ENGINE Workshop Manual 4G9 (E-W)

1 INFORMATION 11A-0-3.. 1. SPECIFICATIONS 11A-1-1.. SERVICE SPECIFICATIONS 11A-1-1.. REWORK DIMENSIONS 11A-1-4.. TORQUE SPECIFICATIONS 11A-1-5.. NEW TIGHTENING METHOD BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA 11A-1-7.. SEALANT 11A-1-7.. FORM-IN-PLACE GASKET 11A-1-8.. 2. SPECIAL TOOLS 11A-2-1.. 3. ALTERNATOR AND IGNITION SYSTEM 11A-3-1.. 4. TIMING BELT 11A-4-1.. 5. FUEL AND EMISSION CONTROL SYSTEM 11A-5-1.

2 5a. THROTTLE BODY AND EGR SYSTEM (GDI) 11A-5a-1.. 6. INTAKE AND EXHAUST MANIFOLD 11A-6-1.. 6a. INTAKE MANIFOLD (GDI) 11A-6a-1.. 6b. EXHAUST MANIFOLD (GDI) 11A-6b-1.. 6c. INJECTOR AND FUEL PUMP ASSEMBLY (GDI) 11A-6c-1.. 6d. INTAKE AND EXHAUST MANIFOLD <4G94 GDI for PAJERO io> 11A-6d-1.. 7. WATER PUMP AND WATER HOSE 11A-7-1.. 8. ROCKER ARMS AND CAMSHAFTS 11A-8-1.. 8a. ROCKER COVER AND CAMSHAFTS (MIVEC) 11A-8a-1.. 8b. ROCKER ARMS AND ROCKER SHAFT CAPS (MIVEC) 11A-8b-1.. 9. CYLINDER HEAD AND VALVES 11A-9-1.. 10. FRONT CASE AND OIL PUMP 11A-10-1.. 11. PISTON AND CONNECTING ROD 11A-11-1.. 12. CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE PLATE 11A-12-1.

3 11A-0-1 ENGINE4G9 SERIESCONTENTSPWEE9502-IEMar. 2001 Mitsubishi Motors 1995 Mitsubishi Motors ENGINE (E - W) -General Information11A-0-3 PWEE9502-CEJuly 1997 Mitsubishi Motors CorporationRevisedGENERAL INFORMATION4G92 Descriptions4G92-SOHC4G92-DOHC-MIVECType In-line OHV, SOHCIn-line OHV, DOHCN umber of cylinders44 Combustion chamberPentroof typePentroof typeTotal displacement dm31,5971,597 Cylinder bore stroke timingIntakevalveOpens(BTDC)20_,14_*17_( Low-speed cam) (High-speed cam)Closes(ABDC)42_,58_*31_(Low-speed cam) (High-speed cam)ExhaustvalveOpens(BBDC)54_,52_*41_(L ow-speed cam)70_(High-speed cam)Closes(ATDC)2_,16_*11_(Low-speed cam)35_(High-speed cam)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 type*.

4 LANCER for general export and CARISMA for 6B ENGINE (E-W) -General Information11A-0-44G93 Descriptions4G93-SOHC4G93-DOHC4G93-DOHC- GDITypeIn-line OHV, SOHCIn-line OHV, DOHCIn-line OHV, DOHCN umber of cylinders444 Combustion chamberPentroof typePentroof typePentroof typeTotal displacement dm31,8341,8341,834 Cylinder bore stroke , *1, *2 Valve timingIntakevalveOpens(BTDC)14_20_15_Clo ses(ABDC)50_60_56_ExhaustvalveOpens(BBDC )58_61_55_Closes(ATDC)10_15_15_Lubricati on systemPressure feed, full-flow filtrationPressure feed, full-flow filtrationPressure feed, full-flow filtrationOil pump typeTrochoid typeTrochoid typeTrochoid typeCooling systemWater-cooled forcedcirculationWater-cooled forcedcirculationWater-cooled forcedcirculationWater pump typeCentrifugal impellertypeCentrifugal impellertypeCentrifugal impellertype*1: Up to 1999 model*2.

5 From 2000 modelPWEE9502-GEMay 2000 Mitsubishi Motors ENGINE (E W) General Information11A-0-5 PWEE9502-CEJuly 1997 Mitsubishi Motors CorporationRevised4G94 Descriptions4G94 SOHC4G94 DOHC GDITypeIn-line OHV, SOHCIn-line OHV, DOHCN umber of cylinders44 Combustion chamberPentroof typePentroof typeTotal displacement dm31,9991,999 Cylinder bore stroke timingIntakevalveOpens(BTDC)2_15_Closes( ABDC)58_51_ExhaustvalveOpens(BBDC)58_55_ Closes(ATDC)10_15_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 typePWEE9502-IEMar.

6 2001 Mitsubishi Motors ENGINE (E W) Specifications11A-1-11. SPECIFICATIONSSERVICE SPECIFICATIONSI temsStandard valueLimitTiming beltAuto-tensioner rod protrusion amount (When removed from ENGINE )mm11 Auto-tensioner rod stroke mmWithin 1 Auto-tensioner rod protrusion amount (When checking with installedon ENGINE ) Rocker arms and camshaftCamshaft cam height mm4G92 SOHC* SOHC* SOHC* SOHC* SOHC* DOHC DOHC DOHC DOHC clearance Camshaft journal Rocker cover and camshaft (MIVEC)Camshaft height mmIntake clearance (cold ENGINE ) *1: LANCER for Europe and CARISMA for Europe*2: LANCER for general export and CARISMA for 6B model*3: LANCER for Europe (from 2001 model) and CARISMA for Europe (from 2001 model)*4: Except for Europe*5: For EuropePWEE9502-KEJun.

7 2002 Mitsubishi Motors ENGINE (E W) Specifications11A-1-2 ItemsStandard valueLimitCylinder head and valveCylinder head gasket surface flatness mmLess than limit of cylinder head gasket surface mm*Total resurfacing depth of both cylinder head and cylinder block *Cylinder head overall height DOHC DOHC Thickness of valvehead (margin) (margin) overall spring free length mmSOHC (with lash ad-juster) (with adjust-ing screw) spring out-of-squarenessMax. 2_4_Valve stem to valveguide clearance mmExcept DOHC GDIfor PAJERO clearance mmfor PAJERO GDI for PAJERO PAJERO seat valve contact width Valve guide projection from cylinder headpper s rface upper surface PWEE9502-KEJun.

8 2002 Mitsubishi Motors ENGINE (E W) Specifications11A-1-3 ItemsLimitStandard valueValve stem projec-tion head bolt shank length mm stem Valve face angle45_ Valve spring load/installed height N/mmSOHC216 DOHC255 DOHC MIVEC255 DOHC GDI196 Valve guide Font case, oil pump and oil panOil pump tip clearance Oil pump side clearance Oil pump body clearance and connecting rodPiston ring to piston ring groove clearancemmNo. ring end gapmmNo. 14G92, ringSOHC (4G92, 4G93) (4G94), pin oil clearance pin press-in load N [Room temperature]4,500 14,700 Connecting rod big end side clearance pin Piston mm4G92, Crankshaft, cylinder block, flywheel and drive plateCrankshaft journal oil clearance block gasket surface flatness limit of cylinder block gasket surface mm *Total resurfacing depth of both cylinder head and cylinder block *PWEE9502-IEMar.

9 2001 Mitsubishi Motors ENGINE (E W) Specifications11A-1-4 ItemsLimitStandard valueCylinder block overall height Cylinder block mm4G92, Piston to cylinder clearance Bearing cap bolt shank length mm end play journal mm50 Crankshaft pin mm45 REWORK DIMENSIONSI temsStandard valueCylinder head and valveOversize rework dimensions of valve guide hole (both intake andexhaust) ) rework dimensions of intake valveseat hole hole rework dimensions of exhaust valveseat hole hole , flywheel and drive plateCrankshaft out of roundness and taper of journal and pin : Outer : Inner : Oversize diameterPWEE9502-IEMar.

10 2001 Mitsubishi Motors ENGINE (E W) Specifications11A-1-5 TORQUE SPECIFICATIONSI temsNmAlternator and ignition systemOil level gauge13 Distributor12 Ignition coil10 Spark plug25 Crankshaft bolt182 4 Alternator brace (M8)23 Alternator brace (M10)49 Lock bolt23 Adjusting bolt5 Power steering pump pulley25 Power steering pump bracket stay49 Power steering pump bracket (M8)21 Power steering pump bracket (M10)44 Alternator pivot bolt44 Center cover3 Ignition failure sensor (M6)5 Ignition failure sensor (M8)23 Ignition failure sensor bracket10 Cam position sensor9 Cam position sensor support13 Cam position sensing cylinder21 ENGINE beltCamshaft sprocket bolt88 Cam position angle belt rear cover11 Timing belt rear upper cover11 Timing belt tensioner24 ENGINE support bracket, right49 Accessory mount49 Timing belt cover11 Tensioner pulley bolt49 Tensioner arm bolt44 Auto-tensioner bolt13 Idler pulley bolt36 PWEE9502-KEJun.