Summary of the content on the page No. 1
11A-0-1
ENGINE
4G9 SERIES
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-0-3
1.SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1
REWORK DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-4
TORQUE SPECIFICAT
Summary of the content on the page No. 2
11A-0-2 NOTES E Mitsubishi Motors Corporation May 1995 PWEE9502 www.mivec.co.nz
Summary of the content on the page No. 3
4G9 ENGINE (E-W) - General Information 11A-0-3 GENERAL INFORMATION 4G92 Descriptions 4G92-SOHC 4G92-DOHC-MIVEC Type In-line OHV, SOHC In-line OHV, DOHC Number of cylinders 4 4 Combustion chamber Pentrooftype Pentrooftype 3 Totaldisplacement dm 1,597 1,597 Cylinder bore mm 81.0 81.0 Pistonstroke mm 77.5 77.5 Compression ratio 10.0 11.0 Valve timing Intake Opens 20_,14_* 17_ (Low-speed cam) valve (BTDC) 47.5_ (High-speed cam) Closes 42_,58_* 31_ (Low-speed cam) (ABDC) 72.5_ (High-speed cam) Exhaus
Summary of the content on the page No. 4
11A-0-4 4G9 ENGINE (E-W) - General Information 4G93 Descriptions 4G93-SOHC 4G93-DOHC 4G93-DOHC-GDI Type In-line OHV, SOHC In-line OHV, DOHC In-line OHV, DOHC Number of cylinders 4 4 4 Combustion chamber Pentroof type Pentroof type Pentroof type 3 Total displacement dm 1,834 1,834 1,834 Cylinder bore mm 81.0 81.0 81.0 Piston stroke mm 89.0 89.0 89.0 1 2 Compression ratio 10.0, 9.5 10.5 11.7* , 12.0* Valve timing Intake Opens 14_ 20_ 15_ valve (BTDC) Closes 50_ 60_ 56_ (ABDC) Exhaust Opens 58_ 61_
Summary of the content on the page No. 5
4G9 ENGINE (E–W) – General Information 11A-0-5 4G94 Descriptions 4G94–SOHC 4G94–DOHC–GDI Type In-line OHV, SOHC In-line OHV, DOHC Number of cylinders 4 4 Combustion chamber Pentroof type Pentroof type 3 Total displacement dm 1,999 1,999 Cylinder bore mm 81.5 81.5 Piston stroke mm 95.8 95.8 Compression ratio 9.5 10.6 Valve timing Intake Opens 2 15 valve (BTDC) Closes 58 51 (ABDC) Exhaust Opens 58 55 valve (BBDC) Closes 10 15 (ATDC) Lubrication system Pressure feed, full-flow filtration Pr
Summary of the content on the page No. 6
11A-1-1 4G9 ENGINE (E–W) – Specifications 1. SPECIFICATIONS SERVICE SPECIFICATIONS Items Standard value Limit Timing belt Auto-tensioner rod protrusion amount (When removed from engine) 11 – mm Auto-tensioner rod stroke mm Within 1 – Auto-tensioner rod protrusion amount (When checking with installed 3.8 – 4.5 – on engine) mm Rocker arms and camshaft Camshaft cam 1 Intake 37.34 36.84 4G92–SOHC* GS C height mm height mm Exhaust 36.79 36.29 2 Intake 37.78 37.28 4G92–SOHC* GS C Exhaust 37.83 37.33 3
Summary of the content on the page No. 7
11A-1-2 4G9 ENGINE (E–W) – Specifications Items Standard value Limit Cylinder head and valve Cylinder head gasket surface flatness mm Less than 0.03 0.2 Grinding limit of cylinder head gasket surface mm – 0.2* *Total resurfacing depth of both cylinder head and cylinder block Cylinder head overall height mm SOHC 119.9 – 120.1 – DOHC 131.9 – 132.1 – DOHC–MIVEC 119.8 – 120.0 – DOHC–GDI 131.9 – 132.1 – Thickness of valve SOHC Intake 1.0 0.5 head head (margin) mm (margin) mm Exhaust 1.3 0.8 DOHC Inta
Summary of the content on the page No. 8
11A-1-3 4G9 ENGINE (E–W) – Specifications Items Standard value Limit Valve stem projec- SOHC Intake 49.30 49.80 tion tion mm mm Exhaust 49.35 49.85 DOHC Intake 46.70 47.20 Exhaust 46.65 47.15 DOHC–MIVEC Intake 58.13 58.63 Exhaust 57.85 58.35 DOHC–GDI Intake 46.70 47.20 Exhaust 46.65 47.15 Cylinder head bolt shank length mm – 96.4 Valve stem O.D. mm 6.0 – Valve face angle 45 – 45.5 – Valve spring load/installed height N/mm SOHC 216/44.2 – DOHC 255/44.5 – DOHC–MIVEC 255/44.5 – DOHC–GDI 196/37.5
Summary of the content on the page No. 9
11A-1-4 4G9 ENGINE (E–W) – Specifications Items Standard value Limit Cylinder block overall height mm 4G92 243.5 – 4G93 263.5 – 4G94 286.7 – Cylinder block I.D. mm 4G92, 4G93 81.0 – 4G94 81.5 – Piston to cylinder clearance mm 0.02 – 0.04 – Bearing cap bolt shank length mm – 71.1 Crankshaft end play mm 0.05 – 0.25 0.4 Crankshaft journal O.D. mm 50 – Crankshaft pin O.D. mm 45 – REWORK DIMENSIONS Items Standard value Cylinder head and valve Oversize rework dimensions of valve guide hole (both intak
Summary of the content on the page No. 10
11A-1-5 4G9 ENGINE (E–W) – Specifications TORQUE SPECIFICATIONS Items Nm Alternator and ignition system Oil level gauge 13 Distributor 12 Ignition coil 10 Spark plug 25 Crankshaft bolt 182 ± 4 Alternator brace (M8) 23 Alternator brace (M10) 49 Lock bolt 23 Adjusting bolt 5 Power steering pump pulley 25 Power steering pump bracket stay 49 Power steering pump bracket (M8) 21 Power steering pump bracket (M10) 44 Alternator pivot bolt 44 Center cover 3 Ignition failure sensor (M6) 5 Ignition failure
Summary of the content on the page No. 11
11A-1-6 4G9 ENGINE (E–W) – Specifications Items Nm Fuel system and emission system Breather tube 21 Fuel pump 18 Carburetor 17 EGR valve 21 Cover 12 Fuel return pipe 9 Delivery pipe 12 Fuel pressure regulator 9 Throttle body stay 23 Throttle body stay <4G94> 24 Throttle body 19 Throttle cable bracket 19 Stay 24 Harness bracket 11 Vacuum hose and pipe assembly (Flange bolt) 11 Vacuum hose and pipe assembly (Bolt
Summary of the content on the page No. 12
11A-1-6a 4G9 ENGINE (E–W) – Specifications Items Nm Intake manifold and exhaust manifold Exhaust manifold (M8) 18 Exhaust manifold (M10) 29 Exhaust manifold bracket (M8) 19 Exhaust manifold bracket (M10 Bolt and washer assembly) 35 Exhaust manifold bracket (M10 Flange bolt) 98 Engine hanger (Bolt with head mark “4”) 12 Engine hanger (Bolt with head mark “7”) 19 Oil level gauge guide 14 Boost sensor 5 Intake air temperature sensor 13 Heat protector 13 Intake manifold 20 Intake manifold stay 31 Ox
Summary of the content on the page No. 13
11A-1-6b 4G9 ENGINE (E–W) – Specifications Items Nm Exhaust manifold (M8) 17 Exhaust manifold (M10) 29 Injector and fuel pump assembly (GDI) Fuel low pressure pipe (M6) 18 Fuel low pressure pipe (M8) 9 Fuel nipple 9 Clamp 9 Fuel feed pipe 11 Fuel pump 17 Harness bracket 11 Fuel pipe 11 Fuel return pipe 11 Fuel return pipe clamp 9 Fuel high pressure regulator 18 Fuel pressure sensor 23 Fuel pressure sensor 18 Spacer 18 Pump camshaft case 23 Injector holder 2
Summary of the content on the page No. 14
11A-1-6c 4G9 ENGINE (E–W) – Specifications Items Nm Water inlet fitting 19 Water inlet fitting 24 Water by-pass fitting 24 Water pipe 14 Water outlet fitting 19 Water outlet fitting 24 Engine coolant temperature gauge unit 10 Engine coolant temperature sensor 29 Water fitting 24 Rocker arms and camshaft Lock nut 9 Rocker arm shaft 31 Harness bracket 10 Rocker cover 3.5 Bearing cap bolt (M6) 11 Bearing cap bolt (M8) 24 Beam camshaft ca
Summary of the content on the page No. 15
11A-1-6d 4G9 ENGINE (E–W) – Specifications Items Nm Upper oil pan (M8) 24 Lower oil pan 11 Cover 7 Baffle plate 7 Baffle plate 11 Drain plug 39 Oil pressure switch 10 Transmission stay 23 Piston and connecting rod Connecting rod cap nut 20 + 90 to 100 Crankshaft, cylinder block, flywheel and drive plate Bearing cap bolt 25 + 90 to 100 Oil seal case 11 Bell housing cover (Flange bolt) 10 Bell housing cover (Bolt and washer assembly) 9 Rear plate 10 Re
Summary of the content on the page No. 16
11A-1-7 4G9 ENGINE (E-W) - 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 for some parts of the engine. The tightening method for bolts of this type 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
Summary of the content on the page No. 17
11A-1-8 4G9 ENGINE (E-W) - 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 eliminate
Summary of the content on the page No. 18
11A-2-1 4G9 ENGINE (E-W) - Special Tools 2. SPECIAL TOOLS Tool Number Name Use MB990938 Handle UsewithMD998776 MB990767 Crankshaft pulley Holding camshaft sprocket when loosening holder and tightening of bolt. UsewithMD998719 MD998440 Leak-down tester Leak-down test of lash adjuster MD998442 Air bleed wire Air bleeding of lash adjuster MD998713 Camshaft oil seal Installation of camshaft oil seal installer MD998716 Crankshaft wrench Rotation of crankshaft when installing piston and timing belt. M
Summary of the content on the page No. 19
11A-2-2 4G9 ENGINE (E-W) - Special Tools Tool Number Name Use MD998719 Pulley holder pin UsewithMB990767 (2) MD998727 Oil pan remover Removal of the oil pan MD998754 Pin UsewithMB990767 MD998767 Tensioner pulley Adjustment of timing belttension socket wrench MD998772 Valve spring Removal and installation of valve and related compressor parts MD998774 Valve stem seal Installation of valve stem seal installer MD998775 Valve stem seal Installation of valve stem seal installer MD998776 Crankshaft re
Summary of the content on the page No. 20
11A-2-3 4G9 ENGINE (E-W) - Special Tools Tool Number Name Use MD998780 SETTING TOOL Removal and installation of piston pin Pistonpin MD998735 Valve spring Compression of valve spring compressor MD998781 Flywheel stopper Holding flywheel and drive plate MB991477 Valve adjusting Adjustment of valve clearance (MIVEC) wrench MB991478 Valve adjusting Adjustment of valve clearance (MIVEC) wrench feeler gauge set MB991479 Rocker arm Adjustment of valve clearance (MIVEC) piston checker MD998784 Valve sp
