Mitsubishi Canter 2000 User Manual
ENGINE
4M41
CONTENTS
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
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
11B-0-2
NOTES
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
4M41 ENGINE -
General Information
GENERAL INFORMATION
Descriptions Specifications
11B-0-3
Total displacement dm
No. and arrangement of cylinders 4 in-line
Combustion chamber Direct injection
No. of intake/exhaust valves (per cylinder) 2 each
V alve 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
3
3200
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
4M41 ENGINE -
Specifications
1. SPECIFICATIONS
SERVICE SPECIFICATIONS
Descriptions Standard Limit
Glow plug
11B-1-1
Unit: mm
Glow plug Resistance
Turbocharger assembly
Turbocharger Actuator operating pressure
(when operating 1 mm) kPa
Rocker cover, camshaft holder assembly, camshaft assembly
Camshaft
Rocker Rocker roller radial play 0.03 - 0.07 -
Injection nozzle
Injection nozzle Injection pressure
End play 0.10 - 0.18 0.3
Cam lobe lift Intake
Bend Less than 0.015 0.03
Journal oil clearance 0.05 - 0.09 0.15
(valve opening
pressure)
W
Front 6.16 6.11
Rear 6.10 6.05
Exhaust
No. 1 valve opening pressure
No. 2 valve opening pressure
Front 5.91 5.86
Rear 6.16 6.11
MPa
MPa
1.1 -
161 -
17.60 - 18.58 -
22.6 - 23.6 -
Pre-lift 0.05 - 0.07 -
Needle valve lift 0.23 - 0.28 -
Cylinder head and valve mechanism
Valve spring
Valve Intake
Valve guide Stem-to-guide clearance
Free height 51.3 -
Load (installed height: 39.5) N 255 -
Out-of-squareness 2
Stem diameter 6.560 - 6.575 6.45
Sinkage from cylinder head
bottom
Margin 1.0 0.8
V alve seat angle 45
Exhaust
Stem diameter 6.53 - 6.55 6.45
Sinkage from cylinder head
bottom
Margin 1.0 0.8
V alve seat angle 45
_
0.05 - 0.55 0.8
_ ±
15’ -
0.05 - 0.55 0.8
_ ±
15’ -
Intake 0.02 - 0.06 0.10
Exhaust 0.05 - 0.09 0.15
_
4
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
11B-1-2
Descriptions LimitStandard
Valve seat Seat width 1.8 - 2.2 2.8
Cylinder head Bottom surface distortion Less than 0.05 0.2
Vacuum pump
4M41 ENGINE -
Specifications
V acuum pump Performance
Timing gears and balance shafts
Backlash between gears
End play
Timing chain elongation (minimum distance between chain spans facing each
other when pressing on tensioner lever)
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
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
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
Attained degree of vacuum 93 kPa or more -
Pump speed 1500 r/min -
16.5 9
Oil pump
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 ring Ring-to-ring
Driven gear shaft-to-oil pump case and cover
clearance
Side clearance 0.05 - 0.10 0.15
Tip clearance 0.15 - 0.26 0.27
Piston pin-to-connecting rod bush clearance 0.03 - 0.05 0.1
Piston pin-to-piston clearance 0.007 - 0.021 0.05
No.1 compression ring 0.03 - 0.08 0.15
groove clearance
End gap
No.2 compression ring 0.07 - 0.10 0.15
Oil ring 0.03 - 0.06 0.15
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
0.03 - 0.05 0.15
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
4M41 ENGINE -
Descriptions LimitStandard
Specifications
11B-1-3
Connecting rod
Connecting rod bearing
Crankshaft and crankcase
Crankshaft
Main bearing Main bearing-to-
Upper crankcase
End play 0.15 - 0.45 0.6
Bend - 0.05
Twist - 0.1
Oil clearance 0.03 - 0.05 0.1
Free span - 58.8 max.
End play 0.10 - 0.28 0.4
Bend Less than 0.02 0.05
Pin and journal
crankshaft clearance
Free span - 73.16 max.
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
Out-of-roundness Less than 0.01 -
Conicity Less than 0.006 -
No.1, 2, 4 and 5 journal 0.04 - 0.06 0.1
No.3 journal 0.06 - 0.08 0.1
0.04 - 0.05 -
Balance shaft bush
Balance shaft Clearance between balance shaft and balance shaft
bush
0.06 - 0.11 0.16
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
11B-1-4
4M41 ENGINE -
Specifications
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
Cam sprocket mounting bolt 88 ± 10
Camshaft cap mounting bolt 20 ± 1
Adjust screw locknut 9.5 ± 0.5
Pivot bolt 38 ± 8
E
Feb. 2000Mitsubishi Motors Corporation Added
Injection nozzle side 13 ± 2
Cylinder head side 11 ± 1
PWEE9409-D
4M41 ENGINE -
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_
Specifications
11B-1-5
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
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
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
4M41 ENGINE -
Specifications
STANDARD BOLT AND NUT TIGHTENING TORQUE TABLE
1. Fasten the parts and equipment of vehicle using the specified standard bolts a n d 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
Strength
Code
Head Mark
Nominal
Diameter mm
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
4T 7T 8T
(Stud)
(Stud)
(Stud)
Unit: Nm
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
Hexagon flange bolts
4M41 ENGINE -
Specifications
11B-1-7
Unit: Nm
Strength
Code
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
4T 7T 8T
Hexagon nuts
Strength Code
Head Mark
4T 6T
Unit: Nm
Nominal
Diameter mm
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
Standard
Thread
Coarse Thread Standard Thread Coarse Thread
Hexagon flange nuts
Unit: Nm
Strength Code
Head Mark
Nominal
Diameter mm
4T
Standard
Thread
Coarse Thread
M6 5 ± 1 -
M8 13 ± 2 -
M10 26 ± 4 24 ± 4
M12 41 ± 8 42 ± 9
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
11B-1-8
4M41 ENGINE -
Specifications
SEALANT
Location Specified sealant
Mating surface of front plate to cylinder head gasket 3M ATD Part No.8660 or equivalent
Inner surface of sealing cap press-fitting hole THREEBOND TB1386, LOCTITE 962T or equivalent
Mating surface of timing gear case to front plate* Mitsubishi Genuine Part No. MD970389 or equivalent
Upper crankcase assembly-to-lower crankcase assembly mounting surface*
Rear oil seal case-to-upper or lower crankcase assembly
mounting surface*
Upper or lower crankcase assembly-to-front plate
mounting surface*
*: FIPG to be applied
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.
Since the FIPG used in the engine hardens as it reacts with the moisture in the atmospheric air, it is
normally used in the metallic flange areas.
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 gasket scraper may be lightly hammered in between the joined surfaces.
In this case, however, care must be taken to prevent damage to the joined surfaces.
Surface Preparation
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be 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 remaining in the bolt holes.
Form-In-Place Gasket Application
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.
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
4M41 ENGINE -
Special Tools
2. SPECIAL TOOLS
Tool Number Name Use
11B-2-1
MB990767 Front hub and
flange yoke holder
MD998754 Crankshaft pulley
holder pin
157944-9520
(Zexel)
105789-0010
(Zexel)
157892-4420 Adjusting device D Adjustment of valve opening pressure
157892-4400: A Holder
Plate Removal and installation of retaining nut
Nozzle cleaning
tool
D Removal of crankshaft puley
D Installation of injection pump assembly
Cleaning of nozzle and needle valve
D Checking needle valve maximum lift
D Checking needle valve maximum lift
D Checking injection nozzle assembly
A
B
C
B
A
157892-1000: B Nut
157954-3801 Dial gauge
157892-7200 Pin
157892-5120 Retaining nut
157892-5100: A Retaining nut
026508-1140: B Gasket
157892-1600: C Plug
157892-3200 Gasket
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
11B-2-2
Tool UseNameNumber
4M41 ENGINE -
Special Tools
MH063490 Cam sprocket
holder kit
MD998772 Valve spring com-
pressor
MD998784 Valve spring com-
pressor adaptor
plate
MD999597 Valve spring com-
pressor
Holding cam sprocket
Removal and installation of valve cotter
11.5
f
6.6
f
MD998665 Valve guide remov-erRemoval of valve guide
MH06361 1: A Calking ring inlet Installation of valve seat
8
f
C
A, B
A, B
35: A
f
33: B
f
MH063612: B Calking ring ex-
haust
MH063613: C Calking tool body
12
MH063610 Valve guide install-erInstallation of valve guide
f
21
f
16.5
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
4M41 ENGINE -
Special Tools
Tool Number Name Use
11B-2-3
18
f
15.4
f
f
27.5
f
41.5
f
60 - 120
MH063609 Valve stem seal
6.6
f
f
32
f
46
f
MH062463 Idler gear bush
f
28
42
MH062462 Idler sprocket bush
installer
puller
puller
Installation of valve stem seal
Removal and installation of idler gear bush
Removal and installation of idler sprocket
bush
MH060014 Piston ring tool Removal and installation of piston rings
f
98.5
MH062574 Connecting rod
Removal of connecting rod bush
bush puller kit
MH063484 Piston guide Installation of piston
MH062469 Gear puller Removal of crankshaft gear
MH062490 Balance shaft bush
Removal of balance shaft bush
remover
MH062717 Balance shaft bush
installer
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
11B-2-4
Tool Number Name Use
MH062567 Gear puller Removal of injection pump gear
4M41 ENGINE -
Special Tools
MH063473 Pin wrench arm
assembly
Assembling of injection pump gear
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
4M41 ENGINE -
3. GENERATOR ASSEMBLY
REMOVAL AND INSTALLATION
1
Generator Assembly
2
11B-3-1
4
Removal steps
1. Wiring harness
2. Adjusting bolt
3. Bolt
4. V-belt (Refer to page 11B-5-1.)
"AA 5. Generator
5
3
REMOVAL SERVICE POINT
"AA
Caution in Handling Generator
The following caution should be taken when servicing the
generator5.
Be sure to connect the generator5to t he battery correctly.
Reversed polarity causes an excessive current to flow from
the battery to the generator5, damaging the diodes and
voltage regulator.
GENERATOR INSPECTION
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
4M41 ENGINE -
4. GLOW PLUG
REMOVAL AND INSTALLATION
Glow Plug
11B-4-1
18±1Nm
5
4
13±1Nm
3
1
7
2
6
Removal steps
1. Nut
2. Glow plug wiring harness
3. Connection plate
4. Glow plug
5. Coolant temperature sensor
(For engine control)
6. Glow relay
7. Engine ECU
INSPECTION
GLOW PLUG
Measure resistance of the glow plug4. Replace the glow
plug if the reading deviates from the specified standard value.
Standard value: 1.1
W
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
4M41 ENGINE -
Cooling Fan, V-belt and Water Pump
5. COOLING FAN, V-BELT AND WATER PUMP
REMOVAL AND INSTALLATION
8
5
11B-5-1
1
10±1Nm
24±2Nm
4
6
2
Removal steps
1. Bolt
2. Cooling fan
3. Nut
4. Auto-cooling fan coupling
5. V-belt
6. Bolt
7. Coupling plate
8. Water pump pulley
9. Water pump assembly
10. O-ring
7
*1
10
9
3
24±2Nm
*1: Timing gear case
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
11B-5-2
A
4M41 ENGINE -
Cooling Fan, V-belt and Water Pump
INSPECTION
1. AUTO-COOLING FAN COUPLING
Check th e auto-cooling fan coupling4, and replace if
any of the following conditions exists:
(1) Hydraulic fluid is leaking from the hermetically sealed
housing.
(2) The coupling turns irregularly or produces an
abnormal sound when rotated by hand due to
defective inside bearing.
(3) The coupling has an excessive axial play when moved
with the engine in a cold state.
2. V-BELT
5
(1) Push the V-belt
approximately 98 N as shown and read the amount of
deflectionA.
(2) If the reading deviates from the specified standard value,
accomplish the following adjustment.
at its midpoint with a force of
5
(3) Loosen the bolt an d nutBholding the generator, and
adjust the tension of the V-belt5using the adjusting
B
C
B
boltC.
Caution
1. Be sure to retighten the bolt and nut securely
after the adjustment.
2. Excessive tension damages not only the V-belt
5 itself but bearings elsewhere.
3. Be sure to replace the V-belt 5, when necessary,
in pairs and keep it slush-free.
CLEANING
Remove foreign matters, if any, from the bimetalAusing
care not to apply unnecessary force to it.
A
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
4M41 ENGINE -
6. WATER HOSES AND PIPES
REMOVAL AND INSTALLATION
3
4
Water Hoses and Pipes
11B-6-1
8
25±2Nm
Removal steps
1. Turbocharger water outlet pipe
2. Turbocharger water inlet pipe
3. Heater return pipe
"AA 4. O-ring
5. Harness
6. Coolant temperature sensor
7. Water outlet pipe
8. Gasket
2
25±2Nm
(For water temperature gauge)
1
25±2Nm
6
7
9±1Nm
5
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
11B-6-2
4M41 ENGINE -
INSTALLATION SERVICE POINTS
"AA
Caution
Engine oil swells O-rings. When installing the O-rings
4, be sure that they are free of engine oil.
Water Hoses and Pipes
O-RING INSTALLATION
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
4M41 ENGINE -
7. THERMOSTAT
REMOVAL AND INSTALLATION
5
2
Thermostat
3
11B-7-1
4
6
1
Removal steps
1. Thermostat cover
"BA 2. Thermostat
3. Bypass pipe
"AA 4. O-ring
5. Thermostat case
"AA 6. O-ring
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
11B-7-2
4M41 ENGINE -
INSTALLATION SERVICE POINTS
"AA
Caution
Engine oil swells O-rings. When installing the O-rings
4 and 6, be sure that they are free of engine oil.
O-RING INSTALLATION
Thermostat
5
A
Install the thermostat2with its jiggle valveAlocated at the
uppermost position.
"BA
THERMOSTAT INSTALLATION
2
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
4M41 ENGINE -
8. EGR VALVE ASSEMBLY
REMOVAL AND INSTALLATION
EGR Valve Assembly
11B-8-1
*a
5
10
4
2
1
3
2
8
6
7
9
Removal steps
1. EGR pipe
2. Gasket
3. EGR pipe stay
4. EGR valve
5. Gasket
6. Insulator
7. EGR pipe
*b
8
8. Gasket
9. EGR box
10. EGR box bracket
*a: Intake manifold
*b: Exhaust manifold
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
4M41 ENGINE -
9. INTAKE MANIFOLD
REMOVAL AND INSTALLATION
2
Intake Manifold
11B-9-1
*b
18
*a
3
17±1Nm
12
11
3
13
17
15±1Nm
4
Removal steps
1. Side cover
2. EGR valve
3. Gasket
4. Boost air temperature sensor
5. Gasket
6. Air inlet fitting
7. O-ring
8. Throttle body assembly
9. O-ring
10. Boost pressure sensor
11. Boost hose
10
16
9
8
15
14
1
5
7
6
12. Gas filter assembly
13. Rubber spacer A
14. Nut
15. Spring
16. Intake manifold
17. Rubber spacer B
"AA 18. Gasket
*a. EGR pipe
*b. Cylinder head
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
11B-9-2
Cylinder
head
Cylinder head
4M41 ENGINE -
Gasket
Gasket
Intake Manifold
INSTALLATION SERVICE POINT
"AA
Fit the gasket to the cylinder head in the direction shown
in the illustration.
GASKET INSTALLATION
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
4M41 ENGINE -
Turbocharger Assembly
10. TURBOCHARGER ASSEMBLY
REMOVAL AND INSTALLATION
54±5Nm
10
11B-10-1
*1
*2
25±2Nm
*3
11
14
20 Nm
2
3
5
49±4Nm
1
4
13
6
8
7
9
49±4Nm
12
Removal steps
1. Eyebolt
2. Oil feed pipe
3. Oil return pipe
4. Nut
5. Coupler insulator
6. Insulator
7. Coupler
8. Gasket
9. Nut
10. Bolt
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
"AA 14. Turbocharger assembly
11. Insulator B
12. Insulator A
13. Gasket
*1: Exhaust manifold
*2: Turbocharger water outlet pipe
(Refer to page 11B-6-1.)
*3: Turbocharger water inlet pipe
(Refer to page 11B-6-1.)
11B-10-2
4M41 ENGINE -
Turbocharger Assembly
A
INSTALLATION SERVICE POINT
"AA
TURBOCHARGER ASSEMBLY INSTALLATION
(1) Prior to installing the turbocharger assembly14, pour
engine oil into it through the oil inlet holeAto lubricate
its component parts for smooth movement.
(2) Using a tester, apply pressure to the actuatorBand read
the pressure at which the rod
begins to move
C
(approximately 1 mm).
If the reading deviates from the specified standard value,
replace the actuator.
C
B
Standard value: 161 kPa
Caution
Do not load the actuator B with any more pressure
than 181 kPa nor carry the turbocharger by holding
the rod C, or the diaphragm may be damaged.
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
4M41 ENGINE -
11. EXHAUST MANIFOLD
REMOVAL AND INSTALLATION
*1
Exhaust Manifold
3
2
6
11B-11-1
1
30±3Nm
*3
49±4Nm
7
*2
5
4
Removal steps
1. Insulator
2. Insulator
3. Bolt
4. Nut
5. Nut
6. Exhaust manifold
7. Gasket
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
*1: EGR pipe
*2: Cylinder head
*3: Turbocharger
4M41 ENGINE -
Injection Pump Assembly
12. INJECTION PUMP ASSEMBLY
REMOVAL AND INSTALLATION
6
2
1
20
18
9
8
11B-12-1
4
7
5
17
11
13
25±2Nm
14
18±2Nm
12
19
Removal steps
1. Injection pump cover B
2. Injection pump cover A
3. Rubber spacer
4. Rubber spacer
5. Harness
6. Harness
7. Harness
8. Harness
9. Harness
10. Fuel return hose
10
15
16
3
11. Fuel leak-off hose
12. Fuel suction hose
AA""BA 13. Injection pipe
14. Bolt
15. Pump stay
16. Pump stay
"AA 17. Injection pump assembly
18. O-ring
19. Rubber spacer
20. Stay
Caution
1. Fuel is highly flammable. Keep it away from flames and sources of heat.
2. Be sure to wipe up spilt fuel completely. It could catch fire.
3. Have the injection pump assembly 17 serviced at an appropriate Zexel service station.
4. Dust particles entering the injection pump assembly 17 can seriously affect the engine
performance. To prevent it, fully cover the openings left after the removal of parts such as
pipes and hoses.
5. Before installing the injection pipe 13, check to ensure that the pipe seating surface is free
from any damage and unevenness.
E
Feb. 2000Mitsubishi Motors Corporation Added
PWEE9409-D
Loading...