MITSUBISHI 4G63 S4M Engine

Mitsubishi 4G63 S4M (Chery Tiggo 2.0): Experiences, Issues, Fuel Consumption and Maintenance

Introduction and engine origin

The 4G63 engine is one of the most famous powerplants in automotive history. While its turbo versions powered the legendary Mitsubishi Lancer Evolution models, the S4M version (SOHC – single overhead camshaft) found in Chery Tiggo (T11) models is a “civilian”, workhorse variant designed for longevity rather than racing.

In Chery models this engine is not just a random Chinese copy, but a licensed unit that shares a huge number of parts with models such as the Mitsubishi Galant, Space Wagon or the first-generation Outlander. This is good news for owners, as it means you are not dependent solely on Chinese spare parts, but can use quality Japanese aftermarket parts. It was primarily installed in the Chery Tiggo 2.0, offering a solid balance between power and ease of maintenance.

Technical specifications

Parameter	Value
Displacement	1997 cc (2.0 L)
Power	92 kW (125 hp) at 6000 rpm
Torque	168 Nm at 3000–4500 rpm
Engine code	4G63 S4M
Injection type	MPI (Multi-Point Injection)
Aspiration	Naturally aspirated
Number of valves	16 (SOHC – single camshaft)
Camshaft drive	Timing belt

Reliability and Maintenance

Does this engine have a timing belt or a chain?

This engine uses a timing belt. However, this is where the most important technical note lies: it has two belts. One is the main timing belt that drives the camshaft, and the other is a smaller belt that drives the balance shafts (used to reduce vibrations). If the small balance shaft belt snaps, it almost always gets caught under the main timing belt, causing the timing to jump and severe engine damage (piston-to-valve contact). That’s why both belts must be replaced at the same time.

What are the most common issues with this engine?

Although the engine is robust, age and mileage take their toll:

• Hydraulic lifters: A “ticking” or “clattering” noise is often heard when the engine is cold. This indicates dirty or worn hydraulic lifters. Good-quality oil can alleviate the problem.
• Idle air control valve (IAC): Symptoms include fluctuating idle speed or stalling when stopping at traffic lights. Cleaning sometimes helps, but replacement is often required.
• Ignition coils and leads: The ignition system is sensitive to moisture and age. Faults show up as jerking while driving or rough engine operation.
• Oil leaks: Most commonly from the valve cover gasket (easy to replace) or crankshaft oil seals.

At what mileage should the major service be done?

The recommended interval for replacing the timing belt, tensioners, water pump and balance shaft belt is between 60,000 km and 80,000 km, or every 5 years, whichever comes first. Due to the risk of the small belt snapping, it’s advisable to stick to a 60,000 km interval, especially if you use mid-range aftermarket parts.

How many liters of oil does this engine take and which grade is recommended?

The sump holds approximately 4.0 to 4.3 liters of oil (including the filter). The recommended grade is 5W-40 or 10W-40 (semi-synthetic). For higher-mileage engines (over 200,000 km), 10W-40 is a better choice, as it is thicker and seals better.

Does it consume oil between services?

A small amount of oil consumption is normal for this engine design. Up to 0.5 to 0.8 liters per 10,000 km is considered acceptable. However, if consumption exceeds 1 liter over a service interval, the usual culprits are hardened valve stem seals (common on older 4G63 engines) or stuck oil control rings.

At what mileage should the spark plugs be replaced?

This engine uses standard spark plugs. Replacement is recommended every 30,000 to 40,000 km if you use standard copper/nickel plugs. If you fit iridium plugs, the interval can be extended to 60,000 km or more. Regular replacement is crucial to protect the ignition coils.

Specific Parts (Costs)

Does the engine have a dual-mass flywheel?

No, the petrol 4G63 in the Chery Tiggo generally uses a solid flywheel. This is a big advantage, as it makes clutch replacement significantly cheaper compared to modern diesels.

What type of injection system does it have and are the injectors problematic?

It uses a classic MPI (Multi-Point Injection) system. Petrol injectors are very durable and rarely cause issues, unless extremely poor-quality fuel is used. Preventive ultrasonic injector cleaning is recommended every 100,000 km.

Does the engine have a turbocharger, DPF filter or AdBlue?

No, no and no. This engine is naturally aspirated (no turbo), which means there are no expensive turbocharger overhauls. As a petrol engine of that era, it has no DPF filter and does not use AdBlue fluid. There is a catalytic converter and an EGR valve (depending on market), but they are far less problematic than on diesel engines. Exhaust aftertreatment maintenance is minimal.

Fuel Consumption and Performance

What is the real-world fuel consumption in city driving?

Expect higher figures. The Chery Tiggo has poor aerodynamics and a fairly high weight. In pure city driving, real consumption ranges from 11 to 13 liters per 100 km. In winter or heavy traffic, it can reach 14 liters. This is not an engine for those who want to save on petrol.

Is this engine “lazy” for the weight of the car?

With 125 hp and 168 Nm, the engine is adequate but not sporty. At low revs (below 2500 rpm) it feels somewhat sluggish (“lazy”), as maximum torque is reached at higher revs. To get enough power for overtaking, you need to rev it above 3500–4000 rpm, when it becomes noisier but also livelier.

How does the engine behave on the motorway and at what revs does it cruise at 130 km/h?

Due to the short-ratio gearbox (5 speeds), at 130 km/h the engine spins at a fairly high 3500 to 3800 rpm. This results in increased cabin noise and motorway consumption of around 8.5 to 9.5 liters. It’s not an ideal long-distance cruiser at high speeds, but it is perfectly capable of trips at a more moderate pace (110–120 km/h).

Additional Options and Modifications

Is this engine suitable for LPG conversion?

Absolutely yes. This is one of the best candidates for LPG conversion. It has a metal intake manifold (in most versions) and hydraulic valve lifters, which means it does not require expensive manual valve clearance adjustment. With a quality sequential LPG system, running costs drop dramatically and the engine handles this fuel very well.

How much can this engine be safely “chipped” (Stage 1)?

Since this is a naturally aspirated engine, remapping (chip tuning) doesn’t make much sense. The power gain would be negligible (at most 5–8 hp), which you won’t really feel in everyday driving. It’s better to invest that money in proper maintenance (plugs, leads, filters) so the engine can deliver its original 125 hp.

Gearbox

Which gearboxes are fitted and what are the most common issues?

This engine is most commonly paired with a 5-speed manual gearbox. A 4-speed automatic, also of older design, is less common.

• Manual gearbox: Generally reliable, but the shift feel is somewhat “rubbery”. The most common issue is with the second-gear synchro, which shows up as grinding when shifting quickly from first to second. The shift cables can also seize.
• Automatic gearbox: Slow and increases fuel consumption by about 1–2 liters. If the oil is not changed regularly, it starts to jerk when changing gears.

How much does clutch replacement cost?

Since there is no dual-mass flywheel, replacing the clutch kit (pressure plate, disc, release bearing) falls into the category of affordable repairs. Parts are reasonably priced (varies by market, but not expensive), and the job is routine for any mechanic.

At what mileage should the gearbox be serviced?

For the manual gearbox, it is recommended to change the oil every 60,000 to 80,000 km (75W-90 is used). For the automatic gearbox, oil and filter changes are mandatory every 60,000 km to extend its service life.

Used Car Buying and Conclusion

When buying a used Chery Tiggo with this engine, pay attention to the following:

• Noise on cold start: Sharp ticking indicates worn hydraulic lifters.
• Exhaust smoke: Bluish smoke when you press the throttle or after idling is a clear sign of worn valve stem seals or piston rings.
• Timing belt service history: If the seller has no proof of replacement, treat the car as if the belt change is urgent and factor the cost of a major service into the price.
• Vibrations: Strong vibrations in the steering wheel at idle may indicate worn engine mounts or incorrectly timed balance shafts.

Conclusion: The Mitsubishi 4G63 S4M in the Chery Tiggo body is a good choice for drivers who want simplicity and low maintenance costs, and are willing to accept higher fuel consumption and somewhat poorer sound insulation. It is ideal for those planning to install LPG and drive on rougher roads, where the robustness of this engine really shines. It is not for those seeking sporty performance or low city fuel consumption.