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
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ENov. 1995Mitsubishi Motors Corporation
GENERAL INFORMATION

4G1 ENGINE (E-W) - General Information
11A-0-4
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4G1 ENGINE (E-W) - General Information 11A-0-5
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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
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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
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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
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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

4G1 ENGINE (E- W) - Specifications 11A-1-2a
PWEE9520
ENov. 1995Mitsubishi Motors Corporation
Item Standard Limit
Pistons and connecting rods
Piston outside diameter mm 4G13 71.0 -
4G15 75.5 -
4G18 76.0 -
Piston ring side clearance mm No. 1 ring 0.03- 0.07 -
No. 2 ring 0.02- 0.06 -
Piston ring end gap No. 1 ring 0.20- 0.35 0.8
clearance No. 2 ring 0.35- 0.50 0.8
Oil ring 4G13, 4G15 0.20 - 0.50 1.0
4G18 0.10 - 0.40 1.0
Piston pin O. D. mm 18.0 -
Piston pin press-in load (at room temperature) N 4,900 - 14,700 -
Crankshaft pin oil clearance mm 0.02 - 0.04 0.1
Connecting rod big end side clearance mm 0.10 - 0.25 0.4
Crankshaft and cylinder block
Crankshaft end play mm 0.05 - 0.18 0.25
Crankshaft journal diameter mm 48.0 -
Crankshaft pin diameter mm 42.0 -
Crankshaft journal oil clearance mm 0.02 - 0.04 0.1
Cylinder block gasket surface flatness mm 0.05 or less -
Cylinder block gasket surface grinding limit (including grinding of
cylinder head gasket surface) mm
- 0.2
Cylinder block overall height mm 256 -
Cylinder bore cylindricity mm 0.01 -
Cylinder bore I. D. mm 4G13 71.0 -
4G15 75.5 -
4G18 76.0 -
Piston-to-cylinder clearance mm 0.02- 0.04 -
PWEE9520-D
EAug. 2000Mitsubishi Motors Corporation Revised

4G1 ENGINE (E-W) - Specifications
11A-1-2b
PWEE9520
ENov. 1995Mitsubishi Motors Corporation
Intentionally blank
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4G1 ENGINE (E–W) – Specifications 11A-1-3
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REWORK DIMENSIONS
Item Standard Limit
Cylinder head and valves
Cylinder head oversize valve guide
hole diameter mm
SOHC 12-VALVE 0.05 O. S. 12.040–12.058 –
hole diameter mm 0.25 O. S. 12.240–12.258 –
0.50 O. S. 12.490–12.508 –
SOHC 16-VALVE 0.05 O. S. 10.550–10.568 –
0.25 O. S. 10.750–10.768 –
0.50 O. S. 11.000–11.018 –
DOHC 0.05 O. S. 10.550–10.568 –
0.25 O. S. 10.750–10.768 –
0.50 O. S. 11.000–11.018 –
DOHC GDI 0.05 O. S. 10.610–10.620 –
0.25 O. S. 10.810–10.820 –
0.50 O. S. 11.060–11.070 –
Oversizevalveseat
ring hole diameter
SOHC
12 VALVE
Intake (primary) 0.3 O. S. 27.300–27.325 –
ring hole diameter
mm 12-VALVE 0.6 O. S. 27.600–27.625 –
mm
Intake (secondary) 0.3 O. S. 32.300–32.325 –
0.6 O. S. 32.600–32.625 –
Exhaust 0.3 O. S. 35.300–35.325 –
0.6 O. S. 35.600–35.625 –
SOHC
16 VALVE
Intake 0.3 O. S. 28.300–28.321 –
16-VALVE
<4G13> 0.6 O. S. 28.600–28.621 –
<4G13>
Exhaust 0.3 O. S. 26.300–26.321 –
0.6 O. S. 26.600–26.621 –
SOHC
16 VALVE
Intake 0.3 O. S. 30.300–30.321 –
16-VALVE
<4G18> 0.6 O. S. 30.600–30.621 –
<4G18>
Exhaust 0.3 O. S. 28.300–28.321 –
0.6 O. S. 28.600–28.621 –
DOHC Intake 0.3 O. S. 31.300–31.325 –
0.6 O. S. 31.600–31.625 –
Exhaust 0.3 O. S. 27.800–27.825 –
0.6 O. S. 28.100–28.125 –
PWEE9520-E
EFeb. 2001Mitsubishi Motors Corporation Revised

4G1 ENGINE (E–W) – Specifications
11A-1-4
PWEE9520
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TORQUE SPECIFICATIONS
Item Nm
Alternator and ignition system
Water pump pulley bolt 9
Alternator brace bolt (alternator side) 22
Alternator brace bolt (tightened with water pump) 23
Alternator pivot bolt 44
Oil level gauge guide bolt (Flange) 23
Oil level gauge guide bolt (Washer) 19
Crankshaft bolt (M12) 125
Crankshaft bolt (M14) 181
Spark plug 25
Distributor bolt 11
Ignition coil bolt 10
Ignition failure sensor bolt 5
Camshaft position sensor bolt 9
Camshaft position sensor support bolt 13
Camshaft position sensing cylinder bolt 21
Timing belt
Timing belt cover bolt 11
Timing belt tensioner bolt 23
Crankshaft angle sensor bolt 9
Bracket bolt 21
Engine support bracket bolt (M8) 21
Engine support bracket bolt, nut (M10) 35
Idler pulley bolt 35
Camshaft sprocket bolt 88
Fuel and emission control system
Vacuum pipe & hose bolt 9
Delivery pipe bolt 11
Fuel pressure regulator bolt 9
Throttle body bolt 18
Hose clamp bolt 10
Fuel pump bolt (SOHC 12-VALVE–CARBURETOR) 12
Fuel pump bolt (SOHC 16-VALVE–CARBURETOR) 19
Breather tube clamp bolt 22
Carburetor bolt 17
Air temperature sensor 13
Cover bolt (Except M8 ×16) 12
PWEE9520-G
EApr. 2003Mitsubishi Motors Corporation Revised

4G1 ENGINE (E–W) – Specifications 11A-1-4a
PWEE9520
ENov. 1995Mitsubishi Motors Corporation
Item Nm
Cover bolt (M8 ×16) 18
EGR valve bolt 21
PWEE9520-G
EApr. 2003Mitsubishi Motors Corporation Revised

4G1 ENGINE (E–W) – Specifications
11A-1-4b
PWEE9520
ENov. 1995Mitsubishi Motors Corporation
Intentionallyblank
PWEE9520-F
EAug. 2001Mitsubishi Motors Corporation Added

4G1 ENGINE (E- W) - Specifications 11A-1-5
PWEE9520
ENov. 1995Mitsubishi Motors Corporation
Item Nm
Intake manifold and throttle body (GDI)
Accelerator cable bolt 10
Throttle body bolt 19
Air intake plenum resonator bolt 10
Power plant stay right bolt 49
Intake manifold stay bolt 30
EGR valve bolt 19
EGR valve support bolt 19
EGR valve support nut 24
Intake manifold bolt, nut 20
Exhaust manifold (GDI)
Oxygen sensor 44
Exhaust manifold cover bolt 30
Exhaust manifold bracket bolt 35
Exhaust manifold nut (M8) 18
Exhaust manifold nut (M10) 29
Power plant stay left bolt 35
Water pump and water hose
Water inlet fitting bolt 22
Water inlet pipe bolt (M8) 12
Water inlet pipe bolt (M10) 25
Fitting bolt 23
Water outlet fitting bolt (Front wheel drive) 23
Water outlet fitting bolt (Rear wheel drive) 18
Thermostat case bolt 23
Thermo valve 27
Engine coolant temperature gauge unit 11
Engine coolant temperature sensor 29
Water pump bolt 13
Exhaust manifold and intake manifold
Boost sensor bolt 5
Solenoid valve assembly bolt 9
Intake manifold bolt, nut 17
Intake manifold stay bolt <MPI> (M8) 17
Intake manifold stay bolt <MPI> (M10) 31
Intake manifold stay bolt <carburetor> 30
Engine hanger bolt 19
Exhaust manifold cover bolt 29
PWEE9520-D
EAug. 2000Mitsubishi Motors Corporation Revised

4G1 ENGINE (E- W) - Specifications 4G1 ENGINE (E- W) - Specifications 4G1 ENGINE (E- W) - Specifications
11A-1-5a
PWEE9520
ENov. 1995Mitsubishi Motors Corporation
Item Nm
Exhaust manifold nut (M8) 17
Exhaust manifold nut (M10) 29
Exhaust manifold bracket A bolt 35
Exhaust manifold bracket B bolt 35
Power plant stay right bolt 49
Power plant stay left bolt 35
Oxygen sensor 44
Fuel system (GDI)
Fuel pipe bolt 12
Fuel pump bolt 4.9 ®17 ±2
Flange bolt 24
Harness bracket bolt 9.8
Injector holder bolt 23
Delivery pipe and injector bolt 12
Rocker arms and camshaft
Fuel pump cover bolt 12
Rocker cover bolt <SOHC> 3.5
Rocker cover bolt <DOHC> 4
Rocker shaft assembly bolt 31
Adjusting screw 15
Bearing cap bolt (M6) 11
Bearing cap bolt (M8) 24
Rocker arms and camshaft (GDI)
Engine hanger bolt 19
Rocker cover bolt 3.5
Beam camshaft cap bolt (M6) 11
Beam camshaft cap bolt (M8) 25
Cylinder head and valves
Cylinder head bolt 20 + 90_+90
_
Tighten to 49 Nm, then completely loosen and retighten as described.
Oil pump and oil pan
Transmission stay bolt 23
Oil pan bolt (M6) 7
Oil pan bolt (M8) 24
Drain plug 39
Oil screen bolt 19
Front case bolt 14
Relief plug 44
PWEE9520-D
EAug. 2000Mitsubishi Motors Corporation Revised

4G1 ENGINE (E- W) - Specifications 11A-1-5b
PWEE9520
ENov. 1995Mitsubishi Motors Corporation
Item Nm
Oil pump cover bolt 10
Pistons and connecting rods
Connecting rod nut 17 + 90_to 100_
Crankshaft and cylinder block
Flywheel bolt 132
Drive plate bolt <Except GDI> 132
Drive plate bolt <GDI> 98
Rear plate bolt 10
Bell housing cover bolt 10
Rear oil seal case bolt 11
Bearing cap bolt 34 + 30_to 34_
Oil pressure switch 19
Knock sensor 23
PWEE9520-D
EAug. 2000Mitsubishi Motors Corporation Revised

4G1 ENGINE (E- W) - Specifications
11A-1-6
PWEE9520
EApr. 2000Mitsubishi Motors Corporation
NEW TIGHTENING METHOD USING PLASTIC REGION TIGHTENING BOLTS
Parts of the engine use plastic region tightening bolts. The tightening procedure for these is different
from that of conventional bolts and is described in relevant parts of this manual. Note that plastic region
tightening bolts have fixed service limits. These limits are indicated in relevant parts of this manual and
must be strictly observed.
DPlastic region tightening bolts are used for the following applications:
(1) Cylinder head bolts
(2) Connecting rod cap bolts
(3) Bearing cap bolt
DThe tightening procedure is basically as follows:
After tightening a bolt to the specified torque, tighten it by a further 90_+90
_,90 _–100_or 30_–34_.
The exact tightening procedure differs depending on the bolt and is described in relevant parts of
this manual.
SEALANTS
Item Specified sealant Quantity
Cam position sensor support Mitsubishi Genuine Part No. MD970389 or equivalent As required
Water pump Mitsubishi Genuine Part No. MD970389 or equivalent As required
Thermo valve Mitsubishi Genuine Part No. MD970389 or equivalent As required
Thermostat housing Mitsubishi Genuine Part No. MD970389 or equivalent As required
Water outlet fitting Mitsubishi Genuine Part No. MD970389 or equivalent As required
Engine coolant temperature sensor 3M Nut Locking Part No. 4171 or equivalent As required
Engine coolant temperature gauge unit 3M ATD Part No. 8660 or equivalent As required
Camshaft bearing cap 3M ATD Part No. 8660 or equivalent As required
Semi-circular packing 3M ATD Part No. 8660 or equivalent As required
Rocker cover 3M ATD Part No. 8660 or equivalent As required
Beam camshaft cap Mitsubishi Genuine Part No. MD970389 or equivalent As required
Oil pump case Mitsubishi Genuine Part No. MD970389 or equivalent As required
Oil pan Mitsubishi Genuine Part No. MD970389 or equivalent As required
Oil pressure switch 3M ATD Part No. 8660 or equivalent As required
Rear oil seal case Mitsubishi Genuine Part No. MD970389 or equivalent As required
Drive plate bolt 3M Nut Locking Part No. 4171 or equivalent As required
PWEE9520-D
EAug. 2000Mitsubishi Motors Corporation Revised