Mitsubishi 4G6 series Manuale di istruzioni

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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TORQUE SPECIFICATIONS 11A-1-4

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NEW TIGHTENING METHOD -

BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA 11A-1-9

SEALANTS 11A-1-9

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FORM-IN-PLACE GASKET 11A-1-10

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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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3a. INTAKE MANIFOLD (GDI) 11A-3a-1

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4. TIMING BELT 11A-4-1

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4a. EXHAUST MANIFOLD (GDI) 11A-4a-1

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

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5a. FUEL PARTS (GDI) 11A-5a-1

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6. WATER PUMP AND INTAKE MANIFOLD 11A-6-1

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6a. WATER PUMP AND WATER HOSE (GDI) 11A-6a-1

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7. EXHAUST MANIFOLD 11A-7-1

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

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8a. ROCKER ARMS AND CAMSHAFTS (GDI) 11A-8a-1

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

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10. FRONT CASE, COUNTERBALANCE SHAFTS AND OIL PAN 11A-10-1

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

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12. CRANKSHAFT, FLYWHEEL AND DRIVE PLATE 11A-12-1

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11A-0-1

ENGINE

4G6 SERIES

CONTENTS

RevisedPWEE9616-A

EAug. 1998Mitsubishi Motors Corporation

11A-0-2

PWEE9616

EDec. 1996Mitsubishi 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 dm31,997

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 dm32,351

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

RevisedPWEE9616-A

EAug. 1998Mitsubishi 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 dm32,351

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.

AddedPWEE9616-A

EAug. 1998Mitsubishi 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 -

RevisedPWEE9616-A

EAug. 1998Mitsubishi Motors Corporation

4G6 ENGINE <E-W> - Specifications

11A-1-2

Items LimitStandard 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 -

RevisedPWEE9616-A

EAug. 1998Mitsubishi Motors Corporation

4G6 ENGINE <E-W> - Specifications 11A-1-3

Items LimitStandard 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 -

RevisedPWEE9616-A

EAug. 1998Mitsubishi 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

RevisedPWEE9616-B

EAug. 1999Mitsubishi 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

RevisedPWEE9616-B

EAug. 1999Mitsubishi Motors Corporation

4G6 ENGINE <E-W> - Specifications

11A-1-6

Items Nm

Fuel pump 4.9 ®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

RevisedPWEE9616-B

EAug. 1999Mitsubishi Motors Corporation

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