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4G94-DOHC-GDI
Mitsubishi 4G94-DOHC-GDI Manuals
Manuals and User Guides for Mitsubishi 4G94-DOHC-GDI. We have
2
Mitsubishi 4G94-DOHC-GDI manuals available for free PDF download: User Manual, Workshop Manual
Mitsubishi 4G94-DOHC-GDI User Manual (172 pages)
4G9 Series
Brand:
Mitsubishi
| Category:
Engine
| Size: 4.59 MB
Table of Contents
Table of Contents
1
General Information
3
Technical Data
3
Service Specifications
6
1-1
6
Rework Dimensions
9
Torque Specifications
10
New Tightening Method - by Use of Bolts to be Tightened in Plastic Area
16
Sealant
16
Form-In-Place Gasket
17
Disassembly
17
Surface Preparation
17
Form-In-Place Gasket Application
17
2 Special Tools
18
2-1
18
4G9 Engine (E
18
3 Alternator and Ignition System
21
3-1
21
Removal and Installation <SOHC> (Engines with Distributor)
21
Removal and Installation (SOHC for Other than Pajero) (Engines Without Distributor)
22
Removal and Installation <SOHC for Pajero Io> (Engines Without Distributor)
23
Removal and Installation (DOHC)
25
Removal and Installation (DOHC-MIVEC)
26
Removal and Installation (DOHC–GDI for Carisma, Space Star, Space Runner, Galant)
27
Alternator Brace (M8)
28
Cam Position Sensing Cylinder
28
Cam Position Sensor Support
28
Crankshaft Bolt
28
Ignition Coil
28
Oil Level Gauge
28
Power Steering Pump Pulley
28
Removal and Installation (DOHC-GDI for Pajero Io)
28
Spark Plug
28
"BA Front Flange/Crankshaft Pulley/Crankshaft Bolt Installation
29
Installation Service Points "AA Cam Position Sensor Support
29
Removal Service Point AA" Crankshaft Bolt Removal
29
4-1
30
Camshaft Sprocket Bolt
30
Engine Support Bracket, Right
30
Timing Belt Rear Cover
30
Timing Belt Removal and Installation (SOHC for Carisma (up for 1999 Model)
30
Timing Belt Removal and Installation (SOHC for Carisma (from 2000 Model), Lancer (from 2001 Model for Europe), Space Star)
31
Accessory Mount
33
Timing Belt Cover
33
Timing Belt Removal and Installation (SOHC for Pajero Io)
33
Timing Belt Removal and Installation (DOHC)
34
Timing Belt Removal and Installation (DOHC-MIVEC)
35
Timing Belt Removal and Installation (DOHC-GDI for Carisma, Space Star, Space Runner)
36
Timing Belt Removal and Installation (DOHC-GDI for Galant)
37
Timing Belt Removal and Installation (DOHC-GDI for Pajero Io)
38
"AA Camshaft Sprocket Bolt Installation
40
AA" Timing Belt Removal
40
AB" Camshaft Sprocket Bolt Removal
40
"BA Timing Belt Tensioner Installation
41
"CA Tensioner Spring Installation
41
"DA Timing Belt Installation
41
"EA Auto-Tensioner Installation
42
"FA Timing Belt Installation
43
"GA Crankshaft Sensing Blade/Crankshaft Spacer/Crankshaft Sprocket Installation
45
Timing Belt Inspection
45
Tensioner Pulley, Idler Pulley Inspection
46
5 Fuel and Emission Control System
47
5-1
47
SOHC Carburetor Removal and Installation
47
Fuel and Emission Control System Removal and Installation (SOHC-MPI for Other Tnan Pajero Io)
48
Fuel and Emission Control System Removal and Installation (SOHC-MPI for Pajero Io)
49
Fuel and Emission Control System Removal and Installation (DOHC)
50
"AA Injectors Installation
51
"BA Fuel Pressure Regulator Installation
51
"CA Gasket Installation
51
5A. THROTTLE BODY and EGR SYSTEM (GDI)
53
Throttle Body and EGR System Removal and Installation (up to 2000 Model for Carisma, 1999 Model for Space Star, Spacer Runner)
53
Throttle Body and EGR System Removal and Installation (from 2001 Model for Carisma, Space Star and Galant)
54
Throttle Body and EGR System Removal and Installation (for Pajero Io - 4G93)
55
Throttle Body and EGR System Removal and Installation (for Pajero Io - 4G94)
56
"BA Intake Manifold Stay Installation
57
6 Intake and Exhaust Manifold
58
Installation Service Points: "AA Throttle Body Gasket
57
6-1
58
Intake and Exhaust Manifold Removal and Installation (SOHC-Carburetor)
58
Intake and Exhaust Manifold Removal and Installation (SOHC-MPI-Front Wheel Drive (4G92 and 4G93–Except from 2001 Model for Europe))
59
Intake and Exhaust Manifold Removal and Installation (SOHC-MPI-Front Wheel Drive (4G92 and 4G93– from 2001 Model for Europe))
60
Intake and Exhaust Manifold Removal and Installation (SOHC-MPI-Front Wheel Drive (4G94)
61
Intake and Exhaust Manifold Removal and Installation (SOHC-MPI-Rear Wheel Drive (4G93 - Except from 2002 Model for Europe)
62
Intake and Exhaust Manifold Removal and Installation (SOHC-MPI-Rear Wheel Drive (4G93 - from 2002 Model for Europe)
63
Intake and Exhaust Manifold Removal and Installation (SOHC-MPI-Rear Wheel Drive (4G94)
64
Intake and Exhaust Manifold Removal and Installation (DOHC)
66
"AA Exhaust Manifold Bracket Installation
67
"BA Intake Manifold Stay - Installation
67
Rear Wheel Drive
67
6A. INTAKE MANIFOLD (GDI)
68
Intake Manifold (GDI) Removal and Installatoin (up to 2000 Model for CARISMA, 1999 Model for Space Star, Space Runner)
68
Intake Manifold (GDI) Removal and Installation (from 2001 Model for Carisma, Space Star and Galant)
69
Intake Manifold (GDI) Removal and Installation (for Space Runner)
71
Intake Manifold (GDI) Removal and Installation (for Pajero Io)
72
"AA Intake Manifold Stay Installation
73
6B. EXHAUST MANIFOLD (GDI)
74
Exhaust Manifold (GDI) Removal and Installation (for Carisma, Space Star, Space Runner)
74
Exhaust Manifold (GDI) Removal and Installation (for Galant)
75
Exhaust Manifold (GDI) Removal and Installation (for Pajero Io)
77
Exhaust Manifold Bracket Installation
78
6C. INJECTOR and FUEL PUMP ASSEMBLY (GDI)
79
Injector and Fuel Pump Assembly (GDI) (up to 2000 Mode for Carisma, 1999 Model for Space Star, Space Runner)
79
Injector and Fuel Pump Assembly (GDI) (from 2001 Model for Carisma, Space Star and Galant)
80
Injector and Fuel Pump Assembly (GDI) (for Pajero Io - 4G94)
81
Injector and Fuel Pump Assembly (GDI) (for Pajero Io - 4G93)
82
Backap Ring/O-Ring/Corrugated Washer Installation
83
Delivery Pipe and Injector Assembly Installation
83
Fuel High Pressure Regulator Installation
84
Fuel Pressure Sensor Installation
84
Pump Camshaft Case Installation
84
Fuel Pump/Fuel Feed Pipe Installation
85
O-Ring/Backup Ring/Fuel Pipe Installation
86
O-Ring/Fuel Pump Installation
86
JA O-Ring/Fuel Pump Installation
87
O-Ring/Backup Ring/Fuel Pressure Sensor Installation
87
Intake and Exhaust Manifold <4G94 - GDI for PAJERO Io> Removal and Installation
88
Intake Manifold Stay Installation
89
To Install the Exhaust Manifold Bracket
89
7-1
90
Water Pump and Water Hose Removal and Installation (SOHC - Front Wheel Drive)
90
Water Pump and Water Hose Removal and Installation (SOHC - Rear Wheel Drive)
91
Water Pump and Water Hose Removal and Installation (DOHC - Front Wheel Drive)
92
Water Pump and Water Hose Removal and Installation (DOHC - Rear Wheel Drive)
93
Thermostat Installation
94
Water Inlet Pipe (Front Wheel Drive/Water Pipe, Rear Wheel Drive/O-Ring Installation)
94
Water Outlet Fitting Installation
94
Water Pump Installation
94
Engine Coolant Temperature Gauge Unit Installation
95
Engine Coolant Temperature Sensor Installation
95
Water By-Pass Fitting Installation
95
8-1
96
Rocker Arms and Camshafts Removal and Installation (SOHC (with Adjusting Screw))
96
Rocker Arms and Camshafts Removal and Installation (SOHC (with Lash Adjuster))
97
Rocker Arms and Camshafts Removal and Installation (DOHC)
99
Rocker Arms and Camshafts Removal and Installation (DOHC-GDI)
100
Rocker Arms and Camshafts Removal and Installation (DOHC-GDI for Carisma (up to 2000 Model), Space Star (1999 Model), Space Runner)
102
Rocker Arms and Camshafts Removal and Installation (DOHC-GDI for Carisma, Space Star and Galant (from 2001 Model))
103
Rocker Arms and Camshafts Removal and Installation (DOHC-GDI for Pajero Io - 4G94)
104
Rocker Arms and Camshafts Removal and Installation (DOHC-GDI for Pajero Io - 4G93)
105
Adjusting Screw Installation
106
Lash Adjuster Removal
106
Rocker Arm Shaft Installation
106
Rocker Arms and Rocker Arm Shaft Installation
106
Bearing Cap Installation
107
Camshaft Installation
107
Lash Adjuster Installation
107
Oil Seal Installation
107
Beam Camshaft Cap Installation
108
O-Ring/Cover Installation
110
Sealant Application on Rocker Cover
110
Sealant Application on Semi-Circular Parking
110
Valve Clearance Adjustment
110
Camshaft Inspection
113
Lash Adjuster (SOHC)
113
Lash Adjuster (DOHC)
116
Rocker Cover and Camshafts (MIVEC) Removal and Installation
119
Camshaft - Inspection
120
Oil Control Valve Inspection
120
Camshaft Bearing Cap/Camshaft Holder Installation
121
Camshaft Holder Assembly Installation
121
Install the Camshaft
121
Semi-Circular Packing Installation
121
Installation of the Oil Seal
122
Oil Control Valve Installation
122
Rocker Arm Piston Inspection
123
Rocker Cover Installation
123
To Adjust the Valve Clearance
123
Rocker Arms and Rocker Shaft Caps (MIVEC) Removal and Installation
124
Rocker Arm Assembly Installation
125
9-1
126
Cylinder Head and Valves Removal and Installation (SOHC)
126
Cylinder Head and Valves Removal and Installation (DOHC)
127
Cylinder Head and Valves Removal and Installation (DOHC-MIVEC)
128
Cylinder Head and Valves Removal and Installation (DOHC-GDI)
129
Cylinder Head Bolt Removal
131
Retainer Lock Removal
131
Valve Handling Precautions
132
Valve Stem Seal Removal
132
Valve Stem Seal Installation
133
Cylinder Head Bolt Installation
134
Retainer Lock Installation
134
Valve Spring Installation
134
Sealant Application to Oil Pressure Switch
135
Cylinder Head Inspection
136
Valve Inspection
136
Valve Guide Inspection
137
Valve Seat Inspection
137
Valve Spring Inspection
137
Valve Guide Replacement
138
Valve Seat Reconditioning Procedure
138
Valve Seat Replacement Procedure
138
10-1
140
Front Case and Oil Pump Removal and Installation (SOHC (4G92, 4G93))
140
Front Case and Oil Pump Removal and Installation (SOHC (4G94 Except for Pajero Io))
141
Front Case and Oil Pump Removal and Installation (SOHC (4G94 for Pajero Io))
142
Front Case and Oil Pump Removal and Installation (DOHC (Except GDI for Pajero Io))
143
Front Case and Oil Pump Removal and Installation (DOHC-GDI for Pajero Io)
144
Inner Rotor/Outer Rotor Installation
145
Oil Pan Removal
145
Outer Rotor/Inner Rotor Removal
145
Sealant Application to Oil Pump Case
145
Crankshaft Front Oil Seal Installation
146
Oil Pan/Upper Oil Pan/Lower Oil Pan Installation
146
Oil Filter Installation
147
Oil Pump Inspection
147
11-1
149
Piston and Connecting Rod Removal and Installation
149
Connecting Rod Cap Removal
150
Piston Pin Removal
150
Piston Pin Installation
151
Oil Ring Installation
152
Piston and Connecting Rod Installation
153
Piston Ring #2/Piston Ring #1 Installation
153
Connecting Rod Bearing Installation
154
Connecting Rod Cap Installation
155
Connecting Rod Cap Nut Installation
155
Crankshaft Pin Oil Clearance (Plastigauge Method)
156
Piston Ring Instpection
156
Crankshaft, Cylinder Block, Flywheel and Drive Plate Removal and Installation (Manual Transmission)
157
Automatic Transmission Removal and Installation
158
Crankshaft, Cylinder Block, Flywheel and Drive Plate Removal and Installation (Pajero Io)
159
Crankshaft Bearing Installation
160
Oil Jet Installation
160
Oil Jet Removal
160
Bearing Cap/Bearing Cap Bolt Installation
162
Crankshaft Journal Oil Clearance (Plastigauge Method)
163
Drive Plate Bolt/Flywheel Bolt Installation
163
Sealant Application to Oil Seal Case
163
To Install the Oil Seal
163
Boring Cylinder Inspection
164
Cylinder Block Inspection
164
Hydro-Flywheel (DOHC-GDI for Pajero Io) Inspection
165
Service Bulletins
167
Crankshaft Weight
169
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Mitsubishi 4G94-DOHC-GDI Workshop Manual (156 pages)
4G9 Series (E-W)
Brand:
Mitsubishi
| Category:
Engine
| Size: 5.66 MB
Table of Contents
Introduction
2
Maintenance and Servicing Procedures
2
Symbols for Lubrication, Sealants and Adhesives
2
List of Effective Pages
4
Engine 4G9 Series
5
Contents
5
General Information 4G92
7
General Information 4G93
8
General Information 4G94
9
Service Specifications
10
Rework Dimensions
13
Torque Specifications
13
New Tightening Method-By Use of Bolts to be Tightened in Plastic Area
20
Sealant
20
Form-In-Place Gasket
21
Special Tools
22
Alternator and Ignition System
25
Removal Steps
25
Removal and Installation-SOHC for Other than PAJERO
26
Removal and Installation-SOHC for PAJERO
27
Removal and Installation-DOHC
29
Removal and Installation-DOHC-MIVEC
30
Removal and Installation-DOHC-GDI for CARISMA, SPACE STAR, SPACE RUNNER, GALANT
31
Removal and Installation-DOHC-GDI for PAJERO
32
Crankshaft Bolt Removal
33
Cam Position Sensor Support Installation
33
Timing Belt
34
Removal and Installation-SOHC for CARISMA (up to 1999 Model), LANCER (up to 2000 Model), GALANT
34
Removal and Installation-SOHC for CARISMA (from 2000 Model), LANCER (from 2001 Model)
35
Removal and Installation-DOHC-GDI for CARISMA, SPACE STAR, SPACE RUNNER
40
Removal and Installation-DOHC-GDI for GALANT
41
Timing Belt Removal
44
Camshaft Sprocket Bolt Removal
44
Camshaft Sprocket Bolt Installation
44
Timing Belt Tensioner Installation
45
Tensioner Spring Installation
45
Timing Belt Installation
45
Auto-Tensioner Installation
46
Inspection
49
Tensioner Puller, Idler Pulley
50
Auto-Tensioner
50
Fuel and Emission Control System
51
Removal and Installation-SOHC-CARBURETOR
51
Removal and Installation-SOHC-MPI for Other than PAJERO
52
Removal and Installation-SOHC-MPI for PAJERO
53
Injectors Installation
55
Fuel Pressure Regulator Installation
55
Gasket Installation
55
Throttle Body and EGR System (GDI)
57
Removal and Installation-Up to 2000 Model for CARISMA, 1999 Model for SPACE STAR, SPACE RUNNER
57
Removal and Installation-From 2001 Model for CARISMA, from 2001 Model for SPACE STAR, GALANT
58
Removal and Installation-For PAJERO
59
Throttle Body Gasket
60
Intake Manifold Stay Installation
60
Intake and Exhaust Manifold
61
Removal and Installation-SOHC-MPI (up to 2000 Model)
62
Removal and Installation-SOHC-MPI (from 2001 Model)
63
Exhaust Manifold Installation
66
Intake Manifold (GDI)
67
Removal and Installation-For SPACE RUNNER
70
Exhaust Manifold (GDI)
73
Removal and Installation-For CARISMA, SPACE STAR, SPACE RUNNER
73
Removal and Installation-For GALANT
74
Exhaust Manifold Bracket Installation
77
Injector and Fuel Pump Assembly (GDI)
78
Backup Ring/O-Ring/Corrugated Washer Installation
82
Delivery Pipe and Injector Assembly Installation
82
Pump Camshaft Case Installation
83
Fuel Pressure Sensor Installation
83
Fuel Pump/Fuel Feed Pipe Installation
84
O-Ring/Fuel Pump Installation
85
O-Ring/Backup Ring/Fuel Pipe Installation
85
O-Ring/Backup Ring/Fuel Pressure Sensor Installation
86
Water Pump and Water Hose
87
Removal and Installation-SOHC
87
Water Pump Installation
90
Water Inlet PIPE SOHC, DOHC/WATER PIPE DOHC-GDI for PAJERO/O-RING Installation
90
Thermostat Case Installation
90
Water Outlet Fitting Installation
90
Engine Coolant Temperature Gauge Unit Installation
91
Engine Coolant Temperature Sensor Installation
91
Water By-Pass Fitting Installation
91
Water Fitting Installation
91
Rocker Arms and Camshafts
92
Removal and Installation-SOHC (up to 2000 Model)
92
Removal and Installation-SOHC (from 2001 Model)
93
Removal and Installation-DOHC-GDI for CARISMA (up to 2000 Model), SPACE STAR (1999 Model), SPACE RUNNER
96
Removal and Installation-DOHC-GDI for CARISMA (from 2001 Model), SPACE STAR (from 2001 Model), GALANT
97
Adjusting Screw Installation
100
Rocker Arm Shaft Installation
100
Rocker Arms and Rocker Arm Shaft Installation
100
Rocker Arm Spring Installation
100
Oil Seal Installation
101
Lash Adjuster Installation
101
Camshaft Installation
101
Bearing Cap Installation
101
Beam Camshaft Cap Installation
102
Sealant Application on Semi-Circular Packing
104
Sealant Application on Rocker Cover
104
Valve Clearance Adjustment
104
Camshaft
105
Lash Adjuster (SOHC)
105
(Dohc)
108
Rocker Cover and Camshafts (MIVEC)
111
Oil Control Valve
112
Semi-Circular Packing Installation
113
Camshaft Holder Assembly Installation
113
Camshaft Bearing Cap/Camshaft Holder Installation
113
Oil Control Valve Installation
114
Rocker Cover Installation
115
Rocker Arm Piston Inspection
115
Rocker Arms and Rocker Shaft Caps (MIVEC)
116
Rocker Arm Assembly Installation
117
Cylinder Head and Valves
118
Removal and Installation-DOHC-GDI
121
Cylinder Head Bolt Removal
123
Retainer Lock Removal
123
Valve Stem Seal Removal
124
Valve Handling Precautions
124
Valve Stem Seal Installation
125
Valve Spring Installation
126
Retainer Lock Installation
126
Cylinder Head Bolt Installation
126
Sealant Application to Oil Pressure Switch
127
Cylinder Head
128
Valve
128
Valve Spring
129
Valve Seat
129
Valve Guide
129
Valve Seat Reconditioning Procedure
130
Valve Seat Replacement Procedure
130
Valve Guide Replacement
130
Front Case and Oil Pump
132
Oil Pan Removal
135
Outer Rotor/Inner Rotor Removal
135
Inner Rotor/Outer Rotor Installation
135
Sealant Application to Oil Pump Case
135
Crankshaft Front Oil Seal Installation
136
Oil Pan/Upper Oil Pan/Lower Oil Pan Installation
136
Oil Filter Installation
137
Piston and Connecting Rod
139
Connecting Rod Cap Removal
140
Piston Pin Removal
140
Piston Pin Installation
141
Oil Ring Installation
142
Piston Ring No.2/Piston Ring No.1 Installation
142
Piston and Connecting Rod Installation
143
Connecting Rod Bearing Installation
143
Connecting Rod Cap Installation
144
Connecting Rod Cap Nut Installation
144
Piston Ring
145
Crankshaft Pin Oil Clearance (Plastigage Method)
146
Crankshaft, Cylinder Block, Flywheel and Drive Plate
147
Removal and Installation (Manual Transmission)
147
Removal and Installation (Automatic Transmission)
148
Oil Jet Removal
150
Oil Jet Installation
150
Crankshaft Bearing Installation
150
Bearing Cap/Bearing Cap Bolt Installation
151
Sealant Application to Oil Seal Case
152
Drive Plate Bolt/Flywheel Bolt Installation
153
Crankshaft Journal Oil Clearance (Plastigauge Method)
153
Cylinder Block
153
Boring Cylinder
154
Hydro-Flywheel DOHC-GDI for PAJERO
155
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