Mitsubishi 4G1 series Manuel utilisateur

BACKUP

Service

Manual

ENGINE

GROUP INDEX

1992

1993

Introduction

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

FOREWORD

The information contained in this service manual

has been prepared for the professional automotive

technician involved in daily repair operations. In-

formation in this manual is divided into groups by

engine models. Each group is further divided to

address individual components within the group.

These groups contain general information, specifica-

tion, removal and installation, disassembly and

reassembly procedures for the components. The

first page of each group contains an alphabetical

index to assist in finding the location of the

component. The information, descriptions and spe-

cifications were in effect at the time this manual

was released.

This

BACKUP DSM manual

to be used ONLY as a BACKUP. Please DO NOT REDISTRIBUTE

WHOLE SECTIONS.

This

BACKUP was sold to you under the fact that you do

indeed

OWN

a GENUINE DSM MANUAL. It CANNOT BE considered a REPLACEMENT (Unless your original

manual was lost or destroyed.)

Please See

README.N

READMEHTML

for

additional

Information.

Thank you. [email protected]

WE SUPPORT

VOLUNTARY TECHNICIAN

CERTIFICATION THROUGH

National

lnstit~te

for

AUTOMOTIVE

SERVICE

EXCELLENCE

Engine

4G1l

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4G33

. . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . .

4G6

<1992>>

. . . . . . . . . . . . . . . . . . . . . . . .

4G99

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...*..

6G77

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4G6

<1993>>

. . . . . . . . . . . . . . . . . . . . . . . .

CCT

Mitsubishi Motors Co[poration reserves the right to make changes

dew?

or to make addltlons to or improvements in its products

WIthout

impoang

any obligations upon itself to install them on its products

previously manufactured.

1992

Mitsubishi Motors Corporation

Printed in Japan

INTRODUCTION

CONTENTS

ENGINE MODEL TABLE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOL NOTE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXPLANATION OF MANUAL CONTENTS

. . . . . . . .

2TORQUE REFERENCES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..I.....

FORM-IN-PLACE GASKET

. . . . . . . . . . . . . . . . . ..I................

Disassembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Form-In-Place Gasket Application

._......................

Surface

Preparation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

‘-:

INTRODUCTION

EXPLANATION OF MANUAL CONTENTS

Maintenance and Servicing Procedures

(1) A diagram of the component parts is

provided near the front of each section in

order to give the reader a better under-

standing of the installed condition of

component parts.

(2) The numbers provided within the diagram

indicate the sequence for maintenance

and servicing procedures; the symbol

indicates a non-reusable part; the tighten-

ing torque is provided where applicable.

Removal steps:

The part designation number corresponds

to the number in the illustration to indicate

removal steps.

l Disassembly steps:

The part designation number corresponds

to the number in the illustration to indicate

disassembly steps.

Installation steps:

Specified in case installation is impossible

in reverse order of removal steps. Omit-

ted if installation is possible in reverse

order of removal steps.

l Reassembly steps:

Specified in case reassembly is

im$ossi-

ble

in reverse order of disassembly

Omitted if reassembly is possible

verse order of disassembly steps.

Classification of Major Maintenance/

Service Points

When there are major points relative to mainte-

nance and servicing procedures (such as essential

maintenance and service points, maintenance and

service standard values, information regarding the

use of special tools, etc.), these are arranged

together as major maintenance and service points

and explained in detail.

GAO:

Indicates that there are essential points for

removal or disassembly.

I)A4:

Indicates that there are essential points for

installation or reassembly.

Symbols for Lubrication, Sealants and

Adhesives

Information concerning the locations for

lubrica-

tion and for application of sealants and adhesives

is provided, by using symbols, in the diagram of

component parts, or on the page following the

component parts page, and explained.

. . Grease

(multrpurpose grease unless there is

a brand or type specified)

. . . . .

Sealant or adhesive

. . . . .

Brake fluid, automatic transmission

fllid

or air conditioning compressor

. . . . . Engine oil or gear oil

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INTRODUCTION

Indicates the

section title.

Denotes non-reusable

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This number corresponds to the

number appearing in “Removal

steps”, “Disassembly steps”,

“ln-

stallation steps” or “Reassembly

steps” I

Operating procedures, cautions,

etc. on removal, installation, dis-

assembly and reassembly are de-

scribed.

INTRODUCTION

ENGINE MODEL TABLE

1992

Engine

Series,

4Gl

4G3

4G6

4G9

6G7

4693

1.8

IO)

6672

3.0

83)

6G72 3.0 (183)

In-line,

SOHC

6O”V.

SOHC

(per bank)

6O”V.

DOHC

(per bank)

E$po

LRV

bgmante,

h&ntero,

Truck

Diamante,

3000GT

6G72

Turbo

3.0 (183)

6O“V.

DOHC

(per bank)

43000GT

ENGINE MODEL TABLE

1993

4G9

6G7

4664

2.4(146) In-line, SOHC

E$po-LRV.

Expo

4G93

1.8

IO)

In-line, SOHC 4

@age,

Expo LRV

6672

3.0 (I 83)

6O”V.

SOHC

Diamante,

(per bank)

Mhtero,

Truck

6672

3.0 (183)

6O”V,

DOHC 4

(per bank)

C$mante,

3000GT

6G72

Turbo

3.0 (183)

6O”V.

DOHC

43600GT

(per bank)

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INTRODUCTION

SPECIAL TOOL NOTE .

Please refer to the special tool cross reference chart which is located in the service manual at the beginning of

each group, for a cross reference from the MMC special tool number to the special tool number that is

available in your market.

iiS

*‘l

*.j,

l”

“...!:

‘/’

TORQUE REFERENCES

General tightening torque is as shown in the following table.

The specific part tightening torque is shown at the beginning of each group.

Size mm

(dia.

pitch)

0.8

1.0

1.25

10x1.25

12x

1.25

14x1.5

Bolt with spring washer Flange bolt

Head mark 4 Head mark 7 Head mark 10 Head mark 4

Heaid.

i-MC 7

ft.lbs. Nm ft.lbs. Nm ft.lbs. Nm ft.lbs. Nm

ft.lbS.

NEW TIGHTENING METHOD

BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA

A new type of bolts, to be tightened in plastic area, is currently used in

so’me

parts of the engine. The

tightening method for the bolts is different from the conventional one. Be sure to observe the

method

described in the text when tightening the bolts.

Service limits are provided for the bolts. Make sure that the service limits described in the text are strictly

observed.

l Areas where the bolts are in use:

(1) Cylinder head bolts

(2)

Main bearing cap bolts

(3) Connecting rod cap bolts

Remarks:

The bolts in

(1)

and (2) apply to the

4G6

993>

and

4G93

engines.

The bolts in (3) apply to the

4G15,

4G6

<1993>

and

4693

engines.

l Tightening Method

After tightening the bolts to the specified torque, tighten them another

90”

or 180” (twice 90”). The

tightening method varies on different areas. Observe the tightening method described in the text.

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INTRODUCTION

FORM-IN-PLACE GASKET

The engine has several areas where the form-in-place gasket

(FIPG)

is in use. To ensure that the gasket fully

serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size,

continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick a bead, on

the other hand, could be squeezed out of location, causing blocking or narrowing of the fluid feed line. To

eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to apply the gasket evenly

without a break, while observing the correct bead size.

The

FIPG

used in the engine is a room temperature vulcanization (Rn/) type and is supplied in a loo-gram

tube (Part No. MD970389 or

MD9971

10).

Since the

RTV

hardens as it reacts with the moisture in the

atmospheric air, it is normally used in the metallic flange areas. The FIPG, Part No.

MD970389,

can be used

for sealing both engine oil and coolant, while Part No. 997110 can only be used for engine oil sealing.

Disassembly

The parts assembled with the

FIPG

can be easily disassembled without use of a special method. In some

cases, however, the sealant between the joined surfaces may have to be broken

bylightly

striking with a

mallet or similar tool. A flat gasket scraper may be lightly hammered in between the joined surfaces. In this

case, however, care must be taken to prevent damage to the joined surfaces.

Surface

Preparation

Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper or

wire brush. Check to ensure that the surfaces to which the

FIPG

is to be applied is flat.‘ Make sure that there

are no oils, greases and foreign substances deposited on the application surfaces. Do:not forget to remove

the old sealant remaining in the bolt holes.

Form-In-Place Gasket Application

When assembling parts with the FIPG, you must observe some precautions, but the procedure is very simple

as in the case of a conventional precut gasket.

Applied

FIPG

bead should be of the specified size and without breaks. Also be sure

toencircle

the bolt hole

circumference with a completely continuous bead. The

FIPG

can be wiped away unless it is hardened. While

the

FIPG

is still moist (in less than 15 minutes), mount the parts in position. When the parts are mounted,

make sure that the gasket is applied to the required area only.

The

FIPG

application procedure may vary on different areas. Observe the procedure described in the text

when applying the FIPG.

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4G15

BRACKET

................................................................

CRANKSHAFT, FLYWHEEL AND

DRIVE PLATE

........................................................ 51

CYLINDER HEAD AND VALVES

........................

EXHAUST MANIFOLD AND

WATER PUMP

....................................................

FRONT CASE AND OIL PUMP

............................

FUEL AND EMISSION PARTS

............................

GENERAL INFORMATION

................................

GENERAL SPECIFICATIONS

............................

GENERATOR AND IGNITION SYSTEM

........

CONTENTS

INTAKE

MANIFOLD

............................................

PISTON AND CONNECTING ROD

....................

ROCKER ARMS AND CAMSHAFT

....................

SEALANT

................................................................ 11

SERVICE SPECIFICATIONS

................................

SPECIAL TOOLS

....................................................

THROlTLE

BODY

................................................

TIMING

BELT

........................................................

TORQUE SPECIFICATIONS

................................

IlA-2

4Gl

ENGINE

General Information

GENERAL INFQRMATION

ENGINE SECTIONAL VIEW

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