Mitsubishi 4D68 manual

GENERAL INFORMA TION 1 1A-0-3 ..................................... 1. SPECIFICA TIONS 1 1A-1-1 .......................................... SERVICE SPECIFICA TIONS 1 1A-1-1 ............................ REWORK DIMENSIONS 1 1A-1-3 ................................. T ORQUE SPECIFICA TIONS 1 1A-1-4 ............................. NEW TIGHTENING METHOD - B[...]

1 1A-0-2 PWEE9609 E Dec. 1996 Mitsubishi Motors Corporation NOTES[...]

4D68 ENGINE (E - W) - General Information 1 1A-0-3 GENERAL INFORMA TION SECTIONAL VIEW OF ENGINE PWEE9609 E Dec. 1996 Mitsubishi Motors Corporation[...]

4D68 ENGINE (E - W) - General Information 1 1A-0-4 SECTIONAL VIEW OF ENGINE PWEE9609 E Dec. 1996 Mitsubishi Motors Corporation[...]

4D68 ENGINE (E - W) - General Information 1 1A-0-5 GENERAL SPECIFICA TIONS Descriptions Specifications T ype Diesel engine Number of cylinders 4 in-line Combustion chamber Swirl chamber T otal displacement dm 3 1.998 Cylinder bore mm 82.7 Piston stroke mm 93 Compression ratio 22.4 V alve timing Intake valve Opens (BTDC) 20 ° Closes (ABDC) 48 ° Ex[...]

4D68 ENGINE (E - W) - Specifications 1 1A-1-1 1. SPECIFICA TIONS SERVICE SPECIFICA TIONS Item Standard value Limit Drive belt and glow plug Glow plug resistance W 0.5 - Timing belt T iming belt deflection mm 4.0 - 5.0 - T iming belt “B” deflection mm 5.0 - 7.0 - Rocker arms, rocker shaft and camshaft Camshaft cam height mm Intake 41.90 41.40 Ex[...]

4D68 ENGINE (E - W) - Specifications 1 1A-1-2 Item Limit Standard value Oil cooler by-pass valve dimension (L) [by-pass hole closing temperature (97 - 103 ° C or more)] mm 40.0 - Oil pump side clearance Drive gear 0.08 - 0.14 - Driven gear 0.06 - 0.12 - Pistons and connecting rods Piston O.D. mm 82.7 - Piston ring to piston ring groove clearance m[...]

4D68 ENGINE (E - W) - Specifications 1 1A-1-3 REWORK DIMENSIONS Item Standard value Limit Cylinder head, valves and valve springs Cylinder head oversize valve guide hole 0.05 O.S. 13.050 - 13.068 - (both intake and exhaust) mm 0.25 O.S. 13.250 - 13.268 - 0.50 O.S. 13.500 - 13.518 - Cylinder head oversize intake valve seat ring hole mm 0 .3 O.S. 38.[...]

4D68 ENGINE (E - W) - Specifications 1 1A-1-4 TORQUE SPECIFICA TIONS Items Nm Drive belt and glow plug Oil level gauge guide bolt 13 Pulley bolt (for power steering pump drive) 9 Alternator brace bolt 23 Lock bolt 23 Adjusting bolt 10 Alternator pivot nut 44 Crankshaft pulley bolt 25 Glow plug 18 Glow plug nut 1.8 Timing belt T iming belt cover Fla[...]

4D68 ENGINE (E - W) - Specifications 1 1A-1-5 Items Nm Injection nozzle 54 Fuel injection pump bracket nut 23 Intake and exhaust manifold Air temperature sensor 14 Air intake fitting bolt 17 EGR valve bolt 24 EGR pipe bolt and nut 17 T urbocharger heat protector bolt M8 13 M6 11 Exhaust fitting heat protector bolt 13 W ater pipe “A” and “B”[...]

4D68 ENGINE (E - W) - Specifications 1 1A-1-6 Items Nm Adjusting nut 15 Camshaft bearing cap bolt M8 ¢ 25, M8 ¢ 40 20 M8 ¢ 55 29 Cylinder head, valves and valve springs Cylinder head bolt 90 ¯ Fully loosen ¯ 40 + 90 ° +9 0 ° Front case, counterbalance shafts and o il pan Drain plug 39 Oil level sensor bolt 9 Oil pan bolt 7 Oil screen bolt 19[...]

4D68 ENGINE (E - W) - Specifications 1 1A-1-7 NEW TIGHTENING METHOD - BY USE OF BOL TS TO BE TIGHTENED IN PLASTIC AREA A new type of bolts, to be tightened in plastic area, is currently used some parts of the engine. The tightening method for the bolts is dif ferent from the conventional one. Be sure to observe the method described in the text when[...]

4D68 ENGINE (E - W) - Specifications 1 1A-1-8 FORM-IN-PLACE GASKET The engine has several areas where the form-in-place gasket (FIPG) is in use. T o ensure that the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size, continuity and location are of paramount importance. T oo thin a bead c[...]

4D68 ENGINE (E - W) - Special T ools 1 1A-2-1 2. SPECIAL TOOLS T ool Number Name Use MB990767 End yoke holder Holding camshaft sprocket or fuel injection pump when loosening or tightening bolts. Use with MD998719 MB991603 Bearing installer stopper A guide for removal and installation o f counterbalance shaft left rear bearing MD990938 Handle Instal[...]

4D68 ENGINE (E - W) - Special T ools 1 1A-2-2 T ool Use Name Number MD998375 Crankshaft front oil seal installer Installation of crankshaft front oil seal MD998388 Injection pump sprocket puller Removal of injection pump sprocket MD998702 Connecting-rod small-end bushing replacement tool Replacement of connecting-rod small-end bushing MD998705 Sile[...]

4D68 ENGINE (E - W) - Special T ools 1 1A-2-3 T ool Use Name Number MD998776 Crankshaft rear oil seal installer Installation of crankshaft rear oil seal (Use with MB990938) MD998778 Crankshaft sprocket puller Removal of crankshaft sprocket MD998781 Flywheel stopper Holding of flywheel and drive plate MD998783 Plug wrench retainer Removal and instal[...]

4D68 ENGINE (E - W) - Drive Belt and Glow Plug 1 1A-3-1 3. DRIVE BEL T A ND GLOW PLUG REMOV AL AND INST ALLA TION DEN0885 1 2 3 4 5 6 7 8 9 10 11 12 13 Nm 18 Nm 1.8 Nm 44 Nm 10 Nm 23 Nm 9N m 25 Nm Removal steps 1. Oil level gauge 2. O-ring 3. Oil level gauge guide 4. O-ring 5. Drive belt (V -type) 6. Pulley (for power steering pump drive) 7. W ater[...]

4D68 ENGINE (E - W) - Drive Belt and Glow Plug 1 1A-3-2 REMOV AL SERVICE POINTS A A " GLOW PLUG REMOV AL (1) When removing the glow plug, you may loosen using a tool up to the point where one or more threads are left in engagement. Beyond this point, loosen with fingers. Caution D Do not reuse a glow plug that has been dropped from a height of[...]

4D68 ENGINE (E - W) - Timing Belt 1 1A-4-1 4. TIMING BEL T REMOV AL AND INST ALLA TION DEN0886 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 11 N m 45 Nm 18 Nm 11 N m 11 N m 9N m 9N m 9N m 49 Nm 48 Nm 48 Nm 83 Nm 88 Nm 54 Nm 11 8 N m 13 Nm 28 Removal steps 1. T iming belt front upper cover 2. T iming belt front center cove[...]

4D68 ENGINE (E - W) - Timing Belt 1 1A-4-2 REMOV AL SERVICE POINTS A A " TIMING BEL T REMOV AL (1) Using chalk, etc., mark an arrow on the back of t he timing belt to indicate the direction of rotation. This is to ensure correct installation of the belt in case it is reused. (2) Attach a bolt to the front end face of the timing belt tensioner [...]

4D68 ENGINE (E - W) - Timing Belt 1 1A-4-3 A E " CRANKSHAFT BOL T LOOSENING A F " CRANKSHAFT SPROCKET REMOV AL A G " OIL PUMP SPROCKET REMOV AL (1) Before loosening the oil pump sprocket nut (flange nut), remove the timing belt and then the plug at the left side of the cylinder block and insert a Phillips screwdriver [shank diameter [...]

4D68 ENGINE (E - W) - Timing Belt 1 1A-4-4 A I " COUNTERBALANCE SHAFT SPROCKET REMOV AL A J " CRANKSHAFT SPROCKET “B” REMOV AL INST ALLA TION SERVICE POINTS " A A SP ACER INST ALLA TION (1) Install t he spacer with t he chamfered e nd toward t he oil seal. " B A COUNTERBALANCE SHAFT SPROCKET INST ALLA TION " C A TIMING [...]

4D68 ENGINE (E - W) - Timing Belt 1 1A-4-5 (3) Make sure that the pulley center and the bolt center are located as shown in the illustration. (4) More the tensioner “B” in the direction of arrow while lifting with a finger to give a sufficient tension to the tension side of the timing belt. In this condition, tighten the bolt to secure tensione[...]

4D68 ENGINE (E - W) - Timing Belt 1 1A-4-6 " F A INJECTION PUMP SPROCKET NUT TIGHTENING " G A CAMSHAFT SPROCKET BOL T TIGHTENING " H A TIMING BEL T TENSIONER INST ALLA TION (1) Set the tensioner spring ends against the tensioner bracket and the projection of the injection pump bracket. (2) Attach a bolt to the front end face of the t[...]

4D68 ENGINE (E - W) - Timing Belt 1 1A-4-7 (4) Remove the plug on the cylinder block and insert a Phillips screwdriver [shank diameter 8 mm] through the hole. If it can be inserted as deep as 60 mm or more, the timing marks are correctly aligned. If the inserted depth is only 20 - 2 5 mm, turn the oil pump sprocket one turn and realign the timing m[...]

4D68 ENGINE (E - W) - Timing Belt 1 1A-4-8 INSPECTION TIMING BEL TS The timing belts must be checked closely . Should the following defects be evident, replace the belt with a new one. (1) Hardened back surface rubber Glossy , non-elastic, and so hard that n o mark is produced even when scratched by fingernails. (2) Cracked back surface rubber (3) [...]

4D68 ENGINE (E - W) - Glow Plug, Fue l Injec tion Pum p And Inje ct ion Noz zle 1 1A-5-1 5. GLOW PLUG, FUEL INJECTION PUMP AND INJECTION NOZZLE REMOV AL AND INST ALLA TION DEN0887 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 18 Nm 18 Nm 13 Nm 13 Nm 23 Nm 23 Nm 35 Nm 54 Nm 29 Nm 29 Nm 29 Nm 5N m 5N m Removal steps A A "" D A 1. Injectio[...]

4D68 ENGINE (E - W) - Glow Plug, Fue l Injec tion Pum p And Inje ct ion Noz zle 1 1A-5-2 REMOV AL SERVICE POINTS A A " INJECTION PIPE REMOV AL (1) When loosening the union nuts on the injection pump, hold the delivery valve holder on the fuel injection pump head with a spanner to prevent it from rotating along with the union nut. Caution D If [...]

4D68 ENGINE (E - W) - Glow Plug, Fue l Injec tion Pum p And Inje ct ion Noz zle 1 1A-5-3 INST ALLA TION SERVICE POINTS " A A NOZZLE GASKET / HOLDER GASKET INST ALLA TION (1) Clean nozzle holder installation areas of the cylinder head. (2) Fit a new nozzle gasket and holder gasket into the nozzle holder hole in the cylinder head. " B A INJ[...]

4D68 ENGINE (E - W) - Intake and Exhaust Manifolds 1 1A-6-1 6. INT AKE AND EXHAUST MANIFOLDS REMOV AL AND INST ALLA TION DEN0888 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 26 27 28 29 30 23 18 32 36 35 34 37 31 33 39 38 17 Nm 17 Nm 17 Nm 11 N m 11 N m 14 Nm 13 Nm 13 Nm 13 Nm 13 Nm 14 Nm 10 Nm 10 Nm 16 Nm 16 Nm 23 Nm 30 Nm 59 Nm 59 Nm 59 [...]

4D68 ENGINE (E - W) - Intake and Exhaust Manifolds 1 1A-6-2 INST ALLA TION SERVICE POINTS " A A OIL RETURN PIPE GASKET INST ALLA TION (1) Install the oil return pipe gasket in such a way that its projection is located at the illustrated position. " B A EYEBOL T INST ALLA TION (1) Before installing the oil pipe eyebolt (at top of the turbo[...]

4D68 ENGINE (E - W) - W ater Pump, Thermostat, Hose and Pipes 1 1A-7-1 7. W A TER PUMP , THERMOST A T , HOSE AND PIPES REMOV AL AND INST ALLA TION DEN0889 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 9N m 23 Nm 23 Nm 22 Nm 16 Nm 12 Nm 35 Nm 11 N m 45 Nm 13 Nm 19 Nm 12 Nm Removal steps 1. Eyebolt 2. Gasket 3. Oil pipe 4. Gasket 5. Eyebol[...]

4D68 ENGINE (E - W) - W ater Pump, Thermostat, Hose and Pipes 1 1A-7-2 INST ALLA TION SERVICE POINTS " A A THERMOST A T HOUSING INST ALLA TION (1) Apply a 3 mm bead of form-in-place gasket (FIPG) to the mounting surface. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent. " B A W A TER OUTLET FITTING INST ALLA TION (1) [...]

4D68 ENGINE (E - W) - W ater Pump, Thermostat, Hose and Pipes 1 1A-7-3 " F A ENGINE COOLANT TEMPERA TURE GAUGE UNIT INST ALLA TION (1) If the water temperature sensor is to be reused, apply the specified sealant to its thread. Specified sealant: 3M Nut Locking Part No. 4171 or equivalent. PWEE9609 E Dec. 1996 Mitsubishi Motors Corporation DEN0[...]

4D68 ENGINE (E - W) - Rocker Arms, Rocker Shaft and Camshaft 1 1A-8-1 8. ROCKER ARMS, ROCKER SHAFT AND CAMSHAFT REMOV AL AND INST ALLA TION DEN0891 1 2 3 4 5 6 7 8 9 10 11 12 13 29 Nm 29 Nm 20 Nm 20 Nm 15 Nm 6N m 29 Nm 12 12 12 Apply engine oil to all moving parts before installation. Removal steps 1. Breather hose 2. Rocker cover 3. Rocker cover g[...]

4D68 ENGINE (E - W) - Rocker Arms, Rocker Shaft and Camshaft 1 1A-8-2 INST ALLA TION SERVICE POINTS " A A CAMSHAFT BEARING CAP INST ALLA TION (1) Install the bearing caps in the designated position confirming the identification numbers stamped on the cap front. The No.5 cap has no identification number stamped. " B A FRONT , REAR CAMSHAFT[...]

4D68 ENGINE (E - W) - Rocker Arms, Rocker Shaft and Camshaft 1 1A-8-3 V AL VE CLEARANCE ADJUSTMENT (1) T urn the crankshaft clockwise an d align the timing mark on camshaft sprocket with that on the injection pump bracket. (2) Adjust the valve clearance at the points shown in the illustration. (3) Loosen the adjusting screw lock nut. (4) Using a th[...]

4D68 ENGINE (E - W) - Rocker Arms, Rocker Shaft and Camshaft 1 1A-8-4 (5) While holding the adjusting screw with a screwdriver , tighten the lock nut. (6) Rotate clockwise the crankshaft one complete turn (360 degrees). (7) Adjust the valve clearance at the points shown in the illustration. (8) Repeat steps (3) to (5) to adjust the valve clearance [...]

4D68 ENGINE (E - W) - Cylinder Head, V alves and V alve Springs 1 1A-9-1 9. CYLINDER HEAD, V AL VES AN D V AL VE SPRINGS REMOV AL AND INST ALLA TION DEN0777 Apply engine oil to all moving parts before installation. Removal steps A A "" E A 1. Cylinder head bolt 2. Cylinder head assembly " D A 3. Cylinder head gasket A B "" [...]

4D68 ENGINE (E - W) - Cylinder Head, V alves and V alve Springs 1 1A-9-2 REMOV AL SERVICE POINTS A A " CYLINDER HEAD BOL T REMOV AL (1) Using a 12 mm - 12 points socket wrench, loosen the cylinder head bolts. A B " RET AINER LOCK REMOV AL (1) Store removed valves, springs and other parts, tagged to indicate their cylinder No. and location[...]

4D68 ENGINE (E - W) - Cylinder Head, V alves and V alve Springs 1 1A-9-3 " C A RET AINER LOCK INST ALLA TION (1) The valve spring, if excessively compressed, causes the bottom end of the retainer to be in contact with, and damage, the stem seal. " D A CYLINDER HEAD GASKET INST ALLA TION (1) In case any of the cylinder block, piston, conne[...]

4D68 ENGINE (E - W) - Cylinder Head, V alves and V alve Springs 1 1A-9-4 (3) Using the special tool (MB991654) a nd according to the tightening sequence, tighten the bolts to the specified torque. T ightening torque: 90 Nm (4) Loosen all bolts fully . (5) Retighten the loosened bolts to a torque of 40 Nm in the specified tightening sequence. (6) Ma[...]

4D68 ENGINE (E - W) - Cylinder Head, V alves and V alve Springs 1 1A-9-5 VA LV E (1) Check the valve face for correct contact. If incorrect, reface using a valve refacer . V alve seat contact should be maintained uniform at the center of valve face. (2) If the margin is smaller than the service limit, replace the valve. Standard value: 1.5 mm Limit[...]

4D68 ENGINE (E - W) - Cylinder Head, V alves and V alve Springs 1 1A-9-6 (2) Install the valve and, while pressing the valve against the valve seat, measure the valve stem projection between the valve stem end and the valve spring seat seating surface. Standard value: 43.45 mm Limit: 43.95 mm V AL VE SEA T RECONDITIONING PROCEDURE (1) Before correc[...]

4D68 ENGINE (E - W) - Cylinder Head, V alves and V alve Springs 1 1A-9-7 V AL VE GUIDE REPLACEMENT PROCEDURE (1) Using the special tool and a press, remove the valve guide toward the cylinder head gasket surface. (2) Rebore the valve guide hole to the new oversize valve guide outside diameter . V alve guide hole diameter 0.05 O.S.: 13.050 - 13.068 [...]

4D68 ENGINE (E - W) - Fro nt Case, C ounterba lanc e Sha fts a nd Oil Pan 1 1A-10-1 10. FRONT CASE, COUNTERBALANCE SHAFTS AND OIL P AN REMOV AL AND INST ALLA TION DEN0892 5 1 3 4 6 7 11 12 13 14 15 16 17 31 19 20 21 22 23 24 25 26 27 28 29 30 10 2 8 9 18 24 Nm 10 Nm 54 Nm 18 Nm 44 Nm 23 Nm 36 Nm 24 Nm 16 Nm 10 Nm 19 Nm 39 Nm 9N m 7N m Apply engine [...]

4D68 ENGINE (E - W) - Fro nt Case, C ounterba lanc e Sha fts a nd Oil Pan 1 1A-10-2 REMOV AL SERVICE POINTS A A " OIL P AN REMOV AL (1) Knock the special tool deeply between the oil pan and the cylinder block. (2) Hitting the side of the special tool, slide the special tool along the oil pan to remove it. A B " PLUG REMOV AL (1) If the pl[...]

4D68 ENGINE (E - W) - Fro nt Case, C ounterba lanc e Sha fts a nd Oil Pan 1 1A-10-3 A E " RIGHT COUNTERBALANCE SHAFT REAR BEARING / LEFT COUNTERBALANCE SHAFT REAR BEARING REMOV AL (1) Using the special tool, remove two rear bearings from the cylinder block. (2) T o remove the left rear bearing, install the special tool, Silent Shaft Bearing In[...]

4D68 ENGINE (E - W) - Fro nt Case, C ounterba lanc e Sha fts a nd Oil Pan 1 1A-10-4 (4) Insert the installer aligning with the guide pin and install the bearing. " C A COUNTERBALANCE SHAFT FRONT BEARING INST ALLA TION (1) Remove the rear bearing installing portion from the special tool. (2) Install the guide pin of the special tool to the thre[...]

4D68 ENGINE (E - W) - Fro nt Case, C ounterba lanc e Sha fts a nd Oil Pan 1 1A-10-5 (5) Insert the installer aligning with the guide pin and install the bearing. " D A OIL PUMP OIL SEAL INST ALLA TION " E A COUNTERBALANCE SHAFT OIL SEAL INST ALLA TION " F A CRANKSHAFT FRONT OIL SEAL INST ALLA TION (1) Using the special tool, install [...]

4D68 ENGINE (E - W) - Fro nt Case, C ounterba lanc e Sha fts a nd Oil Pan 1 1A-10-6 " G A OIL PUMP DRIVEN GEAR / OIL PUMP DRIVE GEAR INST ALLA TION (1) Apply engine oil amply to the gears and line up the alignment marks. " H A FRONT CASE INST ALLA TION (1) Install the special tool at the front end of the crankshaft and apply a thin coat o[...]

4D68 ENGINE (E - W) - Fro nt Case, C ounterba lanc e Sha fts a nd Oil Pan 1 1A-10-7 " J A PLUG INST ALLA TION (1) Fit a new O-ring in the front case. (2) T ighten the plug to the specified torque using the special tool. " K A OIL PRESSURE SWITCH INST ALLA TION Specified sealant: 3M A TD Part No. 8660 or equivalent Caution D Keep the end o[...]

4D68 ENGINE (E - W) - Fro nt Case, C ounterba lanc e Sha fts a nd Oil Pan 1 1A-10-8 COUNTERBALANCE SHAFT (1) Check the oil holes for clogging. (2) Check the journals for seizure, damage, and contact with bearing. If there is anything wrong with the journal, replace the counterbalance shaft, bearing or front case assembly . OIL COOLER BYP ASS V AL V[...]

4D68 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-1 1 1. PISTONS AND CONNECTING RODS REMOV AL AND INST ALLA TION DEN0771 Apply engine oil to all moving parts before installation. Removal steps " F A 1. Connecting rod cap nut A A "" E A 2. Connecting rod cap " C A 3. Connecting rod bearing " D A 4. Piston and connec[...]

4D68 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-2 REMOV AL SERVICE POINTS A A " CONNECTING ROD CAP REMOV AL (1) Mark the cylinder number on the side of t he connecting rod big end for correct reassembly . INST ALLA TION SERVICE POINTS " A A PIST ON PIN / PISTON / CONNECTING ROD INST ALLA TION (1) Assemble the piston and connect[...]

4D68 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-3 " D A PIST ON AND CONNECTING ROD ASSEMBL Y INST ALLA TION (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 as shown in the illustration. (3) Rotate the crankshaft so that the crank pin is on the[...]

4D68 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-4 " F A CONNECTING ROD CAP NUT INST ALLA TION Caution D If the cylinder head has been installed before installing the connecting rod cap nut, be sure to remove the spark plugs. (1) Since the connecting rod cap bolts and nuts are torqued using the plastic area tightening method, the bol[...]

4D68 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-5 INSPECTION PISTON RING (1) Check for side clearance. If the limit is exceeded, replace the ring or piston, or both. (2) In the case of semi-keystone type piston rings, check the ring to ring groove clearance as illustrated. Standard value: No. 1 0.05 - 0.07 mm No. 2 0.05 - 0.07 mm Limit: [...]

4D68 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-6 CONNECTING ROD BUSHING REPLACEMENT (1) Using the special tool, remove the bushing. (2) Using the special tool, install the bushing, aligning the oil hole of t he bushing with t he oil hole at the small end of the connecting rod. (3) Finish the bushing I.D. to the standard value. Bushing I[...]

4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel 1 1A-12-1 12. CRANKSHAFT , CYLINDER BLOCK AND FL YWHEEL REMOV AL AND INST ALLA TION DEN0893 1 2 3 4 5 6 7 89 10 11 12 13 14 15 16 17 18 “A” 11 N m 32 Nm 132 Nm 11 N m Apply engine oil to all moving parts before installation. Removal steps 1. Flywheel bolt 2. Adapter plate 3. Flexible[...]

4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel 1 1A-12-2 INST ALLA TION SERVICE POINTS " A A CRANKSHAFT BEARING INST ALLA TION When the bearing needs replacing, select and install a proper bearing by the following procedure. (1) Measure the crankshaft journal diameter a nd confirm its classification from the following table. In [...]

4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel 1 1A-12-3 " B A BEARING CAP / BEARING CAP BOL T INST ALLA TION (1) Install the bearing caps so that their arrows are directed to the timing belt side. (2) Before installing the bearing cap bolts, check that the shank length of each bolt meets the limit. If t he limit is exceeded, re[...]

4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel 1 1A-12-4 " C A OIL SEAL INST ALLA TION " D A OIL SEAL CASE INST ALLA TION Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent INSPECTION CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE METHOD) (1) Remove oil from t he crankshaft journal and the crankshaft bearing. (2[...]

4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel 1 1A-12-5 CYLINDER BLOCK (1) Visually check for cracks, rust, and corrosion, and inspect the cylinder block using a flaw detecting agent. Rectify defects where possible or replace the cylinder block. (2) Check the cylinder block’ s top surface for distortion using a straight edge and t[...]

4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel 1 1A-12-6 (4) Bore all cylinders to the calculated boring finish dimension. Caution T o prevent distortion that may result from temperature rise during honing, bore cylinders, in the order of No. 2, No. 4, No. 1 and No. 3. (5) Hone to the final finish dimension (Piston O.D. + clearance b[...]

4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel 1 1A-12-7 INSPECTION (1) After removing the cylinder sleeve, check th e cylinder block sleeve hole surface. If there is damage, insufficient interference-fit-margin or other problems, bore the cylinder block sleeve hole to an oversize. (2) T o check the interference, measure both the cyl[...]

4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel 1 1A-12-8 (5) Chamfer the cylinder sleeve top en d as illustrated. (6) The service cylinder sleeve has the I.D. machined to 81.5 to 81.7 mm. After installation of the sleeve, therefore, hone the I.D. to the standard value. Cylinder I.D.: 82.70 - 82.73 mm Honing finished surface roughness[...]

NOTES[...]