EasyManua.ls Logo

Mitsubishi 4g63 User Manual

Mitsubishi 4g63
68 pages
To Next Page IconTo Next Page
To Next Page IconTo Next Page
Page #1 background imageLoading...
Page #1 background image
11D-1
GROUP 11D
ENGINE OVERHAUL
<4G63-Turbo>
CONTENTS
HOW TO USE THIS MANUAL. . . . . . 11D-2
GENERAL INFORMATION . . . . . . . . 11D-4
GENERAL SPECIFICATIONS . . . . . . 11D-4
SERVICE SPECIFICATIONS. . . . . . . 11D-5
REWOK DIMENSIONS . . . . . . . . . . . 11D-6
TORQUE SPECIFICATIONS . . . . . . . 11D-7
SEALANTS . . . . . . . . . . . . . . . . . . . . 11D-10
SPECIAL TOOLS. . . . . . . . . . . . . . . . 11D-11
ALTERNATOR AND IGNITION
SYSTEM. . . . . . . . . . . . . . . . . . . . . . . 11D-14
REMOVAL AND INSTALLATION . . . . . . . . 11D-14
SOLENOID AND VACUUM HOSE . . 11D-15
REMOVAL AND INSTALLATION . . . . . . . . 11D-15
TIMING BELT. . . . . . . . . . . . . . . . . . . 11D-16
REMOVAL AND INSTALLATION . . . . . . . . 11D-16
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 11D-26
FUEL AND EMISSION PARTS . . . . . 11D-28
REMOVAL AND INSTALLATION . . . . . . . . 11D-28
INLET MANIFOLD . . . . . . . . . . . . . . . 11D-30
REMOVAL AND INSTALLATION . . . . . . . . 11D-30
EXHAUST MANIFOLD . . . . . . . . . . . . 11D-31
REMOVAL AND INSTALLATION . . . . . . . . 11D-31
WATER PUMP AND WATER
HOSE . . . . . . . . . . . . . . . . . . . . . . . . . 11D-33
REMOVAL AND INSTALLATION . . . . . . . . 11D-33
ROCKER ARMS AND CAMSHAFT . . 11D-35
REMOVAL AND INSTALLATION . . . . . . . . 11D-35
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11D-37
CYLINDER HEAD AND VALVES. . . . 11D-40
REMOVAL AND INSTALLATION . . . . . . . . 11D-40
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11D-43
OIL PAN AND OIL PUMP. . . . . . . . . . 11D-46
REMOVAL AND INSTALLATION . . . . . . . . 11D-46
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11D-53
PISTON AND CONNECTING ROD . . 11D-55
REMOVAL AND INSTALLATION . . . . . . . . 11D-55
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11D-60
CRANKSHAFT AND CYLINDER
BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 11D-62
REMOVAL AND INSTALLATION . . . . . . . . 11D-62
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11D-66
Question and Answer IconNeed help?

Do you have a question about the Mitsubishi 4g63 and is the answer not in the manual?

Mitsubishi 4g63 Specifications

General IconGeneral
Engine TypeInline-4
ValvetrainDOHC 16-valve
Firing Order1-3-4-2
Block MaterialCast Iron
Head MaterialAluminum
Fuel TypeGasoline
Displacement2.0 L (1997 cc)
Bore x Stroke85.0 mm x 88.0 mm (3.35 in x 3.46 in)
TurbochargerAvailable (depending on variant)
Naturally AspiratedAvailable (depending on variant)

Summary

Crankshaft and Cylinder Block - Part 1

Crankshaft and Cylinder Block Removal

Lists parts for removing the crankshaft and cylinder block assembly.

Alternator and Ignition System

Alternator and Ignition System Removal/Installation

Details steps for removing and installing the alternator and ignition system.

Solenoid and Vacuum Hose

Solenoid and Vacuum Hose Removal/Installation

Details steps for removing and installing solenoid and vacuum hose assemblies.

Timing Belt - Part 1

Timing Belt Removal and Installation

Details steps for removing and installing the timing belt system.

Timing Belt Removal Steps

Lists components for removal of the timing belt system.

Timing Belt - Part 2

Timing Belt Removal Procedures

Details specific procedures and precautions for timing belt removal.

Oil Pump Sprocket Removal

Details the procedure for removing the oil pump sprocket.

Crankshaft Bolt Removal

Details the procedure for removing the crankshaft bolt.

Timing Belt - Part 3

Crankshaft Sprocket Removal

Details the procedure for removing the crankshaft sprocket.

Counterbalancer Shaft Sprocket Removal

Details the procedure for removing the counterbalancer shaft sprocket.

Crankshaft Sprocket "B" Removal

Details the procedure for removing the crankshaft sprocket "B".

Camshaft Sprocket Bolt Removal

Details the procedure for removing the camshaft sprocket bolt.

Timing Belt - Part 4

Camshaft Sprocket Bolt Installation

Details the procedure for installing the camshaft sprocket bolt.

Timing Belt - Part 5

Crankshaft Sprocket "B" Installation

Details the procedure for installing crankshaft sprocket "B".

Timing Belt - Part 6

Counterbalancer Shaft Sprocket Installation

Details the procedure for installing the counterbalancer shaft sprocket.

Timing Belt "B" Installation

Details the procedure for installing the timing belt "B".

Timing Belt - Part 7

Crankshaft Installation Procedures

Details installation of crankshaft bolt, sprocket, and sensing blade.

Oil Pump Sprocket Installation

Details the procedure for installing the oil pump sprocket.

Auto-Tensioner Installation

Details the procedure for installing the auto-tensioner.

Timing Belt - Part 8

Tensioner Pulley Installation

Details the procedure for installing the tensioner pulley.

Timing Belt Installation - Initial Steps

Covers initial steps for timing belt installation.

Timing Belt - Part 9

Timing Belt Installation - Steps 2-9

Continues timing belt installation procedures from step 2.

Timing Belt - Part 10

Timing Belt Installation - Steps 10-19

Continues timing belt installation procedures from step 10.

Timing Belt - Part 11

Timing Belt Inspection and Conditions

Details how to inspect the timing belt for wear and damage.

Fuel and Emission Parts - Part 1

Fuel and Emission Parts Removal/Installation

Details steps for removing and installing fuel and emission parts.

Fuel and Emission Parts - Part 2

Injector Installation Procedures

Details the procedure for installing fuel injectors.

Fuel Pressure Regulator Installation

Details the procedure for installing the fuel pressure regulator.

Inlet Manifold

Inlet Manifold Removal and Installation

Details steps for removing and installing the inlet manifold.

Exhaust Manifold - Part 1

Exhaust Manifold Removal and Installation

Details steps for removing and installing the exhaust manifold.

Exhaust Manifold - Part 2

Exhaust Manifold Installation

Details the procedure for installing the exhaust manifold.

Water Pump and Water Hose - Part 1

Water Pump and Water Hose Removal/Installation

Details steps for removing and installing the water pump and hose assembly.

Rocker Arms and Camshaft - Part 1

Rocker Arms and Camshaft Removal/Installation

Details steps for removing and installing rocker arms and camshafts.

Lash Adjuster Removal Procedure

Details the procedure for removing lash adjusters.

Rocker Arms and Camshaft - Part 2

Lash Adjuster Installation

Details the procedure for installing lash adjusters.

Camshaft Installation

Details the procedure for installing the camshaft.

Rocker Arms and Camshaft - Part 4

Lash Adjuster Cleaning Procedure

Details the procedure for cleaning lash adjusters.

Rocker Arms and Camshaft - Part 5

Lash Adjuster Cleaning Procedure - Part 2

Continues the procedure for cleaning lash adjusters.

Cylinder Head and Valves - Part 1

Cylinder Head and Valves Removal/Installation

Details steps for removing and installing the cylinder head and valves.

Cylinder Head and Valves Removal Steps

Lists components for removal of the cylinder head and valves.

Cylinder Head and Valves - Part 2

Cylinder Head Bolt Removal

Details the procedure for removing cylinder head bolts.

Valve Stem Seal Installation

Details the procedure for installing valve stem seals.

Cylinder Head and Valves - Part 3

Cylinder Head Bolt Installation

Details the procedure for installing cylinder head bolts.

Cylinder Head and Valves - Part 4

Cylinder Head Bolt Tightening Sequence

Details the sequence and angles for tightening cylinder head bolts.

Cylinder Head and Valves - Part 6

Valve Seat Reconditioning and Lapping

Details how to recondition and lap valve seats.

Valve Seat Replacement Procedure

Details the procedure for replacing valve seats.

Oil Pan and Oil Pump - Part 1

Oil Pan and Oil Pump Removal/Installation

Details steps for removing and installing the oil pan and oil pump.

Oil Pan and Oil Pump - Part 7

Piston and Connecting Rod - Part 1

Piston and Connecting Rod Removal/Installation

Details steps for removing and installing pistons and connecting rods.

Piston and Connecting Rod - Part 2

Piston and Connecting Rod - Part 4

Piston and Connecting Rod - Part 5

Piston and Connecting Rod Assembly Installation

Details the procedure for installing the piston and connecting rod assembly.

Piston and Connecting Rod - Part 6

Connecting Rod Cap Nut Installation

Details the procedure for installing connecting rod cap nuts using torque-to-yield method.

Piston and Connecting Rod - Part 7

Crankshaft and Cylinder Block - Part 1

Crankshaft and Cylinder Block Removal/Installation

Details steps for removing and installing the crankshaft and cylinder block.

Crankshaft and Cylinder Block - Part 3

Crankshaft and Cylinder Block - Part 5

Cylinder Boring Procedures

Related product manuals