Mitsubishi 4G1 series Configuration guide

GENERAL INFORMATION 11A-0-3
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1. SPECIFICATIONS 11A-1-1
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SERVICE SPECIFICATIONS 11A-1-1
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REWORK DIMENSIONS 11A-1-3
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TORQUE SPECIFICATIONS 11A-1-4
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NEW TIGHTENING METHOD-BY USE OF BOLTS TO BE
TIGHTENED IN PLASTIC AREA 11A-1-6
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SEALANT 11A-1-6
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FORM-IN-PLACE GASKET 11A-1-7
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2. SPECIAL TOOLS 11A-2-1
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3. ALTERNATOR AND IGNITION SYSTEM 11A-3-1
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4. TIMING BELT 11A-4-1
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5. FUEL AND EMISSION CONTROL SYSTEMS 11A-5-1
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5a. INTAKE MANIFOLD AND THROTTLE BODY (GDI) 11A-5a-1
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5b. EXHAUST MANIFOLD (GDI) 11A-5b-1
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6. WATER PUMP AND WATER HOSE 11A-6-1
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7. INTAKE AND EXHAUST MANIFOLDS 11A-7-1
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7a. FUEL SYSTEM (GDI) 11A-7a-1
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8. ROCKER ARMS AND CAMSHAFTS 11A-8-1
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8a. ROCKER ARMS AND CAMSHAFTS (GDI) 11A-8a-1
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9. CYLINDER HEAD AND VALVES 11A-9-1
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10. OIL PUMP AND OIL PAN 11A-10-1
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11. PISTONS AND CONNECTING RODS 11A-11-1
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12. CRANKSHAFT AND CYLINDER BLOCK 11A-12-1
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11A-0-1
PWEE9520
ENov. 1995Mitsubishi Motors Corporation
ENGINE
4G1 SERIES
CONTENTS
PWEE9520-D
EAug. 2000Mitsubishi Motors Corporation Revised

11A-0-2
PWEE9520
ENov. 1995Mitsubishi Motors Corporation
NOTES

4G1 ENGINE (E-W) - General Information 11A-0-3
PWEE9520
ENov. 1995Mitsubishi Motors Corporation
GENERAL INFORMATION

4G1 ENGINE (E-W) - General Information
11A-0-4
PWEE9520
ENov. 1995Mitsubishi Motors Corporation

4G1 ENGINE (E-W) - General Information 11A-0-5
PWEE9520
ENov. 1995Mitsubishi Motors Corporation
Descriptions 4G13 12-VALVE- CARBURETOR 4G13 12-VALVE- MPI
Type In-line OHV, SOHC In-line OHV, SOHC
Number of cylinders 4 4
Combustion chamber Pentroof type Pentroof type
Total displacement dm31,299 1,299
Cylinder bore mm 71.0 71.0
Piston stroke mm 82.0 82.0
Compression ratio 9.5 9.5
Number of Intake 8 8
valves
Exhaust 4 4
Valve timing Intake opens BTDC 14_BTDC 19_
Intake closes ABDC 48_ABDC 43_
Exhaust opens BBDC 55_BBDC 60_
Exhaust closes ATDC 13_ATDC 8_
Lubrication system Pressure feed, full-flow filtration Pressure feed, full-flow filtration
Oil pump type Trochoid type Trochoid type
Cooling system Water-cooled, forced circulation Water-cooled, forced circulation
Water pump type Centrifugal impeller type Centrifugal impeller type
PWEE9520-A
EDec. 1998Mitsubishi Motors Corporation Revised

4G1 ENGINE (E–W) –General Information
11A-0-6
PWEE9520
ENov. 1995Mitsubishi Motors Corporation
Descriptions 4G13 16-VALVE–CARBURETOR 4G13 16-VALVE–MPI
Type In-line OHV, SOHC In-line OHV, SOHC
Number of cylinders 4 4
Combustion chamber Pentroof type Pentroof type
Total displacement dm31,299 1,299
Cylinder bore mm 71.0 71.0
Piston stroke mm 82.0 82.0
Compression ratio 9.5 10, 9.5*1
Number of
valves
Intake 8 8
va
l
ves Exhaust 8 8
Valve timing Intake opens BTDC 12_BTDC 17_
Intake closes ABDC 48_ABDC 39_
Exhaust opens BBDC 48_BBDC 49_
Exhaust closes ATDC 12_ATDC 7_
Lubrication system Pressure feed, full-flow filtration Pressure feed, full-flow filtration
Oil pump type Trochoid type Trochoid type
Cooling system Water-cooled, forced circulation Water-cooled, forced circulation
Water pump type Centrifugal impeller type Centrifugal impeller type
*1: LANCER for General Export
PWEE9520-E
EFeb. 2001Mitsubishi Motors Corporation Revised

4G1 ENGINE (E–W) – General Information 11A-0-7
PWEE9520
ENov. 1995Mitsubishi Motors Corporation
Descriptions 4G15–
CARBURETTOR 4G15–MPI 12-VALVE 4G15–MPI 16-VALVE 4G15–GDI
Type In-line OHV, SOHC In-line OHV, SOHC In-line OHV, DOHC In-line OHV, DOHC
Number of cylinders 4 4 4 4
Combustion chamber Semi spherical type Semi spherical type Pentroof type Pentroof + Curved
piston head
Total displacement dm31,468 1,468 1,468 1,468
Cylinder bore mm 75.5 75.5 75.5 75.5
Piston stroke mm 82.0 82.0 82.0 82.0
Compression ratio 9.0 9.0 9.5 11.0
Number
o
f
valves
Intake 8 8 8 8
o
f
va
l
ves Exhaust 4 4 8 8
Valve
timing Intake opens BTDC 14_BTDC 14_, BTDC 13_*1BTDC 16_BTDC 12_
Intake closes ABDC 48_ABDC 48_,
ABDC 47_*1ABDC 40_ABDC 44_
Exhaust
opens BBDC 55_BBDC 55_, BBDC 56_*1BBDC 45_BBDC 48_
Exhaust
closes ATDC 13_ATDC 13_, ATDC 8_*1ATDC 15_ATDC 12_
Lubrication system Pressure feed,
full-flow filtration Pressure feed, full-flow filtration Pressure feed, full-flow filtration Pressure feed, full-flow filtration
Oil pump type Trochoid type Trochoid type Trochoid type Trochoid type
Cooling system Water-cooled,
forced circulation Water-cooled, forced circulation Water-cooled, forced circulation Water-cooled, forced circulation
Water pump type Centrifugal impeller
type Centrifugal impeller type Centrifugal impeller type Centrifugal impeller type
*1: Special low-emission engines on vehicles for Australia
PWEE9520-E
EFeb. 2001Mitsubishi Motors Corporation Revised

4G1 ENGINE (E–W) – General Information
11A-0-8
PWEE9520
ENov. 1995Mitsubishi Motors Corporation
Descriptions 4G18 16-VALVE–CARBURETOR 4G18 16-VALVE–MPI
Type In-line OHV, SOHC In-line OHV, SOHC
Number of cylinders 4 4
Combustion chamber Pentroof type Pentroof type
Total displacement dm31,584 1,584
Cylinder bore mm 76.0 76.0
Piston stroke mm 87.3 87.3
Compression ratio 9.5 9.5, 10*1*2
Number of
valves
Intake 8 8
va
l
ves Exhaust 8 8
Valve timing Intake opens BTDC 12_BTDC 17_, BTDC 9_*1, BTDC 17_*2
Intake closes ABDC 48_ABDC 39_, ABDC 51_*1, ABDC 43_*2
Exhaust opens BBDC 48_BBDC 49_, BBDC 49_*1, BBDC 53_*2
Exhaust closes ATDC 12_ATDC 7_, ATDC 15_*1, ATDC 7_*2
Lubrication system Pressure feed, full-flow filtration Pressure feed, full-flow filtration
Oil pump type Trochoid type Trochoid type
Cooling system Water-cooled, forced circulation Water-cooled, forced circulation
Water pump type Centrifugal impeller type Centrifugal impeller type
*1: SPACE STAR for Europe
*2: LANCER for General Export
PWEE9520-E
EFeb. 2001Mitsubishi Motors Corporation Revised

4G1 ENGINE (E–W) – Specifications 11A-1-1
PWEE9520
ENov. 1995Mitsubishi Motors Corporation
1. SPECIFICATIONS
SERVICE SPECIFICATIONS
Item Standard Limit
Rocker arms and camshaft
Camshaft cam
height mm
SOHC 12-VALVE Intake (primary) 38.78 38.28
height mm Intake (secondary) 38.78 38.28
Exhaust*139.01 38.51
Exhaust*238.97 38.47
SOHC 16-VALVE*3Intake 36.99 36.49
Exhaust 36.85 36.35
SOHC 16-VALVE*4Intake 36.86 36.36
Exhaust 36.68 36.18
SOHC 16-VALVE*5Intake 37.30 36.80
Exhaust 37.16 36.66
SOHC 16-VALVE*6Intake 37.17 36.67
Exhaust 36.99 36.49
DOHC Intake 34.67 34.17
Exhaust 34.26 33.76
DOHC GDI Intake 34.85 34.35
Exhaust 34.59 34.09
Camshaft journal diameter mm SOHC 45.93–45.94 –
SOHC 16-VALVE*744.93–44.94 –
DOHC 25.95–25.97 –
Cylinder head and valves
Flatness of cylinder head gasket surface mm 0.05 or less –
Cylinder head gasket surface grinding limit (including grinding of
cylinder block gasket surface) mm – 0.2
Cylinder head overall height mm SOHC 12-VALVE 106.9–107.1 –
SOHC 16-VALVE 119.9–120.1 –
DOHC 131.9–132.1 –
Cylinder head bolt nominal length mm – 103.2
Valve margin mm Intake 1.0 0.5
Exhaust 1.5 1.0
Valve stem diameter mm SOHC 12-VALVE 6.6 –
SOHC 16-VALVE 5.5 –
DOHC 5.5 –
*1: With low pollution system
*2: Without low pollution system
*3: Except 2001 model front wheel drive vehicles
*4: 2001 model front wheel drive vehicles for Europe
*5: 2001 model front wheel drive vehicles for General Export
*6: 2002 model front wheel drive vehicles for Europe
*7: SOHC 16-VALVE MPI for Europe
PWEE9520-E
EFeb. 2001Mitsubishi Motors Corporation Revised

4G1 ENGINE (E- W) - Specifications
11A-1-2
PWEE9520
ENov. 1995Mitsubishi Motors Corporation
Item LimitStandard
Valve stem-to-guide SOHC 12-VALVE Intake 0.020- 0.050 0.10
clearance mm Exhaust 0.035- 0.050 0.15
SOHC 16-VALVE Intake 0.020 - 0.047 0.10
Exhaust 0.030 - 0.057 0.15
DOHC Intake 0.020- 0.047 0.10
Exhaust 0.030- 0.062 0.15
Valve face angle 45°- 45.5°-
Valve stem projec- SOHC 12-VALVE Intake 43.70 44.20
tion mm Exhaust 43.30 43.80
SOHC 16-VALVE Intake 53.21 53.71
Exhaust 54.10 54.60
DOHC Intake 48.80 49.30
Exhaust 48.70 49.20
Overall valve length SOHC 12-VALVE Intake 100.75 100.25
mm Exhaust 101.05 105.55
SOHC 16-VALVE Intake 111.56 111.06
Exhaust 114.71 114.21
DOHC Intake 106.35 105.85
Exhaust 106.85 106.35
Valve spring free SOHC 12-VALVE Intake 46.1 45.6
height mm Exhaust 46.8 46.3
SOHC 16-VALVE 50.9 50.4
DOHC 49.1 48.6
Valve spring load/ SOHC 12-VALVE Intake 226/40.0 -
installed height N/
mm Exhaust 284/39.6 -
mm
SOHC 16-VALVE 216/44.2 -
DOHC 177/40.0 -
Valve spring squareness 2°4°
Valve seat contact width mm 0.9- 1.3 -
Valve guide internal diameter mm SOHC 12-VALVE 6.6 -
SOHC 16-VALVE 5.5 -
DOHC 5.5 -
Valve guide projection mm SOHC 12-VALVE 17.0 -
SOHC 16-VALVE 23.0 -
DOHC 23.0 -
Oil pump and oil pan
Oil pump tip clearance mm 0.06- 0.18 -
Oil pump side clearance mm 0.04- 0.10 -
Oil pump body clearance mm 0.10- 0.18 0.35
PWEE9520-C
EApr. 2000Mitsubishi Motors Corporation Revised