Mitsubishi 4G6 series Instruction manual

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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TORQUE SPECIFICATIONS 11A-1-4
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NEW TIGHTENING METHOD -
BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA 11A-1-9
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SEALANTS 11A-1-9
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FORM-IN-PLACE GASKET 11A-1-10
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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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3a. INTAKE MANIFOLD (GDI) 11A-3a-1
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4. TIMING BELT 11A-4-1
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4a. EXHAUST MANIFOLD (GDI) 11A-4a-1
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5. FUEL AND EMISSION CONTROL PARTS 11A-5-1
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5a. FUEL PARTS (GDI) 11A-5a-1
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6. WATER PUMP AND INTAKE MANIFOLD 11A-6-1
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6a. WATER PUMP AND WATER HOSE (GDI) 11A-6a-1
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7. EXHAUST MANIFOLD 11A-7-1
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8. ROCKER ARMS AND CAMSHAFT 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. FRONT CASE, COUNTERBALANCE SHAFTS AND OIL PAN 11A-10-1
11. PISTON AND CONNECTING ROD 11A-11-1
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12. CRANKSHAFT, FLYWHEEL AND DRIVE PLATE 11A-12-1
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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