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Proton WAJA 1.6L 4G18 2.0L 6A12 V6 Engine Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Proton Model: Waja Engine Variants Covered: 1.6L (4G18), 2.0L (6A12 V6) Codes Engine Code 1.6L: 4G18 Engine Code 2.0L V6: 6A12 👋 Introduction Market Position Target Audience: Proton Waja owners, independent repair shops, DIY enthusiasts Competitive Analysis Value Proposition: Provides professional-level repair and maintenance information, saving costs on dealership services. Key Features Content Richness: Hundreds of pages with detailed photos and diagrams, step-by-step instructions. Accessibility: Instant download, usable on multiple devices and computers for life. 📋 Manual Details Coverage Areas Coverage: Complete Service, Repair, and Workshop Procedures Page Count Estimated Pages: Hundreds (specific count not provided, described as 'hundreds of pages') Manual Type Type: Factory Service Repair Workshop Manual Language Language: English (implied by product description and common industry standard) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, lubrication, cooling, fuel, ignition, emissions control, engine management systems (ECU) Drivetrain Systems: Transmission (manual/automatic), clutch, driveshafts, differentials, axles Chassis Systems: Suspension (front and rear), steering, brakes (hydraulic, ABS), wheels, tires Electrical Systems: Battery, charging system, starting system, lighting, instrumentation, body electrical, infotainment wiring, engine control wiring harnesses Body And Interior: Body panels, doors, windows, locks, seats, trim, HVAC system Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups, inspections Repair: Engine overhaul, transmission repair, brake system repair, suspension component replacement, electrical component diagnosis and repair, bodywork repair Troubleshooting: Diagnostic procedures, fault finding for all major systems, error code interpretation Specifications: Torque specifications, clearances, fluid capacities, wiring diagrams, component specifications Installation: Component removal and installation procedures Technical Depth Depth: Comprehensive: Covers all repair, servicing, and troubleshooting. Includes step-by-step instructions, detailed photos, and exploded diagrams. 📊 Manual Specifications File Format File Type: PDF Searchable Text: Likely searchable (standard for professional PDF manuals) Print Quality Printable: Yes, individual pages or entire manual Binding Type Binding: Digital Download (N/A for physical binding) Paper Type Paper Quality: Digital Download (N/A for physical paper type) Licensing Usage License: Lifetime usage on unlimited devices, no expiry Compatibility Operating Systems: Windows and macOS compatible Version Version Status: Full, unrestricted version ⚙️ Engine Specifications Primary Engine Engine 1.6L Designation: 4G18 (Mitsubishi Sirius family) Engine 1.6L Type: Inline-4, DOHC, 16-valve Engine 1.6L Displacement: 1584 cc Engine 2.0L V6 Designation: 6A12 Engine 2.0L V6 Type: V6, SOHC, 24-valve Engine 2.0L V6 Displacement: 1998 cc Performance Engine 1.6L Horsepower Approx: 103-110 PS (76-81 kW) Engine 2.0L V6 Horsepower Approx: 145-150 PS (107-110 kW) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Recommended Fuel: Unleaded gasoline (RON 95 or higher) Ignition System Ignition Type: Electronic Ignition (Distributorless Ignition System - DIS for 4G18, Distributor for 6A12) 🔧 Transmission Standard Standard Transmission 1.6L: 5-speed Manual Standard Transmission 2.0L V6: 4-speed Automatic (INVECS-II) Optional Optional Transmission 1.6L: 4-speed Automatic (INVECS-II) Features Transmission Control: Electronic control unit (ECU) for automatic transmissions, potentially with a sport/economy mode. Fluid Specifications Automatic Transmission Fluid: Dexron III or equivalent (refer to manual for exact specification and capacity) 📐 Dimensions Exterior Body Style: 4-door Sedan Length Approx: 4475 mm Width Approx: 1740 mm Height Approx: 1445 mm Weights Curb Weight Approx 1.6L: 1250-1300 kg Curb Weight Approx 2.0L V6: 1350-1400 kg Gross Vehicle Weight Rating Approx: 1700-1750 kg 🛡️ Safety Features Ratings Safety Standards: Compliant with Malaysian safety standards of the era. Active Features Active Safety: Optional ABS (Anti-lock Braking System), Power Steering Passive Features Passive Safety: Driver and front passenger airbags (standard/optional depending on trim), seatbelt pretensioners, reinforced body structure. 💡 Technology Features Infotainment Infotainment System: Basic AM/FM radio with CD player, likely optional upgraded system with more speakers. Driver Assistance Driver Assistance Features: Limited to power steering and ABS (optional). Connectivity Connectivity Options: Basic, typically no advanced Bluetooth or USB connectivity in early models. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 km or 3 months, whichever comes first (typical for the era; refer to manual for precise details) Timing Belt Replacement: Recommended every 60,000 - 80,000 km or 4-5 years for 4G18 and 6A12 engines (critical maintenance item). Fluid Specifications Engine Oil Specification: API SG/SH/SJ, ACEA A2/A3. Viscosity 10W-40 or 5W-30 recommended (refer to manual for exact grade and capacity). Coolant Specification: Ethylene Glycol based coolant (e.g., 50/50 mix with distilled water). Refer to manual for specific type and capacity. Brake Fluid Specification: DOT 3 or DOT 4 (refer to manual for exact type and capacity). Known Issues Common Issues 1.6L: Engine mounts degradation, minor oil leaks, potential cooling system issues if not maintained. Common Issues 2.0L V6: More complex V6 engine may require specialized attention; potential for spark plug tube seal leaks, cooling system maintenance is crucial. General Issues: Electrical connectors can be prone to corrosion in humid climates, suspension wear (bushings, ball joints), rust on body panels if not protected. 📚 Vehicle History Brand Heritage Proton Origin: Malaysian national car manufacturer, initially...
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Proton WAJA 1.6L 4G18 2.0L 6A12 V6 Engine Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Proton
Model:
Waja
Engine Variants Covered:
1.6L (4G18), 2.0L (6A12 V6)
Codes
Engine Code 1.6L:
4G18
Engine Code 2.0L V6:
6A12
👋 Introduction
Market Position
Target Audience:
Proton Waja owners, independent repair shops, DIY enthusiasts
Competitive Analysis
Value Proposition:
Provides professional-level repair and maintenance information, saving costs on dealership services.
Key Features
Content Richness:
Hundreds of pages with detailed photos and diagrams, step-by-step instructions.
Accessibility:
Instant download, usable on multiple devices and computers for life.
📋 Manual Details
Coverage Areas
Coverage:
Complete Service, Repair, and Workshop Procedures
Page Count
Estimated Pages:
Hundreds (specific count not provided, described as 'hundreds of pages')
Manual Type
Type:
Factory Service Repair Workshop Manual
Language
Language:
English (implied by product description and common industry standard)
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, lubrication, cooling, fuel, ignition, emissions control, engine management systems (ECU)
Drivetrain Systems:
Transmission (manual/automatic), clutch, driveshafts, differentials, axles
Chassis Systems:
Suspension (front and rear), steering, brakes (hydraulic, ABS), wheels, tires
Electrical Systems:
Battery, charging system, starting system, lighting, instrumentation, body electrical, infotainment wiring, engine control wiring harnesses
Body And Interior:
Body panels, doors, windows, locks, seats, trim, HVAC system
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups, inspections
Repair:
Engine overhaul, transmission repair, brake system repair, suspension component replacement, electrical component diagnosis and repair, bodywork repair
Troubleshooting:
Diagnostic procedures, fault finding for all major systems, error code interpretation
Specifications:
Torque specifications, clearances, fluid capacities, wiring diagrams, component specifications
Installation:
Component removal and installation procedures
Technical Depth
Depth:
Comprehensive: Covers all repair, servicing, and troubleshooting. Includes step-by-step instructions, detailed photos, and exploded diagrams.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Likely searchable (standard for professional PDF manuals)
Print Quality
Printable:
Yes, individual pages or entire manual
Binding Type
Binding:
Digital Download (N/A for physical binding)
Paper Type
Paper Quality:
Digital Download (N/A for physical paper type)
Licensing
Usage License:
Lifetime usage on unlimited devices, no expiry
Compatibility
Operating Systems:
Windows and macOS compatible
Version
Version Status:
Full, unrestricted version
⚙️ Engine Specifications
Primary Engine
Engine 1.6L Designation:
4G18 (Mitsubishi Sirius family)
Engine 1.6L Type:
Inline-4, DOHC, 16-valve
Engine 1.6L Displacement:
1584 cc
Engine 2.0L V6 Designation:
6A12
Engine 2.0L V6 Type:
V6, SOHC, 24-valve
Engine 2.0L V6 Displacement:
1998 cc
Performance
Engine 1.6L Horsepower Approx:
103-110 PS (76-81 kW)
Engine 2.0L V6 Horsepower Approx:
145-150 PS (107-110 kW)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Recommended Fuel:
Unleaded gasoline (RON 95 or higher)
Ignition System
Ignition Type:
Electronic Ignition (Distributorless Ignition System - DIS for 4G18, Distributor for 6A12)
🔧 Transmission
Standard
Standard Transmission 1.6L:
5-speed Manual
Standard Transmission 2.0L V6:
4-speed Automatic (INVECS-II)
Optional
Optional Transmission 1.6L:
4-speed Automatic (INVECS-II)
Features
Transmission Control:
Electronic control unit (ECU) for automatic transmissions, potentially with a sport/economy mode.
Fluid Specifications
Automatic Transmission Fluid:
Dexron III or equivalent (refer to manual for exact specification and capacity)
📐 Dimensions
Exterior
Body Style:
4-door Sedan
Length Approx:
4475 mm
Width Approx:
1740 mm
Height Approx:
1445 mm
Weights
Curb Weight Approx 1.6L:
1250-1300 kg
Curb Weight Approx 2.0L V6:
1350-1400 kg
Gross Vehicle Weight Rating Approx:
1700-1750 kg
🛡️ Safety Features
Ratings
Safety Standards:
Compliant with Malaysian safety standards of the era.
Active Features
Active Safety:
Optional ABS (Anti-lock Braking System), Power Steering
Passive Features
Passive Safety:
Driver and front passenger airbags (standard/optional depending on trim), seatbelt pretensioners, reinforced body structure.
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM radio with CD player, likely optional upgraded system with more speakers.
Driver Assistance
Driver Assistance Features:
Limited to power steering and ABS (optional).
Connectivity
Connectivity Options:
Basic, typically no advanced Bluetooth or USB connectivity in early models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 km or 3 months, whichever comes first (typical for the era; refer to manual for precise details)
Timing Belt Replacement:
Recommended every 60,000 - 80,000 km or 4-5 years for 4G18 and 6A12 engines (critical maintenance item).
Fluid Specifications
Engine Oil Specification:
API SG/SH/SJ, ACEA A2/A3. Viscosity 10W-40 or 5W-30 recommended (refer to manual for exact grade and capacity).
Coolant Specification:
Ethylene Glycol based coolant (e.g., 50/50 mix with distilled water). Refer to manual for specific type and capacity.
Brake Fluid Specification:
DOT 3 or DOT 4 (refer to manual for exact type and capacity).
Known Issues
Common Issues 1.6L:
Engine mounts degradation, minor oil leaks, potential cooling system issues if not maintained.
Common Issues 2.0L V6:
More complex V6 engine may require specialized attention; potential for spark plug tube seal leaks, cooling system maintenance is crucial.
General Issues:
Electrical connectors can be prone to corrosion in humid climates, suspension wear (bushings, ball joints), rust on body panels if not protected.
📚 Vehicle History
Brand Heritage
Proton Origin:
Malaysian national car manufacturer, initially licensed technology from Mitsubishi.
Model Evolution
Waja Development:
Launched in 2000 as Proton's first major in-house designed car, based on the Mitsubishi Carisma platform.
Waja Facelifts:
Received minor styling and feature updates throughout its production run.
Production
Production Period:
2000-2011
🏆 Awards & Recognition
Recognitions
Awards Achievements:
As a mass-market vehicle of its time, specific individual awards are less documented. Primarily recognized for affordability and accessibility in its target markets.
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