Mitsubishi 4G1 series Instruction manual

GENERAL INFORMATION 11A-0-3
...........................................
1. SPECIFICATIONS 11A-1-1
.................................................
SERVICE SPECIFICATIONS 11A-1-1
....................................
REWORK DIMENSIONS 11A-1-3
........................................
TORQUE SPECIFICATIONS 11A-1-4
.....................................
NEW TIGHTENING METHOD-BY USE OF BOLTS TO BE
TIGHTENED IN PLASTIC AREA 11A-1-6
...............................
SEALANT 11A-1-6
........................................................
FORM-IN-PLACE GASKET 11A-1-7
......................................
2. SPECIAL TOOLS 11A-2-1
.................................................
3. ALTERNATOR AND IGNITION SYSTEM 11A-3-1
........................
4. TIMING BELT 11A-4-1
......................................................
5. FUEL AND EMISSION CONTROL SYSTEM 11A-5-1
....................
6. WATER PUMP AND WATER HOSE 11A-6-1
.............................
7. INTAKE AND EXHAUST MANIFOLD 11A-7-1
............................
8. ROCKER ARMS AND CAMSHAFT 11A-8-1
..............................
9. CYLINDER HEAD AND VALVES 11A-9-1
.................................
10. OIL PUMP AND OIL PAN 11A-10-1
.......................................
11. PISTON AND CONNECTING ROD 11A-11-1
..............................
12. CRANKSHAFT, CYLINDER BLOCK 11A-12-1
...........................
11A-0-1
PWEE9520
ENov. 1995Mitsubishi Motors Corporation
ENGINE
4G1 SERIES
CONTENTS

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-MPI 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 dm31,299 1,584
Cylinder bore mm 71.0 76.0
Piston stroke mm 82.0 87.3
Compression ratio 10 9.5
Number of Intake 8 8
valves
Exhaust 8 8
Valve timing Intake opens BTDC 17_BTDC 17_
Intake closes ABDC 39_ABDC 39_
Exhaust opens BBDC 49_BBDC 49_
Exhaust closes ATDC 7_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
PWEE9520-A
EDec. 1998Mitsubishi Motors Corporation Revised

4G1 ENGINE (E-W) - General Information 11A-0-7
PWEE9520
ENov. 1995Mitsubishi Motors Corporation
Descriptions 4G15-CARBURETTOR 4G15-MPI
Type In-line OHV, SOHC In-line OHV, DOHC
Number of cylinders 4 4
Combustion chamber Semi spherical type Pentroof type
Total displacement dm31,468 1,468
Cylinder bore mm 75.5 75.5
Piston stroke mm 82.0 82.0
Compression ratio 9.0 9.5
Number of Intake 8 8
valve
Exhaust 4 8
Valve timing Intake opens BTDC 14_BTDC 16_
Intake closes ABDC 48_ABDC 40_
Exhaust opens BBDC 55_BBDC 45_
Exhaust closes ATDC 13_ATDC 15 _
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 Added

NOTES

4G1 ENGINE (E-W) - Specifications 11A-1-1
PWEE9520
ENov. 1995Mitsubishi Motors Corporation
1. SPECIFICATIONS
SERVICE SPECIFICATIONS
Item Standard Limit
Rocker arms, rocker shafts, and camshaft
Camshaft cam SOHC 12-VALVE Intake (primary) 38.78 38.28
height mm Intake (secondary) 38.78 38.28
Exhaust 39.10 38.60
SOHC 16-VALVE Intake 36.99 36.49
Exhaust 36.85 36.35
DOHC Intake 34.67 38.28
Exhaust 34.26 38.60
Camshaft journal diameter mm SOHC 45.93 - 45.94 -
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 -
Valve stem-to-guide SOHC 12-VALVE Intake 0.020 - 0.050 0.10
clearance mm Exhaust 0.050 - 0.085 0.15
SOHC 16-VALVE Intake 0.020 - 0.047 0.10
Exhaust 0.030 - 0.062 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
PWEE9520-A
EDec. 1998Mitsubishi Motors Corporation Revised

4G1 ENGINE (E-W) - Specifications
11A-1-2
PWEE9520
ENov. 1995Mitsubishi Motors Corporation
Item LimitStandard
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
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 0.02- 0.06 -
No. 2 ring 0.02- 0.06 -
Piston ring end gap clearance No. 1 ring 0.20- 0.35 0.8
No. 2 ring 0.35- 0.50 0.8
Oil ring 0.20- 0.50 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
PWEE9520-A
EDec. 1998Mitsubishi Motors Corporation Revised