Mitsubishi 4G6 series User manual

ENGINE <4G6> 11A............................................

ENGINE <6A1> 11B............................................

ENGINE <4D6> 11C............................................

11A-1

ENGINE

CONTENTS 11109000276

11A-2

ENGINE <4G6>

CONTENTS 11109000603

GENERAL INFORMATION 3..................

SERVICE SPECIFICATIONS 3.................

SEALANTS 4................................

SPECIAL TOOLS 4...........................

ON-VEHICLE SERVICE 6.....................

Drive Belt Tension Check and Adjustment 6......

Ignition Timing Check 7.........................

Idle Speed Check 8............................

Idle Mixture Check 8...........................

Compression Pressure Check 9.................

Manifold Vacuum Check 10.....................

Lash Adjuster Check 11........................

CRANKSHAFT PULLEY 15...................

CAMSHAFT AND CAMSHAFT OIL SEAL 16...

OIL PAN 19..................................

CRANKSHAFT OIL SEAL 20..................

CYLINDER HEAD GASKET 22................

TIMING BELT 26.............................

TIMING BELT B 30...........................

ENGINE ASSEMBLY 33.......................

ENGINE <4G6> - General Information/Service Specifications 11A-3

GENERAL INFORMATION 11100010469

Items 4G63

Total displacement mL 1,997

Bore ´Stroke mm 85.0 ´88.0

Compression ratio 10.0

Combustion chamber Pentroof type

Camshaft arrangement SOHC

Intake 8

Number of valve

Exhaust 8

Opening BTDC 11_

Intake

Closing ABDC 53_

Valve timing

Opening BBDC 63_

Exhaust

Closing ATDC 21_

Fuel system Electronically controlled multipoint fuel injection

Rocker arm Roller type

Auto-lash adjuster Equipped

SERVICE SPECIFICATIONS 11100030489

Items Standard value Limit

When checked 294 - 490 -

Tension N When a used belt is installed 343 - 441 -

Alternator drive When a new belt is installed 490 - 686 -

belt

tension When checked 7.7 - 12.3 -

Deflection

(Reference When a used belt is installed 8.4 - 10.6 -

value) mm

When a new belt is installed 5.9 - 7.7 -

When checked 392 - 588 -

Tension N When a used belt is installed 441 - 539 -

Power steering

oil pump and When a new belt is installed 637 - 833 -

A/C compressor

drive belt When checked 11.7 - 15.3 -

tension Deflection

mm When a used belt is installed 12.5 - 14.3 -

When a new belt is installed 8.8 - 11.0 -

Basic ignition timing 5_BTDC±2_-

Ignition timing Approx. 10_BTDC -

ENGINE <4G6> - Service Specifications/Sealants/Special Tools

11A-4

Items LimitStandard value

Idle speed r/min 750 ±100 -

CO contents % 0.5 or less -

HC contents ppm 100 or less -

Compression pressure (250 - 400 r/min) kPa 1,400 Min. 1,060

Compression pressure difference of all cylinder kPa - Max. 100

Intake manifold vacuum kPa -Min. 69

Cylinder head bolt shank length mm -99.4

Auto-tensioner push rod movement mm Within 1 -

Timing belt tension torque Nm (Reference value) 3.5 -

Auto-tensioner rod protrusion amount mm 3.8 - 4.5 -

Timing belt B tension mm 5-7 -

SEALANTS 11100050201

Items Specified sealants Remarks

Rocker cover and cylinder head

Semi-circular packing

3M ATD Part No.8660 or equivalent -

Oil pan

Thermostat case

MITSUBISHI GENUINE PART

MD970389 or equivalent

Semi-drying sealant

Flywheel bolt 3M Stud Locking 4170 or equivalent -

SPECIAL TOOLS 11100060457

Tool Number Name Use

MB991502 MUT-II sub assem-

bly

DChecking the idle speed

DErasing diagnosis code

MB990767 End yoke holder DHolding the camshaft sprocket

DHolding the crankshaft sprocket

MD998719 or

MD998754

Crankshaft pulley

holder pin

DHolding the camshaft sprocket

DHolding the crankshaft sprocket

ENGINE <4G6> - Special Tools 11A-5

Tool UseNameNumber

MD998713 Camshaft oil seal

installer

Press-in of the camshaft oil seal

MD998443 Auto-lash adjuster

holder

Supporting of auto-lash adjuster

MD998727 Oil pan remover Removal of oil pan

MD998781 Flywheel stopper Securing the flywheel

MD998776 Crankshaft rear oil

seal installer

Press-in of the crankshaft rear oil seal

MB990938 Handle Press-in of the crankshaft rear oil seal

MD998767 Tension pulley

socket wrench

Timing belt tension adjustment

GENERAL

SERVICE

TOOL

MZ203827

Engine lifter Supporting the engine assembly during

removal and installation of the transmission

MB991453 Engine hanger

assembly

ENGINE <4G6> - On-vehicle Service

11A-6

ON-VEHICLE SERVICE 11100090432

DRIVE BELT TENSION CHECK AND

ADJUSTMENT

ALTERNATOR DRIVE BELT TENSION CHECK

Use a belt tension gauge to check that the belt tension is

at the standard value at a point half-way between the two

pulleys as shown in the illustration. In addition, press this

section with a force of 98 N and check that the amount of

belt deflection is at the standard value.

Standard value:

Tension N 294 - 490

Deflection (Reference value) mm 7.7 - 12.3

ALTERNATOR DRIVE BELT TENSION ADJUSTMENT

1. Loosen the nut of the alternator pivot bolt.

2. Loosen the lock bolt.

3. Use the adjusting bolt to adjust the belt tension and belt

deflection to the standard values.

Standard value:

Items When a used

belt is installed

When a new

belt is installed

Tension N 343 - 441 490 - 686

Deflection (Reference

value) mm

8.4 - 10.6 5.9 - 7.7

4. Tighten the nut of the alternator pivot bolt.

Tightening torque: 44 Nm

5. Tighten the lock bolt.

Tightening torque: 22 Nm

6. Tighten the adjusting bolt.

Tightening torque: 10 Nm

Water pump

pulley

Alternator pulley

Crankshaft pulley

Adjusting bolt

Lock bolt

ENGINE <4G6> - On-vehicle Service 11A-7

POWER STEERING OIL PUMP AND AIR CONDITIONER

COMPRESSOR DRIVE BELT TENSION CHECK AND

ADJUSTMENT 11100130127

1. Use a belt tension gauge to check that the belt tension

is at the standard value at a point half-way between the

two pulleys (indicated by an arrow in the illustration).

In addition, press this section with a force of 98 N and

check that the amount of belt deflection is at the standard

value.

Standard value:

Items When

checked

When a

used belt is

installed

When a new

belt is

installed

Tension N 392 - 588 441 - 539 637 - 833

Deflection

(Reference

value) mm

11.7 - 15.3 12.5 - 14.3 8.8 - 11.0

2. If the tension or deflection is outside the standard value,

adjust by the following procedure.

(1) Loosen tensioner pulley fixing nut A.

(2) Adjust the amount of belt deflection using adjusting

bolt B.

(3) Tighten fixing nut A.

Tightening torque: 25 Nm

(4) Check the belt deflection amount and tension, and

readjust if necessary.

Caution

Check after turning the crankshaft once or more

clockwise (right turn).

IGNITION TIMING CHECK 11100170297

1. Before inspection, set the vehicle to the pre-inspection

condition.

2. Connect the MUT-II to the diagnosis connector.

3. Set up a timing light.

4. Start the engine and run at idle.

5. Check that engine idle speed is within the standard value.

Standard value: 750 ±100 r/min

6. Select No.17 of the MUT-II Actuator test.

Oil pump pulley

98 N

Crankshaft

pulley

Tensioner pulley

98 N

Crankshaft

pulley

Tensioner

pulley

A/C

compressor

pulley

Oil pump pulley

ENGINE <4G6> - On-vehicle Service

11A-8

7. Check that basic ignition timing is within the standard

value.

Standard value: 5_BTDC±2_

8. If the basic ignition timing is outside the standard value,

inspect the MPI system while referring to GROUP 13A

- Troubleshooting.

9. Press the MUT-II clear key (Select a forced driving cancel

mode) to release the Actuator test.

Caution

If the test is not cancelled, a forced driving will

continue for 27 minutes. Driving under this condition

may damage the engine.

10. Check that ignition timing is at the standard value.

Standard value: approx. 10_BTDC

NOTE

1. Ignition timing is variable within about ±7_, even

under normal operating.

2. And it is automatically further advanced by about

5_from standard value at higher altitudes.

IDLE SPEED CHECK 11100350066

1. Before inspection, set the vehicle to the pre-inspection

condition.

2. Turn the ignition switch to OFF and connect the MUT-II

to the diagnosis connector.

3. Check the basic ignition timing.

Standard value: 5_BTDC±2_

4. Run the engine at idle for 2 minutes.

5. Check the idle speed. Select item No. 22 and take a

reading of the idle speed.

Standard value: 750 ±100 r/min

NOTE

The idle speed is controlled automatically by the idle speed

control (ISC) system.

6. If the idle speed is outside the standard value, inspect

the MPI components by referring to GROUP 13A -

Troubleshooting.

IDLE MIXTURE CHECK 11100210418

1. Before inspection, set the vehicle to the pre-inspection

condition.

2. Turn the ignition switch to OFF and connect the MUT-II

to the diagnosis connector.

3. Check that the basic ignition timing is within the standard

value.

Standard value: 5_BTDC±2_

4. Run the engine at 2,500 r/min for 2 minutes.

ENGINE <4G6> - On-vehicle Service

ENGINE <4G6> - On-vehicle Service 11A-9

5. Set the CO, HC tester.

6. Check the CO contents and the HC contents at idle.

Standard value

CO contents: 0.5% or less

HC contents: 100 ppm or less

7. If there is a deviation from the standard value, check

the following items:

DDiagnosis output

DClosed-loop control (When the closed-loop control

is normal, the output signal of the oxygen sensor

changes between 0 - 400 mV and 600 - 1,000 mV

at idle.)

DFuel pressure

DInjector

DIgnition coil, spark plug cable, spark plug

DLeak in the EGR system and in the EGR valve

DEvaporative emission control system

DCompression pressure

NOTE

Replace the three way catalyst when the CO and HC

contents are not within the standard value, even though

the result of the inspection is normal on all items.

COMPRESSION PRESSURE CHECK 11100260499

1. Before inspection, check that the engine oil, starter and

battery are normal. In addition, set the vehicle to the

pre-inspection condition.

2. Disconnect the spark plug cables.

3. Remove all of the spark plugs.

4. Disconnect the crank angle sensor connector.

NOTE

Doing this will prevent the engine-ECU from carrying out

ignition and fuel injection.

5. Cover the spark plug hole with a shop towel etc., and

after the engine has been cranked, check that no foreign

material is adhering to the shop towel.

Caution

1. Keep away from the spark plug hole when

cranking.

2. If compression is measured with water, oil, fuel,

etc., that hascome from cracksinside the cylinder,

these materials will become heated and will gush

out from the spark plug hole, which is dangerous.

ENGINE <4G6> - On-vehicle Service

11A-10

6. Set compression gauge to one of the spark plug holes.

7. Crank the engine with the throttle valve fully open and

measure the compression pressure.

Standard value (at engine speed of 250-400 r/min):

1,400 kPa

Limit (at engine speed of 250-400 r/min):

Min. 1,060 kPa

8. Measure the compression pressure for all the cylinders,

and check that the pressure differences of the cylinders

are below the limit.

Limit: Max. 100 kPa

9. If there is a cylinder with compression or a compression

difference that is outside the limit, pour a small amount

of engine oil through the spark plug hole, and repeat

the operations in steps 7 and 8.

(1) If the compression increases after oil is added, the

cause of the malfunction is a worn or damaged piston

ring and/or cylinder inner surface.

(2) If the compression does not rise after oil is added,

the cause is a burnt or defective valve seat, or pressure

is leaking from the gasket.

10. Connect the crank angle sensor connector.

11. Install the spark plugs and spark plug cables.

12. Use the MUT-II to erase the diagnosis codes.

NOTE

This will erase the diagnosis code resulting from the crank

angle sensor connector being disconnected.

MANIFOLD VACUUM CHECK 11100270409

1. Start the engine and allow it to warm up until the

temperature of the engine coolant reaches 80 to 95_C.

2. Connect a tachometer.

3. Attach a three-way union to the vacuum hose between

the fuel pressure regulator and the air intake plenum,

and connect a vacuum gauge.

4. Start the engine and check that idle speed is within

standard value. Then read off the vacuum gauge.

Limit: Min. 69 kPa

Compression gauge

Vacuum gage

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