MITSUBISHI MAGNA & VERADA Service Repair Manual

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 11A-1-10 .................................... 2. SPECIAL TOOLS 11A-2-1 ................................................. 3. ALTERNATOR AND IGNITION SYSTEM 11A-3-1 ........................ 3a. INTAKE MANIFOLD (GDI) 11A-3a-1 ..................................... 4. TIMING BELT 11A-4-1 ..................................................... 4a. EXHAUST MANIFOLD (GDI) 11A-4a-1 .................................. 5. FUEL AND EMISSION CONTROL PARTS 11A-5-1 ...................... 5a. FUEL PARTS (GDI) 11A-5a-1 ............................................ 6. WATER PUMP AND INTAKE MANIFOLD 11A-6-1 ....................... 6a. WATER PUMP AND WATER HOSE (GDI) 11A-6a-1 ..................... 7. EXHAUST MANIFOLD 11A-7-1 ........................................... 8. ROCKER ARMS AND CAMSHAFT 11A-8-1 .............................. 8a. ROCKER ARMS AND CAMSHAFTS (GDI) 11A-8a-1 ................... 9. CYLINDER HEAD AND VALVES 11A-9-1 ................................ 10. FRONT CASE, COUNTERBALANCE SHAFTS AND OIL PAN 11A-10-1 11. PISTON AND CONNECTING ROD 11A-11-1 ............................. 12. CRANKSHAFT, FLYWHEEL AND DRIVE PLATE 11A-12-1 ............. 11A-0-1 ENGINE 4G6 SERIES CONTENTS Revised PWEE9616-A E Aug. 1998 Mitsubishi Motors Corporation

11A-0-2 PWEE9616 E Dec. 1996 Mitsubishi Motors Corporation NOTES

4G6 ENGINE <E-W> - General Information 11A-0-3 GENERAL INFORMATION SOHC-4G63 Descriptions Specifications Type In-line OHV, SOHC Number of cylinders 4 Combustion chamber Pentroof type Total displacement dm 3 1,997 Cylinder bore mm 85.0 Piston stroke 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 Oil pump type Involute gear type SOHC-4G64 Descriptions Specifications Type In-line OHV, SOHC Number of cylinders 4 Combustion chamber Pentroof type Total displacement dm 3 2,351 Cylinder bore mm 86.5 Piston stroke mm 100.0 Compression ratio 10 Valve timing Intake valve Opens (BTDC) 16_ Closes (ABDC) 53_ Exhaust valve Opens (BBDC) 50_ Closes (ATDC) 16_ Lubrication system Pressure feed, full-flow filtration Oil pump type Involute gear type Revised PWEE9616-A E Aug. 1998 Mitsubishi Motors Corporation

4G6 ENGINE <E-W> - General Information 11A-0-4 GDIt Descriptions Specifications Type In-line OHV, SOHC Number of cylinders 4 Combustion chamber Pentroof + curved top piston type Total displacement dm 3 2,351 Cylinder bore mm 86.5 Piston stroke 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 Oil pump type Involute gear type NOTE GDI is a trademark of Mitsubishi Motors Corporation. Added PWEE9616-A E Aug. 1998 Mitsubishi Motors Corporation

4G6 ENGINE <E-W> - Specifications 11A-1-1 1. SPECIFICATIONS SERVICE SPECIFICATIONS Items Standard value Limit Timing belt Auto-tensioner rod projection length mm 12 - Auto-tensioner rod pushed-in amount [when pushed with a force of 98 - 196 N] mm 1.0 or less - 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 [diesel fuel at 15 - 20_C] seconds/mm 3 - 20/1.0 - Camshaft journal outer diameter mm 45 - Rocker arms and camshaft (GDI) Camshaft cam height mm Intake 35.79 35.29 Exhaust 37.14 36.64 Lash adjuster leak down time [diesel fuel at 15 - 20_C] seconds/mm 3 - 20/1.0 - Camshaft journal outer diameter mm 26 - Cylinder head and valves Cylinder head flatness of gasket surface mm Less than 0.05 0.2 Cylinder head grinding limit of gasket surface mm Total resurfacing depth of both cylinder head and cylinder block - 0.2 Cylinder head overall height mm SOHC 120 - GDI 132 - Cylinder head bolt shank length mm - Maximum 99.4 Valve thickness of valve head (margin) mm SOHC Intake 1.0 0.5 Exhaust 1.2 0.7 GDI Intake 1.0 0.5 Exhaust 1.5 1.0 Valve overall height mm SOHC Intake 112.30 111.80 Exhaust 114.11 113.61 GDI Intake 105.5 105.0 Exhaust 105.7 105.2 Valve stem outer diameter mm 6.0 - Revised PWEE9616-A E Aug. 1998 Mitsubishi Motors Corporation

4G6 ENGINE <E-W> - Specifications 11A-1-2 Items Limit Standard value 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_ - Valve spring free length mm SOHC 51.0 50.0 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 mm 0.9 - 1.3 - Valve guide inner diameter mm SOHC 6.0 - GDI 6.6 - Valve guide projection from cylinder head SOHC 14.0 - upper surface mm GDI 19.5 - Valve stem projection mm SOHC 49.30 49.80 GDI Intake 49.20 49.70 Exhaust 48.40 48.90 Oversize rework dimensions of valve guide 0.05 Oversize diameter 11.05 - 11.07 - hole (SOHC) mm 0.25 Oversize diameter 11.25 - 11.27 - 0.50 Oversize diameter 11.50 - 11.52 - Oversize rework dimensions of valve guide 0.05 Oversize diameter 12.05 - 12.07 - hole (GDI) mm 0.25 Oversize diameter 12.25 - 12.27 - 0.50 Oversize diameter 12.50 - 12.52 - Intake oversize rework dimensions of valve 0.3 Oversize diameter 34.30 - 34.33 - seat hole (SOHC) mm 0.6 Oversize diameter 34.60 - 34.63 - Intake oversize rework dimensions of valve 0.3 Oversize diameter 35.30 - 35.33 - seat hole (GDI) mm 0.6 Oversize diameter 35.60 - 35.63 - Exhaust oversize rework dimensions of 0.3 Oversize diameter 34.30 - 34.33 - valve seat hole (SOHC) mm 0.6 Oversize diameter 34.60 - 34.63 - Exhaust oversize rework dimensions of 0.3 Oversize diameter 33.30 - 33.33 - valve seat hole (GDI) mm 0.6 Oversize diameter 33.60 - 33.63 - Revised PWEE9616-A E Aug. 1998 Mitsubishi Motors Corporation

4G6 ENGINE <E-W> - Specifications 11A-1-3 Items Limit Standard value 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 Piston outer diameter mm 4G63 85.0 - 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 side rail 0.10 - 0.40 1.0 Piston pin outer diameter mm 22.0 - Piston pin press-in load N (Room temperature) 7,350 - 17,200 - Crankshaft pin oil clearance mm 0.02 - 0.05 0.1 Connecting rod big end side clearance mm 0.10 - 0.25 0.4 Crankshaft, flywheel and drive plate Crankshaft end play mm 0.05 - 0.25 0.40 Crankshaft journal outer diameter mm 57.0 - Crankshaft pin outer diameter mm 45.0 - Crankshaft journal oil clearance mm 0.02 - 0.04 0.1 Bearing cap bolt shank length mm - Maximum 71.1 Piston to cylinder clearance mm 0.02 - 0.04 - Cylinder block flatness of gasket surface mm 0.05 0.1 Cylinder block grinding limit of gasket surface mm Total resurfacing depth of both cylinder head and cylinder block - 0.2 Cylinder block overall height mm 4G63 284 - 4G64 290 - Cylinder block inner diameter mm 4G63 85.0 - 4G64 86.5 - Cylindricity mm 0.01 - Revised PWEE9616-A E Aug. 1998 Mitsubishi Motors Corporation

4G6 ENGINE <E-W> - Specifications 11A-1-4 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 level gauge guide 13 Idler pulley bracket (M8) (Vehicle for Hong Kong) 22 Idler pulley bracket (M10) (Vehicle for Hong Kong) 49 Idler pulley (Vehicle for Hong Kong) 49 Intake manifold (GDI) Vacuum pipe and hose (Flange bolt) 11 Vacuum pipe and hose (Bolt, washer assembly) 8.8 Solenoid valve 8.8 Vacuum pipe 11 Throttle body 11 Intake manifold stay (M6) 8.8 Intake manifold stay (M8) 30 Air intake plenum resonator (Flange bolt) 11 Air intake plenum resonator (Bolt, washer assembly) 8.8 EGR valve 23 EGR valve support 23 Intake manifold 19 Timing belt Timing belt cover flange bolt 11 Revised PWEE9616-B E Aug. 1999 Mitsubishi Motors Corporation

4G6 ENGINE <E-W> - Specifications 11A-1-5 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 and emission parts Carburetor (Carburetor) 17 Fuel vapor separator (Carburetor) 23 Throttle body (Multipoint fuel injection) 18 EGR valve (Except General Export) 22 Injectors and delivery pipe (Multipoint fuel injection) 12 Fuel pressure regulator (Multipoint fuel injection) 9 Fuel part (GDI) Fuel low pressure pipe (M6) 8.8 Fuel low pressure pipe (M8) 18 Fuel pump return nipple 8.8 Clamp A 8.8 Fuel pipe bracket 11 Fuel feed pipe 11 Revised PWEE9616-B E Aug. 1999 Mitsubishi Motors Corporation

4G6 ENGINE <E-W> - Specifications 11A-1-6 Items Nm Fuel pump 4.9 ﬁ 17 – 2 Harness bracket 8.8 Fuel return pipe 11 Fuel high pressure regulator 18 Fuel pressure sensor 18 Pump camshaft case 23 Injector holder 22 Delivery pipe and 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 Intake manifold 19 Engine hanger 11 Detonation sensor (Multipoint fuel injection) 23 Water pump and water hose (GDI) Engine coolant temperature sensor 29 Engine coolant temperature gauge unit 11 Water inlet fitting 12 Water outlet fitting 12 Thermostat housing 23 Water inlet pipe 12 Water pump 13 Knock sensor 22 Exhaust manifold Exhaust manifold cover 13 Revised PWEE9616-B E Aug. 1999 Mitsubishi Motors Corporation

MITSUBISHI MAGNA & VERADA Service Repair Manual

You're Reading a Preview

Recently Viewed