Mitsubishi 4G6 series- Manuals

Page 2 - NOTES

11A-0-2 PWEE9616 E Dec. 1996 Mitsubishi Motors Corporation NOTES

Page 3 - General Information; GENERAL INFORMATION

4G6 ENGINE <E - W> - General Information 11A-0-3 GENERAL INFORMATION SOHC-4G63 Descriptions Specifications Type In-line OHV, SOHC Number of cylinders 4 Combustion chamber Pentroof type Total displacement dm 3 1,997 Cylinder bore mm 85.0 Piston stroke mm 88.0 Compression ratio 10 Valve timing I...

Page 4 - GDI; NOTE

4G6 ENGINE <E - W> - General Information 11A-0-4 GDI t Descriptions Specifications Type In-line OHV, SOHC Number of cylinders 4 Combustion chamber Pentroof + curved top piston type Total displacement dm 3 2,351 Cylinder bore mm 86.5 Piston stroke mm 100.0 Compression ratio 11.5 Valve timing In...

Page 5 - Specifications; SERVICE SPECIFICATIONS; Timing belt

4G6 ENGINE <E - W> - Specifications 11A-1-1 1. SPECIFICATIONS SERVICE SPECIFICATIONS Items Standard value Limit Timing belt Auto-tensioner rod projection length mm 12 - Auto-tensioner rod pushed-in amount [when pushed with a force of 98 - 196 N] mm 1.0 or less - Rocker arms and camshaft Camsha...

Page 7 - Front case, counterbalance shaft and oil pan

4G6 ENGINE <E - W> - Specifications 11A-1-3 Items Limit Standard value Front case, counterbalance shaft and oil pan Oil pump side clearance mm Drive gear 0.08 - 0.14 - Driven gear 0.06 - 0.12 - Oil pressure at curb idle speed kPa [Oil temperature is 75 to 90 _ C] 78 or more - Piston and connec...

Page 8 - TORQUE SPECIFICATIONS; Alternator and ignition system

4G6 ENGINE <E - W> - Specifications 11A-1-4 TORQUE SPECIFICATIONS Items Nm Alternator and ignition system Water pump pulley 9 Adjusting bolt 10 Lock bolt 22 Alternator brace 23 Alternator pivot nut 44 Crankshaft pulley 25 Ignition coil (Multipoint fuel injection) 10 Spark plug 25 Distributor (...

Page 9 - Fuel and emission parts

4G6 ENGINE <E - W> - Specifications 11A-1-5 Items Nm Timing belt cover washer bolt 9 Power steering bracket 49 Crankshaft angle sensor (Multipoint fuel injection) 9 Tensioner arm 22 Tensioner puller 48 Auto tensioner 23 Idler pulley 35 Engine support bracket 49 Oil pump sprocket 54 Crankshaft ...

Page 10 - Water pump and intake manifold

4G6 ENGINE <E - W> - Specifications 11A-1-6 Items Nm Fuel pump 4.9 ® 17 ± 2 Harness bracket 8.8 Fuel return pipe 11 Fuel high pressure regulator 18 Fuel pressure sensor 18 Pump camshaft case 23 Injector holder 22 Delivery pipe and injector assembly 11 Engine hanger 11 Water pump and intake man...

Page 11 - Rocker arms and camshaft

4G6 ENGINE <E - W> - Specifications 11A-1-7 Items Nm Heat protector 13 Exhaust manifold (M8) 29 Exhaust manifold (M10) 49 Water outlet fitting 13 Rocker arms and camshaft Rocker cover 3.4 Rocker arm shaft 31 Rocker arms and camshafts (GDI) Camshaft position sensor 8.8 Cover 9.8 Camshaft positi...

Page 12 - Piston and connecting rod

4G6 ENGINE <E - W> - Specifications 11A-1-8 Items Nm Oil pan lower 6.9 Baffle plate 6.9 Oil pan upper 6.9 Piston and connecting rod Connecting rod cap 20 + 90 _ ® 100 _ Crankshaft, flywheel and drive plate Flywheel bolt 132 Drive plate bolt 132 Rear plate 11 Bell housing cover 8.8 Oil seal cas...

Page 13 - described in the text when tightening the bolts.; SEALANTS

4G6 ENGINE <E - W> - Specifications 11A-1-9 NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED INPLASTIC AREA A new type of bolts, to be tightened in plastic area, is currently used some parts of the engine. The tightening method for the bolts is different from the conventional one. Be su...

Page 14 - Disassembly; forget to remove the old sealant remained in the bolt holes.

4G6 ENGINE <E - W> - Specifications 11A-1-10 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 lo...

Page 15 - Special Tools

4G6 ENGINE (E - W) - Special Tools 11A-2-1 2. SPECIAL TOOLS Tool Number Name Use MB990767 Crankshaft pulley holder Holding camshaft sprocket Use with MD998719. MD990938 Handle Installation of crankshaft rear oil seal Use with MD998776. MB991603 Silent shaft bearing puller stopper Guide stopper for r...

Page 19 - Alternator and Ignition System; ALTERNATOR AND IGNITION SYSTEM; Removal steps; High tension cable

4G6 ENGINE (E - W) - Alternator and Ignition System 11A-3-1 3. ALTERNATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION <CARBURETOR> 9 10 4 5 3 1 7 6 12 Nm 25 Nm 24 Nm 10 Nm 9 Nm 25 Nm 22 Nm 44 Nm 8 2 Removal steps 1. Drive belt 2. Water pump pulley 3. Alternator brace 4. Alternator 5. Cranksha...

Page 20 - REMOVAL AND INSTALLATION ; Ignition coil assembly

4G6 ENGINE (E - W) - Alternator and Ignition System 11A-3-2 REMOVAL AND INSTALLATION <MULTIPOINT FUEL INJECTION> 11 10 4 5 2 3 1 7 9 22 Nm 14 Nm 24 Nm 22 Nm 9 Nm 25 Nm 44 Nm 25 Nm 6 10 Nm 10 Nm r 10 Nm 8 Removal steps 1. Drive belt 2. Water pump pulley 3. Alternator brace 4. Alternator 5. Cran...

Page 21 - Oil level gauge guide

4G6 ENGINE (E - W) - Alternator and Ignition System 11A-3-3 REMOVAL AND INSTALLATION (GDI) 11 10 4 5 2 3 1 7 9 22 Nm 13 Nm 25 Nm 22 Nm 49 Nm 23 Nm 49 Nm 25 Nm 6 49 Nm 9.8 Nm 8.8 Nm 8 12 9.8 Nm Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Drive belt 5. Water pump pulley 6. A...

Page 22 - INSTALLATION SERVICE POINTS

4G6 ENGINE (E - W) - Alternator and Ignition System 11A-3-4 INSTALLATION SERVICE POINTS " A A CAMSHAFT POSITION SENSOR SUPPORTINSTALLATION (1) Apply a 3 mm bead of form-in-place gasket (FIPG) to the area shown. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent " B A DISTR...

Page 24 - Vacuum pipe and hose

4G6 ENGINE (E - W) - Intake Manifold (GDI) 11A-3a-2 REMOVAL AND INSTALLATION (GALANT) 23 Nm 8.8 Nm 8.8 Nm 11 Nm 2 1 3 19 Nm 4 15 16 19 Nm 5 6 7 8 9 11 10 14 12 13 23 Nm 8.8 Nm 30 Nm 11 Nm Removal steps 1. Vacuum pipe and hose 2. Solenoid valve 3. Throttle body " D A 4. Throttle body gasket "...

Page 25 - INTAKE MANIFOLD STAY INSTALLATION

4G6 ENGINE (E - W) - Intake Manifold (GDI) 11A-3a-3 INSTALLATION SERVICE POINTS " A A EGR SUPPORT / HOSE CLAMP / GASKETINSTALLATION (1) Install the gasket, EGR support and hose clamp to the cylinder head in that order and tighten the fasteners temporarily. (2) Install the EGR support assembly to...

Page 26 - Timing Belt

4G6 ENGINE (E - W) - Timing Belt 11A-4-1 4. TIMING BELT REMOVAL AND INSTALLATION (SOHC) 1 2 10 4 23 22 9 11 6 20 14 8 13 15 21 7 17 18 45 Nm 14 Nm 11 Nm 22 Nm 9 Nm 48 Nm 88 Nm 54 Nm 118 Nm 49 Nm 16 45 Nm 18 Nm 19 35 Nm 23 Nm 5 12 3 49 Nm 9 Nm Removal steps 1. Timing belt front upper cover 2. Timing ...

Page 28 - REMOVAL SERVICE POINTS; TIMING BELT REMOVAL

4G6 ENGINE (E - W) - Timing Belt 11A-4-3 REMOVAL SERVICE POINTS A A " TIMING BELT REMOVAL (1) Mark belt running direction for reinstallation. NOTE (1) Water or oil on the belt shorten its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and water. These...

Page 29 - CRANKSHAFT BOLT LOOSENING

4G6 ENGINE (E - W) - Timing Belt 11A-4-4 A D " CRANKSHAFT BOLT LOOSENING (1) Hold the drive plate with the special tool as shown. (2) Remove the crankshaft bolt. A E " CRANKSHAFT SPROCKET REMOVAL (1) If it is difficult to remove the sprocket, use the special tool. A F " TIMING BELT “B” R...

Page 30 - CRANKSHAFT SPROCKET “B” REMOVAL; CAMSHAFT SPROCKET BOLT TIGHTENING

4G6 ENGINE (E - W) - Timing Belt 11A-4-5 A H " CRANKSHAFT SPROCKET “B” REMOVAL (1) If it is difficult to remove the sprocket, use the special tool. A I " CAMSHAFT SPROCKET BOLT LOOSENING (1) Using the special tools shown in the illustration, lock the camshaft sprocket in position. (2) Loosen...

Page 31 - ENGINE SUPPORT BRACKET INSTALLATION

4G6 ENGINE (E - W) - Timing Belt 11A-4-6 " C A ENGINE SUPPORT BRACKET INSTALLATION (1) Coat the bolts illustrated with sealant before tightening. Specified sealant: 3M ATD Part No. 8660 or equivalent " D A SPACER INSTALLATION (1) Install the spacer with the chamfered end toward the oil seal....

Page 32 - CRANKSHAFT BOLT TIGHTENING

4G6 ENGINE (E - W) - Timing Belt 11A-4-7 (4) Move the tensioner “B” in the direction of arrow while lifting with a finger to give a sufficient tension to the tension side of timing belt. In this condition, tighten bolt to secure tensioner “B”. When the bolt is tightened, use care to prevent shaft fr...

Page 33 - Caution

4G6 ENGINE (E - W) - Timing Belt 11A-4-8 (4) Insert a wire (1.4 mm in diameter) into the set holes. (5) Unclamp the auto tensioner from the vise. (6) Install the auto tensioner to front case and tighten to the specified torque. Caution D Leave the wire installed in the auto tensioner. " J A TENS...

Page 35 - TIMING BELT INSTALLATION

4G6 ENGINE (E - W) - Timing Belt 11A-4-10 (14)After giving two clockwise turns to the crankshaft, let it alone for approx. 15 minutes. Then, make sure that the auto tensioner setting wire moves freely.NOTE If the wire does not move freely, repeat step (10) above until it moves freely. (15)Remove the...

Page 38 - INSPECTION; TIMING BELT

4G6 ENGINE (E - W) - Timing Belt 11A-4-13 (16)Set the special tool as shown and screw it in up to the position where the wire inserted in the auto-tensioner when installing it can be moved lightly. (17)Loosen the retaining bolt of the tensioner pulley. Caution D Loosening the retaining bolt can caus...

Page 39 - AUTO TENSIONER

4G6 ENGINE (E - W) - Timing Belt 11A-4-14 (2) Cracks on rubber back. (3) Cracks or peeling of canvas. (4) Cracks on rib root. (5) Cracks on belt sides. (6) Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife. (7) Abnormal wear on teeth. (8) Missing tooth. AUTO TE...

Page 40 - REMOVAL AND INSTALLATION; Exhaust manifold gasket

4G6 ENGINE (E - W) - Exhaust Manifold (GDI) 11A-4a-1 4a. EXHAUST MANIFOLD (GDI) REMOVAL AND INSTALLATION 4 5 3 1 13 Nm 49 Nm 2 29 Nm 13 Nm 11 Nm 49 Nm 29 Nm Removal steps 1. Exhaust manifold cover (Vehicle for Europe) 2. Exhaust manifold (Vehicle for Europe) 3. Exhaust manifold (Vehicle for Hong Kon...

Page 41 - Fuel and Emission Control Parts; FUEL AND EMISSION CONTROL PARTS; Fuel vapor separator

4G6 ENGINE (E - W) - Fuel and Emission Control Parts 11A-5-1 5. FUEL AND EMISSION CONTROL PARTS REMOVAL AND INSTALLATION <CARBURETOR> 1 2 3 4 5 7 8 23 Nm 17 Nm 22 Nm 6 Removal steps 1. Fuel hose 2. Fuel hose 3. Fuel vapor separator 4. Water hose 5. Carburetor 6. Gasket 7. EGR valve (For GCC) 8...

Page 42 - REMOVAL AND INSTALLATION ; Throttle body gasket

4G6 ENGINE (E - W) - Fuel and Emission Control Parts 11A-5-2 REMOVAL AND INSTALLATION <MULTIPOINT FUEL INJECTION - GALANT> 1 10 13 12 7 9 18 Nm 2 11 8 12 Nm 6 5 22 Nm 3 4 9 Nm 14 Removal steps 1. Throttle body " C A 2. Throttle body gasket 3. EGR valve (With EGR valve) 4. Cover (Without EG...

Page 44 - INJECTORS INSTALLATION; lubricated with a drop of clean engine oil to aid in; FUEL PRESSURE REGULATOR INSTALLATION; Insert the fuel pressure regulator into the delivery pipe; Remove the fuel pressure regulator and check the O-ring; GASKET INSTALLATION; GALANT

4G6 ENGINE (E - W) - Fuel and Emission Control Parts 11A-5-4 INSTALLATION SERVICE POINTS " A A INJECTORS INSTALLATION (1) Before installing an injector, the rubber O-ring must be lubricated with a drop of clean engine oil to aid in installation. (2) Install injector top end. Be careful not to da...

Page 45 - REMOVAL AND INSTALLATION (1999 MODEL SPACE WAGON)

4G6 ENGINE (E - W) - Fuel Part (GDI) 11A-5a-1 5a. FUEL PART (GDI) REMOVAL AND INSTALLATION (1999 MODEL SPACE WAGON) 9 10 11 Nm 11 13 23 Nm 31 27 32 33 35 34 36 37 1 2 3 8.8 Nm 8.8 Nm 8.8 Nm 4 5 6 7 8 12 14 15 16 17 18 19 20 21 22 23 24 25 18 Nm 8.8 Nm 4.9 Nm ® 17 Nm ± 2 Nm 11 Nm 11 Nm 11 Nm 11 Nm 18...

Page 47 - REMOVAL AND INSTALLATION (2000 MODEL SPACE WAGON and GALANT)

4G6 ENGINE (E - W) - Fuel Part (GDI) 11A-5a-2a REMOVAL AND INSTALLATION (2000 MODEL SPACE WAGON and GALANT) 9 10 11 Nm 11 13 23 Nm 35 31 36 37 39 38 40 41 1 2 3 8.8 Nm 8.8 Nm 8.8 Nm 4 5 6 7 8 12 14 15 16 17 18 19 20 21 22 23 28 29 18 Nm 8.8 Nm 4.9 Nm ® 17 Nm ± 2 Nm 11 Nm 11 Nm 11 Nm 11 Nm 18 Nm 30 3...

Page 52 - Water Pump and Intake Manifold; WATER PUMP AND INTAKE MANIFOLD

4G6 ENGINE (E - W) - Water Pump and Intake Manifold 11A-6-1 6. WATER PUMP AND INTAKE MANIFOLD REMOVAL AND INSTALLATION <CARBURETOR> 1 2 17 10 12 Nm 11 12 13 14 Nm 14 Nm 8 13 Nm 11 Nm 5 16 20 Nm 15 31 Nm 4 6 7 8 9 24 Nm 13 Nm 3 14 Removal steps 1. Water hose 2. Water hose " C A 3. Engine co...

Page 57 - water to the O-ring to make installation easy.

4G6 ENGINE (E - W) - Water Pump and Water Hose (GDI) 11A-6a-2 INSTALLATION SERVICE POINTS " A A O-RING / WATER INLET PIPE INSTALLATION (1) Replace the O-ring of the water inlet pipe, and then apply water to the O-ring to make installation easy. Caution D Never apply any oil or grease to the O-ri...

Page 58 - Exhaust Manifold; Water outlet fitting

4G6 ENGINE (E - W) - Exhaust Manifold 11A-7-1 7. EXHAUST MANIFOLD REMOVAL AND INSTALLATION (GALANT) 1 2 13 Nm 13 Nm 6 5 49 Nm 13 Nm 29 Nm 4 3 13 Nm 13 Nm Removal steps " A A 1. Water outlet fitting 2. Heat protector (Multipoint fuel injection) 3. Exhaust manifold cover (Carburetor) 4. Engine han...

Page 59 - Mitsubishi

4G6 ENGINE (E - W) - Exhaust Manifold 6EN1170 3 mm diameter bead sealant 11A-7-2 REMOVAL AND INSTALLATION (SPACE WAGON) 1 2 13 Nm 5 4 49 Nm 29 Nm 3 13 Nm Removal steps " A A 1. Water outlet fitting 2. Exhaust manifold cover 3. Engine hanger 4. Exhaust manifold 5. Exhaust manifold gasket INSTALLA...

Page 60 - Rocker Arms and Camshaft; ROCKER ARMS AND CAMSHAFT

4G6 ENGINE (E - W) - Rocker Arms and Camshaft 11A-8-1 8. ROCKER ARMS AND CAMSHAFT REMOVAL AND INSTALLATION 3 2 18 16 31 Nm 3.4 Nm 17 10 7 9 11 12 10 11 12 10 11 10 12 11 14 15 15 15 15 13 6 8 5 4 1 12 Apply engine oil to all moving parts before installation. Removal steps 1. Breather hose 2. P.C.V. ...

Page 61 - REMOVAL SERVICE POINT; LASH ADJUSTER INSTALLATION

4G6 ENGINE (E - W) - Rocker Arms and Camshaft 11A-8-2 REMOVAL SERVICE POINT A A " ROCKER ARMS AND ROCKER ARM SHAFTSREMOVAL Caution D If the lash adjuster is re-used, clean the lashadjuster. (Refer to 11A-8-3.) (1) Set special tool MD998443 to prevent the lash adjuster from coming free and fallin...

Page 67 - (1) Fit the lash adjuster onto the rocker arm without allowing

4G6 ENGINE (E - W) - Rocker Arms and Camshafts (GDI) 11A-8a-2 REMOVAL SERVICE POINTS A A " LASH ADJUSTER REMOVAL Caution D If the lash adjuster is re-used, clean the lashadjuster. (Refer to 11A-8a-4.) INSTALLATION SERVICE POINTS " A A LASH ADJUSTER INSTALLATION Caution D If the lash adjuster...

Page 73 - Cylinder Head and Valves; CYLINDER HEAD AND VALVES

4G6 ENGINE (E - W) - Cylinder Head and Valves 11A-9-1 9. CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION (SOHC) 20 18 13 5 12 16 6 4 7 11 19 17 15 10 8 14 9 3 Apply engine oil to all moving parts before installation. 2 1 Removal steps A A " " E A 1. Cylinder head bolt 2. Cylinder head asse...

Page 75 - PRECAUTION FOR REMOVED PARTS; Keep removed parts in order according to the cylinder number; CYLINDER HEAD BOLTS REMOVAL; to indicate their cylinder No. and location for reassembly.

4G6 ENGINE (E - W) - Cylinder Head and Valves 11A-9-3 REMOVAL SERVICE POINTS PRECAUTION FOR REMOVED PARTS Keep removed parts in order according to the cylinder number and intake/exhaust. A A " CYLINDER HEAD BOLTS REMOVAL (1) Using the special tool, loosen the cylinder head bolts. Loosen evenly, ...

Page 76 - VALVE STEM SEAL REMOVAL; VALVE STEM SEAL INSTALLATION; (2) The special tool must be used to install the valve stem; (1) Direct the valve spring end with identification color toward

4G6 ENGINE (E - W) - Cylinder Head and Valves 11A-9-4 A C " VALVE STEM SEAL REMOVAL (1) Do not reuse removed stem seal. INSTALLATION SERVICE POINTS " A A VALVE STEM SEAL INSTALLATION (1) Install the valve spring seat. (2) The special tool must be used to install the valve stem seal. Improper...

Page 77 - RETAINER LOCK INSTALLATION; bottom end of the retainer to be in contact with, and; CYLINDER HEAD GASKET IDENTIFICATION; shank length of each bolt meets the limit. If the limit is; Tightening torque: 78 Nm; (5) Retighten the loosened bolts to a torque of 20 Nm in

4G6 ENGINE (E - W) - Cylinder Head and Valves 11A-9-5 " C A RETAINER LOCK INSTALLATION (1) The valve spring, if excessively compressed, causes the bottom end of the retainer to be in contact with, and damage, the stem seal. " D A CYLINDER HEAD GASKET IDENTIFICATION Identification mark: 4G63N...

Page 79 - VALVE; using a valve refacer. Valve seat contact should be; VALVE SPRING

4G6 ENGINE (E - W) - Cylinder Head and Valves 11A-9-7 VALVE (1) Check the valve face for correct contact. If incorrect, reface using a valve refacer. Valve seat contact should be maintained uniform at the center of valve face. (2) If the margin exceeds the service limit, replace the valve. Item Stan...

Page 80 - VALVE GUIDE; VALVE SEAT RECONDITIONING PROCEDURE

4G6 ENGINE (E - W) - Cylinder Head and Valves 11A-9-8 VALVE GUIDE (1) Measure the clearance between the valve guide and valve stem. If the limit is exceeded, replace the valve guide or valve, or both. Item Standard value mm Limit mm SOHC Intake 0.02 - 0.05 0.10 Exhaust 0.03 - 0.07 0.15 GDI Intake 0....

Page 81 - VALVE SEAT REPLACEMENT PROCEDURE; Valve seat ring hole diameter

4G6 ENGINE (E - W) - Cylinder Head and Valves 11A-9-9 VALVE SEAT REPLACEMENT PROCEDURE (1) Cut the valve seat to be replaced from the inside to thin the wall thickness. Then, remove the valve seat. (2) Rebore the valve seat hole in the cylinder head to a selected oversize valve seat diameter. Valve ...

Page 82 - VALVE GUIDE REPLACEMENT PROCEDURE; (1) Force the valve guide out toward the cylinder block using; Item; (3) Press-fit the valve guide until it protrude specified value; valve to check for smooth sliding motion.

4G6 ENGINE (E - W) - Cylinder Head and Valves 11A-9-10 VALVE GUIDE REPLACEMENT PROCEDURE (1) Force the valve guide out toward the cylinder block using a press. (2) Machine the valve guide hole in the cylinder head to the size of the oversize valve guide to be installed. Caution D Do not use the valv...

Page 83 - Front Case, Counterbalance Shafts and Oil Pan; FRONT CASE, COUNTERBALANCE SHAFTS AND OIL PAN

4G6 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan 11A-10-1 10. FRONT CASE, COUNTERBALANCE SHAFTS AND OIL PAN REMOVAL AND INSTALLATION <GDI ENGINE - VEHICLE FOR EUROPE ANDSOHC ENGINE> 3 4 5 32 13 28 29 31 33 2 23 Nm 16 Nm 19 Nm 39 Nm 7 21 Nm 8 9.8 Nm 18 Nm 44 Nm 18 19 26 23 Nm ...

Page 84 - REMOVAL AND INSTALLATION

4G6 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan 11A-10-2 REMOVAL AND INSTALLATION <GDI ENGINE - VEHICLE FOR HONG KONG> 3 4 5 33 22 16 31 30 32 34 2 23 Nm 16 Nm 9.8 Nm 6.9 Nm 12 Nm 7 9.8 Nm 18 Nm 44 Nm 19 20 28 23 Nm 21 1 24 29 26 Apply engine oil to all moving parts before i...

Page 86 - Be sure to remove the front bearing first.; that oil hole of bearing is aligned with oil hole of cylinder

4G6 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan 11A-10-4 (3) Loosen the flange bolt. A F " COUNTERBALANCE SHAFT FRONT BEARINGREMOVAL (1) Using the special tool, remove the counterbalance shaft front bearing from the cylinder block.NOTE Be sure to remove the front bearing first...

Page 87 - (2) Apply engine oil to the rear bearing outer circumference

4G6 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan 11A-10-5 " B A LEFT COUNTERBALANCE SHAFT REARBEARING INSTALLATION (1) Install the special tool (Guide Plate) to the cylinder block. (2) Apply engine oil to the rear bearing outer circumference and bearing hole in the cylinder blo...

Page 88 - OIL PUMP OIL SEAL INSTALLATION

4G6 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan 11A-10-6 " E A OIL PUMP OIL SEAL INSTALLATION " F A CRANKSHAFT FRONT OIL SEAL INSTALLATION (1) Using the special tool, install the crankshaft front oil seal into the front case. " G A OIL PUMP DRIVEN GEAR / OIL PUMP DRIVE...

Page 93 - Piston and Connecting Rod; PISTON AND CONNECTING ROD

4G6 ENGINE (E - W) - Piston and Connecting Rod 11A-11-1 11. PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION 10 678 9 11 4 3 2 1 5 12 Apply engine oil to all moving parts before installation. Removal steps " G A 1. Nut A A " " F A 2. Connecting rod cap " E A 3. Connecting rod beari...

Page 94 - CONNECTING ROD CAP REMOVAL

4G6 ENGINE (E - W) - Piston and Connecting Rod 11A-11-2 REMOVAL SERVICE POINTS A A " CONNECTING ROD CAP REMOVAL (1) Mark the cylinder number on the side of the connecting rod big end for correct reassembly. (2) Keep the removed connecting rods, caps, and bearings in order according to the cylind...

Page 95 - PISTON PIN INSTALLATION

4G6 ENGINE (E - W) - Piston and Connecting Rod 11A-11-3 INSTALLATION SERVICE POINTS " A A PISTON PIN INSTALLATION (1) Measure the following dimensions of the piston, piston pin and connecting rod. A: Piston pin insertion hole length B: Distance between piston bosses C: Piston pin length D: Conne...

Page 96 - OIL RING INSTALLATION

4G6 ENGINE (E - W) - Piston and Connecting Rod 11A-11-4 (10)Check that the piston moves smoothly " B A OIL RING INSTALLATION (1) Fit the oil ring spacer into the piston ring groove. NOTE 1. The side rails and spacer may be installed in either direction. 2. New spacers and side rails are colored ...

Page 97 - CONNECTING ROD BEARINGS INSTALLATION

4G6 ENGINE (E - W) - Piston and Connecting Rod 11A-11-5 " C A PISTON RING NO. 2 / PISTON RING NO. 1INSTALLATION (1) Using piston ring expander, fit No. 2 and then No. 1 piston ring into position.NOTE 1. The ring end is provided with identification mark. Item Identification mark No. 1 ring 4G63 S...

Page 98 - CONNECTING ROD CAP NUT INSTALLATION

4G6 ENGINE (E - W) - Piston and Connecting Rod 11A-11-6 (2) The connecting rod bearing identification mark is stamped at the position shown in the illustration. Crankshaft pin Connecting rod bearing Classi- fication Identifica- tion mark Identifi- cation color O. D. mm Identi- fication mark Thicknes...

Page 100 - Oil ring

4G6 ENGINE (E - W) - Piston and Connecting Rod 11A-11-8 (3) Install the piston ring into the cylinder bore. Force it down with a piston, its crown being in contact with the ring, to correctly position it at right angles to the cylinder wall. Then, measure the end gap with a feeler gauge. If the ring...

Page 101 - Crankshaft, Flywheel and Drive Plate; Apply engine oil to all; Bell housing cover; assembled

4G6 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate 11A-12-1 12. CRANKSHAFT, FLYWHEEL AND DRIVE PLATE REMOVAL AND INSTALLATION 1 2 3 4 5 10 11 13 14 15 16 17 18 12 21 A 11 Nm 132 Nm 9 Nm 132 Nm 6 7 8 9 11 Nm Apply engine oil to all moving parts before installation. <GALANT> <SPACE WAG...

Page 107 - (4) Bore all cylinders to the calculated boring finish dimension.

4G6 ENGINE (E - W) - Crankshaft, Flywheel and Drive Plate 11A-12-7 (4) Bore all cylinders to the calculated boring finish dimension. Caution D To prevent distortion that may result fromtemperature rise during honing, bore cylinders,working from No. 2, No. 4, No. 1 to No. 3. (5) Hone to final finish ...