Mitsubishi 4g63 Service Manual
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Mitsubishi 4g63 Service Manual

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ENGINE OVERHAUL

GENERAL INFORMATION . . . . . . . .
REWOK DIMENSIONS . . . . . . . . . . .
TORQUE SPECIFICATIONS . . . . . . .
SEALANTS . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS. . . . . . . . . . . . . . . .
SYSTEM . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
TIMING BELT. . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
GROUP 11D
<4G63-Turbo>
CONTENTS
INLET MANIFOLD . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
EXHAUST MANIFOLD . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
HOSE . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
OIL PAN AND OIL PUMP. . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
BLOCK . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
11D-1
Table of Contents
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Frequently Asked Questions (9)

  • Is the Mitsubishi 4g63 an interference engine?

    Yes, the Mitsubishi 4g63 engine is an interference engine. You should never remove the timing belt with any piston at the top dead center (TDC) because if a piston is at TDC, the exhaust valves of the cylinder are pushed by the exhaust cams, compressing the valve springs. Removing the belt under this condition could cause the sprocket to turn in the reverse direction due to spring force, which may result in injury.

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  • What are the correct spark plug specifications for the Mitsubishi 4g63 engine?

    The spark plugs should be tightened to a torque of 25 ± 5 N·m.

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  • What are the correct valve clearance specifications for the Mitsubishi 4g63 engine?

    The Mitsubishi 4g63 engine uses Hydraulic lash adjusters, which typically do not require manual adjustment for valve clearance.

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  • What are the head bolt torque specifications for the Mitsubishi 4g63 engine?

    The head bolt torque specifications for the Mitsubishi 4g63 engine are as follows:

    1. Tighten the bolts to 78 ± 2 N·m in the indicated sequence.
    2. Loosen all the bolts completely.
    3. Tighten the bolts again to a torque of 20 ± 2 N·m in the indicated sequence.
    4. Make paint marks on each bolt's head and on the cylinder head.
    5. Turn the bolts 90° in the tightening direction and in the indicated sequence.
    6. Give another 90° turn in the tightening direction to each bolt, ensuring the paint mark on the bolt head aligns with that on the cylinder head.

    For more information, see pages 9, 42 and 43 of the manual.
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  • How do I set the ignition timing on a Mitsubishi 4g63 engine with a distributor?

    The Mitsubishi 4g63 engine uses an Electronically controlled two-coil system for ignition, not a distributor. Therefore, there is no distributor timing adjustment procedure.

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  • How do I replace the valve cover gasket on a Mitsubishi 4g63 engine?

    To replace the valve cover gasket (rocker cover gasket "A"), follow these steps:

    1. Remove the rocker cover.
    2. Apply beads of FIPG (Mitsubishi Genuine Part No.MD970389 or equivalent) on the surfaces of the rocker cover.
    3. Install the rocker cover gasket "A" on the rocker cover before the FIPG hardens.
    4. Apply beads of FIPG (Mitsubishi Genuine Part No.MD970389 or equivalent) to the surfaces of the rocker cover indicated in the drawing.
    5. Install the rocker cover on the cylinder head before the FIPG hardens.
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  • How do I replace the spark plug wires on a Mitsubishi 4g63 engine?

    To replace the spark plug wires, follow these steps:

    1. Remove the spark plug cable by pulling it off the spark plug and ignition coil.

    Installation is the reverse of removal.

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  • How is the injection pump timing adjusted on a diesel Mitsubishi 4g63 engine?

    The Mitsubishi 4g63 engine uses an Electronically controlled multi-point injection (MPI) system. It is a gasoline engine, not a diesel engine, and therefore does not have an injection pump for timing adjustment.

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  • What are common issues with the carburetor on older Mitsubishi 4g63 engines?

    The Mitsubishi 4g63 engine uses an Electronically controlled multi-point injection (MPI) system, not a carburetor.

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Summary of Contents for Mitsubishi 4g63

  • Page 1: Table Of Contents

    11D-1 GROUP 11D ENGINE OVERHAUL <4G63-Turbo> CONTENTS HOW TO USE THIS MANUAL..11D-2 INLET MANIFOLD ....11D-30 REMOVAL AND INSTALLATION ..

  • Page 2: How To Use This Manual

    11D-2 ENGINE OVERHAUL <4G63-Turbo> HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL M1113025100296 HOW TO USE THIS MANUAL Scope of Service Explanations This manual describes service procedures performed after removal of the engine from the vehicle. For removal of the engine from the vehicle, installation of the engine in the vehicle, and on-vehicle inspection and service of the engine, please use the separate Workshop Manuals prepared for the vehicle.
  • Page 3 11D-3 ENGINE OVERHAUL <4G63-Turbo> HOW TO USE THIS MANUAL Page number Group title Section title ENGINE OVERHAUL 11-54 CRANKSHAFT AND CYLINDER BLOCK CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION Denotes non-reusable part. Apply engine oil to all moving 11 ± 1 N·m parts before installation.

  • Page 4: General Information

    11D-4 ENGINE OVERHAUL <4G63-Turbo> GENERAL INFORMATION GENERAL INFORMATION M1113000100523 VEHICLE AND ENGINE MODELS Vehicle name Vehicle Engine model Displacement Specification model OUTLANDER CU2W 4G63-7 1,997 Double overhead camshaft, 16-valve GENERAL SPECIFICATIONS M1113000200779 Item Specification Bore × stroke mm 85 × 88...

  • Page 5: Service Specifications

    11D-5 ENGINE OVERHAUL <4G63-Turbo> SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS M1113000300776 Item Standard value Limit TIMING BELT 3.8 − 4.5 Auto-tensioner rod extension length − (with timing belt installed) mm Auto-tensioner rod extension length (when free) mm 12.0 − Auto-tensioner rod retraction length Less than 1 −...

  • Page 6: Rewok Dimensions

    11D-6 ENGINE OVERHAUL <4G63-Turbo> REWOK DIMENSIONS Item Standard value Limit Oil pressure at curb idle speed kPa 78 or more − [oil temperature is 75 to 90°] PISTONS AND CONNECTING RODS Piston outside diameter mm 85.0 − 0.03 − 0.07 Piston ring side clearance in ring No.

  • Page 7: Torque Specifications

    11D-7 ENGINE OVERHAUL <4G63-Turbo> TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS M1113023400989 Item N⋅m ALTERNATOR AND IGNITION COIL 13 ± 1 Oil level gauge guide bolt 79 ± 5 Idler pulley bolt 24 ± 4 Auto-tensioner assembly bolt (M8) 44 ± 10 Auto-tensioner assembly bolt (M10) 8.8 ±...
  • Page 8 11D-8 ENGINE OVERHAUL <4G63-Turbo> TORQUE SPECIFICATIONS Item N⋅m FUEL SYSTEM 19 ± 3 Throttle body bolts 9.0 ± 2.0 Fuel pressure regulator bolts 11 ± 1 Delivery pipe and injector assembly bolts INLET MANIFOLD 31 ± 3 Inlet manifold stay bolts 20 ±...
  • Page 9 11D-9 ENGINE OVERHAUL <4G63-Turbo> TORQUE SPECIFICATIONS Item N⋅m CYLINDER HEAD AND VALVES 78 ± 2 → 0 → 20 ± 2 → + 90° + 90° Cylinder head bolts OIL PUMP CASE AND OIL PAN 39 ± 5 Drain plug Oil filter 14 ±...

  • Page 10: Sealants

    Engine support bracket bolts Mitsubishi Genuine Part No.MD970389 or equivalent Semicircular packing 3M ATD No.8660 or equivalent Rocker cover Mitsubishi Genuine Part No. MD970389 or equivalent Engine coolant temperature e gauge unit 3M Nut Locking Part No.4171 or equivalent Engine coolant temperature sensor 3M ATD No.8660 or equivalent...

  • Page 11: Special Tools

    11D-11 ENGINE OVERHAUL <4G63-Turbo> SPECIAL TOOLS SPECIAL TOOLS M1113000600788 Tool Number Name MD998781 Flywheel stopper Retention of flywheel D998781 MD998778 Crankshaft sprocket Removal of crankshaft sprocket puller and crankshaft sprocket B MD998785 Sprocket stopper Retention of counterbalancer shaft sprocket MD998767...
  • Page 12 11D-12 ENGINE OVERHAUL <4G63-Turbo> SPECIAL TOOLS Tool Number Name MB991654 Cylinder head bolt Removal and installation of wrench cylinder head bolts B991654 MD998772 Valve spring Compression of valve spring compressor MD998735 Valve spring Compression of valve spring compressor MD998737 Valve stem seal...
  • Page 13 11D-13 ENGINE OVERHAUL <4G63-Turbo> SPECIAL TOOLS Tool Number Name MB991603 Silent shaft bearing Guide and stopper for removal installer stopper and press-fitting of counterbalancer shaft rear bearing MD998705 Silent shaft bearing Press-fitting of counterbalancer installer shaft front and rear bearings...

  • Page 14: Alternator And Ignition System

    11D-14 ENGINE OVERHAUL <4G63-Turbo> ALTERNATOR AND IGNITION SYSTEM ALTERNATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION M1113001000701 3.0 ± 0.5 N·m 10 ± 2 N·m 13 ± 1 N·m 25 ± 5 N·m 44 ± 10 N·m 22 ± 4 N·m 44 ±...

  • Page 15: Solenoid And Vacuum Hose

    11D-15 ENGINE OVERHAUL <4G63-Turbo> SOLENOID AND VACUUM HOSE SOLENOID AND VACUUM HOSE REMOVAL AND INSTALLATION M1113025300074 20 ± 2 N·m 19 ± 3 N·m 23 ± 4 N·m 9.0 ± 1.0 N·m 36 ± 6 N·m 11 ± 1 N·m 11 ±...

  • Page 16: Timing Belt

    11D-16 ENGINE OVERHAUL <4G63-Turbo> TIMING BELT TIMING BELT REMOVAL AND INSTALLATION M1113001900867 3.5 ± 0.5 N·m 11 ± 1 N·m 48 ± 5 N·m 21 ± 4 N·m 11 ± 1 N·m 23 ± 3 N·m 11 ± 1 N·m 11 ±...
  • Page 17 11D-17 ENGINE OVERHAUL <4G63-Turbo> TIMING BELT Removal steps (Continued) CAUTION 23. PCV valve gasket Never remove the timing belt with any piston at 24. Oil filler cap the top dead center (TDC). If a piston is at TDC, >>D<< 25. Rocker cover the exhaust valves of the cylinder are pushed by >>D<<...
  • Page 18 11D-18 ENGINE OVERHAUL <4G63-Turbo> TIMING BELT <<D>> CRANKSHAFT SPROCKET <<F>> COUNTERBALANCER SHAFT REMOVAL SPROCKET REMOVAL MD998778 MD998785 AK304176 AK300138 Use the special tool Crankshaft sprocket puller 1. Use the special tool Sprocket stopper (MD998778) if the sprocket is stuck and hard to (MD998785) to prevent the counterbalancer shaft remove.
  • Page 19 Specified sealant: 3M ATD No.8660 or equivalent AK202743AB 1. Remove thoroughly the old sealant remaining on the indicated bolt and in its hole. 2. Coat the bolt with sealant, then install and tighten Specified sealant: Mitsubishi Genuine Part No.MD970389 or equivalent...
  • Page 20 NOTE: Degreasing is necessary to prevent lack of Specified sealant: frictional coefficient between the mating surfaces. Mitsubishi Genuine Part No.MD970389 or equivalent >>F<< SPACER INSTALLATION 2. Install the rocker cover gasket "A" on the rocker cover before the FIPG hardens.
  • Page 21 11D-21 ENGINE OVERHAUL <4G63-Turbo> TIMING BELT >>G<< COUNTERBALANCER SHAFT Tension section of belt Tensioner "B" SPROCKET INSTALLATION Timing belt "B" MD998785 Tensioner "B" centre Mounting bolt centre AK305992 3. Make sure that the tensioner "B" center is positioned as shown in the drawing relative to the AK300138 mounting bolt center.
  • Page 22 11D-22 ENGINE OVERHAUL <4G63-Turbo> TIMING BELT >>I<< CRANKSHAFT >>J<< OIL PUMP SPROCKET BOLT/CRANKSHAFT INSTALLATION SPROCKET/CRANKSHAFT SENSING BLADE INSTALLATION Sensing blade Crankshaft bolt Sprocket Crankshaft Clean AK300172 Washer 1. Prevent the counterbalancer shaft from rotating in Degrease Big chamfered side the same method as in the removal procedure.
  • Page 23 11D-23 ENGINE OVERHAUL <4G63-Turbo> TIMING BELT NOTE: If the timing marks were aligned, the exhaust camshaft would be turned counterclockwise by one sprocket tooth and stay there by the force of the valve springs. Timing marks AK300154 2. Install the auto-tensioner in position. Leave the wire installed until the auto-tensioner is completely installed.
  • Page 24 11D-24 ENGINE OVERHAUL <4G63-Turbo> TIMING BELT (2) Insert a crosspoint screwdriver with a shank 6. Turn the intake camshaft sprocket diameter of 8 mm through the plug hole. If it counterclockwise to bring the timing mark on it can be inserted 60 mm or more, the sprocket one sprocket tooth away from the mating timing is in the correct phase.
  • Page 25 11D-25 ENGINE OVERHAUL <4G63-Turbo> TIMING BELT NOTE: Turning slightly the intake camshaft sprocket counterclockwise will facilitate installa- tion of the belt on the tensioner pulley. MD998738 Crankshaft sprocket AK202774 14.Install the special tool Set screw (MD998738) and turn down the tool until the wire (inserted in the...

  • Page 26: Inspection

    11D-26 ENGINE OVERHAUL <4G63-Turbo> TIMING BELT Cracks Cracks Extension Peeling of canvas amount Cracks in sides Cracks in tooth roots AK202829 AK202793 20.Check that the wire (inserted in the auto-tensioner 2. Cracks in back rubber surface. when it was installed) can be moved freely. If the 3.
  • Page 27 11D-27 ENGINE OVERHAUL <4G63-Turbo> TIMING BELT AUTO-TENSIONER 3. Measure the extension length of the rod. If it is not within the standard value range, replace the auto-tensioner. Standard value: 12 mm 12 mm 98 to 196 N Movement AK301307AD 1. Check the auto-tensioner for leaks from the sealed sections.

  • Page 28: Fuel And Emission Parts

    11D-28 ENGINE OVERHAUL <4G63-Turbo> FUEL AND EMISSION PARTS FUEL AND EMISSION PARTS REMOVAL AND INSTALLATION M1113002200708 9.0 ± 2.0 N·m 11 ± 1 N·m 19 ± 3 N·m AK400297 AB Removal steps (Continued) Removal steps 7. O-ring 1. Throttle body >>A<<...
  • Page 29 11D-29 ENGINE OVERHAUL <4G63-Turbo> FUEL AND EMISSION PARTS INSTALLATION SERVICE POINTS 3. Check that the fuel pressure regulator turns smoothly. If it does not, the O-ring may be >>A<< INJECTOR INSTALLATION jamming, so remove the fuel pressure regulator 1. Apply a thin coat of engine oil to a new O-ring.

  • Page 30: Inlet Manifold

    11D-30 ENGINE OVERHAUL <4G63-Turbo> INLET MANIFOLD INLET MANIFOLD REMOVAL AND INSTALLATION M1113026100062 36 ± 6 N·m 36 ± 6 N·m 20 ± 2 N·m 23 ± 2 N·m 31 ± 3 N·m AK400302 INSTALLATION SERVICE POINTS Removal steps >>A<< 1. Inlet manifold stay >>A<<...

  • Page 31: Exhaust Manifold

    11D-31 ENGINE OVERHAUL <4G63-Turbo> EXHAUST MANIFOLD EXHAUST MANIFOLD REMOVAL AND INSTALLATION M1113004900725 19 ± 3 N·m 23 ± 3 N·m 59 ± 5 N·m 17 ± 2 N·m 33 ± 6 N·m 17 ± 2 N·m 11 ± 1 N·m 19 ±...
  • Page 32 11D-32 ENGINE OVERHAUL <4G63-Turbo> EXHAUST MANIFOLD INSTALLATION SERVICE POINT >>B<< OIL RETURN PIPE GASKET INSTALLATION >>A<< EXHAUST MANIFOLD INSTALLATION 1. Hand tighten all the exhaust manifold mounting nuts. 2. Tighten the M8 nuts to 29 ± 3 N⋅m in the indicated sequence.

  • Page 33: Water Pump And Water Hose

    11D-33 ENGINE OVERHAUL <4G63-Turbo> WATER PUMP AND WATER HOSE WATER PUMP AND WATER HOSE REMOVAL AND INSTALLATION M1113017900372 13 ± 2 N·m 13 ± 2 N·m 13 ± 2 N·m 23 ± 4 N·m 10.8 ± 1.0 N·m 29 ± 10 N·m 14 ±...
  • Page 34 NOTE: A new engine coolant temperature gauge Specified sealant: unit is coated with sealant. It does not require Mitsubishi Genuine Part No.MD970389 or coating with sealant before installation. equivalent 2. Apply sealant to the indicated threads of the engine coolant temperature gauge unit.

  • Page 35: Rocker Arms And Camshaft

    11D-35 ENGINE OVERHAUL <4G63-Turbo> ROCKER ARMS AND CAMSHAFT ROCKER ARMS AND CAMSHAFT REMOVAL AND INSTALLATION M1113005400853 10 ± 2 N·m 20 ± 1 N·m 14 ± 1 N·m 22 ± 4 N·m 10.8 ± 1.0 N·m 11 ± 1 N·m...
  • Page 36 11D-36 ENGINE OVERHAUL <4G63-Turbo> ROCKER ARMS AND CAMSHAFT INSTALLATION SERVICE POINTS 2. The bearing caps No. 2 to 5 are identical in shape for both intake and exhaust camshafts. Check the >>A<< LASH ADJUSTER INSTALLATION identification mark on each cap before installation.

  • Page 37: Inspection

    Standard value: indicated surface of the camshaft position sensor Intake: 35.79 mm support. Exhaust: 35.49 mm Specified sealant: Limit: Mitsubishi Genuine Part No.MD970389 or Intake: 35.29 mm equivalent Exhaust: 34.99 mm >>F<< CAMSHAFT POSITION SENSING LASH ADJUSTERS CYLINDER INSTALLATION CAUTION •...
  • Page 38 11D-38 ENGINE OVERHAUL <4G63-Turbo> ROCKER ARMS AND CAMSHAFT CAUTION The hole in the side of the lash adjuster must be directed toward the inside of container A. Never direct it against any person. 4. Take the lash adjuster out of the container, then...
  • Page 39 11D-39 ENGINE OVERHAUL <4G63-Turbo> ROCKER ARMS AND CAMSHAFT 8. Place the lash adjuster upright with the plunger at the top. Push the plunger firmly until it makes a full stroke, then return the plunger slowly and release the hold of the steel ball to allow the pressure chamber to be filled with diesel fuel.

  • Page 40: Cylinder Head And Valves

    11D-40 ENGINE OVERHAUL <4G63-Turbo> CYLINDER HEAD AND VALVES CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION M1113006900787 78 ± 2 N·m → 0 N·m → 20 ± 2 N·m → +90˚ → +90˚ Apply engine oil to all moving parts before installation.
  • Page 41 11D-41 ENGINE OVERHAUL <4G63-Turbo> CYLINDER HEAD AND VALVES NOTE: Store removed valves, springs and other Removal steps (Continued) <<C>> >>A<< 14. Valve stem seal parts, after putting to each of them a tag that 15. Valve spring seat identifies its cylinder No. or installation location.
  • Page 42 11D-42 ENGINE OVERHAUL <4G63-Turbo> CYLINDER HEAD AND VALVES Compress the valve spring using the special tool Intake valve stem seal Exhaust valve stem seal Valve spring compressor (MD998735 or MD998772), Colour: Gray Colour: Grayish green then install the retainer lock.

  • Page 43: Inspection

    11D-43 ENGINE OVERHAUL <4G63-Turbo> CYLINDER HEAD AND VALVES CAUTION The thickness of the metal that can be removed by grinding from both the cylinder head and the mating cylinder block is limited to 0.2 mm in 90˚ total. 3. Check the cylinder head gasket surface for warp using a straightedge and thickness gauge.

  • Page 44: Valve Guide

    11D-44 ENGINE OVERHAUL <4G63-Turbo> CYLINDER HEAD AND VALVES VALVE GUIDE Valve guide Total length AK202876 Stem diameter Guide inside diameter AK300168 3. Measure the total length of the valve. Measure the valve guide inside diameter and valve Replace the valve if the length is less than the stem diameter to calculate the clearance between limit.

  • Page 45: Valve Seat Reconditioning

    11D-45 ENGINE OVERHAUL <4G63-Turbo> CYLINDER HEAD AND VALVES VALVE SEAT RECONDITIONING Intake valve seat hole diameters: 0.3 oversize: 35.30 − 35.33 mm 1. Before reconditioning the valve seat, check the 0.6 oversize: 35.60 − 35.63 mm clearance between the valve guide and valve stem and, if necessary, replace the valve guide.

  • Page 46: Oil Pan And Oil Pump

    11D-46 ENGINE OVERHAUL <4G63-Turbo> OIL PAN AND OIL PUMP OIL PAN AND OIL PUMP REMOVAL AND INSTALLATION M1113008100657 19 ± 3 N·m Apply engine oil to all moving parts before installation. 23 ± 3 N·m 10 ± 2 N·m 54 ± 5 N·m 23 ±...
  • Page 47 11D-47 ENGINE OVERHAUL <4G63-Turbo> OIL PAN AND OIL PUMP REMOVAL SERVICE POINTS <<D>> FLANGE BOLT REMOVAL <<A>> OIL PAN LOWER REMOVAL Remove the oil pan by tapping it through a piece of wood applied to a side with a plastic hammer.
  • Page 48 11D-48 ENGINE OVERHAUL <4G63-Turbo> OIL PAN AND OIL PUMP <<F>> COUNTERBALANCER SHAFT REAR BEARING REMOVAL MB991603 MD998705 Rear bearing AK300619AG 1. Install special tool Silent shaft bearing installer MD998372 AK300175AD stopper (MB991603) to the cylinder block. 2. Apply engine oil to the rear bearing outer surface 1.
  • Page 49 11D-49 ENGINE OVERHAUL <4G63-Turbo> OIL PAN AND OIL PUMP MD998705 MD998705(Guide pin) MD998705(Guide pin) AK300179 AK300178 2. Install the guide pin of the Silent shaft bearing installer (MD998705) in the threaded hole of the MD998705 cylinder block as shown. Ratchet ball...
  • Page 50 11D-50 ENGINE OVERHAUL <4G63-Turbo> OIL PAN AND OIL PUMP >>G<< OIL PUMP DRIVEN GEAR/OIL 5. Using special tool Silent shaft bearing installer (MD998705), install the rear bearing. Make sure PUMP DRIVE GEAR INSTALLATION that the oil hole of the bearing is aligned with the oil hole of the cylinder block.
  • Page 51 11D-51 ENGINE OVERHAUL <4G63-Turbo> OIL PAN AND OIL PUMP >>I<< FLANGE BOLT INSTALLATION >>K<< OIL PRESSURE SWITCH INSTALLATION CAUTION AK300172 1. Insert a correspond screwdriver (shank diameter 8 mm) into the hole in the left side of the cylinder AK300715 AB...
  • Page 52 Specified sealant: 2. Apply a 4 mm diameter bead of FIPG to the flange Mitsubishi Genuine Part No.MD970389 or surface all around the oil pan. equivalent Specified sealant: NOTE: In the grooved areas on the oil pan flange, Mitsubishi Genuine Part No.MD970389 or...

  • Page 53: Inspection

    11D-53 ENGINE OVERHAUL <4G63-Turbo> OIL PAN AND OIL PUMP >>M<< OIL FILTER INSTALLATION CAUTION Installing the gasket with the wrong side facing the oil pan will result in oil leakage. Replace the drain plug gasket with a new one. Install it with the side indicated in the drawing toward the oil pan.
  • Page 54 11D-54 ENGINE OVERHAUL <4G63-Turbo> OIL PAN AND OIL PUMP OIL COOLER BY-PASS VALVE 2. Ensure that the dimension L measures the standard value under normal temperature and humidity. Standard value: 34.5 mm 3. The dimension must be the standard value when measured after the valve has been dipped in 97 to 103°C oil.

  • Page 55: Piston And Connecting Rod

    11D-55 ENGINE OVERHAUL <4G63-Turbo> PISTON AND CONNECTING ROD PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION M1113008400863 Apply engine oil to all moving parts before installation. 20 ± 2 N·m + 90º to 94º AK306012AC Removal steps (Continued) Removal steps >>C<<...
  • Page 56 11D-56 ENGINE OVERHAUL <4G63-Turbo> PISTON AND CONNECTING ROD REMOVAL SERVICE POINTS <<A>> CONNECTING ROD CAP REMOVAL Push rod Cylinder Front mark number Front mark Guide C AK300189 Base Mark the cylinder number on the side of the connecting rod big end as a guide for reassembly.
  • Page 57 11D-57 ENGINE OVERHAUL <4G63-Turbo> PISTON AND CONNECTING ROD 7. Insert the assembly of piston pin, Push rod, and Cylinder bore size mark Piston size mark Guide A (put together in step 4.) into the piston holes from the front mark side.
  • Page 58 11D-58 ENGINE OVERHAUL <4G63-Turbo> PISTON AND CONNECTING ROD >>B<< OIL RING INSTALLATION >>C<< PISTON RING NO. 2/PISTON RING NO. 1 INSTALLATION Lower Upper side side rail rail end gap end gap Piston ring expander Spacer end gap AK202879 AK202786 1. Fit the oil ring spacer into the piston ring groove.
  • Page 59 11D-59 ENGINE OVERHAUL <4G63-Turbo> PISTON AND CONNECTING ROD >>D<< PISTON AND CONNECTING ROD Locations of crankshaft pin diameter ASSEMBLY INSTALLATION marks 1. Apply engine oil generously to the piston's outside surface, piston rings, and oil ring. Side rail No. 2 No.

  • Page 60: Inspection

    11D-60 ENGINE OVERHAUL <4G63-Turbo> PISTON AND CONNECTING ROD >>F<< CONNECTING ROD CAP 3. Finger-tighten the nuts on the bolts, then tighten the nuts alternately and repeatedly to install the INSTALLATION cap properly. 4. Tighten the nuts to a torque of 20 ± 2 N⋅m.
  • Page 61 11D-61 ENGINE OVERHAUL <4G63-Turbo> PISTON AND CONNECTING ROD CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE METHOD) Push in by piston 1. Wipe off oil from the crankshaft pin and connecting rod bearing. 2. Cut a piece of plastic gauge whose length is equivalent to the width of the bearing and place it on the crankshaft pin in parallel with its axis.

  • Page 62: Crankshaft And Cylinder Block

    11D-62 ENGINE OVERHAUL <4G63-Turbo> CRANKSHAFT AND CYLINDER BLOCK CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION M1113008700875 11 ± 1 N·m 132 ± 5 N·m 9.0 ± 1.0 N·m 11 ± 1 N·m Apply engine oil to all moving parts before installation.
  • Page 63 11D-63 ENGINE OVERHAUL <4G63-Turbo> CRANKSHAFT AND CYLINDER BLOCK REMOVAL SERVICE POINTS NOTE: Applying engine oil to the bearings will help facilitate holding them in position. <<A>> OIL JET REMOVAL >>C<< CRANKSHAFT BEARING INSTALLATION Location of crankshaft journal diameter marks No. 2 AK304984 No.
  • Page 64 11D-64 ENGINE OVERHAUL <4G63-Turbo> CRANKSHAFT AND CYLINDER BLOCK >>D<< BEAM BEARING CAP/BEARING Crankshaft journal Cylinder Crankshaft CAP BOLT INSTALLATION diameter block bearing bearing 1. Install the beam bearing cap on the cylinder block bore with the arrow pointing to the timing belt.
  • Page 65 11D-65 ENGINE OVERHAUL <4G63-Turbo> CRANKSHAFT AND CYLINDER BLOCK >>E<< REAR OIL SEAL INSTALLATION CAUTION • If the tightening angle is less than 90°, ade- quate tightness could not be assured. MB990938 • If the tightening angle exceeds 100°, loosen the bolt completely and then perform the MD998776 tightening again beginning with the first step.

  • Page 66: Inspection

    11D-66 ENGINE OVERHAUL <4G63-Turbo> CRANKSHAFT AND CYLINDER BLOCK INSPECTION CYLINDER BLOCK M1113008800645 1. Visually check the cylinder block for scratches, CRANKSHAFT OIL CLEARANCE rust, and any other corrosion. Also check it for (PLASTIC GAUGE METHOD) cracks using a flaw detecting penetrant.
  • Page 67 11D-67 ENGINE OVERHAUL <4G63-Turbo> CRANKSHAFT AND CYLINDER BLOCK BORING CYLINDERS 3. Based on the piston diameter measurement, calculate the boring finish dimension. 1. Select an oversize of the pistons to be used • Boring finish dimension = [Piston diameter] + based on the largest of the cylinder bores.
  • Page 68 NOTES...

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