ENGINE Workshop Manual 4G6 (E-W)

1 GENERAL TIGHTENING METHOD -BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC SPECIAL ALTERNATOR AND IGNITION INTAKE MANIFOLD (GDI) TIMING EXHAUST MANIFOLD (GDI) FUEL AND EMISSION CONTROL FUEL PARTS (GDI) WATER PUMP AND INTAKE WATER PUMP AND WATER HOSE (GDI) EXHAUST ROCKER ARMS AND ROCKER ARMS AND CAMSHAFTS (GDI) CYLINDER HEAD AND FRONT CASE, COUNTERBALANCE SHAFTS AND OIL PAN 11A-10-111. PISTON AND CONNECTING CRANKSHAFT, FLYWHEEL AND DRIVE SERIESCONTENTSR evisedPWEE9616-AEAug. 1998 Mitsubishi Motors Corporation11A-0-2 PWEE9616 EDec. 1996 Mitsubishi Motors CorporationNOTES4G6 ENGINE <E - W> -General Information11A-0-3 GENERAL INFORMATIONSOHC-4G63 DescriptionsSpecificationsTypeIn-line OHV, SOHCN umber of cylinders4 Combustion chamberPentroof typeTotal displacement dm31,997 Cylinder bore stroke ratio10 Valve timingIntake valveOpens (BTDC)18_Closes (ABDC)58_Exhaust valveOpens (BBDC)58_Closes (ATDC)

2 18_Lubrication systemPressure feed, full-flow filtrationOil pump typeInvolute gear typeSOHC-4G64 DescriptionsSpecificationsTypeIn-line OHV, SOHCN umber of cylinders4 Combustion chamberPentroof typeTotal displacement dm32,351 Cylinder bore stroke ratio10 Valve timingIntake valveOpens (BTDC)16_Closes (ABDC)53_Exhaust valveOpens (BBDC)50_Closes (ATDC)16_Lubrication systemPressure feed, full-flow filtrationOil pump typeInvolute gear typeRevisedPWEE9616-AEAug. 1998 Mitsubishi Motors Corporation4G6 ENGINE <E - W> -General Information11A-0-4 GDItDescriptionsSpecificationsTypeIn-lin e OHV, SOHCN umber of cylinders4 Combustion chamberPentroof + curved top piston typeTotal displacement dm32,351 Cylinder bore stroke timingIntake valveOpens (BTDC)16_Closes (ABDC)60_Exhaust valveOpens (BBDC)56_Closes (ATDC)16_Lubrication systemPressure feed, full-flow filtrationOil pump typeInvolute gear typeNOTEGDI is a trademark of Mitsubishi Motors 1998 Mitsubishi Motors Corporation4G6 ENGINE <E - W> -Specifications11A-1-11.

3 SPECIFICATIONSSERVICE SPECIFICATIONSI temsStandard valueLimitTiming beltAuto-tensioner rod projection length mm12-Auto-tensioner rod pushed-in amount [when pushed with a force of 98- 196 N] or less-Rocker arms and camshaftCamshaft cam height adjuster leak down time[diesel fuel at 15 - 20_C] seconds/mm3 - 20 journal outer diameter mm45-Rocker arms and camshaft (GDI)Camshaft cam height adjuster leak down time[diesel fuel at 15 - 20_C] seconds/mm3 - 20 journal outer diameter mm26-Cylinder head and valvesCylinder head flatness of gasket surface mmLess than head grinding limit of gasket surface mmTotal resurfacing depth of both cylinder head and cylinder head overall height mmSOHC120-GDI132-Cylinder head bolt shank length mm-Maximum thickness of valve head (margin)

4 Overall height stem outer diameter 1998 Mitsubishi Motors Corporation4G6 ENGINE <E - W> -Specifications11A-1-2 ItemsLimitStandard valueValve thickness to valve guide - - - - face angle mm45_- spring free length spring load/installed height N/mmSOHC267 spring out-of-squarenessSOHC2_or lessMaximum lessMaximum 4_Valve seat valve contact width - guide inner diameter guide projection from cylinder surface stem projection rework dimensions of valve Oversize - (SOHC) Oversize - Oversize - rework dimensions of valve Oversize - (GDI) Oversize - Oversize - oversize rework dimensions of Oversize - hole (SOHC) Oversize - oversize rework dimensions of Oversize - hole (GDI) Oversize - oversize rework dimensions Oversize - seat hole (SOHC) Oversize - oversize rework dimensions Oversize - seat hole (GDI)

5 Oversize - 1998 Mitsubishi Motors Corporation4G6 ENGINE <E - W> -Specifications11A-1-3 ItemsLimitStandard valueFront case, counterbalance shaft and oil panOil pump side clearance mmDrive - - pressure at curb idle speed kPa [Oil temperature is 75 to 90_C]78 or more-Piston and connecting rodPiston outer diameter ring side clearance mmNo. - - ring end gap mmNo. - - ring side - pin outer diameter pin press-in load N (Room temperature)7,350 - 17,200-Crankshaft pin oil clearance - rod big end side clearance - , flywheel and drive plateCrankshaft end play - journal outer diameter pin outer diameter journal oil clearance - cap bolt shank length mm-Maximum to cylinder clearance - block flatness of gasket surface block grinding limit of gasket surface mmTotal resurfacing depth of both cylinder head and cylinder block overall height mm4G63284-4G64290-Cylinder block inner diameter 1998 Mitsubishi Motors Corporation4G6 ENGINE <E - W> -Specifications11A-1-4 TORQUE SPECIFICATIONSI temsNmAlternator and ignition systemWater pump pulley9 Adjusting bolt10 Lock bolt22 Alternator brace23

6 Alternator pivot nut44 Crankshaft pulley25 Ignition coil (Multipoint fuel injection)10 Spark plug25 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 guide13 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) pipe11 Throttle body11 Intake manifold stay (M6) manifold stay (M8)30 Air intake plenum resonator (Flange bolt)11 Air intake plenum resonator (Bolt, washer assembly) valve23 EGR valve support23 Intake manifold19 Timing beltTiming belt cover flange bolt11 RevisedPWEE9616-BEAug.

7 1999 Mitsubishi Motors Corporation4G6 ENGINE <E - W> -Specifications11A-1-5 ItemsNmTiming belt cover washer bolt9 Power steering bracket49 Crankshaft angle sensor (Multipoint fuel injection)9 Tensioner arm22 Tensioner puller48 Auto tensioner23 Idler pulley35 ENGINE support bracket49 Oil pump sprocket54 Crankshaft bolt118 Tensioner B 18 Counterbalance shaft sprocket45 Camshaft sprocket bolt88 Exhaust manifold (GDI)Exhaust manifold cover13 Exhaust manifold (M10)49 Exhaust manifold (M8)29 ENGINE hanger11 Fuel and emission partsCarburetor (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) low pressure pipe (M8)18 Fuel pump return pipe bracket11 Fuel feed pipe11 RevisedPWEE9616-BEAug.

8 1999 Mitsubishi Motors Corporation4G6 ENGINE <E - W> -Specifications11A-1-6 ItemsNmFuel 17 2 Harness return pipe11 Fuel high pressure regulator18 Fuel pressure sensor18 Pump camshaft case23 Injector holder22 Delivery pipe and injector assembly11 ENGINE hanger11 Water pump and intake manifoldEngine coolant temperature sensor29 ENGINE coolant temperature gauge unit11 Water inlet fitting13 Thermostat housing24 Water inlet pipe13 Water pump14 Oil level gauge guide14 Intake manifold stay31 Intake manifold19 ENGINE hanger11 Detonation sensor (Multipoint fuel injection)23 Water pump and water hose (GDI) ENGINE coolant temperature sensor29 ENGINE coolant temperature gauge unit11 Water inlet fitting12 Water outlet fitting12 Thermostat housing23 Water inlet pipe12 Water pump13 Knock sensor22 Exhaust manifoldExhaust manifold cover13 RevisedPWEE9616-BEAug.

9 1999 Mitsubishi Motors Corporation4G6 ENGINE <E - W> -Specifications11A-1-7 ItemsNmHeat protector13 Exhaust manifold (M8)29 Exhaust manifold (M10)49 Water outlet fitting13 Rocker arms and camshaftRocker arm shaft31 Rocker arms and camshafts (GDI)Camshaft position position sensing cylinder21 Camshaft position sensing support13 Beam camshaft cap20 Cylinder head and valvesCylinder 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 panDrain plug39 Oil level sensor (For Europe) (For Europe)21 Oil screen18 Oil pressure switch (4G63)19 Oil pressure switch (4G64) plug44 Oil filter bracket18 Plug23 Flange bolt36 Oil pump cover bolt16 Oil pump cover case23 Transmission stay (GDI ENGINE )21 Oil level gauge guide12 RevisedPWEE9616-BEAug.

10 1999 Mitsubishi Motors Corporation4G6 ENGINE <E - W> -Specifications11A-1-8 ItemsNmOil pan pan and connecting rodConnecting rod cap20 + 90_ 100_Crankshaft, flywheel and drive plateFlywheel bolt132 Drive plate bolt132 Rear plate11 Bell housing seal case bolt11 Bearing cap bolt25 + 90_ 100_RevisedPWEE9616-BEAug. 1999 Mitsubishi Motors Corporation4G6 ENGINE <E - W> -Specifications11A-1-9 NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED INPLASTIC AREAA new type of bolts, to be tightened in plastic area, is currently used some parts of the ENGINE . Thetightening method for the bolts is different from the conventional one.