Mitsubishi 4G6 series Specifications

ENGINE4G61, 4663, 4664<1992>CONTENTSIBRACKET. . . . . . . . . . . . . . . . . . . . .,. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IIC-104G6 ENGINE <1992>- Service SpecificationsSERVICE SPECIFICATIONSmm (in.)Cylinder head - SOHCFlatness of gasket surfaceGrinding limit of gas

IIC-100DOHC4G6 ENGINE <1992>- Piston and Connecting RodNon-turboTurbo6EN0497No. 1a /pulleysideNo. 2 ring gapand spacer gap‘Lowerrail6EN0549Timin

4G6 ENGINE <1992>- Piston and Connecting Rod1 IC-101TSB Revision

IIC-1024G6 ENGINE <1992> -Crankshaft, Flywheel and Drive PlateCRANKSHAFT, FLYWHEEL AND DRIVE PLATE135 NmREMOVAL AND INSTALLATION2 98ftJbs.I I182

4G6 ENGINE <1992>- Crankshaft, Flywheel and Drive Plate1 x-1036EN055C1 EN027’I-,3EN0184INSPECTIONCRANKSHAFT OIL CLEARANCE (PLASTIC GAUGEMETHOD)(

IIC-1044G6 ENGINE <1992>- Crankshaft. Flvwheel and Drive Plate(4) Check cylinder walls for scratches and seizure. If defectsare evident, correct

4G6 ENGINE <1992>- Crankshaft, Flywheel and Drive PlateIIC-105IIOHCGroovelessLower bearing(for No. 1.2.4.5)Upper bearing(for No. 1,2.4,5)Upper a

IIC-1064G6 ENGINE <1992>- Crankshaft, Flywheel and Drive PlateI1MD998376-01DEN0052Oil sealOil separator-case\-00&a2800?nilt-= hole6EN055iI)c

BRACKET4G6 ENGINE <1992> - Bracket1 I-C-I 07Rear wheel drive and four wheel drive33 ft.lbs.I,Engine support bracket, right/45 Nm2.Engine support

NOTES

466 ENGINE <1992>- Service Specification3IWwlmm (in.)Camshaft - SOHCIdentification mark: DCam heightIntakeExhaustIdentification mark: ARCam heig

IIC-12466 ENGINE c1992>- Service Specificationsmm (in.)StandardLimitValve - SOHCOverall lengthIntake4663109.8(4.321)4664106.6 (4.197)Exhaust4G63 10

4G6 ENGINE <1992>- Service Snebificationsmm (in.)Valve guide - DOHCOverall lengthI.D.O.D.Service sizePress-in temperatureVa Ive seatSeat angleVa

466 ENGINE <1992>- Service Specificationsmm (in.)Piston ring - SOHCEndgapRing-to-ring grooveclearanceService sizeNo. 1 ringNo. 2 ring46634664Oil

466 ENGINE t1992> - Service SbecificationsCylinder blockCylinder I.D.4G6146634664Flatness of gasket surfaceGrinding limit* Total resurfacing depth

IIC-164G6 ENGINE <1992>- Torque SpecificationsTORQUE SPECIFICATIONSGenerator and ignition system - SOHCCooling fan boltWater pump pulley bolt -

4G6 ENGINE <1992>- Toraue SDecificationsIIC-17Fuel and emission partsEGR valve boltThrottle body stay nut - DOHCThrottle body bolt - SOHCThrottl

TurbochargerTurbocharger waste gateactuator boltRocker arms and camshaft- SOHCRocker cover boltBearing cap boltM8x25M8x65Camshafts and rocker arms - D

4G6 ENGINE <1992>- Torque Specifications / Sealant1 IC-19BracketLeft and right engine support bracket bolt4533Roll stopper bracket bolt, front65

IIC-2466 ENGINE <1992> - General InformationGENERAL INFQRMATIONIENGINE SECTIONAL VIEW - SOHC6EN0313TSB Revision. I

11 c-20466 ENGINE <1992> - Special ToolsSPECIAL TOOLSToolNumber andtool nameSupersessionMB990767M 8990767-01End yoke holderUse with MIT308239Use

4G6 ENGINE <1992> - Special ToolsMD998713MD998713-01Camshaft oil sealinstallerMD99871 9Pulley holdingpins (2)M IT308239Holding camshaft sprocket

IIC-224G6 ENGINE <1992> - Special ToolsM D998779Sprocket stopperHolding silent shaft sprocketMD998780Piston pinsetting toolM IT2 16941Removal an

466 ENGINE <1992>- Generator and Ignition System - SOHCGENERATOR AND IGNITION SYSTEM - SOHCREMOVAL AND INSTALLATION1 IC-2325 Nm14 NmlOft.lbs. -1

1 IC-24466 ENGINE <1992> -Generator and Ignition System - SOHC1ELOOlfINSTALLATION SERVICE ,POINTSr)A4 DISTRIBUTOR INSTALLATION(1) Align the mark

4G6 ENGINE <1992>- Generator and Ignition Svstem - SOHC1 ICE-25WaterpulleyCrankshaft pulley6EN0593Alternpulley/‘,Water pump pulley6EN059EBRACE B

11 C-264G6 ENGINE <1992>- Generator and Ignition System - DOHCGENERATOR AND IGNITION SYSTEM - DOHCREMOVAL AND INSTALLATION18 ft.lbs.19 Nm14 ftlb

466 ENGINE <1992>- Generator and Ignition System - DOHCIIC-27INSTALLATION SERVICE POINTS#A4 CRANKSHAFT POSITION INSTALLATION(1) Turn the cranksh

11 C-284G6 ENGINE <1992> - Timing Belt - SOHCTIMING BELT - SOHCREMOVAL AND INSTALLATIONEE NmiF--- --~~~”87 ft.lbs.1” . . . . .40 ft.lbs.18Remova

4G6 ENGINE <1992> - Timing Belt - SOHCIIC-296EN05636EN056~REMOVAL SERVICE POINTSQAo TIMING BELT REMOVAL(1) Mark the belt running direction for r

4G6 ENGINE <1992> - General Information6EN0314TSB RevisionI

4G6 ENGINE <1992> - Timing Belt - SOHC\&00B0008EN006ZPeelingCracksCracks1 EN0249(IF0SILENT SHAFT SPROCKET REMOVALQGt) CRANKSHAFT SPROCKET “B

4G6 ENGINE <1992> - Timing Belt - SOHC1 IC-31RoundededgeAbnormal wear(Fluffy strand)8EN006;Rubber exposedTooth missingand canvas fiber8EN006tSpa

11 C-32466 ENGINE <1992> - Timing Belt - SOHCCenter ofyxtensioner -\ -mkP,...*-- -L L-Or./W6EN057’+D4 TIMING BELT “B” ‘INSTALLATION(1) Align tim

4G6 ENGINE <1992> - Timing Belt - SOHC1 IC-33Screwdriver6EN0564Tensloner -6EN0555Timing markfor on-vehicleservice onlyI)F4 OIL PUMP SPROCKET INS

IIC-344G6 ENGINE <1992> - Timing Belt - SOHC6EN05636EN0564Tensioner spacerTiming mark(3) Remove the plug on the cylinder block and insert a Phi

4G6 ENGINE <1992> - Timinn Belt - SOHC1 tc-35i-(8) Tighten the tensioner attaching bolt, then tighten thetensioner spacer.CautionIf the tensione

WC-364G6 ENGINE <1992> - Timing Belt - DOHCTIMING BELT - DOHCREMOVAL AND INSTALLATION3Nm2.2 ft.lbs. -flA24*? Ie1 87ft.lbs.TENO***: Engine withou

466 ENGINE <1992> - Timing ,Felt - DOHCIIC-37REMOVAL SERVICE POINTSOAi) TIMING BELT REMOVAL(1) Make a mark on the back of the timing belt indica

1 IC-384G6 ENGINE <1992> - Timing Belt - DOHCOF0SILENT SHAFT SPROCKET REMOVALQGo CRANKSHAFT SPROCKET “B” REMOVAL(IHO CAMSHAFT SPROCKET REMOVAL(1

4G6 ENGINE <1992> - Timina Belt - DOHCIX-39a-100‘il;012mm( 47 in.)6EN0161IBrass oraluminum lawsaluminum jaws'6EN0404AUTO TENSIONER(1) Check

IIC-4466 ENGINE <1992> - General Information,NGlNE SECTIONAL VIEW - DOHCTSB Revision

11 c-404G6 ENGINE <1992> - Timing Belt - DOHCApply sealantd::.:..‘:-.-.*...a.. .. . . . . . . . . . . . . . . ..-..::::::::.:.:.:.:.:.:...*.-.-

4G6 ENGINE <1992> - Timing Belt - DOHC1 x-47I)04 SPACER INSTALLATION (ENGINE WITH SILENTSHAFTS)Refer to “eB4 SPACER INSTALLATION” on page 11 C-3

11 C-42466 ENGINE <1992> - Timing Belt - DOHC6EN015,4Wir>e y-A\J040E1)14 AUTO TENSIONER INSTALLATION(1) If the auto tensioner rod is in its f

466 ENGINE <1992> - Timina Belt - DOHC1 IC-43Camshaft sprocketTiming marks6EN02846ENOll EEngine with silent shafts1Screwdriver6EN0564r)K4 TIMING

4G6 ENGINE <1992> - Timing Belt - DOHC.(5) Thread the timing belt over the intake side camshaftsprocket and fix it at indicated position by a cl

4G6 ENGINE <1992> - Timing Belt - DOHCIIC-456EN0285(14)lnstall the special tools, Socket Wrench and TorqueWrench, on the tensioner pulley, and l

11 C-464G6 ENGINE <1992> -Fuel and Emission Control PartsFUEL AND EMISSION CONTROL PARTSREMOVAL AND INSTALLATION - SOHC for GALANT/EXPOP-12 Nm9

466 ENGINE <1992> -Fuel and Emission Control PartsIIC-47REMOVAL AND INSTALLATION - SOHC for TRUCKI----12 Nm9 ft.lbs.512 Nm9 ft.lbs.9Nm7 ft.lbs.1

11 C-484G6 ENGINE <1992> -Fuel and Emission Control PartsIEMOVAL AND INSTALLATION - DOHC12 Nm9 ft.lbs.819 Nm14 ftlbs.19Nm14 ft.lbs.Removal steps

466 ENGINE <1992> -Fuel and Emission Control PartsIX-496EMO3RLIINJECTORS6FU1920SOHC6EN0520DOHC6EN0521INSPECTIONEGR VALVE(1) Check EGR valve for

6EN0244TSB Revision\

11 c-504G6 ENGINE <1992> - Throttle BodyTHROTTLE BODYDISASSEMBLY AND REASSEMBLYSOHC for EXPODisassembly steps1. Accelerator wire bracket@8 *A4 2

4G6 ENGINE <1992> - Throttle BodyIIC-51DOHC2Nm1.4ft.lbs.5Disassembly steps(IAI) *AC I. Throttle position sensorOAO2. Idle air control motor (ste

11 C-524G6 ENGINE <1992> - Throttle BodvMD998463Red clBlue7FUO29(1MD9984637FUO29CMD9984637F11007FDISASSEMBLY SERVICE POINTSQAo THROTTLE POSITION

4G6 ENGINE <1992> - Throttle BodvIlC-537FUO295position sensorconnectorIdle speed control6FU125i6FU125:(3) Holding the idle air control motor as

1 IC-54466 ENGINE <1992> - Throttle BodyThrottle positionsensor outputGroundClosed throkle position\switchThrottle positionsensor power7FUO535RE

466 ENGINE <1992> - Throttle BodvIlC-55Throttle positionsensor powerroundThrottle positionsensor output7FUO535I(2) Turn the throttle position se

11 C-56466 ENGINE <1992> - Intake ManifoldINTAKE MANIFOLDREMOVAL AND INSTALLATION - SOHC18 Nm(FWD)9(RWD)18 Nm13 ftlbs..- ._...14ttlbs.u wrn13 ft

4G6 ENGINE <1992> - Intake ManifoldIIC-57{EMOVAL AND INSTALLATION - DOHC(TO turbocharger) ;Xzr, ,, Nm4i -8 ft.lbs.Lieg(To oil cooler)Qd20 ftlbs.

11 C-584G6 ENGINE <1992> - Intake Manifold6lNOO49SealantSealantSEN0092INSTALLATION SERVICE POINTS*A4INTAKE MANIFOLD INSTALLATION - DOHC(1) Tight

4G6 ENGINE <1992>- Exhaust Manifold and Water PumnEXHAUST MANIFOLD AND WATER PUMPREMOVAL AND INSTALLATION - SOHC14 Nm*10 ftlbs.18 Nm13 ft.lbs.24

IIC-6466 ENGINE <1992> - General InformationENGINE LUBRICATION SYSTEM - SOHCRocker shaft\CamshaftOil pressureswitch\rankshaft6LUOO39ENGINE LUBRI

11 C-60466 ENGINE <1992>- Exhaust Manifold and Water PumpIEMOVAL AND INSTALLATION - DOHC FOR NON-TURBO28 Nm20 ftlbs.I14 Nm10 ft.lbs.10 ft.lbs. 4

4G6 ENGINE <1992> -Exhaust Manifold and Water PumpIEMOVAL AND INSTALLATION - DOHC TURBO1 X-61604343Nm31ft.lbs.14Nm-11 Nm8 ftlbs.14Nm10ft.lbs.164

11 C-624G6 ENGINE <1992>- Exhaust Manifold and Water PumpO-ring_jlr6EN059INSTALLATION SERVICE POINTI)A4 WATER PIPE/O-RING INSTALLATION(1) Wet th

4G6 ENGINE <1992> - Turbocharger1 K-63TURBOCHARGERDISASSEMBLY AND REASSEMBLYDisassembly stepsW4inspection of turbocharger waste gateactuator ope

11 C-644G6 ENGINE <1992> - Turbocharger6lN0055Comr,whekl3EN020EChamfered 1assembly6lN0070INSPECTIONTURBINE HOUSING(1) Check the housing for trac

4G6 ENGINE <1992> - Turbocharger11 C-65Coupling6lN005!eD4 TURBINE HOUSING INSTALLATION(1) Install the turbine housing on the compressor cover wh

llC=664G6 ENGINE <1992>- Rocker Arms and Camshaft - SOHCROCKER ARMS AND CAMSHAFT - SOHCREMOVAL AND INSTALLATIONnemoval stepsQ-----71.Breather h

F&l~lluC /1663\ _Rack r Arms and Camshaft - SOWI ‘K-67---MD998443-01I6EN056E7EN006L.REMOVAL SERVICE POINT(IAOROCKER ARM AND CAMSHAFT REMOVAL(1) Be

IIC-684G6 ENGINE <1992>- Rocker Arms and Camshaft - SOHC6EN057tDivision = 1 mm LO4 in.)7EN0438Notch(1) Immerse the lash adjuster in clean diesel

4G6 ENGINE <1992>- Rocker Arms and Camshaft - SOHC11 C-69Wavewasherside rocker arm-6EN057Zb Timing belt sideidentificationNo. 1 No. 2No. 3 No. 4

4G6 ENGINE <1992> - General InformationENGINELUBRICATION SYSTEMDOHC-TURBOOilToCamshaftee EIeSilent shaftFrom thermostat casenfilter\K Oil cooler

4G6 ENGINE <1992>- Rocker Arms and Camshaft - SOHCApply sealantDEN0052IOmmSemi-circularpackingGasketr$ ofcvlinder head6EN042I)F4 CAMSHAFT OIL S

4G6 ENGINE <1992>- Camshafts and Rocker Arms - DOHC1 IC-71CAMSHAFTS AND ROCKER ARMS - DOHCREMOVAL AND INSTALLATION20 Nm14 t=t.lbs.-611 Nm8 ftlbs

11 C-724G6 ENGINE <1992>- Camshafts and Rocker Arms - DOHCRollerTipI6EN018!Scale = 1 mm (.039 in.)M[\6EN035Nut6EN035INSPECTIONCAMSHAFT(1) Measur

4G6 ENGINE <1992>- Camshafts and Rocker Arms - DOHC1 IC-73cCamshaft sprocket sideIntake sidecamshaft6EN0289Dowel pinCap numberSymbol identifying

11 c-744G6 ENGINE <1992>- Cylinder Head and Valves - SOHCCYLINDER HEAD AND VALVES - SOHCREMOVAL AND INSTALLATION095 Nm69 fklbs. --11e--2Removal

4G6 ENGINE <1992>- Cvlinder Head and Valves - SOHCIIC-75REMOVAL SERVICE POINTSPRECAUTION FOR REMOVED PARTS(1) Keep removed parts in order accord

1 IC-76466 ENGINE <1992>- Cvlinder Head and Valves - SOHC11 6EN0542FreeIheight1 EN0264Gu:de I.D.Guide O.D.1 EN0279INSPECTIONCYLINDER HEAD(1) Che

4G6 ENGINE <1992>- Cylinder Head and Valves - SOHCIIC-776EN0490.5 - 1 mm (.020- ,039 in.)0.5-I mm(.020-,039 in.)1 EN027~1 EN02RemovalInstallatio

1 IC-78466 ENGINE <1992>- Cylinder Head and Valves - SOHCMD998729-014-l5ENOOl EIdentificationcolorStem seal)LSpring seal1;61I6EN043iIAINSTALLATI

4G6 ENGINE <1992>- Cylinder Head and Valves - SOHCIIC-796EN0545Identification mark(=ICamshaft sprocket side6EN05413MD998051-01OPTIONAL\ -I)D4 CY

IIC-8-4G6 ENGINE <1992> - General SpecificationsGENERAL SPECIFICATIONS4G63 SOHCTypeNumber of cylindersCombustion chamberTotal displacementcm3 (c

11 C-80466 ENGINE <1992>- Cylinder Head and Valves - DOHCCYLINDER HEAD AND VALVES - DOHCREMOVAL AND INSTALLATIONRemoval stepsOArJ )E41. Cylinder

4G6 ENGINE <1992>- Cylinder Head and Valves - DOHC1 W-81MD998735-01REMOVAL SERVICE POINTSOAo CYLINDER HEAD BOLT REMOVAL(1) Using the special too

11 C-824G6 ENGINE <1992>- Cylinder Head and Valves - DOHCCYLINDER HEADCylinder head height (when new):131.9 -132.1 mm (5.193 - 5.201 in.)6EN0491

4G6 ENGINE <1992>- Cylinder Head and Valves - DOHC1 IC-83ValveseathI6EN020!Identification-colorVALVE SEAT REPLACEMENT PROCEDURE(1) Refer to Page

11 C-844G6 ENGINE <1992>- Cylinder Head and Valves - DOHC6EN0209a Camshaft sprocket sidei6 6b 6 66EN0211I)& RETAINER LOCK INSTALLATION(1) Us

4G6 ENGINE <1992> - Front Case, Silent Shaft and Oil Pan1 X-85FRONT CASE, SILENT SHAFT AND OIL PANREMOVAL AND INSTALLATION22 **24 Nm ****40 ftlb

IIC-86466 ENGINE <1992> -Front Case, Silent Shaft and Oil Pan19=-Q&2ow33 Nm24 ft.lbs.-1891\m5-??45 Nm33 ft.lbs.:***** 55 Nm40 ft.lbs.:-55 Nm

4G6 ENGINE <1992>- Front Case, Silent Shaft and Oil Pan1 IC-87Service tool :OlLO583OlLO584Engine with silent shafts6EN0563 16EN05641Engine with

4G6 ENGINE <1992>- Front Case, Silent Shaft and Oil PanEngine with silent shafts(2) Remove the oil pump sprocket nut.OEoSILENT SHAFT FRONT BEARI

4G6 ENGINE <1992>- Front Case, Silent Shaft and Oil PanIIC-89IEngine with silent shaftsIDEN0711-I6LUOO136EN0589Engine with silent shaftsaSocket

4G6 ENGINE <1992>- General Specifications1 TG94661 DOHCTypeNumber of cylindersCombustion chamberTotal displacementcm3 (cu. in.)Cylinder boremm (

IIC-904G6 ENGINE <1992> -Front Case, Silent Shaft and Oil Pan6EN04946EN0494IIEngine without silent shaftsml6EN033YEngine without silent shafts\\

4G6 ENGINE <1992>- Front Case, Silent Shaft and Oil PanIIC-91APP~3EN02219ENOOSLEngine with silent shaftsMD998373-01 6EN05t6EN058I)F~ISEALANT APP

IIC-924G6 ENGINE <1992>- Front Case. Silent Shaft and Oil PanEngine with silent shafts6EN0578Engine with silent shaftsMD998$73-016EN0581Cylinder

4G6 ENGINE <1992> -Front Case, Silent Shaft and Oil PanIIC-93r= Bolt length Imm (in.)]6EN031:tIngine with silent shafts16EN0564Ingi6EN049E(3) Mo

IIC-944G6 ENGINE <1992>- Front Case, Silent Shaft and Oil PanI)N4 OIL PAN INSTALLATION(1) Clean both mating surface of the oil pan and the cylin

4G6 ENGINE <1992>- Piston and Connecting RodPISTON AND CONNECTING ROD1 IC-95REMOVAL AND INSTALLATION6784?9ll-Removal steps1. Nut(IAO )E4 2. Conn

11 C-96466 ENGINE <1992>- Piston and Connecting Rodnumber‘iston pin setting001 MIT2169417EN042E811Press pin--is“‘q::::::::::::. ...: ‘.:.:.y,:,P

4G6 ENGINE <1992>- Piston and Connectina RodlW97v5EN0066f?StOn ring End gapf?StOn ring End gap6EN05413INSPECTIONPISTON(1) Replace the piston if

11 C-984G6 ENGINE <1992>- Piston and Connecting Rod1 EN0271I17EN0428Press pin4:.y.;,):,:‘,’ .:.:A, \/Connecting rod-----guide pin--\ Locknut(3)

4G6 ENGINE <1992> -Piston and Connecting Rodm-996EN02986EN058ESide rail gapd-,1 EN026-t7EN045iSOHC6EN052(8) Check that the piston moves smoothly