Table Of Contents - Mitsubishi 4G1 Series General Information Manual

Table of Contents

Table Of Contents1
General Information3
Service Specifications9
1-19
Rework Dimensions13
Torque Specifications14
New Tightening Method Using Plastic Region Tightening Bolts20
Sealants20
Form-In-Place Gasket21
Surface Preparation21
Form-In-Place Gasket Application21
Special Tools23
2-123
Alternator And Ignition System26
Removal And Installation26
3-126
Removal And Installation Distributor)>27
Removal And Installation Cam Position Sensor>28
Removal And Installation Sohc 16-Valve - Rear Wheel Drive29
Removal And Installation Dohc30
Removal And Installation Dohc-Gdi31
Removal Service Point Aa Crankshaft Bolt Removal32
Installation Service Points Aa Distributor Installation32
Crankshaft Pulley / Bolt Installation32
Cam Position Sensor Support Installation32
Timing Belt33
4-133
Removal Service Points37
Timing Belt / Tensioner Spring / Timing Belt Tensioner Removal37
Camshaft Sprocket Bolt Removal37
Timing Belt Removal37
Timing Belt Inspection38
Tensioner Pulley And Idler Pulley Inspection38
Installation Service Points39
Camshaft Sprocket Bolt Installation39
Timing Belt Tensioner / Tensioner Spring Installation39
Timing Belt Installation40
Timing Belt Tensioner And Tensioner Spring Installation42
Fuel And Emission Control Systems44
5-144
Injector Installation51
Fuel Pressure Regulator Installation51
5A. Intake Manifold And Throttle Body (Gdi)52
Removal Service Point53
Intake Manifold Removal53
Intake Manifold Stay Installation53
Exhaust Manifold (Gdi) Removal And Installation54
5B. Exhaust Manifold (Gdi)54
Water Pump And Water Hose55
6-155
Water Pump Installation65
O-Ring / Water Pipe Installation65
Thermostat Installation65
Engine Coolant Temperature Gauge Unit Installation65
Thermo Valve Installation66
Thermostat Housing Installation66
Water Outlet Fitting Installation66
Intake And Exhaust Manifold Removal And Installation67
7-167
Reed Valve, Bracket And Air Pipe Installation75
Fuel System (Gdi) Removal And Installation76
7A. Fuel System (Gdi)76
Backup Ring / O-Ring Installation77
Corrugate Washer Installation77
Delivery Pipe And Injector Installation77
Fuel Pump / Backup Ring / O-Ring / Fuel Pipe Installation78
Rocker Arms And Camshafts79
8-179
Rocker Arms And Rocker Arm Shafts Removal83
Lash Adjuster Removal83
Camshaft85
Lash Adjusters85
Camshaft Installation90
Bearing Cap Installation91
Adjusting Screw Installation91
Rocker Arm Shaft Installation91
Rocker Arm / Rocker Shaft Assembly Installation92
Camshaft Oil Seal Installation92
Semi-Circular Packing Installation92
Rocker Cover Installation93
Lash Adjuster Installation93
Valve Clearance Adjustment93
Rocker Arms And Camshafts (Gdi) Removal And Installation96
Exhaust Camshaft / Intake Camshaft Installation97
Beam Camshaft Cap Installation97
Oil Seal Installation98
P.c.v. Valve Installation98
Camshaft Inspection99
Lash Adjuster99
Cylinder Head And Valves Removal And Installation102
9-1102
Cylinder Head Bolt Removal106
Retainer Lock Removal106
Valve Stem Seal Removal107
Cylinder Head Inspection107
Valves Inspection107
Valve Springs108
Valve Guides109
Valve Seats109
Valve Seat Correction Service Points110
Valve Seat Replacement Service Points111
Valve Seat Hole Diameters111
Valve Guide Replacement Service Points112
Valve Stem Seal Installation112
Valve Spring Installation113
Retainer Lock Installation113
Cylinder Head Bolt Installation114
Oil Pump And Oil Pan Removal And Installation115
10-1115
Oil Pan Removal118
Oil Pump Inspection118
Front Oil Seal Case Installation119
Front Oil Seal Installation119
Oil Pan Installation119
Drain Plug Gasket Installation119
Oil Filter Installation120
Pistons And Connecting Rods Removal And Installation121
11-1121
Connecting Rod Cap Removal122
Piston Pin Removal122
Piston Rings Inspection122
Crankshaft Pin Oil Clearance123
Piston Pin Installation123
Oil Ring Installation124
Piston Ring No. 2 / Piston Ring No. 1 Installation125
Piston And Connecting Rod Assembly Installation125
Connecting Rod Bearing Installation126
Connecting Rod Cap Installation127
Connecting Rod Cap Nut Installation127
Crankshaft And Cylinder Block Removal And Installation129
12-1129
Oil Pressure Switch Removal133
Crankshaft Oil Clearance133
Cylinder Block133
Boring Cylinders134
Oil Pressure Switch Installation134
Crankshaft Bearing Installation135
Rear Oil Seal Installation137
Rear Oil Seal Case Installation138
Flywheel Bolt / Drive Plate Bolt Installation138
Service Bulletins139
M12 Crankshaft Bolt145
M14 Crankshaft Bolt147