Mitsubishi 4g63 User Manual

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

Mitsubishi 4g63 Specifications

General

Engine Type	Inline-4
Valvetrain	DOHC 16-valve
Firing Order	1-3-4-2
Block Material	Cast Iron
Head Material	Aluminum
Fuel Type	Gasoline
Displacement	2.0 L (1997 cc)
Bore x Stroke	85.0 mm x 88.0 mm (3.35 in x 3.46 in)
Turbocharger	Available (depending on variant)
Naturally Aspirated	Available (depending on variant)