket
^f 7. T h e r m o s t a t

NOTE
(1) Reverse the removal procedures to reinstall
(2) 4 + ' Refer to "Service Points of Removal".
(3) M : Refer to "Service Points of installation'
(4) E l : Non-reusable parts

© Mitsubishi Motors Corporation Jun. 1994 PWWE8608 O REVISED

 COOLING - Thermostat 14-16
SERVICE POINTS OF REMOVAL
3. DISCONNECTION OF RADIATOR HOSE LOWER
«Vehicles built from June 1994>
After making mating marks on the radiator hose and the hose
clamp, disconnect the radiator hose.

INSPECTION E14GCA,
Mating marks • Check that valve closes tightly at room temperature.
• Check for defects or damage.
04W0044 • Check for rust or encrustation on valve. Remove if any.
• Immerse thermostat in container of water. Stir to raise water
temperature and check that thermostat opening valve tem-
perature and the temperature with valve fully open [valve lift-
—&^ZJ¥—-M
over 8 m m (0.32 in.)] are at the standard value.
—"- Standard value
\yz Petrol-powered vehicles
^5 x£^ Vehicles for Europe

m
- i — 1\ - 4G32, 4G63 - 8 valve, 4G64 (Cold regions),
W J G64B
Opening valve temperature 8 8 C (190 F)
(o) (a) 6? Ö Ö Ö

4G3, 4G6 - 8 v a l v e
. 04 LI 0016

co Full-open temperature 100'C (212 a F)

4G63 - 16 valve {FBC and MPI), G63B, 4G64
Opening valve temperature 8 2 C (180 F)
Full-open temperature 9 5 C ( 2 0 3 F )
4G63 - 16 valve (conventional carburettor)
gn
Opening valve temperature 7 6 . 5 C ( 1 7 0 F )
Full-open temperature 90 C (194' F)
Vehicles for General Export
4G92 (FBC),4G63 - 1 6 valve (Standard specifi-
ia

cations for conventional carburettor)

Opening valve temperature 76.5°C (170 F)
Full-open temperature 90°C ( 1 9 4 F )
rd

04U0018 Other than above

4G9, 4G6 - 16 v a l v e , 4D5
Opening valve temperature 82°C (180 F)
Full-open temperature 95°C (203°F)
ca

Vehicles for Australia

4G64 - 8 valve
Opening valve temperature 88 Q C (190=F)
Full-open temperature 100°C (212°F)
4G63 - 8 valve, 4G64 - 16 valve
Opening valve temperature 82 C C (180 F)
Full-open temperature 95°C (203 F)
-zz=) £. 4G63 - 16 valve.
04U0017 Opening valve temperature 76.5°C (170°F)
Full-open temperature 90°C (194 F)
Diesel-powered vehicles
Vehicles without turbocharger
Opening valve temperature 82°C (180 F)
Full-open temperature 95°C (203°F)
Vehicles with turbocharger
Opening valve temperature 7 6 . 5 C ( 1 7 0 F )
Full-open temperature 90°C (194 F)
NOTE
Measure valve height when fully closed. Calculate lift by measuring the
he.ght when fully open.

© Mitsubishi M o t o r s Corporation Jun. 1994 PWWE8608 O REVISED

14-16-1 C O O L I N G - Thermostat

SERVICE POINTS OF INSTALLATION E^GDAD

Petrol-powered vehicles
7. INSTALLATION OF THERMOSTAT
<Vehicies built up to May 1994>
Caution
8 1. Check to ensure that flange of thermostat is correct-
ly seated in socket of thermostat housing. If thermo-
stat is installed in wrong direction, bottom of ther-
mostat will touch rib inside inlet manifold, making it
impossible to seat flange in position.
2. Make sure that flange is not projecting from socket
1C0007 section.
Diesel-powered vehicles

. U '.

m
Dcoon

.Mark

Jiggle valve
co
<Vehicles built from June 1994>
install the thermostat so that the jiggle valve is facing straight
up and is aligned with the mark on the thermostat case as
gn
shown in the illustration.
Caution
Make absolutely sure that no oil is adhering to the rub-
ber ring of the thermostat. In addition, be careful not to
ia

-Rubber ring
fold over or scratch the rubber ring when inserting.
rd

04X0005

CONNECTION OF RADIATOR HOSE LOWER

ca

(1) Insert each hose as far as the projection of the water out-
Projection let fitting or water inlet fitting.

Water outlet fitting or

water inlet fitting
04S0033

(2) Align the mating marks on the radiator hose and hose
clamp, and then connect the radiator hose.

Mating marks

04W0044

PWWE8608-O ADDED
Mitsubishi Motors Corporation Jun. 1994
 COOLING - Water Pump (petrol-powered vehicles 4G32, 4G33) 14-17
WATER PUMP (PETROL-POWERED VEHICLES 4G32, 4G33) E14MA-

REMOVAL AND INSTALLATION

Pre-removal Operation Post-installation Operation

• Removal of driving seat Installation of radiator shroud
• Removal of seat underframe Supplying of coolant
(Refer to GROUP 01 GENERAL- (Refer to P. 14-7.)
Engine Compartment Work.) Installation of seat underframe
• Drainage of coolant Installation of driving seat
• Removal of radiator shroud
(Referto P.14-9.)

20-27 Nm
2.0-2.7 kgm
14-19 ft.lbs

m
Water pump kit
. 04BOO19

co
gn
10-12 Nm
1.0-1.2 kgm
7.2-9.0 ft.lbs
ia

15-18 Nm
1.5-1.8 kgm
rd

11-13 ft.lbs.
ca

10-12 Nm
1.0-1.2 kgm
7.2-9.0 ftlbs.

O4G0043

Removal steps
+m 1. Air conditioner compressor V-belt
(vehicles with an air conditioner)
* " • 2. Alternator V-belt
3. Cooling fan
4. Water pump pulley
5. Tension pulley bracket
(vehicles with an air conditioner)
6. Radiator lower hose
7. Crank shaft pulley
8. Timing belt upper cover NOTE
9. Timing belt lower cover (1) Reverse the removal procedures to reinstall.
• • • • - • 1 0 . Timing belt (2) • • : Refer to "Service Points of Removal".
* * 1 1 . Water pump (3) * • : Refer to "Service Points of Installation"
12. Water pump gasket (4) EJ : Non-reusable parts

© Mitsubishi Motors Corporation NOV. B6 PWWE8608

 14-18 COOLING - Water Pump (petrol-powered vehicles 4G32, 4G33)

SERVICE POINTS OF REMOVAL E14MBAD

10. REMOVAL OF TIMING BELT

Refer to GROUP 11 ENGINE-Timing Belt
99
INSPECTION
BELT
• Check the surface for damage, peeling or cracks.
• Check the surface for presence of oil or grease.
• Check the rubber for wear or hardening.
1C0004

WATER PUMP
• Check the each part for cracks, damage or wear, and replace
the water pump assembly if necessary.
/
• Check the bearing for damage, abnormal noise and sluggish
rotation, and replace the water pump assembly if necessary.
• Check the seal unit for leaks, and replace the water pump
assembly if necessary.
• Check for water leakage. If water leaks from hole "A" seal unit

m
is faulty. Replace as an assembly.

1C0005

. co
SERVICE POINTS OF INSTALLATION
11. INSTALLATION OF WATER PUMP
EUMDAE

Water pump installation bolt size are different and caution

gn
must be paid to ensure that they are properly installed.

No. Hardness category d x e Torque Nm

(Head mark) m m (in.) (kgm, ft.lbs.)
ia

Indication for 1 4T 8x28(0.31x1.10) 12-15

hardness category 04U002S ~2~ (1.2-1.5.
4T 8x55(0.31x2.17)
9-11)
rd

20-27
Alternator 3 7T (2.0-2.7,
8x70(0.31x2.76)
brace 14-19)
Az-
ca

10. INSTALLATION OF TIMING BELT

Refer to GROUP 11 ENGINE-Timing Belt
2. INSTALLATION OF ALTERNATOR V-BELT/1. AlR CONDI-
TIONER COMPRESSOR V-BELT
Install V-belts. Check belt tension.
(Refer to GROUP 11 ENGINE-Service Adjustment
Procedures.)
04GOO38

© Mitsubishi Motors Corporation NOV. 86 PWWE8608

 C O O L I N G - W a t e r P u m p (4G92) 14-18-1
WATER PUMP (4G92)
REMOVAL AND INSTALLATION

Pre-removal and Post-installation Op-

eration
• Engine Coolant Draining and Sup- 8-12 Nm
plying (Refer to P. 14-7.) 0.8-1.2 kgm
• Timing Belt Removal and Installa- 6-9 ft.lbs.
tion
(Refer to GROUP 11 - Timing Belt.)

20-27 Nm
2.0-2.7 kgm
14-20 ft.lbs.

m
.
Removal steps
co
gn
1. Alternator brace
2. Timing belt rear cover 35-55 Nm
M 3. Water pump 3.5-5.5 kgm 04X0007
25-40 ft.lbs.
ia

8x20
(0.31 xO.79)
rd
ca

8x35
(0.31 x 1.38)
04CO01O 04S0003
Bolt diameter x length: mm (in
Specified Sealant:
Mitsubishi Genuine Parts No.
NOTE
(1) Reverse the removal procedures to reinstall MD970389 or equivalent
(2) M : Refer to "Service Points of Installation"

SERVICE POINTS OF INSTALLATION

3. INSTALLATION OF WATER PUMP
Squeeze out the sealant from the tube evenly and apply it so
that there is not too much sealant and no places without seal-
ant.
Specified Sealant: Mitsubishi Genuine Parts No.
MD970389 or equivalent

"•" 04S0003
[Bead diameter: 2.4-3.0 mm (0.09-0.12 in.)]

X Mitsubishi Motors Corporation Jun. 1994 PWWE8608O ADDED

14-19 C O O L I N G — Water Pump (petrol-powered vehicles 4G63 - 8 valve, 4G64 - 8 valve, G63B, G64B]

WATER PUMP {PETROL-POWERED VEHICLES 4G63-8 VALVE, 4G64

8 VALVE, G63B, G64B)
REMOVAL AND INSTALLATION

Pre-removal Operation Post-installation Operation

• Removal of driving seat • Supplying of coolant
• Removal of seat underframe (Referto P. 14-7.)
Referto GROUP 01 GENERAL- • Installation of radiator cover or shroud
Engine Compartment Work.) (Referto P. 14-9.)
• Drainage of coolant • Installation of seat underframe
• Removal of radiator cover or shroud • Installation of driving seat
(Refer to P.14-9.)

20-27 Nm 16 CI 13
2.0-2.7 kgm
14-19 ft.lbs.

m
Water pump kit
. 10-12 Nm
1.0-1.2 kgm
7.2-9.0 ft.lbs.
co 12-15 Nm
.2-1.5 kgm
ETI 5

11 ft.lbs.
gn
ia
rd

8 - 1 0 Nm
0.8-1.0 kgm
ca

6-7.2 ft.lbs.
20-30 Nm
2.0-3.0 kgm
14-22 ft.lbs.
Removal steps
* * 1. Power steering oil pump V belt
(vehicles with a power steering) ^
• « 2. Air conditioner compressor V-belt
(vehicles with an air conditioner)
» 4 3. Alternator V-belt
4. Cooling fan
5. Water pump pulley
6. Tension pulley
(vehicles with an air conditioner)
7. Radiator lower hose
8. Crankshaft pulley
9. Timing belt upper cover
10. Timing belt lower cover
• • M 1 1 , Timing belt
« • • • 1 2 . Timing belt B
(vehicles for Europe and Australia) NOTE
13. Water pipe connection (1) Reverse the removal procedures to reinstall.
* • • 14. Water pump (2) Refer to "Service Points of Removal'
15. Water pump gasket (3) Refer to "Service Points of Installation"
• • • 1 6 . O-ring (4) CI Non-reusable parts

S Mitsubishi M o t o r s Corporation Jun. 1994 PWWE8608O REVISED

 C O O L I N G — W a t e r P u m p ( p e t r o l - p o w e r e d vehicles 4G63 - 8 v a l v e , 4G64 - 8 v a l v e . G63B, G64B) 14-20
SERVICE POINTS OF REMOVAL E^B«
11. REMOVAL OF TIMING BELT/12. TIMING BELT B
Referto GROUP 11 ENGINE-Timing Belt, Timing Belt B
®«
INSPECTION E14MCAC
BELT
• Check surface for damage, peeling or cracks.
• Check surface for presence of oil or grease.
• Check the rubber for wear or hardening.
1C0004

WATER PUMP
• Check each part for cracks, damage or wear, and replace the
water pump assembly if necessary.
• Check the bearing for damage, abnormal noise and sluggish
rotation, and replace the water pump assembly if necessary.
• Check the seal unit for leaks, and replace the water pump

m
assembly if necessary.
• Check for water leakage. If water leaks from hole "A" seal unit
is faulty. Replace as an assembly.

1C0005

co
r
SERVICE POINTS OF INSTALLATION EHMDAF
.
16. INSTALLATION OF WATER PIPE O-RING
gn

j y
) O-ring Fit water pipe O-ring in the groove provided at water pipe end,
wet the periphery of water pipe O-ring and insert water pipe.
Caution
ia

/ Water pipe
1. Do not apply oil and grease to water pipe O-ring.

E 2. Keep the water pipe connections free of sand, dust,

etc.
rd

3. Insert water pipe until its end bottoms.

04B0009 14. INSTALLATION OF WATER PUMP
ca

Water pump installation bolt size are different and caution

must be paid to ensure that they are properly installed.

d No. Hardness category d x t Torque Nm

(Head mark) mm (in.) (kgm, ft.lbs.)
1 4T 8x20(0.31x0.79) 12-15
2 4T (1.2-1.5,
i 8 x 3 0 (0.31x1.18)
9-11)
3 7T 8 x 6 5 (0.31x2.26) 20-27
Indication for
hardness category 04U0025
(2.0-2.7,
14-19)
4 4T 8x40 (0.31x1.57) 12-15
Alternatoi (1.2-1.5,
brace 9-11)

12. INSTALLATION OF TIMING BELT B/11. TIMING BELT

Referto GROUP 11 ENGINE-Timing Belt, Timing Belt B.
3. INSTALLATION OF ALTERNATOR V-BELT/2. AIR CONDI-
TIONER COMPRESSOR V BELT/1. POWER STEERING OIL
PUMP V-BELT
nstall V-belt. Check belt tension
(Refer to GROUP 11 ENGINE-Service Adjustment
04B0041 Precedures.)
Mitsubishi Motors Corporation Jun. 1994 PWWE8608-O REVISED
14-20-1 C O O L I N G - W a t e r P u m p (4G63, 4G64 - 16 valve)

WATER PUMP (4G63, 4G64 - 16 VALVE)

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Op

eration
• Engine Coolant Draining and Sup-
plying (Refer to P.14-7.)
• Drive Belt Removal and Installation
(Refer to GROUP 11 - Tming Belt

m
20-27 Nm __jgr
2.0-2.7 kgm
14-20 ft.lbs.
. co
12-15 Nm
1.2-1.5 kgm
9-11 ft.lbs.
04C0027
gn
8 x28
(0.31 x 1.10) 8x22
(0.31 x0.87)
ia

1
rd

Removal steps
1.
2.
Alternator brace
Water pump 8 x 65
(0.31 x 2.56) ywy
*J&*7 \A3y£A
8x14
ca

3. Water pump gasket (0.31 x0.55)

8 x 2 8 ^ ^
M 4. O-ring (0.31 x 1.10)
04U0O21

NOTE Bolt diameter x length: mm (in.

(1) Reverse the removal procedures to reinstall
(2) M • Refer to "Service Points of installation"
(3) m : Non-reusable parts

,-Water pump
SERVICE POINTS OF INSTALLATION
4. INSTALLATION OF O-RING
Insert the O-ring to the water inlet pipe, and coat the outlet
Circumference of the O-ring with water. By coating with wa-
Water pipe
ter, the insertion to the water pump will become easier.
n Caution
1.. Care must betaken not to permit engine oil or other
greases to adhere to the O-ring.
2. When inserting the pipe, check to be sure that there
is no sand, dirt, etc. on its inner surface.

-: Mitsubishi Motors Corporation Jun. 1994 PWWE8608-O ADDED

 COOLING - Water Pump (diesel-powered vehicles) 14-21
WATER PUMP {DIESEL-POWERED VEHICLES)
REMOVAL AND INSTALLATION

Pre-removal Operation Post-installation Operation

• Removal of driving seat • Supplying of coolant
• Removal of seat underframe (Referto P. 14-7.)
(Refer to GROUP 01 GENERAL- • Installation of radiator cover
Engine Compartment Work.) (Referto P. 14-9.)
• Drainage of coolant • Installation of seat underframe
• Removal of radiator cover • Installation of driving seat
(Referto P. 14-9.)
14-21 Nm
1.4-2.1 kgm
14-21 Nm 10-15 ft.lbs.
1.4-2.1 kgm
10-15 ft.lbs.

m
25-33 Nm
2.5-3.3 kgm
18-24 ft.lbs

10-13 Nm
1.0-1.3 kgm
7.2-9.4 ft.lbs
. co
115E116 18

>®>
gn
10-12 Nm
1.0-1.2 kgm 19 0 2 0 0
7.2-9 ft.lbs. 12-15 Nm
ia

1.2-1.5 kgm
170-190 Nm 9 - 1 1 ft.lbs.
17-19 kgm
rd

123-137 ft.lbs
20-27 Nm
1.2-1.5 kgm 2.0-2.7 kgm
9 - 1 1 ft.lbs 14-19 ft.lbs.
ca

15 19
1

10-12 Nm
6mHN
A\)
1.0-1.2 kgm
7.2-9 ft.lbs 18 ^ )

04G0045 Water pump kit

Removal steps
• • 1. Power steering oil pump V-belt ••13. Power steering oil pump and bracket
(vehicles with a power steering) 14. Water pump fitting
• • 2. Air conditioner compressor V-belt 15. Water pump fitting gasket
(vehicles with an air conditioner) 16. Thermostat
* * 3. Alternator V-belt 17. Water pipe connection
4. Cooling fan ••18. Water pump
5. Water pump pulley 19. Water pump gasket
6. Tension pulley bracket ••20. Water pipe O-ring
(vehicles with an air conditioner)
7. Radiator lower hose
8. Crankshaft pulley NOTE
9. Timing belt upper cover (1) Reverse the removal procedures to reinstall.
10. Timing belt lower cover (2) * * Refer to "Service Points of Removal".
• ^ • - « 1 1 . Timing belt (3) • • Refer to "Service Points of Installation".
• • • * 1 2 . Timing belt B (4) 13 Non-reusable parts
© Mitsubishi Motors Corporation NOV. 86 PWWE8608
14-22 COOLING - Water Pump (diesel-powered vehicles)

SERVICE POINTS OF REMOVAL

11. REMOVAL OF TIMING BELT/12. TIMING BELT B
Refer to GROUP 11 ENGINE-Timing Belt. Timing Belt B
99
INSPECTION
BELT
• Check the surface for damage, peeling or cracks.
• Check the surface for presence of oil or grease.
• Check the rubber for wear or hardening.
1C0004

WATER PUMP
• Check each part for cracks, damage or wear, and replace the
water pump assembly if necessary.
• Check the bearing for damage, abnormal noise and sluggish
rotation, and replace the water pump assembly if necessary.
• Check the seal unit for leaks, and replace the water pump
assembly if necessary.
• Check for water leakage. If water leaks from hole "A" seal unit

m
is defective. Replace as an assembly.

1C000S

co
SERVICE POINTS OF INSTALLATION
20. INSTALLATION OF WATER PIPE O-RING
E,<MDAG

f
.
y
/ O-ring Fit water pipe O-ring in the groove provided at water pipe end,

3
gn
wet the periphery of water pipe O-ring and insert water pipe.

y Water pipe Caution

1. Do not apply oil and grease to water pipe O-ring.
/ 2. Keep the water pipe connections free of sand, dust,
ia

etc.
• . 3. Insert water pipe until its end bottoms.
rd

04BOOO9

18. INSTALLATION OF WATER PUMP

Water pump installation bolt size are different and caution
ca

must be paid to ensure that they are properly installed.

No. Hardness category dx e Torque Nm

(Head mark) mm (in.) (kgm, ft.lbs.)
1 4T 8x25(0.31x0.98) 12-15
(1.2-1.5
2 4T 8x40(0.31x1.57)
Indication for 9-11)
hardness category 04U0025
20-27
3 7T 8x70(0.31x2.76) (2.0-2.7
14-19)

13. INSTALLATION OF POWER STEERING OIL PUMP AND

BRACKET
Refer to GROUP 37 STEERING-Power Steering Oil Pump.

04G0037

I Mitsubishi Motors Corporation NOV. 86 PWWE8608

 COOLING - Water Pump (diesel-powered vehicles) 14-23

12. INSTALLATION OF TIMING BELT B/11. TIMING BELT

Referto GROUP 11 ENGINE-Timing Belt, Timing Belt B.
3. INSTALLATION OF ALTERNATOR V-BELT/2. AIR CONDI-
TIONER COMPRESSOR V-BELT/1. POWER STEERING OIL
PUMP V-BELT
Install V-belts. Check belt tension.
(Refer to GROUP 11 ENGINE-Service Adjustment
Procedures.)

m
. co
gn
ia
rd
ca

© Mitsubishi Motors Corporation NOV. 86 PWWE8608

14-24 COOLING - Water Hose and Water Pipe

WATER HOSE AND WATER PIPE

REMOVAL AND INSTALLATION

Pre-removat Operation Post-installation Operation

* Drainage of coolant • Supplying of coolant
• Removal of driving seat (Referto P. 14-7.)
• Removal of seat underframe • Installation of driving seat
(Refer to GROUP 01 GENERAL--Engine • Installation of seat underframe
Compartment Work.)
4G33.4G32 4G63 - 8 valve, G63B
10-12 Nm 12-15 Nm
1.0-1.2 kgm 1.2-1.5 kgm
7.2-8.6 ft.lbs. 8.6-11 ft.lbs.

m
. \ co
gn
04G0047
Q4G0046
4D56 12-15 Nm
4 G 6 4 - 8 valve, G64B 12-15 Nm «Vehicles built up to June 1993> 1.2-1.5 kgm
ia

1.2-1.5 kgm 8.6-11 ft.lbs.

8.6—11 ft.lbs. 9
iom
rd

iom 10-12 Nm
1.0-1.2 kgm
7.2-8.6 ft.lbs.
ca

04G0048 04G0008

Removal steps
1. Water hose
3. Heater hose
9. Water pipe assembly
M 10. 0-rmg

NOTE
(1) Reverse the removal procedures to reinstall.
(2) • • : Refer to "Service Points of Installation'
(3) E l : Non-reusable parts
(4) * indicates vehicles for Europe and Australia.

S Mitsubishi Motors Corporation Jun. 1994 PWWE8608O REVISED

 COOLING - Water Hose and Water Pipe 14-24-1
4G92 4G63 - 16 valve (Except MPI) 19-28 Nm
1.9-2.8 kgm
14-20 ft.lbs.
10-15 Nm
1.0-1.5 kgm
7-11 ft.lbs. 43-55 Nm
19-28 Nm 4.3-5.5 kgm
1.9-2.8 kgm 31-40 ft.lbs.
14-20 ft.lbs.

43-55 Nm

m
4.3-5.5 kgm
31-40 ft.lbs.
O4G0O91
22-25 Nm

co
2.2-2.5 kgm \
16-18 ft.lbs. A

4G63, 4G64 - 16 valve (MPI) 4D56 «Vehicles built from July 1993>
. 35-50 Nm
gn
19-28 Nm 3.5-5.0 kgm 1 f t _ 1 o M m
1.9-2.8 kgm 35-50 Nm 25-36 ft.lbs. i 0 - l 2 kqm
y
14-20 ft.lbs. 3.5-5.0 kgm \ 7 1 9 ft | b
25-36 ft.lbs. m
10-15 Nm ^ 12-15 Nm
1.0-1.5 kgm 12-1.5 kgm
ia

43-55 Nm
7-11 ft.lbs. ßJ1 9-11 ft.lbs.
4.3-5.5 kgm
19-28 Nm 31-40 ft.lbs.
1.9-2.8 kgm m -m
rd

14-20 ft.lbs. J» A5> m «4

mio-xQ
ca

10-12 Nm
1.0-1.2 kgm
7-9 ft.lbs.

yy

"•- - •• O4GO106

R emoval steps
1. Water hose 9. Water pipe assembly
2. Water hose M 10. O-ring
3. Heater hose 11. Thermostat case assembly
4. Water hose 12. Water hose
5. Water pipe assembly (B) 13. Water inlet pipe
6. Water pipe assembly (A) M 14. 0-rmg
7. Water hose
M 8. Water by-pass fitting NOTE
* : Vehicles with turbocharger.

'£; Mitsubishi Motors Corporation Jun. 1994 PWWE8608-O ADDED

14-25 COOLING - Water Hose and Water Pipe

INSPECTION E1 4TCAI3

• Check the water pipe for cracks, damage or clogging.

• Check the water hose for crack, damage, wear or clogging.

SERVICE POINTS OF INSTALLATION EUTDAB

14./10 INSTALLATION OF O-RING
Replace O-ring on water inlet pipe front end. Wet O-ring for
easy insertion into water pump.
Caution
Do not apply grease (engine oil or other) on O-ring.

m
. Water by-pass
fitting
6C0035

co
8. INSTALLATION OF WATER BY-PASS FITTING
(1) Use a gasket scraper or wire brush to clean all foreign
materials from the surface of the gasket.
gn
(2) Apply an even amount of specified sealant to the surface
of the gasket.
Specified sealant:
ia

Mitsubishi Genuine Parts No.

MD970389 or equivalent
01GO290
(3) Before the sealant has dried (within 15 minutes), install
rd

IBead diameter: 2.4-3.0 mm (0.09-0.12 in.)] the water bypass fitting.

ca

© Mitsubishi Motors Corporation Jun. 1994 PWWE8608-O REVISED

 COOLING - Engine Coolant Temperature Gauge Unit. Thermo Switch and Engine Coolant Temperature Sensor 1 4 - 2 6

ENGINE COOLANT TEMPERATURE GAUGE UNIT, THERMO SWITCH

AND ENGINE COOLANT TEMPERATURE SENSOR
REMOVAL AND INSTALLATION E14UA—

Pre-removal Operation Post-installation Operation

• Drainage of coolant • Supplying of coolant
• Removal of driving seat and seat underframe (L.H.D.) (Refer to P. 14-7.)
(Refer to GROUP 01 -Engine Compartment Work.) • Installation of driving seat and seat underframe (L.H.D.

4G33 , 4G32 8-10 Nm» 3 4G63 - 8 valve, G63B

0.8-1.0 kgm* 3
5.8-7.2 ft.lbs.*3
10-12 Nm* 4
1.0-1.2 kgm* 4
7.2-8.6 ftlbs.* 4 20-40 Nm
2.0-4.0 kgm
14-29 ft.lbs.

m
20-40 Nm

. co 6 - 9 Nm
2.0-4.0 kgm
14-29 ft.lbs.

0.6-0.9 kgm
gn
4.3-6.5 ft.lbs.

04G0O49
04G0Q51
8-10 Nm* 3 10-12 Nm* 4
0.8-1.0 kgm* 3 1.0-1.2 kgm* 4
ia

5.8-7.2 ft.lbs.*3 7.2-8.6 ft.lbs.*4

4 G 6 4 - 8 valve, G64B 4D56

10-12 Nm* 4 8-10 Nm* 3 3 7-9 Nm
rd

1.0 -1.2 kgm** 0.8- 1.0 kgm* 3 0.7-0.9 kgm

4
7.2 -8.6 ft.lbs.* 5.8- 8.6 ft.lbs.* 5.1-6.5 ft.lbs.
ca

ry® 6 - 9 Nm
0.6-0.9 kgm
4.3-6.5 ft.lbs.

20-40 Nm
2.0-4.0 kgm
14-29 ft.lbs.

' 8 - 1 0 Nm* 3 10-12 Nm*

0.8-1.0 kgm* 3 3 1 ° - H £ 9 . ? . 44
5.8-7.2 ft lbs.* 7.2-8.6 ft.lbs.»
04GO05O
04G0071

NOTE
*«1. Engine coolant temperature gauge unit (1) +m : Refer to "Service Points of Installation .
•»•2. Thermo switch (only for Europe 4G63 and (2) * 1 indicates for G63B.
automatic transmission equipped vehicles (3) *2 indicates vehicles with automatic transmission.
for Australia) (4) *:i indicates vehicles built up to September 1987.
Engine coolant temperature sensor (5) *4 indicates vehicles built from October 1987.
Thermo switch < 4 W D >

REVISED
© Mitsubishi Motors Corporation Jun. 1994 PWWE8608O
 I *|-^Ö- I C O O L I N G — Engine Coolant Temperature Gauge Unit, Thermo Switch and Engine Coolant Temperature Sensor

Pre-removal Operation Post-installation Operation

• Drainage of coolant • Supplying of coolant
• Removal of driving seat and seat (Refer to P. 14-7.)
underframe (L.H.D.) • Installation of driving seat and seat underframe
• Removal of driving seat and seat
underframe (R.H.D.)
<4G63, 4G64>
(Refer to GROUP 01 - Engine 20-40 Nm
Compartment Work 2.0-4.0 kgm
14-29 ft.lbs.

1
10-12 Nm
1.0-1.2 kgm
7-9 ft.lbs.

m
. co
gn

04G0121
ia

4G63, 4G64 - 16 valve

rd

10-12 Nm
6-9 Nm 1.0-1.2 kgm
0.6-0.9 kgm 7-9 ft.lbs.
4-7 ft.lbs.
ca

AZA

m<yk^z-y,
w \yfyyyAy .
x AAAyAyAAyy
y y ^ j j i i X------A o
\ A :A "y
NX x
V 20-4.0 Nm
2.0-4.0 kgm
A \ X A- 14-12 ft.lbs.
A
H 1- Engine coolant temperature gauge unit
H 2. Thermo switch <Vehicles with automatic transmission>
M 3. Engine coolant temperature sensor
<Except vehicles with conventional carburetor>

NOTE
( D M : Referto "Service Points of Installation'

© Mitsubishi Motors Corporation Jun. 1994 PWWE8608O ADDEO

 —
COOLING Engine Coolant Temperature Gauge Unit, Thermo Switch and Engine Coolant Temperature Sensor 1 **'£.!

INSPECTION E14UCAA.
Petrol-powered Diesel-powered ENGINE COOLANT TEMPERATURE GAUGE UNIT AND EN-
vehicles vehicles GINE COOLANT TEMPERATURE SENSOR
Raise the water temperature and measure the resistance if within
the standard value.
^Terminal
Terminal (A) Engine coolant temperature gauge unit
Standard value
Petrol-powered vehicles
104±13.5 Q [at 70°C {158°F)]
Diesel-powered vehicles
04G0034 Terminal A
6C0003
104±13.5 Q [at 70°C (158°F)]
Terminal B
3.25±0.33 kQ [at 20°C (68°F)]
300 Ü [at 80°C {176°F)]

® NOTE
Terminal A is for engine coolant temperature gauge. Terminal B is

m
for glow control.

. 04G0O31
co
Engine coolant temperature sensor
gn
Standard value
<Vehicles built up to May 1994>
2.45 ±0.24 kQ [at 2 0 C (68°F)]
296±32Q[at80°C(176°F>]
®J
ia

f-v—Y^ <Vehicles built from May 1994>

2.37 ± 0.24 kQ [at 2 0 C (68 F)]
\ 290±32Q[at80°C(176F)]
> LJ
rd

J
04G0O32
ca

THERMO SWITCH
Raise water temperature and check continuity when it reaches
the specified temperature.
m Standard value
4G63 for Europe
Ct_/tL -A „®, 65°C (149°F) or more No continuity
_._.._, 65°C (149°F) dimmer Continuity
Ohmmeter Vehicles with automatic transmission
\ ' JP I
50°C (122°F) or more Continuity
v .X 50°C (122°F) dimmer No continuity
A
sensor 04G0033 Diesel powered vehicles "4WD>
115°C (239°F)or more Continuity
115°C (239°F) dimmer No continuity

© Mitsubishi Motors Corporation Jun. 1994 PWWE8608O REVISED

I 4 ~ 2 8 COOLIIMG — Engine Coolant Temperature Gauge Unit, Thermo Switch and Engine Coolant Temperure Sensor

Sealant
SERVICE POINTS OF INSTALLATION EI4UOAA.

il : / 4. INSTALLATION OF THERMO SWITCH/3. ENGINE COOL-

ANT TEMPEARTURE SENSOR/2. THERMO SWITCH/
1. ENGINE COOLANT TEMPERATURE GAUGE UNIT
h
1
!
\
i
1
zwV Specified sealant
Thermo switch. Engine coolant temperature sen-
~J— \ A
• M

sor. Engine coolant temperature gauge

unit(Diesel powered vehicles)
3M Nut Locking Part No.4171 or equivalent
6CD043
Engine coolant temperature gauge unit
(Petrol-powered vehicles)
3M ATD Part No.8660 or equivalent

m
. co
gn
ia
rd
ca

C Mitsubishi Motors Corporation Jun. 1930 PWWE8608-H ADDED

 15-1

INTAKE AND
EXHAUST
CONTENTS E15AA—

AIR CLEANER - 6

m
GENERAL INFORMATION

SPECIFICATIONS 3 INTAKE MANIFOLD - 12

General Specifications
Service Specifications
Torque Specifications
Sealant and Adhesive
. co
3
4
4
5
EXHAUST MANIFOLD

INTAKE AND EXHAUST MANIFOLD

EXHAUST PIPES AND MUFFLERS

18

22

24
gn
TROUBLESHOOTING 5
ia
rd
ca

REVISED
© Mitsubishi Motors Corporation Jun. 1994 PWWEB608-O
 15-2 INTAKE AND EXHAUST - General Information

GENERAL INFORMATION E15BAAG

All models are equipped with dry type air cleaners. A resonator is installed on all models except 4G32 and 4G33
to prevent resonance in induction system.
An air flow sensor and intake air temperature sensor are installed for MPI air cleaner.
The exhaust system is divided into the front exhaust pipe and main muffler, between which a catalytic converter
is installed on FBC and MPI vehicles.

P e t r o l - p o w e r e d vehicles w i t h o u t M.P.I. Petrol-powered vehicles w i t h M.P.I.

(4G63, G63B) (4G64, G64B)
Air duct B Air duct C Air duct B . Air duct C

Air duct A Air cleaner Air cleaner

m
Air duct A
Resonator
Air intake hose

Air horn
. co Air intake hose
gn
Resonator Air horn
ia
rd

31N062 05G0022

Diesel-powered vehicles
ca

Air duct C
Air duct B
Resonator
Air cleaner

Air intake hose

Air duct A

X
D1N013

© Mitsubishi M o t o r s Corporation N O V . BE PWWE8608

 INTAKE AND EXHAUST - Specifications 15-3

SPECIFICATIONS
GENERAL SPECIFICATIONS E,5CA-
<Vehicles built up t o May 1994>
VEHILCES FOR EUROPE

Petrol-powered vehicles
Items Diesel-powered vehicles
Without M.P-I- With M.P.I.

Air filter
Type Dry type Dry type Cyclone type
Heated air intake Vacuum motor type
Element. Unwoven cloth type Unwoven cloth type Filter paper type

Exhaust system
Front exhaust pipe Single or dual type* Dual type Single type
Muffler Expansion resonance type Expansion resonance type Expansion resonance type
Coupling Spherical coupling or Flat coupling Spherical coupling

m
flat coupling*
Suspension system Rubber hangers Rubber hangers Rubber hangers

NOTE
* indicates 4G63 (Mini-bus) and G63B.

VEHICLES FOR GENERAL EXPORT

. co
gn
Items Petrol-powered vehicles Diesel-powered vehicles

Air filter
Type Dry type (cyclone type)* Cyclone type
ia

Heated air intake Vacuum motor type*

Element Filter paper type Filter paper type

Exhaust system
rd

Front exhaust pipe Single type

Muffler Expansion resonance type
ca

Coupling Spherical coupling

Suspension system Rubber hangers

NOTE
* indicates vehicles for Gulf countries. Optional for other vehicles.

VEHICLES FOR AUSTRALIA

Petrol-powered vehicles
Items Diesel-powered vehicles
Without M.P.I. With M.P.I.
Air filter
Type Cyclone type Cyclone type Cyclone type
Heated air intake Vacuum motor type
Element Filter paper type Filter paper type Filter paper type

Exhaust system
Front exhaust pipe Single*1 or dual* 7 type Dual type Single type
Muffler Expansion resonance type Expansion resonance type Expansion resonance type
Coupling Spherical*1 or flat* 2 coupling Flat coupling Spherical coupling
Suspension system Rubber hangers Rubber hangers Rubber hangers

NOTE
(1) «i indicates Van (4G63 engine) [Vehicles built up to September 1988].
(2) *'1 indicates Van (4G63 engine) [Vehicles built from October ] and Mini-bus.
© Mitsubishi Motors Corporation Jun. 1994 PWWE8608-O
 15-3-1 INTAKE A N D E X H A U S T - Specifications

<Vehicles built from June 1994>

VEHICLES FOR EUROPE

Petrol-powered vehicles
Items
Without M.P.I. With M.P.I. uiebti-puwetBu veimjieb

Air filter •—
Type Dry type (cyclone type)* Cyclone type
Dry type (cyclone type)*
Heated air intake Vacuum motor type
Element Unwoven cloth type Unwoven cloth type Filter paper type
(Filter paper type)* (Filter paper type)*
Exhaust system
Front exhaust pipe Single type Single type
Muffler Expansion resonance type Expansion resonance type
Coupling Spherical coupling and flat coupling Spherical coupling
Suspension system Rubber hangers Rubber hangers

NOTE
* indicates optional

m
V E H I C L E S FOR G E N E R A L E X P O R T

Petrol-powered
H vehicles i n. . ,
! Diesel-powered

co
Items
4G92 4G63 (Van) 4G63 (Mini-bus) vehicles
Air filter
Type Dry type (cyclone Cyclone type Dry type (cyclone Cyclone type
. type)*1 type)* 3
gn
Heated air intake Vacuum motor type* 2 - ; Vacuum motor type* 1
:
Element Filter paper type Filter paper type Filter paper type Filter paper type
(Unwoven cloth type)*2 | : (Unwoven cloth type)* 1
Exhaust system
ia

Front exhaust pipe Single type Single type

Muffler Expansion resonance type Expansion resonance
type
rd

Coupling Spherical coupling and flat coupling Spherical coupling

Suspension system Rubber hangers Rubber hangers
ca

NOTE
(1) * 1 indicates optional
(2) * 2 indicates vehicles with FBC. Optional for other vehicles.
(3) * 3 indicates vehicles for Gulf countries. Optional for other vehicles.

V E H I C L E S FOR A U S T R A L I A

Petrol-powered vehicles
Items Diesel-powered vehicles
Without M.P.I With M.P.I.
Air filter
Type Cyclone type Cyclone type
Heated air intake Vacuum motor type
Element Filter paper type Filter paper type
Exhaust system
Front exhaust pipe Single type Single type
Muffler Expansion resonance type Expansion resonance type
Coupling Spherical coupling and flat coupling Spherical coupling
Suspension system Rubber hangers Rubber hangers

«S Mitsubishi Motors Corporation Jun. 1994 PWWE860BO ADDED

 INTAKE A N D E X H A U S T - Specifications 15-4
SERVICE SPECIFICATIONS E15CB--

Specifications
Items

Standard value
Distortion of the cylinder head installation surface mm (in.) Less than 0.15 (0.006)
Turbocharger super charge pressure 2
kPa (kg/cm , psi) Approx. 7 0 - 8 6 (0.70- 0.80, 1 0 - 1 2 )
Operation starting pressure of waste gate actuator kPa (kg/cm z , psi) Approx. 77 (0.77, 11)

Limit
Distortion of the installation surface mm (in.) 0.2 (0.008)

E15CC
TORQUE SPECIFICATIONS
Nm kgm ft.lbs.
Items
17-20 1.7-2.0 12-14
Water outlet fitting to intake manifold* 1

m
Intake manifold to cylinder head* 2 15-20 1.5-2.0 11 - 1 4
Distributor to intake manifold 10-13 1.0-1.3 7-9
Delivery pipe to intake manifold* 1 0 - 13 1.0-1.3 7-9
Ignition coil to intake manifold*
Intake manifold stay to intake manifold*
Surge tank to intake manifold*
.
Surge tank stay to surge tank
co 12-15
18-25
15-20
15-20
1.2-1.5
1.8-2.5
1.5-2.0
1.5-2.0
9-11
13-18
11 - 1 4
11 - 1 4
gn
Throttle body assembly to surge tank*
Vehicles built up to June 1989 10-13 1.0-1.3 7-9
Vehicles built from July 1989 15-22 1.5-2.2 11-16
10-12 1.0-1.2 7.2-8.6
ia

Air intake pipe to rocker cover*

Connector clamp bracket assembly to rocker cover* 12-15 1.2-1.5 9-11
Fuel high pressure hose and delivery pipe* 25-35 2.5-3.5 18-25
rd

Exhaust manifold to cylinder head* 2 15-20 1.5-2.0 11 - 1 4

Inlet fitting to intake manifold 10-13 1.0-1.3 7-9
Oil pipe flare bolt 16-24 1.6-2.4 12-17
ca

Oil pipe to intake manifold 8-10 0.8-1.0 6-7

Oil pipe eye bolt 14-19 1.4-1.9 10-14
Waste gate actuator to intake manifold 15-22 1.5-2.2 11-16
Turbocharger to exhaust manifold 50-70 5.0-7.0 36-51
Oil return pipe to turbocharger 8-10 0.8-1.0 6-7
Heat protector (B) to exhaust manifold 8-10 0 . 8 - 1.0 6-7
Heat protector (C) to exhaust fitting
Vehicles built up to October 1987 12-15 1.2-1.5 8.7-11
Vehicles built from November 1987 27-33 2.7-3.3 20-23
Exhaust fitting to turbocharger 50-70 5.0-7.0 36-51
Heat protector (A) to turbocharger 8-10 0 . 8 - 1.0 6-7
Engine bracket and exhaust manifold to cylinder head
Vehicles built up to October 1987 12-15 1.2-1.5 8.7-11
Vehicles built from November 1987 27-33 2.7-3.3 20-23
Heat cowl to exhaust manifold 8-10 0.8-1.0 5.8-7.2

NOTE
* ; 4G64- 8 valve (M.P.I.)
*T Except 4G63-16 valve
* 2 : Except 4G92 and 4G63 - 16 valve

PWWE8608-O REVISED
© Mitsubishi Motors Corporation Jun. 1994
 15-4-1 INTAKE AND EXHAUST - Specifications

Items Nm kgm ft.lbs.

—
Air pipe assembly to exhaust manifold 20-30 2.0-3.0 18-22
Air pipe assembly to exhaust manifold* 70-100 7.0-10.0 51-72
Air pipe assembly to air pipe stay 10-13 1.0-1.3 7.2-9.4
Air pipe stay to exhaust manifold
Vehicles built up to October 1987 12-15 1.2-1.5 8.7-11
Vehicles built from November 1987 27-33 2.7-3.3 20-23
Reed valve to reed valve stay 10-13 1.0-1.3 7.2-9.4
Oxygen sensor to exhaust manifold 40-50 4.0-5.0 29-36
Front exhaust pipe to exhaust manifold
Single exhaust pipe (petrol-powered vehicles)* 1 25-35 2.5-3.5 18-25
Single exhaust pipe (diesel-powered vehicles) 30-40 3.0-4.0 22-29
Dual exhaust pipe 40-55 4.0-5.5 29-40
Front exhaust pipe bracket 20-30 2.0-3.0 14-22
Front exhaust pipe to under catalytic converter* 2 50-70 5.0-7.0 36-50
Under catalytic converter to main muffler* 2 30-40 3.0-4.0 22-29
Front exhaust pipe to main muffler

m
20-30 2.0-3.0 14-22
Fuel vapor separator and vapor hose and
pipe assembly to intake manifold 19-28 1.9-2.8 14-20
Thermo valve to intake manifold (upper)

co
20-35 2.0-3.5 14-25
Engine coolant temperature sensor to intake manifold 20-40 2.0-4.0 14-29
Engine coolant temperature gauge unit
to intake manifold 10-12 1.0-1.2 7-9
EGR valve to intake manifold
.
gn
4G92 17-22 1.7-2.2 12-16
4G63, 4G64 17-26 1.7-2.6 12-19
EGR valve to inlet fitting 15-20 1.5-2.0 11-14
Intake manifold stay
ia

4G92 27-34 2.7-3.4 20-25

4G63, 4G64 12-15 1.2-1.5 9-11
Vacuum pipe assembly to intake manifold
rd

8-12 0.8-1.2 5.8-8.9

Thermo valve to intake manifold (lower)
Single joint type 20-50 2.0-5.0 14-36
Except single joint type
ca

20-40 2.0-4.0 14-29

Kick-down cable bracket to intake manifold 12-15 1.2-1.5 9-11
Intake manifold to cylinder head* 3 17-22 1.7-2.2 12-16
Water outlet fitting to cylinder head* 4 17-22 1.7-2.2 12-16
Heat protector to exhaust manifold 12-15 1.2-1.5 9-11
Secondary air pipe
Reed valve side 50-60 5.0-6.0 36-43
j Exhaust manifold side 70-100 7.0-10.0 51-72
NOTE
*: G63B
A Vehicles with spherical coupling exhaust pipe
* 2 : Except 4G92 (Hong Kong)
* 3 : 4G92, 4G63 and 4G64 - 16 valve
* 4 : 4G63 and 4G64 - 16 valve

X Mitsubishi Motors Corporation Jun. 1994 PWWE86080

 INTAKE AND EXHAUST - Specifications/Troubleshooting 15-5

Items Nm kgm ft.lbs.

Exhaust manifold attaching nut A

4G92 15-20 1.5-2.0 11-14
4G63 and 4 G 6 4 - 1 6 valve 25-30 2.5-3.0 18-22
Exhaust manifold attaching nut B 27-33 2.7-3.3 20-24
Inlet fitting to intake manifold 10-13 1.0-1.3 7-9
EGR pipe 15-20 1.5-2.0 11-14
Water pipe to turbocharger 34-49 3.5-5.0 25-36
Front exhaust pipe to exhaust manifold* 1 40-60 4.0-6.0 29-43
Front exhaust pipe to under catalytic converter* 2 30-40 3.0-4.0 22-29
Under catalytic converter to main muffler* 2 50-70 5.0-7.0 36-50

NOTE
* 1 : Vehicles with flat coupling exhaust pipe.
* 2 : 4G92 (Hong Kong)

m
SEALANT AND ADHESIVE

co
Items Specified sealant and adhesive Remarks

Engine coolant temperature 3M ATD Part No. 8660 or equivalent Semi drying sealant
gauge unit
.
Engine coolant temperature 3M Nut Locking Part No. 4171 or equivalent Drying sealant
gn
sensor
Thermo switch

Water outlet fitting • Mitsubishi Genuine Parts No. MD970389or Semi drying sealant
ia

: equivalent
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TROUBLESHOOTING
ca

Symptom Probable cause Remedy Reference page

Exhaust gas Loose joints Retighten 15-24,25
leakage Broken pipe or muffler Repair or replace 15-24, 25
Abnormal noise Broken separator in muffler Replace 15-24, 25
Broken rubber hangers Replace 15-24, 25
Interference of pipe or muffler with vehicle Correct 15-24, 25
body
Broken pipe or muffler Repair or replace 15-24, 25

S Mitsubishi Motors Corporation Jun. 1994 PWWE8608 0 REVISED

15-6 INTAKE AND EXHAUST - Air Cleaner

AIR CLEANER
REMOVAL AND INSTALLATION [Petrol-powered vehicles (except M.P.I.)]

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Removal steps
1. Air intake hose
2. Resonator
3. Inner vent hose
4 Air duct C
5. Air duct B 05GO101
6. Air duct A
7. Secondary air hose
8. Vacuum hose
9. Air cleaner cover
10. Air cleaner element
11. Heat duct
12 Air cleaner body
NOTE
(1) Reverse the removal procedures to reinstall.
(2) *i : Vehicles with a secondary air pipe
(3) * 2 : Vehicles with a hot air control valve
(4) * 3 : Vehicles built from June 1994
';;: Mitsubishi M o t o r s Corporation J u n . 1994 PWWE8608-O REVISED
 INTAKE AND EXHAUST - Air Cleaner 15-7
INSPECTION EiMCAc
Cover • Check the air cleaner body, cover or packing for deformation,
corrosion or damage.
• Check the air duct for damage.
Packing

Z
35G0019

Check the air cleaner element for clogging, contamination or

damage.
If element is slightly clogged, remove dust by blowing air from
inside of element.

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Vacuum motor
. 01R0196
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CHECKING OF THE HOT AIR CONTROL VALVE
Check to ensure that when negative pressure is applied to nipple
gn
\ Negative of vacuum motor, valve operates as indicated by arrow.
pressure
ia
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Hot air control valve

51N003
ca

© Mitsubishi Motors Corporation NOV. 86 PWWE8608

15-8 INTAKE AND EXHAUST - Air Cleaner

REMOVAL AND INSTALLATION [Petrol-powered vehicles (with M.P.I.}]

Ayz
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^

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11
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8 05G0017

Removal steps
1. Air intake hose
2. Air duct C
3. Air duct B
4. Air duct A
5. Air cleaner cover
6. Air cleaner element
7. Air cleaner body
8. Resonator
• * 9. Air flow sensor
10. Air flow sensor gasket
11. Noise reduction filter
NOTE
(1) Reverse the removal procedures to reinstall.
(2) mm Refer to "Service Points of Removal".
(3) ß l : Non-reusable parts

© Mitsubishi Motors Corporation JUL 87 PWWE8608-B REVISED

 INTAKE AND EXHAUST - Air Cleaner 15-9
SERVICE POINTS OF REMOVAL »»»c
9. REMOVAL OF AIR FLOW SENSOR
Remove air flow sensor from air cleaner case.
Caution
Do not pull air flow sensor harness, because its grommet
is fitted in air cleaner case.

INSPECTION »»«a
• Check the air cleaner body, cover or packing for deformation,
Cover
corrosion or damage.
• Check the air duct for damage.
Packing

m
. Body

05GOO19
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Check the air cleaner element for clogging, contamination or
damage.
gn
If element is slightly clogged, remove dust by blowing air from
inside of element.
Check the air cleaner for clogging, contamination or damage.
ia
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01R0196
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CHECKING OF THE AIR FLOW SENSOR

For inspection of air flow sensor, refer to GROUP 13 FUEL
—Checking of the air flow sensor

© Mitsubishi Motors Corporation NOV 86 PWWE8608

 15-10 INTAKE AND EXHAUST - Air Cleaner

REMOVAL AND INSTALLATION (Diesel-powered vehicles)

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05G0018

Removal steps
1. Air intake hose
2. Air duct C
' 3. Air duct B
4. Air duct A
5. Air cleaner assembly
6. Dust pan assembly
7. Wing bolt
8. Air cleaner element
NOTE
Reverse the removal procedures to reinstall.

© Mitsubishi Motors Corporation NOV. 86 PWWE8608

 INTAKE AND EXHAUST - Air Cleaner 15-11

a INSPECTION
•

•
™°«G
Check the air cleaner body, cover or packing for deformation,
corrosion or damage.
Check the air duct for damage.

Air cleaner body

y»
ft

A ka— — Packing
-Dust pan assembly
05G002O

Check the air cleaner element for clogging, contamination or

damage.
If element is slightly clogged, remove dust by blowing air from
inside of element.

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. 01R0196
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© Mitsubishi Motors Corporation NOV. 86 PWWE8608

 ID- IZ I N T A K E A N D E X H A U S T - Intake Manifold [Petrol-powered Vehicles built up to May 1994 (except M.P.I. I]

INTAKE MANIFOLD [PETROL-POWERED VEHICLES BUILT UP TO MAY

1994 (EXCEPT M.P.I.)]
REMOVAL AND INSTALLATION

Pre-removal Operation
Removal of driver's scat <4G32, 4G33)
Removal of seat under frame
(Refer to GROUP 01-Engine Compartment 04G0012
Work..)
Draining of engine coolant

Post-installation Operation
Filling of engine coolant
(Refer to GROUP 14-Service Adjustment
Procedures)
Installation of seat under frame
* Installation of driver's seat

17-20 Nm (4G63, G63B)

1.7-2.0 kgm
12-14 ft.lbs.

m
4

. P" X(t^ co 15-20 Nm

1.5-2.0 kgm
gn
11-14 ft.lbs.
ia

15* El
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10

1315 15-20 Nm
ca

1.5-2.0 kgm
11-14 ft.lbs.

10 13 Nm 05G0015
1.0-1.3 kgm
7 9 ft.lbs.
Removal steps
1. Breather hose
2. Air horn
mm 3. Carburetor
mm 4. Water outlet fitting
5. Water outlet fitting gasket
6. Thermostat
mm 7. Distributor
8. Purge control valve hose
9. Water hose
10. Heater hose
11. Brake booster vacuum hose NOTE
mm 12. Vacuum hose (1) Reverse the removal procedures t o reinstall.
13. Connection of water temperature gauge (2) ••*• : Referto "Service Points of Removal".
unit to wiring harness connector (3) mm Refer to "Service Points of Installation'
14. Intake manifold (4) d Non-reusable parts
15. Intake manifold gasket (5) * Indicates 4G63 and G63B.

© Mitsubishi Motors Corporation Jun. 1994 PWWE8608-O REVISED

 INTAKE A N D E X H A U S T - Intake Manifold [Petrol-powered Vehicles built up to May 1994 (except M.P.I.)] 1 5" 1 3

SERVICE POINTS OF REMOVAL EISMBAC

3. REMOVAL OF CARBURETOR
Referto GROUP 13-Removal, Installation and Inspection of
carburetor.
4 REMOVAL OF WATER OUTLET FITTING
Referto GROUP 14 Removal, Installation and Inspection of
thermostat.

INSPECTION E15MBBA
Check the following points; replace the part if a problem is found.
INTAKE MANIFOLD
1. Check for damage or cracking of any part.
2. Check for obstruction of the negative pressure (vacuum) outlet

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port, and for obstruction of the water passage or gas passage.

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SERVICE POINTS OF INSTALLATION
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12. INSTALLATION OF VACUUM HOSES
Refer to GROUP 17-Service Adjustment Procedures.
7. INSTALLATION OF DISTRIBUTOR
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Refer to GROUP 16-lgnition System.

rd
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© Mitsubishi Motors Corporation Jun. 1994 PWWE8608 O REVISED

 It)-1*1 I N T A K E A N D E X H A U S T — Intake Manifold [Petrol-powered Vehicles built up to May 1994 (with M.P.I.)]

INTAKE MANIFOLD [PETROL-POWERED VEHICLES BUILT UP TO MAY

1994 (WITH M.P.I.)] E15MA-
REMOVAL AND INSTALLATION
Post-installation Operation
Pre-removal Operation • Filling of engine coolant
• Removal of driver s seat (Refer to GROUP 14-Service Adjustment
• Removal of seat under frame Procedures)
(Refer tc GROUP 01 -Engine Compartment • Installation of seat under frame
Work.) • Installation of driver's seat
• Draining of engine coolant • Adjustment of accelerator cable
(Refer to GROUP 13-Service Adjustment
Procedures)
• Inspection of fuel pressure
(Refer to GROUP 13-Service Adjustment
Procedures)
Surge Tank
[Vehicles built up to June 1989)
4
10-13 Nm
1.0-1.3 kgm
7 - 9 ft.lbs.

m
10-12 Nm

. 1 0 - 1 . 2 kgm
7 - 9 ft.lbs
12-15 Nm
1.2-1.5 kgm
9-11 ft.lbs
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[Vehicles built from July 1989)
3 15-22 Nm 25-35 Nm 15-20 Nm
1.5-2.2 kgm 2.5-3.5 kgm
ia

1.5-2.0 kgm
11-16 ft.lbs. 18-25 ft.lbs 11-14 ft.lbs.
rd

15-20 Nm
14 1.5-2.0 kgm
17GI 13
ca

11-14 ft.lbs.

05G0029
10-12 Nm
1.0-1.2 kgm
7 - 9 ft.lbs.
12-15 Nm
1.2-1.5 kgm
9-11 ft.lbs.
25-35 Nm
2.5—3.5 kgm
18-25 ft.lbs. 15-20 Nm
1.5-2.0 kgm
11-14 ft.lbs.
Removal steps
1. Air intake hose Throttle body
2. Breather hose Water hose
3. Wiring harness connector Gasket
4. Air intake pipe P.C.V.hose
Air hose Brake booster vacuum hose
Accelerator cable and kick-down cable Vacuum hose connection
(vehicles with automatic transmission Fuel high pressure hose connection
7. Water hose Surge tank assembly
Surge tank gasket
• « 8 . Vacuum hose connection
Vacuum hose and pipe

£ Mitsubishi M o t o r s Corporation Jun. 1994 PWWE8608-O REVISED

 INTAKE AND EXHAUST - Intake Manifold [Petrol-powered Vehicles built up to May 1994 (with M.P.I.)] 15-15

Inkate Manifold 10-13 Nm

1.0-1.3 kgm
7 - 9 ft.lbs.

022
1 2 - 1 5 Nm
1.2-1.5 kgm
9 - 1 1 ft.lbs.

1 5 - 2 0 Nm

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1.5-2.0 kgm
1 1 - 1 4 ft.lbs.

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1 5 - 2 0 Nm
1.5-2.0 kgm
1 7 - 2 0 Nm 1 1 - 1 4 ft.lbs.
1.7-2.0 kgm
1 2 - 1 4 ft.lbs.
ia

10-13 Nm
1.0-1.3 kgm
rd

7 - 9 ft.lbs.
ca

1 8 - 2 5 Nm
1 0 - 1 3 Nm 1 . 8 - 2 . 5 kgm
1.0-1.3 kgm 1 3 - 1 8 ft.lbs.
7 - 9 ft.lbs.

05G0052

Removal steps
19. Fuel injector harness connector 28. Distributor
20. Fuel high pressure hose connection 29. Ignition coil
• » • • 2 1 . Delivery pipe, fuel injector and pressure 30. Surge tank stay
regulator 31. Intake manifold stay
••-•22. Insulator 32. Intake manifold
23. Heater hose 33. Intake manifold gasket
24. Wiring harness connector
25. Water outlet fitting NOTE
26. Water outlet fitting gasket (1) Reverse the removal procedures to reinstall
27. Thermostat (2) • • Refer to "Service Points of Removal"
(3) • • Refer to "Service Points of Installation"
(4) m Non-reusable parts

© Mitsubishi Motors Corporation Jun. 1994 PWWE8608-O REVISED

 lt)-lÖ I N T A K E A N D E X H A U S T — Intake Manifold [Petrol-powered Vehicles built up to May 1994 1 with MPi l l

SERVICE POINTS OF REMOVAL EI5MBAD

15. DISCONNECTION OF FUEL HIGH PRESSURE HOSE

Relieve pressure in the fuel pipe line to prevent fuel outflow.
(See GROUP 13-Service Adjustment Procedures)
Caution
Cover fuel pipe line with rag after relieving pressure as
certain pressure may still remain.
21. REMOVAL OF DELIVERY PIPE, FUEL INJECTOR AND
PRESSURE REGULATOR
Remove delivery pipe with fuel injector and pressure regulator
on.
Caution
Do not drop injector when removing delivery pipe.

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INSPECTION
Check the following points; replace the part if a problem is found.
E15MBBB
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INSPECTION OF SURGE TANK
1. Check surge tank for defect or cracks. Replace if defective or
cracked.
2. Check load (negative pressure) oi drain port. Check cooling
ia

water and jet air passages for clogging. Clean if required.

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INTAKE MANIFOLD
1. Check for damage or cracking of any part.
2. Check load (negative pressure) of drain port. Check cooling
water and jet air passages for clogging. Clean if required.

X Mitsubishi Motors Corporation Jun. 1994 PWWE8608-O REVISED

 INTAKE A N D E X H A U S T - Intake Manifold [Petrol-powered Vehicles built up to May 1994 (with M.P.I.)] 1 5" 1 7

SERVICE POINTS OF INSTALLATION E15MBCB

nsulator 22. INSTALLATION OF INSULATOR

Insert insulators (4) into intake manifold.

EC1400

21. INSTALLATION OF DELEVERY PIPE, FUEL INJECTOR AND

yyyc y
-^AA
PRESSURE REGULATOR
Ensure that insulators are correctly inserted into delivery pipe
hole.
?A A 14/8. CONNECTION TO VACUUM HOSE
A % > \ ^ -

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M A ^ / T Ö "ZAy
Refer to GROUP 17 EMISSION CONTROL-Service Adjust-
ment Procedures
AA AAA A&z^d

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A, 7 nsulator
'ZAAy
5. INSTALLATION OF AIR HOSE
=tfj
.
Air hose band J : ?* cd When installing air hose, tighten with the air hose band bolt
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about 45° against the horizontal surface.
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05G0021
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K Mitsubishi M o t o r s Corporation Jun. 1994 PWWE8608 O REVISED

15-17-1 INTAKE AND EXHAUST - Intake manifold (4G92)

INTAKE MANIFOLD (4G92)

REMOVAL AND INSTALLATION
Pre-removal and Post-i installation 4. ->
Operation
• Carburetor Assembly Removal and
installatior
(Refer to GROUP 13 • Carburetor.)
A y

i i
1

J
I

ml / CZZli

—y — 12
05X0031 05Y0O36 05Y0037

Specified sealant: 3 M Nut Locking Part

No. 4171 or equivalent
20-4.0 Nm
-x-fe 2.0-4.0 kgm
14-29 ft.lbs.

A \
zy AZ
^y _..yy
2 Nm
2 kgm
7-9 ft.lbs.
A yy

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r-.A 20-35 Nm
2.0-3.5 kgm \
yAZ
t zfy^-
yyyyy A..-/ 14-25 ft.lbs. \
y "-• V A

-, \
A
V AyyAA
1 y
. A x \\\ _
7\
IJi
• V \ .
\ 1 9 - 2 8 Nm1
X 1.9-2.8 kgm<
.
d ft.ibs.
A IA14-20
co 17-22 Nm
1.7-2.2 kgm

iWmwm 12-16 ft.lbs.

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A. \
E117
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14
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20-50 Nm 8-12 Nm /
2.0-5.0 kgm 0.8-1.2 kgm
05G00?
05G0100 14-36 ft.lbs. 27-34 Nm 5.8-8.9 ftlbs. "
2.7-3.4 kgm
Specified sealant: 20-25 ft.lbs.
3 M ATD Part No.
8660 or equivalent

Removal steps
l Vapor hose and pipe assembly M 13 Engine coolant temperature sensor
'X
Fuel vapor separator M 14 Engine cooiant temperature gauge unit
3 PCV hose M 15 Intake manifold stay
4 Brake booster vaexum hose connection 16 intake manifoid
5 Water hose 17 intake manifold gasket
6 Heater hose
7 Vacuum pipe assembly NOTE
3 Vacuum connector joint (1) Reverse the removal procedures to reinstall
9 EGR valve (21 M Refer to "Service Points of Installation'
10 EGR gasket (3)13 Non-reusable parts
M 11 Thermo valve (4)* Vehicles with FBC
M 12 Thermo valve (5) * 1 Vehicles with power steering
(6) *2 Vehicles with EGR system

z- Mitsubishi Motors Corporation Jun. 1994 PWWE8608 O ADDED

 I N T A K E A N D E X H A U S T - Intake manifold (4G92) 15-17-2
INSPECTION E15MBBA
Check the following points; replace the part if a problem is found.
INTAKE MANIFOLD
1. Check for damage or cracking of any part.
2. Check for obstruction of the negative pressure (vacuum) out-
let port, and for obstruction of the water passage or gas pas-
sage.

make manifold stay SERVICE POINTS OF INSTALLATION

p-—- 15. INSTALLATION OF INTAKE MANIFOLD STAY
A, (1) Install the intake manifold stay so that the identification
mark is facing towards the intake manifold.
(2) After provisionally tightening the bolts at both ends,
dentification check to be sure that the stay is secure against the boss,

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mark
and then tighten to the specified torque.

. 11N032

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14. INSTALLATION OF ENGINE COOLANT TEMPERATURE
GAUGE UNIT
gn
Apply the specified sealant around the thread of engine cool-
ant temperature gauge unit and install on the intake man-
ifold.
Specified sealant: 3 M ATD Part No. 8660 or
ia

equivalent
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13. INSTALLATION OF ENGINE COOLANT TEMPERATURE

SENSOR/12. 11. THERMO VALVE
Apply the specified sealant around the thread of engine cool-
ant temperature sensor, thermo valve and install on the in-
take manifold.
Specified sealant: 3M Nut Locking Part No. 4171 or
equivalent

PWWE8608O ADDED
; Mitsubishi Motors Corporation Jun. 1994
 1 5 - 1 7 - 3 INTAKE AND EXHAUST - Intake manifold [4G63 - 16 valve (except M.RL)]

INTAKE MANIFOLD [4G63 - 16 VALVE (EXCEPT M.P.I.)]

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

• Carburetor Assembly Removal and installation
(Refer to GROUP 13 - Carburetor)

1 7 - 2 6 Nm
} 1.7-2.6 kgm
1 2 - 1 9 ft.lbs
1 9 - 2 8 Nm 05GOO78 05X0031
1 1.9-2.8 kgm
\ 1 4 - 2 0 ft.lbs. S p e c i f i e d sealant
3 M N u t L o c k i n g Part N o .

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4 1 7 1 or e q u i v a l e n t

1 7 - 2 2 Nm

. co 1.7-2.2 kgm
1 2 - 1 6 ft.lbs
gn
1 2 - 1 5 Nm
1.2-1.5 kgm
9 - 1 1 ft.lbs.
1 7 - 2 2 Nm
ia

1.7-2.2 kgm
1 2 - 1 6 ft.lbs ^
rd

8-12 Nm
III? 0 . 8 - 1 . 2 kgm
5 . 8 - 8 . 9 ft.lbs.
ca

1 7 - 2 2 Nm
1.7-2.2 kgm
< \ _ 2 0 - 5 0 Nm
1 2 - 1 6 ftlbs. 20-40 Nm
^ < 3 2 . 0 - 5 . 0 kgm 05GO1O2
2 . 0 - 4 . 0 kgm
R e m o v a l steps 14 36 ft.lbs.
1 4 - 2 9 ft.lbs.
1 Vapor hose and pipe a s s e m b l y M 14. T h e r m o valve
2. Fuel vapor separator 15. V a c u u m c o n t r o l vaive
3. PCV hose 16. V a c u u m c o n t r o l valve bracket
4. Brake b o o s t e r v a c u u m hose c o n n e c t i o n 17. Intake m a n i f o l d
4+ M 5. Radiator h o s e c o n n e c t i o n 18. Intake m a m f o i d g a s k e t
6. W a t e r hose c o n n e c t i o n
7. Heater hose c o n n e c t i o n NOTE
M 8. Water outlet fitting (1) Reverse the removal procedures to reinstall.
9. V a c u u m pipe a s s e m b l y (2)«» Referto "Service Points of Removal"
10 V a c u u m c o n e c t o r joint (3IM Refer to "Service Points of Installation"
11. EGR valve (4) 0 Non-reusable parts
12. EGR valve g a s k e t (5)* Vehicles with EGR system
13. K i c k - d o w n cable bracket (6) * 1 Except vehicles for Europe with FBC and
(Vehicles w i t h a u t o m a t i c transmission) Australia - A / T
(7)*2
Vehicles for Europe with FBC and Australia
[8)*3
Vehicles for GCC
(9)*4 Except vehicles for General Export
(10) * 5 Except vehicles for Europe with FBC

I Mitsubishi Motors Corporation Jun. 1994 PWWE8608-O ADDED

 INTAKE AND EXHAUST - Intake manifold [4G63 - 16 valve (except M.P.I.)] 15-17-4

SERVICE POINTS OF REMOVAL

5. DISCONNECTION OF RADIATOR HOSE
After making mating marks on the radiator hose and the hose
clamp, disconnect the radiator hose.

INSPECTION E15MBBA
Mating marks Check the following points; replace the part if a problem is found.
INTAKE MANIFOLD
1. Check for damage or cracking of any part.
2. Check for obstruction of the negative pressure (vacuum) out-
et port, and for obstruction of the water passage or gas pas-
sage.

SERVICE POINTS OF INSTALLATION

14. INSTALLATION OF THERMO VALVE

m
Apply the specified sealant around the thread of thermo
valve and install on the intake manifold.

co
Specified sealant: 3 M Nut Locking Part No. 4171 or
equivalent

Water outlet
8. INSTALLATION OF WATER OUTLET FITTING
fitting 1. Use a gasket scraper or wire brush to clean all foreign
.
materials from the surface of the gasket.
gn
2. Apply an even amount of specified sealant to the surface
of the gasket.
Specified sealant:
ia

Mitsubishi Genuine Parts No.

MD970389 or equivalent
3. Before the sealant has dried (within 15 minutes), install
rd

I Bead diameter: 2.4-3.0 mm (0.09-0.12in.)]

the water outlet fitting.
05W0017
Do not apply sealant to any places other than where nec-
essary.
ca

5. CONNECTION OF RADIATOR HOSE

Projection
1. Insert each hose as far as the projection of the water out-
let fitting or water inlet fitting.

/
Water outlet fitting

04S0033

Align the mating marks on the radiator hose and hose

clamp, and then connect the radiator hose.

Mating marks

'•S' Mitsubishi Motors Corporation Jun. 1994 PWWE8608O ADDED

 • 5-17-5 I N T A K E A N D E X H A U S T - Intake manifold [4G63 and 4G64-16 valve (with M.P.I.)]

INTAKE MANIFOLD [4G63 AND 4G64 - 16 VALVE (WITH M.RL)]

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

• Injector Removal and Installation (Refer to GROUP 13 - injector)
• Throttle Body Removal and Installation (Refer to GROUP 13 - Throttle Body.!

17-26 Nm
1.7-2.6 kgm
12-19 ft.lbs.

17-22 Nm
1.7-2.2 kgm
12-16 ftlbs.

AAA
A 0 8-0^^ /

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17-22 Nm
1.7-2.2 kgm
. •JA^ 12-16 ft.lbs.

fö
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011
ia
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12-15 Nm
1.2-1.5 kgm
9-11 ft.lbs.
/
17-22 Nm 05G0088
1.7-2.2 kgm
12-16 ft.lbs.

Removal steps
1. PCV hose
2 Brake booster vacuum hose connection
O M 3. Radiator hose connection
4. Water hose connection
5. Heater hose connection
M 6. Water outlet fitting
7. EGR valve '-,., , . , ___ NOTE
8. EGR valve gasket f ( V e h l c l e s W l t h E G R s Y s t e m ) (1) Reverse the removal procedures to reinstall.
9. Intake manifold stay (2)41 Refer to "Service Points of Removal".
10. ntake manifold
(3)M Refer to "Service Points of Installation".
11. Intake manifold gasket
(4) El Vehicles with EGR system.

'& Mitsubishi Motors Corporation Jun. 1994 PWWE8608O ADDED

 INTAKE A N D E X H A U S T - Intake manifold [4G63 and 4G64-16valve (with M.P.I.)] 15-17-6
SERVICE POINTS OF REMOVAL
3. DISCONNECTION OF RADIATOR HOSE
After making mating marks on the radiator hose and the hose
clamp, disconnect the radiator hose.

INSPECTION
Mating marks Check the following points; replace the part if a problem is found.
INTAKE MANIFOLD
1. Check for damage or cracking of any part.
2. Check for obstruction of the negative pressure (vacuum) out-
let port, and for obstruction of the water passage or gas pas-
sage.

m
. Water outlet
fitting
co
SERVICE POINTS OF INSTALLATION
6. INSTALLATION OF WATER OUTLET FITTING
1 Use a gasket scraper or wire brush to clean all foreign
gn
materials from the surface of the gasket.
2. Apply an even amount of specified sealant to the surface
of the gasket.
ia

Specified sealant:
Mitsubishi Genuine Parts No.
[Bead diameter: 2.4-3.0 mm (0.09-0.12m.)] MD970389 or equivalent
rd

05W0017 3. Before the sealant has dried (within 15 minutes), install

the water outlet fitting.
Do not apply sealant to any places other than where nec-
ca

Projection essary.
CONNECTION OF RADIATOR HOSE
1. Insert each hoseasfarasthe projection of the water out-
let fitting or water inlet fitting.
-s»_>—j

Water outlet fitting

04S0033

Align the mating marks on the radiator hose and hose

clamp, and then connect the radiator hose.

Mating marks

PWWE8608O ADDED
© Mitsubishi Motors Corporation Jun. 1994
 15-18 INTAKE AND EXHAUST- Exhaust Manifold (Petrol-powered vehicles built up to M a y 1994)

EXHAUST MANIFOLD (PETROL-POWERED VEHICLES BUILT UP TO

MAY 1994)
REMOVAL AND INSTALLATION
4G32, 4G33
10-13 Nm i*i
1.0-1.3 kgm
7.2-9.4 ft.lbs.

8 - 1 0 Nm
0.8-1.0 kgm
5.8-7.2 ft.lbs.

20-30 Nm
2.0-3.0 kgm
18-22 ft.lbs.
10-13 Nm

m
1.0-1.3 kgm
7.2-9.4 ft.lbs.

12-15 N m * 1
.
1.2-1.5 kgm* 2
co V.
gn
8.7-11 ft.lbs.*2
27-33 Nm* 3
2.7-3.3 kgm* 3
20-23 ft. lbs.*3 j
I
ia

15-20 Nm
1.5-2.0 kgm
11 —ISft.lbs.
rd

15-20 Nm
ca

1.5-2.0 kgm
11-18 ft.lbs. 05GOO2S

Pre-removal Operation
• Removal of driver's seat (R.H.D.)
• Removal of seat under frame
(Refer to GROUP 01 -Engine
Compartment Work.)

Post-installation Operation
• Installation of seat under frame
• Installation of driver's seat (R.H.D.!

Removal steps
1. Vacuum hose
2. Air hose
3. Reed valve and air pipe
4. Air nozzle NOTE
5. Hot air duct (1) Reverse the removal procedures to reinstall.
6. Heat cowl (2) * 1 : Vehicles for Europe.
7. Exhaust manifold (3) * 2 : Vehicles built up to October 1987.
8. Exhaust manifold gasket (4) * 3 : Vehicles built from Nobember 1987.

'£• Mitsubishi Motors Corporation Jun. 1994 PWWE8608O REVISED

 INTAKE A N D E X H A U S T - Exhaust Manifold (Petrol-powered vehicles built up to May 1994} 1 5 " 1 9

4G63
12-15 Nm* 3
1.2-1.5 kgm* 3 ,*i 10-13 Nm
8.7-11 ftlbs.* 3 1.0-1.3 kgm
\\ 7.2-9.4 ft.lbs
27-33 Nm* 4
2.7-3.3 kgm* 4
\\
20-23 ft.lbs.*4

15-20 Nm
1.5-2.0 kgm
11-18 ft.lbs.

8-10 Nm
0.8-1.0 kgm
5.8-9.4 ft.lbs.

m
. 15-20 Nm
1.5-2.0 kgm
11-18 ft.lbs.
co u
gn
ia
rd

20-30 Nm* 2 2
2.0-3.0 kgm*
ca

18-22 ft.lbs.**

15-20 Nm
1.5-2.0 kgm
11-18 ft.lbs.
y
05G0027

Removal steps
1. Vacuum hose
2. Air hose NOTE
3. Reed valve and air pipe (1) Reverse
Re the removal procedures to reinstall.
4. Air nozzle (2) Gl Non-reusable parts
5. Hot air duct (3) * Vehicles for Australia.
6. Heat cowl (4) *z Vehicles equipped with a dual type front exhaust
7. Exhaust manifold pipe.
8. Gasket (5) * 3 Vehicles built up to October 1987.
9, Exhaust manifold gasket (6) * < ] Vehicles built from November 1987.

X Mitsubishi Motors Corporation Jun. 1994 PWWE8608 O REVISED

1 5-20 I N T A K E A N D E X H A U S T - Exhaust Manifold (Petrol-powered vehicles built up to May 1994)

G63B, G64B, 4G64

12-15 Nm* 2 10-13 Nm

1.2-1.5 kgm* 2 1.0-1.3 kgm
7.2-9.4 ft.lbs.
8.7-11 ft.lbs.*2
27-33 Nm* 3
2.7-3.3 kgm* 3
20-23 ftlbs.* 3

10-13 Nm
1.0-1.3 kgm
7.2-9.4 ft.lbs.

70-100 Nm
7.0-10 kgm
51-72 ft.lbs.
15-20 Nm
1.5-2.0 kgm
8 - 1 0 Nm 11-18 ft.lbs.
0.8-1.0 kgm
5.8-7.2 ft.lbs.

15-20 Nm

m
1.5-2.0 kgm
11-18 ft.lbs.
40-50 Nm

co
4.0-5.0 kgm
29-36 ft.lbs.
6^
. 7

&
gn
ia
rd

20-30 Nm
2.0-3.0 kgm
ca

18-22 ft.lbs.

05G0028

Removal steps
1. Vacuum hose
2. Air hose
3. Reed valve and air pipe
4. Hot air duct NOTE
5. Heat cowl (1) Reverse the removal procedures to reinstall
6. Gasket (2) El Non-reusable parts
7. Oxygen sensor (3) * i G63B engine
8. Exhaust manifold (4) . 2 Vehicles built up to October 1987.
9. Exhaust manifold gasket (5) * 3 Vehicles built from November 1987.

© Mitsubishi M o t o r s Corporation J u n . 1994 PWWE8608-O REVISED

 INTAKE A N D E X H A U S T - Exhaust Manifold (Petrol-powered vehicles built up to May 1994) 1 0 ~ 2 1

INSPECTION E15NCAA
Check the following points; replace the part if a problem is found.
EXHAUST MANIFOLD
Check for damage or cracking of any part.
EXHAUST MANIFOLD GASKET
Check for flaking or damage of the gasket.

m
. co
gn
ia
rd
ca

© Mitsubishi Motors Corporation Jun. 1994 PWWE8608-O REVISED

15-21-1 INTAKE AND EXHAUST - Exhaust Manifold {4G92,4G63 and 4G64 - 16 valve)

EXHAUST MANIFOLD (4G92, 4G63 AND 4G64 - 16 VALVE)

REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
• Front exhaust pipe removal and installation
(Refer to P.15-24.)
• Air intake hose removal and installation
(Refer to P. 15-6.)
4 0 - 5 0 Nm
<4G92> 4 . 0 - 5 . 0 kgm
2 9 - 3 6 ft.lbs.
^ 1 2 - 1 5 Nm
gr 1.2-1.5 kgm
1 9 - 1 1 ft.lbs.

1 2 - 1 5 Nm
1.2-1.5 kgm —<\
9 - 1 1 ft.lbs.

m
<4G63, 4G64>
50-60 Nm

. 5.0-6.0 kgm
3 6 - 4 3 ft.lbs.

4 0 - 5 0 Nm
co
gn
4 . 0 - 5 . 0 kgm
2 9 - 3 6 ft.lbs.

70-100
7 . 0 - 1 0 . 0 kgm
ia

5 1 - 7 2 ft.lbs.
rd

12-15 Nm
1.2-1.5 kgm
czA
z z.
9 - 1 1 ft.lbs.
A •zdA$AS-%
ca

El 7 •• I /-
hAyy%y.Azz~yd7A.
x-=r-r
.•7.^-.,. '<..s>/ *-"_r ••.'•'
y \y yy\r-y\yyi

•y. yy
A A \\
Ay

R e m o v a l steps
1. Secondary air pipe NOTE
2 Heat d u c t (1) Reverse the removal procedures to reinstall
4* 3. Oxygen sensor (2)« Refer to "Service Points of Removal".
4. Heat p r o t e c t o r (3)M Referto "Service Points of Installation".
5. Engine hanger
(4i m Non-reusable parts
M 6. Exhaust m a n i f o l d lb) 2~ Vehicles with hot air control valve
7. Exhaust m a n i f o l d gasket (6)* Vehicles with FBC
(7) .3 Vehicles with secondary air supply system
(8)*4 Vehicles for Australia with MPI

© Mitsubishi M o t o r s Corporation Jun. 1994 PWWE8608 O ADDED

 INTAKE A N D E X H A U S T - Exhaust Manifold (4G92, 4G63 and 4G64-16 valvel 15-21-2
SERVICE POINTS OF REMOVAL
3. REMOVAL OF OXYGEN SENSOR
3998703

05G0068

INSPECTION
EXHAUST MANIFOLD
Check for damage or cracking of any part.

m
. co
SERVICE POINTS OF INSTALLATION
gn
6. INSTALLATION OF EXHAUST MANIFOLD

Nut A NutB
Engine items
Tightening torque Tightening torque
ia

1 5 - 2 0 Nm 2 7 - 3 3 Nm
4G92 1.5-2.0 kgm 2.7-3.3 kgm
rd

1 1 - 1 4 ft.lbs. 2 0 - 2 4 ft.lbs.

05G0069 2 5 - 3 0 Nm 2 7 - 3 3 Nm
4G63, 4G64 2.5-3.0 kgm 2.7-3.3 kgm
ca

18-22 ft.lbs. 2 0 - 2 4 ft.lbs.

Mitsubishi Motors Corporation Jun. 1994 PWWE8608O ADDED

15-22 I N T A K E A N D E X H A U S T — Intake and Exhaust Manifold (Diesel-powered vehicles)

INTAKE AND EXHAUST MANIFOLD (DIESEL-POWERED VEHICLES) E15UA-A

REMOVAL AND INSTALLATION (VEHICLES WITHOUT A TURBOCHARGER)

1 5 - 2 0 Nm
1.5-2.0 kgm
1 1 - 1 4 ft.lbs.

1 5 - 2 0 Nm
1.5-2.0 kgm
1 1 - 1 4 ft.lbs.

X&b

m
A"
1 5 - 2 0 Nm
1.5-2.0 kgm

co
1 1 - 1 4 ft.lbs.

.
gn
1 2 - 1 5 Nm
1.2-1.5 kgm
8.7-11 ftlbs OQ
ia
rd
ca

3 0 - 4 0 Nm
3 . 0 - 4 . 0 kgm
2 2 - 2 9 ft.lbs.
O5G0026
Pre-removal Operation
• Removal of driver's seat (R.H.D.)
• Removal of seat under frame
(Refer to GROUP 01 GENERAL-Engine
Compartment Work.)

Post-installation Operation
• Installation of seat under frame
• installation of driver's seat (R.H.D.)

Removal steps
1. Air intake hose
2. Breather hose
3. Intake manifold
4. Heat protector
(except Mini-bus for Europe)
5. Exhaust manifold
6. Intake and exhaust manifold cgasket

NOTE
(1) Reverse the removal procedures to reinstall.
(2) d : Non-reusable parts

(g> Mitsubishi Motors Corporation NOV. 87 PWWE8608-C REVISED

 INTAKE A N D EXHAUST — Intake and Exhaust Manifold (diesel-powered vehicles) 1 5~23

INSPECTION EWU«*

Check the following points; replace the part if a problem is found.

INTAKE AND EXHAUST MANIFOLD
Check for damage or cracking of any part.

m
. co
gn
ia
rd
ca

© Mitsubishi Motors Corporation DEC. 88 PWWE8608-E REVISED

15-23-1 INTAKE AND EXHAUST — Intake and Exhaust Manifold {diesel-powerd vehicles)

REMOVAL A N D INSTALLATION
(VEHICLES WITH A TURBOCHARGER BUILT UP TO JUNE 1993)
Pre-removal Operation
• Removal of seat under frame
(Refer to GROUP 01 GENERAL-Engine
Compartment Work.)

Post-installation Operation 15-20 Nm

• Installation of seat under frame 1.5-2.0 kgm
10-13 Nm 11-14 ft.lbs.
1.0-1.3 kgm
7 - 9 ft.lbs.

15-20 Nm 50-70 Nm
1.5-2.0 kgm 5.0-7.0 kgm
11-14 ft.lbs. 3 6 - 5 1 ft.lbs.
o

m
16-24 Nm
14-19 Nm 10 1.6-2.4 kgm
1.4-1.9 kgm / 12-17 ft.lbs.
10-14 ft.lbs. -*&* / <3p
8-10 Nm

. 15-22 Nm
1.5-2.2 kgm
11-16 ft.lbs.
0.8-1.0 kgm
JB-7 ftlbs.

co 8-10 Nm
0.8-1.0 kgm
6 - 7 ft.lbs.
gn
15-20 Nm
1.5-20 kgm
ia

Hd 11-14 ft.lbs
£? 12-15 Nm
^~~~~~ 1.2-1.5 kgm
50-70 Nm 9 - 1 1 ftlbs.
5.0-7.0 kqm i»
rd

n • * 0c
Removal steps 3 6 _ 5 1 ft fts
1. Boost hose
2. Inlet fitting
ca

3. Inlet fitting gasket

8-10 Nm 15
4. Air hose
5. Heat protector (B) 0.8-1.0 kgm
M>
8-10 Nm
6. Heat protector (A) 6 - 7 ftlbs. 0.8-1.0 kgm
7. Waste gate actuator 6 - 7 ft.lbs. /
8. Intake manifold
9. Engine hanger ,••
* * 10. Oil pipe
11. Gasket
12. Oil hose
13. Turbocharger
14. Turbocharger gasket
15. Oil return pipe
16. Oil return pipe gasket
17. Exhaust fitting
18. Exhaust fitting gasket
19. Heat protector (C)
20. Exhaust manifold
21. Intake and exhaust manifold gasket
NOTE
(1) Reverse the removal procedures to reinstall.
(2) mm: Refer to "Service Points of Installation".
(3) E | : Non-reusable parts

© Mitsubishi Motors Corporation July 1993 PWWE8608-N REVISED

 INTAKE A N D EXHAUST — intake and Exhaust Manifold (diesel-powerd vehicles) 15"23-2

INSPECTION E15UCAC

A
\ V
-XA A
^
- j
CHECKING TURBOCHARGER SUPER CHARGE PRESSURE
•

A
\ r I
(A Caution
The driving test is conducted in a two seat vehicle at a place
where high speed, full throttle driving is safe. The pressure
gauge indicated values are to be read by a person in the
passenger seat.
(1) Remove the hose from the waste gate actuator and install a
\ pressure gauge to a two way connector placed between the
A DIN010
hose and the nipple.
(2) Drive the vehicle at full throttle in second gear and measure
super charge pressure with engine rpm above 3000.
Standard value: Approximately 70—86 kPa
(0.70-0.86 kg/sm 2 , 1 0 - 1 2 psi)
Caution
When turbocharger pressure is not with in the standard

m
value, it should not be immediately assumed that there is
a problem with the turbocharger, but the following
checked first:
Turbo charge pressure high:

. co Waste gate actuator malfunction

Turbo charge pressure low:
Waste gate actuator malfunction
Turbo charger pressure leak
gn
Turbo charger malfunction
ia

CHECKING THE WASTE GATE ACTUATOR

rd

(1) Connect a hand pump (pressurizer type) to the waste gate

actuator nipple, then slowly increase pressure until the waste
gate actuator rod beings to move (about a 1 mm stroke) and
check the pressure. Continue to apply pressure, checking to
ca

ensure that the rod moves smoothly.

Standard value: Approximately 77 kPa
X (0.77 kg/cm 2 , 11 psi)
til*
Caution
T ! To prevent damage to the diaphragm, keep the pressure
under 93 kPa (0.93 kg/cm 2 , 14 psi).
(2) When the result differs greatly from the standard value, check
the actuator and the waste gate valve, replacing if necessary.
A INTAKE AND EXHAUST MANIFOLD
•• '0 DIN023
Check for damage or cracking of any part,
SERVICE POINTS OF INSTALLATION E 1 5 UD*A
10. INSTALLATION OF OIL PIPE
Install the oil pipe, then, before installing the eye bolt (on top
of the turbocharger), fill the turbocharger with clean oil and
check to ensure that the turbine compresser wheel rotates
smoothly.

© Mitsubishi Motors Corporation DEC. 88 PWWE8608E REVISED

1 5-23-3 I N T A K E A N D E X H A U S T — Intake and Exhaust Manifold (diesel-powered vehicles)

REMOVAL A N D INSTALLATION
(VEHICLES WITH A TURBOCHARGER BUILT FROM JULY 1993)

Pre-removal and Post-installation

Operation
Removal and Installation of Seat
Under Frame
(Refer to GROUP 01 GENERAL -
Engine Compartment Work.)
Draining and Supplying of the
Coolant
1 5 - 2 0 Nm Draining and Supplying of the
1.5-2.0 kgm Engine Oil
1 1 - 1 4 ft.lbs Removal and Installation of Air
1 0 - 1 3 Nm Cleaner Duct
1 . 0 - 1 . 3 kgm
7 - 9 ft.lbs.

8 - 1 0 Nm
0 . 8 - 1 . 0 kgm
6 - 7 ft.lbs.
14-19Nm
1.4-1.9 kgm
1 0 - 1 4 ftlbs. 20 Nm
2.0 kgm

m
1 5 - 22 Nm 14 ft.lbs
1.5- -2.2 kgm
1 1 - 16 ft.lbs. 5 0 - 7 0 Nm
5 . 0 - 7 . 0 kgm
3 6 - 5 1 ft.lbs.

. co
1 6 - 2 4 Nm
1.6-2.4 kgm
1 2 - 1 7 ft.lbs
1 5 - 2 0 Nm
1.5-2.0 kgm
1 1 - 1 4 ft.lbs
3 0 - 4 0 Nm
3 . 0 - 4 . 0 kgm
2 2 - 2 9 ft lbs.
/
/
gn
El
3 4 - 4 9 Nm ®
3 . 5 - 5 . 0 kgm
2 5 - 3 6 ft.lbs. 5 0 - 70 Nm
5 . 0 - 7 . 0 kgm ——©,-,
ia

3 6 - 5 1 ft.lbs. ' 5 4 K A ^
1 2 - 1 5 Nn
m 1.2-1.5 kgm
9 - 1 1 ft.lbs.
rd

8 - 1 0 Nm
0 . 8 - 1 . 0 kgm
6 - 7 ft.lbs.
ca

8-10Nm
0 . 8 - 1 . 0 kgm
6 - 7 ftlbs.
EI 23
3 4 - 4 9 Nm
3 . 5 - 5 . 0 kgm A-
2 5 - 3 6 ft.lbs. X...
05G0056

Removal steps
1. Front exhaust pipe c o n n e c t i o n 16. Water pipe B c o n n e c t o r
2. Heat protector • * 17. Turbocharger assembly
3. Exhaust fitting 18. T u r b o c h a r g e r gasket
4. Exhaust fitting gasket 19 Heat protector (B)
5 Boost hose 20 Oil return pipe
6. V a c u u m hose .21. Oil hose
7. Inlet fitting 22. Exhaust manifold
8. Air hose 23. Intake and exhaust manifold gasket
9. Heat protector (A)
10. W a s t e gate actuator NOTE
11. EGR pipe (1) Reverse the removal procedures to reinstall.
12. EGR valve (2) m+: Refer to "Service Points of Installation".
13. Oil pipe (3) E} : Non-reusable parts
14. Intake manifold (4) * : Vehicles with EGR system
1 5. W a t e r pipe A c o n n e c t i o n

© Mitsubishi Motors Corporation July 1993 PWWE8608 I\J ADDED

 INTAKE A N D E X H A U S T - Intake and Exhaust Manifold (Diesel-powered vehicles) 1 5 " 2 3 - 4

INSPECTION E15UCAC
CHECKIMG TURBOCHARGER SUPER CHARGE PRESSURE
Caution
The driving test is conducted in a two seat vehicle at a
place where high speed, full throttle driving is safe. The
pressure gauge indicated values are to be read by a person
in the passenger seat.
(1) Remove the hose from the waste gate actuator and install a
pressure gauge to a two way connector placed between the
hose and the nipple.
(2) Drive the vehicle at full throttle in second gear and measure
super charge pressure with engine rpm above 3000.
Standard value: Approximately 7 0 - 8 6 kPa
( 0 . 7 0 - 0 . 8 6 k g / c m 2 , 1 0 - 1 2 psi)
Caution
When turbocharger pressure is not with in the standard
value, it should not be immediately assumed that there

m
is a problem with the turbocharger, but the following
checked first:

co
Turbo charge pressure high:
Waste gate actuator malfunction
Turbo charge pressure low:
Waste gate actuator malfunction
. Turbo charger pressure leak
gn
Turbo charger malfunction
ia

CHECKING THE WASTE GATE ACTUATOR

(1) Connect a hand pump (pressunzer type) to the waste gate
rd

actuator nipple, then slowly increase pressure until the waste

gate actuator rod beings to move (about a 1 mm stroke) and
check the pressure. Continue to apply pressure, checking to
ca

ensure that the rod moves smoothly.

Standard value: Approximately 7 7 kPa
(0.77 k g / c m 2 , 11 psi)
Caution
To prevent damage to the diaphragm, keep the pressure
under 9 3 kPa (0.93 k g / c m 2 , 14 psi).
(2) When the result differs greatly from the standard value,
check the actuator and the waste gate valve, replacing if
necessary.
05G0044
INTAKE A N D EXHAUST MANIFOLD
Check for damage or cracking of any part.

SERVICE POINTS OF INSTALLATION

17.INSTALLATION OF TURBOCHARGER ASSEMBLY
(1) Clean the alignment surfaces shown in the illustration.
(2) Supply clean engine oil through the oil pipe installation
hole of the turbocharger assembly.
Caution
When cleaning, take care that no foreign material
05G0057 gets into the engine coolant or oil passages hole.
© Mitsubishi Motors Corporation July 1993 PWWE8608-N ADDED
15-24 INTAKE AND EXHAUST - Exhaust Pipes and Mufflers

EXHAUST PIPES AND MUFFLERS

REMOVAL AND INSTALLATION
E15RA-
VEHICLES FOR EUROPE

4G32
4G63 8 valve (Van) HD
4D56

20-30 Nm* 1 20-30 Nm

2.0-3.0 kgm* 1 2.0-3.0 kgm
14-22 ft.lbs.*1 14-22 ft.lbs

30-40 Nm* 2
A 25-35Nm* 1
2.5-3.5 kgm*'
3.0-4.0 kgm* 2 1 8 - 2 5 ft. lbs
22-29 ft.lbs.*2

m
4G63 - 8 valve (Mini-bus)
20-30 Nm
03
. 2.0-3.0 kgm
14-22 ftlbs.
/ co 09G0076
gn
20-30 Nm
2.0-3.0 kgm
14-22 ft.lbs. ^

40-55 Nm
ia

G63B 4.0-5.5 kgm

4G64 - 8 valve
G64B
29-40 ft.lbs.
50-70 Nm J0«*©
2 0 - 3 0 Nm
rd

E13 2.0-3.0 kgm 5.0-7.0 kgm

14-22 ft.lbs. 36-50 ft.lbs.
ca

30-40 Nm O9G0075
3.0-4.0 kgm
40-55 Nm 22-29 ft.lbs.
4.0-5.5 kgm
29-40 ft. lbs.

Removal steps
M 2. Front exhaust pipe
3. Gasket
5. Rubber hanger
6. Hanger bracket NOTE
10. Catalytic converter (1) Reverse the removal procedures to reinstall.
11. Gasket (2) Refer to "Service Points of Installation"
12. Rubber hanger (3) Gl Non-reusable parts
13. Rubber hanger (4} Petrol-powered vehicles
M 15. Main muffler (5) Diesel-powered vehicles

© Mitsubishi Motors Corporation Jun. 1994 PWWE8608 O REVISED

 INTAKE A N D E X H A U S T - Exhaust Pipes and Mufflers 15-24-1
4G63 - 16 valve

<Conventional carburetor>

20-30 IMm
2.0-3.0 kgm
14-22 ft.lbs.

03

©a»
40-60 Nm \
4.0-6.0 kgm 20-30 Nm 05G0094
29-43 ft.lbs. 2.0-3.0 kgm
14-22 ft.lbs.

m
<Feedback carburetor>

20-30 Nm
2.0-3.0 kgm

. 14-22 ft.lbs.

co
gn
mM^\
30-40 Nm
40-60 Nm 3.0-4.0 kgm
4.0-6.0 kgm 1101 22-29 ft.lbs.
ia

29-43 ftlbs.
0SG0095
50-70 Nm
5.0-7.0 kgm
rd

36-51 ft.lbs. 12
y
<M.P.I.>
ca

20-30 Nm
2.0-3.0 kgm
14-22 ft.lbs.
\3^
03

30-40 Nm
40-60 Nm 3.0-4.0 kgm
4.0-6.0 kgm 110
22-29 ft.lbs.
29-43 ft.lbs. 05G0096
50-70 Nm
5.0-7.0 kgm
36-51 ft.lbs.
Removal steps
ff 2. Front exhaust pipe
3. Gasket 10 Catalytic converter
4. Oxygen sensor 11 Gasket
5. Rubber hanger NOTE
12 Rubber hanger
6. Hanger bracket 13 (1) Reverse the removal procedures to reinstall.
Rubber hanger
7. Heat protector 15 (2) }f : Refer to "Service Points of Installation'
M Main muffler
(3) 0 : Non-reusable parts

P' Mitsubishi Motors Corporation Jun. 1994 PWWE8608-0 ADDEO

15-25 INTAKE AND EXHAUST - Exhaust Pipes and Mufflers

VEHICLES FOR GENERAL EXPORT

4G32
4G33
4G63 - 8 valve 2 0 - 3 0 N m * 1 2 0 - 3 0 Nm
4D56 2 . 0 - 3 . 0 k g m * 1 2 . 0 - 3 . 0 kgm
1 4 - 2 2 ftlbs.* 1 4 - 2 2 ft.lbs.

05GOOO9

30-40 Nm*2 25-35Nm'1

3.0-4.0 kgm*2 2.5-3.5kgnrr'
2 2 - 2 9 ft.lbs.* 2 18 - 25 ftlbs.* 1

m
4G64 - 8 valve
. co
gn
5 0 - 7_,0 N,m
[33
20-30Nm
2.0 - 3.0 kgm
c
= ° - 7C»kgm _ y^Nt,
ia

1 4 - 2 2 ftlbs. 3 6 - 5 0 ft.lbs ~>

3 0 - 4 0 Nm
rd

3 . 0 - 4 . 0 kgm
2 2 - 2 9 ftlbs.
ca

40 - 55 N m
4.0 - 5.5 kgm
2 9 - 4 0 ft.lbs.
09G0166

Removal steps
1 Heat protector
»•* 2. h o n t exrxiust o;pe
q Gastet
0. Rubber hanger
6. Hanger bracket
9. \ ieat protector
' 0 . Catalytic converter
NOTE
11 Gasket (1 i Reverse iho removal procedures to re-nstall.
12 Rubber hanger (2) m-m . Referto "Service Points of Installation'
13 RuDber hanger (3) 0 : Non-reusable parts
14. Protector (4) •' : Petrol-powered vehicles
• • * 15. Mam muffler (5) *2 : D ; esel-powered vehicles

'-' Mitsubishi Motors Corporation Jun. 1994 PWWE8608-O REVISED

 I N T A K E A N D E X H A U S T - Exhaust Pipes and Mufflers 15-25-1
G33B

20 - 30 Nm
2.0-3.0 kgm
1 4 - 2 2 ft.lbs.

50 - 70 Nm
5 . 0 - 7.0 kgm
3 6 - 5 0 ft.lbs.

25 - 35 Nm
2.5-3.5 kgm
1 8 - 2 5 ft.lbs.
30 - 40 Nm 09G0164
3.0-4.0 kgm
22 - 29 ft.lbs

m
4G92 <Hong Kong> *=©

co
20-30 Nm
2.0-3.0 kgm
14-22 ft.lbs
. S©
gn
40-60 Nm
4.0-6.0 kgm
29-43 ft.lbs.
ia

70 Nm O5G0097
30-40 Nm 5.0-7.0 kgm
rd

3.0-4.0 kgm
22-29 ft.lbs. 36-51 ft.lbs.

Removal steps
ca

*-* 2 Front exhaust pipe

3. Gasket
5. Rubber hanger
6. Hanger bracket
7. Heat protector
Protector (Except for Hong Kong G33B)
9. Heat protector
10. Catalytic converter
11. Gasket NOTE
12. Rubber hanger (1) Reverse the removal procedures to reinstall.
13. Rubber hanger (2) • ^ : Refer to "Service Points of Installation"
14. Protector (3) 0 : Non-reusable parts
Main muffler

X Mitsubishi Motors Corporation Jun. 1994 PWWE8608-O REVISED

15-25-2 INTAKE AND EXHAUST - Exhaust Pipes and Mufflers

4G92 [Except for Hong Kong]

4G63 - 16 valve

•«Conventional carburetor>

20-30 Nm
2.0-3.0 kgm
14-22 ft.lbs.
/

03

40-60 Nm 05G0094
4.0-6.0 kgm 20-30 Nm

m
29-43 ft.lbs. 2.0-3.0 kgm
14-22 ft.lbs.

4G63 - 16 valve
<MPI>
. co
gn
^
20-30 Nm
ia

2.0-3.0 kgm ^
14-22 ft.lbs.
rd

03
Vife* (& vA IffS,.
ca

30-40 Nm
40-60 Nm 3.0-4.0 kgm
4.0-6.0 kgm 22-29 ft.lbs.
29-43 ft.lbs.
05G0096
x.

50-70 Nm
5.0-7.0 kgm
36-51 ft lbs.
Removal steps
M 2. Front exhaust pipe
3. Gasket
4. Oxygen sensor
5. Rubber hanger
6. Hanger bracket
7. Heat protector
10. Catalytic converter
11. Gasket NOTE
12. Rubber hanger (1) Reverse the removal procedures to reinstall.
13. Rubber hanger (2) M : Refer to "Service Points of Installation'
M 15. Main muffler (3) 0 : Non-reusable parts

© Mitsubishi Motors Corporation Jun. 1994 PWWE8608O REVISED

 INTAKE A N D E X H A U S T - Exhaust Pipes and Mufflers 15-25-3
VEHICLES FOR AUSTRALIA
VAN (4G63 engine)
[Vehicles built up to September 1988]
Diesel powered Van
20 - 30 Nm
2.0-3.0 kgm
1 4 - 2 2 ft.lbs.

05G0009

25 - 35 Nm
2.5-3.5 kgm
1 8 - 2 5 ft.lbs.

Van (4G64 engine)

[Vehicles built up to September 1988]

m
Petrol powered Van
[Vehicles built from October 1988 up to May 1994]
Mini-bus

co
[Vehicles built up to May 1994]

20 - 30 Nm
.
2.0-3.0 kgm 50 - 70 Nm
1 4 - 2 2 ft.lbs. 5.0 -7.0 kgm
gn
36 - 50 ft.lbs.

E33
ia

30 - 40 Nm
3.0-4.0 kgm
2 2 - 2 9 ft.lbs.
rd

40 - 55 Nm
L<m®
4.0-5.5 kgm
29 - 40 ft.lbs.
ca

09G0165

Removal steps
1. Heat protector
* * 2. Front exhaust pipe
3. Gasket
5. Rubber hanger
6. Hanger bracket
8. Protector
9. Heat protector
10. Catalytic converter NOTE
11. Gasket (1) Reverse the removal procedures to reinstall.
12. Rubber hanger (2) • • • : Refer to "Service Points of Installation"
13. Rubber hanger (3) 0 : Non-reusable parts
14. Protector (4) "•• : 2WD
•-•15. Main muffler

X Mitsubishi Motors Corporation Jun. 1994 PWWE8608-O REVISED

15-25-4 INTAKE A N D E X H A U S T - Exhaust Pipes and Mufflers

4G63 and 4G64 - 16 valve

<2WD>

"S&

20-30 Nm
2.0-3.0 kgm
14-22 ft.lbs. "*©

30-40 Nm
03 3.0-4.0 kgm
22-29 ft.lbs.

40-60 Nm
4.0-6.0 kgm
29-43 ft.lbs.

m
\ 50-70 Nm
5.0-7.0 kgm
36-51 ft.lbs. 05G0098

<4WD>
. co
gn
^
20-30 Nm
2.0-3.0 kgm
ia

14-22 ft.lbs.
rd

03
ca

40-60 Nm 30-40 Nm
4.0-6.0 kgm 3.0-4.0 kgm
29-43 ft.lbs. 22-29 ft.lbs. 0SG0099
\ 50-70 Nm
5.0-7.0 kgm
36-51 ft.lbs.
Removal steps
M 2. Front exhaust pipe
3. Gasket
5. Rubber hanger
6. Hanger bracket
7. Heat protector
9. Heat protector
10. Catalytic converter
11. Gasket
12. Rubber hanger NOTE
13. Rubber hanger (1) Reverse the removal procedures to reinstall.
14. Protector (2) ff : Refer to "Service Points of Installation"
M 15. Main muffler (31 0 : Non-reusable parts

PWWE8608O ADDED
<S. Mitsubishi Motors Corporation Jun. 1994
 INTAKE AND EXHAUST - Exhaust Pipes and Mufflers 15-26

INSPECTION E15RCAA
• Check the mufflers and pipes for corrosion or damage.
• Check rubber hangers for deterioration or damage.
• Check for gas leakage from mufflers or pipes.

SERVICE POINTS OF INSTALLATION EI5RDAD

15. INSTALLATION OF MAIN MUFFLER / 2 . FRONT EX-
HAUST PIPE
After fully tightening front exhaust pipe and main muffler,
check to be sure there is no contact with the chassis at any
place and there is no twisted hanger.

m
. co
gn
ia
rd
ca

© Mitsubishi Motors Corporation Jun. 1994 PWWE8608-D REVISED

NOTES

m
. co
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ca

X Mitsubishi Motors Corporation Jun. 1994 PWWE8608O ADDED