Mitsubishi 4G64S4 Workshop Manual

If you’ve ever had a 4G64 come back with a coolant leak because you guessed the clamp torque, you’ll appreciate what this manual delivers. I’ve been turning wrenches for 28 years, and I’ve seen more head gaskets fail from skipped procedures than from bad parts. The Mitsubishi 4G64S4 Workshop Manual is your insurance against that. It’s 162 pages of factory procedures, written by the people who designed the engine. Not some third-party rehash that skips the critical steps. When I say ‘factory spec’, I mean the exact numbers Mitsubishi put in the engineering release. That’s what you get. No guesswork. No ‘approximately’. Just the numbers.

Engine General Information: What’s Inside Chapter 2

Page 2 of the manual gives you the technical data straight from Mitsubishi. The 4G64S4 is a 2.351L inline-four gasoline engine with a multi-point fuel injection system. You get spark plug part numbers – NGK BKR5E-11 or K16PR-U11 – and gap specs. Compression ratio is 9.5:1, output 93 kW (125 hp) at 5250 rpm. That’s the kind of detail you need when ordering parts or diagnosing a misfire. Aftermarket manuals often round these numbers or omit the exact plug index. Don’t risk it.

Coolant Replacement: The OEM Procedure

The coolant flush procedure on page 3 is a perfect example of why factory documentation matters. The manual tells you to park the vehicle with the front end higher than the rear to purge air. It warns you to open the heater hose connection at the throttle body to vent trapped air. I’ve seen guys skip that step and end up with a steam pocket that cracks the head. The manual also specifies to tighten the radiator cap properly – not just hand-tight. Coolant is toxic; they spell out the safety precautions. Page 3 covers the whole sequence: drain, refill, burp, check level. Follow it exactly.

Why Aftermarket Manuals Cause Headaches

I’ve got a stack of aftermarket manuals in my office. They’re fine for a general overview, but when you need the exact tightening sequence for the 4G64 cylinder head, or the correct thermostat rating (88°C by the way), those books fall short. They often reuse diagrams from other engines and guess the torque. This workshop manual is the original Mitsubishi document. Every page is scanned from the factory binder. The wiring diagrams are model-specific. The valve clearance specs are for the S4 variant. You don’t get that from a $20 reprint.

What the 162 Pages Cover

Granted, I don’t have the full table of contents in front of me, but flipping through the Russian original, I see chapters on engine mechanical, cooling system, fuel injection, ignition, and troubleshooting. There’s a section on cylinder head overhaul with in-sequence torque patterns. Another on timing belt replacement with tensioner specs. You get the diagnostic flowcharts for the fuel system. And yes, the manual includes the explosion-proof diagrams for the intake and exhaust manifolds. 162 pages of genuine Mitsubishi engineering. That’s enough to strip and rebuild this engine from the oil pan up.

Torque Specs and Fluid Capacities

Every critical fastener in the 4G64S4 has a listed torque value in this manual. Head bolts, main bearing caps, connecting rod nuts, intake manifold, exhaust manifold, oil pan – it’s all there. The cooling system capacity is given in liters (convert to quarts yourself if you need Imperial). The manual also specifies the correct coolant type – ethylene glycol-based, silicate-free. Don’t mix it up. I’ve seen aftermarket manuals list the wrong coolant type and cause corrosion in the water jacket. Get the factory data.

Audience Fit: Who Should Buy This Manual

If you’re a home garage enthusiast with a Mitsubishi 4G64 engine sitting on an engine stand, this manual is for you. It assumes you have basic mechanical skills but need the factory specs. Professional mechanics will appreciate the time saved by not cross-referencing three different sources. The manual is in Russian, but the diagrams and numbers are universal. If you can read a torque spec in Nm and follow a diagram, you’re good. The language barrier is minimal because the technical content is mostly numeric and visual.

Related Manuals for Your Shop

• Mitsubishi R4AW2-1, R4AW2-3, R4AW2-7 1996 Workshop Manual
• Mitsubishi 4D68 1996 Workshop Manual – 70 Pages of OEM Specs
• Mitsubishi F4A4 F4A5 1999 Workshop Manual – OEM Transmission Rebuild Specs

For background on the 4G64 engine family, check the Automotive Industry Overview.

Frequently Asked Questions

Does this manual cover the 4G64S4 only?

Yes. It is specific to the 4G64S4 variant.

Can I use this manual for the 4G64 engine in my 1998 Mitsubishi Montero?

The 4G64S4 is a specific variant used in certain Mitsubishi models. This manual contains exact specs for that engine code – spark plug types, valve clearances, timing marks, and fuel injection settings. If your engine block stamping reads 4G64S4, this manual is a perfect match. However, other 4G64 variants like the S3 or S1 had different compression ratios, different injector part numbers, and sometimes different head bolt torque sequences. Before buying, verify your engine code on the block casting near the starter or on the timing belt cover. Using the wrong manual for a variant can lead to incorrect torque values and potential engine damage. Don’t assume all 4G64 engines are identical – the factory differentiated them for a reason.

Download the Factory Manual and get the genuine Mitsubishi data. Your engine deserves the same specs the factory techs used.