Mitsubishi Canter 2000 User Manual

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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

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-0-2

NOTES

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

3200

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)

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

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

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

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

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

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

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)

Unit: Nm

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

Standard Thread

Coarse Thread

M6 5 ± 1 -

M8 13 ± 2 -

M10 26 ± 4 24 ± 4

M12 41 ± 8 42 ± 9

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.

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

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

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

6.6

MD998665 Valve guide remov-erRemoval of valve guide

MH06361 1: A Calking ring inlet Installation of valve seat

A, B

35: A

33: B

MH063612: B Calking ring ex-

haust

MH063613: C Calking tool body

MH063610 Valve guide install-erInstallation of valve guide

16.5

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Special Tools

Tool Number Name Use

11B-2-3

15.4

27.5

41.5

60 - 120

MH063609 Valve stem seal

6.6

MH062463 Idler gear bush

MH062462 Idler sprocket bush

installer

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

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

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

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

3. GENERATOR ASSEMBLY

REMOVAL AND INSTALLATION

Generator Assembly

11B-3-1

Removal steps

1. Wiring harness

2. Adjusting bolt

3. Bolt

4. V-belt (Refer to page 11B-5-1.)

"AA 5. Generator

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

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

4. GLOW PLUG

REMOVAL AND INSTALLATION

Glow Plug

11B-4-1

18±1Nm

13±1Nm

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

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

11B-5-1

10±1Nm

24±2Nm

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

24±2Nm

*1: Timing gear case

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-5-2

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

(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

(3) Loosen the bolt an d nutBholding the generator, and

adjust the tension of the V-belt5using the adjusting

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.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

6. WATER HOSES AND PIPES

REMOVAL AND INSTALLATION

Water Hoses and Pipes

11B-6-1

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

25±2Nm

(For water temperature gauge)

25±2Nm

9±1Nm

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

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

7. THERMOSTAT

REMOVAL AND INSTALLATION

Thermostat

11B-7-1

Removal steps

1. Thermostat cover

"BA 2. Thermostat

3. Bypass pipe

"AA 4. O-ring

5. Thermostat case

"AA 6. O-ring

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

Install the thermostat2with its jiggle valveAlocated at the uppermost position.

"BA

THERMOSTAT INSTALLATION

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

8. EGR VALVE ASSEMBLY

REMOVAL AND INSTALLATION

EGR Valve Assembly

11B-8-1

Removal steps

1. EGR pipe

2. Gasket

3. EGR pipe stay

4. EGR valve

5. Gasket

6. Insulator

7. EGR pipe

8. Gasket

9. EGR box

10. EGR box bracket

*a: Intake manifold *b: Exhaust manifold

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

9. INTAKE MANIFOLD

REMOVAL AND INSTALLATION

Intake Manifold

11B-9-1

17±1Nm

15±1Nm

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

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

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-9-2

Cylinder head

4M41 ENGINE -

Gasket

Intake Manifold

INSTALLATION SERVICE POINT

"AA

Fit the gasket to the cylinder head in the direction shown in the illustration.

GASKET INSTALLATION

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Turbocharger Assembly

10. TURBOCHARGER ASSEMBLY

REMOVAL AND INSTALLATION

54±5Nm

11B-10-1

25±2Nm

20 Nm

49±4Nm

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

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

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

(approximately 1 mm). If the reading deviates from the specified standard value, replace the actuator.

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.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

11. EXHAUST MANIFOLD

REMOVAL AND INSTALLATION

Exhaust Manifold

11B-11-1

30±3Nm

49±4Nm

Removal steps

1. Insulator

2. Insulator

3. Bolt

4. Nut

5. Nut

6. Exhaust manifold

7. Gasket

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

11B-12-1

25±2Nm

18±2Nm

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

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.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-12-2

“0”

MB990767

4M41 ENGINE -

MD998754

MB990767

Injection Pump Assembly

REMOVAL SERVICE POINT

AA"

Loosen the union nutBof the fuel injection pipe locking the delivery valve holderAto prevent it from rotating together.

INJECTION PIPE REMOVAL

while

INSTALLATION SERVICE POINTS

"AA

(1) Turn the crankshaft pulleyAclockwise with the specified

INJECTION PUMP ASSEMBLY INSTALLATION

special tool to place the No.1 piston at the TDC on the compression stroke. Align the notchCin the crankshaft pulley with the timing mark “0” on the timing gear case

Caution

1. If the dent D on the camshaft faces upward, the No.1 piston is at the TDC on the compression stroke. If not, rotate the crankshaft pulley A one more turn in normal direction.

2. Never rotate the crankshaft pulley A in reverse direction (counterclockwise). It may cause damage to the timing chain tensioner. If the crankshaft is accidentally rotated in reverse direction, remove and reinstall the tensioner according to the correct installation procedure.

(2) Align the notchFon the injection pump gearEwith the

mating mark “H” on the flange plateG.

4ME0542

(3) Align the guide barJof the flange plateGwith the guide

holeLof the front plateKand insert t he injection pump assembly into the front plate just before the injection pump

gearEmeshes with the idler gear.

4ME0543

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Injection Pump Assembly

11B-12-3

(4) Confirm that the notchFon the injection pump gear

is aligned with the mating mark “H” on the flange plate

. Then push the injection pump assembly further into

the front plate. When meshing the gears, the notchFon the gear should move in the directionM.

4ME0544

"BA

Tighten the union nutBof the fuel injection pipe

INJECTION PIPE INSTALLATION

while

locking the delivery valve holderAto prevent it from rotating

together.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

13. INJECTION PUMP GEAR

REMOVAL AND INSTALLATION

Locating pin

Injection Pump Gear

11B-13-1

180±10 Nm

5±1Nm

38±2Nm

5±1Nm

Locating pin

Removal steps

"AA

11. Flange plate

12. Bolt

13. Engine speed sensorII(Backup)

14. O-ring

15. Bolt

16. Engine speed sensorI(Main)

17. O-ring

18. O-ring

19. Key

20. Injection pump

AA"

"BA

1. Nut

2. Injection pump gear assembly

3. Snap ring

4. Injection pump sub gear

5. Spring

6. Pin

7. Injection pump gear

8. Bolt

9. Sensor plate

10. Nut

Caution Have the injection pump 20 serviced at an appropriate Zexel service station.

4ME0568

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-13-2

MH062567

4M41 ENGINE -

Injection Pump Gear

REMOVAL SERVICE POINT

AA"

Using the special tool, remove the injection pump gear7.

INJECTION PUMP GEAR REMOVAL

INSTALLATION SERVICE POINTS

"AA

Install the flange plate

FLANGE PLATE INSTALLATION

while aligning the mating marks

on the flange plate and the injection pump20.

Locating pin

"BA

INJECTION PUMP GEAR ASSEMBLY INSTALLATION

(1) Clamp the injection pump gear7in a viceB. Protect

the gear teeth with pieces of waste clothAor the like as shown.

(2) Remove t he locating pin from the pump gear7.

Caution

1. Check the removed locating pin for deformation or damage before using it again.

2. Replace the locating pin if deformed or damaged.

(3) Install the injection pump sub gear4, spring5and pins

onto the injection pump gear7as shown.

(4) Hook each pin6on the spring5atC.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Injection Pump Gear

11B-13-3

MH063473

(5) Fit the snap ring3onto the injection pump gear.

(6) Fit the special tool in the holeDin the sub gear4. Turning

the sub gear with the special tool counter-clockwise, align the holeEin the sub gear4with the holeFin the pump gear7, then install the boltG.

(7) In that state, strike the locating pin into the holeHin

the sub gear4, then remove the boltG.

Locating pin

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Rocker Cover, Camshaft Holder Assembly and Camshaft

11B-14-1

14. ROCKER COVER, CAMSHAFT HOLDER ASSEMBLY AND CAMSHAFT

REMOVAL AND INSTALLATION

Apply engine oil to all moving parts before

13±2Nm

installation.

11±1Nm

3.0±0.3 Nm

20±1Nm

38±8Nm

9.5±0.5 Nm

88±10 Nm

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-14-2

Removal steps

1. Oil filler cap

2. Bolt

3. Washer

"BA 4. Rocker cover assembly "BA 5. Rocker cover gasket

6. Eyebolt

7. Gasket

8. Eyebolt

9. Gasket

10. Fuel leak-off pipe

11. Bolt

12. Upper guide plate

AA""AA 13. Bolt

14. Bolt

15. No.1 camshaft cap

16. No.2 camshaft cap

17. No.3 camshaft cap

18. No.4 camshaft cap

4M41 ENGINE -

Rocker Cover, Camshaft Holder Assembly and Camshaft

19. No.5 camshaft cap

20. Intake camshaft

21. Exhaust camshaft

22. No.1 camshaft holder

23. No.2 camshaft holder

24. No.3 camshaft holder

25. No.4 camshaft holder

26. No.5 camshaft holder

27. Rocker assembly (short)

28. Lock nut

29. Adjusting screw

30. Rocker (short)

31. Rocker assembly (long)

32. Lock nut

33. Adjustng screw

34. Rocker (long)

35. Pivot bolt

Caution Since the camshaft caps 15 through 19 and camshaft holders 22 through 26 have been machined in pairs, replacement of either one of the pair is not allowed. Also, never alter their original combination.

PRE-REMOVAL INSPECTION

CAMSHAFT END PLAY

Measure the end play, and if th e reading deviates from the specified value, replace the defective part.

Standard value: 0.10 - 0.18 mm

Limit: 0.3 mm

REMOVAL SERVICE POINT

AA"

Caution

1. When removing the bolt 13, be sure to lock the

2. The bolt 13 is inversely threaded. The arrow mark

3. The camshaft sprockets *a and timing chain *b must

BOLT REMOVAL

camshaft 20, 21 by holding the hexagonal part A with a proper wrench. Do not use the timing chain *b for the locking.

on its head B indicates its turning direction when tightened. To remove, turn the bolt in the reverse direction.

be meshed in a fixed position. Do not remove the timing chain from the camshaft sprockets unless absolutely necessary.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Rocker Cover, Camshaft Holder Assembly and Camshaft

11B-14-3

INSTALLATION SERVICE POINTS

"AA

BOLT INSTALLATION

Caution The bolt 13 is inversely threaded. The arrow mark on

its head B indicates its turning direction when tightened.

"BA

ROCKER COVER GASKET / ROCKET COVER ASSEMBLY INSTALLATION

Before installing the rocker cover4, remove all deposites, especially oil in the gasket grooveA.

Caution

Install the rocker cover gasket 5 using care so that it is not distorted.

INSPECTION

1. CAMSHAFT

(1) Cam Lobe Lift (Difference between Cam Height and Base

Circle Diameter)

If the specified service limit is exceeded, replace the camshaft20,21.

: Cam height

20, 21

: Base circle diameter

Standard value:

Intake

Front 6.16 mm Rear 6.10 mm

Exhaust

Front 5.91 mm Rear 6.16 mm

Limit:

Intake

Front 6.11 mm Rear 6.05 mm

Exhaust

Front 5.86 mm Rear 6.11 mm

(2) Bend

With the camshaft

20, 21

supported at No.1 journal

and No.5 journalD, measure the bend at No.3 journal

20, 21

. If the reading exceeds the specified service limit,

replace the camshaft

20, 21

Standard value: 0.015 mm or less

Limit: 0.03 mm

NOTE The actual shaft bend is a half of what the dial gauge reads when the camshaft

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

20, 21

is given one turn.

11B-14-4

15 - 19

22 - 26

20, 21

4M41 ENGINE -

Rocker Cover, Camshaft Holder Assembly and Camshaft

(3) Oil Clearance at Journals

Measure the oil clearance at each journal. If the reading exceeds the specified limit, replace the defective part.

Standard value: 0.05 - 0.09 mm

Limit: 0.15 mm

Caution Be sure to replace the camshaft 15 through 19 together with the camshaft holder 22 through 26.

2. ROCKER

If radial playBat the rollerAof the rocker30,34exceeds the specified standard value, replace the defective part.

Standard value: 0.03 - 0.07 mm

30, 34

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

15. INJECTION NOZZLE

REMOVAL AND INSTALLATION

Injection Nozzle

11B-15-1

21±2Nm

Cylinder head

13±2Nm

11±1Nm

35±5Nm

AA""AA

Removal steps

1. Injection pipe

2. Injection pipe seal

3. Eyebolt

4. Return pipe

5. Eyebolt

6. Gasket

7. Eyebolt

8. Leak-off pipe

9. Bolt

10. Injection nozzle assembly

11. Retaining nut

12. Nozzle tip

13. Needle valve

14. Pin

11±1Nm

33±3Nm

4ME0506

15. Spacer

16. Llift piece

17. Spring seat

18. Shim

19. No.2 spring

20. Push rod

21. Collar

22. Spring seat

23. No.1 spring

24. Shim

25. Nozzle holder

26. O-ring

27. Nozzle gasket

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-15-2

4M41 ENGINE -

Injection Nozzle

Caution

1. Fuel is highly flammable. Keep it away from flames and sources of heat.

2. Wipe up spilt fuel completely. It could catch fire.

3. Remove all deposited carbon from the injection nozzle assembly 10 before disassembling,

reassembling and adjusting it. Prior to intended disassembly, check the injection nozzle 10 for abnormal injection pressure, abnormal spray pattern and fuel leaks. If it is in order, the disassembly is not needed.

4. Never change the original combination of needle valve 13 and nozzle tip 12 when reassembling

each injection nozzle assembly 10.

5. Dust particles can seriously affect the engine performance. To prevent the ingress of dust,

fully cover and close up the opening left after removal of each injection nozzle assembly 10.

PRE-REMOVAL INSPECTION

Install the nozzle testerAto the injection nozzle assembly

and perform the following checks:

Caution Prior to proceeding with the checks, bleed air from the fuel injection nozzle by pumping the nozzle tester lever two or three times.

1. VALVE OPENING PRESSURE CHECK

(1) Operate the nozzle testerAlever at 1 to 2 seconds per

stroke. Read the pressure when, after a gradual increase, the pointer deflects rapidly.

(2) If the reading deviates from the specified standard value,

disassemble the fuel injection nozzle, clean and reassemble. Then, make necessary pressure adjustment using adjusting shims

18, 24

(3) If the reading still deviates after the adjustment, replace

the fuel injection nozzle assembly10.

2. SPRAY PATTERN CHECK

(1) Inject fuel continuously by pumping the nozzle tester

lever quickly (1 to 2 seconds per stroke).

: Even spray from all five injection orifices (Good)

: Even and symmetrical spray (Good)

: Asymmetrical spray (Bad)

: Branched spray (Bad)

: Thin spray (Bad)

: Irregular spray (Bad)

(2) Disassemble, clean and recheck t he fuel injection nozzle

assembly

if necessary. If the problem still remains

after another check, replace the fuel injection nozzle assembly.

(3) Check that the fuel injection nozzle does not dribble after

injection.

Caution Do not touch the spray that comes out of the nozzle.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

3. OIL TIGHTNESS CHECK

(1) Slowly increase the nozzle internal pressure and maintain

it at a pressure 1960 kPa lower than the specified 1st valve opening pressure. In this condition, check that the fuel injection nozzle does not start dribbling within10 seconds.

(2) If the dribbling begins in less than 10 seconds,

disassemble, clean and recheck the fuel injection nozzle assembly10. If the problem still remains after another check, replace the fuel injection nozzle assembly.

Injection Nozzle

11B-15-3

157944-9520

REMOVAL SERVICE POINTS

AA"

RETAINING NUT REMOVAL

Using the special tool, remove the retaining nut.

4ME0510

Caution

1. Be sure not to touch the sliding surface A of the needle valve 13 with dirty hands.

2. Be sure not to change the original combination of the needle valve 13 and nozzle tip 12 removed.

4ME0511

157944-9520

INSTALLATION SERVICE POINT

"AA

RETAINING NUT INSTALLATION

Using the special tool, install the retaining nut.

4ME0510

Caution

1. Be sure not to touch the sliding surface A of the needle valve 13 with dirty hands.

2. Be sure not to change the original combination of the needle valve 13 and nozzle tip 12 removed.

4ME0511

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-15-4

4M41 ENGINE -

Injection Nozzle

105789-0010

NOZZLE TIP, NEEDLE VALVE CLEANING

Wash the needle valve

and nozzle tip

removed in

clean kerosene (cleaning oil) and remove deposited carbon from them in the following manners using the specified special tools. (1) Remove carbon deposited on the tip of the needle valve

using the special tool Cleaning Bar.

Caution For cleaning, never use a wire brush or any other hard metal tool.

(2) Remove carbon deposited in the nozzle hole area of

the nozzle tip12by turning the special tool Needle Cleaner that runs through the nozzle hole.

Cleaning needle diameter: Less thanf0.21 mm

(3) Clean the seat of the nozzle tip

using the special

tool Cleaning Scraper.

(4) To remove baked carbon, use the Fuso Carbon

Remover.

NOZZLE TIP, NEEDLE VALVE INSPECTION

(1) Wash the needle valve

and nozzle tip

clean in

clean kerosene (cleaning oil) prior to reassembly.

(2) Pull out the needle valve

to approximately o ne third

of its length, let go of it and see if it slides down by

gravity. (Repeat this procedure a few times after turning the needle valve each time.)

4ME0515

(3) If the needle valve

it again and give it another check. Replace the needle valve

and nozzle tip

fails to slide down by itself, wash

as a set.

Caution

1. If a nozzle tip 12 is to be replaced, use a Nozzle

Service Kit to replace the needle valve 13, pin 14, lift piece 16 and spacer 15 at the same time.

2. After replacing the nozzle tip 12, be sure to readjust

the prelift to bring the valve opening pressure to the specified standard value.

Standard value: 0.05 - 0.07 mm

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

INJECTION NOZZLE ASSEMBLY ADJUSTMENT

While reassembling parts, adjust and check the injection nozzle assembly in the sequence shown below.

Caution

1. Before starting adjustments and checks, wash all parts clean in clean kerosene (cleaning oil) to ensure that they are entirely free of dirt and other foreign matters.

2. Never touch the sliding contact surface of the needle valve 13.

Injection Nozzle

Adjusting 1st valve opening pressure

Checking full lift of needle valve

Checking prelift

Adjusting 2nd valve opening pressure

11B-15-5

157892-3200

157892-5100

15 20

4ME0516

4ME0517

Checking nozzle tip and needle valve

ADJUSTING 1ST VALVE OPENING PRESSURE

(1) Fit parts

(2) Fit the lift piece

through

to the nozzle holder25.

in the illustrated direction.

(3) Fit the special tool Gasket onto the nozzle tip12, then

secure the nozzle tip to the nozzle holder

with the special tool Retaining Nut (for adjustment). Turn the special tool Retaining Nut (for adjustment) handtight, then tighten it to the specified torque (34 5 Nm).

4ME0518

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-15-6

4M41 ENGINE -

Injection Nozzle

157892-5100

(4) Attach the nozzle holder

(5) Pumping the nozzle testerB, measure the 1st valve

to the nozzle testerA.

opening pressure.

Standard value: 17.60 - 18.58 MPa

4ME0519

(6) If the reading deviates from the specified standard value,

disassemble the nozzle holder adjustment by changing the existing shim

and make pressure

for a shim

with appropriate thickness.

Thicknesses of available shims (outside diameter:

6.2 mm) for 1st valve opening pressure adjustment:

0.40, 0.50, 0.52, 0.54, 0.56, 0.58, 0.60, 0.70 mm

4ME0520

CHECKING FULL LIFT OF NEEDLE VALVE

157892-1600

The full lift check is performed to determine if the seat of the nozzle tip12is abnormally worn and if the injection nozzle assembly

is in order as well.

(1) Fit the special tool Gasket an d the special tool Plug onto

026508-1140

the special tool Retaining Nut (for adjustment).

157892-4400

157892-1000

157892-4400

4ME0521

(2) Fit the nozzle holder

to the special tool Plate with

its nozzle tip side down.

157944-9520

4ME0522

(3) Fit the special tool Holder to th e nozzle holder25.

(4) Mount the special tool Nut on the special tool Holder.

4ME0523

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Injection Nozzle

11B-15-7

157954-3801

157892-7200

157954-3801

157892-1000

157892-7200

(5) Connect the special tool Pin to the special tool Dial Gauge.

(6) Fit the special tool Dial Gauge onto the nozzle holder

and secure it with the special tool Nut in such a manner

that the special tool Pin contacts the upper end of the spring seat22.

Caution

1. Secure the special tool Dial Gauge so that a stroke

of 2 mm or so can be measured.

2. Do not overtighten the special tool Nut. If it is

too tight, the shaft C of the special tool Dial Gauge may be stuck.

157954-3801

157892-5100

Needle valve lift (mm)

157892-1600

1st valve opening pressure

Pipe pressure (MPa)

4ME0525

zero the special tool Dial Gauge.

(7) Attach the nozzle holder

to the nozzle testerB, then

(8) Loosen the special tool Plug, then operate the nozzle

testerBto bleed all air out of the special tool Retaining Nut (for adjustment). Check for fuel leakage at the same time.

4ME0526

(9) Using the nozzle tester, increase the pipe pressure up

to somewhere between 34.3 and 44.1 MPa to make the needle valve13lift to the full level. Record the dial gauge readingDof full lift.

Standard value: 0.23 - 0.27 mm

Caution This check is necessary to determine if the seat of the nozzle tip 12 is abnormally worn.

34.3 - 44.1

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-15-8

Needle

valve lift (mm)

1st valve opening pressure

Pipe pressure (MPa)

4M41 ENGINE -

CHECKING PRELIFT

(1) With the needle valve

of the nozzle testerB. This causes the pipe pressure to decrease with a concomitant drop in dial gauge reading (needle valve lift).

: Amount of needle valve full lift

(2) Read the dial gauge when the 2nd spring19has stopped

acting, or when the needle valve13has stopped lowering (at prelift levelE), a n d ascertain that the reading is within the specified limits of standard value.

Standard value: 0.05 - 0.07 mm

(3) Read the dial gauge with the needle valve

prelift measuring pointF(1st valve opening pressure + approx. 1 MPa). (Observe the dial gauge while lowering the pressure.)

Injection Nozzle

fully lifted, release the handle

at the

157954-3801

4ME0529

4ME0530

(4) If the dial gauge reading deviates from the specified limits

of standard value, replace the pin14, lift piece16, spacer

, nozzle tip

and needle valve

with a Nozzle

Service Kit.

: Capsule (Zexel part No. 105019-1240)

Standard value: 0.05 - 0.07 mm

ADJUSTING 2ND VALVE OPENING PRESSURE

(1) After checking the prelift, operate the nozzle tester

and increase the pipe pressure to 34.3 - 44.1 MPa so that the needle valve lifts fully.

(2) Release the handle of the nozzle testerB. The pipe

pressure will lower with a concomitant drop in dial gauge reading (needle valve lift).

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

Needle valve lift (mm)

1st valve opening pressure

E + 0.05

34.3 - 44.1

Pipe pressure (MPa)

4M41 ENGINE -

2nd valve opening pressure

Injection Nozzle

11B-15-9

(3) Note the value indicated by the pressure gaugeHthe

moment the dial gauge indicates the specified amount of needle valve lift (normally preliftE+ 0.05 mm).

: Needle valve full lift

Standard value: 22.6 - 23.6 MPa

157954-3801

(4) If the dial gauge reading deviates from the specified limits

of standard value, disassemble the nozzle holder25and make pressure adjustment by changing the existing shim

for a shim with appropriate thickness.

Thicknesses of available 2nd valve opening pressure adjusting shims (outside diameter:f7.2 mm):

0.10, 0.20, 0.30, 0.40, 0.50, 0.51, 0.52, 0.53, 0.54,

0.55, 0.56, 0.57, 0.58, 0.59 mm

Caution Adjusting the 1st valve opening pressure changes the 2nd valve opening pressure. After the lst valve opening pressure is altered, therefore, be sure to check and readjust the 2nd valve opening pressure.

CHECKING INJECTION NOZZLE ASSEMBLY

157954-3801

157892-1000

Upon completion of all necessary adjustments, perform a final check on the injection nozzle assembly by the following procedure.

157892-4400

(1) Remove the special tools Dial Gauge, Nut and Holder.

157892-3200

157892-5120

4ME0533

(2) Remove the special tools Retaining Nut (for adjustment)

and Gasket.

(3) Check that the pin

regular retaining nut

is secured in position. Install the

handtight. then tighten it to the

specified torque.

(4) Attach the nozzle holder25to the nozzle testerB. Using

the nozzle testerB, check the 1st valve opening pressure, spray form and seat oiltightness. Check that all parts are leak-free at the same time.

4ME0534

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Cylinder Head and Valve Mechanism

16. CYLINDER HEAD AND VALVE MECHANISM

REMOVAL AND INSTALLATION

11B-16-1

Apply engine oil to all moving parts before installation.

58±6Nm

21±2Nm

49±5Nm+90_+90

3 4

49±5Nm+90_+90

1.3±1.0 Nm

18±2Nm

Removal steps

1. Bolt

2. Injection nozzle

3. O-ring

4. Nozzle gasket

5. Nut

6. Connecting plate

7. Glow plug

8. Timing gear upper cover

"HA "HA

AA""GA AA""FA

9. Tensioner

10. Gasket

11. Bolt (M10)

12. Cylinder head bolt (M12: long)

13. Cylinder head bolt (M12: short)

14. Washer

15. Cylinder head assembly

16. Cylinder head gasket

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-16-2

4M41 ENGINE -

Cylinder Head and Valve Mechanism

Apply engine oil to all moving parts before installation.

47±5Nm

Removal steps

17. Valve cap

AB""EA 18. Valve cotter

19. Valve spring retainer

"DA 20. Valve spring

21. Valve spring seat

"CA 22. Valve stem seal

23. Exhaust valve

24. Intake valve

AC""BA 25. Exhaust valve guide AC""BA 26. Intake valve guide AD""AA 27. Exhaust valve seat AD""AA 28. Intake valve seat

29. Sealing cap (f35 mm)

30. Stud

31. Water joint

32. Cylinder head

Caution

1. The cylinder head bolt 12, 13 is tightened to the plastic area. If the bolt shows the evidence of having been tightened three times, replace it with a new ones.

2. The timing chain slips out of place if the camshaft sprocket is removed from it. If the chain comes off, remove the timing gear case assembly and put the chain back in position.

3. Replace the valve stem seal 22 with a new one once the exhaust valve 23 or intake valve 24 is removed.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Cylinder Head and Valve Mechanism

11B-16-3

REMOVAL SERVICE POINTS

AA"

Caution When removing the cylinder head gasket 16, use care not to scratch the cylinder head assembly 15, crankcase assembly and timing gear case assembly.

CYLINDER HEAD ASSEMBLY / CYLINDER HEAD GASKET REMOVAL

12, 13

1318

(1) Loosen the cylinder head bolts stepwise in the sequence

of the numbers shown, then remove them.

Caution Provide one punch mark G on the head of the cylinder head bolt 12, 13 each time the bolt is tightened. Replace the bolt that already has three punch marks (the evidence of having been tightened three times).

(2) Lift up the cylinder head assembly straight and remove,

while keeping the camshaft sprockets*ain engagement with the timing chain*b.

(3) After the cylinder head assembly is removed, hold the

camshaft sprockets*awith the special tool to keep the timing chain

on it.

Component Parts of the Special Tool MH063490 - Cam Sprocket Holder Kit

: Nut

: Washer

: Spacer

: Adjusting plate

: Nut

: Bolt

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-16-4

4M41 ENGINE -

Cylinder Head and Valve Mechanism

MD998772

MD998784

AB"

VALVE COTTER REMOVAL

<Method 1> Using the special tools, remove the valve cotters18as follows.

Component parts of special tool MD998772 Valve Spring Compressor

: Wing bolt

: Retainer

: Handle

: Nut

: Bolt

: Slotted screw

: Stay

: Lock nut

: Tension spring

: Mobile nut

: Washer

: Snap ring

: Retainer holder

(1) Install the special tools on the cylinder head32as shown

in the illustration.

MD998784

MD998772

: Bolt (M8 x 12.5 mm)

(2) Install the special tool MD998772 on the special tools

MD998784.

: Washer

: Nut (M6 x 1 mm)

(3) Move the retainerBand mobile nutKinto a position

where the retainer holderNpresses the valve spring retainer

from right above, then secure them with the

wing boltA.

Use the nutsDto adjust the vertical position of the stay

NOTE

Set the stayGlevel.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Cylinder Head and Valve Mechanism

11B-16-5

(4) Turning the handleCclockwise to depress the valve spring

retainer19, remove the valve cotters18.

<Method 2> Using the special tool, compress the valve spring20to remove

MD999597

the valve cotters18.

: Protector

AC"

MD998665

Remove the valve guide25,

EXHAUST VALVE GUIDE / INTAKE VALVE GUIDE REMOVAL

using the special tool.

25, 26

AD"

27, 28

The valve seat27,

EXHAUST VALVE SEAT / INTAKE VALVE SEAT REMOVAL

is shrink-fitted. To remove it, grind

its inside surface to reduce its thickness, then pull it out at room temperature.

: Material to be removed by grinding

0.5 - 1.0 mm

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-16-6

MH063613

MH063611 or MH063612

27, 28

4M41 ENGINE -

Cylinder Head and Valve Mechanism

INSTALLATION SERVICE POINTS

"AA

(1) Measure a diameter of the valve seat holeJ,Hin the

(2) Rebore the valve seat holeJ,Hto the diameter appropriate

(3) Immerse the valve seat27,

(4) Using the special tools MH063613, MH063611 and

(5) After installing the valve seat27,28, lap it and the valve

"BA

(1) Measure a diameter of the valve guide25,

(2) Rebore the valve guide holeAto the diameter appropriate

INTAKE VALVE SEAT / EXHAUST VALVE SEAT INSTALLATION

cylinder head32and select an oversize valve seat which can provide proper amount of cylinder head-to-valve seat interference.

to the selected oversize valve seat.

Unit: mm

Oversize valve seat used

: Intake valve seat hole

inside diameter

: Exhaust valve seat hole

inside diameter

0.30 0.60

35.3 - 35.325 35.6 - 35.625

33.3 - 33.325 33.6 - 33.625

in liquid nitrogen to cool

enough.

MH063612, press the valve seat27, head

until it bottoms.

in the cylinder

for proper fit.

INTAKE VALVE GUIDE / EXHAUST VALVE GUIDE INSTALLATION

hole in

the cylinder head32and select an oversize valve guide which can provide proper amount of cylinder head-to-valve guide interference.

to the selected oversize valve guide.

MH063610

16.5 mm

25, 26

Caution Do not install a valve guide of the same size as removed.

Oversize valve guide used

Valve guide hole inside diameter

(3) Install the valve spring seat

0.05 0.25 0.50

12.05 -

12.068

12.25 -

12.268

in the cylinder head32,

12.50 -

12.518

then install the valve guide by striking the special tool until it comes into full contact with the valve spring seat

Caution The installed depth of the valve guide shall be as specified. Be sure to use the special tool for installation.

(4) The intake valve guide

is longer than the exhaust

valve guide25. Be sure to install right valve guide in right place.

Unit: mm

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Cylinder Head and Valve Mechanism

11B-16-7

23, 24

25, 26

MD998772

MD998784

MH063609

"CA

VALVE STEM SEAL INSTALLATION

(1) Apply a thin coat of engine oil to the lipAof the valve

stem seal22, then press in the valve stem seal

by hand until its lower endBcontacts the top of the valve guide25,26.

(2) Install the valve stem seal

striking the special tool vertically until it comes into full

in position by carefully

to fully contact with the valve spring seat surface in the cylinder head32.

"DA

VALVE SPRING INSTALLATION

Install the valve spring20with the blue painted endAupward.

"EA

VALVE COTTER INSTALLATION

<Method 1> Using the special tools, install the valve cotters18as follows.

MD998784

Component parts of special tool MD998772 Valve Spring Compressor

: Wing bolt

: Retainer

: Handle

: Nut

: Bolt

: Slotted screw

: Stay

: Lock nut

: Tension spring

: Mobile nut

: Washer

: Snap ring

: Retainer holder

(1) Install the special tools on the cylinder head32as shown

in the illustration.

: Bolt (M8 x 12.5 mm)

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-16-8

4M41 ENGINE -

Cylinder Head and Valve Mechanism

MD998784

MD998772

(2) Install the special tool MD998772 on the special tools

MD998784.

: Washer

: Nut (M6 x 1 mm)

(3) Move the retainerBand mobile nutKinto a position

where the retainer holderNpresses the valve spring retainer

from right above, then secure them with the

wing boltA.

Use the nutsDto adjust the vertical position of the stay

NOTE

Set the stayGlevel.

(4) Turning the handleCclockwise to depress the valve spring

retainer19, install the valve cotters18.

MD999597

<Method 2> Using the special tool, compress the valve spring20to install the valve cotters18.

: Protector

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Cylinder Head and Valve Mechanism

11B-16-9

ABCD

“A” - “D”

"FA

CYLINDER HEAD GASKET INSTALLATION

The cylinder head gasket16is a part that needs to be selected for use. Select the appropriate gasket in the following manner. (1) When replacing the cylinder head gasket alone-Identify;

the crankcase assembly*dby the crankcase identification mark

“A”,“B”,“C”or“D”

stamped on its top surface

and select a gasket of the size corresponding to the mark.

(2) When replacing the piston and connecting rod as well;

1) Measure the piston protrusion from each cylinder.

2) Select the gasket

corresponding in thickness to

the largest of the measured piston protrusions.

NOTE The gasket varies in type according to the number of notches in its notched endE.

Unit: mm

Piston projection

Maximum piston projection Crankcase identification

mark

0.03 - 0.11 A A (1 notch) 0.67 - 0.73

- 0.05 - 0.03 B B (2 notches) 0.72 - 0.78

- 0.13 - - 0.05 C C (3 notches) 0.77 - 0.83

- 0.23 - - 0.15 D D (4 notches) 0.82 - 0.88

"GA

12, 13

Caution

Cylinder head gasket

Type by size Tightened thickness

CYLINDER HEAD ASSEMBLY INSTALLATION

Before installing the cylinder head bolt 12, 13, check the number of punch marks D on its head. (The bolt is reusable if it is two or less.) The number of punch marks corresponds to that of times the bolt has been tightened to the plastic area. If the bolt has three punch marks, replace it.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-16-10

4M41 ENGINE -

Cylinder Head and Valve Mechanism

(1) Apply a coat of specified sealant to the upper surface

of the front plate*cthat joins the cylinder head gasket

Specified sealant:

ThreeBond 1211 or equivalent

(2) Within 3 minutes after the sealant application, install the

cylinder head assembly

together with the cylinder head gasket16.

to the crankcase assembly

Caution

1. Check to ensure that the surface H is clean and

free of oil and other foreign matters before sealant application.

2. During installation of the cylinder head assembly,

use care that the sealant is kept in place.

3. Do not start the engine for at least 1 hour after

the cylinder head assembly is installed.

4. Whenever the cylinder head bolt 11, 12, 13 is

loosened or removed after the cylinder head assembly has been installed, always apply a fresh coat of specified sealant.

(3) Tighten the M12 cylinder head bolts12and13(1 through

18) at M10 bolts

1) Fit the washer

, with its shear-droop sideJfacing in the direction

in the following manner.

onto the cylinder head bolt12,

shown.

2) Apply a thin coat of engine oil to the threaded part

and seating surface of each cylinder head bolt12,

12, 13

, then tighten the bolts to a torque of 98 ± 10

Nm in the sequence of the numbers shown.

3) Loosen the tightened bolts in the reverse order of

the numbers shown and retighten them to a torque of 49 ± 5 Nm in t h e order of the numbers shown.

4) After tightening, give the bolts an additional 90 degree

turn in the sequence of the numbers shown.

5) Then, give the bolts another 90 degree turn to tighten

them completely.

6) After tightening the cylinder head bolt12,13, tighten

the bolt

to the specified torque.

Caution The cylinder head bolt 12, 13 has been tightened up to the plastic area by the above procedure. Once tightened completely, do not attempt to retighten the bolt.

"HA

(1) Fit the gasket

GASKET / TENSIONER INSTALLATION

to the cylinder head assembly

the direction shown in the illustration.

: Sealant coated surface

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Cylinder Head and Valve Mechanism

11B-16-11

(2) Turn the camAof the tensioner9to thrust the plunger

in and lock the plunger with the hookC. Then, install

the tensioner in that state.

(3) Crank the engine in the normal direction (clockwise).

Caution

1. If the tensioner 9 is installed without thrusting

the plunger B in, the timing chain *b may be

damaged by excessive tension.

2. The tensioner 9 stretches the timing chain *b to

optimum tension by means of the internal ratchet mechanism. If the engine is cranked counterclockwise (as viewed from the front) after the tensioner 9 is installed, an excessive thrust is exerted to the plunger B and the cam A may be damaged as a result. Should the engine be cranked counterclockwise, remove the tensioner and re-install it in the sequence described above.

NOTE If the engine is cranked in the normal direction (clockwise) after the tensioner has been installed, the hookCwill be released automatically, the timing chain being adjusted to optimum tension by means of the internal ratchet mechanism.

23, 24

INSPECTION

1. INTAKE AND EXHAUST VALVES

(1) Checking Stem for Wear

Replace the valve23, specified service limit or uneven wear is recognized.

Standard value:

Intake 6.560 - 6.575 mm Exhaust 6.53 - 6.55 mm

Limit: 6.45 mm

Caution If the valve 23, 24 is new, be sure to lap it and the valve seat 27, 28 for proper seating.

(2) Valve Seat Angle and Valve Margin

Correct or replace the valve23,24if the specified service limit is exceeded.

Standard value:

Valve seat angle 45 Valve margine 1.0 mm

if the diameter is below the

_ ±

15’

Limit:

Feb. 2000Mitsubishi Motors Corporation Added

Valve margine 0.8 mm

: Valve seat angle

: Valve margin

PWEE9409-D

11B-16-12

23, 24

4M41 ENGINE -

27, 28

Cylinder Head and Valve Mechanism

2. VALVE SEAT

(1) Valve Seat Width

Replace the valve seat27, limit is exceeded.

: Valve seat width

Standard value: 1.8 - 2.2 mm

Limit: 2.8 mm

Caution When the valve seat 27, 28 has been corrected or replaced, lap it and the valve 23, 24 for proper seating.

(2) Valve Sinkage from Cylinder Head Bottom

If the specified service limit is exceeded, correct or replace the defective part.

: Valve sinkage

Standard value: 0.05 - 0.55 mm

Limit: 0.8 mm

if the specified service

23, 24

25, 26

3. VALVE AND VALVE GUIDE

If the clearance exceeds the specified service limit, replace the defective part.

Standard value:

Intake 0.02 - 0.06 mm Exhaust 0.05 - 0.09 mm

Limit:

Intake 0.10 mm Exhaust 0.15 mm

4. VALVE AND VALVE SEAT

(1) Apply an even coat of minium to the valve seating surface

of the valve seat27,28.

(2) Strike the valve23,

against the valve seat27,

once while taking care that the valve is not rotated.

: Valve Lapper

Caution Before proceeding with the contact check, examine the valve 23, 24 and valve guide 27, 28 in detail to see if they are in normal condition.

(3) Determine the valve seating condition from minium pattern

printed on the valve23,24. If any abnormal contact is found, take the following corrective action.

Condition Corrective action

Minor defect Lap valve for better seating.

Major defect Correct or replace valve and valve

seat.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Cylinder Head and Valve Mechanism

5. CYLINDER HEAD ASSEMBLY

Measure the distortion of the bottom surface of the cylinder head31. If the measured value exceeds the limit, replace the cylinder head.

Standard value: 0.05 mm or less

Limit: 0.2 mm

CORRECTION

1. INTAKE VALVE AND EXHAUST VALVE

Caution

1. The grinding should be minimum.

2. If the valve margin deviates from the specified

service limit after grinding, replace the valve 23,

24.

3. After grinding, lap the valve 23, 24 and valve seat

27, 28 for proper seating.

11B-16-13

2. VALVE SEAT

(1) Grind the valve seat27,

using a valve seat cutter

or a valve seat grinder.

(2) Polish the ground surface lightly using a #400 sandpaper

27, 28

23, 24

held between the cutter and valve seat.

(3) Correct the seat widthCof the valve23,24to the specified

value using a 15_ or 75_ cutter.

: Valve seat angle

Standard value: 45

15’

Caution

1. Be sure that the sinkage E of the valve 16, 17

does not exceed the specified service limit as a result of the correction.

Limit: 0.8 mm

2. After the correction, lap the valve 23, 24 and valve

seat 27, 28 for proper seating.

3. VALVE AND VALVE SEAT

Lap the valve and valve seat as follows: (1) Apply a thin coat of lapping compound evenly to the

23, 24

valve seating surfaceAof the valve seat27,28.

Caution

1. Keep the stem C of the valve 23, 24 free from the lapping compound.

2. Use an intermediate-mesh compound (120 -

150 meshes) first, then a fine-mesh compound (over 200 meshes).

3. To achieve even application of the lapping compound, a mix with a small quantity of engine oil is recommended.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-16-14

4M41 ENGINE -

Cylinder Head and Valve Mechanism

23, 24

(2)Using Valve Lapper, strike the valve23,

the valve seat27,

by little.

: Valve Lapper

a few times while turning little

against

(3) Wash off the lapping compound in kerosene. (4) Apply a thin coat of engine oil to the seating surface

of the valve seat27,

(5) Check the seat contact between the valve23,

and oil lap.

and valve seat27,28.

(6) Replace the valve seat27,

if necessary.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

17. VACUUM PUMP

REMOVAL AND INSTALLATION

Vacuum Pump

11B-17-1

20±2Nm

5.4±0.4 Nm

Removal steps

1. Vacuum hose

2. Vacuum pipe

3. Eyebolt

4. Oil pipe

5. Vacuum pump assembly

6. Bolt

7. Cover

8. O-ring

9. Vane

10. Body assembly

11. O-ring

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-17-2

4M41 ENGINE -

Vacuum Pump

INSPECTION

VACUUM PUMP ASSEMBLY

(1) Connect a vacuum tank (capacity: 10 liters) to the vacuum

pump assembly5through a vacuum gaugeA.

: Engine oil inlet

: Engine oil outlet (to oil pan)

(2) With the engine running, read the engine speed when

the vacuum builds up to the standard value.

Standard value:

Degree of vacuum: 93 kPa or more Pump speed: 1500 r/min

(3) If the reading deviates from the specified standard value,

replace the vacuum pump.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

18. TIMING GEAR CASE

REMOVAL AND INSTALLATION

Apply engine oil to all moving parts before installation.

Timing Gear Case

11B-18-1

323±32 Nm

23±2Nm

Removal steps

1. Timing gear lower cover

2. Bolt

3. Washer

AA" 4. Crankshaft pulley

5. Power steering pump assembly

6. O-ring

7. Vacuum pump assembly

"BA 11. Front oil seal

"AA 13. Timing gear case

Caution Do not remove the front oil seal unless absolutely necessary.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

8. O-ring

9. Bearing block

10. O-ring

12. Cap nut

14. Key

11B-18-2

MB990767

MD998754

4M41 ENGINE -

REMOVAL SERVICE POINT

AA"

Holding the crankshaft pulley4with the special tool, remove the bolt2.

INSTALLATION SERVICE POINTS

"AA

Apply an even bead of sealant to the entire joint surface of the timing gear case

mm.

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or equivalent

Caution Squeeze out the sealant uniformly without excess and discontinuity.

"BA

Apply a thin coat of engine oil to the lipC, and install the front oil seal11in the timing gear case13with the lip directed as shown until its end surfaceAbecomes flush with the end surfaceBof the case.

: End surface (front oil seal)

: End surface (timing gear case)

: Lip

Timing Gear Case

CRANKSHAFT PULLY REMOVAL

TIMING GEAR CASE INSTALLATION

as shown. Bead diameter: 3.5

FRONT OIL SEAL INSTALLATION

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Timing Gear and Balance Shaft

19. TIMING GEAR AND BALANCE SHAFT

REMOVAL AND INSTALLATION

Apply engine oil to all moving parts before installation.

36±4Nm

11B-19-1

33±3Nm

40±4Nm

10 9

12±1Nm

36±4Nm

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-19-2

"GA 3. Timing chain

"FA 12. Balance shaft assembly RH

4M41 ENGINE -

Removal steps

1. Upper guide plate

2. Cam sprocket

4. Bolt

5. Tension lever

6. Tension lever shaft

7. Lower guide plate

8. Bolt

9. Guide plate washer

10. Guide plate

11. Bolt

13. Bolt

14. Washer

15. Balance shaft gear RH

16. Thrust spacer

17. Oil pump assembly

18. Key

19. Balance shaft RH

20. O-ring

21. O-ring

22. Bolt

23. Idler washer

Timing Gear and Balance Shaft

"EA 24. Idler gear assembly LH

AA""DA 25. Idler gear bush LH

26. Idler gear LH

27. Idler shaft

28. Bolt

"CA 29. Balance shaft assembly LH

30. Bolt

31. Washer

32. Balance shaft gear LH

33. Thrust spacer

34. Bush

35. Thrust plate

36. O-ring

37. Key

38. Balance shaft LH

39. Oil jet assembly

40. Bolt

41. Idler washer

"BA 42. Idler gear and sprocket assembly

AB""AA 43. Idler sprocket bush

44. Idler gear and sprocket

45. Idler shaft

Caution After installing the bolt 4, check that the tension lever 5 moves smoothly.

PRE-REMOVAL INSPECTION

1. BACKLASH

Measure backlash between gears, pair by pair, at three or more points. If the reading exceeds the specified service limit, replace defective part.

Standard value:

Balance shaft gear RH and oil pump gear

Oil pump gear and crankshaft gear

Crankshaft gear and idler gear 0.04 - 0.18 mm Idler gear and idler gear LH 0.04 - 0.19 mm Idler gear LH and balance shaft gear LH

Idler gear and injection pump gear

0.04 - 0.19 mm

0.04 - 0.18 mm

0.04 - 0.22 mm

0.04 - 0.21 mm

Limit:

Balance shaft gear RH and oil pump gear

0.3 mm Oil pump gear and crankshaft gear 0.3 mm Crankshaft gear and idler gear 0.3 mm Idler gear and idler gear LH 0.3 mm Idler gear LH and balance shaft gear LH

0.4 mm Idler gear and injection pump gear 0.4 mm

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Timing Gear and Balance Shaft

11B-19-3

2. END PLAY

If the reading exceeds the specified service limit, replace defective part.

Standard value:

Balance shaft LH, RH 0.09 - 0.24 mm Idler gear and sprocket assembly

0.05 - 0.20 mm

Idler gear LH assembly 0.05 - 0.20 mm

Limit:

Balance shaft LH, RH 0.3 mm Idler gear and sprocket assembly 0.3 mm Idler gear LH assembly 0.3 mm

MH062463

MH062462

“0”

REMOVAL SERVICE POINTS

AA"

Using the special tool, remove the idler gear bush25.

AB"

Using the special tool, remove the idler sprocket bush43.

IDLER GEAR BUSH LH REMOVAL

IDLER SPROCKET BUSH REMOVAL

INSTALLATION SERVICE POINTS

"AA

Using the special tool, press-fit the idler sprocket bush into the idler gear and sprocket the match mark

IDLER SPROCKET BUSH INSTALLATION

from the side showing

“0”

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-19-4

4M41 ENGINE -

Timing Gear and Balance Shaft

“1”

“0”

"BA

IDLER GEAR AND SPROCKET ASSEMBLY INSTALLATION

Install the idler gear and sprocket assembly42onto the idler shaft45while aligning the mark “1” with that on the crankshaft gear*c.

"CA

BALANCE SHAFT LH ASSEMBLY INSTALLATION

(1) Assemble the parts shown in the illustration to the balance

shaft LH Be sure that the washer

38.

and thrust spacer

face in correct direction as shown. Install the balance shaft gear LH

with the side showing the match mark

“0”

outward.

: Shear droop side

(2) Insert the completed balance shaft LH assembly

the crankcase assembly

and set it in position with

into

the dowel pin on the crankcase assembly.

MH062463

“F”

“3”

“0”

Caution

1. Do not rotate the balance shaft LH assembly 29

during insertion into the crankcase assembly *a. This may cause the O-ring 35 to be slipped out of place.

2. Insert the balance shaft LH assembly 29 using

care not to damage the inner surface of the balance shaft bush in the crankcase.

"DA

Using the special tool, press-fit the idler gear bush LH into the idler gear LH marks “3” and

"EA

IDLER GEAR BUSH LH INSTALLATION

from the side showing the match

“0”

IDLER GEAR LH ASSEMBLY INSTALLATION

(1) Install the idler gear LH assembly24onto the idler shaft

. At this time, be sure to align the match marks “3”

and marks on the idler gear and sprocket assembly

on the idler gear with the corresponding match

“0”

and

the balance shaft gear LH32.

(2) Then, install the idler washer

to the idler gear LH

assembly with its front mark “F” facing outward.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Timing Gear and Balance Shaft

11B-19-5

“0”

"FA

(1) Assemble the parts shown in the illustration to the balance

BALANCE SHAFT RH ASSEMBLY INSTALLATION

shaft RH Be sure to install the washer

19.

and thrust spacer

in the direction shown in t he illustration, and install the balance shaft gear RH15with its mating mark

“0”

aligned

with the mating mark “6” on the oil pump gear*d.

: Shear droop side

“5”

(2) Insert the completed balance shaft RH assembly

the crankcase assembly while aligning the mating marks “5” on the oil pump gear*dand the crankshaft gear*c,

into

and set the shaft assembly in position with the dowel pin on the crankcase assembly

*a.

Caution

Insert the balance shaft RH assembly using care not to damage the inner surface of the balance shaft bush in the crankcase.

(3) After the timing gears are installed in position, check that

all the rotary parts smoothly rotate.

"GA

(1) Hold the camshaft sprocket2using the special tool.

TIMING CHAIN INSTALLATION

Component Parts of Special Tool MH063490 - Cam Sprocket Holder Kit

: Nut

: Washer

: Spacer

: Adjusting plate

: Nut

: Bolt

(2) Check that the match mark “1” on the idler gear and

sprocket assembly crankshaft gear*c.

(3) Align the match mark

assembly

with the mark link plateHof the timing

is in alignment with that on the

on the idler gear and sprocket

“0”

chain3.

“0”

Caution The timing chain 3 has the match mark provided at two places: one bright white link plate H at one place

“1”

and a pair of bright white link plates J at the other.

(4) Place the timing chain3around the camshaft sprockets

“F”

while aligning th e timing mark

sprockets with the mark link plateJon the timing chain.

(5) After installing the timing chain3, attach the idler washer

with the front mark “F” facing outward.

on the camshaft

“0”

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-19-6

4M41 ENGINE -

Timing Gear and Balance Shaft

INSPECTION

1. TIMING CHAIN

(1) Aligning the stamped linesLon the adjusting plate

and nutE, set the camshaft sprocket2in position.

(2) Push the tension lever5by hand to take up the slack

of the timing chain3. Measure the minimum clearance

between the chain spans facing each other. If the

reading deviates from the specified limit, replace the timing chain.

Standard value: 16.5 mm

Limit: 9 mm

2. TENSION LEVER AND TENSION LEVER SHAFT

(1) Replace the tensioner lever5if it shows any cracks or

flakes on the surfaceAthat makes sliding contact with the timing chain and the tensioner contact surfaceB.

(2) If the tensioner lever5to tension lever shaft6clearance

exceeds the specified limit, replace the defective part.

Standard value: 0.06 - 0.18 mm

Limit: 0.3 mm

3. GUIDE PLATE

Replace the guide plate

if it shows any cracks or

flakes on the surfaceAthat makes sliding contact with the timing chain.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Timing Gear and Balance Shaft

11B-19-7

4. IDLER GEAR BUSH LH AND IDLER SHAFT

If the idler gear bush25to idler shaft27clearance exceeds the specified limit, replace the defective part.

Standard value: 0.02 - 0.05 mm

Limit: 0.1 mm

5. IDLER SPROCKET BUSH AND IDLER SHAFT

If the idler sprocket bush

to idler shaft

clearance

exceeds the specified limit, replace the defective parts.

Standard value: 0.02 - 0.06 mm

Limit: 0.1 mm

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

20. OIL PUMP

REMOVAL AND INSTALLATION

44±4Nm

Oil Pump

10±1Nm

11B-20-1

36±3Nm

Removal steps

1. Balance shaft RH assembly

2. Bolt

3. Washer

4. Balance shaft gear RH

5. Thrust spacer

6. Key

7. Balance shaft RH

8. Oil pump assembly

9. Screw

10. Oil pump cover

11. Driven gear assembly

12. Plug

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

13. Relief valve spring

14. Steel ball

15. Gear and body assembly

16. O-ring

17. O-ring

18. O-ring

*1: Crankcase

(Refer to page 11B-25-1.) *2: Crankshaft gear *3: Drive gear

A: Locating pin

11B-20-2

4M41 ENGINE -

Oil Pump

INSPECTION

OIL PUMP

(1) Shaft to Oil Pump Case and Cover Clearances

In either case, if the measurement exceeds the specified service limit, replace oil pump assembly.

Standard value: 0.03 - 0.05 mm

Limit: 0.15 mm

(2) Difference between Gear Height a nd Oil Pump Case

Depth If the difference exceeds the specified service limit, replace defective part.

Standard value: 0.05 - 0.10 mm

Limit: 0.15 mm

(3) Gear Tooth Crest-to-Oil Case Clearance

If the clearance exceeds the specified service limit, replace defective part.

Standard value: 0.15 - 0.26 mm

Limit: 0.27 mm

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Oil Cooler and Oil Filter

21. OIL COOLER AND OIL FILTER

REMOVAL AND INSTALLATION

11B-21-1

44±4Nm

30±3Nm

20±2Nm

44±4Nm

Removal steps

"AA 1. Oil filter

2. Oil cooler assembly

3. Nut

4. O-ring

5. Oil cooler element

6. Plug

7. Bypass valve spring

8. Plunger

9. Plug

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

10. Regulator valve spring

11. Plunger

12. Water drain plug

13. Oil cooler body

14. O-ring

15. Gasket

16. Water separate lip

*: Crankcase assembly

11B-21-2

4M41 ENGINE -

Oil Cooler and Oil Filter

CLEANING

(1) Check the oil cooler element5for deposited carbon and

sludge in oil passage and bypass, and wash it clean in cleaning oil, if necessary.

(2) Wash the oil cooler element5and the oil cooler body

if they are much contaminated with scale.

INSPECTION

OIL COOLER ELEMENT

(1) Immerse the oil cooler element5in a water tank, with

the oil outletAclosed. Connect a hose to the engine oil inletB.

(2) Apply an air pressure of 1470 kPa into the oil cooler

element5through the connected hose, and check for air leaks.

(3) Replace the oil cooler element5if it leaks.

MH061590

INSTALLATION SERVICE POINT

"AA

(1) Clean the surface of the oil cooler assembly2which

(2) Apply a thin coat of engine oil to the gasketAon the

(3) Holding the gasketAin contact with the oil cooler assembly

OIL FILTER INSTALLATION

contacts the oil filter1.

oil filter1.

, tighten the cover 5/8 turn.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Oil Pan, Oil Strainer and Oil Jet

22. OIL PAN, OIL STRAINER AND OIL JET

REMOVAL AND INSTALLATION

11B-22-1

32±3Nm

Removal steps

1. Drain plug

2. Oil pan cover LH

3. Oil pan cover RH

4. Oil pan cover

5. Bolt

"AA 6. Oil pan

7. Oil level sensor

8. Oil strainer

9. O-ring

39±3Nm

10. Check valve (Refer to page 11B-25-1.)

11. Oil jet (Refer to page 11B-25-1.)

*1: Lower crankcase

(Refer to page 11B-25-1.)

*2: Upper crankcase

(Refer to page 11B-25-1.)

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-22-2

4M41 ENGINE -

Oil Pan, Oil Strainer and Oil Jet

INSTALLATION SERVICE POINT

"AA

OIL PAN INSTALLATION

(1) Apply sealant at the bottomBof the mating surface of

lower crankcaseCand timing gear caseD.

(2) Apply even beads of sealant

without skips to the

circumferential mating surface of the oil pan6as shown.

Bead diameter:f3.5±1mm

Specified sealant:

3.5±1mm

(3) Install the oil pan6to the lower crankcase within 15

Mitsubishi Genuine Part No. MD970389 or equivalent.

minutes after the application of sealantA.

Caution

1. The surface to be coated with sealant A must be clean and free of slush and other foreign matters.

2. When installing, take care that sealant A does not smear other places.

3. After the oil pan 6 is installed, wait for at least one hour before starting the engine.

4. Remove and reinstall the oil pan 6 with fresh beads of sealant A whenever the bolts 5 (holding the oil pan) were loosened or removed after the installation.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Piston and Connecting Rod

23. PISTON AND CONNECTING ROD

REMOVAL AND INSTALLATION

11B-23-1

Apply engine oil to all moving parts before installation.

29±3Nm+49±5Nm+45_+45

4ME0597

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-23-2

4M41 ENGINE -

Piston and Connecting Rod

Apply engine oil to all moving parts before installation.

Removal steps

AA" 1. Nut

"FA 2. Lower connecting rod bearing

3. Connecting rod cap

"FA 4. Upper connecting rod bearing "EA 5. Piston and connecting rod assem-

bly

AB""DA 6. 1st compression ring AB""DA 7. 2nd compression ring

AB""DA 8. Oil ring

9. Snap ring

AC""CA 10. Piston pin AC""CA 11. Piston AC""CA 12. Connection rod assembly AD""BA 13. Connecting rod bush

"AA 14. Connecting rod bolt

15. Connecting rod

Caution

1. Do not remove the connecting rod bolt 14 unless absolutely necessary.

2. The nut 1 and connecting rod bolt 14 are tightened to the plastic area. If the nut 1 has three punch marks indicating that they have been tightened three items, replace both the nut 1 and the connecting rod bolt 14.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Piston and Connecting Rod

11B-23-3

PRE-REMOVAL INSPECTION

1. PISTON PROTRUSION FROM CRANKCASE TOP

Caution Do not fail to check piston protrusions. The engine performance are directly influenced by them.

(1) Position each piston at the TDC. (2) There are five reference points A on the upper

crankcase*bthat serve as a zero level each. Check piston protrusions with respect to these reference points. (Piston protrusion = Measuring point B Reference point A)

(3) Measure piston protrusions at two points per cylinder

(8 in total) using the closest reference point, and average the readings.

(4) If the average deviates from the specified standard

value, check clearances at necessary points.

Standard value: - 0.20 - -0.30 mm

(5) Select the cylinder head gasket having a thickness

that corresponds with the average of piston protrusions (measured at 8 points).

2. CONNECTING ROD END PLAY

(1) Measure end play of each connecting rod. (2) If the measurement exceeds the specified service limit,

replace defective part.

Standard value: 0.15 - 0.45 mm

MH060014

Limit: 0.6 mm

REMOVAL SERVICE POINTS

AA"

Caution Provide one punch mark A on the head of the nut 1 each time it is used to tighten the connecting rod bolt 14. If it has three punch marks (the evidence of having been tightened 3 times), replace both the nut 1 and the connecting rod bolt 14.

AB"

Using the special tool, remove each piston ring.

NUT REMOVAL

PISTON RING REMOVAL

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-23-4

4M41 ENGINE -

Piston and Connecting Rod

MH062574

AC"

Remove the piston pin

PISTON PIN / PISTON / CONNECTING ROD ASSEMBLY REMOVAL

using an appropriate push-out

barDas shown.

NOTE To make the piston pin

over an appropriate heater or in hot water if necessary.

AD"

CONNECTING ROD BUSH REMOVAL

easy to remove, warm the piston

Use the special tool to remove the connecting rod bush13.

Component Parts of Special Tool MH062574 - Connecting Rod Bush Puller Kit

: Collar

: Puller

: Base

: Bracket

: Plate

: Nut

1. Secure the connecting rod

to the baseDwith the

bracketEand plateF.

2. Attach the collarAonto the pullerCas shown, and remove the connecting rod bush

slowly under a press ram

loadHof approximately 49,035 N.

INSTALLATION SERVICE POINTS

"AA

(1) Check that the bolt holeAin the connecting rod

(2) Apply a thin coat of engine oil to the knurled portion

CONNECTING ROD BOLT INSTALLATION

free of damage, burrs, etc.

of the connecting bolt14. Then, fit it in the connecting

rod with the notchCin the head inward under a press ram load of less than 4,903 N.

: Notch in bolt head

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Piston and Connecting Rod

11B-23-5

"BA

CONNECTING ROD BUSH INSTALLATION

Use the special tool to install the connecting rod bush13.

Component Parts of Special Tool MH062574 - Connecting Rod Bush Puller Kit

: Collar

: Puller

: Base

: Bracket

: Plate

: Nut

(1) Apply a thin coat of engine oil to the outside surface

of the connecting rod bush

in the connecting rod15.

(2) Set the collarB, connecting rod bush

and the bush fitting hole

and collar

on the pullerCas shown and secure them with the nut

(3) Aligning the oil holesJ, press-fit the connecting rod bush

into the connecting rod

slowly under a press ram

loadHof approximately 49,035 N.

(4) After press-fitting, ream the connecting rod bush

for

the specified push-to-piston pin clearance.

Standard value: 0.03 - 0.05 mm

Limit: 0.1 mm

Caution After reaming, insert the piston pin 10 into the connecting rod bush 13 to ensure that it smoothly moves with little play.

"CA

(1) Use a piston

PISTON / PISTON PIN / CONNECTING ROD ASSEMBLY INSTALLATION

having the same size mark

as that stamped beside each cylinder on the upper

“C”

“A”,“B”

crankcase. (The marks are found in the order of the cylinders No. 1, 2, 3 and 4 starting from the engine front

: Location of stamped size mark

Caution A mismatch of size marks can result in the piston 11 being seized while in motion.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-23-6

4M41 ENGINE -

Piston and Connecting Rod

“¬”

“1”

“¬”

(2) Apply a thin coat of engine oil to the piston pin

prior

to insertion. Assemble the connecting rod12and piston

facing in the directions shown.

: Connecting rod identification mark

“1”

: Front mark

“¬”

NOTE To make the piston pin10easy to install, warm the piston

over an appropriate heater or in hot water if necessary.

Caution After inserting the piston pin 10, check to ensure that the piston moves smoothly with little play.

"DA

(1) Install the oil ring8onto the piston

PISTON RING INSTALLATION

with its end gap

positioned atAand the abutting end of the expander spring atBas shown.

(2) Install the compression rings6,7onto the piston11,

with their manufacturer’s markC(stamped near the end gap) facing upward and their end gapD,Epositioned

6, 7

as shown.

: End gap of 1st compression ring

: End gap of 2nd compression ring

: Front mark

“¬”

"EA

PISTON AND CONNECTING ROD ASSEMBLY INSTALLATION

Caution Before installing the piston and connecting rod assembly 5, check the head of the nut 1 for punch marks. The

number of punch marks corresponds to the number of times the mating connecting rod bolt has been tightened

to the plastic area (bolts with two punch marks or less are reusable). If there are three (the evidence of having been tightened 3 times), replace both the nut 1 and the connecting rod bolt B.

(1) Check that the e n d gaps of the piston ringsCare in

position.

(2) Check that the size marksDon the pistons are the same

as the respective marks on the upper crankcase.

(3) Sheathe the connecting rod boltBwith a vinyl hose

so as not to damage the cylinder inside surface of the

upper crankcase*band th e pin of the crankshaft assembly

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Piston and Connecting Rod

11B-23-7

“¬”

(4) Using the special tool, install the piston and connecting

rod assembly in position, with the front mark“¬”on the piston crown facing toward the engine frontF.

MH063484

(5) Press the piston down. Apply a thin coat of engine oil

to the threaded part of the connecting rod bolt, then install the connecting rod cap3while aligning the lugsHof the upper connecting rod bearing shell

and lower

connecting rod bearing shell2.

(6) Tighten the nuts1alternately in the following manner.

1) Tighten the nut1to a torque of 29 ± 3 Nm.

2) Tighten further to a torque of 49 ± 5 Nm.

3) Give a 45_ ± 5_ turn.

4) Give another 45_ ± 5_ turn to complete the tightening.

Caution The nut is tightened to a point where the bolt is plastically deformed. Do not tighten it any more than the final turn.

(7) After the connecting rod cap3is secured, check t he

following.

1) Connecting rod end play

2) Piston protrusion

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-23-8

4M41 ENGINE -

Piston and Connecting Rod

"FA

CONNECTING ROD BEARING INSTALLATION

The connecting rod bearing2,4to be used must have an appropriate thickness that matches the big end I.D. of the connecting rod and the pin O.D. of the crankshaft assembly. There are two methods available for selecting an appropriate bearing.

(1) Measure the big e nd I.D. of the connecting rod (with

connecting rod bearing2,4removed) and the pin O.D. of the crankshaft assembly.

: Measuring point

Connecting rod: 1 point in vertical direction Crankshaft: 1 point in any direction

Caution Before measuring the big end O.D. of the connecting

rod, tighten the nut B to a torque of 49±5 Nm.

(2) Select connecting rod bearing shells2,4having the

thickness that matches the respective measured values from the table below. Install the selected connecting rod bearing shells with their lugCfitted in the mating groove of the connecting rod.

: Location of connecting rod bearing identification color

(side)

Caution The upper connecting rod bearing shell 4 has an oil hole E, while the lower connecting rod bearing shell 2 has no oil hole. Be careful not to install them in wrong place.

Crankshaft pin O.D. Connecting rod big end I.D. Compatible connecting rod bearing

identification color (Figures in brackets are sheet thicknesses)

53.980 - 53.988 58.010 - 58.019 mm None (1.992 - 1.996 mm)

58.000 - 58.010 mm Blue (1.988 - 1.992 mm)

53.971 - 53.980 58.010 - 58.019 mm Yellow (1.996 - 2.000 mm)

58.000 - 58.010 mm None (1.992 - 1.996 mm)

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Piston and Connecting Rod

11B-23-9

Select appropriate connecting rod bearings through the combination of the big end I.D. identification color marked on each connecting rod and the appropriate pin O.D. identification color on the crankshaft assembly*aas shown in the table below.

: Location of identification color

Identification color on crankshaft (Shown in brackets is identification mark)

None (1) None Blue

Blue (2) None None

Identification color on connecting rod

Blue None

Blue Blue

Compatible connecting rod bearing identification color

The crankshaft assembly has additional pin O.D. identification

marks (

apply to No. 1 pin, No. 2 pin and so forth sequentially from

“1”

) stamped atGas shown. The 4 marks

“2”

the engine front to rear.

“1” or “2”

: Location of crankshaft journal O.D. identification mark

INSPECTION

1. CONNECTING ROD BEARING

Caution

1. Do not use connecting rod bearings 2, 4 expanded

with force.

2. Replace the connecting rod bearing 2, 4 as a set

of upper and lower shells.

(1) Free Span

If the reading is less than the specified limit, replace the connecting rod bearing2,4.

Limit: Less than 58.8 mm

2, 4

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-23-10

4M41 ENGINE -

Piston and Connecting Rod

(2) Connecting Rod Bearing-to-Crankshaft Clearance

(Oil clearance)

1) Fit the lower connecting rod bearing shell2and upper

connecting rod bearing shell4in the connecting rod cap3and the piston and connecting rod assembly

, respectively. Tighten the nuts1to a torque of 49

± 5 Nm.

2) Measure the I.D. of the connecting rod bearing2,

and the pin O. D. at

the readings exceed the specified limit, replace the defective part(s).

Standard value: 0.03 - 0.05 mm

Limit: 0.1 mm

3) When the connecting rod bearing2,4is replaced

with an undersize bearing, adjust the pin O.D. of the crankshaft

to the specified undersize

dimension.

of the crankshaft*a.If

6, 7, 8

2. PISTON RING

(1) Piston Ring En d Gap

1) Place the piston ring6,7,8level in the cylinder

of the upper crankcase using the crown of the piston

2) Holding the piston ring6,7,8in place, measure

its end gap with a feeler gaugeG. If the reading exceeds the specified limit, replace the piston ring.

Standard value:

1st compression ring 0.3 - 0.45 mm 2nd compression ring 0.4 - 0.55 mm Oil ring 0.3 - 0.5 mm

Limit: 0.8 mm

Caution

1. To place the piston ring 6, 7, 8 level in the cylinder F, be sure to use the piston 11.

2. Place the piston ring 6, 7, 8 at the lower part of the cylinder F where the cylinder wall wears less than elsewhere.

3. When it becomes necessary to replace any of the piston rings 6, 7 and 8, replace all of them as a set.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Piston and Connecting Rod

11B-23-11

6, 7, 8

4ME0454

(2) Piston Ring-to-Piston Ring Groove Clearance

1) If the measured clearance exceeds the specified limit, replace the defective part.

Standard value:

1st compression ring 0.03 - 0.08 mm 2nd compression ring 0.07 - 0.10 mm Oil ring 0.03 - 0.06 mm

Limit: 0.15 mm

NOTE The 1st compression ring6is of full keystone type. Measure the clearance with a feeler gauge

while pressing the ring against the piston pin groove bottom with a straight edgeH.

Caution

1. Clear all carbon deposits from the ring groove

of the piston 11 and measure the clearance all around the ring groove.

2. When it becomes necessary to replace any of

the rings 6, 7 and 8, replace all of them as a set.

3. PISTON PIN

(1) Measure the clearance between piston pin10and piston

. If the reading exceeds the specified limit, replace

the defective part.

Standard value: 0.007 - 0.021 mm

Limit: 0.05 mm

(2) Measure the clearance between piston pin

connecting rod bush13. If the reading exceeds the limit, replace the defective part.

Standard value: 0.03 - 0.05 mm

Limit: 0.1 mm

and

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-23-12

4M41 ENGINE -

Piston and Connecting Rod

100 mm

4. CONNECTING ROD

(1) Fit the connecting rod bush

and piston pin

in the

connecting rod15.

(2) Measure the bendAand twistBof the connecting rod

. If either reading exceeds the specified limit, replace

the connecting rod.

: Connecting rod aligner (measuring device)

Limits:

Bend 0.05 mm Twist 0 .1 mm

Caution

1. Attach the connecting rod 15 to the connecting

rod aligner C with the upper and lower connecting rod bearing shells installed in place.

2. Tighten the connecting rod cap nut to a torque

of 49±5 Nm.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

24. DRIVE PLATE

REMOVAL AND INSTALLATION

Drive Plate

11B-24-1

123±12 Nm

"AA

AA""BA

"AA

Removal steps

1. Bolt

2. Adaptor plate

3. Drive plate assembly

4. Ring gear

5. Drive plate

6. Crankshaft adaptor

4ME0598

REMOVAL SERVICE POINT

AA"

(1) Heat the ring gear4evenly using an acetylene torch

(2) Remove the ring gear4by tapping it evenly all around.

RING GEAR REMOVAL

or any other suitable heat source.

Caution Use care not to be burned.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-24-2

4M41 ENGINE -

Drive Plate

INSTALLATION SERVICE POINTS

"AA

Attach the adaptor plate2and the crankshaft adaptor6to the drive plate assembly, facing in the directionsAshown.

"BA

(1) Heat the ring gear4with an acetylene torch or any other

(2) Fit the ring gear

CRANKSHAFT ADAPTOR / ADAPTOR PLATE INSTALLATION

: Drive plate side

RING GEAR INSTALLATION

suitable heat source for 3 minutes. (Approx. 100°C)

Caution Use care not to be burned.

onto the drive plate

non-chamfered teeth side toward the drive plate.

: Chamfered side of ring gear

with the

INSPECTION

RING GEAR

Check the ring gear4for damage and abnormal wear. Replace the ring gear4if necessary.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Crank Shaft and Crank Case

25. CRANK SHAFT AND CRANK CASE

REMOVAL AND INSTALLATION

11B-25-1

32±3Nm

Apply engine oil to all moving parts before installation.

47±5Nm

20±2Nm+ 90_+90

25±3Nm

4ME0599

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-25-2

4M41 ENGINE -

Crank Shaft and Crank Case

Removal steps

1. Bolt

"FA 2. Front plate

3. Stiffener

4. Stiffener RH

5. Stiffener LH

6. Bolt

7. Rubber spacer

8. Dust cover

9. Rear plate

10. Bolt

"EA 11. Rear oil seal "EA 12. Rear oil seal case

13. Bolt

14. Main cap bolt

AB""CA 20. Crankshaft gear

"AA 16. Lower main bearing

17. Lower crankcase

"BA 18. Lower thrust plate

19. Crankshaft assembly

21. Key

22. Crankshaft

"BA 23. Upper thrust plate

24. Upper crankcase assembly

"AA 25. Upper main bearing

26. Check valve

27. Oil jet

28. O-ring

29. Upper crankcase

AA""DA 15. Lower crankcase assembly

Caution

1. The lower crankcase 17 and upper crankcase 29 have been machined in a pair. Therefore, replacing either one of the pair is not allowed.

2. The front plate 2 is held in position with the idler shaft, in addition to locating pin.

3. The main cap bolt 14 is tightened to a plastically deformed point. If it shows the evidence of having been tightened three times, replace it.

4. Do not remove the crankshaft gear 20 unless absolutely necessary.

MH062469

PRE-REMOVAL INSPECTION

CRANKSHAFT

Before removing the lower crankcase assembly15, measure the end play of the crankshaft assembly19. If the reading exceeds the specified limit, replace the thrust plate18,

with an oversize one.

Standard value: 0.10 - 0.28 mm

Limit: 0.4 mm

+0.15 mm, +0.30 mm, +0.45 mm

REMOVAL SERVICE POINTS

AA"

LOWER CRANKCASE ASSEMBLY CREMOVAL

(1) Gradually loosen the bolts13in the sequence of numbers

1 - 16 shown in the illustration.

(2) Then, gradually loosen the main bearing cap bolts

in the sequence of numbers 17 - 26 shown, and remove.

AB"

CRANKSHAFT GEAR REMOVAL

Using the special tool, remove the crankshaft gear20.

Caution

1. Before attaching the special tool, install a protective bolt A (M16 x 1.5 mm ; 30 mm long) to the crankshaft end so that the crankshaft will not be damaged by the special tool.

2. Do not tap on the crankshaft gear 20 to remove it.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

<No.1, 2, 4, 5>

<No.3 >

4M41 ENGINE -

Crank Shaft and Crank Case

11B-25-3

INSTALLATION SERVICE POINTS

<No.1, 2, 4, 5>

<No.3 >

"AA

The main bearings

MAIN BEARING INSTALLATION

and

must have a proper plate

thickness that matches the difference between the bearing mounting hole I.D. of the crankcase assembly

17, 29

and the journal O.D. of the crankshaft22. (1) Measure the bearing mounting hole I.D. of the crankcase

assembly

: Measuring point (One point in vertical direction for

17, 29

and the journal O.D. of the crankshaft

crankcase)

Caution Tighten the main bearing cap bolts 14 by specified procedure before measuring the bearing mounting hole I.D. of the crankcase assembly 17, 29.

NOTE (1) The bearing mounting hole I.D. of the crankcase17,

can be known by the identification markBon

the right side of the crankcase rear end.

: No. 1 journal,D: No. 2 journal

: No. 3 journal,F: No. 4 journal

: No. 5 journal

(2) The journal O.D. of the crankshaft22can be identified

by the identification color on the crankshaft.

: Identification color position

(2) Select appropriate thickness main bearings

16, 25

from

the following table.

: Identification color position

: Lug

: Oil hole

Caution The main bearing shells 16 and 25 must be installed in the specified direction. The main bearing shells for No. 3 journal are different in thickness from the others. The upper main bearing shell for No. 3 journal is different also in shape from the others.

Unit: mm

Crankshaft

Identification color

None 67.970 - A 72.010 - Black/Black No.1, 2, 4, 5 1.992 - 1.996 0.040 - 0.065

Blue 67.961 - A 72.010 - Yellow/Yel- No.1, 2, 4, 5 1.996 - 2.000 0.040 - 0.066

Journal O.D.

67.798 72.019

67.970 72.019 low

Crankcase Main bearing

Size mark

B 72.000 - Blue/Blue No.1, 2, 4, 5 1.988 - 1.992 0.038 - 0.064

Bearing mounting hole I.D.

72.010

Identification color (L/U)

Journal No. Plate

Thickness

No.3 1.982 - 1.986 0.060 - 0.085

No.3 1.978 - 1.982 0.058 - 0.084

No. 3 1.986 - 1.990 0.060 - 0.086

Oil Clearance

B 72.010 - Black/Black No.1, 2, 4, 5 1.992 - 1.996 0.038 - 0.065

72.019

L: Lower main bearing shell U: Upper main bearing shell

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

No.3 1.982 - 1.986 0.058 - 0.085

11B-25-4

4M41 ENGINE -

Crank Shaft and Crank Case

"BA

Install the thrust plates

with the oil grooveAoriented outward.

THRUST PLATE INSTALLATION

and23to the crankshaft assembly

at No.5 journal only. Install all halves of the thrust plates

Caution

If any oversize thrust plates are to be used, be sure to use an upper thrust plate 23 and lower thrust plate 18 of the same size at one side. However, using the same size upper (or lower) thrust bearings on both sides is not necessary.

"CA

(1) Before installing, heat the crankshaft gear

CRANKSHAFT GEAR INSTALLATION

approximately 100_C with a piston heater or the like.

Caution Use care not to be burned.

(2) Align the notchBin the crankshaft gear20with the key

of the crankshaft22, then install the crankshaft gear

onto the crankshaft by tapping on the end face lightly

with a plastic hammer.

"DA

LOWER CRANKCASE ASSEMBLY INSTALLATION

Caution Before installing the lower crankcase assembly 15, check the head of the main cap bolt 14 for punch marks A. The number of punch marks corresponds to the number of times the bolt has been tightened to the plastic area (bolts with two or less punch marks are reusable). If there are three, replace the main cap bolt 14.

(1) Apply a 2 mm thick bead of specified sealant to the fitting

surface of the upper crankcase assembly

Specified sealant:

as shown.

Mitsubishi Genuine Part No. MD970389 or equivalent

Caution

1. Apply sealant evenly, not broken or oversupplied.

2. Use care not to let the applied sealant slip out of place during installation.

(2) Apply a thin coat of engine oil to the threaded part and

seating surface of each main cap bolt14, then tighten the bolts to a torque of 20 ± 2 Nm in the sequence of the numbers shown (17 - 26).

(3) After tightening, give the bolts an additional 90_ turn. (4) Then, give the bolts another 90_ turn to tighten them

completely.

(5) Following the main cap bolts14, tighten the bolts

to the specified torque in the sequence of the numbers shown (1 - 16).

(6) After installing the lower crankcase assembly15, check

3 6

Feb. 2000Mitsubishi Motors Corporation Added

the following:

1) Smooth rotation of crankshaft assembly

2) E nd play of the crankshaft assembly

PWEE9409-D

4M41 ENGINE -

Crank Shaft and Crank Case

11B-25-5

"EA

REAR OIL SEAL / REAR OIL SEAL CASE INSTALLATION

(1) Apply a thin coat of engine oil to the lipAof the rear

oil seal11. Press the rear oil seal all the way into the rear oil seal case

in the direction shown. Be sure

that the end faceBof the rear oil seal is flush with the end faceCof rear oil seal case.

(2) Apply a 3 mm thick bead of the specified sealant to the

fitting surface of the rear oil seal case12.

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or equivalent

Caution

1. Apply the sealant evenly, not broken or oversupplied.

2. Use care not to let the applied sealant slip out of place during installation.

"FA

FRONT PLATE INSTALLATION

Apply a 2 mm thick bead of the specified sealant to the lower

crankcase assembly where indicated in the illustration.

and upper crankcase assembly

Specified sealant:

Mitsubishi Genuine Part No. MD970389 or equivalent

Caution

1. Apply the sealant evenly, not broken or oversupplied.

2. Use care not to let the applied sealant slip out of place during installation.

3. The bolt 1 that holds the front plate 2 is also used to secure the timing gear case. Attach the front plate with a temporary bolt until the timing gear case is installed.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

11B-25-6

4M41 ENGINE -

16, 25

Crank Shaft and Crank Case

INSPECTION

1. MAIN BEARINGS

Caution

1. Be sure not to use the main bearings 16 and 25 expanded forcedly.

2. When either the main bearing 16 or 25 is defective, replace them in pairs.

(1) Free Span

If the reading for either main bearing shell16,25exceeds the specified service limit, replace them in pairs.

Limit: Less than 73.16 mm

(2) Main Bearing-to-Crankshaft Clearance

1) Fit the upper main bearing shells bearing shells lower crankcase cap bolts

into the upper crankcase

respectively, then tighten main

to a torque of 20 ± 2 Nm.

2) Measure the I.D. of the main bearings16, the journal O.D. at

of the crankshaft22. If the

and lower main

and

measurements exceed the specified limits, replace the defective part(s).

Standard value:

No. 1, 2, 4, 5 journal 0.04 - 0.06 mm No. 3 journal 0.06 - 0.08 mm

Limit: 0.1 mm

2. CRANKSHAFT

(1) Out-of-Roundness and Conicity of Crankshaft Journal

and Pin If the measured value exceeds the limit, replace the crankshaft22.

: Out-of-Roundness

: Conicity

Standard value:

Out-of-Roundness 0.01 mm or less Conicity 0.006 mm or less

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

4M41 ENGINE -

Crank Shaft and Crank Case

11B-25-7

(2) Bend

1) To measure the bend of the crankshaft22, support it at No. 1 journalCand No. 5 journalDand read the runout at No. 3 journalE.

2) If the reading exceeds the specified service limit, replace the crankshaft22.

Standard value: 0.02 mm or less

Limit: 0.05 mm

NOTE The bend of the crankshaft22is a half of the dial gauge reading obtained when the crankshaft is rotated one turn.

3. UPPER CRANKCASE

(1) Top Surface Distortion

If the reading exceeds the specified limit, eliminate distortion using a surface grinder.

: Measuring direction

Cylinder

20 mm

80 mm

130 mm

53.5 mm

Standard value: 0.05 mm or less

Limit: 0.1 mm

Caution The surface grinding of the upper crankcase 29 should be limited to such an extent that piston protrusions do not deviate from specified standard value.

(2) Cylinder Inside Diameter

If the cylinder inside diameter exceeds the specified limit, bore the cylinder to the next oversize.

Standard value: 98.5 - 98.53 mm

Limit: 98.75 mm

: Measuring direction in cylinder

(axial direction of crankshaft)

: Measuring direction in cylinder

(right angled to crankshaft)

: Measuring direction on piston

(right angled to piston pin hole)

Caution

1. If any of the cylinders exceeds the limit, bore all the cylinders to the next oversize.

2. Irrespective of the cylinder I.D. being within the specified limit, replace the piston and piston rings if the cylinder-to-piston clearance deviates from the standard value.

Feb. 2000Mitsubishi Motors Corporation Added

PWEE9409-D

Mitsubishi Canter 2000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1. SPECIFICATIONS

SERVICE SPECIFICATIONS

TORQUE SPECIFICATIONS

SEALANT

2. SPECIAL TOOLS

3. GENERATOR ASSEMBLY

4. GLOW PLUG

5. COOLING FAN, V-BELT AND WATER PUMP

6. WATER HOSES AND PIPES

7. THERMOSTAT

8. EGR VALVE ASSEMBLY

9. INTAKE MANIFOLD

10. TURBOCHARGER ASSEMBLY

11. EXHAUST MANIFOLD

12. INJECTION PUMP ASSEMBLY

13. INJECTION PUMP GEAR

14. ROCKER COVER, CAMSHAFT HOLDER ASSEMBLY AND CAMSHAFT

15. INJECTION NOZZLE

16. CYLINDER HEAD AND VALVE MECHANISM

17. VACUUM PUMP

18. TIMING GEAR CASE

19. TIMING GEAR AND BALANCE SHAFT

20. OIL PUMP

21. OIL COOLER AND OIL FILTER

22. OIL PAN, OIL STRAINER AND OIL JET

23. PISTON AND CONNECTING ROD

24. DRIVE PLATE

25. CRANK SHAFT AND CRANK CASE