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Mitsubishi 4G6 series User Manual
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4G6
ENGINE
(E
-
W)
-
Special
T
ools
1
1A-2-4
T
ool
Use
Name
Number
MD998783
Plug
wrench
retainer
Removal
and
installation
of
front
case
cap
plug
MD998785
Sprocket
stopper
Holding
silent
shaft
sprocket
Added
PWEE9616-A
E
Aug.
1998
Mitsubishi
Motors
Corporation
17
19
Table of Contents
Default Chapter
1
Table of Contents
1
General Information 11A-0-3
3
Sohc-4G63
3
Sohc-4G64
3
Gdit
4
Service Specifications
5
1-1
5
Torque Specifications
8
New Tightening Method - by Use of Bolts to be Tightened in Plastic Area
13
Sealants
13
Form-In-Place Gasket
14
Disassembly
14
Surface Preparation
14
Form-In-Place Gasket Application
14
2 Special Tools
15
2-1
15
3 Alternator and Ignition System
19
Removal and Installation: Carburetor
19
3-1
19
Water Pump Pulley
19
Alternator Brace
19
Crankshaft Pulley
19
Spark Plug
19
Removal and Installation: Multipoint Fuel Injection
20
Camshaft Position Sensing Cylinder (Multipoint Fuel Injection)
20
Camshaft Position Sensor (Multipoint Fuel Injection)
20
Oil Level Gauge Guide
21
Removal and Installation (GDI)
21
Idler Pulley Bracket (M8) (Vehicle for Hong Kong)
21
Idler Pulley Bracket (M10) (Vehicle for Hong Kong)
21
Idler Pulley (Vehicle for Hong Kong)
21
Installation Service Points
22
"AA Camshaft Position Sensor Support
22
"BA Distributor Assembly Installation
22
Removal and Installation (Space Wagon)
23
3A. INTAKE MANIFOLD (GDI)
23
Vacuum Pipe and Hose (Flange Bolt)
23
Vacuum Pipe and Hose (Bolt, Washer Assembly)
23
Solenoid Valve
23
Vacuum Pipe
23
Throttle Body
23
Intake Manifold Stay (M6)
23
Air Intake Plenum Resonator (Flange Bolt)
23
EGR Valve
23
Removal and Installation (Galant)
24
"AA EGR Support / Hose Clamp / Gasket Installation
25
"BA Air Intake Plenum Resonator
25
"CA Intake Manifold Stay Installation
25
"DA Throttle Body Gasket Installation
25
4 Timing Belt
26
4-1
26
Auto Tensioner
26
Engine Support Bracket
26
Idler Pulley
26
Power Steering Bracket
26
Removal and Installation (SOHC)
26
Tensioner Arm
26
AA" Timing Belt Removal
28
AB" Timing Belt Removal
28
AC" Oil Pump Sprocket Removal
28
AD" Crankshaft Bolt Loosening
29
AE" Crankshaft Sprocket Removal
29
AF" Timing Belt "B" Removal
29
AG" Counterbalance Shaft Sprocket
29
"AA Camshaft Sprocket Bolt Tightening
30
"BA Camshaft Sprocket Bolt Tightening
30
AH" Crankshaft Sprocket "B" Removal
30
AI" Camshaft Sprocket Bolt Loosening
30
"CA Engine Support Bracket Installation
31
"DA Spacer Installation
31
"EA Timing Belt "B" Installation
31
"FA Timing Belt "B" Installation
31
"GA Crankshaft Bolt Tightening
32
"HA Oil Pump Sprocket Installation
32
"IA Auto Tensioner Installation
32
"JA Tensioner Pulley Installation
33
"KA Timing Belt Installation
33
"LA Timing Belt Installation
35
Inspection
38
Auto Tensioner
39
Engine Hanger
40
4A. EXHAUST MANIFOLD (GDI)
40
5 Fuel and Emission Control Parts
41
5-1
41
Removal and Installation: Multipoint Fuel Injection - Galant
42
Removal and Installation: Multipoint Fuel Injection - Space Wagon
43
"AA Injectors Installation
44
"BA Fuel Pressure Regulator Installation
44
Removal and Installation (1999 Model Space Wagon)
45
5A. FUEL PARTS (GDI)
45
Fuel Pipe Bracket
46
Fuel Feed Pipe
46
Fuel Return Pipe
46
Fuel High Pressure Regulator
46
Fuel Pressure Sensor
46
Removal and Installation (2000 Model Space Wagon and Galant)
47
"AA Backup Ring/Corrugated Washer
49
"BA Delivery Pipe and Injectior Assembly
49
"CA Pump Camshaft Case Installation
50
"DA Fuel Pressure Sensor Installation
50
"EA Fuel High Pressure Regulator/Fuel Return Pipe Installation
50
"FA Fuel Pump/Fuel Feed Pipe Installation
51
6 Water Pump and Intake Manifold
52
Engine Coolant Temperature Gauge Unit
52
Water Inlet Fitting
52
Thermostat Housing
52
Water Inlet Pipe
52
6-1
52
"AA Water Pipe/O-Ring Installation
55
"BA Sealant Application to Thermostat
55
"CA Sealant Application to Engine Coolant
55
"DA Sealant Application to Engine Coolant
55
Knock Sensor
56
Thermostat Housing
56
Water Inlet Pipe
56
Water Outlet Fitting
56
6A. WATER PUMP and WATER HOSE (GDI)
56
"AA O-Ring/Water Inlet Pipe Installation
57
"BA Thermostat Case Installation
57
"CA Water Outlet Fitting Installation
57
"DA Engine Coolant Temperature Gauge Unit Installation
57
7 Exhaust Manifold
58
Heat Protector
58
Water Outlet Fitting
58
7-1
58
8 Rocker Arms and Camshaft
60
8-1
60
"AA Lash Adjuster Installation
61
"BA Rocker Shaft Spring/Rocker Arms and Rocker Arm Shaft Installation
61
"CA Camshaft Oil Seal Installation
61
AA" Rocker Arms and Rocker Arms Shafts Removal
61
Camshaft
62
Lash Adjusters
62
Rocker Arm
62
Beam Camshaft Cap
66
Camshaft Position Sensing Cylinder
66
8A. ROCKER ARMS and CAMSHAFTS (GDI)
66
AA" Lash Adjuster Removal
67
"BA Beam Camshaft Cap Gasket/Beam Camshaft Cap/Camshaft/Oil Seal Installation
67
"CA Camshaft Position Sensing Cylinder Support Installation
68
"DA Camshaft Position Sensing Cylinder Installation
68
Lash Adjuster
69
9 Cylinder Head and Valves
73
9-1
73
AA" Cylinder Head Bolts Removal
75
AB" Retainer Lock Removal
75
AC" Valve Stem Seal Removal
76
"AA Valve Stem Seal Installation
76
"BA Valve Spring Installation
76
"CA Retainer Lock Installation
77
"DA Cylinder Head Gasket Identification
77
"EA Cylinder Head Bolt Installation
77
Cylinder Head
78
Valve
79
Valve Spring
79
Valve Guide
80
Valve Seat
80
Valve Seat Reconditioning Procedure
80
Valve Seat Replacement Procedure
81
Valve Guide Replacement Procedure
82
Removal and Installation: GDI Engine - Vehicle for Europe and SOHC Engine
83
10 Front Case, Counterbalance Shafts and Oil Pan 11A-10-1
83
Oil Screen
83
Relief Plug
83
Oil Filter Bracket
83
Flange Bolt
83
Removal and Installation: GDI Engine - Vehicle for Hong Kong
84
Oil Level Gauge Guide
84
AA" Oil Pan Removal
85
AB" Oil Pan Lower Removal
85
AC" Oil Pan Upper Removal
85
AD" Plug Removal
85
AF" Counterbalance Shaft Front Bearing Removal
86
AG" Counterbalance Shaft Rear Bearing Removal
86
"AA Right Counterbalance Shaft Rear Bearing Installation
86
"BA Left Counterbalance Shaft Rear Bearing Installation
87
"CA Counterbalance Shaft Front Bearing Installation
87
"DA Counterbalance Shaft Oil Seal Installation
87
"EA Oil Pump Oil Seal Installation
88
"FA Crankshaft Front Oil Seal Installation
88
"GA Oil Pump Driven Gear/Oil Pump Drive Gear Installation
88
"HA Front Case Assembly Installation
88
"IA Sealant Application to Oil Pressure
89
"JA Flange Bolt Installation
89
"KA Plug Installation
89
"LA Oil Pan Installation
89
"MA Oil Pan Upper/Oil Pan Lower Installation
90
"NA Drain Plug Gasket Installation
91
"OA Oil Filter Installation
91
Front Case
92
Oil Seal
92
Counterbalance Shaft
92
Oil Pump
92
Driven Gear 0.06 -
92
11 Piston and Connecting Rod
93
11-1
93
AA" Connecting Rod Cap Removal
94
AB" Piston Pin Removal
94
"AA Piston Pin Installation
95
"BA Oil Ring Installation
96
"CA Piston Ring No. 2/Piston Ring No. 1 Installation
97
"DA Piston and Connecting Rod Assembly Installation
97
"EA Connecting Rod Bearings Installation
97
"FA Connecting Rod Cap Nut Installation
98
"GA Connecting Rod Cap Nut Installation
99
Piston Ring
99
Crankshaft Pin Oil Clearance (Plastic Gauge Method)
100
12 Crankshaft, Flywheel and Drive Plate
101
12-1
101
AA" Oil Jet Removal
102
"AA Oil Jet Installation
102
"BA Crankshaft Thrust Bearing Installation
102
"CA Crankshaft Bearing Installation
102
"DA Bearing Cap/Bearing Cap Bolt Installation
104
"EA Oil Seal Installation
105
"FA Sealant Application to Oil Seal Case
105
Crankshaft Oil Clearance (Plastigage Method)
105
Cylinder Block
106
Boring Cylinder
106
5
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Mitsubishi 4G6 series Specifications
General
Brand
Mitsubishi
Model
4G6 series
Category
Engine
Language
English
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