General Mitsubishi Workshop Manual of 4G9 engine (4G92, 4G93, 4G94), that are mounted on Lancer, Carisma, Pajero, Galant, Space Star, Space Runner either with MIVEC, GDI, SOHC or DOHC. 4G92 SOHC and 4G92 DOHC MIVEC engine also are used on Mitsubishi Colt sixth generation (19922000), a super mini car built by Mitsubishi. This document mostly gives information on general maintenance on overhaul of Mitsubishi engine type above, inspecting and adjusting also given, with pictures and words work together explains things quickly.
11A-0-1 ENGINE 4G9 SERIES CONTENTS GENERAL INFORMATION 11A-0-3 SPECIFICATIONS 11A-1-1 www.mivec.co.nz SERVICE SPECIFICATIONS 11A-1-1 REWORK DIMENSIONS 11A-1-4 TORQUE SPECIFICATIONS 11A-1-5 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 SPECIAL TOOLS 11A-2-1 ALTERNATOR AND IGNITION SYSTEM 11A-3-1 TIMING BELT 11A-4-1 FUEL AND EMISSION CONTROL SYSTEM 11A-5-1 5a THROTTLE BODY AND EGR SYSTEM (GDI) 11A-5a-1 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 6d INTAKE AND EXHAUST MANIFOLD 11A-6d-1 WATER PUMP AND WATER HOSE 11A-7-1 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 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 E Mitsubishi Motors Corporation Mar 2001 PWEE9502-I Revised 11A-0-2 www.mivec.co.nz NOTES Ε Mitsubishi Motors Corporation May 1995 PWEE9502 4G9 ENGINE (E - W) - General Information 11A-0-3 GENERAL INFORMATION Dεσχριπτιονσ 4Γ92− ΣΟΗΧ 4Γ92− DΟΗΧ− ΜΙςΕΧ Τψπε Ιν−λινε ΟΗς, ΣΟΗΧ Ιν−λινε ΟΗς, DΟΗΧ Νυmβερ οφ χψλινδερσ 4 Χοmβυστιον χηαmβερ Πεντροοφ τψπε Πεντροοφ τψπε Τοταλ δισπλαχεmεντ δm3 1,597 1,597 Χψλινδερ βορε mm 81.0 81.0 Πιστον στροκε mm 77.5 77.5 Χοmπρεσσιον ρατιο 10.0 11.0 Οπενσ (ΒΤDΧ) 20_, 14_∗ 17_ (Λοω−σπεεδ χαm) 47.5_ (Ηιγη−σπεεδ χαm) Χλοσεσ (ΑΒDΧ) 42_, 58_∗ 31_ (Λοω−σπεεδ χαm) 72.5_ (Ηιγη−σπεεδ χαm) Οπενσ (ΒΒDΧ) 54_, 52_∗ 41_ (Λοω−σπεεδ χαm) 70_ (Ηιγη−σπεεδ χαm) Χλοσεσ (ΑΤDΧ) 2_, 16_∗ 11_ (Λοω−σπεεδ χαm) 35_ (Ηιγη−σπεεδ χαm) Λυβριχατιον σψστεm Πρεσσυρε φεεδ, φυλλ−φλοω φιλτρατιον Πρεσσυρε φεεδ, φυλλ−φλοω φιλτρατιον Οιλ πυmπ τψπε Τροχηοιδ τψπε Τροχηοιδ τψπε Χοολινγ σψστεm Wατερ−χοολεδ φορχεδ χιρχυλατιον Wατερ−χοολεδ φορχεδ χιρχυλατιον Wατερ πυmπ τψπε Χεντριφυγαλ ιmπελλερ τψπε Χεντριφυγαλ ιmπελλερ τψπε ςαλϖε τιmινγ Ιντακε ϖαλϖε Εξηαυστ ϖαλϖε ∗: ΛΑΝΧΕΡ φορ γενεραλ εξπορτ ανδ ΧΑΡΙΣΜΑ φορ 6Β mοδελ Ε Mitsubishi Motors Corporation July 1997 PWEE9502-C Revised www.mivec.co.nz 4G92 11Α−0−4 4Γ9 ΕΝΓΙΝΕ (Ε − W) − Γενεραλ Ινφορmατιον Dεσχριπτιονσ 4Γ93 − ΣΟΗΧ 4Γ93 − DΟΗΧ 4Γ93 − DΟΗΧ − ΓDΙ Τψπε Ιν−λινε ΟΗς, ΣΟΗΧ Ιν−λινε ΟΗς, DΟΗΧ Ιν−λινε ΟΗς, DΟΗΧ Νυmβερ οφ χψλινδερσ 4 Χοmβυστιον χηαmβερ Πεντροοφ τψπε Πεντροοφ τψπε Πεντροοφ τψπε Τοταλ δισπλαχεmεντ δm3 1,834 1,834 1,834 Χψλινδερ βορε mm 81.0 81.0 81.0 Πιστον στροκε mm 89.0 89.0 89.0 Χοmπρεσσιον ρατιο 10.0, 9.5 10.5 11.7∗1, 12.0∗2 Οπενσ (ΒΤDΧ) 14_ 20_ 15_ Χλοσεσ (ΑΒDΧ) 50_ 60_ 56_ Οπενσ (ΒΒDΧ) 58_ 61_ 55_ Χλοσεσ (ΑΤDΧ) 10_ 15_ 15_ ςαλϖε τιmινγ Ιντακε ϖαλϖε Εξηαυστ ϖαλϖε Λυβριχατιον σψστεm Πρεσσυρε φεεδ, φλοω φιλτρατιον Οιλ πυmπ τψπε Τροχηοιδ τψπε Χοολινγ σψστεm Wατερ−χοολεδ χιρχυλατιον Wατερ πυmπ τψπε Χεντριφυγαλ τψπε φυλλ− Πρεσσυρε φεεδ, φλοω φιλτρατιον φυλλ− Τροχηοιδ τψπε φορχεδ ιmπελλερ Wατερ−χοολεδ χιρχυλατιον Χεντριφυγαλ τψπε Πρεσσυρε φεεδ, φλοω φιλτρατιον φυλλ− Τροχηοιδ τψπε φορχεδ ιmπελλερ Wατερ−χοολεδ χιρχυλατιον Χεντριφυγαλ τψπε φορχεδ ιmπελλερ ∗1: Υπ το 1999 mοδελ ∗2: Φροm 2000 mοδελ Ε Μιτσυβισηι Μοτορσ Χορπορατιον Μαψ 2000 ΠWΕΕ9502−Γ Ρεϖισεδ www.mivec.co.nz 4Γ93 4G9 ENGINE (E–W) – General Information 11A-0-5 Descriptions 4G94–SOHC 4G94–DOHC–GDI Type In-line OHV, SOHC In-line OHV, DOHC Number of cylinders 4 Combustion chamber Pentroof type Pentroof type Total displacement dm3 1,999 1,999 Cylinder bore mm 81.5 81.5 Piston stroke mm 95.8 95.8 Compression ratio 9.5 10.6 Opens (BTDC) 2_ 15_ Closes (ABDC) 58_ 51_ Opens (BBDC) 58_ 55_ Closes (ATDC) 10_ 15_ 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 Valve timing Intake valve Exhaust valve E Mitsubishi Motors Corporation July 2001 1997 Mar PWEE9502-C PWEE9502-I www.mivec.co.nz 4G94 Revised Revised 11A-1-1 4G9 ENGINE (E–W) – Specifications SPECIFICATIONS SERVICE SPECIFICATIONS Standard value Limit Auto-tensioner rod protrusion amount (When removed from engine) mm 11 – Auto-tensioner rod stroke mm Within – Auto-tensioner rod protrusion amount (When checking with installed on engine) mm 3.8 – 4.5 – Intake 37.34 36.84 Exhaust 36.79 36.29 Intake 37.78 37.28 Exhaust 37.83 37.33 Intake 36.92 36.42 Exhaust 36.70 36.65 Intake 37.53 37.03 Exhaust 37.64 37.14 Intake 37.11 36.61 Exhaust 37.15 36.65 Intake 37.91 37.41 Exhaust 37.70 37.20 Intake 35.31 34.81 Exhaust 35.20 34.70 Intake 35.49 34.99 Exhaust 34.73 34.23 Intake 35.49 34.99 Exhaust 34.91 34.41 Intake 0.09 – Exhaust 0.20 – SOHC 26.0 – DOHC 45.0 – Intake A 36.41 36.91 Intake B 33.58 33.08 Exhaust A 35.83 35.33 Exhaust B 34.24 33.74 Intake 0.1 – Exhaust 0.2 – Items Timing belt Camshaft cam height mm G S C1 4G92–SOHC* G S C2 4G92–SOHC* G S C3 4G92–SOHC* G S C4 4G93–SOHC* 4G93–SOHC* G S C5 4G94–SOHC S C 4G93–DOHC G C 4G93–DOHC–GDI 4G93 DOHC GDI 4G94–DOHC–GDI 4G94 DOHC GDI Valve clearance mm Camshaft journal O.D mm www.mivec.co.nz Rocker arms and camshaft Rocker cover and camshaft (MIVEC) Camshaft height mm Valve clearance (cold engine) mm *1: *2: *3: *4: *5: LANCER for Europe and CARISMA for Europe LANCER for general export and CARISMA for 6B model LANCER for Europe (from 2001 model) and CARISMA for Europe (from 2001 model) Except for Europe For Europe E Mitsubishi Motors Corporation Jun 2002 PWEE9502-K Revised 11A-1-2 4G9 ENGINE (E–W) – Specifications Items Standard value Limit 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* 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 – Intake 1.0 0.5 Exhaust 1.3 0.8 Intake 1.0 0.5 Exhaust 1.2 0.7 Intake 110.15 109.65 Exhaust 113.70 113.20 Intake 104.19 103.69 Exhaust 103.87 103.37 Intake 115.63 115.13 Exhaust 115.63 115.13 Intake 104.19 103.69 Exhaust 103.87 103.37 SOHC (with lash adjuster) 50.9 49.9 SOHC (with adjusting screw) 49.5 48.5 DOHC 45.0 44.0 DOHC–MIVEC 51.5 50.5 DOHC–GDI 44.8 43.8 Max 2_ 4_ Thickness of valve head (margin) mm SOHC DOHC Valve overall height mm SOHC DOHC DOHC–MIVEC DOHC–GDI Valve spring free length mm Valve spring out-of-squareness Valve stem to valve guide clearance mm Except DOHC–GDI for PAJERO io Intake 0.02 – 0.05 0.10 Exhaust 0.05 – 0.09 0.15 DOHC–GDI for PAJERO io Intake 0.02 – 0.05 0.10 Exhaust 0.04– 0.06 0.15 0.9 – 1.3 – SOHC 14.0 – DOHC 19.0 – Valve seat valve contact width mm Valve guide projection from cylinder head upper pper surface s rface mm E Mitsubishi Motors Corporation Jun 2002 PWEE9502-K www.mivec.co.nz Cylinder head and valve Revised Items Standard value Limit Intake 49.30 49.80 Exhaust 49.35 49.85 Intake 46.70 47.20 Exhaust 46.65 47.15 Intake 58.13 58.63 Exhaust 57.85 58.35 Intake 46.70 47.20 Exhaust 46.65 47.15 Cylinder head bolt shank length mm – 96.4 Valve stem O.D mm 6.0 – Valve face angle 45_ – 45.5_ – SOHC 216/44.2 – DOHC 255/44.5 – DOHC–MIVEC 255/44.5 – DOHC–GDI 196/37.5 – 6.0 – 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 Valve stem projection mm SOHC DOHC DOHC–MIVEC DOHC–GDI Valve spring load/installed height N/mm Valve guide I.D mm www.mivec.co.nz 11A-1-3 4G9 ENGINE (E–W) – Specifications Font case, oil pump and oil pan Piston and connecting rod Piston ring to piston ring groove clearance mm No 0.03 – 0.07 0.1 No 0.02 – 0.06 0.1 Piston ring end gap mm 4G92, 4G93 0.25 – 0.40 0.8 4G94 0.15 – 0.30 0.8 0.40 – 0.55 0.8 SOHC (4G92, 4G93) 0.20 – 0.60 1.0 SOHC (4G94), 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 – 4G92, 4G93 81.0 – 4G94 81.5 – 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* No No Oil ring Piston O.D mm Crankshaft, cylinder block, flywheel and drive plate E Mitsubishi Motors Corporation Mar 2001 PWEE9502-I Revised 11A-1-4 4G9 ENGINE (E–W) – Specifications Items Standard value Limit 4G92 243.5 – 4G93 263.5 – 4G94 286.7 – 4G92, 4G93 81.0 – 4G94 81.5 – 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 – Cylinder block overall height mm Cylinder block I.D mm REWORK DIMENSIONS Items Standard value Oversize rework dimensions of valve guide hole (both intake and exhaust) mm Oversize rework dimensions of intake valve seat hole mm SOHC DOHC Oversize rework dimensions of exhaust valve seat hole mm SOHC DOHC 0.05 O.S 11.05 – 11.07 0.25 O.S 11.25 – 11.27 0.50 O.S 11.50 – 11.52 0.30 O.S 31.80 – 31.83 0.60 O.S 32.10 – 32.13 0.30 O.S 34.30 – 34.32 0.60 O.S 34.60 – 34.62 0.30 O.S 29.30 – 29.32 0.60 O.S 29.60 – 29.62 0.30 O.S 30.80 – 30.82 0.60 O.S 31.10 – 31.13 www.mivec.co.nz Cylinder head and valve 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 E Mitsubishi Motors Corporation Mar 2001 PWEE9502-I Revised 4G9 ENGINE (E–W) – Specifications 11A-1-5 TORQUE SPECIFICATIONS Items Nm Oil level gauge 13 Distributor 12 Ignition coil 10 Spark plug 25 Crankshaft bolt 182 ± Alternator brace (M8) 23 Alternator brace (M10) 49 Lock bolt 23 Adjusting bolt 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 Ignition failure sensor (M6) Ignition failure sensor (M8) 23 Ignition failure sensor bracket 10 Cam position sensor Cam position sensor support 13 Cam position sensing cylinder 21 Engine cover 2.9 www.mivec.co.nz Alternator and ignition system Timing belt Camshaft sprocket bolt 88 Cam position sensor 9.8 Crank angle sensor 9.8 Timing belt rear cover 11 Timing belt rear upper 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 E Mitsubishi Motors Corporation Jun 2002 PWEE9502-K Revised 4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate 11A-12-1 12 CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE PLATE REMOVAL AND INSTALLATION (MANUAL TRANSMISSION) 23 Nm SPACE STAR 10 Nm 19 11 21 10 98 Nm 20 17 16 15 98 Nm A Flange 10 Nm Washer Nm 14 Apply engine oil to all moving parts before installation 13 12 Nm Removal steps Flywheel bolt Flywheel "FA Flywheel bolt Plate Adapter plate Flywheel Adapter plate Rear plate Bell housing cover "EA 10 Rear oil seal case "DA 11 Oil seal 12 Baffle plate "FA "CA 13 Bearing cap bolt "CA 14 Bearing cap "BA 15 Crankshaft bearing, lower 16 Crankshaft "BA 17 Thrust plate "BA 18 Crankshaft bearing, upper 19 Knock sensor AA" "AA 20 Oil jet 21 Cylinder block www.mivec.co.nz 11 Nm 18 Caution On the flexible wheel equipped engines, not remove any of the bolts “A” of the flywheel shown in the illustration The balance of the flexible flywheel is adjusted in an assembled condition Removing the bolt, therefore, can cause the flexible flywheel to be out of balance, giving damage to the flywheel E Mitsubishi Motors Corporation July 1997 Apr 2002 PWEE9502-C PWEE9502-J Revised Revised 11A-12-1a 4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate REMOVAL AND INSTALLATION (AUTOMATIC TRANSMISSION) SPACE STAR 10 Nm Except SPACE STAR 11 Nm 23 Nm 18 10 20 98 Nm 11 Nm 19 16 15 98 Nm 14 Flange 10 Nm Washer Nm 13 Apply engine oil to all moving parts before installation 12 11 Nm "FA "FA "EA "DA Removal steps Flywheel bolt Adapter plate Drive plate Drive plate bolt Adapter plate Drive plate Rear plate Bell housing cover Rear oil seal case 10 Oil seal 11 Baffle plate E Mitsubishi Motors Corporation Apr 2002 "CA 12 Bearing cap bolt "CA 13 Bearing cap "BA 14 Crankshaft bearing, lower 15 Crankshaft "BA 16 Thrust plate "BA 17 Crankshaft bearing, upper 18 Knock sensor AA" "AA 19 Oil jet 20 Cylinder block PWEE9502-J Revised www.mivec.co.nz 17 4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate 11A-12-1b REMOVAL AND INSTALLATION Apply engine oil to all moving parts before installation 12 23 Nm 22 11 Nm 15 23 98 Nm 14 11 Nm www.mivec.co.nz 21 98 Nm 13 20 19 A Flange bolt 10 Nm Bolt, washer assembly Nm 18 11 17 98 Nm 10 16 Removal steps Flywheel bolt Flywheel "FA Flywheel bolt Plate Adapter plate Flywheel Adapter plate "FA Drive plate bolt Adapter plate 10 Drive plate 11 Crankshaft adaptor 12 Rear plate "FA "EA "DA "CA "CA "BA "BA "BA 13 Bell housing cover 14 Rear oil seal case 15 Oil seal 16 Bearing cap bolt 17 Bearing cap 18 Crankshaft bearing, lower 19 Crankshaft 20 Thrust plate 21 Crankshaft bearing, upper 22 Knock sensor 23 Cylinder block Caution On the flexible wheel equipped engines, not remove any of the bolts “A” of the flywheel shown in the illustration The balance of the flexible flywheel is adjusted in an assembled condition Removing the bolt, therefore, can cause the flexible flywheel to be out of balance, giving damage to the flywheel E Mitsubishi Motors Corporation Jun 2002 PWEE9502-K Revised 11Α−12−2 4Γ9 ΕΝΓΙΝΕ (Ε − W) − Χρανκσηαφτ, Χψλινδερ Βλοχκ, Φλψωηεελ ανδ Dριϖε Πλατε ΡΕΜΟςΑΛ ΣΕΡςΙΧΕ ΠΟΙΝΤ ΑΑ∀ ΟΙΛ ϑΕΤ ΡΕΜΟςΑΛ (1) Κνοχκ ουτ τηε οιλ ϕετσ υσινγ αν αππροπριατε mεταλ ροδ Χαυτιον Βε χαρεφυλ νοτ το σχρατχη τηε χψλινδερ ωαλλ Dο νοτ ρευσε τηε ρεmοϖεδ οιλ ϕετσ ΙΝΣΤΑΛΛΑΤΙΟΝ ΣΕΡςΙΧΕ ΠΟΙΝΤΣ Χηεχκ διγιτ Νο Νο Νο Νο Νο Χρανκ πιν Ο.D ιδεντιφι− χατιον mαρκ ϑουρναλ Ο.D ιδεντιφι− χατιον mαρκ ∀ΒΑ ΧΡΑΝΚΣΗΑΦΤ ΒΕΑΡΙΝΓ ΙΝΣΤΑΛΛΑΤΙΟΝ (1) Wηεν τηε βεαρινγσ αρε το βε ρεπλαχεδ, σελεχτ χορρεχτ ονεσ ανδ ινσταλλ τηεm ιν τηε χορρεχτ ποσιτιονσ αχχορδινγ το τηε ιδεντιφιχατιον mαρκσ σταmπεδ ον τηε χρανκσηαφτ ανδ τηε τοπ συρφαχε οφ τηε χψλινδερ βλοχκ Χρανκσηαφτ ϕουρναλ Χψλινδερ βλοχκ βεαρινγ βορε Χρανκσηαφτ βεαρινγ Ιδεντιφιχατιον mαρκ Ιδεντιφιχατιον mαρκ Ιδεντιφιχατιον mαρκ (σερϖιχε παρτσ) Ιδεντιφιχατιον χολουρ (Λινε προδυχτιον παρτσ) Σ1 Βροων Σ2 Βλαχκ Σ3 Γρεεν Σ2 Βλαχκ Σ3 Γρεεν Σ4 Ψελλοω Σ3 Γρεεν Σ4 Ψελλοω Σ5 Πινκ∗ ∗: Ολδερ βεαρινγσ mαψ βε mαρκεδ ιν ρεδ Ε Μιτσυβισηι Μοτορσ Χορπορατιον Νοϖ 1995 Μαψ 2000 ΠWΕΕ9502−Α ΠWΕΕ9502−Γ Ρεϖισεδ Ρεϖισεδ www.mivec.co.nz ∀ΑΑ ΟΙΛ ϑΕΤ ΙΝΣΤΑΛΛΑΤΙΟΝ (1) Υσινγ α 4.5 mm διαmετερ πιν πυνχη, δριϖε ιν τηε οιλ ϕετ το τηε χρανκσηαφτ ϕουρναλ υντιλ ιτ σεατσ το τηε βοττοm 4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate 11A-12-3 P P view No.5 No.4 No.3 No.2 Oil pan view www.mivec.co.nz No.1 Cylinder head view (Reference) Timing belt side Timing belt side No No No No No No No Oil groove Grooves Identification mark No No No (2) Install the bearings having an oil groove to the cylinder block (3) Install the bearings having no oil groove on the bearing caps (4) Install the thrust bearings at the No upper bearing with the grooved side towards the crank web IdentificaIdentification tion colour Identification colour colour E Mitsubishi Motors Corporation Nov 2001 1995 Mar PWEE9502-A PWEE9502-I Revised Revised 11A-12-4 4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate "CA BEARING CAP/BEARING CAP BOLT INSTALLATION (1) Install the bearing caps so that their arrows are positioned on the time belt side (2) When installing the bearing cap bolts, check that the shank length of each bolt meets the limit If the limit is exceeded, replace the bolt Limit: max 71.1 mm (3) Apply engine oil to the threaded portion and bearing surface of the bolt Length of shank (8) (7) (4) (1) (5) (9) (3) (2) (6) (10) www.mivec.co.nz (4) Tighten the bearing cap bolts to 25 Nm torque in the tightening sequence Arrow Paint marks Paint marks 90_ – 100_ (5) Make a paint mark on the head of each bolt (6) Make a paint mark on the area around the bolt bearing surface at location 90_ to 100_ in the direction of tightening the bolt, as referenced from the paint mark on the bolt head (7) Give a 90_ to 100_ turn to the bolts in the tightening sequence Make sure that the paint mark on the bolt and that on the area around the bolt bearing surface are in alignment Caution If the bolt is turned less than 90_, proper fastening performance may not be expected When tightening the bolt, therefore, be careful to give a sufficient turn to it If the bolt is overtightened (exceeding 100_), loosen the bolt completely and then retighten it by repeating the tightening procedure from step (1) (8) After installing the bearing caps, make sure that the crankshaft turns smoothly and the end play is correct If the end play exceeds the limit, replace crankshaft bearings Standard value: 0.05 – 0.25 mm Limit: 0.4 mm E Mitsubishi Motors Corporation Nov 2001 1995 Mar PWEE9502-A PWEE9502-I Revised Revised 4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate 11A-12-5 "DA OIL SEAL INSTALLATION MB990938 MD998776 "EA SEALANT APPLICATION TO OIL SEAL CASE Part No MD970389 or www.mivec.co.nz Specified sealant: Mitsubishi Genuine equivalent "FA DRIVE PLATE BOLT/FLYWHEEL BOLT INSTALLATION (1) Remove all the ramaining sealant from bolts and thread holes of crankshaft (2) Apply engine oil to the flange of bolt (3) Apply engine oil into the thread holes of crankshaft (4) Apply specified sealant to the thread of bolts Specified sealant: 3M Nut Locking Part No 4171 or equivalent (5) Tighten the bolts to specified torque INSPECTION Plastigauge CRANKSHAFT JOURNAL OIL CLEARANCE (PLASTIGAUGE METHOD) (1) Remove oil from the crankshaft journal and he crankshaft bearing (2) Install the crankshaft (3) Cut the Plastigauge to the same length as the width of bearing and place it on the journal in parallel with its axis (4) Install the crankshaft bearing cap carefully and tighten the bolts to the specified torque (5) Carefully remove the crankshaft bearing cap (6) Measure the width of the Plastigauge at its widest part by using a scale printed on the Plastigauge package Standard value: 0.02 – 0.04 mm Limit: 0.1 mm Plastigauge E Mitsubishi Motors Corporation Nov 2001 1995 Mar PWEE9502-A PWEE9502-I Revised Revised 11A-12-6 4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate CYLINDER BLOCK (1) Using a straightedge and thickness gauge, check the block top surface for warpage Make sure that the surface is free from gasket chips and other foreign matter Standard value: 0.05 mm or less Limit: 0.1 mm (2) If the distortion is excessive, correct within the allowable limit or replace Grinding limit: 0.2 mm The total thickness of the stock allowed to be removed from cylinder block and mating cylinder head 0.2 mm at maximum Cylinder block height (when new): 243.5 mm 263.5 mm 286.7 mm www.mivec.co.nz (3) Check the cylinder walls for scratches and seizure If defects are evident, correct (bored to oversize) or replace (4) Using a cylinder gauge, measure the cylinder bore and cylindricity If worn badly, correct the cylinder to an oversize and replace the piston and piston rings Measure at the points shown in illustration A B Standard value: 12 mm Cylinder inner diameter: 4G92, 4G93 81.00 – 81.03 mm 4G94 81.50 – 81.53 mm Centre Bottom Out-of-roundness and taper of cylinder bore: 0.01 mm or less BORING CYLINDER (1) Oversize pistons to be used should be determined on the basis of the largest bore cylinder Piston size identification Thrust direction Piston O.D Size Identification mark 0.50 mm O.S 0.50 1.00 mm O.S 1.00 NOTE Size mark is stamped on the piston top (2) Measure outside diameter of piston to be used Measure it in thrust direction as shown (3) Based on the measured piston O.D., calculate the boring finish dimension Boring finish dimension = Piston O.D + (Clearance between piston O.D and cylinder) – 0.02 mm (honing margin) (4) Bore all cylinders to the calculated boring finish dimension E Mitsubishi Motors Corporation Nov 2001 1995 Mar PWEE9502-A PWEE9502-I Revised Revised 4G9 ENGINE (E–W) – Crankshaft, Cylinder Block, Flywheel and Drive Plate 11A-12-7 Caution To prevent distortion that may result from temperature rise during honing, bore cylinders, in the order of No 2, No 4, No.1 and No (5) Hone to the final finish dimension (Piston O.D + clearance between piston O.D and cylinder.) (6) Check the clearance between piston and cylinder Clearance between piston and cylinder: 0.02 – 0.04 mm www.mivec.co.nz NOTE When boring cylinders, finish all of four cylinders to the same oversize Do not bore only one cylinder to an oversize HYDRO-FLYWHEEL (1) Check the rear side of the flywheel for color of the hatched area A in the illustration, and determine whether it is serviceable or not in accordance with the criteria given in the following table A If judged unendurable for reuse, replace the flywheel assembly 4ME0272 Flywheel Distance moved Color Purple Judgment Reusable Dark blue Light blue Gray Not reusable (2) Measure the play in the circumferential direction using the following procedure (3) Turn the flywheel clockwise and anticlockwise to measure the distance over which the dowel pin moves freely Limit: mm Dowel pin 4ME0273 (4) Check the friction surface for runout in the following manner (5) Apply a thrust force of approx 98 N by hand on the flywheel to move it in the axial direction, and measure the runout at the dowel pin position If the limit is exceeded, replace the flywheel assembly Runout Dowel pin Limit: 0.75 mm Flywheel 4ME0274 E Mitsubishi Motors Corporation Nov 2001 1995 Mar PWEE9502-A PWEE9502-I Revised Revised NOTES www.mivec.co.nz Σερϖιχε Βυλλετινσ www.mivec.co.nz Χλιχκ ον τηε αππλιχαβλε βοοκmαρκ το σελεχτ τηε Σερϖιχε Βυλλετιν SERVICE BULLETIN QUALITY INFORMATION ANALYSIS OVERSEAS SERVICE DEPT MITSUBISHI MOTORS CORPORATION SERVICE BULLETIN Subject: Group: No.: MSB-99E11-001 Date: 1999-12-15 CHANGE IN POSITIONS OF CRANKSHAFT IDENTIFICATION MARKS Draft No.: 99EN531509 ENGINE INFORMATION INTERNATIONAL CAR ADMINISTRATION OFFICE T.NITTA - PROJECT LEADER AFTER SALES SERVICE & CS PROMOTION (EC) COLT (CJ,CK) (EC) LANCER (CJ,CK) (EC) SPACE STAR (DG1A, DG5A) (EC) CARISMA (EC) SPACE RUNNER (N60,N90) (EC) PAJERO iO (H6, H7) 96-10 96-10 96-10 96-10 96-10 96-10 This Service Bulletin informs you that the journal O.D identification marks and the pin O.D identification marks have been changed in their positions Applicable Manuals: Manual ’98 4G9 Series (E-W) Engine Supplement ’96 4G9 Series Engine Supplement Effective Date: From September 1997 Effective model: 4G93-G-10Z3K (HP9123) Pub No PWEE9502-E PWES9503-E PWEF9504-E PWEG9505-E PWED9506-E PWEW9507-E PWEE9101-E PWES9102-E PWEF9103-E PWEG9104-E PWED9105-E PWEW9106-E Language Page(s) (English) 11A-12-2 (Spanish) (French) (German) (Dutch) (Swedish) (English) 11A-18-6 (Spanish) (French) (German) (Dutch) (Swedish) www.mivec.co.nz Description: • Crankshaft weight Front Journal O.D identification mark Journal O.D identification mark Pin O.D identification mark New Old www.mivec.co.nz Pin O.D identification mark SERVICE PUBLICATION & TRAINING INTERNATIONAL AFTER-SALES DEPARTMENT MITSUBISHI MOTORS CORPORATION NO : MSB–03E11–001 DATE : 2003–01–20 DISUSE OF INJECTOR BACKUP RINGS IN GDI ENGINES SUBJECT : GROUP : ENGINE INFORMATION DRAFTNO : 02EN516 INTERNATIONAL AFTERĆSALES DEPARTMENT T Kobayashi T K b hi – Manager M SERVICE S RVIC PUBLICATION & TRAINING (EUR)CARISMA(DX) 97–01 (EUR)SPACE RUNNER(DZ) (EUR)SPACE WAGON(DZL) (EUR)GALANT(ST41) (EUR)SPACE STAR ((MGX)) (EUR)PAJERO PININ(KR) (EUR)PAJERO/ MONTERO(CK) www.mivec.co.nz SERVICE BULLETIN Description: This service bulletin informs you of disuse of one of the backup rings that has been used in each fuel injector on GDI engines Applicable Manuals: See attachment Effective date: From the engines produced in the middle of July 2002 This modification is also applicable to the engines produced before that date, as modified injectors will be supplied as service parts for these engines Details: The backup ring indicated by the arrow in the drawing below has been disused Backup ring O-ring Backup ring Fuel injector Disused Insulator MSB–03E11–001 Attachment Applicable Manuals: Manual ENGINE 4G6 (E–W) W k h Manual Workshop M l Pub No PWEE9616 (English) PWES9617 (Spanish) Page 11A-5a-1, 11A 11A-5a-2a PWEF9618 (French) PWEG9619 (German) PWED9620 (Dutch) PWEW9621 (Swedish) PWEE9502 (English) PWES9503 (Spanish) PWEF9504 (French) 11A-6c-1, 11A 11A-6c-1a, 11A-6c-1b, 11A-6c-2 PWEG9505 (German) PWED9506 (Dutch) PWEW9507 (Swedish) ENGINE 6G7 (E–W) W k h Manual Workshop M l PWEE9061 (English) PWES9062 (Spanish) 11A-6c-1, 11B 11B-8-3 PWEF9063 (French) PWEG9064 (German) PWED9065 (Dutch) PWEW9066 (Swedish) ’98 CARISMA GDI W k h Manual Workshop M l chassis h i PWDE9502-C (English) 13J-103, 104 PWDS9503-C (Spanish) PWDF9504-C (French) PWDG9505-C (German) PWDD9506-C (Dutch) PWDW9507-C (Swedish) 2001 CARISMA W k h Manual Workshop M l chassis h i PWDE9502-E (English) PWDS9503-E (Spanish) PWDF9504-E (French) PWDG9505-E (German) PWDD9506-E (Dutch) PWDW9507-E (Swedish) MSB–03E11–001 13J-134, 135 www.mivec.co.nz ENGINE 4G9 (E–W) W k h Manual Workshop M l ... cam height mm G S C1 4G92 –SOHC* G S C2 4G92 –SOHC* G S C3 4G92 –SOHC* G S C4 4G93 –SOHC* 4G93 –SOHC* G S C5 4G94 –SOHC S C 4G93 –DOHC G C 4G93 –DOHC–GDI 4G93 DOHC GDI 4G94 –DOHC–GDI 4G94 DOHC GDI Valve... plate E Mitsubishi Motors Corporation Mar 2001 PWEE9502-I Revised 11A-1-4 4G9 ENGINE (E–W) – Specifications Items Standard value Limit 4G92 243.5 – 4G93 263.5 – 4G94 286.7 – 4G92 , 4G93 81.0 – 4G94 ... 0.1 No 0.02 – 0.06 0.1 Piston ring end gap mm 4G92 , 4G93 0.25 – 0.40 0.8 4G94 0.15 – 0.30 0.8 0.40 – 0.55 0.8 SOHC (4G92 , 4G93 ) 0.20 – 0.60 1.0 SOHC (4G94 ), DOHC 0.10 – 0.35 1.0 Crankshaft pin oil