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4G9 series
Mitsubishi 4G9 series Manuals
Manuals and User Guides for Mitsubishi 4G9 series. We have
6
Mitsubishi 4G9 series manuals available for free PDF download: Service Manual, User Manual, Manual, Workshop Manual
Mitsubishi 4G9 series Service Manual (522 pages)
1992-1993
Brand:
Mitsubishi
| Category:
Engine
| Size: 18.67 MB
Table of Contents
Introduction
3
Table of Contents
3
Engine Model Table
6
Special Tool Note
7
Torque References
7
Form-In-Place Gasket
8
Disassembly
8
Form-In-Place Gasket Application
8
Surface Preparation
8
Table of Contents
9
Crankshaft, Flywheel and Drive Plate
19
Cylinder Head and Valves
19
Generator and Ignition System
22
Water Pump
27
Fuel and Emission Parts
30
Rocker Arms and Camshaft
38
Front Case and Oil Pump
47
Engine
63
General Information
64
General Specifications
67
Timing Belt
72
Torque Specifications
72
Bracket
73
Generator and Ignition System
78
Exhaust Manifold and Water Pump
94
Intake Manifold
125
Sealant
125
Service Specifications
125
Special Tools
125
Throttle Body
125
Removal and Installation
160
Fuel and Emission Control Parts
170
Engine 4G93
233
Exhaust Manifold
260
Front Case and Oil Pump
268
Contents Intake Manifold
285
General Information
288
General Specifications
296
Piston and Connecting Rod
306
Sealant
307
Timing Belt
333
Inspection Piston/Pin/Ring
511
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Mitsubishi 4G9 series 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
Mitsubishi 4G9 series Manual (130 pages)
4G9 Series
Brand:
Mitsubishi
| Category:
Engine
| Size: 3.36 MB
Table of Contents
Engine
1
Table of Contents
1
General Information
3
1 Specifications
5
1-1
5
Service Specifications
5
Rework Dimensions
8
Torque Specifications
8
Table of Contents
9
New Tightening Method - by Use of Bolts to be Tightened in Plastic Area
13
Sealant
13
Form-In-Place Gasket
14
2 Special Tools
15
2-1
15
3-1
18
4-1
27
4G9 Engine (E
35
Timing Belt
38
Auto-Tensioner Bolt
39
3 Alternator and Ignition System
18
4 Timing Belt
27
5 Fuel and Emission Control System
40
5-1
40
Breather Tube
40
Carburetor
40
EGR Valve
40
Fuel Pump
40
Delivery Pipe
41
Fuel Pressure Regulator
41
Fuel Return Pipe
41
Throttle Body
43
5A. THROTTLE BODY and EGR SYSTEM (GDI)
46
Throttle Body Stay
43
Air Intake Resonator
46
Intake Manifold Stay
46
Throttle Body
47
6 Intake and Exhaust Manifold
49
Water Hose Clamp
47
Water Pipe
47
6A. INTAKE MANIFOLD (GDI)
53
6B.exhaust MANIFOLD (GDI)
57
Exhaust Manifold (M8)
59
6C. INJECTOR and FUEL PUMP ASSEMBLY (GDI)
60
Clamp
60
Fuel Low Pressure Pipe (M6)
60
Fuel Low Pressure Pipe (M8)
60
Fuel Nipple
60
Injector and Fuel Pump Assembly (GDI)
60
Delivery Pipe and Injector
61
7 Water Pump and Water Hose Water Pump
65
Fuel Feed Pipe
61
Fuel High Pressure Regulator
61
Fuel Return Pipe
61
Injector Holder
61
Spacer
61
7-1
65
Thermostat Case
65
Water Inlet Pipe
65
Water By-Pass Fitting
67
Water Fitting
67
8 Rocker Arms and Camshafts
70
Water Pipe
67
8-1
70
Rocker Arm Shaft
70
Rocker Cover
70
Beam Camshaft Cap (M8)
74
8A. ROCKER COVER and CAMSHAFTS (MIVEC)
85
8B.rocker ARMS and ROCKER SHAFT CAPS (MIVEC)
90
9 Cylinder Head and Valves
92
9-1
92
10-1
106
10 Front Case and Oil Pump
106
11-1
113
11 Piston and Connecting Rod
113
12 Crankshaft, Cylinder Block, Flywheel and Drive Plate
121
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Mitsubishi 4G9 series Workshop Manual (105 pages)
Brand:
Mitsubishi
| Category:
Engine
| Size: 3.03 MB
Mitsubishi 4G9 series Workshop Manual (101 pages)
Brand:
Mitsubishi
| Category:
Engine
| Size: 4.17 MB
Mitsubishi 4G9 series Workshop Manual (4 pages)
Brand:
Mitsubishi
| Category:
Engine
| Size: 0.1 MB
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