Mitsubishi 4G9 series User manual

GENERAL INFORMATION 11A-0-3

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1.SPECIFICATIONS 11A-1-1

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SERVICE SPECIFICATIONS 11A-1-1

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REWORK DIMENSIONS 11A-1-4

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TORQUE SPECIFICATIONS 11A-1-4

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NEW TIGHTENING METHOD-BY USE OF BOLTS TO BE

TIGHTENED IN PLASTIC AREA 11A-1-7

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SEALANT 11A-1-7

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FORM-IN-PLACE GASKET 11A-1-8

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2.SPECIAL TOOLS 11A-2-1

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3.ALTERNATOR AND IGNITION SYSTEM 11A-3-1

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4.TIMING BELT 11A-4-1

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5.FUEL AND EMISSION CONTROL SYSTEM 11A-5-1

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5a.THROTTLE BODY AND EGR SYSTEM (GDI) 11A-5a-1

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6.INTAKE AND EXHAUST MANIFOLD 11A-6-1

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6a.INTAKE MANIFOLD (GDI) 11A-6a-1

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6b.EXHAUST MANIFOLD (GDI) 11A-6b-1

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6c.INJECTOR AND FUEL PUMP ASSEMBLY (GDI) 11A-6c-1

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7.WATER PUMP AND WATER HOSE 11A-7-1

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8.ROCKER ARMS AND CAMSHAFTS 11A-8-1

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8a.ROCKER COVER AND CAMSHAFTS (MIVEC) 11A-8a-1

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8b.ROCKER ARMS AND ROCKER SHAFT CAPS (MIVEC) 11A-8b-1

.....

9.CYLINDER HEAD AND VALVES 11A-9-1

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10.FRONT CASE AND OIL PUMP 11A-10-1

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11. PISTON AND CONNECTING ROD 11A-11-1

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12.CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE

PLATE 11A-12-1

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11A-0-1

ENGINE

4G9 SERIES

CONTENTS

PWEE9502-E

EDec. 1998Mitsubishi Motors Corporation Revised

11A-0-2

PWEE9502

EMay 1995Mitsubishi Motors Corporation

NOTES

4G9 ENGINE (E-W) - General Information 11A-0-3

PWEE9502-C

EJuly 1997Mitsubishi Motors Corporation Revised

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 Pentroof type Pentroof type

Total displacement dm31,597 1,597

Cylinder bore mm 81.0 81.0

Piston stroke mm 77.5 77.5

Compression ratio 10.0 11.0

Valve timing Intake

valve

Opens

(BTDC)

20_,14

_* 17_(Low-speed cam)

47.5_(High-speed cam)

Closes

(ABDC)

42_,58

_* 31_(Low-speed cam)

72.5_(High-speed cam)

Exhaust

valve

Opens

(BBDC)

54_,52

_* 41_(Low-speed cam)

70_(High-speed cam)

Closes

(ATDC)

2_,16

_*11_(Low-speed cam)

35_(High-speed cam)

Lubrication system Pressure feed, full-flow filtration Pressure feed, full-flow filtration

Oil pump type Trochoid type Trochoid type

Cooling system Water-cooled forced circulation Water-cooled forced circulation

Water pump type Centrifugal impeller type Centrifugal impeller type

*: LANCER for general export and CARISMA for 6B model

4G9 ENGINE (E-W) - General Information

11A-0-4

PWEE9502-C

EJuly 1997Mitsubishi Motors Corporation Revised

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

Total displacement dm31,834 1,834 1,834

Cylinder bore mm 81.0 81.0 81.0

Piston stroke mm 89.0 89.0 89.0

Compression ratio 10.0, 9.5 10.5 11.7

Valve timing Intake

valve

Opens

(BTDC)

14_20_15_

Closes

(ABDC)

50_60_56_

Exhaust

valve

Opens

(BBDC)

58_61_55_

Closes

(ATDC)

10_15_15_

Lubrication system Pressure feed, full-

flow filtration

Pressure feed, full-

flow filtration

Pressure feed, full-

flow filtration

Oil pump type Trochoid type Trochoid type Trochoid type

Cooling system Water-cooled forced

circulation

Water-cooled forced

circulation

Water-cooled forced

circulation

Water pump type Centrifugal impeller

type

Centrifugal impeller

type

Centrifugal impeller

type

4G9 ENGINE (E-W) - Specifications 11A-1-1

1. SPECIFICATIONS

SERVICE SPECIFICATIONS

Items Standard value Limit

Timing belt

Auto-tensioner rod protrusion amount (When removed from engine)

11 -

Auto-tensioner rod stroke mm Within 1 -

Auto-tensioner rod protrusion amount (When checking with installed

on engine) mm

3.8 - 4.5 -

Rocker arms and camshaft

Camshaft cam 4G92-SOHC*1Intake 37.34 36.84

height mm 4G92-SOHC*

Exhaust 36.79 36.29

4G92-SOHC*2Intake 37.78 37.28

4G92-SOHC*

Exhaust 37.83 37.33

4G93-SOHC Intake 37.53 37.03

Exhaust 37.64 37.14

4G93-DOHC Intake 35.31 34.81

Exhaust 35.20 34.70

4G93-DOHC-GDI*3Intake 35.49 34.99

Exhaust 34.91 34.41

4G93-DOHC-GDI*4Intake 35.49 34.99

Exhaust 34.73 34.23

Valve clearance mm Intake 0.09 -

Exhaust 0.20 -

Camshaft journal O.D. mm SOHC 26.0 -

DOHC 45.0 -

Rocker cover and camshaft (MIVEC)

Camshaft height mm Intake A 36.41 36.91

Intake B 33.58 33.08

Exhaust A 35.83 35.33

Exhaust B 34.24 33.74

Valve clearance (cold engine) mm Intake 0.1 -

Exhaust 0.2 -

Cylinder head and valve

Cylinder head gasket surface flatness mm Less than 0.03 0.2

Grinding limit of cylinder head gasket surface mm

*Total resurfacing depth of both cylinder head and cylinder block

- 0.2*

*1: LANCER for Europe and CARISMA for Europe

*2: LANCER for general export and CARISMA for 6B model

*3: For CARISMA

*4: For PAJERO io

PWEE9502-E

EDec. 1998Mitsubishi Motors Corporation Revised

4G9 ENGINE (E-W) - Specifications

11A-1-2

Items Standard value Limit

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 (margin) mm Exhaust 1.3 0.8

DOHC Intake 1.0 0.5

Exhaust 1.2 0.7

Valve overall height SOHC Intake 110.15 109.65

mm Exhaust 113.70 113.20

DOHC Intake 104.19 103.69

Exhaust 103.87 103.37

DOHC- MIVEC Intake 115.63 115.13

Exhaust 115.63 115.13

DOHC- GDI Intake 104.19 103.69

Exhaust 103.87 103.37

Valve spring free length mm SOHC 50.9 49.9

DOHC 45.0 44.0

DOHC- MIVEC 51.5 50.5

DOHC- GDI 44.8 43.8

Valve spring out-of-squareness Max. 2_4_

Valve stem to valve Except DOHC- GDI Intake 0.02 - 0.05 0.10

guide clearance mm for PAJERO io Exhaust 0.05 - 0.09 0.15

DOHC- GDI Intake 0.02 - 0.05 0.10

for PAJERO io Exhaust 0.04- 0.06 0.15

Valve seat valve contact width mm 0.9 - 1.3 -

Valve guide projection from cylinder head SOHC 14.0 -

upper surface mm DOHC 19.0 -

Valve stem projec- SOHC Intake 49.30 49.80

tion 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

PWEE9502-E

EDec. 1998Mitsubishi Motors Corporation Revised

4G9 ENGINE (E-W) - Specifications 11A-1-3

Items LimitStandard value

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 -

Valve guide I.D. mm 6.0 -

Font case, oil pump and oil pan

Oil pump tip clearance mm 0.06 - 0.18 -

Oil pump side clearance mm 0.04 - 0.10 -

Oil pump body clearance mm 0.10 - 0.18 0.35

Piston and connecting rod

Piston ring to piston ring groove clearance No. 1 0.03 - 0.07 0.1

mm No. 2 0.02 - 0.06 0.1

Piston ring end gap No. 1 0.25 - 0.40 0.8

mm No. 2 0.40 - 0.55 0.8

Oil ring SOHC 0.20 - 0.60 1.0

DOHC 0.10 - 0.35 1.0

Crankshaft pin oil clearance mm 0.02 - 0.05 0.1

Piston pin press-in load N [Room temperature] 4,500 - 14,700 -

Connecting rod big end side clearance mm 0.10 - 0.25 0.4

Piston pin O.D. mm 19.0 -

Piston O.D. mm 81.0 -

Crankshaft, cylinder block, flywheel and drive plate

Crankshaft journal oil clearance mm 0.02 - 0.04 0.1

Cylinder block gasket surface flatness mm 0.05 0.1

Grinding limit of cylinder block gasket surface mm

*Total resurfacing depth of both cylinder head and cylinder block

- 0.2*

Cylinder block overall height mm 4G92 243.5 -

4G93 263.5 -

Cylinder block I.D. mm 81.0 -

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 -

PWEE9502-E

EDec. 1998Mitsubishi Motors Corporation Revised

4G9 ENGINE (E-W) - Specifications

11A-1-4

REWORK DIMENSIONS

Items Standard value

Cylinder head and valve

Oversize rework dimensions of valve guide hole (both intake and 0.05 O.S. 11.05 - 11.07

exhaust) mm 0.25 O.S. 11.25 - 11.27

0.50 O.S. 11.50 - 11.52

Oversize rework dimensions of intake valve SOHC 0.30 O.S. 31.80 - 31.83

seat hole mm 0.60 O.S. 32.10 - 32.13

DOHC 0.30 O.S. 34.30 - 34.32

0.60 O.S. 34.60 - 34.62

Oversize rework dimensions of exhaust valve SOHC 0.30 O.S. 29.30 - 29.32

seat hole mm 0.60 O.S. 29.60 - 29.62

DOHC 0.30 O.S. 30.80 - 30.82

0.60 O.S. 31.10 - 31.13

Crankshaft, flywheel and drive plate

Crankshaft out of roundness and taper of journal and pin mm 0.005

NOTE

O.D.: Outer diameter

I.D.: Inner diameter

O.S.: Oversize diameter

TORQUE SPECIFICATIONS

Items Nm

Alternator and ignition system

Oil level gauge 13

Distributor 12

Ignition coil 10

Spark plug 25

Crankshaft bolt 181

Alternator brace (M10) 49

Alternator brace (M8) 23

Lock bolt 23

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> 4.9

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

PWEE9502-E

EDec. 1998Mitsubishi Motors Corporation Revised

4G9 ENGINE (E-W) - Specifications 11A-1-5

Items Nm

Ignition failure sensor 23

Cam position sensor 9

Cam position sensor support 13

Cam position sensing cylinder 21

Engine cover 2.9

Timing belt

Camshaft sprocket bolt 88

Cam position sensor <DOHC> 9.8

Crank angle sensor 9.8

Timing belt rear cover 11

Timing belt tensioner 24

Engine support bracket, right 49

Accessory mount 49

Timing belt cover 11

Tensioner pulley bolt 49

Tensioner arm bolt 44

Auto-tensioner bolt 13

Idler pulley bolt 36

Fuel system and emission system

Breather tube 21

Fuel pump 18

Carburetor 17

EGR valve 21

Fuel return pipe 9

Delivery pipe 12

Fuel pressure regulator 9

Throttle body stay 23

Throttle body 19

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 resonator 9

Intake manifold stay 30

Water hose clamp 13

Water pipe 11

Throttle body 18

PWEE9502-E

EDec. 1998Mitsubishi Motors Corporation Revised

4G9 ENGINE (E-W) - Specifications

11A-1-6

Items Nm

EGR valve 18

Engine hanger 18

EGR valve support bolt 18

EGR valve support nut 23

Air by-pass valve 9

Intake manifold and exhaust manifold

Exhaust manifold (M10) 29

Exhaust manifold (M8) 18

Exhaust manifold bracket 19

Engine hanger 12

Oil level gauge guide 14

Boost sensor 5

Intake air temperature sensor 13

Heat protector 13

Intake manifold 20

Intake manifold stay 30

Intake manifold (GDI)

Vacuum pipe and hose <For CARISMA> 11

Vacuum pipe and hose <For PAJERO io> 9

Solenoid valve 9

Fuel pump protector 23

Connector bracket 11

Branch tube (M6 x 18) 9

Branch tube (M6 x 14) 11

Intake manifold stay 30

Accelerator cable bracket 9

Vacuum pipe 11

Intake manifold 19

Exhaust manifold (GDI)

Oil level gauge guide 13

Exhaust manifold cover 13

Engine hanger bolt 18

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-E

EDec. 1998Mitsubishi Motors Corporation Revised

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