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Mitsubishi 4G6 and 4G6-EW engine factory workshop and repair manual download
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Mitsubishi 4G6 and 4G6-EW engine factory workshop and repair manual 1991 onwardson PDF can be viewed using free PDF reader like adobe , or foxit or nitro . It is compressed as a zip file which you can extract with 7zip File size 11 Mb Searchable PDF document with bookmarks. Manual Contents About the 4G6 engineThe Mitsubishi Sirius or 4G6/4D6 engine is the name of one of Mitsubishi Motors' four show of inline 4 automobile engines, along with Astron, Orion, and Saturn. The 4G6 are gasoline engines, the 4D6 diesels. 4G61 The 4G61 displaces 1595 cc (82.3 x 75.0 mm bore/ full length stroke). This engine was not always DOHC 16-valve and used either Multi-point (MPFI) or Electronic Control (ECFI) fuel shot. A turbocharged version was also produced for the Mirage and Lancer. The 4G61 does not have balance shafts like the other 4G6x motors. Instead, it has separate components, some of which can be used on the "Silent Shaft" engine. 4G61 91 kW-124 hp/650 Applications 1988–1992 Mitsubishi Mirage / Mitsubishi Colt (MPFI) 4G62 The bigger 1.8 L 4G62 had been an SOHC 8-valve unit for longitudinal rear-wheel drive and all-wheel drive use. With an 80.6 x 88.0 mm bore / stroke, it displaced 1,795 cc. It was available either in carburetor form, multi-point fuel shot, or ECI Turbo as found in the Lancer EX 1800GSR or 1800GT, and Cordia GSR. 1983–1989 Mitsubishi Cordia 4D65 Known as the "Sirius Diesel", the 4D65 had the same sizes as the 4G62 (1,795 cc). It was available either naturally aspirated or turbocharged, and was used in most Mitsubishi diesel passenger cars in the eighties and beginning of the nineties. 1983-1989 Mitsubishi Galant/Galant S/Eterna S 4G63 The 4G63 was a 1997 cc variation. (85 mm bore x 88 mm stroke) SOHC and DOHC had been produced. Both versions were available in either naturally aspirated and turbocharged form. For front-wheel drive applications, the turbocharged Sirius' name was modified to "Cyclone Dash". As fitted to the fifth generation Galant 200 PS (147 kW) JIS gross were claimed - the output claims afterwards shrank to 170 PS - for the turbocharged and intercooled "Sirius Dash 3x2 valve" engine. This version could switch between breathing through two or three valves per cylinder, to combine maximum top-end power with low-end drivability as well as allowing for economical operation. The DOHC variation had been introduced in 1987 in the Japanese market Galant, and came in turbocharged or naturally aspirated form. It is found in various models including the 1988-92 Galant VR-4 and the U.S. market 1990-1999 Eclipse, as well as the Mitsubishi Lancer Evolution I-IX. Later versions also received Mitsubishi's variable valve-timing system, Mivec. A SOHC carbureted eight-valve version (engine code G63B) had been also available in Mitsubishi's pickup trucks (L200, Strada, Mighty Maximum, Dodge Ram50, etcetera) from the eighties until the mid-nineties. It produces 92 hp (69 kW) at 5,500 rpm in European trim (1989). The SOHC version was also used in Mitsubishi Galant models until 1993. It has 76 kW of output and 157 Nm of torque at 4,750 rpm. Also, a SOHC version was produced until the belated 90s and early 2000s and was used in Mitsubishi cars like the Montero and the 2.0L 2-door Pajero with an production of 101 kW (137 PS) at 4,700 rpm. Additionally the N33 and N83 Spacewagon and Galant (UK market) received the 4G63, in single-cam sixteen-valve format. A similar version, with 100 PS (74 kW), had been additionally used in some light duty Mitsubishi Canters from 1997 on. The Mitsubishi Eclipse, Eagle Talon and Plymouth Laser introduced the DOHC turbocharged intercooled version to the U.S. in 1989 through Diamond celebrity Motors, a joint venture between Mitsubishi Motors and the Chrysler Corporation. From 1990 to late April 1992 came beefier connecting rods and the use of six bolts to protect the flywheel to the crankshaft; May 1992 to 2006 Evolution versions have much lighter rods and use seven bolts to protect the flywheel to the crankshaft. They are referred to as the "six bolt" and "seven bolt" engines, correspondingly. Production for the 2003 US Mitsubishi Lancer Evolution is 271 hp (202 kW) at 6500 rpm with 273 lb·ft (370 N·m) of torque at 3500 rpm. It has a cast iron engine block and aluminum DOHC cylinder head. It makes use of multi-point fuel injection, has 4 valves per cylinder, is turbocharged and intercooled and features forged steel connecting rods. Its turbocharged variant, 4G63T (also occasionally referred to just as the 4G63), has powered Mitsubishi vehicles in World Rally Championships for years in the Mitsubishi Galant VR-4, Lancer Evolution, Carisma GT and Lancer WRC04. It was the powerplant of the Lancer Evolution when Tommi Mäkinen won his four straight WRC championships in his Lancer. MHI and T-4 turbos were both used as power plants for these engines. 2001–2006 Mitsubishi Airtrek 4D68 Known as the "Sirius Diesel", the 4D68 version displaced 1998cc. It was fitted with a 93mm stroke crankshaft and the cylinder bore diameter was 82.7mm. This engine used pistons with a static compression ratio of 22.4:1 and piston pins were 25mm OD. It had been available either naturally aspirated or turbocharged, and replaced the 4D65 as Mitsubishi's "go-to" diesel. 1991-1996 Mitsubishi Mirage/Colt 4G64 The 4G64 is the second largest variant, at 2,351 cc. Early models were 8-valve SOHC, but an afterwards 16-valve SOHC and DOHC version was also produced. All utilized MPFI and had an 86.5 mm bore and 100 mm stroke. The 4G64 was later also available with gasoline direct injection. Output varies between 145 hp (108 kW; 147 PS) at 5,250 rpm with 161 lb·ft (218 N·m) of torque at 4,000 rpm in the Mitsubishi L200 and 152 hp (113 kW; 154 PS) at 5,500 rpm with 162 lb·ft (220 N·m) of torque at 4,000 rpm in the Chrysler Sebring/Stratus. The Chrysler version qualities fracture-split forged powder metal connecting rods. The 4G64 is an interference motor like the 4G63, however, the early 8-valve 4G64 is a non interference engine. From March 1996 an LPG variation with 115 PS (85 kW) at 5,000 rpm was available in the Mitsubishi Canter. 1993-1997 Mitsubishi Chariot 4G67 The 16-valve DOHC 4G67 displaced 1836 cc. Bore x Stroke : 81.5 x 88 Mitsubishi Colt III c58a, c68a The 4G69 is a 2378 cc version built in Shiga, Japan. Bore is 87 mm and stroke is 100 mm. Output is actually 162 hp (119 kW) at 5750 rpm (160 in the Sportback Wagon) with 162 lb·ft (219 N·m) of torque at 4000 rpm. It has a cast iron engine block and an aluminum SOHC cylinder head. It utilizes multi-point fuel injection, has 4 valves per cylinder with roller followers and features forged steel connecting rods, a one-piece cast camshaft, and a cast aluminum intake manifold. The 4G69 incorporates Mitsubishi's MIVEC Variable Valve Timing technology. The 4G69 is an interference engine like the 4G63. 2003–2011 Mitsubishi Grandis NB: From 2005 a slightly detuned variation (115 kW, 220Nm) is actually used across the entire Lancer range in Australia. Mitsubishi 4G6 and 4G6-EW engine factory workshop and repair manual 1991 onwards Download |
#### Tools Required:
- **Basic Hand Tools:**
- **Socket Set:** Use to remove and tighten bolts. Common sizes include 10mm, 12mm, and 14mm. Ensure they fit the bolts securely.
- **Ratchet Wrench:** Works with the socket set to provide leverage for loosening/tightening bolts.
- **Torque Wrench:** Required to ensure bolts are tightened to manufacturer specifications. Important for preventing over-tightening which can damage components.
- **Screwdrivers (Flathead & Phillips):** Useful for removing clips and covers.
- **Specialized Tools:**
- **Torque Converter Clutch Tool:** If available, this tool will help in the disassembly and reassembly of the torque converter clutch assembly. It can simplify the process.
- **Transmission Fluid Pump:** To remove old transmission fluid without making a mess. Necessary for maintaining cleanliness and proper fluid levels during reassembly.
- **Additional Tools:**
- **Pliers:** For gripping and pulling components that may be difficult to remove by hand.
- **Oil Catch Pan:** To collect old transmission fluid during the process. Prevents spills and keeps your workspace clean.
#### Steps for Repair:
- **Preparation:**
- Park the vehicle on a level surface and engage the parking brake.
- Disconnect the negative battery terminal to prevent electrical shorts.
- **Fluid Removal:**
- Use the transmission fluid pump to drain old transmission fluid into the oil catch pan.
- Ensure you dispose of the old fluid following local regulations.
- **Accessing the Torque Converter:**
- Remove any underbody panels or covers that obstruct access to the transmission.
- Locate the torque converter, typically found at the front of the transmission.
- **Removing the Torque Converter:**
- Disconnect any electrical connectors or hoses attached to the torque converter.
- Use the socket set to remove the bolts securing the torque converter to the flex plate.
- Gently pull the torque converter away from the transmission.
- **Inspecting the Torque Converter Clutch:**
- Check for signs of wear, such as cracks or excessive scoring. If found, replacement is necessary.
- Replacement parts may include the torque converter itself or the clutch assembly if damaged.
- **Replacing the Torque Converter Clutch:**
- If replacement is needed, install the new torque converter clutch according to the manufacturer’s instructions.
- Make sure all seals and gaskets are replaced to prevent leaks.
- **Reinstallation:**
- Align the torque converter with the flex plate and secure it with bolts using the torque wrench to the specified settings.
- Reconnect any electrical connectors and hoses that were previously removed.
- **Refilling Transmission Fluid:**
- Refill the transmission with new fluid, following manufacturer specifications for type and amount.
- Start the engine and let it idle, checking for leaks and ensuring the fluid circulates properly.
- **Final Checks:**
- Reinstall any underbody panels or covers.
- Reconnect the negative battery terminal.
- Test drive the vehicle to ensure proper operation of the torque converter clutch.
#### Replacement Parts:
- **Torque Converter Clutch:** If the clutch is slipping or damaged, it needs to be replaced to restore proper function.
- **Seals and Gaskets:** Always replace these to avoid future leaks.
#### Conclusion:
Ensure you follow all safety precautions while working on the vehicle. If unsure about any step, consult a professional or refer to a repair manual specific to your Mitsubishi model.
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