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Mitsubishi 4G1 series General Information
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4G1 ENGINE (E–W) –
Special T
ools
1
1A-2-3
PWEE9520
E
Nov
. 1995
Mitsubishi Motors Corporation
T
ool
Use
Name
Number
MD998781
Flywheel
stopper
Locking flywheel in fixed position
MD998306
Crankshaft front
oil
seal installer
Installation of crankshaft front oil seal
MB991962
Crankshaft front
oil
seal guide
Guide for installation of crankshaft oil seal
PWEE9520-G
E
Apr
. 2003
Mitsubishi Motors Corporation
Revised
24
26
Table of Contents
Default Chapter
1
Table of Contents
1
General Information
3
Service Specifications
9
1-1
9
Rework Dimensions
13
Torque Specifications
14
New Tightening Method Using Plastic Region Tightening Bolts
20
Sealants
20
Form-In-Place Gasket
21
Surface Preparation
21
Form-In-Place Gasket Application
21
2 Special Tools
23
2-1
23
3 Alternator and Ignition System
26
3-1
26
Removal and Installation
26
Removal and Installation Distributor)>
27
Removal and Installation Cam Position Sensor>
28
Removal and Installation SOHC 16-Valve - Rear Wheel Drive
29
Removal and Installation DOHC
30
Removal and Installation DOHC-GDI
31
Cam Position Sensor Support Installation
32
4 Timing Belt
33
Crankshaft Pulley / Bolt Installation
32
Installation Service Points AA Distributor Installation
32
Removal Service Point AA Crankshaft Bolt Removal
32
4-1
33
Camshaft Sprocket Bolt Removal
37
Removal Service Points
37
Timing Belt / Tensioner Spring / Timing Belt Tensioner Removal
37
Timing Belt Removal
37
Tensioner Pulley and Idler Pulley Inspection
38
Timing Belt Inspection
38
Camshaft Sprocket Bolt Installation
39
Installation Service Points
39
Timing Belt Tensioner / Tensioner Spring Installation
39
Timing Belt Installation
40
Timing Belt Tensioner and Tensioner Spring Installation
42
5 Fuel and Emission Control Systems
44
5-1
44
Fuel Pressure Regulator Installation
51
5A. INTAKE MANIFOLD and THROTTLE BODY (GDI)
52
Removal and Installation
52
Intake Manifold Removal
53
Intake Manifold Stay Installation
53
Removal Service Point
53
5B. EXHAUST MANIFOLD (GDI)
54
Exhaust Manifold (GDI) Removal and Installation
54
6 Water Pump and Water Hose
55
Injector Installation
51
6-1
55
Engine Coolant Temperature Gauge Unit Installation
65
O-Ring / Water Pipe Installation
65
Thermostat Installation
65
Water Pump Installation
65
Thermo Valve Installation
66
Thermostat Housing Installation
66
Water Outlet Fitting Installation
66
7-1
67
Intake and Exhaust Manifold Removal and Installation
67
Reed Valve, Bracket and Air Pipe Installation
75
7A. FUEL SYSTEM (GDI)
76
Fuel System (GDI) Removal and Installation
76
Backup Ring / O-Ring Installation
77
Corrugate Washer Installation
77
Delivery Pipe and Injector Installation
77
Fuel Pump / Backup Ring / O-Ring / Fuel Pipe Installation
78
8 Rocker Arms and Camshafts
79
8-1
79
Lash Adjuster Removal
83
Rocker Arms and Rocker Arm Shafts Removal
83
Camshaft
85
Lash Adjusters
85
Camshaft Installation
90
Adjusting Screw Installation
91
Bearing Cap Installation
91
Rocker Arm Shaft Installation
91
Camshaft Oil Seal Installation
92
Rocker Arm / Rocker Shaft Assembly Installation
92
Semi-Circular Packing Installation
92
Lash Adjuster Installation
93
Rocker Cover Installation
93
Valve Clearance Adjustment
93
Rocker Arms and Camshafts (GDI) Removal and Installation
96
Beam Camshaft Cap Installation
97
Exhaust Camshaft / Intake Camshaft Installation
97
Oil Seal Installation
98
P.C.V. Valve Installation
98
Camshaft Inspection
99
Lash Adjuster
99
9-1
102
Cylinder Head and Valves Removal and Installation
102
Cylinder Head Bolt Removal
106
Retainer Lock Removal
106
Cylinder Head Inspection
107
Valve Stem Seal Removal
107
Valves Inspection
107
Valve Springs
108
Valve Guides
109
Valve Seats
109
Valve Seat Correction Service Points
110
Valve Seat Hole Diameters
111
Valve Seat Replacement Service Points
111
Valve Guide Replacement Service Points
112
Valve Stem Seal Installation
112
Retainer Lock Installation
113
Valve Spring Installation
113
Cylinder Head Bolt Installation
114
10-1
115
Oil Pump and Oil Pan Removal and Installation
115
Oil Pan Removal
118
Oil Pump Inspection
118
Drain Plug Gasket Installation
119
Front Oil Seal Case Installation
119
Front Oil Seal Installation
119
Oil Pan Installation
119
Oil Filter Installation
120
11-1
121
Pistons and Connecting Rods Removal and Installation
121
Connecting Rod Cap Removal
122
Piston Pin Removal
122
Piston Rings Inspection
122
Crankshaft Pin Oil Clearance
123
Piston Pin Installation
123
Oil Ring Installation
124
Piston and Connecting Rod Assembly Installation
125
PISTON RING No. 2 / PISTON RING No. 1 INSTALLATION
125
Connecting Rod Bearing Installation
126
Connecting Rod Cap Installation
127
Connecting Rod Cap Nut Installation
127
12-1
129
Crankshaft and Cylinder Block Removal and Installation
129
Crankshaft Oil Clearance
133
Cylinder Block
133
Oil Pressure Switch Removal
133
Boring Cylinders
134
Oil Pressure Switch Installation
134
Crankshaft Bearing Installation
135
Rear Oil Seal Installation
137
Flywheel Bolt / Drive Plate Bolt Installation
138
Rear Oil Seal Case Installation
138
Service Bulletins
139
M12 Crankshaft Bolt
145
M14 Crankshaft Bolt
147
Other manuals for Mitsubishi 4G1 series
User Manual
97 pages
Workshop Manual
99 pages
4
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Mitsubishi 4G1 series Specifications
General
Brand
Mitsubishi
Model
4G1 series
Category
Engine
Language
English
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