1990-1996 Mitsubishi 4G5 and 4G6 Series Engine Service Manual (P/N PWEE9055 / PWEE9037)
152.47 MB • Printable PDFs (ZIP Download)
Mitsubishi Models Covered & Key Technical Specifications
Models: Mitsubishi 4G5 Series, Mitsubishi 4G6 Series
Sub-models / Variants: 8-Valve Single Camshaft, 16-Valve Single Camshaft, Double Camshaft, Engine with Silent Shaft, Engine without Silent Shaft, Engines for Europe and Australia, Engines for General Export
Model Years: 1990–1996
Technical Data:
- Engine displacement: 1,997 cc, 2,350 cc, 2,555 cc
- Engine configuration: In-line 4-cylinder, OHV, SOHC, DOHC
- Compression ratio: 8.2 to 10.5 depending on model variant
- Lubrication system: Pressure feed, full-flow filtration
- Cooling system: Water-cooled forced circulation with centrifugal impeller pump
- Valve angle: 45° seat angle
Mitsubishi Manual Features & Content Preview
- Covers the 1990–1996 Mitsubishi 4G5 and 4G6 engine series, including 8-valve, 16-valve, and DOHC variants with or without silent shafts
- Official Mitsubishi Motors Corporation publications (PWEE9055 and PWEE9037 series) detailing multiple market-specific configurations
- Includes 47 exploded-view assembly diagrams and 35 torque specification tables covering the engine block, cylinder head, and drive system
Technical Walkthrough and Engine Coverage
This reference guide documents the 4G5 and 4G6 engine platforms, detailing major component teardown and reassembly parameters. Topics span cylinder head and valve train mechanics, timing chain and belt drive configurations, piston assembly, and the crankshaft-to-flywheel interface. Specialized sections describe lubrication system schematics, highlighting the specific involute gear and trochoid oil pump types used across the product line. Additional chapters focus on intake manifold assemblies, rocker arm geometry, and the unique clearance requirements for engines equipped with silent shaft chambers.
Specification and Reference Data
Spanning 100 pages, this manual provides meticulous engine specifications to aid in component identification and tolerance measurement. Mechanics will find critical data on valve timing angles, piston ring end gaps, and cylinder bore sizing. Tightening values for all primary fasteners are listed in Nm, kgm, and ft-lbs to ensure precision assembly. The engines feature distinct maintenance requirements regarding plastic-area bolt tightening methods and liquid gasket sealant applications.
For example, cylinder head flatness is limited to 0.2 mm across both engine blocks. Piston ring side clearance for the 4G6 8-valve engine is documented at 0.02–0.06 mm for the No. 1 ring, while intake valve clearance for the 4G5 is specified at 0.07 mm on a cold engine. When working with these precise tolerances and heavy block components, proper lifting equipment and secure engine stands are essential to prevent personal injury or structural damage during teardown.
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