Mitsubishi 4G1 series User manual

BACKUP
Service Manual
ENGINE
GROUP INDEX
1992 - 1993
Introduction
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
FOREWORD
The information contained in this service manual
has been prepared for the professional automotive
technician involved in daily repair operations. In-
formation in this manual is divided into groups by
engine models. Each group is further divided to
address individual components within the group.
These groups contain general information, specifica-
tion, removal and installation, disassembly and
reassembly procedures for the components. The
first page of each group contains an alphabetical
index to assist in finding the location of the
component. The information, descriptions and spe-
cifications were in effect at the time this manual
was released.
This BACKUP DSM manual IS to be used ONLY as a BACKUP. Please DO NOT REDISTRIBUTE
WHOLE SECTIONS. This BACKUP was sold to you under the fact that you do indeed OWN
a GENUINE DSM MANUAL. It CANNOT BE considered a REPLACEMENT (Unless your original
manual was lost or destroyed.)
Please See README.N or READMEHTML for additional Information.
Thank you. [email protected]
WE SUPPORT
VOLUNTARY TECHNICIAN
CERTIFICATION THROUGH
National lnstit~te for
AUTOMOTIVE
SERVICE
EXCELLENCE
Engine
4G1l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
4G33 . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . .
4G6 <1992>> . . . . . . . . . . . . . . . . . . . . . . . .
mm
4G99
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...*..
m
6G77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4G6 <1993>> . . . . . . . . . . . . . . . . . . . . . . . .
CCT
Mitsubishi Motors Co[poration reserves the right to make changes in
dew? or to make addltlons to or improvements in its products WIthout
impoang any obligations upon itself to install them on its products
previously manufactured.
@ 1992 Mitsubishi Motors Corporation
Printed in Japan

INTRODUCTION
:,
CONTENTS
ENGINE MODEL TABLE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
SPECIAL TOOL NOTE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
EXPLANATION OF MANUAL CONTENTS
. . . . . . . . 2TORQUE REFERENCES
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..I.....
5
FORM-IN-PLACE GASKET
. . . . . . . . . . . . . . . . . ..I................
6
Disassembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
1.
Form-In-Place Gasket Application ._...................... 6
Surface Preparation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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2 INTRODUCTION
EXPLANATION OF MANUAL CONTENTS
I
Maintenance and Servicing Procedures
(1) A diagram of the component parts is
provided near the front of each section in
order to give the reader a better under-
standing of the installed condition of
component parts.
(2) The numbers provided within the diagram
indicate the sequence for maintenance
and servicing procedures; the symbol
m
indicates a non-reusable part; the tighten-
ing torque is provided where applicable.
0 Removal steps:
The part designation number corresponds
to the number in the illustration to indicate
removal steps.
l Disassembly steps:
The part designation number corresponds
to the number in the illustration to indicate
disassembly steps.
0 Installation steps:
Specified in case installation is impossible
in reverse order of removal steps. Omit-
ted if installation is possible in reverse
order of removal steps.
l Reassembly steps:
ia
Specified in case reassembly is im$ossi-
ble in reverse order of disassembly
Omitted if reassembly is possible
verse order of disassembly steps.
Classification of Major Maintenance/
Service Points
When there are major points relative to mainte-
nance and servicing procedures (such as essential
maintenance and service points, maintenance and
service standard values, information regarding the
use of special tools, etc.), these are arranged
together as major maintenance and service points
and explained in detail.
GAO: Indicates that there are essential points for
removal or disassembly.
I)A4: Indicates that there are essential points for
installation or reassembly.
Symbols for Lubrication, Sealants and
Adhesives
Information concerning the locations for lubrica-
tion and for application of sealants and adhesives
is provided, by using symbols, in the diagram of
component parts, or on the page following the
component parts page, and explained.
& . . Grease
(multrpurpose grease unless there is
a brand or type specified)
. . . . . Sealant or adhesive
i
. . . . . Brake fluid, automatic transmission
fllid or air conditioning compressor
:m . . . . . Engine oil or gear oil
I
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INTRODUCTION
3
Indicates the
section title.
Denotes non-reusable
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This number corresponds to the
number appearing in “Removal
steps”, “Disassembly steps”, “ln-
stallation steps” or “Reassembly
steps” I
Operating procedures, cautions,
etc. on removal, installation, dis-
assembly and reassembly are de-
scribed.
I

4
INTRODUCTION
ENGINE MODEL TABLE - 1992
Engine
Series,
4Gl
4G3
4G6
4G9
6G7
4693 1.8 (1 IO)
6672 3.0 (I 83)
6G72 3.0 (183)
In-line, SOHC
6O”V. SOHC
(per bank)
6O”V. DOHC
(per bank)
E$po LRV
bgmante,
h&ntero, Truck
Diamante, 3000GT
6G72 Turbo 3.0 (183)
6O“V. DOHC
(per bank)
43000GT
.K
c:
ENGINE MODEL TABLE - 1993
4G9
6G7
4664 . 2.4(146) In-line, SOHC
4 E$po-LRV.
Expo
4G93 1.8 (1 IO)
In-line, SOHC 4
@age, Expo LRV
6672 3.0 (I 83)
6O”V. SOHC 2 Diamante,
(per bank)
Mhtero, Truck
6672 3.0 (183)
6O”V, DOHC 4
(per bank)
C$mante, 3000GT
6G72 Turbo 3.0 (183) 6O”V. DOHC 43600GT
(per bank)
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INTRODUCTION
6
SPECIAL TOOL NOTE .
1
Please refer to the special tool cross reference chart which is located in the service manual at the beginning of
each group, for a cross reference from the MMC special tool number to the special tool number that is
available in your market.
iiS *‘l
*.j,
l”
“...!: ‘/’
TORQUE REFERENCES
General tightening torque is as shown in the following table.
The specific part tightening torque is shown at the beginning of each group.
Size mm
(dia. x pitch)
5 x 0.8
6x 1.0
8 x 1.25
10x1.25
12x 1.25
14x1.5
Bolt with spring washer Flange bolt
Head mark 4 Head mark 7 Head mark 10 Head mark 4
Heaid. i-MC 7
Nm ft.lbs. Nm ft.lbs. Nm ft.lbs. Nm ft.lbs. Nm
ft.lbS.
NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA
A new type of bolts, to be tightened in plastic area, is currently used in so’me parts of the engine. The
tightening method for the bolts is different from the conventional one. Be sure to observe the method
described in the text when tightening the bolts.
Service limits are provided for the bolts. Make sure that the service limits described in the text are strictly
observed.
l Areas where the bolts are in use:
(1) Cylinder head bolts
(2) Main bearing cap bolts
(3) Connecting rod cap bolts
Remarks:
The bolts in (1) and (2) apply to the 4G6 <I 993> and 4G93 engines.
The bolts in (3) apply to the 4G15, 4G6 <1993> and 4693 engines.
l Tightening Method
After tightening the bolts to the specified torque, tighten them another 90” or 180” (twice 90”). The
tightening method varies on different areas. Observe the tightening method described in the text.
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INTRODUCTION
FORM-IN-PLACE GASKET
The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket fully
serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size,
continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick a bead, on
the other hand, could be squeezed out of location, causing blocking or narrowing of the fluid feed line. To
eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to apply the gasket evenly
without a break, while observing the correct bead size.
The FIPG used in the engine is a room temperature vulcanization (Rn/) type and is supplied in a loo-gram
tube (Part No. MD970389 or MD9971 10). Since the RTV hardens as it reacts with the moisture in the
atmospheric air, it is normally used in the metallic flange areas. The FIPG, Part No. MD970389, can be used
for sealing both engine oil and coolant, while Part No. 997110 can only be used for engine oil sealing.
Disassembly
The parts assembled with the FIPG can be easily disassembled without use of a special method. In some
cases, however, the sealant between the joined surfaces may have to be broken bylightly striking with a
mallet or similar tool. A flat gasket scraper may be lightly hammered in between the joined surfaces. In this
case, however, care must be taken to prevent damage to the joined surfaces.
Surface Preparation
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper or
wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat.‘ Make sure that there
are no oils, greases and foreign substances deposited on the application surfaces. Do:not forget to remove
the old sealant remaining in the bolt holes.
Form-In-Place Gasket Application
5
When assembling parts with the FIPG, you must observe some precautions, but the procedure is very simple
as in the case of a conventional precut gasket.
Applied FIPG bead should be of the specified size and without breaks. Also be sure toencircle the bolt hole
circumference with a completely continuous bead. The FIPG can be wiped away unless it is hardened. While
the FIPG is still moist (in less than 15 minutes), mount the parts in position. When the parts are mounted,
make sure that the gasket is applied to the required area only.
The FIPG application procedure may vary on different areas. Observe the procedure described in the text
when applying the FIPG.
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4G15
BRACKET ................................................................
53
CRANKSHAFT, FLYWHEEL AND
DRIVE PLATE ........................................................ 51
CYLINDER HEAD AND VALVES
........................
33
EXHAUST MANIFOLD AND
WATER PUMP
....................................................
28
FRONT CASE AND OIL PUMP
............................
39
FUEL AND EMISSION PARTS
............................
22
GENERAL INFORMATION
................................
2
GENERAL SPECIFICATIONS
............................
5
GENERATOR AND IGNITION SYSTEM
........ 14
CONTENTS
INTAKE MANIFOLD
............................................
26
PISTON AND CONNECTING ROD
....................
43
ROCKER ARMS AND CAMSHAFT
....................
30
SEALANT
................................................................ 11
SERVICE SPECIFICATIONS
................................
6
SPECIAL TOOLS
....................................................
12
THROlTLE BODY
................................................
24
TIMING
BELT
........................................................
17
TORQUE SPECIFICATIONS
................................
10

IlA-2
4Gl ENGINE - General Information
GENERAL INFQRMATION
ENGINE SECTIONAL VIEW
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3
1 EN0086

4Gl ENGINE - General Information
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1

VA-4
4Gl ENGINE - General Information
UBRICATION SYSTEM
P
0’ ‘Z
t7;
:
ii
ii
I
OTJ
09
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4Gl ENGINE - General Specifications
GENERAL SPECIFICATIONS
Y’
1: up to 1992 models
.---
Items
We
Number of cylinders
Combustion chamber
Total displacement
cm3 (cu.in.)
Cylinder bore
mm (in.)
Piston stroke
mm (in.)
Compression ratio
Valve timing
( ): Camshaft identification mark
Intake valve
Opens BTDC
Closes ABDC
Exhaust valve
Opens
BBDC
Closes
ATDC
Lubrication system
Oil pump type
Cooling system
Water pump type
EGR valve
Injector type and number
Injector identification No.
Fuel regulated pressure kpa (psi)
Throttle bore mm (in.)
Throttle position sensor
Closed throttle position switch
“2: From 1993 models
Specifications
In-line OHV, SOHC
4
Pentroof type
1,468 (89.58)
75.5 (2.972)
82 (3.228)
9.2
(1 I*’ (6)**
14” 15”
51” 53”
51” 57”
14” 15”
Pressure feed, full-flow filtration
Trochoid type
Water-cooled forced circulation
Centrifugal impeller type
Single type
Electromagnetic, 4
BDH182
335 (47.6)
46(1.811)
dariable resistor type
Contact type, within idle speed control motor”
Movable contact type within throttle position sensor*’
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I

1 IA-6
4Gl ENGINE - Service Specifications
SERVICE SPECIFICATIONS
“”
mm (in.)
Items Standard value
Limit
Cylinder head
Flatness of gasket surface
d.05 (.0020)
0.2(.008)
Grinding limit of gasket surface
3
"0.2 (.008)
t Total resurfacing depth of both cylinder
head and cylinder block
1
Overall height
106.9-107.1 (4.209-4.217)
“1
Oversize rework dimensions of valve guide hole
(both intake and exhaust)
0.05 (.002)
12.05-12.07 (.4744-.4752)
0.25(.010)
12.25- 12.27 (.4823-.4831)
0.50 (.020)
12.50-12.52 (.4921 -.4929)
'$
Oversize rework dimensions of intake valve
1,
seat ring hole (primary)
0.3 (.012) 27.42-27.44(1.0795-1.0803)
0.6(.024) 27.72-27.74(1.0913-1.0922)
Oversize rework dimensions of intake valve
seat ring hole (secondary)
0.3 (.012)
32.43-32.45 (1.2768-1.2776)
0.6 (.024)
32.73-32.75 (1.2886-1.2894)
Oversize rework dimensions of exhaust valve
seat ring hole
0.3 (.012)
35.43-35.45(1.3949-1.3957)
0.6 (.024)
35.73-35.75(1.4067-1.4075)
I)
1
Camshaft
Cam height
1:
Intake
38.78 (1.5268)
38.28 (1.5071)
!
Exhaust 39.10 (1.5394)
38.60(1.5197)
Journal diameter 45.93-45.94(1.8083-1.8087)
3il clearance 0.06-0.10(.0024-.0039)
qockerarm
.D.
18.91 -18.93(.7445-.7453)
3ocker arm-to-shaft clearance
0.01 -0.04(.0004-.0016) 0.1
(.004)
qockerarmshaft
I.D.
18.89-18.90(.7437-.7441)
3verall length
Intake
365(14.37)
Exhaust
346(13.62)
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4Gl ENGINE - Service Specifications
mm (in.)
Items
Valve
Overall length
Intake
Exhaust
Stem diameter
Intake
Exhaust
Face angle
Thickness of valve head (margin)
Intake
Exhaust
Stem-to-guide clearance
Intake
Exhaust
Valve clearance
Intake
Exhaust
Valve spring
Free height
Intake
Exhaust
-oad/installed height N/mm (Ibs./in.)
Intake
Exhaust
3ut-of-squareness
halve guide
3verall length
Intake
Exhaust
.D.
I.D.
;ervice size
‘Tess-in temperature
lalve seat
;eat angle
lalve contact width
Gnkage
iervice size
Standard value
100.75 (3.9665)
101.05 (3.9783)
6.57 - 6.58 (2587 - .2591)
6.53 - 6.55 (2571 - .2579)
45” - 45”30’
1 .o (.039)
1.5 l.059)
0.02 - 0.05 (0008 - .0020)
0.05 - 0.09 (.0020 - .0035)
0.07 (.0028) Up to 1992 models
0.09 (.0035) From 1993 models
0.17 (0067)
46.1 (1.815)
46.8 (1.843)
230/40 (51/I .57)
290140 (64/l .57)
Max. 2”
44 ( 1.732)
49.5 (1.949)
6.60 - 6.62 (.2598 - .2606)
12.055 - 12.065 (4746 - .4750)
0.05 (.002), 0.25 (.Ol). 0.50 (02) oversize
Room temperature
43”30’ - 44”
0.9 - 1.3 (035 - .051)
0.3 LO1 2), 0.6 (024) oversize
.,_ ..“.. ..“_
Limit
i
..
7/
1 t..
,-i ,
-7, ,i ,,- <
0.5 (020)
1 .o (.039)
0.10 (.0039)
0.15 (.OOSS)
45.1 (1.776)
45.8 (1.803)
4”
. .
0.2 (.008)
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I

IIA-8
4Gl ENGINE - Service Specifications
mm (in.)
Items
Piston
O.D.
Piston-to-cylinder clearance
Service size
Standard value Limit
75.48 - 75.50 (2.9716 - 2.9724)
0.02 - 0.04 (0008 - .0016)
0.25 t.01). 0.50 (.02), 0.75 (.03), 1
.OO (.04)
oversize
Piston ring
End gap
No. 1 ring
No. 2 ring
Oil ring
Ring-to-ring groove clearance
No. 1 ring
No. 2 ring
Service size
0.20 - 0.40 l.0079 - .0157)
0.8 (.031)
0.20 - 0.35 (.0079 - .0138)
0.8 f.031)
0.20 - 0.70 LOO79 - .0276)
1 .o i.039)
0.03 - 0.07 (.0012 - .0028)
0.1 (.004)
0.02 - 0.06 f.0008 - .0024)
0.1 i.004)
0.25 (.Ol), 0.50 (.02), 0.75 (.03), 1
.OO (04)
oversize
Piston pin
O.D.
Press-in load N (psi)
Press-in temperature
Connecting rod
18.003 - 18.005 l.7088 - .7089)
5,000 - 15,000 (1 ,102 - 3,307)
Room temperature
Big end center-to small end center length
Bend
Twist
Big end side clearance
Crankshaft
End play
Journal O.D.
Pin O.D.
Dut-of-roundness and taper of journal and pin
3il clearance of journal
3il clearance of pin
Cylinder block
.D.
Ilatness of gasket surface
Grinding limit of gasket surface
Total resurfacing depth of both cylinder
block and cylinder head
130.95- 131.05 (5.1555-5.1594)
0.05 (.0020)
0.1 (.004)
0.10 - 0.25 (.0039 - .0098)
0.4 f.016)
0.05-0.18 (.0020- .0071)
0.3 (.012)
48 (1.89)
42 (1.65)
0.005 (.0002)
0.02 - 0.05 (.0008 - .0020)
0.1 i.004)
0.02 - 0.05 (.0008 - .0020)
0.1 (.004)
75.50 - 75.53 (2.9724 - 2.9736)
0.05 i.002) 0.1 i.004)
*0.2 (.008)
3verall height
255.9 - 256.1 (10.075 - 10.083)
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4Gl ENGINE - Service Specifications
Items
Oil pump
Tip clearance
Side clearance
Body clearance
Drive belt deflection
New belt
Used belt
Injector
Coil resistance fI?
Throttle position sensor
Resistance kR
Idle speed control motor
Coil resistance rc1
Idle air control motor
Coil resistance 0
Idle speed control motor position sensor
Resistance kfi
Standard value
Limit
rn:fq, (in,
i ,I :, i /
0.03 - 0.08 LOOI 2 - .0031)
.’
0.04-0.10(.0016-.0039)
O.lO-0.18(.0039-.0071) 0.35 (.Orl38)
5.5 -7.0 (.22 - .28)
8.0 (.32)
13 - 16 at 20°C (68°F)
3.5-6.5
5 - 35 at 20°C (68°F)
28 - 33 at 20°C (68°F)
4-6
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1
IA-IO
4Gl ENGINE - Torque Specifications
TORQUE SPECIFICATIONS
Generator and ignition system
Oil level gauge guide mounting bolt
Water pulley bolt
pump
Generator brace bolt
Generator brace mounting bolt
Generator pivot nut
Crankshaft bolt
Crankshaft pulley bolt
Spark plug
Distributor
Timing belt
Engine support bracket, left
Tensioner bolt
Camshaft sprocket bolt
Fuel and emission parts
Throttle body mounting bolts
Fuel rail mounting bolts
Fuel regulator bolts
pressure
EGR valve (California) mounting bolts
Throttle body
Throttle position sensor attaching bolts
Intake manifold
Cable bracket bolt
Engine coolant temperature gauge unit
Engine coolant temperature sensor
Therm0 switch
flater outlet fitting bolt
Thermostat housing bolt and nut
Intake manifold stay bolt
Engine support bracket stay
Intake manifold bolt and nut
Exhaust manifold and water pump
Exhaust manifold cover “A” bolt
Exhaust manifold cover “A” and “B” mounting bolt
Exhaust manifold cover “B” bolt
Exhaust manifold nut
Vater inlet pipe bolt
Vater bolt
pump
Ixygen sensor
jocker arms and camshaft
jocker cover bolt
locker arm shaft bolt
iocker arm lock nut
Nm
11
9
14
24
23
85
14
25
12
36
24
70
19
12
9
13
2.0
14
11
30
8
19
18
22
36
18
30
9
24
18
14
14
45
1.8
32
15
-
ftlbs.
8
7
10
17
17
61
10
18
i
9
ii 26
17
51
14
‘7 9
7
9
1.5
11
8
22
6
14
13
16
26
13
22
7
18
13
11
11
33
1.3
24
11
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461 ENGINE - Torque Specifications / Sealant
Cylinder head and valves
Cylinder head bolt
Front case and oil pump
Oil drain plug
pan
Oil bolt
pan
Oil screen bolt
Oil relief valve plug
Front case bolt
Oil pump cover screw
Piston and connecting rod
Connecting rod cap nut
Crankshaft, flywheel and drive plate
Flywheel and drive plate
Rear plate bolt
Bell housing cover bolt
Oil seal case bolt
Bearing cap bolt
3il switch
pressure
Bracket
Exhaust pipe support bracket
Engine support bracket, front
7011 stopper bracket, front
3011 stopper bracket, rear
Nm
73
40
7
19
45
I4
IO
20 + I/4 turns
135
11
9
11
53
19
36
60
65
120
_ .” .c
ft.lbs.‘, I. ‘-,.‘.,; $8;
53
29
5
14
33
11
8
14.5 + l/4 turns
98
8
7
8
38
14
26
43
47
87
SEALANT
Items
Therm0 switch
Engine coolant temperature sensor
Engine coolant temperature gauge unit
Oil pan
Oil pressure switch threads
Specified sealant
Quantity
3M Nut Locking part No. 4171 or equivalent As required
3M Nut Locking part No. 4171 or equivalent As required
3M ATD Part No. 8660 or equivalent
As required
Mitsubishi Genuine Part No. MD970389 or equivalent
As required
3M ATD Part No. 8660 or equivalent
As required
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1 IA-12
SPECIAL TOOLS
4Gl ENGINE - Special Tools
Tool
MD99801 1
MD99801 I-01 Installation of crankshaft rear oil seal
Crankshaft rear
oil seal installer
Crankshaft front
oil seal installer
MD99871 3 MD998713-01 Installation of camshaft oil seal
Camshaft oil seal
,.
i
. .
Removal of oil pan
ompresslon 0
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