GENERAL INFORMATION 11A03 ........................................... 1. SPECIFICATIONS 11A11 ................................................. SERVICE SPECIFICATIONS 11A11 .................................... REWORK DIMENSIONS 11A13 ........................................ TORQUE SPECIFICATIONS 11A14 ..................................... NEW TIGHTENING METHOD BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA 11A16 ............................... SEALANT 11A16 ........................................................ FORMINPLACE GASKET 11A17 ...................................... 2. SPECIAL TOOLS 11A21 ................................................. 3. ALTERNATOR AND IGNITION SYSTEM 11A31 ........................ 4. TIMING BELT 11A41 ...................................................... 5. FUEL AND EMISSION CONTROL SYSTEM 11A51 .................... 6. WATER PUMP AND WATER HOSE 11A61 ............................. 7. INTAKE AND EXHAUST MANIFOLD 11A71 ............................ 8. ROCKER ARMS AND CAMSHAFT 11A81 .............................. 9. CYLINDER HEAD AND VALVES 11A91 ................................. 10. OIL PUMP AND OIL PAN 11A101 ....................................... 11. PISTON AND CONNECTING ROD 11A111 .............................. 12. CRANKSHAFT, CYLINDER BLOCK
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 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