Table Of Contents - Mitsubishi 4G6 series Workshop Manual

Table of Contents

Table Of Contents1
Sohc-4G633
Sohc-4G643
General Information 11A-0-33
Gdit4
Service Specifications5
1-15
Torque Specifications8
New Tightening Method - By Use Of Bolts To Be Tightened In Plastic Area13
Sealants13
Form-In-Place Gasket14
Disassembly14
Surface Preparation14
Form-In-Place Gasket Application14
Special Tools15
2-115
Alternator And Ignition System19
Removal And Installation: Carburetor19
3-119
Water Pump Pulley19
Alternator Brace19
Crankshaft Pulley19
Spark Plug19
Removal And Installation: Multipoint Fuel Injection20
Camshaft Position Sensing Cylinder (Multipoint Fuel Injection)20
Camshaft Position Sensor (Multipoint Fuel Injection)20
Removal And Installation (Gdi)21
Oil Level Gauge Guide21
Idler Pulley Bracket (M8) (Vehicle For Hong Kong)21
Idler Pulley Bracket (M10) (Vehicle For Hong Kong)21
Idler Pulley (Vehicle For Hong Kong)21
Installation Service Points22
"Aa Camshaft Position Sensor Support22
"Ba Distributor Assembly Installation22
Removal And Installation (Space Wagon)23
3A. Intake Manifold (Gdi)23
Vacuum Pipe And Hose (Flange Bolt)23
Vacuum Pipe And Hose (Bolt, Washer Assembly)23
Solenoid Valve23
Vacuum Pipe23
Throttle Body23
Intake Manifold Stay (M6)23
Air Intake Plenum Resonator (Flange Bolt)23
Egr Valve23
Removal And Installation (Galant)24
"Aa Egr Support / Hose Clamp / Gasket Installation25
"Ba Air Intake Plenum Resonator25
"Ca Intake Manifold Stay Installation25
"Da Throttle Body Gasket Installation25
Timing Belt26
Removal And Installation (Sohc)26
Power Steering Bracket26
Tensioner Arm26
Auto Tensioner26
Idler Pulley26
Engine Support Bracket26
4-126
Aa" Timing Belt Removal28
Ab" Timing Belt Removal28
Ac" Oil Pump Sprocket Removal28
Ad" Crankshaft Bolt Loosening29
Ae" Crankshaft Sprocket Removal29
Af" Timing Belt "B" Removal29
Ag" Counterbalance Shaft Sprocket29
Ah" Crankshaft Sprocket "B" Removal30
Ai" Camshaft Sprocket Bolt Loosening30
"Aa Camshaft Sprocket Bolt Tightening30
"Ba Camshaft Sprocket Bolt Tightening30
"Ca Engine Support Bracket Installation31
"Da Spacer Installation31
"Ea Timing Belt "B" Installation31
"Fa Timing Belt "B" Installation31
"Ga Crankshaft Bolt Tightening32
"Ha Oil Pump Sprocket Installation32
"Ia Auto Tensioner Installation32
"Ja Tensioner Pulley Installation33
"Ka Timing Belt Installation33
"La Timing Belt Installation35
Inspection38
Engine Hanger40
4A. Exhaust Manifold (Gdi)40
Fuel And Emission Control Parts41
5-141
Removal And Installation: Multipoint Fuel Injection - Galant42
Removal And Installation: Multipoint Fuel Injection - Space Wagon43
"Aa Injectors Installation44
"Ba Fuel Pressure Regulator Installation44
Removal And Installation (1999 Model Space Wagon)45
5A. Fuel Parts (Gdi)45
Fuel Pipe Bracket46
Fuel Feed Pipe46
Fuel Return Pipe46
Fuel High Pressure Regulator46
Fuel Pressure Sensor46
Removal And Installation (2000 Model Space Wagon And Galant)47
"Aa Backup Ring/Corrugated Washer49
"Ba Delivery Pipe And Injectior Assembly49
"Ca Pump Camshaft Case Installation50
"Da Fuel Pressure Sensor Installation50
"Ea Fuel High Pressure Regulator/Fuel Return Pipe Installation50
"Fa Fuel Pump/Fuel Feed Pipe Installation51
Water Pump And Intake Manifold52
Engine Coolant Temperature Gauge Unit52
Water Inlet Fitting52
Thermostat Housing52
Water Inlet Pipe52
6-152
"Aa Water Pipe/O-Ring Installation55
"Ba Sealant Application To Thermostat55
"Ca Sealant Application To Engine Coolant55
"Da Sealant Application To Engine Coolant55
Water Outlet Fitting56
Knock Sensor56
6A. Water Pump And Water Hose (Gdi)56
"Aa O-Ring/Water Inlet Pipe Installation57
"Ba Thermostat Case Installation57
"Ca Water Outlet Fitting Installation57
"Da Engine Coolant Temperature Gauge Unit Installation57
Exhaust Manifold58
Heat Protector58
7-158
Rocker Arms And Camshaft60
8-160
Aa" Rocker Arms And Rocker Arms Shafts Removal61
"Aa Lash Adjuster Installation61
"Ba Rocker Shaft Spring/Rocker Arms And Rocker Arm Shaft Installation61
"Ca Camshaft Oil Seal Installation61
Lash Adjusters62
Camshaft62
Rocker Arm62
Camshaft Position Sensing Cylinder66
Beam Camshaft Cap66
8A. Rocker Arms And Camshafts (Gdi)66
Aa" Lash Adjuster Removal67
"Ba Beam Camshaft Cap Gasket/Beam Camshaft Cap/Camshaft/Oil Seal Installation67
"Ca Camshaft Position Sensing Cylinder Support Installation68
"Da Camshaft Position Sensing Cylinder Installation68
Lash Adjuster69
Cylinder Head And Valves73
9-173
Aa" Cylinder Head Bolts Removal75
Ab" Retainer Lock Removal75
Ac" Valve Stem Seal Removal76
"Aa Valve Stem Seal Installation76
"Ba Valve Spring Installation76
"Ca Retainer Lock Installation77
"Da Cylinder Head Gasket Identification77
"Ea Cylinder Head Bolt Installation77
Cylinder Head78
Valve79
Valve Spring79
Valve Guide80
Valve Seat80
Valve Seat Reconditioning Procedure80
Valve Seat Replacement Procedure81
Valve Guide Replacement Procedure82
Removal And Installation: Gdi Engine - Vehicle For Europe And Sohc Engine83
Front Case, Counterbalance Shafts And Oil Pan 11A-10-183
Oil Screen83
Relief Plug83
Oil Filter Bracket83
Flange Bolt83
Removal And Installation: Gdi Engine - Vehicle For Hong Kong84
Aa" Oil Pan Removal85
Ab" Oil Pan Lower Removal85
Ac" Oil Pan Upper Removal85
Ad" Plug Removal85
Af" Counterbalance Shaft Front Bearing Removal86
Ag" Counterbalance Shaft Rear Bearing Removal86
"Aa Right Counterbalance Shaft Rear Bearing Installation86
"Ba Left Counterbalance Shaft Rear Bearing Installation87
"Ca Counterbalance Shaft Front Bearing Installation87
"Da Counterbalance Shaft Oil Seal Installation87
"Ea Oil Pump Oil Seal Installation88
"Fa Crankshaft Front Oil Seal Installation88
"Ga Oil Pump Driven Gear/Oil Pump Drive Gear Installation88
"Ha Front Case Assembly Installation88
"Ia Sealant Application To Oil Pressure89
"Ja Flange Bolt Installation89
"Ka Plug Installation89
"La Oil Pan Installation89
"Ma Oil Pan Upper/Oil Pan Lower Installation90
"Na Drain Plug Gasket Installation91
"Oa Oil Filter Installation91
Front Case92
Oil Seal92
Counterbalance Shaft92
Oil Pump92
Driven Gear 0.06 -92
Piston And Connecting Rod93
11-193
Aa" Connecting Rod Cap Removal94
Ab" Piston Pin Removal94
"Aa Piston Pin Installation95
"Ba Oil Ring Installation96
"Ca Piston Ring No. 2/Piston Ring No. 1 Installation97
"Da Piston And Connecting Rod Assembly Installation97
"Ea Connecting Rod Bearings Installation97
"Fa Connecting Rod Cap Nut Installation98
"Ga Connecting Rod Cap Nut Installation99
Piston Ring99
Crankshaft Pin Oil Clearance (Plastic Gauge Method)100
Crankshaft, Flywheel And Drive Plate101
12-1101
Aa" Oil Jet Removal102
"Aa Oil Jet Installation102
"Ba Crankshaft Thrust Bearing Installation102
"Ca Crankshaft Bearing Installation102
"Da Bearing Cap/Bearing Cap Bolt Installation104
"Ea Oil Seal Installation105
"Fa Sealant Application To Oil Seal Case105
Crankshaft Oil Clearance (Plastigage Method)105
Cylinder Block106
Boring Cylinder106