ENGINE Workshop Manual 4G1 (E-W)

1 GENERAL TIGHTENING METHOD - BY USE OF BOLTS TO BETIGHTENED IN PLASTIC SPECIAL ALTERNATOR AND IGNITION TIMING FUEL AND EMISSION CONTROL WATER PUMP AND WATER INTAKE AND EXHAUST ROCKER ARMS AND CYLINDER HEAD AND OIL PUMP AND OIL PISTON AND CONNECTING CRANKSHAFT, CYLINDER 1995 Mitsubishi Motors CorporationENGINE4G1 SERIESCONTENTS11A-0-2 PWEE9520 ENov. 1995 Mitsubishi Motors CorporationNOTES4G1 ENGINE (E - W) -General Information11A-0-3 PWEE9520 ENov. 1995 Mitsubishi Motors CorporationGENERAL INFORMATION4G1 ENGINE (E - W) -General Information11A-0-4 PWEE9520 ENov. 1995 Mitsubishi Motors Corporation4G1 ENGINE (E - W) -General Information11A-0-5 PWEE9520 ENov.

2 1995 Mitsubishi Motors CorporationDescriptions4G13 12-VALVE-CARBURETOR4G13 12-VALVE-MPITypeIn-line OHV, SOHCIn-line OHV, SOHCN umber of cylinders44 Combustion chamberPentroof typePentroof typeTotal displacement dm31,2991,299 Cylinder bore stroke ofIntake88valvesExhaust44 Valve timingIntake opensBTDC 14_BTDC 19_Intake closesABDC 48_ABDC 43_Exhaust opensBBDC 55_BBDC 60_Exhaust closesATDC 13_ATDC 8_Lubrication systemPressure feed, full-flow filtrationPressure feed, full-flow filtrationOil pump typeTrochoid typeTrochoid typeCooling systemWater-cooled, forced circulationWater-cooled, forced circulationWater pump typeCentrifugal impeller typeCentrifugal impeller typePWEE9520-AEDec.

3 1998 Mitsubishi Motors CorporationRevised4G1 ENGINE (E - W) -General Information11A-0-6 PWEE9520 ENov. 1995 Mitsubishi Motors CorporationDescriptions4G13 16-VALVE-MPI4G18 16-VALVE-MPITypeIn-line OHV, SOHCIn-line OHV, SOHCN umber of cylinders44 Combustion chamberPentroof typePentroof typeTotal displacement dm31,2991,584 Cylinder bore stroke ofIntake88valvesExhaust88 Valve timingIntake opensBTDC 17_BTDC 17_Intake closesABDC 39_ABDC 39_Exhaust opensBBDC 49_BBDC 49_Exhaust closesATDC 7_ATDC 7_Lubrication systemPressure feed, full-flow filtrationPressure feed, full-flow filtrationOil pump typeTrochoid typeTrochoid typeCooling systemWater-cooled, forced circulationWater-cooled.

4 Forced circulationWater pump typeCentrifugal impeller typeCentrifugal impeller typePWEE9520-AEDec. 1998 Mitsubishi Motors CorporationRevised4G1 ENGINE (E - W) -General Information11A-0-7 PWEE9520 ENov. 1995 Mitsubishi Motors CorporationDescriptions4G15-CARBURETTOR4 G15-MPITypeIn-line OHV, SOHCIn-line OHV, DOHCN umber of cylinders44 Combustion chamberSemi spherical typePentroof typeTotal displacement dm31,4681,468 Cylinder bore stroke ofIntake88valveExhaust48 Valve timingIntake opensBTDC 14_BTDC 16_Intake closesABDC 48_ABDC 40_Exhaust opensBBDC 55_BBDC 45_Exhaust closesATDC 13_ATDC 15_Lubrication systemPressure feed, full-flow filtrationPressure feed, full-flow filtrationOil pump typeTrochoid typeTrochoid typeCooling systemWater-cooled, forced circulationWater-cooled.

5 Forced circulationWater pump typeCentrifugal impeller typeCentrifugal impeller typePWEE9520-AEDec. 1998 Mitsubishi Motors CorporationAddedNOTES4G1 ENGINE (E - W) -Specifications11A-1-1 PWEE9520 ENov. 1995 Mitsubishi Motors Corporation1. SPECIFICATIONSSERVICE SPECIFICATIONSItemStandardLimitRocker arms, rocker shafts, and camshaftCamshaft camSOHC 12-VALVEI ntake (primary) mmIntake (secondary) journal diameter head and valvesFlatness of cylinder head gasket surface or less-Cylinder head gasket surface grinding limit (including grinding ofcylinder block gasket surface) head overall height mmSOHC head bolt nominal length margin stem diameter mmSOHC stem-to-guideSOHC - - face stem projec-SOHC 1998 Mitsubishi Motors CorporationRevised4G1 ENGINE (E - W) -Specifications11A-1-2 PWEE9520 ENov.

6 1995 Mitsubishi Motors CorporationItemLimitStandardOverall valve lengthSOHC spring freeSOHC spring load/SOHC 12-VALVEI ntake226 height N/mmExhaust284 16-VALVE216 spring squareness2_4_Valve seat contact width guide internal diameter mmSOHC guide projection mmSOHC pump and oil panOil pump tip clearance pump side clearance pump body clearance and connecting rodsPiston outside diameter ring side clearance mmNo. 1 2 ring end gap clearanceNo. 1 2 pin O. D. pin press-in load (at room temperature) N4,900-14,700-Crankshaft pin oil clearance rod big end side clearance 1998 Mitsubishi Motors CorporationRevised4G1 ENGINE (E - W) -Specifications11A-1-2aPWEE9520 ENov.

7 1995 Mitsubishi Motors CorporationItemStandardLimitCrankshaft and cylinder blockCrankshaft end play journal diameter pin diameter journal oil clearance block gasket surface flatness or less-Cylinder block gasket surface grinding limit (including grinding ofcylinder head gasket surface) block overall height mm256-Cylinder block cylindricity block I. D. clearance 1998 Mitsubishi Motors CorporationAdded4G1 ENGINE (E - W) -Specifications11A-1-2bPWEE9520 ENov. 1995 Mitsubishi Motors CorporationIntentionally blankPWEE9520-AEDec. 1998 Mitsubishi Motors CorporationAddedPWEE9520-AEDec. 1998 Mitsubishi Motors CorporationAdded4G1 ENGINE (E - W) -Specifications11A-1-3 PWEE9520 ENov.

8 1995 Mitsubishi Motors CorporationREWORK DIMENSIONSItemStandardLimitCylinder head and valvesCylinder head oversize valve guideSOHC O. diameter O. O. O. O. O. O. O. O. valveseatSOHCI ntake (primary) O. hole O. (secondary) O. O. O. O. O. <4G13> O. <4G13> O. O. O. <4G18> O. <4G18> O. O. O. O. O. O. 1998 Mitsubishi Motors CorporationRevised4G1 ENGINE (E - W) -Specifications11A-1-4 PWEE9520 ENov. 1995 Mitsubishi Motors CorporationTORQUE SPECIFICATIONSItemNmAlternator and ignitionsystemWater pump pulley bolt9 Alternator brace (alternator side)22 Alternator brace (tightened with water pump)23 Alternator pivot bolt44 Oil level gauge guide23 Crankshaft bolt125 Spark plug25 Distributor11 Ignition coil10 Camshaft position sensor9 Camshaft position sensor support13 Camshaft position sensing cylinder21 Timing beltTiming belt cover11 Timing belt tensioner23 Crankshaft angle sensor (Rear wheel drive)9 ENGINE support bracket (left)

9 35 Idler pulley35 Camshaft sprocket bolt88 Fuel systemDelivery pipe11 Fuel pressure regulator9 Throttle body18 Fuel pump11 Breather tube22 Carburetor17 Air temperature sensor13 EGR valve21 Water pumpWater inlet fitting22 Water inlet pipe assembly12 Water inlet pipeM612M825 Fitting (Rear wheel drive)23 Water outlet fitting (Rear wheel drive)23 Thermostat case23 PWEE9520-AEDec. 1998 Mitsubishi Motors CorporationRevised4G1 ENGINE (E - W) -Specifications11A-1-5 PWEE9520 ENov. 1995 Mitsubishi Motors CorporationItemNmThermo valve27 Water temperature gauge unit11 Water temperature sensor29 Water pump13 Exhaust manifold and intake manifoldBoost sensor5 Solenoid valve assembly9 Intake manifold17 Intake manifold stay (MPI)M817M1021 Intake manifold stay (carburetor)

10 29 Exhaust manifold cover29 Exhaust manifoldM817M1029 Oxygen sensor44 Rocker arms, rocker shafts, and camshaftFuel pump cover12 Rocker cover4 Rocker shaft assembly31 Adjusting screw15 Bearing cap2411 Cylinder head and valvesCylinder head bolt20 + 90_+90_Tighten to 49 Nm, then completely loosen and retighten as pump and oil panTransmission stay23 Oil pan7 Drain plug39 Oil screen18 Front case13 Relief plug44 Oil pump cover10 Pistons and connecting rodsConnecting rod nut17 + 90_to 100_PWEE9520-AEDec. 1998 Mitsubishi Motors CorporationRevised4G1 ENGINE (E - W) -Specifications11A-1-5aPWEE9520 ENov. 1995 Mitsubishi Motors CorporationItemNmCrankshaft and cylinder blockFlywheel132 Drive plate132 Rear plate10 Bell housing cover10 Rear oil seal case11 Bearing cap bolt51 Oil pressure switch18 Knock sensor23 PWEE9520-AEDec.