Tuesday, July 9, 2013

[DL]Service / Workshop Manual Mitsubishi Engine 4G9 Series

Service / Workshop Manual Mitsubishi Engine 4G9 Series Specifications (Service Specifications – Rework Dimensions – Torque Specifications – New Tightening Method by Use of Bolts to be Tightened in Plastic Area – Sealant – Form in Place Gasket). Special Tools. Alternator and Ignition System. Timing Belt. Fuel and Emission Control System (Throttle Body and EGR System (GDI)).

Intake and Exhaust Manifold (Intake Manifold (GDI) – Exhaust Manifold (GDI) – Injector and Fuel Pump Assembly (GDI) – Intake and Exhaust Manifold (4G94-GDI for Pajero io). Water Pump & Water Hose Rocker Arms and Camshafts (Rocker Cover and Camshafts (MIVEC) – Rocker Arms and Rocker Shaft Caps (MIVEC). Cylinder Head and Valves.
Download : Service / Workshop Manual Mitsubishi Engine 4G9 Series

Mitsubishi 4G6 and 4G6-EW engine factory workshop and repair manual 1991 onwards

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


Specifications
Special Tools 
Drive Belt and Timing Belt
Intake and Exhaust Manifolds
Turbocharger
Water pump Thermostat hose and pipe
Procker Arms Rocker shaft and Camshaft
Cylinder Head Valves and Valve Spring
Front Case, Silent Shaft and Oil Pan
Piston and connecting rod
Crankshaft Flywheel and Drive Plate
Cylinder Block
About the 4G6 engine
The 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.
Performance
4G61 91 kW-124 hp/650
4G61T (USA/Canada exclusive) 99 kW-135 hp/6000 191 Nm/3000
4G61T (Japan) 160 hpP-117.68 kW/6000 220.65 Nm/2500
Applications
1988–1992 Mitsubishi Mirage / Mitsubishi Colt (MPFI)
1988–1992 Dodge Colt / Plymouth Colt
1988–1992 Eagle Summit
1992–1995 Hyundai Elantra
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.
Applications
1983–1989 Mitsubishi Cordia
1983-1989 Mitsubishi Tredia
1981-1986 Mitsubishi Delica/L300/Express
1984-1988 Mitsubishi Galant/Eterna
1980-1987 Mitsubishi Lancer EX 1800GSR or 1800GT
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.
Applications
1983-1989 Mitsubishi Galant/Galant S/Eterna S
1983–1992 Mitsubishi Lancer/Lancer Fiore/Mirage Saloon
1983–1987 Mitsubishi Mirage/Colt
1984-1991 Mitsubishi Chariot/Space Wagon
1987-1991 Mitsubishi Mirage/Colt
1987-1992 Mitsubishi Galant/Eterna
1988-1991 Mitsubishi Lancer/Mirage Sedan
1991-1995 Mitsubishi Lancer/Libero
1992-1997 Mitsubishi Chariot/Space Wagon
4G63
G63B Cyclone Dash 3x2 in a fifth generation Galant
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.
Mivec Turbo 4G63 in a Lancer Evo IX
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.
Racing
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.
Applications
2001–2006 Mitsubishi Airtrek
1997–200? Mitsubishi Canter
1983-1998 Mitsubishi Chariot
1988 Mitsubishi Cordia
1994–1998 Mitsubishi Delica
1990–1999 Mitsubishi Eclipse
1989–2003 Mitsubishi Galant
1987-199? Mitsubishi L200/Mighty Max
1992–2006 Mitsubishi Lancer Evolution
1993–1998 Mitsubishi Pajero
1994–1998 Mitsubishi RVR
1988 Mitsubishi Tredia
2004–present Brilliance BS6
1983–1992 Dodge Colt Vista
1987-1989 Dodge Ram 50
1989-1992 Eagle Vista Wagon
1990–1998 Eagle Talon
1987-1988 Hyundai Stellar
1992-1995 Hyundai Elantra
1989-2005 Hyundai Sonata
1990–1994 Plymouth Laser
1996–1999 Proton Perdana
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.
Applications
1991-1996 Mitsubishi Mirage/Colt
1991-1996 Mitsubishi Lancer/Libero
1992-1997 Mitsubishi Chariot/Space Wagon
1996-2000 Mitsubishi Galant
1996-1999 Mitsubishi Lancer/Libero
1997-2002 Mitsubishi Mirage/Colt
1995-2000 Proton Wira 2.0D
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.
Applications
1993-1997 Mitsubishi Chariot
1988–2006 Mitsubishi Delica/Van
1996-2005 Mitsubishi Eclipse
1994–2003 Mitsubishi Galant1990–present Mitsubishi L200
1996–1998 Mitsubishi Magna
1990–1996 Mitsubishi Mighty Max
1998-2005 Mitsubishi Montero (V11 - 2 door) Latin America version
2003 Mitsubishi Outlander
1987–1990 Mitsubishi Sapporo
Mitsubishi Triton
2005 Mitsubishi Zinger
2004–present Brilliance BS6
2008–present Chery V5
2001–2005 Chrysler Sebring/Dodge Stratus
1983–1992 Dodge Colt Vista (AWD only)
1990–1992 Dodge Ram 50
2006–present Great Wall Hover
1986-1998 Hyundai Grandeur
1989–1991 Hyundai Sonata
4G67
The 16-valve DOHC 4G67 displaced 1836 cc. Bore x Stroke : 81.5 x 88
Applications
Mitsubishi Colt III
Mitsubishi Mirage
Mitsubishi Galant
Mitsubishi Lancer
Hyundai Elantra
c58a, c68a
4G69
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.
Applications
2003–2011 Mitsubishi Grandis
2004–2006 Mitsubishi Lancer
2004–2006 Mitsubishi Outlander
2004–present Mitsubishi Galant
2006–present Mitsubishi Eclipse
2009–present Very Good Wall Haval H5 (aka X240)
2011–present BYD S6
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 

Mitsubishi Engine 4G5 Series Workshop Manual

This highly detailed Digital Workshop Repair Manual contains everything you will ever need to repair, maintain, rebuild, refurbish or restore your vehicle. All diagnostic and repair procedures are covered in great detail. This Digital Workshop Repair Manual covers the same information that Professional Technicians and Mechanics have. 
All Repair Procedures Covered From A-Z 
High Quality Photos, Illustrations And Diagrams 
Buy From A Trusted Seller, Selling Genuine Items 
Save Big On Service & Repair Costs 
You can view and print out the complete repair procedures with this easy to use Digital Workshop Repair Manual - you do not need to be skilled with a computer! Once you have found your information, just print it out and start work. No more messy manuals that you have to keep replacing or cant use any more due to wear and tear.
COMPUTER REQUIREMENTS: 
OPERATES ON MICROSOFT WINDOWS 95,98,98SE,2000,NT,ME,XP,VISTA & WINDOWS 7 WILL ALSO WORK ON ALL MAC COMPUTERS

Official Service Repair Manual for Mitsubishi 4G3 Series Engine

This is the COMPLETE Official Service Repair Manual for the MITSUBISHI 4G3 SERIES ENGINE. This manual contains service, repair procedures, assembling, disassembling, wiring diagrams and everything you need to know. 

The Service Manual contains detailed information, electrical and hydraulic diagrams, actual real photo illustrations and schemes, which give you complete step-by-step operations on repair, servicing, technical maintenance & troubleshooting procedures for your machine. this manual offers full information you need for repair your machine. the information in this manual will enable you to find trouble and to understand how to repair and maintain your machine without going into service. all pages are printable, so run off what you need and take it with you into the garage or workshop. 
TABLE OF CONTENTS: 
========== 
ENGINE [11A] 
GENERAL INFORMATION 
1. SPECIFICATIONS 
2. SPECIAL TOOLS 
3. DRIVE BELT AND TIMING BELT 
4. INTAKE MANIFOLD 
5. EXHAUST MANIFOLD AND WATER PUMP 
6. ROCKER ARMS AND CAMSHAFT 
7. ROCKER ARMS AND ROCKER SHAFTS 
8. CYLINDER HEAD AND VALVES 
9. FRONT CASE, OIL PUMP AND OIL PAN 
10. PISTON AND CONNECTING ROD 
11. CRANKSHAFT, FLYWHEEL AND DRIVE PLATE 
12. CYLINDER BLOCK 
=========== 
** Model Specification: MITSUBISHI 4G3 SERIES ENGINE 
** Language: English 
** File Format: PDF 
** Requirements: Adobe PDF Reader & WinZip. 
** ZOOM IN/OUT: YES 
** INSTANT DELIVERY: YES 
** Specifications: FULLY PRINTABLE & BOOKMARKED 
** Compatible: All Versions of Windows & Mac
=========== 
This QUALITY manual is 100 percents COMPLETE and INTACT, no MISSING/CORRUPT pages/sections to freak you out! 
This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find. 
Detailed illustrations, exploded diagrams, drawings and photos guide you through every service repair procedure. 
This manual can be viewed on any computer, as well as zoomed and printed. 
Complete download comes in PDF format which can work under all PC based Windows operating system and Mac also. It saves to your hard-drive and can be burned to CD-ROM.

Official Service Repair Manual for Mitsubishi 4G1 Series Engine

This is the COMPLETE Official Service Repair Manual for the MITSUBISHI 4G1 SERIES ENGINE. This manual contains service, repair procedures, assembling, disassembling, wiring diagrams and everything you need to know. 
The Service Manual contains detailed information, electrical and hydraulic diagrams, actual real photo illustrations and schemes, which give you complete step-by-step operations on repair, servicing, technical maintenance & troubleshooting procedures for your machine. this manual offers full information you need for repair your machine. the information in this manual will enable you to find trouble and to understand how to repair and maintain your machine without going into service. all pages are printable, so run off what you need and take it with you into the garage or workshop. 
TABLE OF CONTENTS: 
========== 
ENGINE [11A] 
GENERAL INFORMATION 
1. SPECIFICATIONS 
2. SPECIAL TOOLS 
3. DRIVE BELT AND TIMING BELT 
4. INTAKE MANIFOLD 
5. EXHAUST MANIFOLD AND WATER PUMP 
6. ROCKER ARMS AND CAMSHAFT 
7. ROCKER ARMS AND ROCKER SHAFTS 
8. CYLINDER HEAD AND VALVES 
9. JET VALVE (ENGINE WITH JET VALVES) 
10. FRONT CASE AND OIL PUMP 
11. PISTON AND CONNECTING ROD 
12. CRANKSHAFT, FLYWHEEL AND DRIVE PLATE 
13. CYLINDER BLOCK 
=========== 
** Model Specification: MITSUBISHI 4G1 SERIES ENGINE 
** Language: English 
** File Format: PDF 
** Requirements: Adobe PDF Reader & WinZip. 
** ZOOM IN/OUT: YES 
** INSTANT DELIVERY: YES 
** Specifications: FULLY PRINTABLE & BOOKMARKED
** Compatible: All Versions of Windows & Mac 
=========== 
This QUALITY manual is 100 percents COMPLETE and INTACT, no MISSING/CORRUPT pages/sections to freak you out! 
This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find. 
Detailed illustrations,sexploded diagrams, drawings and photos guide you through every service repair procedure. 
This manual can be viewed on any computer, as well as zoomed and printed. 
Complete download comes in PDF format which can work under all PC based Windows operating system and Mac also. It saves to your hard-drive and can be burned to CD-ROM.

Official Service Repair Manual for Mitsubishi 4G1 Series Engine(E-W)

This is the COMPLETE Official Service Repair Manual for the MITSUBISHI SERIES 4G1 ENGINE (E-W). This manual contains service, repair procedures, assembling, disassembling, wiring diagrams and everything you need to know. 


The Service Manual contains detailed information, electrical and hydraulic diagrams, actual real photo illustrations and schemes, which give you complete step-by-step operations on repair, servicing, technical maintenance & troubleshooting procedures for your machine. this manual offers full information you need for repair your machine. the information in this manual will enable you to find trouble and to understand how to repair and maintain your machine without going into service. all pages are printable, so run off what you need and take it with you into the garage or workshop. 
TABLE OF CONTENTS: 
========== 
GENERAL INFORMATION 
1. SPECIFICATIONS 
2. SPECIAL TOOLS 
3. ALTERNATOR AND IGNITION SYSTEM 
4. TIMING BELT 
5. FUEL AND EMISSION CONTROL SYSTEM 
6. WATER PUMP AND WATER HOSE 
7. INTAKE AND EXHAUST MANIFOLD 
8. ROCKER ARMS AND CAMSHAFT 
9. CYLINDER HEAD AND VALVES 
10. OIL PUMP AND OIL PAN 
11. PISTON AND CONNECTING ROD 
12. CRANKSHAFT, CYLINDER BLOCK 
========== 
** Model Specification: MITSUBISHI SERIES 4G1 ENGINE (E-W) 
** Language: English 
** File Format: PDF 
** Requirements: Adobe PDF Reader & WinZip. 
** ZOOM IN/OUT: YES 
** INSTANT DELIVERY: YES 
** Specifications: FULLY PRINTABLE & BOOKMARKED 
** Compatible: All Versions of Windows & Mac
=========== 
This QUALITY manual is 100 percents COMPLETE and INTACT, no MISSING/CORRUPT pages/sections to freak you out! 
This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find. 
Detailed illustrations, exploded diagrams, drawings and photos guide you through every service repair procedure. 
This manual can be viewed on any computer, as well as zoomed and printed. 
Complete download comes in PDF format which can work under all PC based Windows operating system and Mac also. It saves to your hard-drive and can be burned to CD-ROM.

Official Service Repair Manual for Mitsubishi Engine 4D68 (E-W)

This is the COMPLETE Official Service Repair Manual for the MITSUBISHI 4D68 SERIES ENGINE. This manual contains service, repair procedures, assembling, disassembling, wiring diagrams and everything you need to know. 


The Service Manual contains detailed information, electrical and hydraulic diagrams, actual real photo illustrations and schemes, which give you complete step-by-step operations on repair, servicing, technical maintenance & troubleshooting procedures for your machine. this manual offers full information you need for repair your machine. the information in this manual will enable you to find trouble and to understand how to repair and maintain your machine without going into service. all pages are printable, so run off what you need and take it with you into the garage or workshop. 
TABLE OF CONTENTS: 
========== 
ENGINE [11A] 
GENERAL INFORMATION 
1. SPECIFICATIONS 
2. SPECIAL TOOLS 
3. DRIVE BELT AND GLOW PLUG 
4. TIMING BELT 
5. GLOW PLUG, FUEL INJECTION PUMP AND INJECTION NOZZLE 
6. INTAKE AND EXHAUST MANIFOLDS 
7. WATER PUMP, THERMOSTAT, HOSE AND PIPES 
8. ROCKER ARMS, ROCKER SHAFT AND CAMSHAFT 
9. CYLINDER HEAD, VALVES AND VALVE SPRINGS 
10. FRONT CASE, COUNTERBALANCE SHAFTS AND OIL PAN 
11. PISTONS AND CONNECTING RODS 
12. CRANKSHAFT, CYLINDER BLOCK AND FLYWHEEL 
=========== 
** Model Specification: MITSUBISHI 4D68 SERIES ENGINE 
** Language: English 
** File Format: PDF 
** Requirements: Adobe PDF Reader & WinZip. 
** ZOOM IN/OUT: YES 
** INSTANT DELIVERY: YES 
** Specifications: FULLY PRINTABLE & BOOKMARKED 
** Compatible: All Versions of Windows & Mac
=========== 
This QUALITY manual is 100 percents COMPLETE and INTACT, no MISSING/CORRUPT pages/sections to freak you out! 
This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find. 
Detailed illustrations, exploded diagrams, drawings and photos guide you through every service repair procedure. 
This manual can be viewed on any computer, as well as zoomed and printed. 
Complete download comes in PDF format which can work under all PC based Windows operating system and Mac also. It saves to your hard-drive and can be burned to CD-ROM.