Motor 4d56

NOTES

11B-1-6

4D56 ENGINE <1994 –>– Specifications

TORQUE SPECIFICATIONS Nm

Drive belt and glow plug C ooling fan bolt …………………………………………… 11 Fan clutch bolt ……………………………………………… 11 V acuu m pipe bo lt (L4 00 ) …………………………………… 10 V acuum pipe bo lt (19 97 L2 00 and after) ………………… 23

To rqu e kgm

ft.lbs.

1.1

8

1.1

8

1.0

7

2.4

17

M 8 x 1 6 …………………………………………………… 12

1.2

9

M 8 x 20 …………………………………………………… 22

2.2

16

E ye bolt ……………………………………………………… 17

1.7

12

A uto tensioner bolt ………………………………………… 44

4.5

33

P ow er stee ring pu m p bracket bo lt (W ashe r) …………… 22

2.2

16

P ow er stee ring pu m p bracket bo lt (Flange ) ……………… 24

2.4

17

M 8 ………………………………………………………… 22

2.2

16

……………………………………………………… 44 B race bolt …………………………………………………… 14

4.5

33

1.4

10

…………………………………………………… 23 A djusting bolt ……………………………………………… 10 C ran kshaft pulley bolt ……………………………………… 25 C ran ksh aft bolt ……………………………………………… 181 O illeve lgauge guide b olt M 6 (L40 0) ………………………………………………… 11 M 8 (E xcept L400 ) ……………………………………… 24 G low plug plate n ut ………………………………………… 1.8 G low plug …………………………………………………… 9 + 3 0 ° to 40 °

2.3

17

1.0

7

2.5

18

18.5

134

1.1

8

2.4

17

0.18

1.3

0.9+ 30 ° to 4 0 °

7+30 ° to 4 0 °

Tim ing belt co ve r bolt ……………………………………… 11

1.1

8

Flange bolt …………………………………………………… 10

1.0

7

Te nsion er spacer nu t ……………………………………… 25

2.6

19

Tim ing belt tensioner bolt ………………………………… 25

2.6

19

C am shaft sprocket bo lt …………………………………… 67

7.0

51

C rank angle se nsor bolt …………………………………… 9

0.9

7

Injection pu m p sprocket nu t ……………………………… 83

8.5

61

…………………… 36 Tim ing belt rear cove r bolt ………………………………… 11

3.7

27

1.1

8

1.4

10

0.5

3.7

3.0

22

1.9

14

2.4

17

2.2

16

2.8

20

5.5

40

3.8

27

Vacuum pipe bolt (2001 m odelPA JER O )

A lternator pivo t bolt M 10

Lock b olt

Timing belt

B alancer shaft sprocke t bolt and nut

Fuel injection pump and injection nozzle Injection p um p protector bolt ……………………………… 14 Injection p ipe clam p b olt …………………………………… 5 Injection pipe union nut …………………………………… 29 Injection pu m p nu t ………………………………………… 19 Injection pum p bolt ………………………………………… 24 Injection p um p bracket bolt………………………………… 22 Fuelreturn pipe nut ………………………………………… 27 Injection n ozzle ……………………………………………… 54 Injection nozzle holder R etaining nut ………………………………………………… 37 G Mitsubishi Motors Corporation May 2001

PWEE9067-G

Revised

11B-1-7

4D56 ENGINE <1994 –> – Specifications

Nm

Intake and exhaust manifolds Air pipe bracket bolt ………………………………………… 22 Vacuum pipe and hose assembly bolt (with turbocharger) ……………………………………… 11 (with variable geometry turbocharger) ………………… 10 Waste gate actuator bolt (tightened to intake manifold) 19 Waste gate actuator bolt (tightened to turbocharger) …… 12 EGR pipe bolt nut …………………………………………… 17 EGR valve bolt ……………………………………………… 25 Eyebolt (water pipe) ………………………………………… 42 Eyebolt (oil pipe) …………………………………………… 17 Heat protector bolt M6 ………………………………………………………… 9 M8 ………………………………………………………… 14 Oil return pipe bolt ………………………………………… 9 Exhaust fitting nut ………………………………………… 59 Turbocharger nut …………………………………………… 59 Relief valve ………………………………………………… 49 Air inlet fitting bolt ………………………………………… 19 Intake manifold bolt ………………………………………… 18 Intake manifold stay bolt …………………………………… 18 Exhaust manifold nut ……………………………………… 18 EGR cooler bolt …………………………………………… 22 Solenoid valve assembly bolt ……………………………… 24 Water pipe and hose bolt…………………………………… 22 Water pipe bolt ……………………………………………… 11 Air temperature sensor …………………………………… 14 Air intake fitting bolt ……………………………………… 18 Oil pipe flare nut …………………………………………… 20 Oil pipe bolt ………………………………………………… 9 Hose clamp bolt …………………………………………… 14 Turbocharger Coupling bolt ………………………………………………… 5 Water pump, thermostat, hose and pipe Water pipe bolt M6 ………………………………………………………… 11 M8 ………………………………………………………… 14 Engine coolant temperature gauge unit ………………… 34 Engine coolant temperature sensor ……………………… 11 Water outlet fitting bolt …………………………………… 12 Water inlet fitting bolt Bolt with spring washer ………………………………… 12 Flange bolt ……………………………………………… 14 Thermostat housing bolt …………………………………… 14 Plate bolt……………………………………………………… 10

G Mitsubishi Motors Corporation Apr. 2002

PWEE9067-H

Torque kgm

ft.lbs.

2.2

16

1.1 1.0 1.9 1.2 1.7

8 7 14 9 12

2.5 4.3 1.7

18 31 12

0.9 1.4

7 10

0.9 6.0 6.0 5.0 1.9 1.8

7 43 43 36 14 13

1.8 1.8 2.2 2.4 2.2 1.1

13 13 16 17 16 8

1.4 1.8 2.0 0.9 1.4

10 13 14 7 10

0.5

4

1.1 1.4

8 10

3.5 1.1 1.2

25 8 9

1.2 1.4

9 10

1.4 1.0

10 7

Revised

11B-1-8


Nm Water pump bolt M8 x 20, M8 x 25, M8 x 40

Torque kgm

ft.lbs.

14

1.4

10

M8 x 70, M8 x 85 ……………………………………… 24 Rocker arms, rocker shaft and camshaft Oil filler bolt ………………………………………………… 13 Rocker cover bolt …………………………………………… 6 Rocker shaft bolt …………………………………………… 37 Lock nut ……………………………………………………… 15

2.4

17

1.3 0.6 3.8 1.5

9 4 27 11

2.0

14

……………………………

Camshaft bearing cap bolt ………………………………… 20 Cylinder head, valves and valve spring Cylinder head bolt Without throttle body …………………………………… 118 With throttle body ……………………………………… 29+120° to 124° Front case and oil pan

12.0 87 3.0+120° to 124° 22+120° to 124°

Oil cooler by-pass valve …………………………………… 54 Oil pressure switch ………………………………………… 10 Oil filter bracket bolt (Except 2001 PAJERO) …………… 14 Oil filter bracket bolt (2001 PAJERO) M6 ………………………………………………………… 11 M8 ………………………………………………………… 23

5.5 1.0 1.4

40 7 10

1.0 2.3

7 17

Oil pan cover bolt …………………………………………… 9 Oil drain plug ………………………………………………… 39 Oil level sensor bolt ………………………………………… 9 Oil pan bolt ………………………………………………… 7 Oil screen bolt and nut …………………………………… 19 Front upper case bolt ……………………………………… 13

0.9 4.0 0.9 0.7 1.9 1.3

7 29 7 5 14 9

Plug cap ……………………………………………………… 24 Balancer shaft driven gear bolt …………………………… 36 Front lower case bolt M8 x 90 …………………………………………………… 24 Except M8 x 90 ………………………………………… 13 Oil pump cover bolt ………………………………………… 12

2.4 3.7

17 27

2.4 1.3 1.2

17 9 9

Balancer shaft gear cover bolt …………………………… 24 Check valve ………………………………………………… 32 Stiffener bolt ………………………………………………… 19 Piston and connecting rod Connecting rod cap nut

2.4 3.3 1.9

17 24 13

Without variable geometry turbocharger ……………… 46 With variable geometric turbocharger ………………… 27+90° to 94° Crankshaft and cylinder block Flywheel bolt ……………………………………………… 132 Drive plate bolt ……………………………………………… 132 Rear plate bolt ……………………………………………… 9

4.7 2.8+90° to 94°

34 20+90° to 94°

13.5 13.5 0.9

98 98 7

Bell housing cover bolt …………………………………… 9 Oil seal case bolt …………………………………………… 11 Bearing cap bolt …………………………………………… 78 Cover bolt …………………………………………………… 6

0.9 1.1 8.0 0.6

7 8 58 4


PWEE9067-H

Revised

11B-1-9


Nm Engine support bracket bolt (Except 2001 PAJERO) Head mark “7” ………………………………………… 44 Head mark “8” ………………………………………… 55 Engine support bracket bolt (2001 PAJERO) M8 ………………………………………………………… 22 M10 ……………………………………………………… 44

Torque kgm

ft.lbs.

4.5

33

5.5

40

2.2 4.5

16 33

SEALANT Specified sealant

Quantity

Semi-circular packing ……………………… 3M ATD Part No. 8660 or equivalent ………………… As required Oil pan gasket ……………………………… MITSUBISHI GENUINE Part No. MD970389 ………… As required or equivalent Oil pressure switch ………………………… 3M ATD Part No. 8660 or equivalent ………………… As required Engine coolant temperature ……………… 3M Nut Locking Part No. 4171 ……………………… As required gauge unit or equivalent Engine coolant temperature ……………… 3M ATD Part No. 8660 or equivalent ………………… As required gauge unit Engine coolant temperature sensor ……… 3M ATD Part No. 8660 or equivalent ………………… As required


PWEE9067-H

Revised

4D56 ENGINE <1994 –> – Special Tools

11B-2-1

2. SPECIAL TOOLS Tool

N um ber

N am e

U se

M B 9 9 07 67

E n d yo ke h old er

H o ld in g cam sh aft sp ro cke t o r fu elin je ctio n pum p sprocket w hen loosening o r tigh ten ing bo lts. (U se w ith M D 99 87 19 )

M B 991614

A ngle gauge

Tightening cylinder head bolt

M D 998051

C ylinder head bolt w rench

Loosening and tightening of cylinder head bolts

M D 998115

Valve guide installer

R em ovaland installation of valve guide

M D 998148

Valve seat cutter pilot

C orrection of valve seat

M D 998158

Valve seat cutter 45°


M D 998165

Valve seat cutter 65°


G Mitsubishi Motors Corporation May 2001

PWEE9067-G

Revised

11B-2-2 Tool

4D56 ENGINE <1994 –>– Special Tools N um ber

N am e

U se

M D 9 981 75

V alve se at cu tte r 3 0°

C orrection of valve se at

M D 99 82 50

B alance r shaft be aring installer

Installation of silen t shaft rear be aring

M D 9982 51

M D 998303

B alancer shaft bearing puller

V alve spring com pressor

R em ovalof silent shaft rear bearing

C om pression of valve spring

M D 99 83 76

C ranksh aft rear oil sealinstaller

Installation of cranksh aft rear oilseal

M D 99 83 80

B earing installer stopper

G uide for rem oval and installation of silen t shaft right rear bearing

M D 9983 81

C am shaft oilseal installer

Installation of cam shaft oilseal


PWEE9067-G

Revised

4D56 ENGINE <1994 –>– Special Tools Tool

N um ber

N am e

11B-2-3

U se

M D 99 83 82

C rankshaft fron t oil sealguide

G uide for installation of crankshaft fron t oil seal

M D 99 83 83

C rankshaft fron t oil sealinstaller

Installation of crankshaft fron t oilseal

M D 998384

Prestroke m easuring adapter

A djustm ent of injection tim ing

M D 99 83 85

B alancer shaft drive g ear Installation of silen t shaft drive o ilseal oilse alguide

M D 998386

C onnecting-rod sm all-en d bu shing rep lacem en t too l

R eplacem ent of connecting-rod sm all-end bu shing

M D 998388

Injection pum p sprocke t puller

R em ovalof injection pum p sprocket

M D 9 98719


P ulley holder pin (2)

PWEE9067-G

U se w ith M B 990767

Revised

11B-2-4 Tool

4D56 ENGINE <1994 –>– Special Tools N um ber M D 998727

N am e

U se

O ilpan sealer cutter

R e m ovalof oilpan

M D 998729

Valve stem seal installer

Installation of valve stem seal

M D 998772

V alve spring com pressor

C om pression of valve spring

M D 9 98 77 8

C ran ksh aft sp ro cke t puller

R e m o valo f cran ksh aft sp ro cke t

M D 9 987 81

F lyw h ee lsto pp er

H o ld in g flyw h ee lan d drive p late


PWEE9067-G

Revised

11B-3-1

4D56 ENGINE <1994 –>– Drive Belt and Glow Plug

3. DRIVE BELT AND GLOW PLUG REMOVAL AND INSTALLATION 10 1.0 7

23 2.4 17

5 Except L400

12

Brace bolt type

17 1.7 12

5 L400

14 1.4 10 6

7N

22

10 1.0 7 12

13

1.8 0.18 1.3

10

Adjuster type

23 9N

23 2.3 17

9 0.9 7 8 +30° to 40°

17 1.7 12

M8

23 2.3 17

M10

44 4.5 33

2

3

11 4 1

25 2.5 18

Except L400

24 2.4 17

18

16 20 14

18

17

L400 19 N

15

11 1.1 8

11 1.1 8 18118.5134

Removal steps EDF 1.D rive belt 2.C ooling fan 3.Fan clutch 4.W ater pum p pulley 5.Vacuum pipe 6.Eyeb olt 7.G asket 8.Eyeb olt 9.G asket 10.O iltube ECF 11 .O ilho se 12.A lternator brace G Mitsubishi Motors Corporation May 2001

19 N

21 N 20 21 N

11 1.1 8

FAE EBF EBF EBF

FBE EAF

13.A lternator 14.C ran kshaft pulley (for A /C ) 15.C ranksh aft bolt 16 .S pecialw asher 17.C ran kshaft pulley 18.O illeve lgau ge 19.O -ring 20.O illevelgauge guide 21.O -ring 22 .G low plug plate 23 .G low plug DEN0327

PWEE9067-G

Revised

11B-3-1a


REMOVAL AND INSTALLATION

22 2.2 16 22 2.2 16 17

4

24 2.4 17 12 1.2 9

12

24 2.4 17

+30° to 21 9 0.9 7 40°

N 6 13

9

17 1.7 12 5

22

19

1.80.18 1.3 20 N

8N 7

10

22 2.2 16

N 18

17 1.7 12 11

44 4.5 33 44 4.5 33 3 1

2

15

16

14

11 1.1 8

18118.5134

11 1.1 8 Removal steps 1.C ooling fan 2.Fan clutch 3.W ater pu m p pu lley 4.Vacuum pipe 5.Eye bo lt 6.G asket 7.Eye bo lt 8.G asket 9.O ilpipe ECF 10 .O ilho se 11 .A uto ten sion er

FAE EBF EBF EBF

FBE EAF

12 .P ow er stee ring p um p bracket 13.A lternator 14.C ranksh aft bolt 15 .S pe cialw asher 16.C ran kshaft pulley 17.O illeve lgau ge 18.O -ring 19.O illevelgauge guide 20.O -ring 21 .G low plug plate 22 .G low plug DEN0328


PWEE9067-G

Revised


11B-3-1b

REMOVAL SERVICE POINTS FAE CRANKSHAFT PULLEY BOLT REMOVAL (1) H old th e flyw he el o r drive plate in po sition w ith th e special toolbefore rem oving the crankshaft pulley bolts.

M D 9 987 81 D E N 0 11 7

FBE GLOW PLUG REMOVAL (CERAMIC TYPE ONLY)

(1) W hen rem oving the g low plug, you m ay loosen using a tool up to the point w here one or m ore threads are left in engagem en t.B eyond this point,loosen w ith fingers.

Caution • Do not reuse a glow plug that has been dropped from a height of 10 cm (4 in.) or more.

INSPECTION GLOW PLUG (1) C he ck the con tinu ity betw ee n the term inal and bo dy as illustrated. R eplace if there is n o continuity o r if there is a large resistance .

Standard value: Metal type Ceramic type

0.9 – 1.1 Ω [at 20°C (68°F)] 0.4 – 0.6 Ω [at 20°C (68°F)]

DEN034


PWEE9067-G

Revised

11B-3-2

4D56 ENGINE

<1994 –>

– Drive Belt and Glow Plug

INSTALLATION SERVICE POINTS EAF

MB991614

GLOW PLUG INSTALLATION

Caution Check that the glow plugs, glow plug mounting threads and plug seating surfaces of cylinder head are dry. •

30° to 40°

DEN0343

(1) Screw in the glow plug with fingers until at least one screw thread engages . (2) Tighten the glow plug to 9 Nm (0.9 kgm, 7 ft.lbs), then turn it further in the tightening direction by 30-40° using the special tool. EBF CRANKSHAFT BOLT/SPECIAL WASHER /

CRANKSHAFT PULLEY INSTALLATION (1) Use the special tool to hold the flywheel or the drive plate.

MD998781

Crankshaft bolt Washer

DEN0117

Crankshaft

Pulley crankshaft

NOTE Degreasing is necessary to prevent decrease in the friction between contacting surfaces.

Clean

Degrease DEN0311


(2) Clean and then degrease the crankshaft sprocket contacting surface of the crankshaft pulley.

(3) Clean the bolt hole in the crankshaft, the crankshaft contacting surface and washer contacting surface of the crankshaft pulley, and the washer. (4) Apply an appropriatery small amount of oil to the threads and seating surface of the crankshaft bolt. (5) Tighten the crankshaft bolt to the specified torque of 181 Nm (18.5 kgm, 134 ft.lbs.).

PWEE9067-H

Revised

NOTES

4D56 ENGINE <1994 –>– Timing Belt

11B-4-1

4. TIMING BELT REMOVAL AND INSTALLATION 7 8

25 2.6 19

67 7.0 51

1

6

5

10 1.0 7

25 2.6 19 4 10

9 3

83 8.5 61

13 11

9 0.9 7 24 12

2

11 1.1 8 22

11 1.1 8

21

25 2.6 19

36 3.7 27 25 2.6 19

20

18

36 3.7 27

16

19

17

23 15 14 Removal steps 1.Tim ing be lt up pe r cover 2.Tim ing be lt low er cover 3.Flange FAE E J F 4.Tim ing be lt 5.Tension er spacer 6.Tensione r spring EIF 7.Tim ing belt tensioner FBE EHF 8.C am shaft sprocket FCE EGF 9.Injection pu m p sp rocket EFF 10 .C rank ang le sen sor (w ith throttle body) EFF 11.Front flange (2001 m odelPA JERO )

EFF FDE EFF EFF FEE EEF

EDF FFE ECF FGE EBF EAF FHE EK F

12 .C rankshaft sensing blade (w ith throttle body) 13 .C rankshaft sprocket 14 .Flange 15.Tim ing belt “ B” 16.G asket 17.Tensioner space r “B ” 18.Te nsioner spring “B ” 19.Tim ing b elt tensioner 20.B alan ce r shaft sprocke t, right 21.B alan ce r shaft sprocke t, left 22.Spacer 23 .C rankshaft sprocket “ B” 24.Tim ing b elt rear cover DEN0329


PWEE9067-G

Revised

11B-4-6

4D56 ENGINE <1994 –> – Timing Belt EEF

TIMING BELT “B” INSTALLATION

(1) A lign tim ing m arks on the crankshaft sprocket “B ”, an d silent sh aft sprockets w ith their tim ing m arks. (2) Install tim ing belt “B ”onto sprocke ts and e nsure that its tension side is not slack.

(3) Lo ose n ten sion er “B ”m ou nting bo lt and n ut, on e to tw o turns. (4) Tighten the tensioner “B ”attaching nut. (5) Tighten the tensioner “B ”attaching bolt. NOTE If the bolt is tightened first, the tensioner “B ”sho uld be turned together, resu lting in reduce d tim ing belt “B ” tension.

B alancer shaft sprocket

(6) E nsure that the deflection is as sp ecified w hen the belt is pushed by the index finger at the position indicated by an arrow .

Belt deflection: 4 – 5 mm (0.16 – 0.20 in.)

EFF

C rankshaft sensing blade or front flan ge Flange C ranksh aft

C lean

C ranksh aft sprocket

CRANKSHAFT SENSING BLADE / FRONT FLANGE / FLANGE / CRANKSHAFT SPROCKET INSTALLATION

(1) C lean and the n d eg rease the follow ing surfaces and p arts: S procke t m o un tin g su rface of cran ksh aft, cran ksh aft se nsin g blad e or fron t flan g e, flan g e, an d cran kshaft sprocket.

D egrease DEN0312

M D 99 87 19 M B 9 987 67

NOTE D e g re asin g is n ec e ssary to pre ve n t d ec rea se in th e friction betw een contacting surface s. (2) C lean the cranksh aft contacting surface of the cranksh aft sprocket. EGF INJ ECTION PUMP SPROCKET INSTALLATION

DEN0129


PWEE9067-G

Revised

4D56 ENGINE <1994–> – Timing Belt C ranksh aft sprocket “B ”

C ranksh aft O ilpum p gear drive shaft

11B-4-9

EK F CRANKSHAFT SPROCKET “B” INSTALLATION C lean and the n d eg rease the fron t face o f the O il pu m p g ear drive shaft, cran kshaft sp rocket “B ”and cranksh aft surface on w hich sprocket “B ”is attached. NOTE D egreasing is necessary to prevent decrease in the friction be tw ee n con tacting surfaces.

D egrease DEN0313


PWEE9067-G

Added

4D56 ENGINE <1994 –> –

Fuel Injection Pump and Injection Nozzle

11B-5-7

NOTE The injection timing can be known from the identification mark stamped on the cylinder head at the position shown in the illustration.

Identification mark

Identification mark

Injection timing

A or B

7 ATDC

C , D, E, G or H

9 ATDC

° °

DEN0175

When higher than the standard value

Front view

When lower than the standard value

(7) If dial indicator reading is not within the standard value range, tilt the injection pump body to the right or left until the reading is within the standard value range. Then, temporarily tighten the injection pump nuts and bolts. (8) Repeat Steps (5) and (6) to make sure that the adjustment has been correctly performed. (9) Tighten the injection pump mounting bolts and nuts to the specified torque. (10)Remove the dial indicator and the special tool.

DEN0107

(11)install new copper gasket and plug, then tighten the plug to specified torque. Copper gasket

Plug

DFU0013


PWEE9067-H

Revised

NOTES

4D56 ENGINE <1994 –>– Intake and Exhaust Manifolds

11B-7-1

7. INTAKE AND EXHAUST MANIFOLDS REMOVAL AND INSTALLATION Engines without turbocharger (Up to 1998 models for L200)

1

2

18 1.8 13 14 1.4 10 3

4 5 N

18 1.8 13

Removal steps 1. E ngine hange r 2. Intake m anifold 3. H eat protector 4. E xhau st m anifold 5. M anifold gasket

DEN0308


PWEE9067-G

Revised

11B-7-1a

4D56 ENGINE <1994 –> – Intake and Exhaust Manifolds

Engines without turbocharger (From 1999 model L200)

25 2.5 18

5

7 8 N

N 6

11 1.1 8

18 1.8 13

2 1

N 4

11

19 1.9 14 10

18 1.8 13

3

18 1.8 13 17 1.7 12

18 1.8 13 13

17 1.7 12

4 N

9 N 12

15

14 1.4 10

14

18 1.8 13 16 17 N

Removal steps 1.Vacuum pipe and hose assem bly 2.Vacuum pipe and hose assem bly 3.EG R pipe 4.G asket 5.EG R valve 6.G asket 7.A ir intake fitting 8.G asket

E ng ine s w ith EG R system

9.Intake m an ifold stay front 10.Intake m anifold stay rear 11 .Intake m anifold u pp er 12 .Intake m anifold gasket 13.Engine hange r 14 .Intake m anifold low er 15 .H eat protector 16 .Exh aust m anifold 17 .M anifold g asket

DEN0331


PWEE9067-G

Revised

11B-7-1b

4D56 ENGINE <1994–> – Intake and Exhaust Manifolds

Engines with turbocharger 11 1.1 8

29

8

25 2.5 18

N 9

49 5.0 36 30

31

12 1.2 9

42 4.3 31 N 28 10 11 N

32 N

27

18 1.8 13 33

34

10 1.0 7

42 4.3 31

2

18 1.8 13

1

9 0.9 7

12

7N

19 1.9 14

9 0.9 7

6

13

5

17 1.7 12

181.813

23

36

35

3

N 7

9 0.9 7

14 1.4 10

37 N

17 1.7 12 9 0.9 7

15 17

4

N 16

18 1.8 13

202.014 N 23

21

59 6.0 43

25 22

59 6.0 43

14

N 19

9 0.9 7

18

14 1.4 10 26 N

20 Disassembly steps 1.Vacuum pipe and hose assem bly (L2 00 ) 2.Vacuum pipe and hose assem bly (L2 00 ) 3.B oo st ho se 4.Snap ring 5.W aste gate actuator 6.EG R pipe E ng ine s w ith 7.G asket 8.EG R valve EG R system 9.G asket 10 .E yeb olt 11.G asket 12 .W ater pipe 13.H eat protector A 14.H eat protector C EAF 15 .E yeb olt 16.G asket 17.O ilpipe 18.O ilreturn pipe G Mitsubishi Motors Corporation May 2001

19.G asket 20 .O ilho se 21.A ir hose (E ngines w ithout interco oler) 22.Exh au st fitting 23.Stay 24.G asket 25 .Tu rbo charge r assem bly 26.G asket 27 .E yeb olt 28.G asket 29 .W ater pipe 30.R elief valve 31.A ir inlet fitting E ng ine s w itho ut 32.G asket 33 .E ng ine hang er interco oler 34.Intake m anifold 35 .H eat protector 36 .E xhaust m anifold 37 .M anifold g asket DEN0332

PWEE9067-G

Revised

11B-7-2


Engines with turbocharger

9

49 5.0 36

30

19 1.9 14

29 18 1.8 13 32

N 31

28 3

25 2.5 18

42 4.3 31

N 10

11 N 27 12 N

42 4.3 31

N 8

17 1.7 12

18 1.8 13 9 0.9 7

9 0.9 7 18

17 1.7 12

7

171.712

20 2.0 14 13

1

33

26

34

22 2.2 16

8N 35 36 N

14

2

16

59 6.0 43

N 17

22

N 23

59 6.0 43

9 0.9 7 18 1.8 13

24

59 6.0 43 4 6

5 15 N 20 19

12 1.2 9 9 0.9 7

25 N

14 1.4 10

21

Disassembly steps 1.A ir pipe 2.A ir pipe bracket 3.A ir intake hose 4.B oo st hose 5.Snap pin 6.W aste gate actuator 7.EG R pipe 8.G asket 9.EG R valve 10.G asket 11 .E yeb olt 12.G asket 13 .W ater pipe 14 .Turbo chargr he at protector 15.Exh aust fitting heat protector EAF 16 .E yeb olt 17.G asket 18.O ilpipe

19.O ilreturn pipe 20.G asket 21 .O ilho se 22.Exh au st fitting 23.G asket 24 .Tu rbo charge r assem bly 25.G asket 26 .E yeb olt 27.G asket 28 .W ater pipe 29.R elief valve 30.A ir intake fitting 31.G asket 32 .E ng ine hang er 33.Intake m anifold 34 .H eat protector 35 .E xhaust m anifold 36 .M anifold g asket D E N 0 3 30


PWEE9067-G

Revised

4D56 ENGINE

11B-7-2a

<1994 –> – Intake and Exhaust Manifolds


11 1.1

18 1.8 13

8

36

25 2.5 18

11 1.1

8

22 2.2 16

19 N

14

9

N 9

0.9

7

0.9

40

0.9

29

N 30

42

43

44 N

41

20 2.0 14 9

7

3 33

25 59 6.0 43

10 1.0

7 18 1.8 13

23

4

N 34

34 N

17 1.7 12

N 24

59 6.0 43

39 N

17 1.7 12

12 N 13 35 9

21 17 1.7 12

38

22 2.2 16

17 1.7 12

19 N

17

N2

11 N

42 4.3 31 N 11

20

37 N

18 1.8 13

42 4.3 31

18 8

10

24 2.4 17

1

17 1.7 12

16

15 N

14 1.4 10

7 18 1.8 13

31 59 6.0 43

5 6 7

22 N 27

12 1.2 9

26

9 0.9

7

32 N

14 1.4 10

28

Disassembly steps 1. Air temperature sensor 2. Gasket 3. Vacuum pipe and hose assembly 4. Solenoid valve assembly 5. Boost hose 6. Snap pin 7. Waste gate actuator 8. Water pipe and hose 9. O-ring 10. EGR upper pipe 11. Gasket 12. EGR valve 13. Gasket 14. Eyebolt 15. Gasket 16. Water pipe B 17. Water hose 18. Eyebolt 19 Gasket 20. Water pipe A 21. Turbocharger heat protector 22. Heat protector C

EAF

23. Eyebolt 24. Gasket 25. Oil pipe 26. Oil return pipe 27. Gasket 28. Oil hose 29. Exhaust fitting 30. Gasket 31. Turbocharger assembly 32. Gasket 33. EGR lower pipe 34. Gasket 35. EGR cooler 36. Air intake fitting 37. Gasket 38. Throttle body 39. Gasket 40. Engine hanger 41. Heat protector 42. Intake manifold 43. Exhaust manifold 44. Manifold gasket DEN0365


PWEE9067-H

Revised

11B-7-2b


Intensionally b lan k

G Mitsubishi Motors Corporation Feb. 2000

PWEE9067-E

Added

4D56 ENGINE

11B-7-4a


Engines with variable geometry turbocharger 11 1.1

18 1.8 13

8 25 2.5 18

11 1.1

13

8

17

16

7

11

18 1.8 13

42 4.3 31

5 14

42 4.3 31

0.9

N 6 14 1.4 10

7

9

59 6.0 43

0.9

29 18 1.8 13

39

40 N

37 0.9

7

18 1.8 13

28 N

7

3

7

20 2.0 14

27

9

N 30

30 N

7

23

N 22

N 25

10 1.0

38

17 1.7 12

17 1.7 12

21

4

35 N

36

0.9

18 17 1.7 12

22 2.2 16

9 N 10 31 9

33 N

N 2

34

N 8 9

24 2.4 17

8 N

17 1.7 12

N 16 15

32

1

17 1.7 12

N 12

22 2.2 16

N

14 1.4 10

24 26 19

14 1.4 10

20 14 1.4 10

Disassembly steps 1. Air temperature sensor 2. Gasket 3. Vacuum pipe and hose assembly 4. Solenoid valve assembly 5. Water pipe and hose ECF ECF 6. O-ring EBF 7. EGR upper pipe 8. Gasket 9. EGR valve 10. Gasket 11. Eyebolt 12. Gasket 13. Water pipe B 14. Water hose 15. Eyebolt 16. Gasket 17. Water pipe A 18. Turbocharger upper heat protector 19. Turbocharger lower heat protector 20. Heat protector

EAF

21. Eyebolt 22. Gasket 23. Oil pipe 24. Oil return pipe 25. Gasket 26. Oil return hose 27. Turbocharger assembly 28. Gasket 29. EGR lower pipe 30. Gasket 31. EGR cooler 32. Air intake fitting 33. Gasket 34. Throttle body 35. Gasket 36. Engine hanger 37. Heat protector 38. Intake manifold 39. Exhaust manifold 40. Manifold gasket

Caution • Never disassemble the turbocharger. Performance of the turbocharger will be seriously impaired by disassembling. DEN0362


PWEE9067-H

Revised

11B-7-4b

4D56 ENGINE


Engines with variable geometry turbocharger 11 1.1

8 18 1.8 13 25 2.5 18

11 1.1

16

8

N 15

22 2.2 16

N

20

19

8

10

14

18 1.8 13

42 4.3 31

N 19 18 42 4.3 31

14 1.4 10

9

21

6

N 34 3

7

33

17 1.7 12

18 1.8 13

23

17 1.7 12

25

N 24

9

0.9

22 2.2 16

43 44 N 1

41

20 2.0 14

31

7

42

17 1.7 12

34 N

10 1.0

39 N

40

0.9

7

38

22 2.2 16

N 13 35

N 9

37 N

N 5

11 N

N 11 12

24 2.4 17

36

4

17 1.7 12

17 1.7 12

17

14 1.4 10

7

N 30

2

29

32 N

18 1.8 13

27 N 19 1.9 14

26

9

59 6.0 43

22

0.9

7

28

14 1.4 10

Disassembly steps 1. Air pipe 2. Air pipe bracket 3. Air hose 4. Air temperature sensor 5. Gasket 6. Vacuum pipe and hose assembly 7. Solenoid valve assembly 8. Water pipe and hose ECF ECF 9. O-ring EBF 10. EGR upper pipe 11. Gasket 12. EGR valve 13. Gasket 14. Eyebolt 15. Gasket 16. Water pipe B 17. Water hose 18. Eyebolt 19. Gasket 20. Water pipe A 21. Turbocharger heat protector 22. Exhaust fitting heat protector

EAF

23. Eyebolt 24. Gasket 25. Oil pipe 26. Oil return pipe 27. Gasket 28. Oil return hose 29. Air inlet fitting 30. Gasket 31. Turbocharger assembly 32. Gasket 33. EGR lower pipe 34. Gasket 35. EGR cooler 36. Air intake fitting 37. Gasket 38. Throttle body 39. Gasket 40. Engine hanger 41. Heat protector 42. Intake manifold 43. Exhaust manifold 44. Manifold gasket

Caution • Never disassemble the turbocharger. Performance of the turbocharger will be seriously impaired by disassembling. DEN0363


PWEE9067-H

Revised

4D56 ENGINE

11B-7-4c


Engines with variable geometry turbocharger

11 1.1

5

8 25 2.5 18

11 1.1

8

14

22 2.2 16

N 17

12

8

15

42 4.3 31

9

0.9

7

7 N 14 1.4 10

0.9

19

35 N

30 N

5 10 1.0

7

38

17 1.7 12

N 30 4

7

29

17 1.7 12

21

17 1.7 12

34 36

N 9 10 N 11 31 9

33 N

N 3

22 2.2 16

17 1.7 12

N 17 16

24 2.4 17

2

9 N

6

18 1.8 13

32

18 1.8 13

42 4.3 31

1

4

14 1.4 10

17 1.7 12

13 N 18

0.5

39

18 1.8 13

40 N

23

N 22

37

20 2.0 14

27

9

0.9

7 18 1.8 13

59 6.0 4.3

28 N 25 N 24

9

0.9

7

26 20

14 1.4 10

Disassembly steps 1. Boost sensor 2. Air temperature sensor 3. Gasket 4. Vacuum pipe and hose assembly 5. Solenoid valve assembly ECF 6. Water pipe and hose 7. O-ring ECF EBF 8. EGR upper pipe 9. Gasket 10. EGR valve 11. Gasket 12. Eyebolt 13. Gasket 14. Water pipe B 15. Water hose 16. Eyebolt 17. Gasket 18. Water pipe A 19. Turbocharger upper heat protector 20. Turbocharger lower heat protector

EAF

21. Eyebolt 22. Gasket 23. Oil pipe 24. Oil return pipe 25. Gasket 26. Oil return hose 27. Turbocharger assembly 28. Gasket 29. EGR lower pipe 30. Gasket 31. EGR cooler 32. Air intake fitting 33. Gasket 34. Throttle body 35. Gasket 36. Engine hanger 37. Heat protector 38. Intake manifold 39. Exhaust manifold 40. Manifold gasket

Caution • Never disassemble the turbocharger. Performance of the turbocharger will be seriously impaired by disassembling. G Mitsubishi Motors Corporation Apr. 2002

PWEE9067-H

DEN0352 Added

11B-7-4d

4D56 ENGINE


Intensionally blank


PWEE9067-H

Added

4D56 ENGINE


11B-7-5

INSPECTION EGR VALVE (1) Remove, the EGR valve and check it for sticking, deposit of carbon, etc. If such condition exists, clean with adequate solvent to ensure correct valve seat contact.

(2) Connect a hand vacuum pump to the EGR valve. (3) Apply a vacuum of 500 mmHg (19.7 in.Hg) and check air tightness. (4) Blow in air from one passage of the EGR to check condition as follows.

3EM135

Vacuum

Normal condition

20 mmHg (0.8 in.Hg) or lower

Air does not blow through

570 mmHg (22.4 in.Hg) or higher

Air blows through

(5) Replace the gasket with a new one and tighten the EGR valve to specified torque.

INSTALLATION SERVICE POINTS EAF

EYEBOLT INSTALLATION

(1) Before installing the oil pipe eyebolt (at top of the turbocharger), fill the turbocharger with clean engine oil. INSPECTION OF WASTE GATE ACTUATOR OPERATION (1) After installation of the actuator, check that the rod moves when approx. 83 kPa (0.84 kg/cm 2, 11.9 psi) or approx. 92 kPa (0.94 kg/cm 2, 13.4 psi) is applied to the actuator using a tester. Caution The diaphragm may break if a pressure exceeding 88 kPa (0.9 kg/cm 2, 12.8 psi) or 108 kPa (1.1 kg/cm 2, 15.6 psi) is applied. •

DIN023

G Mitsubishi Motors Corporation Feb. 1995

PWEE9067-A

Added

11B-7-6

4D56 ENGINE


Projection

EGR UPPER PIPE INSTALLATION

(1) Position the projection as shown in the illustration.

EGR upper pipe

Projection

EBF

DEN0342

ECF

Water pipe

WATER PIPE AND HOSE / O-RING INSTALLATION

(1) Wet the O-ring (with water) to facilitate assembly. Caution Keep the O-ring free of oil or grease. •

O-ring


6EN0594

PWEE9067-H

Added

NOTES

11B-9-1

4D56 ENGINE <1994 –> – Water Pump, Thermostat, Hose and Pipe

9. WATER PUMP, THERMOSTAT, HOSE AND PIPE REMOVAL AND INSTALLATION Engines without throttle body 1

14 1.4 10

2 3

4

11 1.1

N 6

8

5

14 1.4 10

7

14 1.4 10

34 3.5 25

13 14 N

16 N 11 12 15 24 2.4 17

N 10

14 1.4 10

9

8

12 1.2

Removal steps 1. Water hose with 2. Water pipe turbocharger 3. Water hose 4. Water hose 5. Water pipe EDF 6.O-ring ECF 7. Engine coolant temperature gauge unit 8. Engine hanger

9

9. Water outlet fitting 10. Gasket 11. Water inlet fitting EAF 12. Thermostat 13. Thermostat housing 14. Gasket 15. Water pump 16. Gasket DEN0142


PWEE9067-H

Revised

11B-9-1a

4D56 ENGINE <1994 –> – Water Pump, Thermostat, Hose and Pipe

Except engines without throttle body

1 2

3

4 5

6

14 1.4 10

11 1.1 8

N 7 8 12

34 3.5 25

13 14

15 N

17 N

12 1.2 9 12 1.2 9

10 1.0 7 10

16

24 2.4 17 14 1.4 10 11 N 9

Removal steps 1.H ose protector 2.W ater hose 3.W ater pipe 4.W ater hose 5.W ater hose 6.W ater pipe EDF 7.O -ring ECF 8.C oo lant tem pe rature gau ge un it 9.En gine han ge r

10.W ater outlet fitting 11.G asket 12.W ater inlet fitting EBF 13.Therm ostat 14.Plate 15.G asket 16.W ater pum p 17.G asket

D E N 0 3 04


PWEE9067-G

Revised

11B-9-1b

4D56 ENGINE <1994–> – Water Pump, Thermostat, Hose and Pipe Except engines with throttle body

1

2

14 1.4 10

4 3

5

11 1.1 8 6 10

34 3.5 25

11 12

13 N

15 N

12 1.2 9 12 1.2 9

10 1.0 7 24 2.4 17

8

14

14 1.4 10 9 N 7

Removal steps 1.H ose protector 2.W ater hose 3.W ater pipe 4.W ater hose 5.W ater pipe an d ho se EDF 6.C oo lant tem pe rature gau ge un it 7.En gine han ge r 8.W ater outlet fitting

9.G asket 10.W ater inlet fitting EBF 11.Therm ostat 12.Plate 13.G asket 14.W ater pum p 15.G asket

DEN0336


PWEE9067-G

Revised

11B-9-2

4D56 ENGINE

<1994 –>

– Water Pump, Thermostat, Hose and Pipe

Except engines without throttle body

1 2

3

4 5

6

14 1.4 10

11 1.1

N 7 8 12

34 3.5 25

13 14

12 1.2

8

15 N

17 N

9 10 1.0

12 1.2

7

9

10

16 24 2.4 17 14 1.4 10

11 N 9

Removal steps 1. Hose protector 2. Water hose 3. Water pipe 4. Water hose 5. Water hose 6. Water pipe EDF 7. O-ring ECF 8. Engine coolant oolant temperature gauge unit

9. Engine hanger 10. Water outlet fitting 11. Gasket 12. Water inlet fitting EBF 13. Thermostat 14.Plate 15. Gasket 16. Water pump 17. Gasket DEN0304


PWEE9067-H

Revised

4D56 ENGINE

<1994 –>

11B-9-3


Except engines with throttle body

1

2

14 1.4 10

4 3

34 3.5 25

5 11 1.1

11

6

12 13

12 1.2

8

14 N

16 N

9 11 1.1 10 1.0

8

7

24 2.4 17

9

15

7

14 1.4 10

10 N 8 12 1.2

Removal steps 1. Hose protector 2. Water hose 3. Water pipe 4. Water hose 5. Water pipe and hose EFF 6. Engine coolant temperature gauge unit EEF 7. Engine coolant temperature sensor 8. Engine hanger

9

9. Water outlet fitting 10.Gasket 11. Water inlet fitting EBF 12. Thermostat 13.Plate 14.Gasket 15. Water pump 16.Gasket

DEN0364


PWEE9067-H

Revised

11B-9-4

4D56 ENGINE

<1994 –>


Engines with throttle body

1 14 1.4 10

2

3

4

14 1.4 10

5 14 1.4 10

34 3.5 25

11 1.1

6

8

14 1.4 10

13 14

11

16 N

12 11 1.1

24 2.4 17

15

7

9

14 1.4 10

8

10 N 8 12 1.2

Removal steps 1. Hose protector 2. Water hose 3. Water pipe 4. Water hose 5. Water pipe and hose EFF 6. Engine coolant temperature gauge unit EEF 7. Engine coolant temperature sensor 8. Engine hanger

9

9. Water outlet fitting 10. Gasket 11. Water inlet fitting EAF 12. Thermostat 13. Thermostat housing 14. Gasket 15. Water pump 16. Gasket

DEN0353


PWEE9067-H

Added

4D56 ENGINE

<1994 –>


11B-9-5

INSTALLATION SERVICE POINTS 90°

EAF Thermostat housing

Rubber ring

Thermostat bridge Thermostat

THERMOSTAT INSTALLATION

(1) Install the thermostat respecting the shown angle and being careful not to tear off or damage its rubber ring. Caution Never adhere oils and greases on the rubber ring of the thermostat. •

DEN0172

Marking

EBF

THERMOSTAT INSTALLATION

(1) Install the thermostat with its marking positioned at the top.

Thermostat 04E0010

ECF

ENGINE COOLANT TEMPERATURE GAUGE UNIT INSTALLATION

(1) Apply sealant to threads. Specified sealant: 3M Nut locking Part No. 4171 or equivalent

O-ring

EDF

O-RING INSTALLATION

(1) Set the O-ring in the groove of the water pipe and apply water to the outer circumference of the O-ring. Caution Never adhere oils and greases on the O-ring. •

6CO035

EEF

ENGINE COOLANT TEMPERATURE SENSOR INSTALLATION

(1) When reusing the sensor, apply the specified sealant to the threads. Specified sealant: 3M Nut locking Part No. 4171 or equivalent

6AE0070


PWEE9067-H

Added

11B-9-6

4D56 ENGINE

<1994 –>


EFF

ENGINE COOLANT TEMPERATURE GAUGE UNIT INSTALLATION

(1) Apply the specified sealant to the threads. Specified sealant: 3M ATD Part No. 8660 or equivalent

6AE0071


PWEE9067-H

Added

11B-11-1

4D56 ENGINE <1994 –>– Cylinder Head and Valves

11. CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION 11812.0 87 5 6

1

7 11 N 10 N 13

2

29 3.0 22 + 120°to124°

12 N 3

16

14 N N 15 8 4N

9

Removal steps FAE EEF 1.C ylinder head bolt 2.C ylind er he ad b olt w asher 3.C ylind er head assem bly EDF 4.C ylind er he ad g asket FBE ECF 5.Valve sp ring retainer lock 6.Valve spring retainer EBF 7.Valve spring 8.Intake valve 9.Exhaust valve FCE EAF 10 .V alve stem seal 11 .S pring seat 12.Intake valve guide 13 .E xhaust valve gu ide 14 .E xhaust valve seat 15.C ylinder head

Lubricate all internal parts w ith engine oilduring reassem bly.

D E N 0 15 1


PWEE9067-G

Revised

11B-11-6

4D56 ENGINE

<1994 –> – Cylinder Head and Valves

MD998772

DEN0152

ECF RETAINER LOCK INSTALLATION

Caution The valve spring, if excessively compressed, causes the bottom end of the retainer to be in contact with, and damage, the stem seal. •

MD998303

DEN092

EDF CYLINDER HEAD GASKET INSTALLATION

Timing belt side

(1) In case any of the cylinder block, piston, connecting rod and crankshaft has not been replaced, install the gasket of the same rank as before which can be identified by the mark shown in the illustration at left.

Identification mark

Rank A

Rank B

Rank C

Rank D

Identification hole

Rank E DEN0344

Timing belt side Identification mark

Rank C

Rank D

Rank E

Identification hole

1

2 3

4 5

6 7

DEN0345

8

Reference for measurement Protrusion measuring locations (with each piston at top dead center)


DEN0156

(2) In case any of the cylinder block, piston, connecting rod and crankshaft have been replaced, reselect and install the gasket in accordance with the following procedure. 1) With each piston held at the top dead center, measure its protrusion from the upper block surface at the locations shown in the illustration at left (total of eight locations). Be sure to take measurements on the crankshaft center line. 2) Using the average of the eight measurements, select the gasket rank (A, B, C, D or E) in accordance with the table given below. If, however, the maximum protrusion at any one location exceeds the protrusion tolerance shown for any rank in the following table, use the gasket one rank higher that rank. PWEE9067-H

Revised

4D56 ENGINE

<1994 –> – Cylinder Head and Valves

11B-11-7

Protrusion

DEN0798

Engines without turbocharger

mm (in.)

Average value of piston protrusions

Protrusion tolerance for each rank

Thickness of selected gasket (when tightened)

Identification mark

A

0.562 – 0.620 (0.0221 – 0.0244)

0.670 (0.0264)

1.35 ± 0.05 (0.0531 ± 0.0020)

135

B

0.620 – 0.680 (0.0244 – 0.0268)

0.730 (0.0287)

1.40 ± 0.05 (0.0551 ± 0.0020)

140

C

0.680 – 0.774 (0.0268 – 0.0293)

0.794 (0.0313)

1.45 ± 0.05 (0.0571 ± 0.0020)

145

Rank


mm (in.)

Average value of piston protrusions

Protrusion tolerance for each rank

Thickness of selected gasket (when tightened)

Identification mark

C

0.562 – 0.620 (0.0221 – 0.0244)

0.670 (0.0264)

1.45 ± 0.05 (0.0571 ± 0.0020)

145

D

0.620 – 0.680 (0.0244 – 0.0268)

0.730 (0.0287)

1.50 ± 0.05 (0.0590 ± 0.0020)

150

E

0.680 – 0.774 (0.0268 – 0.0293)

0.794 (0.0313)

1.55 ± 0.05 (0.0610 ± 0.0020)

155

Rank

NOTE If the piston projection exceeds the tolerance, replace the piston, connecting rod, crankshaft or cylinder block and check again. EEF

CYLINDER HEAD BOLT INSTALLATION

(1) Set the cylinder head bolt washer with its shear droop toward the bolt head. (2) Apply engine oil to the bolt threads and washer.

(3) Using the special tool and torque wrench, tighten bolts in the shown sequence.

Timing belt side

DGE033


PWEE9067-H

Revised

11B-11-8

4D56 ENGINE <1994 –> – Cylinder Head and Valves (4) R ep e at th e tigh ten in g se qu en ce se ve ral tim es , an d tighten the bolts to 118 N m (12.0 kgm , 87 ft.lbs.) in the finalsequence.

< W ith throttle body> (1) S et the cylinder head bolt w ash er w ith its sh ear droop tow ard the bo lt he ad. (2) A pply engine o ilto the b olt threads and w ashers.

(3) R etigh ten the loo sene d bo lts to a torqu e of 29 N m (3.0 kg m , 22 ft.lbs.) in the specified tightening sequence .

(4) G ive a 12 0 ° turn to the bolts in the sp ecified tightening sequence.

M B 9 91 61 4

Caution If the bolts are tightened by an angle of less than 120°, they may not hold the cylinder head with sufficient strength. If a bolt is overtightened, completely remove all the bolts and carry out the installation procedure again from step (1). •

12 0 °

•

6AE0339


PWEE9067-G

Added

11B-12-1

4D56 ENGINE <1994 –>– Front Case and Oil Pan

12. FRONT CASE AND OIL PAN REMOVAL AND INSTALLATION 14 1.4 10 5N 1 A pply engine oilto allm oving parts before installation.

37 N 36

2

54 5.5 40 3

4

10 1.0 7 21 N

35

24 2.4 17 36 3.7 27

20

32 19

30

31 14 34

24 2.4 17 17

19 1.9 13

12 1.2 9

18 N

28

29

27

13 1.3 9

9 0.9 7 33 N

24 2.4 17

13

39 16

26

13 1.3 9

38 15 N

32 3.3 24

10 24 N

22 N

40 N

25 23

9 N8

11

7 0.7 5

37 3.8 27

7

N 12

6

39 4.0 29

9 0.9 7 19 1.9 14 Removal steps EK F 1.O ilfilter 2.O ilco oler by-pass valve E J F 3.O ilpressu re sw itch 4.O ilfilter bracket 5.O ilfilter bracke t gaske t 6.O ilpan co ver < w ith variable ge om etry turbo charge r> 7.O ildrain plug E IF 8.O ildrain p lug gasket 9.O illevel senso r < P A JE R O > FAE EHF 10.O ilpan 11.O ilscreen 12 .O ilscree n g asket 13.Stiffener 14 .Fron t up pe r case 15 .Fron t up pe r case g asket 16.O ilseal 17 .P lug cap 18.O -ring FBE EGF 19 .Flange bo lt 20 .Fron t low er case

EFF

FCE EEF FCE EEF EDF EDF ECF

FDE EBF EAF

21 .Fron t low er case g asket 22.C ran ksh aft front oilseal 23 .P lug 24.G asket 25.R elief sp ring 26.R elief plunger 27.O ilpum p cover 28.Inner rotor 29 .O uter rotor 30 .B alancer shaft ge ar cover 31.B alancer shaft driven g ear 32.B alancer shaft drive gear 33.O ilseal 34 .O ilpu m p g ear drive shaft 35.B alan ce r sh aft, left 36.B alan ce r sh aft, right 37.B alancer shaft bearing 38 .C he ck valve 39.O iljet 40.G asket DEN0338


PWEE9067-G

Revised

11B-12-1a

4D56 ENGINE <1994 –>– Front Case and Oil Pan


10 1.0 7

37 N 36

4

2

54 5.5 40 A pply e ngine oilto allm oving parts before installation.

11 1.0 7

3

5N 37 N

23 2.3 1.7 35 1

36 3.7 27

24 2.4 17 30

34

19 31

20

13

32

24 2.4 17

21 N

19 1.9 13

12 1.2 9

18 N 33 N 17

29

28

N 15

38

13 1.3 9

24 2.4 17

22 N

13 1.3 9

26 25 24 N 23

39

N 40

27

32 3.3 24

15 N 9

14

10

9 0.9 7

37 3.8 27 7 0.7 5

N 12

11 6

19 1.9 14

Removal steps EK F 1.O ilfilter 2.O ilco oler by-pass valve E J F 3.O ilpressu re sw itch 4.O ilfilter bracket 5.O ilfilter bracke t gaske t 6.O ilpan cover (from 2002 m ode l) 7.O ildrain plug E IF 8.O ildrain plug g aske t 9.O illeve lsenso r FAE EHF 10.O ilpan 11.O ilscreen 12 .O ilscree n g asket 13.Stiffener 14 .Fron t up pe r case 15 .Fron t up pe r case g asket 16.O ilseal 17 .P lug cap 18.O -ring FBE EGF 19 .Flang e bo lt 20 Front low er case G Mitsubishi Motors Corporation May 2001

8N 7

39 4.0 29

9 0.9 7

EFF

FCE EEF FCE EEF EDF EDF ECF

FDE EBF EAF

21 .Fron t low er case g asket 22.C ran ksh aft front oilse al 23 .P lug 24.G asket 25.R elief sp ring 26.R elief plunger 27.O ilpum p cover 28.Inner rotor 29 .O uter rotor 30 .B alancer shaft ge ar cover 31.B alancer shaft driven gear 32.B alancer shaft drive gear 33.O ilseal 34 .O ilpu m p g ear drive shaft 35.B alan ce r sh aft, left 36.B alan ce r sh aft, right 37.B alan ce r sh aft bearing 38 .C he ck valve 39.O iljet 40.G asket DEN0339

PWEE9067-G

Revised

NOTES

4D56 ENGINE

<1994 –>

– Piston and Connecting Rod

11B-13-1

13. PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION

7 8 9 12 11

4

10

14

5

6 13

Lubricate all internal parts with engine oil during reassembly.

3 2 46 4.7 34

1

27 2.8 20 + 90° – 94°

Removal steps EEF 1.Nut FAE EDF 2.Connecting rod cap 3.Connecting rod bearing ECF 4.Piston and connecting rod assembly 5.Connecting rod bearing 6.Bolt EBF 7.Piston ring No. 1 EBF 8.Piston ring No. 2 ECF 9. Oil ring EBF 10.Snap ring EAF 11.Piston pin EAF 12.Piston EAF 13.Connecting rod 14.Bushing DEN0039


PWEE9067-H

Revised

11B-13-4

4D56 ENGINE

<1994 –>


CONNECTING ROD BUSHING REPLACEMENT PROCEDURE (1) Using Connecting Rod Bushing Remover and Installer (special tool), remove the bushing.

(2) Using the special tool, press-fit the bushing into position. At the time, make sure that the oil hole in the bushing is aligned with that in the connecting rod small end.

(3) Machine the bushing I.D. to the standard value. Bushing I.D. standard value: 29.015 – 29.025 mm (1.1423 – 1.1427 in.) Big-to-small-end center parallelism: 0.05 mm (0.002 in.) Torsion: 0.1 mm (0.004 in.)

INSTALLATION SERVICE POINTS

Timing belt side

EAF CONNECTING ROD / PISTON PIN / PISTON

INSTALLATION (1) When replacing the piston pin, read off the cylinder bore size mark on the cylinder block as illustrated, and select a piston according to the following table.

No. 1

No. 2

No. 3

No. 4 AK200853AB

Cylinder bore size mark A B C

Piston class

Piston size mark

A B C

A None C

NOTE The piston size mark shows on the top of the piston. (2) Mate the piston with the connecting rod. (3) Line up the front marks and insert the piston pin. The piston pin must be smoothly pressed by hand into position. Replace the piston pin if there is an excessive play. G Mitsubishi Motors Corporation Apr. 2002

PWEE9067-H

Revised

4D56 ENGINE Identification mark “2T”, “T2”or “2R”


<1994 –>

Identification mark “1T”, “T1” or “1R” Size mark

No. 1 ring No. 2 ring

11B-13-5

EBF PISTON RING NO. 1 / PISTON RING NO. 2 / OIL

RING INSTALLATION (1) Install the coil expander and the oil ring in the piston. (2) Then, install the piston ring No. 2 followed by piston ring No. 1. Install the rings with their side having identification mark and size mark facing up (on the piston crown side). Identification mark: No. 1 ring “T1”, “1T” or “1R” No. 2 ring “2T”, “T2” or “2R”

9EN0524

ECF PISTON AND CONNECTING ROD ASSEMBLY Coil expander

Timing belt side

No. 2 ring

INSTALLATION

No. 1 ring

(1) Liberally coat engine oil on the circumference of the piston, piston ring, and oil ring. (2) Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in the figure. (3) Rotate crankshaft so that crank pin is on center of cylinder bore.

Piston pin

Oil ring 6EN0549

(4) Use suitable thread protectors on connecting rod bolts before inserting piston and connecting rod assembly into cylinder block. Care must be taken not to nick crank pin. (5) Using a suitable piston ring compressor tool, install piston and connecting rod assembly into cylinder block. Caution Insert with the front mark (arrow) on the piston head directed toward the engine front (timing belt side). •

EDF CONNECTING ROD CAP INSTALLATION

(1) Verifying the mark made during disassembly, install the bearing cap to the connecting rod. If the connecting rod is new with no index mark, make sure that the bearing locking notches come on the same side as shown.

DEN0051

(2) Make sure that connecting rod big end side clearance meets the specification. Standard value: 0.10 – 0.25 mm (0.0039 – 0.0098 in.) Limit: 0.40 mm (0.0157 in.)

DEN0162


PWEE9067-H

Revised

11B-13-6

4D56 ENGINE

<1994 –>


EEF

CONNECTING ROD CAP NUT INSTALLATION (WITH VARIABLE GEOMETRY TURBOCHARGER ONLY)

Caution If the cylinder head has been installed before installing the connecting rod cap nut, be sure to remove the spark plugs. •

Paint mark

90° – 94° Paint mark

Nut

Bolt

6AE0298

(1) Before installation of each nut, apply engine oil to the thread portion and bearing surface of the nut. (2) Install each nut to the bolt and tighten it with fingers. Then tighten the nuts alternately to install the cap properly. (3) Tighten the nuts to a torque of 27 Nm (2.8 kgm, 20 ft.lbs). (4) Make a paint mark on the head of each nut. (5) Make a paint mark on the bolt end at the position 90° to 100° from the paint mark made on the nut in the direction of tightening the nut. (6) Give a 90° to 94° turn to the nut and make sure that the paint mark on the nut and that on the bolt are in alignment. Caution If the nut is turned less than 90°, proper fastening performance may not be expected. When tightening the nut, therefore, be careful to give a sufficient turn to it. If the nut is overtightened (exceeding 94°). loosen the nut completely and then retighten it by repeating the tightening procedure from step (1). •

•


PWEE9067-H

Added

11B-14-1

4D56 ENGINE <1994 –>– Crankshaft and Cylinder Block

14. CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION

A pply engine oilto allm oving parts before installation.

13213.5 98

1

3

9 0.9 7

Head mark “7” 44 4.5 33

4

8

2

Head mark “ 8” 54 5.5 40

11 1.1 8 11

24

N 12 13

10

13213.5 98

6

5 22 7

14 N

9 0.9 7

9

18 25 17

N 21

20

19 N 16 23

15

6 0.6 4 Head mark “7” 44 4.5 33

78 8.8 58

Head mark “8” 54 5.5 40 Removal steps 1.Flyw heel For variable 2.B allbearing M /T geom etry 3.A dap ter plate 4.C rankshaft adapter turbocharger 5.A dap ter plate A /T 6.D rive plate 7.C rankshaft adapter 8.R ear plate 9.Space rubber < PA JER O > 10 .B ellho using cover 11.O ilseal case 12.G asket EDF 13.O ilseparator

14.R ear oilseal 15 .B earing cap 16.C ranksh aft bearing, low er 17 .C ranksh aft EAF 18 .C rankshaft be aring , up pe r 19.O -ring 20.C over 21 .Packing 22.Engine b racket, right 23.Engine bracket, left 24.C ylinder sleeve 25.C ylinder block ECF EBF EAF

DEN0340


PWEE9067-G

Revised

11B-14-1a

4D56 ENGINE <1994 –> – Crankshaft and Cylinder Block


13213.5 98

A pply e ngine oilto allm oving parts before installation.

9 0.9 7 4

21 N

2

M10 44 4.5 33 M8

11 1.1 8

22 2.2 16

3 N 9 19

1

10 5

8

7

N 11

15

9 0.9 7

6

22

N 18 14

17

20 13 16 N

12

6 0.6 4 78 88.0 58 44 4.5 33

Removal steps 1.Flyw hee 2.B allbearing 3.A dapter plate 4.C rankshaft adapter 5.R ear plate 6.Space rubber < PA JER O > 7.B ellho using cover 8.O ilse al case 9.G asket EDF 10.O ilseparator ECF 11.R ear oilseal EBF 12 .B earing cap

13.C ranksh aft bearing, low er 14 .C ranksh aft EAF 15 .C rankshaft be aring , up pe r 16.O -ring 17.Cover 18 .Packing 19.Engine b racket, right 20.Engine bracket, left 21.C ylinder sleeve 22.C ylinder block EAF

DEN0307


PWEE9067-G

Revised

11B-14-2

4D56 ENGINE

<1994 –>

– Crankshaft and Cylinder Block

INSPECTION CRANKSHAFT (1) Measure the outside diameter of journal and inside diameter of crankshaft bearing. If the difference between them (oil clearance) exceeds the limit, replace the crankshaft bearing and, if necessary, crankshaft. When the crankshaft is to be reused by machining to undersize, the crankshaft bearings should be changed to undersized ones. 3EN056

Standard value: 0.02 – 0.05 mm (0.0008 – 0.0020 in.) Limit: 0.1 mm (0.0039 in.)

3EN055

(2) When the crankshaft is machined to undersize, finish the fillets of journals and pins to the specified radius.

2.5 mm R (0.098 in.)

2.5 mm R (0.098 in.)

2.5 mm R (0.098 in.)

CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE METHOD)

Plastic gauge

The crankshaft oil clearance can be measured easily by using a plastic gauge, as follows: (1) Remove oil and grease and any other foreign matters from crankshaft journal and bearing inner surface. (2) Install the crankshaft. (3) Cut the plastic gauge to the same length as the width of bearing and place it on journal in parallel with its axis. 6EN043

(4) Gently place the crankshaft bearing cap over it and tighten the bolts to the specified torque. (5) Remove the bolts and gently remove the crankshaft bearing cap. (6) Measure the width of the smashed plastic gauge at its widest section by using a scale printed on the plastic gauge bag. Standard value: 0.02 – 0.04 mm Limit: 0.1 mm 1EN067


PWEE9067-H

Revised

11B-14-6

4D56 ENGINE

<1994 –>

– Crankshaft and Cylinder Block

(5) Chamfer the cylinder sleeve top end as illustrated.

1 mm Cylinder (0.0394 in.) sleeve

30° DEN244

(6) The service cylinder sleeve has the I.D. machined to 89.9 to 90.1 mm (3.539 to 3.547 in.). After installation of the sleeve, therefore, hone the I.D. to the standard value. Cylinder I.D.: 91.10 – 91.13 mm (3.5866 – 3.5878 in.) Honing finished surface roughness: 2 – 4 m Honing cross hatch angle: 15 – 25° Cylinder bore squareness: 0.05 mm (0.0197 in.)

When Boring the Cylinder Block Sleeve Hole (1) Prepare a cylinder sleeve of 0.5 mm (0.0197 in.) oversize (identification color: red). (2) Hone the cylinder block sleeve hole to 94.025 to 94.050 mm (3.7018 to 3.7027 in.). (3) Install the cylinder sleeve and finish the I.D. The installation and machining procedures are the same as in the case when the block sleeve hole has not been bored.

INSPECTION AFTER ASSEMBLY

Protrusion

(1) After assembling the crankshaft, piston, etc., check the piston protrusion. If the protrusion exceeds the limit, change the combination of piston, connecting rod and cylinder in order to reduce the protrusion to within the limit. (2) If the protrusion still exceeds the limit after piston reassembly, replace the cylinder block. Limit: 0.794 mm (0.0313 in.)

DEN0798


PWEE9067-H

Revised

NOTES

Service Bulletins Click on the applicable bookmark to select the Service Bulletin.

SERVICE BULLETIN QUALITY INFORMATION ANALYSIS OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION

SERVICE BULLETIN Subject: Group:

No.: MSB-00E11-509

Date: 2001-04-09 OMISSION OF INJECTION TIMING IDENTIFICATION MARK ENGINE Draft No.: 00EN600614

CORRECTION

INTERNATIONAL CAR ADMINISTRATION OFFICE

ALL

01-10

T. MASAKI-MANAGER TECHNICAL SERVICE PLANNING

1. Description: Omission of a 4D5 engine injection timing identification mark from the following Workshop Manual, has been rectified. 2. Applicable Manuals: Manual ENGINE 4D5 Workshop Manual

Pub. No. PWEE9067 PWES9068 PWEF9069 PWEG9070 PWED9071 PWEW9072

Language Page(s) (English) 11B-5-7 (Spanish) (French) (German) (Dutch) (Swedish)

3. Details:

4D56 ENGINE <1994-> - Fuel Injection Pump and Injection Nozzle

11B-5-7

NOTE The injection timing can be known from the identification mark stamped on the cylinder head at the position shown in the illustration.

Identification mark

Identification mark A or B C or D

Injection timing 7° ATDC 9° ATDC

or E or G

DEN0175

(7)

When higher than the standard value

Front view

When lower than the standard value

If dial indicator reading is not within the standard value range, tilt the injection pump body to the right or left until the reading is within the standard value range. Then, temporarily tighten the injection pump nuts and bolts. (8) Repeat Steps (5) and (6) to make sure that the adjustment has been correctly performed. (9) Tighten the injection pump mounting bolts and nuts to the specified torque. (10) Remove the dial indicator and and the special tool

DEN0107

(11) Install Install new copper copper gasket and plug, plug, then tighten tighten the plug to specified torque.

Copper gasket

Plug

DFU0013

2

SERVICE BULLETIN QUALITY INFORMATION ANALYSIS OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION

SERVICE BULLETIN

No.: MSB-01E11-003 No.: MSB-01E11-003

Subject:

Date: 2002-04-05 CHANGE IN GLOW PLUG TIGHTENING CONDITION AND ADDITION OF NOTE

Group:

ENGINE

INFORMATION

INTERNATIONAL CAR ADMINISTRATION OFFICE

Draft No.: 01EN509 No.: 01EN509

T.Inoue - Manager SERVICE PUBLICATION

(EC)PAJERO/MON97-10 TERO(V10-40, V60-70) (EC)MONTERO SPORT/PAJERO SPORT(K80W,K90W) (EC)L200/4WD L200(K00-K30, K60-K70) (EC)L300(L30,L60, P00,P10,P40) (EC)L400(PA,PB,PD) (EC)GALANT(E50-80, EA0) (EC)GALANT WAGON(EA0W) (EC)SPACERUNNER/ WAGON(N10,N20, N30,N40) (EC)COLT LANCER/ STATION WAGON(CA0,CB0)

1. Description: On the 4D56 and 4D68 engines, the glow plug tightening condition has been changed, and a note added.

2. Applicable Manuals: Manual ENGINE 4D5 Workshop Manual CD

ENGINE 4D6 (W-E) Workshop Manual CD

ENGINE 4D6 (W-E) Workshop Manual CD

2

Pub. No. PWEE9067 PWES9068 PWEF9069 PWEG9070 PWED9071 PWEW9072 PWEH9903R-D PWEH9903R-D PWEH9903R-D PWEK9904R-D PWEK9904R-D PWEK9904R-D PWEE9073 PWES9074 PWEF9075 PWEG9076 PWED9077 PWEW9078 PWEH9903R-D PWEH9903R-D PWEH9903R-D PWEK9904R-D PWEK9904R-D PWEK9904R-D PWEE9609 PWES9610 PWEF9611 PWEG9612 PWED9613 PWEW9614 PWEH9903R-D PWEH9903R-D PWEH9903R-D PWEK9904R-D PWEK9904R-D PWEK9904R-D

Language Page(s) (English) 11B-3-1, 3-1A, 3-2 (Spanish) (French) (German) (Dutch) (Swedish) (English) (Spanish) (Swedish) (French) (German) (Dutch) (English) 11B-3-1, 3-2 (Spanish) (French) (German) (Dutch) (Swedish) (English) (Spanish) (Swedish) (French) (German) (Dutch) (English) 11B-3-1, 3-2 (Spanish) (French) (German) (Dutch) (Swedish) (English) (Spanish) (Swedish) (French) (German) (Dutch)

Motor 4d56

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