Mitsubishi 4D68 User Manual
ENGINE
4D68
CONTENTS
11A-0-1
GENERAL INFORMATION 11A-0-3
1. SPECIFICATIONS 11A-1-1
SERVICE SPECIFICATIONS 11A-1-1
REWORK DIMENSIONS 11A-1-3
TORQUE SPECIFICATIONS 11A-1-4
NEW TIGHTENING METHOD - BY USE OF BOLTS
TO BE TIGHTENED IN PLASTIC AREA 11A-1-7
SEALANT 11A-1-7
FORM-IN-PLACE GASKET 11A-1-8
2. SPECIAL TOOLS 11A-2-1
3. DRIVE BELT AND GLOW PLUG 11A-3-1
4. TIMING BELT 11A-4-1
5. GLOW PLUG, FUEL INJECTION PUMP
AND INJECTION NOZZLE 11A-5-1
6. INTAKE AND EXHAUST MANIFOLDS 11A-6-1
7. WATER PUMP, THERMOSTAT, HOSE AND PIPES 11A-7-1
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8. ROCKER ARMS, ROCKER SHAFT AND CAMSHAFT 11A-8-1
9. CYLINDER HEAD, VALVES AND VALVE SPRINGS 11A-9-1
10. FRONT CASE, COUNTERBALANCE SHAFTS
AND OIL PAN 11A-10-1
11. PISTONS AND CONNECTING RODS 11A-11-1
12. CRANKSHAFT, CYLINDER BLOCK AND FLYWHEEL 11A-12-1
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11A-0-2
NOTES
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4D68 ENGINE (E-W) -
GENERAL INFORMATION
SECTIONAL VIEW OF ENGINE
General Information
11A-0-3
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11A-0-4
4D68 ENGINE (E-W) -
SECTIONAL VIEW OF ENGINE
General Information
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4D68 ENGINE (E-W) -
General Information
GENERAL SPECIFICATIONS
Descriptions Specifications
Type Diesel engine
Number of cylinders 4 in-line
Combustion chamber Swirl chamber
11A-0-5
Total displacement dm
Cylinder bore mm 82.7
Piston stroke mm 93
Compression ratio 22.4
V alve timing Intake valve Opens (BTDC) 20°
Lubrication system Pressure feed, full-flow filtration
Oil pump type External gear type
Cooling system Water-cooled
Water pump type Centrifugal impeller type
EGR type Single type
Fuel system Electronic control distributor-type injection pump
3
Closes (ABDC) 48°
Exhaust valve Opens (BBDC) 54°
Closes (ATDC) 22°
1.998
Supercharging Turbocharger
Rocker arm Roller type
Adjusting screw Elephant foot type
Oil lever sensor Provided
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4D68 ENGINE (E-W) -
Specifications
1. SPECIFICATIONS
SERVICE SPECIFICATIONS
Item Standard value Limit
Drive belt and glow plug
Glow plug resistance W 0.5 -
Timing belt
Timing belt deflection mm 4.0- 5.0 -
Timing belt “B” deflection mm 5.0- 7.0 -
Rocker arms, rocker shaft and camshaft
Camshaft cam height mm Intake 41.90 41.40
Exhaust 41.96 41.46
Valve clearance (on cold engine) mm Intake 0.25 -
Exhaust 0.35 -
11A-1-1
Camshaft journal O.D. mm 30.0 -
Cylinder head, valves and valve springs
Cylinder head gasket surface flatness mm Within 0.03 0.2
Cylinder head overall height mm 86.9- 87.1 -
Valve overall length mm Intake 114.05 113.55
Exhaust 113.80 113.30
Thickness of valve head (margin) mm 1.5 0.7
Valve stem O.D. mm 6.0 -
Valve face angle 45° - 45.5° -
V alve stem to guide clearance mm 0.05- 0.09 0.15
V alve spring free length mm 49.1 48.1
V alve load/installed height N/mm 240/37.9 -
V alve spring out-of-squareness 2° or less Max. 4°
Valve seat valve contact width mm 0.9- 1.3 -
V alve stem projection mm 43.45 43.95
Valve guide I.D. mm 8.0 -
V alve guide projection from cylinder head upper surface mm 15 -
Cylinder head bolt shank length mm - 119.7
Front case, counterbalance shafts and oil pan
Oil cooler by-pass valve dimension (L) [Normal temperature] mm 34.5 -
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11A-1-2
Item LimitStandard value
4D68 ENGINE (E-W) -
Specifications
Oil cooler by-pass valve dimension (L) [by-pass hole closing temperature
(97 - 103°C or more)] mm
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 mm No. 1 0.05- 0.07 0.15
No. 2 0.05- 0.07 0.15
Piston ring end gap mm No. 1 0.20- 0.32 0.8
No. 2 0.35- 0.50 0.8
Oil ring 0.10 - 0.30 0.8
Piston pin O.D. mm 25.0 -
Crankshaft pin oil clearance mm 0.02 - 0.05 0.1
Connecting rod big end side clearance mm 0.10- 0.25 0.4
Connecting rod bushing I.D. mm 25.015- 25.025 -
40.0 -
Connecting rod bushing bend (Parallelism between big end center line and small
end center line) mm
Connecting rod bushing twist (Deflection between big end center line and small
end center line) mm
Crankshaft, cylinder block and flywheel
Crankshaft end play mm 0.05- 0.18 0.25
Crankshaft journal O.D. mm 57.0 -
Crankshaft pin O.D. mm 45.0 -
Crankshaft journal oil clearance mm 0.02- 0.04 0.1
Cylinder block gasket surface flatness mm 0.05 0.1
Cylinder block overall height mm 235 -
Cylinder bore I.D. mm 82.70- 82.73 -
Cylinder conicity mm 0.01 -
Piston to cylinder clearance mm 0.03- 0.05 -
Cylinder sleeve press-fitting force N 2,200 or more -
0.05 -
0.1 -
Piston projection mm 0.823 -
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4D68 ENGINE (E-W) -
Specifications
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. 38.300 - 38.325 -
0.6 O.S. 38.600 - 38.625 -
Cylinder head oversize exhaust valve seat ring hole mm 0.3 O.S. 34.300 - 34.325 -
0.6 O.S. 34.600 - 34.625 -
NOTE
O.D.: Outer diameter
I.D.: Inner diameter
O.S.: Oversize diameter
11A-1-3
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11A-1-4
4D68 ENGINE (E-W) -
Specifications
TORQUE SPECIFICATIONS
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
Timing belt cover Flange bolt 11
Washer bolt 9
Crankshaft position sensor bolt 9
Timing belt tensioner bolt 48
Tensioner spring bolt 13
Timing belt idler pulley bolt 48
Camshaft sprocket bolt 88
Injection pump sprocket flange bolt 9
Injection pump sprocket nut 83
Crankshaft bolt 118
Oil pump sprocket nut 54
Tensioner “B” bolt 18
Counterbalance shaft sprocket bolt 45
Timing belt rear cover bolt 11
Engine support bracket bolt and nut 49
Glow plug, fuel injection pump and injection nozzle
Injection pipe 29
Injection pipe clamp bolt 5
Fuel pipe bolt 13
Engine hanger bolt 18
Fuel injection pump bolt 23
Fuel injection pump nut 18
Fuel injection pump stay bolt 35
Fuel return pipe nut 29
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4D68 ENGINE (E-W) -
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
Turbocharger heat protector bolt M8 13
Exhaust fitting heat protector bolt 13
Water pipe “A” and “B” eye bolt 30
Water pipe “A” and “B” bolt 10
Oil pipe eye bolt 16
Specifications
M6 11
11A-1-5
Exhaust fitting bolt and nut 59
Oil return pipe bolt 9
Heat protector front and rear bolt 13
Turbocharger assembly bolt 59
Exhaust manifold bolt and nut 29
Alternator brace stay bolt 23
Intake manifold bolt and nut 17
Water pump, thermostat, hose and pipe
Oil pipe eye bolt 16
Oil return pipe eye bolt 17
Oil return pipe bolt 9
Engine coolant temperature sensor 35
Engine coolant temperature gauge unit 11
Cover bolt 19
Water pump bolt 13
Water inlet pipe bolt 12
V acuum pump bolt 22
Water inlet fitting bolt 23
Water outlet fitting bolt 12
Thermostat housing bolt 23
Rocker arms, rocker shaft and camshaft
Rocker cover bolt 6
Rocker shaft bolt 29
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11A-1-6
Items Nm
Adjusting nut 15
Camshaft bearing cap bolt M8 ¢ 25, M8 ¢ 40 20
Cylinder head, valves and valve springs
Cylinder head bolt 90
Front case, counterbalance shafts and oil pan
Drain plug 39
Oil level sensor bolt 9
Oil pan bolt 7
Oil screen bolt 19
4D68 ENGINE (E-W) -
Specifications
M8 ¢ 55 29
¯
Fully loosen
¯
40 + 90° +90°
Oil cooler by-pass valve 54
Oil pressure switch 10
Relief plug 44
Oil filter bracket bolt 18
Plug 23
Flange bolt 36
Front case bolt 24
Oil pump cover Bolt 16
Screw 10
Pistons and connection rods
Connecting rod cap nut 20
¯
+90° - 100°
Crankshaft, cylinder block and flywheel
Flywheel bolt 132
Rear plate bolt 11
Oil seal case bolt 11
Bearing cap bolt 25
Check valve 15
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¯
+90° - 100°
4D68 ENGINE (E-W) -
Specifications
11A-1-7
NEW TIGHTENING METHOD - BY USE OF BOLTS 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 different from the conventional one. Be sure to observe the method
described in the text when tightening the bolts.
Service limits are provided for the bolts. Make sure that the service limits described in the text are strictly
observed.
D Areas where the bolts are in use:
(1) Cylinder head bolts
(2) Main bearing cap bolts
(3) Connecting rod cap bolts
D Tightening method
After tightening the bolts to the specified torque, tighten them another 90° or 180° (twice 90°). The
tightening method varies on different areas. Observe the tightening method described in the text.
SEALANT
Items Specified sealant Quantity
Thermostat housing Mitsubishi Genuine Part No. MD970389 or equivalent As required
Engine coolant temperature
gauge unit
Oil pressure switch 3M ATD Part No. 8660 or equivalent As required
Water outlet fitting Mitsubishi Genuine Part No. MD970389 or equivalent As required
Oil pan Mitsubishi Genuine Part No. MD970389 or equivalent As required
Oil seal case Mitsubishi Genuine Part No. MD970389 or equivalent As required
Cover Mitsubishi Genuine Part No. MD970389 or equivalent As required
Camshaft bearing cap 3M ATD Part No. 8660 or equivalent As required
3M Nut Locking Part No. 4171 or equivalent As required
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11A-1-8
4D68 ENGINE (E-W) -
Specifications
FORM-IN-PLACE GASKET
The engine has several areas where the form-in-place gasket (FIPG) is in use. To 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. Too thin a bead could cause leaks. Too thick
a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the
fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to
apply the gasket evenly without a break, while observing the correct bead size.
The FIPG used in the engine is a room temperature vulcanization (RTV) type and is supplied in a 100-gram
tube (Part No. MD970389 or MD997110). Since the RTV hardens as it reacts with the moisture in the
atmospheric air, it is normally used in the metallic flange areas. The FIPG, Part No. MD970389, can
be used for sealing both engine oil and coolant, while Part No. 997110 can only be used for engine
oil sealing.
Disassembly
The parts assembled with the FIPG can be easily disassembled without use of a special method. In
some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking
with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the
joined surfaces. In this case, however, case must be taken to prevent damage to the joined surfaces.
For removal of the oil pan, the special tool “Oil Pa n Remover” (MD998727) is available. Be sure to use
the special tool to remove the oil pan.
Surface Preparation
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that t he surfaces to which the FIPG is to b e applied is flat. Make sure
that there are no oils, greases and foreign substances deposited on the application surfaces. Do not
forget to remove the old sealant remained in the bolt holes.
Form-In-Place Gasket Application
When assembling parts with the FIPG, you must observe some precautions, but the procedures is very
simple as in the case of a conventional precut gasket.
Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the
bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is
hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When
the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do
not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time
(about one hour) has passed after installation is completed.
The FIPG application procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.
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4D68 ENGINE (E-W) -
Special Tools
2. SPECIAL TOOLS
Tool Number Name Use
MB990767 End yoke holder Holding camshaft sprocket or fuel injection
11A-2-1
pump when loosening or tightening bolts.
Use with MD998719
MB991603 Bearing installer
stopper
MD990938 Handle Installation of crankshaft rear oil seal
MB991654 Cylinder head bolt
wrench
MD9981 15 Valve guide
installer
A guide for removal and installation of
counterbalance shaft left rear bearing
(Use with MD998776)
Tightening and loosening of cylinder head bolt
Removal and installation of valve guide
MD998162 Plug wrench Removal and installation of front case cap plug
(Use with MD998783)
MD998285 Crankshaft front oil
seal guide
MD998371 Silent shaft bearing
puller
MD998372 Silent shaft bearing
puller
Guide for installation of crankshaft front oil seal
Removal of counterbalance shaft front bearing
Removal of counterbalance shaft rear bearing
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11A-2-2
Tool UseNameNumber
4D68 ENGINE (E-W) -
Special Tools
MD998375 Crankshaft front oil
seal installer
MD998388 Injection pump
sprocket puller
MD998702 Connecting-rod
small-end bushing
replacement tool
MD998705 Silent shaft bearing
installer
Installation of crankshaft front oil seal
Removal of injection pump sprocket
Replacement of connecting-rod small-end
bushing
Installation of counterbalance shaft bearing
MD998713 Camshaft oil seal
installer
MD998719 Pulley holder pin
(2)
MD998727 Oil pan sealer
cutter
MD998729 Valve stem seal
installer
Installation of camshaft oil seal
Use with MB990767
Removal of oil pan
Installation of valve stem seal
MD998772 Valve spring
compressor
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Compression of valve spring
4D68 ENGINE (E-W) -
Tool UseNameNumber
Special Tools
11A-2-3
MD998776 Crankshaft rear oil
seal installer
MD998778 Crankshaft
sprocket puller
MD998781 Flywheel stopper Holding of flywheel and drive plate
MD998783 Plug wrench
retainer
Installation of crankshaft rear oil seal
(Use with MB990938)
Removal of crankshaft sprocket
Removal and installation of front case cap plug
(Use with MD998162)
MD998785 Sprocket stopper Holding of counterbalance shaft sprocket
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4D68 ENGINE (E-W) -
Drive Belt and Glow Plug
3. DRIVE BELT AND GLOW PLUG
REMOVAL AND INSTALLATION
1
11A-3-1
10 Nm
2
13 Nm
1.8 Nm
12
18 Nm
3
4
8
11
44 Nm
7
9
6
23 Nm
9Nm
5
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)
25 Nm
10
AA""AA
DEN0885
7. Water pump pulley
8. Alternator brace
9. Alternator
10. Crankshaft pulley
11. Glow plug plate
12. Glow plug
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11A-3-2
4D68 ENGINE (E-W) -
REMOVAL SERVICE POINTS
AA"
(1) When removing the glow plug, you may loosen using
INSTALLATION SERVICE POINTS
"AA
(1) When installing the glow plug, screw in one thread or
Drive Belt and Glow Plug
GLOW PLUG REMOVAL
a tool up to the point where o n e 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 10 cm or more.
GLOW PLUG INSTALLATION
more with fingers and then tighten with a tool.
Caution
D
Do not reuse a glow plug that has been dropped
from a height of 10 cm or more.
DEL034
INSPECTION
GLOW PLUG
(1) Check the glow plugs for continuity between the terminal
and the body as shown. Replace the glow plugs which
show no continuity or too large a resistance.
Standard value: 0.5
W
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4D68 ENGINE (E-W) -
4. TIMING BELT
REMOVAL AND INSTALLATION
11 Nm
28
27
26
Timing Belt
11A-4-1
45 Nm
20
18 Nm
21
18
23
22
49 Nm
24
11 Nm
25
11 Nm
1
3
9Nm
88 Nm
83 Nm
10
48 Nm
13
11
9
17
15
16
118 Nm
2
9Nm
14
54 Nm
19
9Nm
5
12
4
6
13 Nm
48 Nm
8
7
DEN0886
AA""IA
"HA
AB""GA
AC""FA
AD"
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Removal steps
1. Timing belt front upper cover
2. T iming belt front center cover
3. Timing belt front lower cover
4. Crankshaft position sensor
5. Timing belt
6. Timing belt tensioner
7. Tensioner spacer
8. Tensioner spring
9. Timing belt idler pulley
10. Camshaft sprocket bolt
11. Camshaft sprocket
12. Flange
13. Injection pump sprocket nut
14. Injection pump sprocket
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AE""EA
AF"
AG""DA
AH""CA
AI""BA
"AA
AJ"
15. Crankshaft bolt
16. Special washer
17. Crankshaft sprocket
18. Crankshaft sensing blade
19. Oil pump sprocket
20. Tensioner “B”
21. T iming belt “B”
22. Counterbalance shaft sprocket
23. Spacer
24. Crankshaft sprocket “B”
25. Key
26. T iming belt rear center cover
27. T iming belt rear right cover
28. Engine support bracket
11A-4-2
4D68 ENGINE (E-W) -
REMOVAL SERVICE POINTS
AA"
(1) Using chalk, etc., mark an arrow on the back of the timing
DEN0739
(2) Attach a bolt to the front end face of the timing belt
(3) Remove the timing belt.
DEN0838
TIMING BELT REMOVAL
belt to indicate the direction of rotation. This is to ensure
correct installation of the belt in case it is reused.
tensioner. Fit an offset wrench onto the bolt and turn the
wrench downward as shown to tighten the tensioner
mounting bolt temporarily.
Caution
D
Use such a short bolt as would not come into
contact with the timing belt tensioner mounting
bolt at the rear end face when it is tightened.
Timing Belt
MB990767
MB998719
MD998719
DEN0741
MB990767
DEN0742
AB"
AC"
AD"
CAMSHAFT SPROCKET BOLT LOOSENING
INJECTION PUMP SPROCKET NUT LOOSENING
INJECTION PUMP SPROCKET REMOVAL
(1) Do not strike the sprocket and drive shaft to remove these
parts.
MD998388
DFU0625
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4D68 ENGINE (E-W) -
Timing Belt
11A-4-3
MD998781
Plug
DEN0743
MD998778
DEN0744
Screwdriver
6EN05646EN0563
AE"
AF"
AG"
CRANKSHAFT BOLT LOOSENING
CRANKSHAFT SPROCKET REMOVAL
OIL PUMP SPROCKET REMOVAL
(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 8 mm] through the plug hole to keep the left
counterbalance shaft in position.
Caution
D
If the nut is loosened without removing the timing
belt, the force produced by loosening the nut will
be borne by the belt and can cause damage to
the belt cogs.
AH"
TIMING BELT “B” REMOVAL
(1) Using chalk, etc., mark an arrow on the back of the timing
belt to indicate the direction of rotation. This is to ensure
correct installation of the belt in case it is reused.
NOTE
(1) Water or oil on the belt shortens its life drastically,
so the removed timing belt, sprocket, an d tensioner
must be free from oil and water. Do not immerse parts
in cleaning solvent.
DEN0745
(2) If there is oil or water on any part, check the front
case oil seals, camshaft oil seal and water pump for
leaks.
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