Workshop manual engine 4g1 series (ew) mitsubishi
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MITSUBISHI
ENGINE
4G1 SERIES (E - W)
WORKSHOP MANUAL
FOREWORD Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A
This Workshop Manual contains procedures for
removal, disassembly, inspection, adjustment,
reassembly and installation, etc. for service
mechanics.
All information, illustrations and product
descriptions contained in this manual are current
as at the time of publication. We, however, reserve
the right to make changes at any time without
prior notice or obligation.
FILING INSTRUCTION
Please keep these manual pages in the binder
No. BN940001.
File these pages according to the signs
“Added”, “Revised” and “Deleted” on the “List
of effective pages” which are interpreted
below.
Added:
File the pages with this sign additionally in
your manual.
Revised, Deleted:
Replace the existing pages with the
corresponding pages with this sign.
Missing sheets will be supplied upon request.
E Mitsubishi Motors Corporation July 1999 Pub. No. PWEE9520-B
INTRODUCTION
EXPLANATION OF MANUAL CONTENTS
Maintenance and Servicing Procedures D Removal steps:
The part designation number corresponds
(1) A diagram of the component parts is
provided near the front of each section in to the number in the illustration to indicate
order to give the reader a better under- removal steps.
standing of the installed condition of
component parts. D Disassembly steps:
(2) The numbers provided within the diagram The part designation number corresponds
indicate the sequence for maintenance and to the number in the illustration to indicate
servicing procedures.
: Indicates a non-reusable part. disassembly steps.
The tightening torque is provided where D Installation steps:
applicable.
Specified in case installation is impossible
in reverse order of removal steps. Omitted
if installation is possible in reverse order
of removal steps.
D Reassembly steps:
Specified in case reassembly is impossible
in reverse order of disassembly steps.
Omitted if reassembly is possible in reverse
order of disassembly steps.
Classification of Major Maintenance/Service Points
When there are major points relative to maintenance and servicing procedures
(such as essential maintenance and service points, maintenance and service stan-
dard values, information regarding the use of special tools, etc.), these are
arranged together as major maintenance and service points and explained in
detail.
AA" : Indicates that there are essential points for removal or disassembly.
"AA : Indicates that there are essential points for installation or reassembly.
Symbols for Lubrication, Sealants and Adhesives
Information concerning the locations for : Grease (multipurpose grease unless
lubrication and for application of sealants there is a brand or type specified)
and adhesives is provided, by using sym-
bols, in the diagram of component parts, or : Sealant or adhesive
on the page following the component parts
page, and explained. : Brake fluid, automatic transmission fluid
or air conditioner compressor oil
: Engine oil or gear oil
INTRODUCTION
Indicates the Indicates the Indicates the Indicates the Indicates the
group title. section title. group number. section num- page number.
ber.
4G1 ENGINE (E- W) - Water Pump and Water Hose 11A-6-1
6. WATER PUMP AND WATER HOSE Denotes tightening
torque.
REMOVAL AND INSTALLATION <SOHC - CARBURETOR>
Denotes non-reusable part.
1 22 Nm
This number corresponds to
2 27 Nm 87 the number appearing in
“Removal steps”,
27 Nm 23 Nm “Disassembly steps”,
“Installation steps” or
4 11 Nm “Reassembly steps”.
12 5 Operating procedures, cau-
6 tions, etc. on removal, installa-
3 tion, disassembly and reas-
11 sembly are described.
9
10
12 Nm
14
13
13 Nm
"FA Removal steps "CA 8. Thermostat
1. Water hose 9. Thermostat case
"FA "BA 10.Gasket
"DA 2. Water hose "BA 11.Water inlet pipe
"BA 12.O-ring
3. Water hose "AA 13.O-ring
14.Water pump
4. Thermo valve (engines with EGR)
5. (T2h0e)rm5.o valve
Thermo valve
6. Water temperature gauge unit
7. Water inlet timing
INSTALLATION SERVICE POINTS
"AA WATER PUMP INSTALLATION
(1)Apply a 3 mm bead of form-in-place gasket (FIPG) to the
mounting surface.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or equivalent.
E Mitsubishi Motors Corporation Nov. 1995 PWEE9520
Issue date Publication number-Revision code
LIST OF EFFECTIVE PAGES
Page Revision Date Remarks Page Revision Date Remarks
Code Code
11A-0-1 to 11A-0-4 11A-7-1 and 11A-7-2
11A-0-5 to 11A-0-7 Nov. 1995 11A-7-2a Nov. 1995
11A-1-1 and 11A-1-2 11A-7-2b
11A-1-2a and 11A-1-2b A Dec. 1998 11A-7-3 A Dec. 1998
11A-1-3 to 11A-1-5 11A-7-4
11A-1-5a and 11A-1-5b A Dec. 1998 11A-8-1 B July 1999 Revised
11A-1-6 and 11A-1-7 11A-8-1a and 11A-8-1b
11A-2-1 A Dec. 1998 11A-8-2 to 11A-8-10 Nov. 1995
11A-2-2 11A-9-1
11A-3-1 A Dec. 1998 11A-9-1a and 11A-9-1b B July 1999 Added
11A-3-1a and 11A-3-1b 11A-9-2 and 11A-9-3
11A-3-2 and 11A-3-3 A Dec. 1998 11A-9-4 to 11A-9-10 A Dec. 1998
11A-4-1 11A-10-1
11A-4-2 to 11A-4-6 Nov. 1995 11A-10-2 to 11A-10-4 A Dec. 1998
11A-5-1 and 11A-5-2 11A-11-1
11A-5-2a and 11A-5-2b Nov. 1995 11A-11-2 A Dec. 1998
11A-5-3 and 11A-5-4 11A-11-3 and 11A-11-4
11A-6-1 and 11A-6-2 A Dec. 1998 11A-11-5 to 11A-11-8 A Dec. 1998
11A-6-2a and 11A-6-2b 11A-12-1 to 11A-12-7
11A-6-3 to 11A-6-5 A Dec. 1998 A Dec. 1998
A Dec. 1998 Nov. 1995
Nov. 1995 A Dec. 1998
A Dec. 1998 A Dec. 1998
Nov. 1995 Nov. 1995
Nov. 1995 Nov. 1995
A Dec. 1998 A Dec. 1998
Nov. 1995 Nov. 1995
Nov. 1995 A Dec. 1998
A Dec. 1998 A Dec. 1998
Nov. 1995
Missing sheets will be supplied upon request.
E Mitsubishi Motors Corporation July 1999 PWEE9520-B Revised
11A-0-1
ENGINE
4G1 SERIES
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-0-3
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1
REWORK DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-4
NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE
TIGHTENED IN PLASTIC AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-6
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-6
FORM-IN-PLACE GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-7
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
6. WATER PUMP AND WATER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-6-1
7. INTAKE AND EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-7-1
8. ROCKER ARMS AND CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-8-1
9. CYLINDER HEAD AND VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-9-1
10. OIL PUMP AND OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-10-1
11. PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-11-1
12. CRANKSHAFT, CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-12-1
E Mitsubishi Motors Corporation Nov. 1995 PWEE9520
11A-0-2
NOTES
E Mitsubishi Motors Corporation Nov. 1995 PWEE9520
4G1 ENGINE (E - W) - General Information 11A-0-3
GENERAL INFORMATION
E Mitsubishi Motors Corporation Nov. 1995 PWEE9520
11A-0-4 4G1 ENGINE (E - W) - General Information
E Mitsubishi Motors Corporation Nov. 1995 PWEE9520
4G1 ENGINE (E - W) - General Information 11A-0-5
Descriptions 4G13 12-VALVE- CARBURETOR 4G13 12-VALVE- MPI
Type In-line OHV, SOHC In-line OHV, SOHC
Number of cylinders 4 4
Combustion chamber Pentroof type Pentroof type
Total displacement dm3 1,299 1,299
Cylinder bore mm 71.0 71.0
Piston stroke mm 82.0 82.0
Compression ratio 9.5 9.5
Number of Intake 8 8
valves 4 4
BTDC 14_ BTDC 19_
Exhaust ABDC 48_ ABDC 43_
Valve timing Intake opens BBDC 55_ BBDC 60_
ATDC 13_ ATDC 8_
Intake closes Pressure feed, full-flow filtration Pressure feed, full-flow filtration
Exhaust opens Trochoid type Trochoid type
Exhaust closes Water-cooled, forced circulation Water-cooled, forced circulation
Lubrication system Centrifugal impeller type Centrifugal impeller type
Oil pump type
Cooling system
Water pump type
E Mitsubishi Motors Corporation NDoecv. 19958 PPWWEEEE99552200-A Revised
11A-0-6 4G1 ENGINE (E - W) - General Information
Descriptions 4G13 16-VALVE- MPI 4G18 16-VALVE- MPI
Type In-line OHV, SOHC In-line OHV, SOHC
Number of cylinders 4 4
Combustion chamber Pentroof type Pentroof type
Total displacement dm3 1,299 1,584
Cylinder bore mm 71.0 76.0
Piston stroke mm 82.0 87.3
Compression ratio 10 9.5
Number of Intake 8 8
valves 8 8
BTDC 17_ BTDC 17_
Exhaust ABDC 39_ ABDC 39_
Valve timing Intake opens BBDC 49_ BBDC 49_
ATDC 7_ ATDC 7_
Intake closes Pressure feed, full-flow filtration Pressure feed, full-flow filtration
Exhaust opens Trochoid type Trochoid type
Exhaust closes Water-cooled, forced circulation Water-cooled, forced circulation
Lubrication system Centrifugal impeller type Centrifugal impeller type
Oil pump type
Cooling system
Water pump type
E Mitsubishi Motors Corporation NDoecv. 19958 PPWWEEEE99552200-A Revised
4G1 ENGINE (E - W) - General Information 11A-0-7
Descriptions 4G15- CARBURETTOR 4G15- MPI
Type In-line OHV, SOHC In-line OHV, DOHC
Number of cylinders 4 4
Combustion chamber Semi spherical type Pentroof type
Total displacement dm3 1,468 1,468
Cylinder bore mm 75.5 75.5
Piston stroke mm 82.0 82.0
Compression ratio 9.0 9.5
Number of Intake 8 8
valve 4 8
BTDC 14_ BTDC 16_
Exhaust ABDC 48_ ABDC 40_
Valve timing Intake opens BBDC 55_ BBDC 45_
ATDC 13_ ATDC 15 _
Intake closes Pressure feed, full-flow filtration Pressure feed, full-flow filtration
Exhaust opens Trochoid type Trochoid type
Exhaust closes Water-cooled, forced circulation Water-cooled, forced circulation
Lubrication system Centrifugal impeller type Centrifugal impeller type
Oil pump type
Cooling system
Water pump type
E Mitsubishi Motors Corporation NDoecv. 19958 PPWWEEEE99552200-A Added
NOTES
4G1 ENGINE (E - W) - Specifications 11A-1-1
1. SPECIFICATIONS
SERVICE SPECIFICATIONS
Item Standard Limit
Rocker arms, rocker shafts, and camshaft 38.78 38.28
38.78 38.28
Camshaft cam SOHC 12-VALVE Intake (primary) 39.10 38.60
height mm Intake (secondary) 36.99 36.49
36.85 36.35
Exhaust 34.67 38.28
34.26 38.60
SOHC 16-VALVE Intake 45.93 - 45.94 -
25.95 - 25.97 -
Exhaust
0.05 or less -
DOHC Intake - 0.2
Exhaust 106.9 - 107.1 -
119.9 - 120.1 -
Camshaft journal diameter mm SOHC 131.9 - 132.1 -
- 103.2
DOHC 1.0 0.5
1.5 1.0
Cylinder head and valves 6.6 -
5.5 -
Flatness of cylinder head gasket surface mm 5.5 -
0.020 - 0.050 0.10
Cylinder head gasket surface grinding limit (including grinding of 0.050 - 0.085 0.15
cylinder block gasket surface) mm 0.020 - 0.047 0.10
0.030 - 0.062 0.15
Cylinder head overall height mm SOHC 12-VALVE 0.020 - 0.047 0.10
0.030 - 0.062 0.15
SOHC 16-VALVE 45_ - 45.5_ -
43.70 44.20
DOHC 43.30 43.80
53.21 53.71
Cylinder head bolt nominal length mm 54.10 54.60
48.80 49.30
Valve margin mm Intake 48.70 49.20
Exhaust
Valve stem diameter mm SOHC 12-VALVE
SOHC 16-VALVE
DOHC
Valve stem-to-guide SOHC 12-VALVE Intake
clearance mm Exhaust
SOHC 16-VALVE Intake
Exhaust
DOHC Intake
Exhaust
Valve face angle
Valve stem projec- SOHC 12-VALVE Intake
tion mm Exhaust
SOHC 16-VALVE Intake
Exhaust
DOHC Intake
Exhaust
E Mitsubishi Motors Corporation NDoecv. 19958 PPWWEEEE99552200-A Revised
11A-1-2 4G1 ENGINE (E - W) - Specifications
Item Standard Limit
100.75 100.25
Overall valve length SOHC 12-VALVE Intake 101.05 105.55
mm Exhaust 111.56 111.06
Intake 114.71 114.21
SOHC 16-VALVE 106.35 105.85
106.85 106.35
DOHC Exhaust 46.1 45.6
Intake 46.8 46.3
50.9 50.4
Valve spring free SOHC 12-VALVE Exhaust 49.1 48.6
height mm Intake 226/40.0 -
Exhaust 284/39.6 -
216/44.2 -
SOHC 16-VALVE 177/40.0 -
2_ 4_
Valve spring load/ DOHC Intake 0.9 - 1.3 -
installed height N/ SOHC 12-VALVE Exhaust 6.6 -
mm 5.5 -
SOHC 16-VALVE 5.5 -
17.0 -
DOHC 23.0 -
23.0 -
Valve spring squareness
0.06 - 0.18 -
Valve seat contact width mm 0.04 - 0.10 -
0.10 - 0.18 0.35
Valve guide internal diameter mm SOHC 12-VALVE
71.0 -
SOHC 16-VALVE 75.5 -
76.0 -
Valve guide projection mm DOHC 0.02 - 0.06 -
SOHC 12-VALVE 0.02 - 0.06 -
0.20 - 0.35 0.8
SOHC 16-VALVE 0.35 - 0.50 0.8
0.20 - 0.50 1.0
DOHC 18.0 -
4,900 - 14,700 -
Oil pump and oil pan 0.02 - 0.04 0.1
0.10 - 0.25 0.4
Oil pump tip clearance mm
Oil pump side clearance mm
Oil pump body clearance mm
Pistons and connecting rods
Piston outside diameter mm 4G13
4G15
Piston ring side clearance mm 4G18
No. 1 ring
Piston ring end gap clearance No. 2 ring
No. 1 ring
No. 2 ring
Oil ring
Piston pin O. D. mm
Piston pin press-in load (at room temperature) N
Crankshaft pin oil clearance mm
Connecting rod big end side clearance mm
E Mitsubishi Motors Corporation NDoecv. 19958 PPWWEEEE99552200-A Revised
4G1 ENGINE (E - W) - Specifications 11A-1-2a
Item Standard Limit
Crankshaft and cylinder block 0.05 - 0.18 0.25
48.0 -
Crankshaft end play mm 42.0 -
Crankshaft journal diameter mm 0.02 - 0.04 0.1
Crankshaft pin diameter mm 0.05 or less -
Crankshaft journal oil clearance mm - 0.2
Cylinder block gasket surface flatness mm 256 -
0.01 -
Cylinder block gasket surface grinding limit (including grinding of 71.0 -
cylinder head gasket surface) mm 75.5 -
76.0 -
Cylinder block overall height mm 0.02 - 0.04 -
Cylinder block cylindricity mm 4G13
Cylinder block I. D. mm 4G15
4G18
Piston-to-cylinder clearance mm
E Mitsubishi Motors Corporation NDoecv. 19958 PPWWEEEE99552200-A Added
11A-1-2b 4G1 ENGINE (E - W) - Specifications
Intentionally blank
E Mitsubishi Motors Corporation NDoecv. 19958 PPWWEEEE99552200-A Added
4G1 ENGINE (E - W) - Specifications 11A-1-3
REWORK DIMENSIONS SOHC 12-VALVE 0.05 O. S. Standard Limit
0.25 O. S.
Item 0.50 O. S. 12.050 - 12.068 -
0.05 O. S. 12.250 - 12.268 -
Cylinder head and valves 0.25 O. S. 12.500 - 12.518 -
Cylinder head oversize valve guide 0.50 O. S. 10.550 - 10.568 -
hole diameter mm 0.05 O. S. 10.750 - 10.768 -
0.25 O. S. 11.000 - 11.018 -
SOHC 16-VALVE 0.50 O. S. 10.550 - 10.568 -
0.3 O. S. 10.750 - 10.768 -
DOHC 0.6 O. S. 11.000 - 11.018 -
0.3 O. S. 27.300 - 27.325 -
Oversize valve seat SOHC Intake (primary) 0.6 O. S. 27.600 - 27.625 -
ring hole diameter 12-VALVE Intake (secondary) 0.3 O. S. 32.300 - 32.325 -
mm Exhaust 0.6 O. S. 32.600 - 32.625 -
Intake 0.3 O. S. 35.300 - 35.325 -
SOHC Exhaust 0.6 O. S. 35.600 - 35.625 -
16-VALVE Intake 0.3 O. S. 28.300 - 28.321 -
<4G13> Exhaust 0.6 O. S. 28.600 - 28.621 -
Intake 0.3 O. S. 26.300 - 26.321 -
SOHC Exhaust 0.6 O. S. 26.600 - 26.621 -
16-VALVE 0.3 O. S. 30.300 - 30.321 -
<4G18> 0.6 O. S. 30.600 - 30.621 -
0.3 O. S. 28.300 - 28.321 -
DOHC 0.6 O. S. 28.600 - 28.621 -
0.3 O. S. 31.300 - 31.325 -
0.6 O. S. 31.600 - 31.625 -
27.800 - 27.825 -
28.100 - 28.125 -
E Mitsubishi Motors Corporation NDoecv. 19958 PPWWEEEE99552200-A Revised
11A-1-4 4G1 ENGINE (E - W) - Specifications
TORQUE SPECIFICATIONS
Item Nm
Alternator and ignition system
Water pump pulley bolt 9
Alternator brace (alternator side) 22
Alternator brace (tightened with water pump) 23
Alternator pivot bolt 44
Oil level gauge guide 23
Crankshaft bolt 125
Spark plug 25
Distributor 11
Ignition coil 10
Camshaft position sensor 9
Camshaft position sensor support 13
Camshaft position sensing cylinder 21
Timing belt
Timing belt cover 11
Timing belt tensioner 23
Crankshaft angle sensor (Rear wheel drive) 9
Engine support bracket (left) 35
Idler pulley 35
Camshaft sprocket bolt 88
Fuel system
Delivery pipe 11
Fuel pressure regulator 9
Throttle body 18
Fuel pump 11
Breather tube 22
Carburetor 17
Air temperature sensor 13
EGR valve 21
Water pump
Water inlet fitting 22
Water inlet pipe assembly 12
Water inlet pipe M6 12
M8 25
Fitting (Rear wheel drive) 23
Water outlet fitting (Rear wheel drive) 23
Thermostat case 23
E Mitsubishi Motors Corporation NDoecv. 19958 PPWWEEEE99552200-A Revised
4G1 ENGINE (E - W) - Specifications 11A-1-5
Item Nm
27
Thermo valve 11
29
Water temperature gauge unit 13
Water temperature sensor 5
9
Water pump 17
17
Exhaust manifold and intake manifold 21
29
Boost sensor 29
17
Solenoid valve assembly 29
44
Intake manifold
12
Intake manifold stay (MPI) M8 4
31
M10 15
24
Intake manifold stay (carburetor) 11
Exhaust manifold cover 20 + 90_ + 90_
Exhaust manifold M8 23
7
M10 39
18
Oxygen sensor 13
44
Rocker arms, rocker shafts, and camshaft 10
Fuel pump cover 17 + 90_ to 100_
Rocker cover
Rocker shaft assembly
Adjusting screw
Bearing cap
Cylinder head and valves
Cylinder head bolt
Tighten to 49 Nm, then completely loosen and retighten as described.
Oil pump and oil pan
Transmission stay
Oil pan
Drain plug
Oil screen
Front case
Relief plug
Oil pump cover
Pistons and connecting rods
Connecting rod nut
E Mitsubishi Motors Corporation NDoecv. 19958 PPWWEEEE99552200-A Revised
11A-1-5a 4G1 ENGINE (E - W) - Specifications
Item Nm
Crankshaft and cylinder block
Flywheel 132
Drive plate 132
Rear plate 10
Bell housing cover 10
Rear oil seal case 11
Bearing cap bolt 51
Oil pressure switch 18
Knock sensor 23
E Mitsubishi Motors Corporation NDoecv. 19958 PPWWEEEE99552200-A Added
