Mitsubishi 4G92, 4g93, 4g94 engine service service manual

GENERAL INFORMATION 11A-0-3 ........................................... 1. SPECIFICATIONS 11A-1-1 ................................................ SERVICE SPECIFICATIONS 11A-1-1 .................................... REWORK DIMENSIONS 11A-1-4 ........................................ TORQUE SPECIFICATIONS 11A-1-4 ................................... NEW TIGHTENING METHOD- BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA 11A-1-7 ............................... SEALANT 11A-1-7 ........................................................ FORM-IN-PLACE GASKET 11A-1-8 ..................................... 2. SPECIAL TOOLS 11A-2-1 ................................................. 3.ALTERNATOR AND IGNITION SYSTEM 11A-3-1 ........................ 4. TIMING BELT 11A-4-1 ..................................................... 5. FUEL AND EMISSION CONTROL SYSTEM 11A-5-1 ..................... 5a. THROTTLE BODY AND EGR SYSTEM (GDI) 11A-5a-1 ................. 6. INTAKE AND EXHAUST MANIFOLD 11A-6-1 ............................ 6a. INTAKE MANIFOLD (GDI) 11A-6a-1 ...................................... 6b. EXHAUST MANIFOLD (GDI) 11A-6b-1 ................................... 6c.INJECTOR AND FUEL PUMP ASSEMBLY (GDI) 11A-6c-1 ............. 7.WATER PUMP AND WATER HOSE 11A-7-1 .............................. 8. ROCKER ARMS AND CAMSHAFTS 11A-8-1 ............................. 8a. ROCKER COVER AND CAMSHAFTS (MIVEC) 11A-8a-1 ............... 8b. ROCKER ARMS AND ROCKER SHAFT CAPS (MIVEC) 11A-8b-1 ..... 9. CYLINDER HEAD AND VALVES 11A-9-1 ................................. 10. FRONT CASE AND OIL PUMP 11A-10-1 ................................. 11. PISTON AND CONNECTING ROD 11A-11-1 .............................. 12.CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE PLATE 11A-12-1 ........................................................... 11A-0-1 ENGINE 4G9 SERIES CONTENTS PWEE9502-E E Dec. 1998 Mitsubishi Motors Corporation Revised

11A-0-2 PWEE9502 E May 1995 Mitsubishi Motors Corporation NOTES

4G9 ENGINE (E-W) - General Information 11A-0-3 PWEE9502-C E July 1997 Mitsubishi 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 dm 3 1,597 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 E July 1997 Mitsubishi 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 dm 3 1,834 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) mm 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* 1 Intake 37.34 36.84 height mm 4G92-SOHC* Exhaust 36.79 36.29 4G92-SOHC* 2 Intake 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* 3 Intake 35.49 34.99 Exhaust 34.91 34.41 4G93-DOHC-GDI* 4 Intake 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 E Dec. 1998 Mitsubishi 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 E Dec. 1998 Mitsubishi Motors Corporation Revised

4G9 ENGINE (E-W) - Specifications 11A-1-3 Items Limit Standard 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 E Dec. 1998 Mitsubishi 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 E Dec. 1998 Mitsubishi 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 E Dec. 1998 Mitsubishi 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 E Dec. 1998 Mitsubishi Motors Corporation Revised

Mitsubishi 4G92, 4g93, 4g94 engine service service manual

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