Specifications

ManualsBrandsMitsubishi ManualsAutomotive4G9 series

ENGINE

<4G9-GDI>

Click on the applicable bookmark to selected the required model year

Summary of content (49 pages)

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ENGINE <4G9-GDI> Click on the applicable bookmark to selected the required model year
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11A-1 ENGINE <4G9-GDI> CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 Lash Adjuster Check . . . . . . . . . . . . . . . . . . . . . . . . 13 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 CRANKSHAFT PULLEY . . . . . . . . . . . . . . . . . . . 16 SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CAMSHAFT AND CAMSHAFT OIL SEAL . . . 17 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 OIL PAN . . . . . . . . . . . . . . . .
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11A-2 ENGINE <4G9-GDI> – General Information/Service Specifications GENERAL INFORMATION Items 4G93-GDI Total displacement mȏ 1,834 Bore × Stroke mm 81 × 89 Compression ratio 12.
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11A-3 ENGINE <4G9-GDI> – Service Specifications/Sealants Items Standard value Limit Vibration frequency Hz 114 – 139 – Tension N 392 – 588 – Deflection (Reference value) mm 10.0 – 12.0 – Vibration frequency Hz 121 – 133 – Tension N 441 – 539 – Deflection (Reference value) mm 10.0 – 11.0 – Vibration frequency Hz 145 – 166 – Tension N 637 – 834 – Deflection (Reference value) mm 7.0 – 9.0 – Basic ignition timing 5_ BTDC ± 3_ – Ignition timing Approx.
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11A-4 ENGINE <4G9-GDI> – Special Tools SPECIAL TOOLS Tool Number Name Use MB991502 MUT-II sub assembly D D D D MB991668 Belt tension meter set Measuring the drive belt tension (used together with the MUT-II) MB990767 End yoke holder D D Holding the camshaft sprocket Holding the crankshaft sprocket Crankshaft pulley holder pin D D Holding the camshaft sprocket Holding the crankshaft sprocket MD998713 Camshaft oil seal installer Press-in of the camshaft oil seal MD998781 Flywheel stoppe
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ENGINE <4G9-GDI> – Special Tools Tool 11A-5 Number Name Use MB991653 Cylinder head bolt wrench Cylinder head bolt removal and installation MD998767 Tension pulley socket wrench Timing belt tension adjustment
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11A-6 ENGINE <4G9-GDI> – On-vehicle Service ON-VEHICLE SERVICE DRIVE BELT TENSION CHECK AND ADJUSTMENT ALTERNATOR DRIVE BELT TENSION CHECK Check the drive belt tension in the following procedure. Standard value: 15_ MB991668 15_ (Microphone) 10 – 20 mm Alternator pulley Crankshaft pulley Vibration frequency Hz 143 – 185 Tension N 294 – 490 Deflection (Reference value) mm 9.7 – 12.9 1. Connect the special tool (belt tension meter set) to the MUT-II. 2.
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11A-7 ENGINE <4G9-GDI> – On-vehicle Service Belt tension gauge Use a belt tension gauge to check that the belt tension is within the standard value. Alternator pulley Crankshaft pulley Apply 98 N of force to the middle of the drive belt between the pulleys (at the place indicated by the arrow) and check that the amount of deflection is within the standard value.
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11A-8 ENGINE <4G9-GDI> – On-vehicle Service Oil pump pulley Tension pulley Crankshaft pulley A B POWER STEERING OIL PUMP AND AIR CONDITIONER COMPRESSOR DRIVE BELT TENSION CHECK AND ADJUSTMENT 1. Check if the belt tension is within the standard value using one of the methods below.
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ENGINE <4G9-GDI> – On-vehicle Service 11A-9 IGNITION TIMING CHECK 1. Before inspection, set the vehicle to the pre-inspection condition. 2. Connect the MUT-II to the diagnosis connector. MUT-II Condenser 3. Set the timing light to the condenser of the No.1 ignition coil power supply line (terminal No.3). 4. Start the engine and run at idle. 5. Check that engine idle speed is within the standard value. Standard value: 600 ± 50 r/min No.
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A-10 ENGINE <4G9-GDI> – On-vehicle Service IDLE SPEED CHECK 1. Before inspection, set the vehicle to the pre-inspection condition. 2. Turn off the ignition switch and then connect the MUT-II to the diagnosis connector. 3. Check the basic ignition timing. MUT-II NOTE Refer to P.11A-9 concerning the check procedure of the basic ignition timing. Standard value: 5_ BTDC ± 3_ 4. Run the engine at idle for 2 minutes. 5. Check the idle speed. Select item No. 22 and take a reading of the idle speed.
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ENGINE <4G9-GDI> – On-vehicle Service 11A-11 6. Check the CO contents and the HC contents at idle. NOTE This measurement should be performed in less than approximately 4 minutes since the engine speed become the idle speed. Standard value CO contents: 0.6% or less HC contents: 200 ppm or less 7.
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11A-12 ENGINE <4G9-GDI> – On-vehicle Service 7. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit. Limit: Max. 100 kPa 8. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps 6 and 7.
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ENGINE <4G9-GDI> – On-vehicle Service 11A-13 LASH ADJUSTER CHECK If an abnormal noise (knocking) that seems to be coming from the lash adjuster is heard after starting the engine and does not stop, carry out the following check. NOTE (1) The abnormal noise which is caused by a problem with the lash adjusters is generated after the engine is started, and will vary according to the engine speed. However, this noise is not related to the actual engine load.
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11A-14 ENGINE <4G9-GDI> – On-vehicle Service NOTE (1) If the vehicle is parked on a slope for a long period of time, the amount of oil inside the lash adjuster will decrease, and air may get into the high pressure chamber when starting the engine. (2) After parking the vehicle for long periods, the oil drains out of the oil passage, and it takes time for the oil to be supplied to the lash adjuster, so air can get into the high pressure chamber.
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ENGINE <4G9-GDI> – On-vehicle Service Drive pattern for air bleeding Gradually open the Close the throttle throttle valve. valve. Approx. 3,000 r/min Idle speed 15 seconds 15 seconds Once 11A-15 2. Run the engine at idle for 1 – 3 minutes to let it warm up. 3. With no load on the engine, repeat the drive pattern shown in the illustration at left and check if the abnormal noise disappears.
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11A-16 ENGINE <4G9-GDI> – Crankshaft Pulley CRANKSHAFT PULLEY REMOVAL AND INSTALLATION Pre-removal Operation Engine Cover and Under Cover Removal Post-installation Operation D Drive Belt Tension Adjustment (Refer to P.11A-7.) D Engine Cover and Under Cover Installation 1 2 177 – 186 Nm 3 4 (Engine oil) Removal steps 1. Drive belt (Power steering and A/C) 2. Drive belt (Alternator) AA" "AA 3. Crankshaft pulley bolt 5 4. Crankshaft pulley washer 5.
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11A-17 ENGINE <4G9-GDI> – Camshaft and Camshaft Oil Seal CAMSHAFT AND CAMSHAFT OIL SEAL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Air Intake Hose and Resonance Tank Removal and Installation (Refer to GROUP 15 – Air Cleaner and Resonance Tank.) D Timing Belt Removal and Installation (Refer to P.11A-29.) D Engine Coolant Draining and Supplying (Refer to GROUP 14 – On-vehicle Service.) D D Intake Manifold Removal and Installation (Refer to GROUP 15.
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11A-18 ENGINE <4G9-GDI> – Camshaft and Camshaft Oil Seal Lubrication points Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent Sealant: 3M ATD Part No.8660 or equivalent (Lip section) (Engine oil) (Engine oil) Sealant: 3M Stud locking 4170 or equivalent Sealant: 3M ATD Part No.
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ENGINE <4G9-GDI> – Camshaft and Camshaft Oil Seal 11A-19 REMOVAL SERVICE POINT MB990767 AA" CAMSHAFT SPROCKET REMOVAL MD998719 Camshaft sprocket side Screw hole "AA CAMSHAFT INSTALLATION 1. Apply engine oil to journals and cams of the camshafts. 2. Install the camshafts on the cylinder head. Caution Be careful not to confuse the intake camshaft with the exhaust one. There is a screw hole for the cam position sensing cylinder mounting bolt on the exhaust-side camshaft. Exhaust camshaft Approx.
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11A-20 ENGINE <4G9-GDI> – Camshaft and Camshaft Oil Seal "CA CAMSHAFT OIL SEAL INSTALLATION 1. Apply engine oil to the entire circumference of the oil seal lip. 2. Press-fit the oil seal as shown in the illustration. MD998713 "DA CAMSHAFT SPROCKET INSTALLATION Use the special tool to secure the camshaft sprocket in the same way as during removal, and then tighten the bolt to the specified torque.
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11A-21 ENGINE <4G9-GDI> – Oil Pan OIL PAN REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Under Cover Removal and Installation D Oil Level Gauge Removal and Installation D Engine Oil Draining and Supplying (Refer to GROUP 12 – On-vehicle Service.
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11A-22 ENGINE <4G9-GDI> – Oil Pan REMOVAL SERVICE POINTS AA" STEERING GEAR BOX INSTALLATION BOLT REMOVAL Remove the steering gear box installation bolts and lower the steering gear box. AB" LOWER OIL PAN REMOVAL Place a piece of wood against the lower oil pan, and tap the piece of wood with a hammer to remove the lower oil pan. Lower oil pan Caution Because the upper oil pan used is made from aluminium, the oil pan remover (MB998727) should not be used.
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11A-23 ENGINE <4G9-GDI> – Crankshaft Oil Seal CRANKSHAFT OIL SEAL REMOVAL AND INSTALLATION 7 93 – 103 Nm 10 93 – 103 Nm 8 5 3 1 6 9 4 2 Crankshaft Lip section (Engine oil: bolt washer surface) 10 5 Crankshaft (Engine oil: bolt washer surface) Lip section (Bolt thread) 8 (Bolt thread) 7 Engine oil Sealant: 3M Stud locking 4170 or equivalent Crankshaft front oil seal removal steps D Timing belt (Refer to P.11A-29.) D Crank angle sensor (Refer to GROUP 16.) 1.
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11A-24 ENGINE <4G9-GDI> – Crankshaft Oil Seal REMOVAL SERVICE POINT AA" ADAPTER PLATE/FLYWHEEL /DRIVE PLATE /CRANKSHAFT ADAPTER REMOVAL Use the special tool to secure the flywheel or drive plate, and remove the bolts. MD998781 INSTALLATION SERVICE POINTS Crankshaft rear oil seal Crankshaft MD990938 "AA CRANKSHAFT REAR OIL SEAL INSTALLATION 1. Apply a small mount of engine oil to the entire circumference of the oil seal lip. 2.
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11A-25 ENGINE <4G9-GDI> – Cylinder Head Gasket CYLINDER HEAD GASKET REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Fuel Discharge Prevention (Refer to GROUP 13A – On-vehicle Service.) D Engine Coolant Draining and Supplying (Refer to GROUP 14 – On-vehicle Service.) D Engine Oil Draining and Supplying (Refer to GROUP 12 – On-vehicle Service.) D Intake Manifold Removal and Installation (Refer to GROUP 15.
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11A-26 ENGINE <4G9-GDI> – Cylinder Head Gasket REMOVAL SERVICE POINTS AA" POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL Remove the power steering oil pump and bracket assembly from the engine with the hose attached. NOTE Place the removed power steering oil pomp and bracket assembly in a place where it will not be a hindrance when removing and installing the cylinder head assembly, and tie it with a cord.
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11A-27 ENGINE <4G9-GDI> – Cylinder Head Gasket 4. Tighten the bolts by the following procedure. Step MB991653 Intake side Operation Remarks 1 Tighten to 74 Nm. Carry out in the order shown in the illustration. 2 Fully loosen. Carry out in the reverse order of that shown in the illustration. 3 Tighten to 20 Nm. Carry out in the order shown in the illustration. 4 Tighten 90_ of a turn. In the order shown in the illustration. Mark the head of the cylinder head bolt and cylinder head by paint.
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11A-28 ENGINE <4G9-GDI> – Timing Belt TIMING BELT REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Engine Cover Removal and Installation D Air Intake Duct Removal and Installation (Refer to GROUP 15 – Air Cleaner and Resonance Tank.) D Crankshaft Pulley Removal and Installation (Refer to P.11A-17.) 1 11 10 – 12 Nm 48 Nm 20 – 25 Nm 3 10 10 – 12 Nm 44 Nm 2 7 2 49 Nm 5 4 8 9 12 12 – 15 Nm 35 Nm 49 Nm 12 Nm 6 10 – 12 Nm Removal steps 1. Timing belt front upper cover 2.
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ENGINE <4G9-GDI> – Timing Belt Timing marks Timing marks 11A-29 REMOVAL SERVICE POINT AA" TIMING BELT REMOVAL 1. Turn the crankshaft clockwise to align each timing mark. Caution The crankshaft must always be turned clockwise. 2. Loosen the tensioner pulley center bolt and remove the timing belt. Caution If the timing belt is to be re-used, use chalk to mark (on its flat side) an arrow indicating the clockwise direction.
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11A-30 ENGINE <4G9-GDI> – Timing Belt Camshaft sprocket Timing marks Timing marks "BA TIMING BELT INSTALLATION 1. Align the timing marks of each camshaft sprocket and the crankshaft sprocket. 2. Loosen the tensioner pulley center bolt. 3. Move the crankshaft sprocket half a tooth width in the anti-clockwise direction. Crankshaft sprocket Timing marks Paper clip Timing marks 4.
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ENGINE <4G9-GDI> – Timing Belt 11A-31 7. Place the belt onto the idler pulley, water pump sprocket, crankshaft sprocket and tensioner pulley in that order. 8. Remove the two paper clips. Idler pulley Tensioner pulley Water pump sprocket Crankshaft sprocket 9. Lift the tensioner pulley in the direction of the arrow and tighten the tensioner pulley bolt. 10. Check to be sure that all timing marks are aligned. 11. Adjust the timing belt tension.
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11A-32 A ENGINE <4G9-GDI> – Timing Belt NOTE Even if the 2 mm Allen wrench cannot be easily inserted, then it is satisfactory if the amount of protrusion of the auto tensioner rod is within the standard value. Standard value (A): 3.8 – 4.5 mm If it is outside the standard value, repeat the operations in steps 1 to 4. 4. Check to be sure that the timing marks on all sprockets are aligned.
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11A-33 ENGINE <4G9-GDI> – Engine Assembly ENGINE ASSEMBLY REMOVAL AND INSTALLATION Caution Mounting locations marked by * should be provisionally tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. Pre-removal and Post-installation Operation D Fuel Discharge Prevention (Refer to GROUP 13A – On-vehicle Service.) D Engine Coolant Draining and Supplying (Refer to GROUP 14 – On-vehicle Service.
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11A-34 ENGINE <4G9-GDI> – Engine Assembly REMOVAL SERVICE POINTS AA" POWER STEERING OIL PUMP REMOVAL Remove the power steering oil pump from the engine with the hose attached. NOTE Place the removed power steering oil pump where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord. AB" A/C COMPRESSOR REMOVAL Disconnect the A/C compressor connector and remove the compressor from the compressor bracket with the hose still attached.
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11A-1 ENGINE <4G9> CONTENTS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 3 Outline of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Idle Mixture Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 SEALANT AND ADHESIVE . . . . . . . . . . . . . . . . .
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11A-2 ENGINE <4G9> – General/General Information/Service Specifications/Sealant and Adhesive GENERAL OUTLINE OF CHANGES Due to the new addition of the 4G94 engine vehicles, the following service procedures have been established regarding the sections which differ from that of the previous models with the 4G93 engine. The same procedures as before are applied except for the items shown below.
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ENGINE <4G9> – Special Tools/On-vehicle Service 11A-3 SPECIAL TOOLS Tools Number Name Use MB990767 Front hub and flange york holder Camshaft sprocket held MD998719 Crankshaft pulley holder pin MD998713 Camshaft oil seal installer Press–fitting camshaft oil seal MB991653 Cylinder head bolt wrench Removal and installation of cylinder head bolt ON-VEHICLE SERVICE IDLE MIXTURE CHECK Standard value CO contents: 0.
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11A-4 ENGINE <4G9> – Camshaft and Camshaft Oil Seal CAMSHAFT AND CAMSHAFT OIL SEAL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operations Fuel Overflow Prevention Operation Fuel Leak Check Air Bleeding The High-pressure Fuel Line [Refer to GROUP 13A – Fuel Pump (High-pressure).
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11A-5 ENGINE <4G9> – Camshaft and Camshaft Oil Seal 3.0 Nm 1 9.0 Nm 13 14 15 12 7 4 (3M ATD Part No. 8121) 6 9 11 6 16 10 3 8 3.5 Nm 14 Nm 5 2 17 3.5 Nm 18 19 20 21 E Removal steps 1. Engine cover 2. Power steering oil pressure switch connector 3. A/C compressor magnetic clutch connector 4. Ignition failure sensor connector 5. Crank angle sensor connector 6. Front wiring harness and injector/EGR wiring harness combination connector 7. Fuel pressure sensor connector 8.
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11A-6 ENGINE <4G9> – Camshaft and Camshaft Oil Seal 19 – 23 Nm Apply engine oil to any rotating area at the installation. 10 – 12 Nm 19 – 23 Nm 29 24 10 – 12 Nm 30 33 32 31 22 22 Nm 25 27 26 12 – 15 Nm 34 35 89 Nm 28 23 36 Nm A 22. 23. 24. D 25. Camshaft sprocket Idler pulley Timing belt rear upper cover Camshaft oil seal Fuel pump (high-pressure) (Refer to GROUP 13A.) 26. Camshaft position sensor support 27. Camshaft thrust cover 28. C 29. 30. B 31. B 32. 33. 34. A 35.
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ENGINE <4G9> – Camshaft and Camshaft Oil Seal 11A-7 LUBRICANT AND SEALANT APPLICATION LOCATIONS Section A – A A φ3 mm A Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent Adhesive: 3M Stud Locking 4170 or equivalent Engine oil (lip) Engine oil Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent
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11A-8 ENGINE <4G9> – Camshaft and Camshaft Oil Seal REMOVAL SERVICE POINT A CAMSHAFT SPROCKET REMOVAL MB990767 Caution To avoid the danger of damage caused by interference of the valve and the piston, rotate the crankshaft from No.1 cylinder compression top dead centre to 90 in the forward direction (clockwise). MD998719 INSTALLATION SERVICE POINTS A LASH ADJUSTER INSTALLATION Caution To use the lash adjuster again, be sure to clean and check it before installation.
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11A-9 ENGINE <4G9> – Camshaft and Camshaft Oil Seal 27 26 19 31 30 22 23 12 11 3 15 16 8 5 7 14 13 1 2 6 9 10 21 20 4 17 18 29 28 24 25 2. Tighten the beam camshaft cap mounting bolt to the specified torque in the order of the numbers shown in the illustration.
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11A-10 ENGINE <4G9> – Cylinder Head Gasket CYLINDER HEAD GASKET REMOVAL AND INSTALLATION Pre-removal and Post-installation Operations Removal and Installation of Engine Cover (Refer to P.11A-5.) Fuel Overflow Prevention Operation Fuel Leak Check Air Bleeding the High-pressure Fuel Line [Refer to GROUP 13A – Fuel Pump (High-pressure).
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11A-11 ENGINE <4G9> – Cylinder Head Gasket 74 Nm → 0 Nm → 20 Nm → +90 → +90 (when the engine is cold) 5 (Engine oil) 2 1 6 7 22 Nm 3 29 Nm 44 Nm 29 Nm 44 Nm Removal steps A C 1. Connection of radiator upper hose 2. Connection of heater hose B 3. Power steering oil pump 4. Power steering oil pump bracket 4 C B 5. Cylinder head bolt 6. Cylinder head assembly A 7.
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11A-12 ENGINE <4G9> – Cylinder Head Gasket REMOVAL SERVICE POINTS A RADIATOR UPPER HOSE REMOVAL Put mating marks on the radiator upper hose and the hose clamp for removal. B POWER STEERING OIL PUMP REMOVAL Remove the power steering oil pump with the hose attached from the bracket. NOTE Tie the removed power steering oil pump and the A/C compressor with strings to set aside so that they will not hinder the removal and installation of the engine assembly.
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ENGINE <4G9> – Cylinder Head Gasket 11A-13 INSTALLATION SERVICE POINTS A CYLINDER HEAD GASKET INSTALLATION 1. Remove gasket attached on the mounting surface of the gasket. Caution Be careful not to let foreign objects get inside the engine coolant and the oil line. 2. Install so that the each hole of the cylinder head is aligned with each hole of the cylinder head gasket. Sagging side (Engine oil) B CYLINDER HEAD BOLT INSTALLATION 1.
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11A-14 ENGINE <4G9> – Cylinder Head Gasket/Timing Belt C RADIATOR UPPER HOSE INSTALLATION 1. Insert the radiator upper hose to the convex section of the water outlet fitting. 2. Align the mating mark on the radiator upper hose with that of the hose clamp to install. TIMING BELT A INSTALLATION SERVICE POINT Timing belt tension adjustment Standard value (A): 4.8 – 5.