ENGINE Workshop Manual 4G9 (E-W)

1 GENERAL TIGHTENING METHOD - BY USE OF BOLTS TO BETIGHTENED IN PLASTIC SPECIAL ALTERNATOR AND IGNITION TIMING FUEL AND EMISSION CONTROL THROTTLE BODY AND EGR SYSTEM (GDI) INTAKE AND EXHAUST INTAKE MANIFOLD (GDI) EXHAUST MANIFOLD (GDI) INJECTOR AND FUEL PUMP ASSEMBLY (GDI) WATER PUMP AND WATER ROCKER ARMS AND ROCKER COVER AND CAMSHAFTS (MIVEC) ROCKER ARMS AND ROCKER SHAFT CAPS (MIVEC) CYLINDER HEAD AND FRONT CASE AND OIL PISTON AND CONNECTING CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND SERIESCONTENTSPWEE9502-EEDec. 1998 Mitsubishi Motors CorporationRevised11A-0-2 PWEE9502 EMay 1995 Mitsubishi Motors CorporationNOTES4G9 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)

2 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*: LANCER for general export and CARISMA for 6B model4G9 ENGINE (E - W) -General Information11A-0-4 PWEE9502-CEJuly 1997 Mitsubishi Motors CorporationRevised4G93 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 , 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 impellertype4G9 ENGINE (E - W) -Specifications11A-1-11.

3 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 ) - arms and camshaftCamshaft cam4G92-SOHC* mm4G92-SOHC* * * * * clearance journal cover and camshaft (MIVEC)Camshaft height mmIntake clearance (cold ENGINE ) 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 **1: LANCER for Europe and CARISMA for Europe*2: LANCER for general export and CARISMA for 6B model*3: For CARISMA*4: For PAJERO ioPWEE9502-EEDec. 1998 Mitsubishi Motors CorporationRevised4G9 ENGINE (E - W) -Specifications11A-1-2 ItemsStandard valueLimitCylinder head overall height - - - - of (margin) overall spring free length spring out-of-squarenessMax.

4 2_4_Valve stem to valveExcept - clearance mmfor PAJERO - - PAJERO seat valve contact width - guide projection from cylinder surface stem head bolt shank length 1998 Mitsubishi Motors CorporationRevised4G9 ENGINE (E - W) -Specifications11A-1-3 ItemsLimitStandard valueValve stem face angle45_- spring load/installed height N/mmSOHC216 guide , oil pump and oil panOil pump tip clearance - pump side clearance - pump body clearance - and connecting rodPiston ring to piston ring groove clearanceNo. - - ring end gapNo. - - - - pin oil clearance - pin press-in load N [Room temperature]4,500 - 14,700-Connecting rod big end side clearance - pin , 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 *Cylinder block overall height block to cylinder clearance - cap bolt shank length end play - journal mm50-Crankshaft pin mm45-PWEE9502-EEDec.

5 1998 Mitsubishi Motors CorporationRevised4G9 ENGINE (E - W) -Specifications11A-1-4 REWORK DIMENSIONSI temsStandard valueCylinder head and valveOversize rework dimensions of valve guide hole (both intake - ) - - rework dimensions of intake - hole - - - rework dimensionsof exhaust - hole - - - , flywheel and drive plateCrankshaft out of roundness and taper of journal and pin : Outer : Inner : Oversize diameterTORQUE SPECIFICATIONSI temsNmAlternator and ignitionsystemOil level gauge13 Distributor12 Ignition coil10 Spark plug25 Crankshaft bolt181 Alternator brace (M10)49 Alternator brace (M8)23 Lock bolt23 Adjusting bolt <Except SOHC for PAJERO io and DOHC-GDI for PAJERO io>10 Adjusting bolt <SOHC-PAJERO io and DOHC-GDI for PAJERO io> 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 PWEE9502-EEDec.

6 1998 Mitsubishi Motors CorporationRevised4G9 ENGINE (E - W) -Specifications11A-1-5 ItemsNmIgnition failure sensor23 Cam position sensor9 Cam position sensor support13 Cam position sensing cylinder21 ENGINE beltCamshaft sprocket bolt88 Cam position sensor <DOHC> angle belt rear 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 Fuel system and emission systemBreather tube21 Fuel pump18 Carburetor17 EGR valve21 Fuel return pipe9 Delivery pipe12 Fuel pressure regulator9 Throttle body stay23 Throttle body19 Vacuum hose and pipe assembly <SOHC-MPI for other than PAJERO io>10 Vacuum hose and pipe assembly <SOHC-MPI for PAJERO io>9 Solenoid valve assembly <SOHC-MPI for other than PAJERO io>11 Solenoid valve assembly <SOHC-MPI for PAJERO io>9 Throttle body and EGR system (GDI)Air intake resonator9 Intake manifold stay30 Water hose clamp13 Water pipe11 Throttle body18 PWEE9502-EEDec.

7 1998 Mitsubishi Motors CorporationRevised4G9 ENGINE (E - W) -Specifications11A-1-6 ItemsNmEGR valve18 ENGINE hanger18 EGR valve support bolt18 EGR valve support nut23 Air by-pass valve9 Intake manifold and exhaust manifoldExhaust manifold (M10)29 Exhaust manifold (M8)18 Exhaust manifold bracket19 ENGINE hanger12 Oil level gauge guide14 Boost sensor5 Intake air temperature sensor13 Heat protector13 Intake manifold20 Intake manifold stay30 Intake manifold (GDI)Vacuum pipe and hose <For CARISMA>11 Vacuum pipe and hose <For PAJERO io>9 Solenoid valve9 Fuel pump protector23 Connector bracket11 Branch tube (M6 x 18)9 Branch tube (M6 x 14)11 Intake manifold stay30 Accelerator cable bracket9 Vacuum pipe11 Intake manifold19 Exhaust manifold (GDI)Oil level gauge guide13 Exhaust manifold cover13 ENGINE hanger bolt18 ENGINE hanger nut (M8)18 ENGINE hanger nut (M10)29 Exhaust manifold bracket (M8 22)35 Exhaust manifold bracket (M8 20)18 Exhaust manifold bracket (M10)98 Exhaust manifold (M10)29 PWEE9502-EEDec.

8 1998 Mitsubishi Motors CorporationRevised4G9 ENGINE (E - W) -Specifications11A-1-6aItemsNmExhaust manifold (M8)17 Injector and fuel pump assembly (GDI)Fuel low pressure pipe (M6)18 Fuel low pressure pipe (M8)9 Fuel nipple9 Clamp9 Fuel feed pipe11 Fuel pump17 Harness bracket11 Fuel return pipe11 Fuel return pipe clamp9 Fuel high pressure regulator18 Fuel pressure sensor <For CARISMA>23 Fuel pressure sensor <For PAJERO io>18 Spacer18 Pump camshaft case23 Injector holder22 Delivery pipe and injector11 Water pump and water hoseWater pump24 Water inlet pipe14 Thermostat case24 Water inlet fitting <Except DOHC-GDI for PAJERO io>19 Water inlet fitting <DOHC-GDI for PAJERO io>23 Water by-pass fitting23 Water pipe13 Water outlet fitting <Except DOHC-GDI for PAJERO io>14 Water outlet fitting <DOHC-GDI for PAJERO io>23 ENGINE coolant temperature gauge unit10 ENGINE coolant temperature sensor29 Water fitting23 Rocker arms and camshaftLock nut9 Rocker arm shaft31 Rocker cap bolt (M6)

9 11 Bearing cap bolt (M8)24 Beam camshaft cap (M8)21 PWEE9502-EEDec. 1998 Mitsubishi Motors CorporationRevised4G9 ENGINE (E - W) -Specifications11A-1-6bItemsNmBeam camshaft cap (M6)11 Rocker cover and camshafts (MIVEC)Rocker cover4 Oil pump11 Arm spring holder11 Camshaft bearing cap (M6)11 Camshaft bearing cap (M8)23 Oil control valve9 Rocker arms and rocker shaft caps (MIVEC)Rocker shaft cap11 Cylinder head and valvesCylInder head bolt74 Nm and then completely loosen,finally tighten 20 Nm + 90_+90_Oil pressure switch10 Front case and oil pumpOil pump cover10 Oil pump case14 Relief plug44 Oil screen19 Oil pan7 Upper oil pan <Only M6 121>7 Upper oil pan <Except M6 121>11 Upper oil pan <M8>24 Lower oil pan7 Cover7 Baffle plate <For CARISMA, SPACE STAR only>7 Drain plug39 Oil pressure switch10 Baffle plate mounting bolt7 Piston and connecting rodConnecting rod cap nut20 + 90_to 100_Crankshaft, cylinder block, flywheel and drive plateBearing cap bolt25 + 90_to 100_Oil seal case11 Bell housing cover9 Rear plate11 Drive plate bolt98 Flywheel bolt98 Baffle plate9 Knock sensor22 PWEE9502-EEDec.

10 1998 Mitsubishi Motors CorporationRevised4G9 ENGINE (E - W) -Specifications11A-1-7 NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED IN PLASTICAREAA new type of bolts, to be tightened in plastic area, is currently used for some parts of the tightening method for bolts of this type is different from the conventional one. Be sure to observethe method described in the text when tightening the limits are provided for the bolts. Make sure that the service limits described in the text are where the bolts are in use:(1) Cylinder head bolts(2) Main bearing cap bolts(3) Connecting rod cap boltsDTightening methodAfter tightening the bolts to the specified torque, tighten them another 90_or 180_(twice 90_). Thetightening method varies on different areas. Observe the tightening method described in the sealantQuantityWater pumpMitsubishi Genuine Part or equivalentAs requiredThermostat caseMitsubishi Genuine Part or equivalentAs requiredWater by-pass fittingMitsubishi Genuine Part or equivalentAs requiredWater fittingMitsubishi Genuine Part or equivalentAs requiredEngine coolant temperature sensor3M Nut Locking Part or equivalentAs requiredEngine coolant temperature gauge unit3M ATD Part or equivalentAs requiredCamshaft bearing cap3M ATD Part or equivalentAs requiredSemi-circular packing3M ATD Part or equivalentAs requiredRocker cover3M ATD Part or equivalentAs requiredBeam camshaft capMitsubishi Genuine Part or equivalentAs requiredCylinder headMitsubishi Genuine Part or equivalentAs requiredOil pressure