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Mitsubishi 4G93 User Manual

Mitsubishi 4G93
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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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REWORK DIMENSIONS 11A-1-4
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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-1-7
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SEALANT 11A-1-7
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FORM-IN-PLACE GASKET 11A-1-8
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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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4. TIMING BELT 11A-4-1
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5. FUEL AND EMISSION CONTROL SYSTEM 11A-5-1
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5a.THROTTLE BODY AND EGR SYSTEM (GDI) 11A-5a-1
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6. INTAKE AND EXHAUST MANIFOLD 11A-6-1
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6a.INTAKE MANIFOLD (GDI) 11A-6a-1
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6b.EXHAUST MANIFOLD (GDI) 11A-6b-1
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6c.INJECTOR AND FUEL PUMP ASSEMBLY (GDI) 11A-6c-1
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7. WATER PUMP AND WATER HOSE 11A-7-1
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8. ROCKER ARMS AND CAMSHAFTS 11A-8-1
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8a.ROCKER COVER AND CAMSHAFTS (MIVEC) 11A-8a-1
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8b.ROCKER ARMS AND ROCKER SHAFT CAPS (MIVEC) 11A-8b-1
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9. CYLINDER HEAD AND VALVES 11A-9-1
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10.FRONT CASE AND OIL PUMP 11A-10-1
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11. PISTON AND CONNECTING ROD 11A-11-1
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12.CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE
PLATE 11A-12-1
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11A-0-1
ENGINE
4G9 SERIES
CONTENTS
PWEE9502-E
E
Dec. 1998Mitsubishi Motors Corporation Revised

Table of Contents

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Mitsubishi 4G93 Specifications

General IconGeneral
Bore x Stroke81.0 mm x 89.0 mm
Block MaterialCast iron
Engine code4G93
Displacement1834 cc
Compression Ratio9.5:1
Fuel SystemMulti-point fuel injection
ValvetrainDOHC, 16 valves
Torque167 Nm
Head MaterialAluminum
Fuel typePetrol
Engine TypeInline 4 cylinder

Summary

1. SPECIFICATIONS

SERVICE SPECIFICATIONS

Details service specifications for engine components.

REWORK DIMENSIONS

TORQUE SPECIFICATIONS

2. SPECIAL TOOLS

3. ALTERNATOR AND IGNITION SYSTEM

REMOVAL AND INSTALLATION <SOHC> (Engines with distributor)

Procedure for removing and installing the alternator and ignition system for SOHC engines.

4. TIMING BELT

REMOVAL AND INSTALLATION <SOHC for other than PAJERO io>

Steps for removing and installing the timing belt on SOHC engines.

5. FUEL AND EMISSION CONTROL SYSTEM

REMOVAL AND INSTALLATION <SOHC-CARBURETOR>

Procedure for removing and installing the fuel and emission control system for SOHC carburetor engines.

5a. THROTTLE BODY AND EGR SYSTEM (GDI)

REMOVAL AND INSTALLATION <For CARISMA>

Steps for removing and installing the throttle body and EGR system for GDI engines.

6. INTAKE AND EXHAUST MANIFOLD

REMOVAL AND INSTALLATION <SOHC-CARBURETOR>

Procedure for removing and installing intake and exhaust manifolds for SOHC carburetor engines.

6a. INTAKE MANIFOLD (GDI)

REMOVAL AND INSTALLATION <For CARISMA, SPACE STAR>

Steps for removing and installing the intake manifold for GDI engines.

6b. EXHAUST MANIFOLD (GDI)

REMOVAL AND INSTALLATION <For CARISMA>

Procedure for removing and installing the exhaust manifold for GDI engines.

6c. INJECTOR AND FUEL PUMP ASSEMBLY (GDI)

REMOVAL AND INSTALLATION <For CARISMA>

Steps for removing and installing the injector and fuel pump assembly for GDI engines.

7. WATER PUMP AND WATER HOSE

REMOVAL AND INSTALLATION <SOHC>

Procedure for removing and installing the water pump and water hose for SOHC engines.

8. ROCKER ARMS AND CAMSHAFTS

REMOVAL AND INSTALLATION <SOHC>

Steps for removing and installing rocker arms and camshafts for SOHC engines.

INSPECTION

CAMSHAFT

Procedures for inspecting the camshaft, including cam height measurement.

LASH ADJUSTER

Guidelines for cleaning and maintaining lash adjusters.

8a. ROCKER COVER AND CAMSHAFTS (MIVEC)

REMOVAL AND INSTALLATION

Procedure for removing and installing rocker cover and camshafts for MIVEC engines.

8b. ROCKER ARMS AND ROCKER SHAFT CAPS (MIVEC)

REMOVAL AND INSTALLATION

Steps for removing and installing rocker arms and rocker shaft caps for MIVEC engines.

9. CYLINDER HEAD AND VALVES

REMOVAL AND INSTALLATION <SOHC>

Procedure for removing and installing the cylinder head and valves for SOHC engines.

REMOVAL SERVICE POINTS

CYLINDER HEAD BOLT REMOVAL

Instructions for removing cylinder head bolts using a special tool.

RETAINER LOCK REMOVAL

Guidance on storing removed valve parts for reassembly.

INSTALLATION SERVICE POINTS

VALVE STEM SEAL INSTALLATION

Instructions for installing valve stem seals using a special tool.

INSPECTION

CYLINDER HEAD

Checking cylinder head flatness, height, and grinding limits.

VALVE

Inspecting valve face contact, margin, and overall height.

VALVE SPRING

VALVE SEAT

VALVE GUIDE

10. FRONT CASE AND OIL PUMP

REMOVAL AND INSTALLATION <SOHC>

Steps for removing and installing the front case and oil pump for SOHC engines.

REMOVAL SERVICE POINTS

OIL PAN REMOVAL

Procedure for removing the oil pan using a special tool.

REMOVAL OF UPPER OIL PAN

Instructions for removing the upper oil pan, noting bolt lengths.

INSTALLATION SERVICE POINTS

ROTOR INSTALLATION

Steps for installing oil pump rotors, ensuring alignment.

11. PISTON AND CONNECTING ROD

REMOVAL AND INSTALLATION

Procedure for removing and installing the piston and connecting rod.

REMOVAL SERVICE POINTS

CONNECTING ROD CAP REMOVAL

Marking connecting rod caps for correct reassembly.

PISTON PIN REMOVAL

Procedure for removing the piston pin using a special tool and press.

12. CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE PLATE

REMOVAL AND INSTALLATION

Steps for removing and installing the crankshaft, cylinder block, flywheel, and drive plate.

REMOVAL SERVICE POINT

OIL JET REMOVAL

Instructions for removing oil jets using a metal rod.

INSTALLATION SERVICE POINTS

OIL JET INSTALLATION

Procedure for driving in oil jets using a pin punch.

BEARING CAP/BEARING CAP BOLT INSTALLATION

OIL SEAL INSTALLATION

SEALANT APPLICATION TO OIL SEAL CASE

DRIVE PLATE BOLT/FLYWHEEL BOLT INSTALLATION

INSPECTION

CRANKSHAFT JOURNAL OIL CLEARANCE (PLASTIGAUGE METHOD)

Method for measuring crankshaft journal oil clearance using Plastigage.

CYLINDER BLOCK

BORING CYLINDER

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