Removal and installation of the 4G13 engine (Mitsubishi Space Star)

Removal

• Disconnect the cable from the negative battery terminal.
• To remove the engine, perform the following operations sequentially.
• Relieve the fuel pressure in the fuel system. See chapter "Reducing pressure in the fuel system" given in the section "Multi-point fuel injection (MPI) system".
• Remove the air filter.
• Remove the hood.
• Remove the radiator.
• Remove the gearbox.
• Disconnect the electrical connectors from the crankshaft position sensor, knock sensor, boost pressure sensor, exhaust gas recirculation solenoid valve, ignition coil, injectors, adsorber cleaning solenoid valve, throttle position sensor, throttle control servo, misfire detection sensor, camshaft position sensor, coolant temperature sensor, temperature indicator sensor cooling liquid and front oxygen concentration sensor, throttle control servo, air conditioner compressor, generator, pressure sensor and starter (Figure 3.53).

Fig. 3.53. Connection points for connectors and hoses to the 4G13 engine: 1 - crankshaft position sensor connector; 2 - knock sensor connector; 3 - boost pressure sensor connector; 4 - EGR solenoid valve connector; 5 - ignition coil connector; 6 - injector connectors;7 - connector of the electromagnetic valve for cleaning the adsorber; 8 - throttle position sensor connector; 9 - Throttle control servo connector; 10 - misfire detection sensor connector; 11 - camshaft position sensor connector; 12 - coolant temperature sensor connector; 13 - coolant temperature gauge sensor connector; 14 - Front oxygen concentration sensor connector; 15 - Throttle control servo connector; 16 - Air conditioning compressor connector; 17 - Generator connector; 18 - pressure sensor connector; 19 - starter connector; 20 - brake booster vacuum hose; 21 - vacuum hose; 22 - Power steering pump and air conditioning compressor drive belt

• Disconnect the vacuum hoses.
• Disconnect the brake booster vacuum hose.
• Remove the bolt and disconnect the wire connecting the engine cylinder block to the ground.
• Loosen and remove the power steering pump and air conditioning compressor drive belt.
• Remove the bolts and remove the power steering pump together with the attached hose and bracket (Fig. 3.54).

Fig. 3.54. Removable elements and fastening elements of the 4G13 engine:1- Power steering pump and bracket; 2 - air conditioning compressor; 3 - heater hoses; 4 - fuel return hose; 5 - high-grade fuel hose; 6 - sealing ring; 7 - engine bracket; 8 - engine

Note: Use a cord or soft wire to secure the removed power steering pump to the engine compartment so that it does not interfere with engine removal.

• Disconnect the connector, unscrew the bolts and remove the air conditioning compressor together with the connected hoses from the bracket.

Note: Use a cord or soft wire to secure the removed compressor in the engine compartment so that it does not interfere with engine removal.

• Loosen the clamps and disconnect the heater hoses.
• Loosen the clamps and remove the fuel return hoses.
• Remove the bolts, disconnect the high pressure fuel hose and remove the sealing ring.
• Remove the special tool used to remove the gearbox from the engine.
• Secure the engine to the crossbar and hang it on a hoist or similar device (Fig. 3.46).
• Place a block of wood between the jack base and the engine oil pan and lift the engine slightly to relieve the jack from the weight of the engine, then remove the engine mount bracket.
• Make sure all wires (electrical connectors), hoses, etc. are disconnected from the engine, and then slowly lift the engine up out of the engine compartment.

Installation

• Installation is carried out in the reverse order of removal, taking into account the following.
• When installing the motor, make sure that no wires, hoses or wire connectors are pinched.
• Place a hydraulic trolley jack under the engine (inserting a wooden block between the jack support foot and the engine oil pan) and install the engine support bracket, adjusting the engine position using the jack.
• Support the engine with a jack and disconnect the hoist.
• When installing the high pressure fuel hose, lubricate the O-ring with a small amount of clean engine oil (Fig. 3.36).

Warning: Do not allow oil to enter the fuel line.

• While slightly turning the flange of the fuel hose to the right and left, carefully insert it into the fuel line so as not to damage the O-ring seal. After installation, check that the hose rotates smoothly in the fuel line.
• If the hose flange jams when turning, damage to the O-ring gasket may occur. Disconnect the flange (complete with hose) from the fuel line and check the gasket for any damage, then insert it back and check that it turns smoothly.
• Install the high pressure fuel hose mounting bolts and tighten them to 5 Nm.
• Further installation is carried out in the reverse order of removal.
• Connect and adjust the accelerator cable.
• Install the gearbox.
• Install the radiator.
• Install the hood.
• Install the air filter.
• Install the lower engine splash shield.
• Connect the cable to the negative terminal of the battery.