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Mitsubishi 4G1 series Workshop Manual
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4G1
ENGINE
(E
-
W)
-
Specifications
1
1A-1-5a
PWEE9520
E
Nov
.
1995
Mitsubishi
Motors
Corporation
Item
Nm
Crankshaft
and
cylinder
block
Flywheel
132
Drive
plate
132
Rear
plate
10
Bell
housing
cover
10
Rear
oil
seal
case
11
Bearing
cap
bolt
51
Oil
pressure
switch
18
Knock
sensor
23
PWEE9520-A
E
Dec.
1998
Mitsubishi
Motors
Corporation
Added
15
17
Table of Contents
Table of Contents
1
Engine 4G1 Series
1
General Information
3
Service Specifications
9
1-1
9
Rework Dimensions
13
Torque Specifications
14
New Tightening Method Using Plastic Region Tightening Bolts
18
Sealants
18
Form-In-Place Gasket
19
Disassembly
19
Surface Preparation
19
Form-In-Place Gasket Application
19
Special Tools
21
2-1
21
Alternator and Ignition System
23
3-1
23
Removal Service Point
27
Installation Service Points
27
Crankshaft Bolt Installation
27
Timing Belt Removal and Installation
29
4-1
29
Camshaft Sprocket Bolt Removal
31
Removal Service Points
31
Camshaft Sprocket Bolt Installation
32
Tensioner Pulley and Idler Pulley
32
Timing Belt Tensioner/Tensioner Spring Installation
32
Timing Belt Installation
33
Fuel and Emission Control System 11A-5-1
35
Fuel Pressure Regulator Installation
40
Injector Installation
40
Water Pump and Water Hose Removal and Installation
41
6-1
41
O-Ring/Water Pipe Installation
46
Thermostat Installation
46
Water Pump Installation
46
Water Temperature Gauge Unit Installation
46
Thermo Valve Installation
47
11A-7-1
49
Intake and Exhaust Manifolds Removal and Installation
49
Reed Valve, Bracket and Air Pipe Installation
54
11A-8-1
56
Rocker Arms and Camshafts Removal and Installation
56
Camshaft Inspection
60
Lash Adjusters Inspection
60
Camshaft Installation
63
Adjusting Screw Installation
64
Bearing Cap Installation
64
Rocker Arm Shaft Installation
64
Camshaft Oil Seal Installation
65
Rocker Arm/Rocker Shaft Assembly
65
Semi-Circular Packing Installation
65
Rocker Cover Installation
66
Valve Clearance Adjustment
66
Cylinder Head and Valves Removal and Installation
68
9-1
68
Valve Stem Seal Removal
73
Cylinder Head Inspection
73
Valves Inspection
73
Valve Springs
74
Valve Guides
75
Valve Seats
75
Valve Seat Correction Service Points
76
Valve Seat Replacement Service Points
76
Valve Stem Seal Installation
77
Valve Guide Replacement Service Points
77
Valve Spring Installation
78
Retainer Lock Installation
78
Cylinder Head Bolt Installation
78
Oil Pump and Oil Pan Removal and Installation
80
10-1
80
Oil Pan Removal
81
Oil Pump Inspection
81
Front Oil Seal Case Installation
82
Front Oil Seal Installation
82
Oil Pan Installation
82
Drain Plug Gasket Installation
82
Oil Filter Installation
83
Pistons and Connecting Rods Removal and Installation
84
11-1
84
Piston Rings Inspection
85
Piston Pin Removal
85
Connecting Rod Cap Removal
85
Crankshaft Pin Oil Clearance (Plastic Gauge Method)
86
Piston Pin Installation
86
Oil Ring Installation
87
Piston Ring Installation
88
Piston and Connecting Rod Assembly Installation
88
Connecting Rod Bearing Installation
89
Connecting Rod Cap Nut Installation
90
Connecting Rod Cap Installation
90
Crankshaft and Cylinder Block Removal and Installation
92
12-1
92
Oil Pressure Switch Removal
94
Crankshaft Oil Clearance
94
Cylinder Block
94
Boring Cylinders
95
Oil Pressure Switch Installation
95
Crankshaft Bearing Installation
96
Rear Oil Seal Installation
98
Other manuals for Mitsubishi 4G1 series
User Manual
97 pages
General Information
147 pages
4
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Mitsubishi 4G1 series Specifications
General
Brand
Mitsubishi
Model
4G1 series
Category
Engine
Language
English
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