Mitsubishi 4M41 Engine Workshop Repair Service Manual

GENERAL INFORMATION 11B-0-3 ................................................... 1. SPECIFICATIONS 11B-1-1 ....................................................... SERVICE SPECIFICATIONS 11B-1-1 ............................................ TORQUE SPECIFICATIONS 11B-1-4 ............................................ SEALANT 11B-1-8 ........................................................... 2. SPECIAL TOOLS 11B-2-1 ....................................................... 3. GENERATOR ASSEMBLY 11B-3-1 ............................................... 4. GLOW PLUG 11B-4-1 ........................................................... 5. COOLING FAN, V-BELT AND WATER PUMP 11B-5-1 ............................... 6. WATER HOSES AND PIPES 11B-6-1 .............................................. 7. THERMOSTAT 11B-7-1 .......................................................... 8. EGR VALVE ASSEMBLY 11B-8-1 ................................................. 9. INTAKE MANIFOLD 11B-9-1 ..................................................... 10. TURBOCHARGER ASSEMBLY 11B-10-1 ......................................... 11. EXHAUST MANIFOLD 11B-11-1 .................................................. 12. INJECTION PUMP ASSEMBLY 11B-12-1 ......................................... 13. INJECTION PUMP GEAR 11B-13-1 .............................................. 14. ROCKER COVER, CAMSHAFT HOLDER ASSEMBLY AND CAMSHAFT 11B-14-1 .... 15. INJECTION NOZZLE 11B-15-1 .................................................. 16. CYLINDER HEAD AND VALVE MECHANISM 11B-16-1 ............................. 17. VACUUM PUMP 11B-17-1 ...................................................... 18. TIMING GEAR CASE 11B-18-1 .................................................. 19. TIMING GEAR AND BALANCE SHAFT 11B-19-1 .................................. 20. OIL PUMP 11B-20-1 ............................................................ 21. OIL COOLER AND OIL FILTER 11B-21-1 ......................................... 22. OIL PAN, OIL STRAINER AND OIL JET 11B-22-1 .................................. 23. PISTON AND CONNECTING ROD 11B-23-1 ...................................... 24. DRIVE PLATE 11B-24-1 ........................................................ 25. CRANK SHAFT AND CRANK CASE 11B-25-1 .................................... 26. BALANCE SHAFT BUSH 11B-26-1 .............................................. 11B-0-1 ENGINE 4M41 CONTENTS PWEE9409-D E Feb. 2000 Mitsubishi Motors Corporation Added

11B-0-2 NOTES PWEE9409-D E Feb. 2000 Mitsubishi Motors Corporation Added

4M41 ENGINE - General Information 11B-0-3 GENERAL INFORMATION Descriptions Specifications Total displacement dm 3 3200 No. and arrangement of cylinders 4 in-line Combustion chamber Direct injection No. of intake/exhaust valves (per cylinder) 2 each Valve mechanism Double overhead camshaft, 4-valve Cylinder bore x stroke mm 98.5 x 105 Compression ratio 17 Supercharger Turbo-charging type Intercooler Air-cooling type Fuel supply Distributor type electronically controlled fuel injection pump PWEE9409-D E Feb. 2000 Mitsubishi Motors Corporation Added

4M41 ENGINE - Specifications 11B-1-1 1. SPECIFICATIONS SERVICE SPECIFICATIONS Unit: mm Descriptions Standard Limit Glow plug Glow plug Resistance W 1.1 - Turbocharger assembly Turbocharger Actuator operating pressure (when operating 1 mm) kPa 161 - Rocker cover, camshaft holder assembly, camshaft assembly Camshaft End play 0.10 - 0.18 0.3 Cam lobe lift Intake Front 6.16 6.11 Rear 6.10 6.05 Exhaust Front 5.91 5.86 Rear 6.16 6.11 Bend Less than 0.015 0.03 Journal oil clearance 0.05 - 0.09 0.15 Rocker Rocker roller radial play 0.03 - 0.07 - Injection nozzle Injection nozzle Injection pressure (valve opening No. 1 valve opening pressure MPa 17.60 - 18.58 - pressure) No. 2 valve opening pressure MPa 22.6 - 23.6 - Pre-lift 0.05 - 0.07 - Needle valve lift 0.23 - 0.28 - Cylinder head and valve mechanism Valve spring Free height 51.3 - Load (installed height: 39.5) N 255 - Out-of-squareness 2_ 4_ Valve Intake Stem diameter 6.560 - 6.575 6.45 Sinkage from cylinder head bottom 0.05 - 0.55 0.8 Margin 1.0 0.8 Valve seat angle 45_ – 15 - Exhaust Stem diameter 6.53 - 6.55 6.45 Sinkage from cylinder head bottom 0.05 - 0.55 0.8 Margin 1.0 0.8 Valve seat angle 45_ – 15 - Valve guide Stem-to-guide clearance Intake 0.02 - 0.06 0.10 Exhaust 0.05 - 0.09 0.15 PWEE9409-D E Feb. 2000 Mitsubishi Motors Corporation Added

4M41 ENGINE - Specifications 11B-1-2 Descriptions Limit Standard Valve seat Seat width 1.8 - 2.2 2.8 Cylinder head Bottom surface distortion Less than 0.05 0.2 Vacuum pump Vacuum pump Performance Attained degree of vacuum 93 kPa or more - Pump speed 1500 r/min - Timing gears and balance shafts Backlash between gears Balance shaft gear RH and oil pump gear 0.04 - 0.19 0.3 Oil pump gear and crankshaft gear 0.04 - 0.18 0.3 Crankshaft gear and idler gear 0.04 - 0.18 0.3 Idler gear and idler gear LH 0.04 - 0.19 0.3 Idler gear LH and balance shaft gear LH 0.04 - 0.22 0.4 Idler gear and injection pump gear 0.04 - 0.21 0.4 End play Balance shaft LH, RH 0.09 - 0.24 0.3 Idler gear/sprocket assembly 0.05 - 0.20 0.3 Idler gear LH assembly 0.05 - 0.20 0.3 Timing chain elongation (minimum distance between chain spans facing each other when pressing on tensioner lever) 16.5 9 Tension lever-to-tension lever shaft clearance 0.06 - 0.18 0.3 Idler gear bush LH-to-idler shaft clearance 0.02 - 0.05 0.1 Idler sprocket bush-to-idler shaft clearance 0.02 - 0.06 0.1 Oil pump Oil pump Driven gear shaft-to-oil pump case and cover clearance 0.03 - 0.05 0.15 Side clearance 0.05 - 0.10 0.15 Tip clearance 0.15 - 0.26 0.27 Oil cooler and oil filter Bypass valve spring Valve opening pressure kPa 490 – 30 - Regulator valve spring Valve opening pressure kPa 620 – 30 - Piston and connecting rod assembly Piston Protrusion -0.20 - -0.30 - Piston pin Piston pin-to-connecting rod bush clearance 0.03 - 0.05 0.1 Piston pin-to-piston clearance 0.007 - 0.021 0.05 Piston ring Ring-to-ring No.1 compression ring 0.03 - 0.08 0.15 groove clearance No.2 compression ring 0.07 - 0.10 0.15 Oil ring 0.03 - 0.06 0.15 End gap No.1 compression ring 0.3 - 0.45 0.8 No.2 compression ring 0.4 - 0.55 0.8 Oil ring 0.3 - 0.5 0.8 PWEE9409-D E Feb. 2000 Mitsubishi Motors Corporation Added

4M41 ENGINE - Specifications 11B-1-3 Descriptions Limit Standard Connecting rod End play 0.15 - 0.45 0.6 Bend - 0.05 Twist - 0.1 Connecting rod bearing Oil clearance 0.03 - 0.05 0.1 Free span - 58.8 max. Crankshaft and crankcase Crankshaft End play 0.10 - 0.28 0.4 Bend Less than 0.02 0.05 Pin and journal Out-of-roundness Less than 0.01 - Conicity Less than 0.006 - Main bearing Main bearing-to- No.1, 2, 4 and 5 journal 0.04 - 0.06 0.1 crankshaft clearance No.3 journal 0.06 - 0.08 0.1 Free span - 73.16 max. Upper crankcase Upper surface distortion Less than 0.05 0.1 Cylinder I.D. 98.5 - 98.53 98.75 Piston and connecting rod assembly-to-upper crankcase cylinder clearance 0.04 - 0.05 - Balance shaft bush Balance shaft Clearance between balance shaft and balance shaft bush 0.06 - 0.11 0.16 PWEE9409-D E Feb. 2000 Mitsubishi Motors Corporation Added

4M41 ENGINE - Specifications 11B-1-4 TORQUE SPECIFICATIONS Items Torque Nm Glow plug Connection plate 1.3 – 1 Glow plug 18 – 1 Cooling fan V-belt and water pump Cooling fan bolt 10 – 1 Auto-cooling fan coupling nut 24 – 2 Water pump bolt 24 – 2 Water hoses and pipes Eyebolt 25 – 2 Coolant temperature sensor 9 – 1 Intake manifold Boost air temperature sensor 15 – 1 Gas filter assembly 17 – 1 Turbocharger assembly Eye bolt (for oil pipe) 20 – 2 Eye bolt (for water pipe) 25 – 2 Coupler nut 49 – 4 Turbocharger nut 49 – 4 Turbocharger bolt 54 – 5 Exhaust manifold Exhaust manifold nut 30 – 3 Injection pump assembly Injection pipe 25 – 2 Pump stay mounting bolt 18 – 2 Injection pump Injection pump gear mounting nut 180 – 10 Sensor plate mounting bolt 5 – 1 Flange plate mounting nut 38 – 2 Engine speed sensor mounting bolt 5 – 1 Rocker cover, camshaft holder assembly, camshaft assembly Rocker cover mounting bolt 3.0 – 0.3 Fuel leak-off pipe eyebolt Injection nozzle side 13 – 2 Cylinder head side 11 – 1 Cam sprocket mounting bolt 88 – 10 Camshaft cap mounting bolt 20 – 1 Adjust screw locknut 9.5 – 0.5 Pivot bolt 38 – 8 PWEE9409-D E Feb. 2000 Mitsubishi Motors Corporation Added

4M41 ENGINE - Specifications 11B-1-5 Items Torque Nm Injection nozzle Injection pipe 33 – 3 Return pipe eyebolt 11 – 1 Injection nozzle assembly eyebolt 13 – 2 Leak-off pipe eye bolt 11 – 1 Injection nozzle assembly mounting bolt 21 – 2 Retaining nut 34 – 5 Cylinder head and valve mechanism Injection nozzle mounting bolt 21 – 2 Connecting plate mounting nut 1.3 – 1.0 Glow plug 18 – 2 Bolt (M10) 58 – 6 Cylinder head bolt (M12: long) 49 – 5 + 90_ + 90_ Cylinder head bolt (M12: short) 49 – 5 + 90_ + 90_ Water joint 47 – 5 Vacuum pump Eyebolt 20 – 2 Cover and body assembly mounting bolt 5.4 – 0.5 Timing gear case Crankshaft pulley mounting bolt 323 – 32 Cap nut 23 – 2 Timing gear and balance shaft Tension lever shaft mounting bolt 40 – 4 Guide plate mounting bolt 33 – 3 Balance shaft gear RH mounting bolt 36 – 4 Thrust plate mounting bolt 12 – 1 Balance shaft gear LH mounting bolt 36 – 4 Oil Pump Balance shaft RH bolt 36 – 3 Plug 44 – 4 Oil pump cover screw 10 – 1 Oil cooler and oil filter Oil cooler element nut 20 – 2 Bypass plug 44 – 4 Regulator plug 44 – 4 Water drain plug 30 – 3 PWEE9409-D E Feb. 2000 Mitsubishi Motors Corporation Added

4M41 ENGINE - Specifications 11B-1-6 Items Torque Nm Oil pan, oil strainer and oil jet Drain plug 39 – 3 Oil jet 32 – 3 Piston and connecting rod Connecting rod cap mounting nut 29 – 3 + 49 – 5 + 45_ + 45_ Drive plate Drive plate assembly and crankshaft mounting bolt 123 – 12 Crankshaft and crankcase Dust cover mounting bolt 47 – 5 Lower crankcase mounting bolt 25 – 3 Main bearing cap bolt 20 – 2 + 90_ + 90_ Check valve 32 – 3 STANDARD BOLT AND NUT TIGHTENING TORQUE TABLE 1. Fasten the parts and equipment of vehicle using the specified standard bolts and nuts. Tighten these bolts and nuts to the torques indicated below, unless otherwise specified. 2. Threads and bearing surfaces must be dry. 3. In case nut and bolt (or stud bolt) differ in strength, tighten them to the torque specified for the bolt. Hexagon head bolts and stud bolts Unit: Nm Strength Code 4T 7T 8T Head Mark Nominal Diameter mm (Stud) (Stud) (Stud) M5 2.5 – 0.5 - 5 – 1 - 6 – 1 - M6 5 – 1 - 9 – 2 - 10 – 2 - M8 11.5 – 2.5 - 21 – 4 - 25 – 4 - M10 23 – 4 22 – 4 44 – 10 41 – 8 52 – 7 55 – 13 M12 41 – 8 38 – 8 81 – 12 74 – 9 96 – 12 86 – 12 PWEE9409-D E Feb. 2000 Mitsubishi Motors Corporation Added

4M41 ENGINE - Specifications 11B-1-7 Hexagon flange bolts Unit: Nm Strength Code 4T 7T 8T Head Mark Nominal Diameter mm M6 5 – 1 - 10 – 2 - 12 – 2 - M8 13 – 2 - 23 – 4 - 27 – 5 - M10 26 – 4 22 – 4 49 – 10 44 – 9 57 – 7 54 – 10 M12 46 – 8 42 – 9 93 – 15 81 – 12 103 – 15 96 – 12 Hexagon nuts Unit: Nm Strength Code 4T 6T Head Mark Nominal Diameter mm Standard Thread Coarse Thread Standard Thread Coarse Thread M5 2.5 – 0.5 - 5 – 1 - M6 5 – 1 - 9 – 2 - M8 12 – 2 - 21 – 4 - M10 23 – 4 22 – 4 44 – 10 41 – 8 M12 41 – 8 38 – 8 81 – 12 73 – 10 Hexagon flange nuts Unit: Nm Strength Code 4T Head Mark Nominal Diameter mm Standard Thread Coarse Thread M6 5 – 1 - M8 13 – 2 - M10 26 – 4 24 – 4 M12 41 – 8 42 – 9 PWEE9409-D E Feb. 2000 Mitsubishi Motors Corporation Added

Mitsubishi 4M41 Engine Workshop Repair Service Manual

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