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11A-0-1
ENGINE
4G6 SERIES
CONTENTS
GENERAL INFORMATION ............................................ 11A-0-3
1. SPECIFICATIONS ................................................ 11A-1-1
SERVICE SPECIFICATIONS .................................... 11A-1-1
TORQUE SPECIFICATIONS ..................................... 11A-1-4
NEW TIGHTENING METHOD -
BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA .. 11A-1-9
SEALANTS ....................................................... 11A-1-9
FORM-IN-PLACE GASKET ....
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11A-0-2 NOTES E Mitsubishi Motors Corporation Dec. 1996 PWEE9616
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11A-0-3 4G6 ENGINE - General Information GENERAL INFORMATION SOHC-4G63 Descriptions Specifications Type In-line OHV, SOHC Number of cylinders 4 Combustionchamber Pentrooftype 3 Totaldisplacement dm 1,997 Cylinderbore mm 85.0 Pistonstroke 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 Oilpumptype Involutegear type SOHC-4G64 Descriptions Specificat
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11A-0-4 4G6 ENGINE - General Information GDIt Descriptions Specifications Type In-line OHV, SOHC Number of cylinders 4 Combustionchamber Pentroof+curved top pistontype 3 Totaldisplacement dm 2,351 Cylinderbore mm 86.5 Pistonstroke 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 Oilpumptype Involutegear type NOTE GDI is a trademark of Mitsubishi
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11A-1-1 4G6 ENGINE - Specifications 1. SPECIFICATIONS SERVICE SPECIFICATIONS Items Standard value Limit Timing belt Auto-tensioner rod projectionlength mm 12 - Auto-tensionerrodpushed-inamount[whenpushedwithaforceof98 1.0 or less - - 196 N] mm 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 3 - 20/1.0 - [dieselfuel at 15 - 20_C] seconds/mm Camshaft journal outer di
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11A-1-2 4G6 ENGINE - Specifications Items Standard value Limit 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_ - SOHC 51.0 50.0 Valve spring free length mm 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 m
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11A-1-3 4G6 ENGINE - Specifications Items Standard value Limit 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 4G63 85.0 - Piston outer diametermm 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 sid
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11A-1-4 4G6 ENGINE - Specifications 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 lev
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11A-1-5 4G6 ENGINE - Specifications 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 a
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11A-1-6 4G6 ENGINE - Specifications Items Nm Fuel pump 4.9® 17± 2 Harness bracket 8.8 Fuel return pipe 11 Fuel highpressure regulator 18 Fuel pressure sensor 18 Pump camshaft case 23 Injector holder 22 Delivery pipeand 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
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11A-1-7 4G6 ENGINE - Specifications Items Nm Heat protector 13 Exhaust manifold (M8) 29 Exhaust manifold (M10) 49 Water outlet fitting 13 Rocker arms and camshaft Rocker cover 3.4 Rocker arm shaft 31 Rocker arms and camshafts (GDI) Camshaft position sensor 8.8 Cover 9.8 Camshaft position sensing cylinder 21 Camshaft position sensing support 13 Beam camshaft cap 20 Cylinder head and valves Cylinder head bolt 20 + 90_ +90_ [Tightento78Nmandthencompletelyloosenbeforefinallytighteningwithabove
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11A-1-8 4G6 ENGINE - Specifications Items Nm Oil pan lower 6.9 Baffle plate 6.9 Oil pan upper 6.9 Piston and connecting rod Connectingrod cap 20 + 90_ ®100_ Crankshaft, flywheel and drive plate Flywheel bolt 132 Drive platebolt 132 Rear plate 11 Bell housing cover 8.8 Oil seal case bolt 11 Bearing cap bolt 25 + 90_®100_ E Mitsubishi Motors Corporation Aug. 1999 PWEE9616-B Revised
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11A-1-9 4G6 ENGINE - Specifications NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA A new type of bolts, to be tightened in plastic area, is currently used some parts of the engine. The tightening method for the bolts is different from the conventional one. Be sure to observe the method described in the text when tightening the bolts. Service limits are provided for the bolts. Make sure that the service limits described in the text are strictly observed. D Areas whe
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11A-1-10 4G6 ENGINE - Specifications FORM-IN-PLACE GASKET The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the fluid feed line. To eliminat
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11A-2-1 4G6 ENGINE (E-W) - Special Tools 2. SPECIAL TOOLS Tool Number Name Use MB990767 Crankshaft pulley Holdingcamshaft sprocket holder Use withMD998719. MD990938 Handle Installationofcrankshaft rear oilseal Use withMD998776. MB991603 Silentshaftbearing Guide stopper for removal and installation of pullerstopper counterbalanceshaft rear bearing Use withMD998372. MB991654 Cylinder head bolt Removalandinstallationofcylinder headbolt wrench (12) MD998162 Plugwrench Removalandinstallationoffrontca
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11A-2-2 4G6 ENGINE (E-W) - Special Tools Tool Number Name Use MD998440 Leak downtester Leak downtest oflashadjuster MD998441 Lash adjuster Airbleedingoflashadjuster retainer MD998442 Lash adjusterwire Airbleedingoflashadjuster MD998443 Lash adjuster Retainerforholdinglashadjusterinrockerarm holder at time of removal and installation of rocker shaft assembly MD998705 Silentshaftbearing Installation of counterbalance shaft front and installer rear bearing MD998713 Camshaft oil seal Installationofc
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11A-2-3 4G6 ENGINE (E-W) - Special Tools Tool Number Name Use MD998738 Setscrew Adjustment oftimingbelttension MD998767 Tensioner puller Adjustment oftimingbelttension socket wrench MD998772 Valvespring Removal and installation of valve and related compressor parts MD998774 Valve stem seal Installationofvalve stem seal installer MD998775 Valve stem seal Installationofvalve stem seal installer MD998776 Crankshaft rear oil Installationofcrankshaft rear oilseal sealinstaller Use withMB990938. MD998
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11A-2-4 4G6 ENGINE (E-W) - Special Tools Tool Number Name Use MD998783 Plugwrench Removalandinstallationoffrontcasecapplug retainer MD998785 Sprocket stopper Holdingsilentshaft sprocket E Mitsubishi Motors Corporation Aug. 1998 PWEE9616-A Added
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11A-3-1 4G6 ENGINE (E-W) - Alternator and Ignition System 3. ALTERNATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION 8 6 12 Nm 7 25 Nm 10 4 9 10 Nm 3 44 Nm 2 22 Nm 24 Nm 5 9Nm 25 Nm 1 Removal steps 1. Drive belt 2. Water pump pulley 3. Alternator brace 4. Alternator 5. Crankshaft pulley 6. Spark plug cable 7. Spark plug 8. High tension cable "BA 9. Distributor assembly 10. O-ring E Mitsubishi Motors Corporation Dec. 1996 PWEE9616
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11A-3-2 4G6 ENGINE (E-W) - Alternator and Ignition System REMOVAL AND INSTALLATION 10 Nm 7 10 Nm 6 9 10 8 25 Nm 11 4 22 Nm 10 Nm 3 14 Nm 44 Nm r 2 22 Nm 24 Nm 5 9Nm 25 Nm 1 Removal steps 1. Drive belt 7. Ignition coil assembly 2. Water pump pulley 8. Spark plug 3. Alternator brace 9. Camshaft position sensor 4. Alternator "AA 10. Camshaft position sensing support 5. Crankshaft pulley 11. Camshaft position sensing cylinder 6. Spark plug cable E Mitsubishi Motors Corpor
