Table Of Contents - Mitsubishi 4G1 series Workshop Manual

Table of Contents

Engine 4G1 Series1
Table Of Contents1
General Information3
Service Specifications9
1-19
Rework Dimensions13
Torque Specifications14
New Tightening Method Using Plastic Region Tightening Bolts18
Sealants18
Form-In-Place Gasket19
Disassembly19
Surface Preparation19
Form-In-Place Gasket Application19
Special Tools21
2-121
Alternator And Ignition System23
3-123
Removal Service Point27
Installation Service Points27
Crankshaft Bolt Installation27
Timing Belt Removal And Installation29
4-129
Removal Service Points31
Camshaft Sprocket Bolt Removal31
Tensioner Pulley And Idler Pulley32
Camshaft Sprocket Bolt Installation32
Timing Belt Tensioner/Tensioner Spring Installation32
Timing Belt Installation33
Fuel And Emission Control System 11A-5-135
Injector Installation40
Fuel Pressure Regulator Installation40
Water Pump And Water Hose Removal And Installation41
6-141
Water Pump Installation46
O-Ring/Water Pipe Installation46
Thermostat Installation46
Water Temperature Gauge Unit Installation46
Thermo Valve Installation47
Intake And Exhaust Manifolds Removal And Installation49
11A-7-149
Reed Valve, Bracket And Air Pipe Installation54
Rocker Arms And Camshafts Removal And Installation56
11A-8-156
Camshaft Inspection60
Lash Adjusters Inspection60
Camshaft Installation63
Bearing Cap Installation64
Adjusting Screw Installation64
Rocker Arm Shaft Installation64
Rocker Arm/Rocker Shaft Assembly65
Camshaft Oil Seal Installation65
Semi-Circular Packing Installation65
Rocker Cover Installation66
Valve Clearance Adjustment66
Cylinder Head And Valves Removal And Installation68
9-168
Valve Stem Seal Removal73
Cylinder Head Inspection73
Valves Inspection73
Valve Springs74
Valve Guides75
Valve Seats75
Valve Seat Correction Service Points76
Valve Seat Replacement Service Points76
Valve Guide Replacement Service Points77
Valve Stem Seal Installation77
Valve Spring Installation78
Retainer Lock Installation78
Cylinder Head Bolt Installation78
Oil Pump And Oil Pan Removal And Installation80
10-180
Oil Pan Removal81
Oil Pump Inspection81
Front Oil Seal Case Installation82
Front Oil Seal Installation82
Oil Pan Installation82
Drain Plug Gasket Installation82
Oil Filter Installation83
Pistons And Connecting Rods Removal And Installation84
11-184
Connecting Rod Cap Removal85
Piston Pin Removal85
Piston Rings Inspection85
Crankshaft Pin Oil Clearance (Plastic Gauge Method)86
Piston Pin Installation86
Oil Ring Installation87
Piston Ring Installation88
Piston And Connecting Rod Assembly Installation88
Connecting Rod Bearing Installation89
Connecting Rod Cap Installation90
Connecting Rod Cap Nut Installation90
Crankshaft And Cylinder Block Removal And Installation92
12-192
Oil Pressure Switch Removal94
Crankshaft Oil Clearance94
Cylinder Block94
Boring Cylinders95
Oil Pressure Switch Installation95
Crankshaft Bearing Installation96
Rear Oil Seal Installation98