Mitsubishi 4G6 series Instruction manual

GENERAL INFORMATION 11A-0-3
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1. SPECIFICATIONS 11A-1-1
................................................
SERVICE SPECIFICATIONS 11A-1-1
....................................
TORQUE SPECIFICATIONS 11A-1-4
.....................................
NEW TIGHTENING METHOD -
BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA 11A-1-9
..
SEALANTS 11A-1-9
.......................................................
FORM-IN-PLACE GASKET 11A-1-10
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2. SPECIAL TOOLS 11A-2-1
.................................................
3. ALTERNATOR AND IGNITION SYSTEM 11A-3-1
........................
3a. INTAKE MANIFOLD (GDI) 11A-3a-1
.....................................
4. TIMING BELT 11A-4-1
.....................................................
4a. EXHAUST MANIFOLD (GDI) 11A-4a-1
..................................
5. FUEL AND EMISSION CONTROL PARTS 11A-5-1
......................
5a. FUEL PARTS (GDI) 11A-5a-1
............................................
6. WATER PUMP AND INTAKE MANIFOLD 11A-6-1
.......................
6a. WATER PUMP AND WATER HOSE (GDI) 11A-6a-1
.....................
7. EXHAUST MANIFOLD 11A-7-1
...........................................
8. ROCKER ARMS AND CAMSHAFT 11A-8-1
..............................
8a. ROCKER ARMS AND CAMSHAFTS (GDI) 11A-8a-1
...................
9. CYLINDER HEAD AND VALVES 11A-9-1
................................
10. FRONT CASE, COUNTERBALANCE SHAFTS AND OIL PAN 11A-10-1
11. PISTON AND CONNECTING ROD 11A-11-1
.............................
12. CRANKSHAFT, FLYWHEEL AND DRIVE PLATE 11A-12-1
.............
11A-0-1
ENGINE
4G6 SERIES
CONTENTS
RevisedPWEE9616-A
EAug. 1998Mitsubishi Motors Corporation

11A-0-2
PWEE9616
EDec. 1996Mitsubishi Motors Corporation
NOTES

4G6 ENGINE <E-W> - General Information 11A-0-3
GENERAL INFORMATION
SOHC-4G63
Descriptions Specifications
Type In-line OHV, SOHC
Number of cylinders 4
Combustion chamber Pentroof type
Total displacement dm31,997
Cylinder bore mm 85.0
Piston stroke mm 88.0
Compression ratio 10
Valve timing Intake valve Opens (BTDC) 18_
Closes (ABDC) 58_
Exhaust valve Opens (BBDC) 58_
Closes (ATDC) 18_
Lubrication system Pressure feed, full-flow filtration
Oil pump type Involute gear type
SOHC-4G64
Descriptions Specifications
Type In-line OHV, SOHC
Number of cylinders 4
Combustion chamber Pentroof type
Total displacement dm32,351
Cylinder bore mm 86.5
Piston stroke mm 100.0
Compression ratio 10
Valve timing Intake valve Opens (BTDC) 16_
Closes (ABDC) 53_
Exhaust valve Opens (BBDC) 50_
Closes (ATDC) 16_
Lubrication system Pressure feed, full-flow filtration
Oil pump type Involute gear type
RevisedPWEE9616-A
EAug. 1998Mitsubishi Motors Corporation

4G6 ENGINE <E-W> - General Information
11A-0-4
GDIt
Descriptions Specifications
Type In-line OHV, SOHC
Number of cylinders 4
Combustion chamber Pentroof + curved top piston type
Total displacement dm32,351
Cylinder bore mm 86.5
Piston stroke mm 100.0
Compression ratio 11.5
Valve timing Intake valve Opens (BTDC) 16_
Closes (ABDC) 60_
Exhaust valve Opens (BBDC) 56_
Closes (ATDC) 16_
Lubrication system Pressure feed, full-flow filtration
Oil pump type Involute gear type
NOTE
GDI is a trademark of Mitsubishi Motors Corporation.
AddedPWEE9616-A
EAug. 1998Mitsubishi Motors Corporation

4G6 ENGINE <E-W> - Specifications 11A-1-1
1. SPECIFICATIONS
SERVICE SPECIFICATIONS
Items Standard value Limit
Timing belt
Auto-tensioner rod projection length mm 12 -
Auto-tensioner rod pushed-in amount [when pushed with a force of 98
- 196 N] mm
1.0 or less -
Rocker arms and camshaft
Camshaft cam height mm 4G63 Intake 37.39 36.89
SOHC Exhaust 37.14 36.64
4G64 Intake 37.39 36.89
SOHC Exhaust 36.83 36.33
Lash adjuster leak down time
[diesel fuel at 15 - 20_C] seconds/mm
3 - 20/1.0 -
Camshaft journal outer diameter mm 45 -
Rocker arms and camshaft (GDI)
Camshaft cam height mm Intake 35.79 35.29
Exhaust 37.14 36.64
Lash adjuster leak down time
[diesel fuel at 15 - 20_C] seconds/mm
3 - 20/1.0 -
Camshaft journal outer diameter mm 26 -
Cylinder head and valves
Cylinder head flatness of gasket surface mm Less than 0.05 0.2
Cylinder head grinding limit of gasket surface mm
Total resurfacing depth of both cylinder head and cylinder block
- 0.2
Cylinder head overall height mm SOHC 120 -
GDI 132 -
Cylinder head bolt shank length mm - Maximum 99.4
Valve thickness of valve head (margin) mm SOHC Intake 1.0 0.5
Exhaust 1.2 0.7
GDI Intake 1.0 0.5
Exhaust 1.5 1.0
Valve overall height mm SOHC Intake 112.30 111.80
Exhaust 114.11 113.61
GDI Intake 105.5 105.0
Exhaust 105.7 105.2
Valve stem outer diameter mm 6.0 -
RevisedPWEE9616-A
EAug. 1998Mitsubishi Motors Corporation

4G6 ENGINE <E-W> - Specifications
11A-1-2
Items LimitStandard value
Valve thickness to valve guide clearance SOHC Intake 0.02 - 0.05 0.10
mm Exhaust 0.03 - 0.07 0.15
GDI Intake 0.02 - 0.05 0.10
Exhaust 0.05 - 0.09 0.15
Valve face angle mm 45_- 45.5_-
Valve spring free length mm SOHC 51.0 50.0
GDI 48.3 47.3
Valve spring load/installed height N/mm SOHC 267/44.2 -
GDI 294/40.0 -
Valve spring out-of-squareness SOHC 2_or less Maximum 4_
GDI 1.5_or less Maximum 4_
Valve seat valve contact width mm 0.9 - 1.3 -
Valve guide inner diameter mm SOHC 6.0 -
GDI 6.6 -
Valve guide projection from cylinder head SOHC 14.0 -
upper surface mm GDI 19.5 -
Valve stem projection mm SOHC 49.30 49.80
GDI Intake 49.20 49.70
Exhaust 48.40 48.90
Oversize rework dimensions of valve guide 0.05 Oversize diameter 11.05 - 11.07 -
hole (SOHC) mm 0.25 Oversize diameter 11.25 - 11.27 -
0.50 Oversize diameter 11.50 - 11.52 -
Oversize rework dimensions of valve guide 0.05 Oversize diameter 12.05 - 12.07 -
hole (GDI) mm 0.25 Oversize diameter 12.25 - 12.27 -
0.50 Oversize diameter 12.50 - 12.52 -
Intake oversize rework dimensions of valve 0.3 Oversize diameter 34.30 - 34.33 -
seat hole (SOHC) mm 0.6 Oversize diameter 34.60 - 34.63 -
Intake oversize rework dimensions of valve 0.3 Oversize diameter 35.30 - 35.33 -
seat hole (GDI) mm 0.6 Oversize diameter 35.60 - 35.63 -
Exhaust oversize rework dimensions of 0.3 Oversize diameter 34.30 - 34.33 -
valve seat hole (SOHC) mm 0.6 Oversize diameter 34.60 - 34.63 -
Exhaust oversize rework dimensions of 0.3 Oversize diameter 33.30 - 33.33 -
valve seat hole (GDI) mm 0.6 Oversize diameter 33.60 - 33.63 -
RevisedPWEE9616-A
EAug. 1998Mitsubishi Motors Corporation

4G6 ENGINE <E-W> - Specifications 11A-1-3
Items LimitStandard value
Front case, counterbalance shaft and oil pan
Oil pump side clearance mm Drive gear 0.08 - 0.14 -
Driven gear 0.06 - 0.12 -
Oil pressure at curb idle speed kPa [Oil temperature is 75 to 90_C] 78 or more -
Piston and connecting rod
Piston outer diameter mm 4G63 85.0 -
4G64 86.5 -
Piston ring side clearance mm No. 1 0.02 - 0.06 0.1
No. 2 0.02 - 0.06 0.1
Piston ring end gap mm No. 1 0.25 - 0.35 0.8
No. 2 0.40 - 0.55 0.8
Oil ring side rail 0.10 - 0.40 1.0
Piston pin outer diameter mm 22.0 -
Piston pin press-in load N (Room temperature) 7,350 - 17,200 -
Crankshaft pin oil clearance mm 0.02 - 0.05 0.1
Connecting rod big end side clearance mm 0.10 - 0.25 0.4
Crankshaft, flywheel and drive plate
Crankshaft end play mm 0.05 - 0.25 0.40
Crankshaft journal outer diameter mm 57.0 -
Crankshaft pin outer diameter mm 45.0 -
Crankshaft journal oil clearance mm 0.02 - 0.04 0.1
Bearing cap bolt shank length mm - Maximum 71.1
Piston to cylinder clearance mm 0.02 - 0.04 -
Cylinder block flatness of gasket surface mm 0.05 0.1
Cylinder block grinding limit of gasket surface mm
Total resurfacing depth of both cylinder head and cylinder block
- 0.2
Cylinder block overall height mm 4G63 284 -
4G64 290 -
Cylinder block inner diameter mm 4G63 85.0 -
4G64 86.5 -
Cylindricity mm 0.01 -
RevisedPWEE9616-A
EAug. 1998Mitsubishi Motors Corporation

4G6 ENGINE <E-W> - Specifications
11A-1-4
TORQUE SPECIFICATIONS
Items Nm
Alternator and ignition system
Water pump pulley 9
Adjusting bolt 10
Lock bolt 22
Alternator brace 23
Alternator pivot nut 44
Crankshaft pulley 25
Ignition coil (Multipoint fuel injection) 10
Spark plug 25
Distributor (Carburetor) 12
Camshaft position sensing cylinder (Multipoint fuel injection) 22
Camshaft position sensor support (Multipoint fuel injection) 14
Camshaft position sensor (Multipoint fuel injection) 10
Oil level gauge guide 13
Idler pulley bracket (M8) (Vehicle for Hong Kong) 22
Idler pulley bracket (M10) (Vehicle for Hong Kong) 49
Idler pulley (Vehicle for Hong Kong) 49
Intake manifold (GDI)
Vacuum pipe and hose (Flange bolt) 11
Vacuum pipe and hose (Bolt, washer assembly) 8.8
Solenoid valve 8.8
Vacuum pipe 11
Throttle body 11
Intake manifold stay (M6) 8.8
Intake manifold stay (M8) 30
Air intake plenum resonator (Flange bolt) 11
Air intake plenum resonator (Bolt, washer assembly) 8.8
EGR valve 23
EGR valve support 23
Intake manifold 19
Timing belt
Timing belt cover flange bolt 11
RevisedPWEE9616-B
EAug. 1999Mitsubishi Motors Corporation

4G6 ENGINE <E-W> - Specifications 11A-1-5
Items Nm
Timing belt cover washer bolt 9
Power steering bracket 49
Crankshaft angle sensor (Multipoint fuel injection) 9
Tensioner arm 22
Tensioner puller 48
Auto tensioner 23
Idler pulley 35
Engine support bracket 49
Oil pump sprocket 54
Crankshaft bolt 118
Tensioner “B” 18
Counterbalance shaft sprocket 45
Camshaft sprocket bolt 88
Exhaust manifold (GDI)
Exhaust manifold cover 13
Exhaust manifold (M10) 49
Exhaust manifold (M8) 29
Engine hanger 11
Fuel and emission parts
Carburetor (Carburetor) 17
Fuel vapor separator (Carburetor) 23
Throttle body (Multipoint fuel injection) 18
EGR valve (Except General Export) 22
Injectors and delivery pipe (Multipoint fuel injection) 12
Fuel pressure regulator (Multipoint fuel injection) 9
Fuel part (GDI)
Fuel low pressure pipe (M6) 8.8
Fuel low pressure pipe (M8) 18
Fuel pump return nipple 8.8
Clamp A 8.8
Fuel pipe bracket 11
Fuel feed pipe 11
RevisedPWEE9616-B
EAug. 1999Mitsubishi Motors Corporation

4G6 ENGINE <E-W> - Specifications
11A-1-6
Items Nm
Fuel pump 4.9 ®17 ±2
Harness bracket 8.8
Fuel return pipe 11
Fuel high pressure regulator 18
Fuel pressure sensor 18
Pump camshaft case 23
Injector holder 22
Delivery pipe and injector assembly 11
Engine hanger 11
Water pump and intake manifold
Engine coolant temperature sensor 29
Engine coolant temperature gauge unit 11
Water inlet fitting 13
Thermostat housing 24
Water inlet pipe 13
Water pump 14
Oil level gauge guide 14
Intake manifold stay 31
Intake manifold 19
Engine hanger 11
Detonation sensor (Multipoint fuel injection) 23
Water pump and water hose (GDI)
Engine coolant temperature sensor 29
Engine coolant temperature gauge unit 11
Water inlet fitting 12
Water outlet fitting 12
Thermostat housing 23
Water inlet pipe 12
Water pump 13
Knock sensor 22
Exhaust manifold
Exhaust manifold cover 13
RevisedPWEE9616-B
EAug. 1999Mitsubishi Motors Corporation

4G6 ENGINE <E-W> - Specifications 11A-1-7
Items Nm
Heat protector 13
Exhaust manifold (M8) 29
Exhaust manifold (M10) 49
Water outlet fitting 13
Rocker arms and camshaft
Rocker cover 3.4
Rocker arm shaft 31
Rocker arms and camshafts (GDI)
Camshaft position sensor 8.8
Cover 9.8
Camshaft position sensing cylinder 21
Camshaft position sensing support 13
Beam camshaft cap 20
Cylinder head and valves
Cylinder head bolt
[Tighten to 78 Nm and then completely loosen before finally tightening with above procedure.]
20 + 90_+90_
Front case, counterbalance shaft and oil pan
Drain plug 39
Oil pan 6.9
Oil level sensor (For Europe) 8.8
Stiffener (For Europe) 21
Oil screen 18
Oil pressure switch (4G63) 19
Oil pressure switch (4G64) 9.8
Relief plug 44
Oil filter bracket 18
Plug 23
Flange bolt 36
Oil pump cover bolt 16
Oil pump cover screw 9.8
Front case 23
Transmission stay (GDI engine) 21
Oil level gauge guide 12
RevisedPWEE9616-B
EAug. 1999Mitsubishi Motors Corporation

4G6 ENGINE <E-W> - Specifications
11A-1-8
Items Nm
Oil pan lower 6.9
Baffle plate 6.9
Oil pan upper 6.9
Piston and connecting rod
Connecting rod cap 20 + 90_®100_
Crankshaft, flywheel and drive plate
Flywheel bolt 132
Drive plate bolt 132
Rear plate 11
Bell housing cover 8.8
Oil seal case bolt 11
Bearing cap bolt 25 + 90_®100_
RevisedPWEE9616-B
EAug. 1999Mitsubishi Motors Corporation

4G6 ENGINE <E-W> - Specifications 11A-1-9
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 some 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.
DAreas where the bolts are in use:
(1) Cylinder head bolts
(2) Main bearing cap bolts
(3) Connecting rod cap bolts
DTightening 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.
SEALANTS
Item Specified sealant Quantity
Cam position sensor support 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
Thermostat case Mitsubishi Genuine Part No. MD970389 or
equivalent
As required
Water outlet fitting Mitsubishi Genuine Part No. MD970389 or
equivalent
As required
Beam camshaft cap Mitsubishi Genuine Part No. MD970389 or
equivalent
As required
Cylinder head Mitsubishi Genuine Part No. MD970389 or
equivalent
As required
Oil pressure switch 3M ATD Part No. 8660 or equivalent As required
Oil pan Mitsubishi Genuine Part No. MD970389 or
equivalent
As required
Oil seal case Mitsubishi Genuine Part No. MD970389 or
equivalent
As required
AddedPWEE9616-A
EAug. 1998Mitsubishi Motors Corporation

4G6 ENGINE <E-W> - Specifications
11A-1-10
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 vulcanisation (RTV) type and is supplied in a 100-gram
tube (Part No. MD970389). 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. MD997110 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 by lightly striking
with a mallet or similar tool. A flat and thin 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.
For removal of the oil pan, the special tool “Oil Pan Remover” (MD998727) is available. Be sure to use
the special tool to remove the oil pan. <Except aluminium die-cast oil pans>
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 remained in the bolt holes.
Form-in-Place Gasket Application
When assembling parts with the FIPG, you must observe some precautions, but the procedures 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 to encircle 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. In addition, do
not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time
(about one hour) has passed after installation is completed.
The FIPG application procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.
AddedPWEE9616-A
EAug. 1998Mitsubishi Motors Corporation

4G6 ENGINE (E-W) - Special Tools 11A-2-1
2. SPECIAL TOOLS
Tool Number Name Use
MB990767 Crankshaft pulley
holder
Holding camshaft sprocket
Use with MD998719.
MD990938 Handle Installation of crankshaft rear oil seal
Use with MD998776.
MB991603 Silent shaft bearing
puller stopper
Guide stopper for removal and installation of
counterbalance shaft rear bearing
Use with MD998372.
MB991654 Cylinder head bolt
wrench (12)
Removal and installation of cylinder head bolt
MD998162 Plug wrench Removal and installation of front case cap plug
Use with MD998783.
MD998285 Crankshaft front oil
seal guide
Guide for installation of crankshaft front oil seal
Use with MD998375.
MD998371 Silent shaft bearing
puller
Removal of counterbalance shaft front bearing
MD998372 Silent shaft bearing
puller
Removal of counterbalance shaft rear bearing
MD998375 Crankshaft front
seal installer
Installation of crankshaft front oil seal
PWEE9616
EDec. 1996Mitsubishi Motors Corporation

4G6 ENGINE (E-W) - Special Tools
11A-2-2
Tool UseNameNumber
MD998440 Leak down tester Leak down test of lash adjuster
MD998441 Lash adjuster
retainer
Air bleeding of lash adjuster
MD998442 Lash adjuster wire Air bleeding of lash adjuster
MD998443 Lash adjuster
holder
Retainer for holding lash adjuster in rocker arm
at time of removal and installation of rocker
shaft assembly
MD998705 Silent shaft bearing
installer
Installation of counterbalance shaft front and
rear bearing
MD998713 Camshaft oil seal
installer
Installation of camshaft oil seal
MD998719 Pulley holder pin Holding camshaft sprocket
Use with MB990767.
MD998727 Oil pan remover Removal of oil pan
MD998735 Valve spring
compressor
Removal and installation of valve and related
parts
PWEE9616
EDec. 1996Mitsubishi Motors Corporation

4G6 ENGINE (E-W) - Special Tools 11A-2-3
Tool UseNameNumber
MD998738 Set screw Adjustment of timing belt tension
MD998767 Tensioner puller
socket wrench
Adjustment of timing belt tension
MD998772 Valve spring
compressor
Removal and installation of valve and related
parts
MD998774 Valve stem seal
installer
Installation of valve stem seal
MD998775 Valve stem seal
installer
Installation of valve stem seal
MD998776 Crankshaft rear oil
seal installer
Installation of crankshaft rear oil seal
Use with MB990938.
MD998778 Crankshaft
sprocket puller
Removal of crankshaft sprocket
MD998780 Piston setting tool Removal and installation of piston pin
MD998781 Flywheel stopper Holding of flywheel and drive plate
RevisedPWEE9616-A
EAug. 1998Mitsubishi Motors Corporation

4G6 ENGINE (E-W) - Special Tools
11A-2-4
Tool UseNameNumber
MD998783 Plug wrench
retainer
Removal and installation of front case cap plug
MD998785 Sprocket stopper Holding silent shaft sprocket
AddedPWEE9616-A
EAug. 1998Mitsubishi Motors Corporation

4G6 ENGINE (E-W) - Alternator and Ignition System 11A-3-1
3. ALTERNATOR AND IGNITION SYSTEM
REMOVAL AND INSTALLATION <CARBURETOR>
9
10
4
5
3
1
7
612 Nm
25 Nm
24 Nm
10 Nm
9Nm
25 Nm
22 Nm
44 Nm
8
2
Removal steps
1. Drive belt
2. Water pump pulley
3. Alternator brace
4. Alternator
5. Crankshaft pulley
6. Spark plug cable
7. Spark plug
8. High tension cable
"BA9. Distributor assembly
10. O-ring
PWEE9616
EDec. 1996Mitsubishi Motors Corporation

4G6 ENGINE (E-W) - Alternator and Ignition System
11A-3-2
REMOVAL AND INSTALLATION <MULTIPOINT FUEL INJECTION>
11
10
4
5
2
3
1
7
9
22 Nm
14 Nm
24 Nm
22 Nm
9Nm
25 Nm
44 Nm
25 Nm
6
10 Nm
10 Nm
r
10 Nm
8
Removal steps
1. Drive belt
2. Water pump pulley
3. Alternator brace
4. Alternator
5. Crankshaft pulley
6. Spark plug cable
7. Ignition coil assembly
8. Spark plug
9. Camshaft position sensor
"AA10. Camshaft position sensing support
11. Camshaft position sensing cylinder
PWEE9616
EDec. 1996Mitsubishi Motors Corporation