Which clearance, torque, or sensor value is correct on a Mitsubishi GK21E or GK25E gasoline engine gets settled by the 161-page Mitsubishi GK21E, GK25E service manual PDF, factory publication 99789-72100. Engine control takes up roughly a third of the book: on-board diagnostic trouble codes, ECM component inspection, the electronic throttle assembly, and both gasoline and LPG injectors, with wiring diagrams showing each sensor and actuator circuit back to the ECM. Mechanical service fills another big share, and the electrical chapter ends with starter and alternator overhauls in exploded view. Gap your plugs at 0.8 to 0.9 mm and fill the crankcase to 3.8 L at the H line. Chasing a dual-fuel fault code with the engine half apart wears thin fast. Bookmarks and a real text layer put you on the right diagnosis page quickly, so you order the correct sensor the first time and have the torque values ready before it goes back together.
What's Inside This Mitsubishi GK21E, GK25E Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction | 5 | - |
| Maintenance | 6-17 | Specifications, Tightening Torque, Maintenance Schedule, Oil and Grease, And Capacity, On Board Inspection and Service, Engine Body Related, Ignition Systems |
| Engine Mechanical | 18-61 | Engine Service |
| Engine Lubrication and Cooling Systems | 62-69 | Lubrication System, Oil Pressure, Engine Coolant System, Water Pump, Thermostat |
| Engine Fuel | 70-89 | Emission Control System, Trouble Diagnosis, Electronic Control Throttle Assembly, Gasoline Fuel Injector, Lpg Injector Holder, Vaporizer |
| Engine Control System | 90-143 | On Board Diagnostic System, Trouble Diagnosis, Basic Inspection, Component Parts Inspection, Ecm Components, Blow-By Gas Recirculation Device |
| Engine Electrical System | 144-161 | Starter Motor, Alternator, Overhaul, Assembly Inspection, Exploded View, Disassembly |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Oil pan drain plug torque | 29.4 - 39.2 N·m | p. 13 |
| Spark plug torque | 19.6 - 29.4 N·m | p. 60 |
| Oil capacity H line | 3.8 L | p. 7 |
| Oil capacity L line | 2.8 L | p. 7 |
| Spark plug gap | 0.8 - 0.9 mm | p. 7 |
| Valve clearance (Hot) Intake | 0.38 mm | p. 7 |
| Valve clearance (Hot) Exhaust | 0.38 mm | p. 7 |
| Oil filter element tightening torque | 14.7 N·m | p. 8 |
| Oil pan drain plug tightening torque | 29.4 - 39.2 N·m | p. 13 |
| Spark plug tightening torque | 19.6 - 29.4 N·m | p. 60 |
| Cylinder head bolt tightening torque | 68.6 N·m | p. 12 |
| Main bearing cap tightening torque | 83.4 - 93.2 N·m | p. 26 |
Mitsubishi GK21E, GK25E Common Problems This Manual Covers
Mitsubishi GK21E GK25E engine low compression pressure with stuck valve or burnt valve seat
Test compression on each cylinder, then pull the head and inspect for a stuck valve, burnt valve seat or excessive cylinder and piston wear. Before the head goes back on, torque cylinder head bolts to 68.6 N·m per page 12, then set valve clearance hot to 0.38 mm intake and exhaust as listed on page 7.
Manual Section: Engine Mechanical TroubleshootingEngine knocking or slapping noise from main bearing, crankshaft, piston or connecting rod
Check where the knock starts. The noise chart lists bearing, crankshaft, piston, connecting rod, camshaft, timing chain, valve gear and water pump as separate causes. If the bottom end is the source, inspect crankshaft bearings and rods, and at reassembly torque main bearing caps to 83.4 to 93.2 N·m following page 26.
Manual Section: Engine Noise TroubleshootingIgnition system check on engine that cranks over normally but will not start
Remove the spark plugs and inspect each one, then set the gap to 0.8 to 0.9 mm as listed on page 7. Reinstall and torque them to 19.6 to 29.4 N·m following page 60. If it still will not fire, work through the ignition system checks in the electrical troubleshooting chart.
Manual Section: Engine Electrical System TroubleshootingStarter motor turns the engine over slowly or does not crank it at all
Check the starter motor against the no or slow cranking steps in the electrical troubleshooting chart. If the motor is at fault, remove it, disassemble it using the exploded view starting at page 148, and inspect each part before the assembly inspection and refit. Inspect the alternator in the same section while you have the electrical system apart.
Manual Section: Engine Electrical System p. 144Water pump or thermostat problem with engine overheating and insufficient coolant circulation
Inspect the coolant system for water leakage and corrosion first, then check the water pump for noise and the thermostat for proper operation. The same chart covers an overcool condition as well as overheating. Replace any pump or thermostat that fails inspection before you bring the engine back up to temperature.
Manual Section: Engine Coolant System TroubleshootingLPG vaporizer operating malfunction with poor starting, low output and rough idle
Check for fuel leakage at the vaporizer and LPG injector holder before anything else. Next, inspect how the vaporizer is operating. The LPG chart lists poor starting, low output, rough idle and excessive fuel consumption alongside vaporizer malfunction. Verify the electronic control throttle assembly works before you condemn the vaporizer.
Manual Section: LPG Fuel System TroubleshootingFrequently Asked Questions
What are the torque specifications for the oil filter element on the Mitsubishi GK21E and GK25E engines?
The tightening torque for the oil filter element is 14.7 N·m (1.5 kgf-m, 11 ft-lb) for the standard value, with a maximum value of 20.6 N·m (2.1 kgf-m, 15 ft-lb). p. 8
What is the standard oil capacity for the GK21E and GK25E engines?
The standard oil capacity is 3.8 liters (3-3/8 Imp qt) when including the filter, and 3.5 liters (3 Imp qt) when not including the filter. p. 14
What is the standard hot valve clearance for the intake and exhaust valves on the Mitsubishi GK21E, GK25E?
The standard valve clearance for both intake and exhaust valves is 0.38 mm (0.0150 in) when the engine is in a hot condition. p. 7
What is the standard spark plug gap for the GK21E and GK25E engines?
The standard spark plug gap is 0.8 - 0.9 mm (0.031 - 0.035 in). p. 136
What is the standard fan belt deflection for the engine?
The standard fan belt deflection is 11 - 13 mm (0.43 - 0.51 in) when pressed by a force of approximately 98 N (10 kgf, 22 lb). p. 66
Do I get instant access to this Mitsubishi GK21E Service Manual?
You download the Service Manual yourself: 161 pages, searchable PDF, available immediately. Keep a copy on every device you use.
Are there any print restrictions on this Mitsubishi GK21E manual?
Yes, print as many copies as you want, and there are no restrictions. Many mechanics print the section they need and bring it to the shop floor.
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