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GROUP 11B
ENGINE OVERHAUL
<4G1>
CONTENTS
HOW TO USE THIS MANUAL. . . . . .
11B-2
GENERAL INFORMATION . . . . . . . .
11B-4
GENERAL SPECIFICATIONS . . . . . .
11B-22
11B-4
ROCKER ARMS AND CAMSHAFT . . 11B-23
SERVICE SPECIFICATIONS. . . . . . .
11B-4
11B-23
11B-25
REWORK DIMENSIONS . . . . . . . . . .
11B-6
TORQUE SPECIFICATIONS . . . . . . .
11B-6
SEALANTS . . . . . . . . . . . . . . . . . . . .
11B-8
11B-27
SPECIAL TOOLS. . . . . . . . . . . . . . . .
11B-9
11B-30
ALTERNATOR AND
IGNITION SYSTEM . . . . . . . . . . . . . .
11B-12
TIMING BELT. . . . . . . . . . . . . . . . . . .
11B-12
11B-14
11B-14
11B-17
11B-33
11B-35
11B-37
11B-43
11B-18
11B-20
CRANKSHAFT AND
CYLINDER BLOCK . . . . . . . . . . . . . . 11B-44
CRANKSHAFT AND CYLINDER BLOCK
REMOVAL AND INSTALLATION . . . . . . . .
11B-44
11B-47
11B-2
. . . . . . . . . . Grease
. . . . . . . . . . Sealant or form-in-place gasket (FIPG)
. . . . . . . . . . Brake fluid
. . . . . . . . . . Engine oil or gear oil
Inspection
Only those inspection procedures which use special tools or measuring appliances are described. You must perform general visual inspection and part cleaning whenever necessary although their procedures are not described in this manual.
AK202851
11B-3
Page number
Group title
Section title
ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK
11-54
11 1 Nm
132 5 Nm
16
11 1 Nm
9.0 1.0 Nm
Tightening torque
15
14
13
12
11
10
25 2 Nm + 90 to 100
AK204351AB
Removal steps
1. Drive plate bolt
2. Adapter plate
3. Drive plate
4. Crankshaft bushing
5. Rear plate
6. Bellhousing cover
>>E<< 7. Oil seal case
>>D<< 8. Oil seal
>>C<< 9. Bearing cap bolt
10. Bearing cap
>>B<< 11. Crankshaft bearing, lower
>>A<< 12. Crankshaft
Grooves
AK100786AB
Procedures and cautions for removal, installation, disassembly, and reassembly are explained under this category of heading.
AK300250
11B-4
GENERAL INFORMATION
GENERAL INFORMATION
M1113000100277
Vehicle name
Vehicle
model
Engine model
Displacement Specification
cc
Lancer
CS1A
4G13-J
1,299
CS3A
4G18-V, 4G18-J
1,584
CA3W
4G18-V, 4G18-J
1,584
Lancer wagon
GENERAL SEPCIFICATIONS
M1113000200520
Items
4G13-SOHC
4G18-SOHC
Bore stroke mm
71 82
76 87.3
Displacement cc
1,299
1,584
Number of cylinders
Valve mechanism
Type
Hydraulic
Rocker arms
Compression ratio
10.0
Lubrication system
Trochoid type
Cooling system
SERVICE SPECIFICATIONS
M1113000300464
Items
Standard value
Limit
Intake
36.86
36.36
Exhaust
36.68
36.18
Intake
37.17
36.67
Exhaust
36.99
36.49
0.03 or less
0.2
0.2
119.9 120.1
103.2
4G13
4G18
11B-5
SERVICE SPECIFICATIONS
Items
Standard value
Limit
Intake
1.0
0.5
Exhaust
1.5
1.0
Intake
0.020 0.047
0.10
Exhaust
0.030 0.057
0.15
Intake
53.21
53.71
Exhaust
54.10
54.60
Intake
111.56
111.06
Exhaust
114.71
114.21
50.87
49.87
2 or less
0.9 1.3
22.7 23.3
0.06 0.18
0.04 0.10
0.10 0.18
0.35
No.1 ring
0.03 0.07
0.1
No.2 ring
0.02 0.06
0.1
No.1 ring
0.20 0.35
0.8
No.2 ring
0.35 0.50
0.8
Oil ring
0.10 0.40
1.0
0.02 0.04
0.1
0.10 0.25
0.4
0.05 0.18
0.25
0.02 0.04
0.1
0.02 0.04
0.05 or less
0.1
0.01 or less
4G13
71.0
4G18
76.0
0.02 0.04
Valve margin mm
Valve stem-to-guide clearance mm
Valve stem projection mm
Overall valve length mm
Cylinder bore mm
Piston-to-cylinder clearance mm
11B-6
REWORK DIMENSIONS
REWORK DIMENSIONS
M1113024300220
Items
Standard value
Intake
Exhaust
0.03 oversize
30.30 30.32
0.06 oversize
30.60 30.62
0.03 oversize
28.30 28.32
0.06 oversize
28.60 28.62
0.05 oversize
10.55 10.57
0.25 oversize
10.75 10.77
0.50 oversize
11.00 11.02
TORQUE SPECIFICATIONS
M1113023400558
Items
Specifications
8.8 1.0 Nm
22 4 Nm
14 1 Nm
181 Nm
23 2 Nm
24 3 Nm
44 10 Nm
10 2 Nm
24 4 Nm
Spark plug
25 4 Nm
9 2 Nm
Timing belt
Camshaft sprocket bolt
88 10 Nm
8.8 1.0 Nm
21 4 Nm
36 6 Nm
11 2 Nm
23 3 Nm
12 1 Nm
9.0 2.0 Nm
9.0 1.0 Nm
19 3 Nm
9.0 1.0 Nm
11B-7
TORQUE SPECIFICATIONS
Items
Specifications
10.8 1.0 Nm
29 9 Nm
24 4 Nm
22 4 Nm
13 2 Nm
14 1 Nm
21 4 Nm
19 3 Nm
35 6 Nm
30 3 Nm
30 3 Nm
18 2 Nm
18 2 Nm
31 3 Nm
18 2 Nm
5.0 1.0 Nm
Oxygen sensor
44 5 Nm
18 2 Nm
35 6 Nm
49 9 Nm
31 3 Nm
3.5 0.5 Nm
20 2 Nm + 90 + 90
39 5 Nm
16 4 Nm
14 2 Nm
7.0 1.0 Nm
14 1 Nm
10 2 Nm
19 3 Nm
Relief plug
44 5 Nm
23 4 Nm
17 2 Nm + 90 to 94
11B-8
Items
Specifications
34 2 Nm + 30 to 34
9.0 1.0 Nm
132 5 Nm
Flywheel bolt
132 5 Nm
19 3 Nm
11 1 Nm
10 2 Nm
SEALANTS
M1113000500457
Items
Specified sealants
Water pump
Oil pan
11B-9
SPECIAL TOOLS
APPLICATION OF FIPG
Applied FIPG bead should be of the specified size
and free of any break. FIPG can be wiped away
unless it has completely hardened. Install the mating
parts in position while the FIPG is still wet (in less
than 15 minutes after application). Do not allow FIPG
to spread beyond the sealing areas during
installation. Avoid operating the engine or letting oils
or water come in contact with the sealed area before
a time sufficient for FIPG to harden (approximately
one hour) has passed. FIPG application method may
vary from location to location. Follow the instruction
for each particular case described later in this
manual.
SPECIAL TOOLS
M1113000600517
Tool
Number
Name
Use
MD998781
Flywheel stopper
MB990767
MD998719
MD998443
MD998713
D998781
B990767
D998719
D998443
D998713
11B-10
SPECIAL TOOLS
Tool
Number
Name
Use
MD998442
MB991653
MD998772
Valve spring
compressor
MD998735
Valve spring
compressor
MD998760
MD998727
MB991962
MD998306
MD998760
D998727
MB991962
MD998306
11B-11
SPECIAL TOOLS
Tool
Number
Name
Use
MD998780
MB991614
Angle gauge
MD998011
MB991614
MD998011
11B-12
10 2 Nm
11
10
8.8 1.0 Nm
13
10
25 5 Nm
12
14
15
11
16
44 10 Nm
22 4 Nm
23 2 Nm
14 1 Nm
7
24 3 Nm
9.0 2.0 Nm
24 4 Nm
2
3
4
8
AK300362AB
181 Nm
1.
2.
3.
4.
5.
6.
7.
<<A>> >>C<< 8.
Removal steps
Oil level
Oil level guide
O-ring
Drive belt
Water pump
Alternator brace
Alternator
Crankshaft pulley bolt
11B-13
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
3. After installation, wait at least one hour. Never
start the engine or let engine oil touch the
adhesion surface during that time.
>>C<< CRANKSHAFT BOLT INSTALLATION
MD998781
AK201769AC
MD998781
AK201768 AD
Crankshaft
MD998781
AK201768 AD
Degrease
Clean
AK300372AB
AK300004AB
Groove
AK201822 AB
11B-14
TIMING BELT
TIMING BELT
REMOVAL AND INSTALLATION
M1113001900555
11
1
11 2 Nm
13
36 6 Nm
88 10 Nm
12
10
5
21 4 Nm
21 4 Nm
23 3 Nm
36 6 Nm
8
9
3
4
8.8 1.0 Nm
2
AK300363AB
<<A>> >>D<<
>>C<<
>>C<<
>>B<<
1.
2.
3.
4.
5.
6.
7.
Removal steps
Timing belt upper cover
Timing belt lower cover
Timing belt
Tensioner spring
Timing belt tensioner
Crankshaft position sensor
Crankshaft sprocket
11B-15
TIMING BELT
AK300006AB
AK300373AB
Sensing
blade
Spacer
Crankshaft
MB990767
Clean
Degrease
AK300007AB
MD998719
AK300005AB
A
A
Pin
Pin hole
AK300207 AB
11B-16
CAUTION
AK300374 AB
Camshaft
sprocket
AK300375AB
Tensioner
pulley
Crankshaft
sprocket
AK300481AB
AK300377AB
11B-17
TIMING BELT
Rounded edge
CAUTION
Abnormal wear
(Fluffy strand)
AK202795 AB
INSPECTION
M1113002000414
TIMING BELT
Check the timing belt closely. Replace the belt with a
new one if any the following defects are evident:
AK202796 AB
AK202794
Peeling of canvas
2.
3.
4.
5.
Cracks
Cracks in sides
AK202793 AB
AK300580
11B-18
9.0 1.0 Nm
7
9.0 2.0 Nm
11 1 Nm
2
9.0 1.0 Nm
9.0 1.0 Nm
8
16
14
3
4
15
13
19 3 Nm
12
10
6
11
AK300364AB
1.
2.
3.
4.
5.
>>C<< 6.
>>C<< 7.
>>B<< 8.
Removal steps
Vacuum pipe and hose
Purge hose
Solenoid valve
Solenoid valve
Throttle body assembly
Gasket
Vacuum hose
Fuel pressure regulator
9.
10.
11.
12.
>>A<< 13.
14.
15.
16.
11B-19
CAUTION
Projection
CAUTION
AK300378AB
11B-20
13 2 Nm
9
10
13 2 Nm
29 9 Nm
11
7
6
22 4 Nm
12
4
24 4 Nm
10.8 1.0 Nm
14 1 Nm
AK300365AB
1.
2.
>>E<< 3.
>>D<< 4.
5.
>>C<< 6.
Removal steps
Water hose
Water hose
Engine coolant temperature sensor
Engine coolant temperature gauge
unit
Water inlet fitting
Thermostat
>>B<<
>>B<<
>>B<<
>>A<<
7.
8.
9.
10.
11.
12.
11B-21
AK300379AB
AK300581
CAUTION
AK300380
11B-22
21 4 Nm
5.0 1.0 Nm
4
44 5 Nm
18 2 Nm
19 3 Nm
12
10
9
13
18 2 Nm
16
49 9 Nm
15
30 3 Nm
5
18 2 Nm
31 3 Nm
18 2 Nm
30 2 Nm
17
35 6 Nm
11
14
19 3 Nm
35 6 Nm
AK300366 AB
1.
2.
3.
4.
5.
6.
7.
8.
9.
Removal steps
Boost sensor
O-ring
EGR valve
EGR gasket
Power plant stay right
Intake manifold stay
Throttle body stay
Intake manifold
Intake manifold gasket
10.
11.
12.
13.
14.
15.
16.
17.
18.
11B-23
2
1
4
5
3.5 0.5 Nm
31 3 Nm
10
14
11
17
13
12
15
18
16
8
19
AK300367AB
1.
2.
3.
4.
5.
6.
7.
8.
>>D<< 9.
<<A>> >>C<< 10.
Removal steps
Breather hose
PCV hose
Oil filler cap
PCV valve
PCV valve gasket
Rocker cover
Rocker cover gasket
Oil seal
Camshaft oil seal
Rocker arms and shaft
12.
13.
14.
15.
16.
17.
18.
19.
Rocker arm a
Rocker arm b
Rocker arm shaft
Lash adjuster
Rocker arm c
Rocker arm shaft
Lash adjuster
Camshaft
11B-24
MD998443
Notch
AK300583 AB
CAUTION
AK300381AB
A B
A B
C
C
C
Identification mark
AK300382AB
CAUTION
11B-25
INSPECTION
M1113005500430
CAMSHAFT
Diesel fuel
AK300587AB
AK300585
Standard
value mm
Limit mm
4G13
36.86
36.36
4G18
37.17
36.67
4G13
36.68
36.18
4G18
36.99
36.49
Diesel fuel
MD998442
LASH ADJUSTERS
!
AK202680 AB
CAUTION
For finish
cleaning
For diesel
fuel filling
CAUTION
AK300586 AB
MD998442
Diesel fuel
AK202681AB
11B-26
CAUTION
Diesel fuel
MD998442
AK202680 AB
CAUTION
Diesel
fuel
AK202683 AB
MD998442
Diesel fuel
AK202681AB
Diesel
fuel
AK202682AB
AK300588
11B-27
49 2 Nm 0 Nm
20 2Nm 90 + 90
1
9
4
10
14
6
15
12
17
13
16
20
19
11
18
7
AK300368 AB
<<A>> >>D<<
<<B>> >>C<<
>>B<<
<<B>> >>C<<
>>B<<
Removal steps
1. Cylinder head bolt
2. Cylinder head assembly
3. Cylinder head gasket
4. Retainer lock
5. Valve spring retainer
6. Valve spring
7. Exhaust valve
8. Retainer lock
9. Valve spring retainer
10. Valve spring
11.
<<C>> >>A<< 12.
13.
<<C>> >>A<< 14.
15.
16.
17.
18.
19.
20.
11B-28
MB991653
AK300589
AK300009AB
AK300012AB
AK300383 AB
MD998772
CAUTION
AK300010AB
Painted
end
Spring
retainer
Stem
seal
Spring
seat
AK300590AB
11B-29
AK300009AB
AK300383 AB
10
AK300384 AB
AK300010AB
90
Paint marks
AK300592 AB
Shank length
AK300591AB
CAUTION
11B-30
INSPECTION
M1113007000420
CYLINDER HEAD
Standard value:
Intake: 1.0 mm
Exhaust: 1.5 mm
Limit:
Intake: 0.5 mm
Exhaust: 1.0 mm
AK201792
Total length
AK103808AC
Free height
Contact
(Should be at
center of face)
AK300594 AB
Margin
AK300593AB
11B-31
VALVE GUIDES
Intake side
Exhaust side
0.9 1.3 mm
0.9 1.3 mm
65
Valve
guide
Stem diameter
Guide inside diameter
65
15
AK300595 AB
43.5 44
AK300385AB
Valve stem
projection
Spring
seating
surface
15
0.5 1 mm
Cut
AK300596 AB
0.5 1 mm
AK300597 AB
Limit:
Intake: 53.71 mm
Exhaust: 54.60 mm
Valve seat
height
11B-32
CAUTION
Protrusion
AK300386AB
CAUTION
11B-33
10 2 Nm
13
15
14
14 1 Nm
8
7
16
17
12
19 3 Nm
39 5 Nm
11
2
10
9
3
7.0 1.0 Nm
44 5 Nm
1
5
23 4 Nm
AK300369AB
>>E<< 1.
2.
>>D<< 3.
4.
<<A>> >>C<< 5.
6.
7.
8.
Removal steps
Oil filter
Drain plug
Gasket
Transmission stay
Oil pan
Oil screen
Gasket
Relief plug
9.
10.
>>B<< 11.
>>A<< 12.
13.
14.
15.
16.
11B-34
M8 25 mm
M8 20 mm
M8 65 mm
M8 30 mm
MD998727
M8 70 mm
AK202493 AD
!
AK300599 AB
CAUTION
AK300388AB
AK300387AB
AK300600AB
2. Apply engine oil to the oil seal lip, then push the
oil seal along the guide by hand until it touches
the front case. Tap the oil seal into place using the
special tool Camshaft oil seal installer
(MD998306).
11B-35
CAUTION
4 mm
AK300390AB
CAUTION
INSPECTION
M1113008200256
OIL PUMP
Oil pan
side
AK300603
AK300601AB
11B-36
AK300391
11B-37
6
7
8
10
12
11
17 2 Nm + 90 to 94
3
1
2
AK300370 AB
<
>>G<
1.
>
<<A>
>>F<< 2.
<
>>D<
3.
<
>>E<
4.
<
>>D<
5.
<
>>C<
6.
Removal steps
Connecting rod nut
Connecting rod cap
Connecting rod bearing
Piston and connecting rod assembly
Connecting rod bearing
Piston ring no.1
>>C< 7.
<
<
>>B<
8.
<<B> >>A<
>
<
9.
10.
11.
12.
11B-38
Push rod
P
Cylinder
number
Front mark
Front mark
P
Guide D
AK300604 AB
Base
Guide B
AK300392AB
Guide A: 18.9 mm
Guide C
Guide A: 20.9 mm
Base
Guide A: 21.9 mm
No.2
Manufacturing
date
AK300605 AB
No.3
No.4
AK300208 AB
11B-39
3 mm + L
Guide A
AK300393 AB
Push rod
Connecting rod
P
Piston
Piston pin
Front mark
Front mark
B
P
Guide A
Base
AK202607 AB
Guide B
AK300394AB
11B-40
AK300606 AB
AK300607 AB
Upper
side rail
Spacer
Identification mark
No.1 ring
1T
No.2 ring
Lower side rail
AK300395AB
4G13
2T
4G18
T2
Identification marks
Size marks
1. Fit the oil ring spacer into the piston ring groove.
Then, fit the upper and lower side rails.
NOTE: The spacer and side rails may be fitted in
either direction. No distinction is made between
top and bottom.
NOTE: Spacer and side rail sizes are color-coded
as follows:
No. 1
No. 2
Size
Color mark
Engine model
Standard
No mark
4G13, 4G18
0.25 mm oversize
White
4G18
0.50 mm oversize
Blue
4G13, 4G18
Size
Size mark
Engine model
Standard
No mark
4G13, 4G18
0.25 mm oversize
25
4G18
0.50 mm oversize
50
4G13, 4G18
1.00 mm oversize
100
4G13
CAUTION
AK300608 AB
11B-41
4G18
No.1
No.4
No.2
No.4
No.2
No.3
No.3
No.2
A
A
No.1
B
B No.1
P
P
No.1
No.2
No.4
No.3
AK300014 AB
AK300396AB
Connecting rod
Identification color or
mark
Size mm
Identification color
Identification color or
mark
Yellow or I
41.995 42.000
White
Yellow or 1
None
Yellow or 1
Yellow
None or 2
White
Yellow or 1
None
None or 2
Yellow
Blue or 3
White
None or 2
None
Blue or 3
Yellow
Blue or 3
None or II
White or III
41.985 41.995
41.980 41.985
11B-42
Connecting bearing
Cylinder
number
Identification
color position
Identification
mark position
AK300397AB
Timing
belt side
No. 2
No. 1
Bearing
locating
notches
AK300604 AC
Piston pin
Side rail
AK300609 AB
AK300610
AK300611
11B-43
90 to 94
Paint marks
Nut
Bolt
Piston ring
End gap
AK300612 AB
CAUTION
INSPECTION
M1113008500417
PISTON RING
AK300614AB
AK300613
AK300615 AB
11B-44
CAUTION
On the flexible flywheel equipped engines, do 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 and resulting
in damage.
Apply engine oil
to all moving
parts before
installtion.
10
10 2 Nm
1
19 3 Nm
2
20
19
132 5 Nm
11 1 Nm
13
4
3
11
132 5 Nm
12
18
10 2 Nm
17
7
9
8
16
15
34 2 Nm + 30 to 34
14
AK300371 AB
1.
2.
3.
4.
5.
6.
7.
8.
Removal steps
Flywheel bolt <M/T>
Flywheel <M/T>
Drive plate bolt <A/T>
Adapter plate <A/T>
Drive plate <A/T>
Crankshaft bushing <A/T>
Rear plate
Bell housing cover
>>E<< 9.
>>D<< 10.
>>C<< 11.
>>C<< 12.
>>B<< 13.
11B-45
MD998054
AK300617AB
AK300616AB
CAUTION
4G13
4G18
No.3
No.4
No.1
No.4
No.1
No.5
No.2
No.5
No.2
No.2 No.3
No.2
No.4
No.1
No.5
No.1
No.4
No.5
No.2
No.4
No.1
No .5
B
AK300015AB
11B-46
Crankshaft bearing
Identification color or
mark
Size mm
Identification mark
Identification color or
mark
Yellow or 1
47.994 48.000
Brown or 1
None or 2
Blue or 3
None or 2
Blue or 3
Yellow or 4
Blue or 3
Yellow or 4
Green or 5
47.988 47.994
None or 2
47.982 47.988
White or 3
Cap No.
Identification
mark position
AK300399 AB
AK300397AC
Grooveless
Grooved
27
300
120
330
90
30
60
Upper bearing
(Nos.1, 2, 4 and 5)
Lower bearing
(Nos.1, 2, 4 and 5)
AK201809AC
Crankshaft bearing
Identification
color position
Arrow
Grooveless
3
AK300398AB
to
0
34
AK201811AC
11B-47
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
3. Install the oil seal into the cylinder block after
applying an appropriate amount of engine oil to
the entire circumference of its lip portion.
4. Install the rear oil seal case by tightening its bolts
to 11 1 Nm.
AK201815
INSPECTION
M1113008800418
AK201813AC
AK201812 AC
AK201814
AK102248
11B-48
Fillet-rolled section
AK300618AB
NOTE: The crankshaft pins and journals are filletrolled and must not be machined to undersize
dimensions.
CYLINDER BLOCK
A
B
F
G
12 mm
Piston outside diameter
AK300400 AB
Size
Size mark
Engine model
0.25 mm oversize
25
4G18
0.50 mm oversize
50
4G13, 4G18
1.00 mm oversize
100
4G13
12 mm
AK201817 AC
CAUTION
11B-49
127(6