Mitsubishi Canter 2000 User Manual

11B-0-1

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

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

11B-0-2

NOTES

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

4M41 ENGINE - General Information		11B-0-3
GENERAL INFORMATION
Descriptions	Specifications
Total displacement dm3	3200
No. and arrangement of cylinders	4 in-line
Combustion chamber	Direct injection
No. of intake/exhaust valves (per cylinder)	2 each
Valve mechanism	Double overhead camshaft, 4-valve
Cylinder bore x stroke mm	98.5 x 105
Compression ratio	17
Supercharger	Turbo-charging type
Intercooler	Air-cooling type
Fuel supply	Distributor type electronically controlled fuel injection pump

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

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

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

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

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

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

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

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		Injection nozzle side	13	± 2
		Cylinder head side	11 ± 1
Cam sprocket mounting bolt			88	± 10
Camshaft cap mounting bolt			20	± 1
Adjust screw locknut			9.5 ± 0.5
Pivot bolt			38	± 8

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

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

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

11B-1-6	4M41 ENGINE - Specifications
Items		Torque Nm
Oil pan, oil strainer and oil jet
Drain plug		39	± 3
Oil jet		32	± 3
Piston and connecting rod
Connecting rod cap mounting nut		29	± 3 + 49 ± 5 + 45_ + 45_
Drive plate
Drive plate assembly and crankshaft mounting bolt		123 ± 12
Crankshaft and crankcase
Dust cover mounting bolt		47	± 5
Lower crankcase mounting bolt		25	± 3
Main bearing cap bolt		20	± 2 + 90_ + 90_
Check valve		32	± 3

STANDARD BOLT AND NUT TIGHTENING TORQUE TABLE

1.Fasten the parts and equipment of vehicle using the specified standard bolts and nuts. Tighten these bolts and nuts to the torques indicated below, unless otherwise specified.

2.Threads and bearing surfaces must be dry.

3.In case nut and bolt (or stud bolt) differ in strength, tighten them to the torque specified for the bolt.

Hexagon head bolts and stud bolts

Unit: Nm

Strength

4T

7T

8T

Code

Head Mark

Nominal

(Stud)

(Stud)

Diameter mm

(Stud)

M5

2.5 ± 0.5

-

5 ± 1

-

6 ± 1

-

M6

5 ± 1

-

9 ± 2

-

10 ± 2

-

M8

11.5 ± 2.5

-

21

± 4

-

25

± 4

-

M10

23 ± 4

22 ± 4

44

± 10

41 ± 8

52

± 7

55 ± 13

M12

41 ± 8

38 ± 8

81

± 12

74 ± 9

96

± 12

86 ± 12

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

4M41 ENGINE - Specifications

11B-1-7

Hexagon flange bolts

Unit: Nm

Strength

4T

7T

8T

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

Hexagon nuts

Unit: Nm

Strength Code

4T

6T

Head Mark

Nominal

Standard

Coarse Thread

Standard Thread

Coarse Thread

Diameter mm

Thread

M5

2.5 ± 0.5

-

5 ± 1

-

M6

5 ± 1

-

9 ± 2

-

M8

12 ± 2

-

21 ± 4

-

M10

23 ± 4

22 ± 4

44 ± 10

41 ± 8

M12

41 ± 8

38 ± 8

81 ± 12

73 ± 10

Hexagon flange nuts

Unit: Nm

Strength Code

4T

Head Mark

Nominal

Standard

Coarse Thread

Diameter mm

Thread

M6

5 ± 1

-

M8

13 ± 2

-

M10

26 ± 4

24 ± 4

M12

41 ± 8

42 ± 9

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

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 assem-
bly mounting surface*
Rear oil seal case-to-upper or lower crankcase assembly
mounting surface*
Upper or lower crankcase assembly-to-front plate
mounting surface*
*: FIPG to be applied

FORM-IN-PLACE GASKET

The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size, continuity and location are of paramount importance.

Too thin a bead could cause leaks. Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to apply the gasket evenly without a break, while observing the correct bead size.

Since the FIPG used in the engine hardens as it reacts with the moisture in the atmospheric air, it is normally used in the metallic flange areas.

Disassembly

The parts assembled with the FIPG can be easily disassembled without use of a special method. In some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking with a mallet or similar tool. A flat gasket scraper may be lightly hammered in between the joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.

Surface Preparation

Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure that there are no oils, greases and foreign substances deposited on the application surfaces. Do not forget to remove the old sealant remaining in the bolt holes.

Form-In-Place Gasket Application

Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time (about one hour) has passed after installation is completed.

The FIPG application procedure may vary on different areas. Observe the procedure described in the text when applying the FIPG.

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

						4M41 ENGINE - Special Tools					11B-2-1
2. SPECIAL TOOLS
Tool					Number		Name		Use
					MB990767		Front hub	and	D	Removal of crankshaft puley
							flange yoke holder		D Installation of injection pump assembly
					MD998754		Crankshaft	pulley
							holder pin
					157944-9520		Plate		Removal and installation of retaining nut
					(Zexel)
					105789-0010		Nozzle cleaning		Cleaning of nozzle and needle valve
					(Zexel)		tool
					157892-4420		Adjusting device		D Adjustment of valve opening pressure
									D Checking needle valve maximum lift
						157892-4400: A	Holder		D	Checking injection nozzle assembly
			A			157892-1000: B	Nut
	B
					157954-3801		Dial gauge
					157892-7200		Pin
					157892-5120		Retaining nut
			C			157892-5100: A	Retaining nut
						026508-1140: B	Gasket
		B
	A					157892-1600: C	Plug
					157892-3200		Gasket

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

11B-2-2	4M41 ENGINE - Special Tools

Tool

f11.5

f6.6

f8

C	A, B f35: A
	f33: B

Number	Name	Use
MH063490	Cam sprocket	Holding cam sprocket
	holder kit
MD998772	Valve spring com-	Removal and installation of valve cotter
	pressor
MD998784	Valve spring com-
	pressor adaptor
	plate
MD999597	Valve spring com-
	pressor
MD998665	Valve guide remov-	Removal of valve guide
	er
MH063611: A	Calking ring inlet	Installation of valve seat
MH063612: B	Calking ring ex-
	haust
MH063613: C	Calking tool body

f12	MH063610	Valve guide install-	Installation of valve guide
		er
f21
16.5

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

			4M41 ENGINE - Special Tools					11B-2-3
Tool			Number	Name			Use
f18		f6.6	MH063609	Valve	stem	seal	Installation of valve stem seal
				installer
f15.4
f27.5	f32	f28	MH062463	Idler	gear	bush	Removal and installation of idler gear bush
				puller
f41.5	f46	f42	MH062462	Idler sprocket bush			Removal and installation of idler sprocket
				puller			bush
f60 - 120			MH060014	Piston ring tool			Removal and installation of piston rings
			MH062574	Connecting rod			Removal of connecting rod bush
				bush puller kit
			MH063484	Piston guide			Installation of piston
	f98.5
			MH062469	Gear puller			Removal of crankshaft gear
			MH062490	Balance shaft bush			Removal of balance shaft bush
				remover
			MH062717	Balance shaft bush
				installer

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

11B-2-4	4M41 ENGINE - Special Tools
Tool	Number	Name	Use
	MH062567	Gear puller	Removal of injection pump gear
	MH063473	Pin wrench arm	Assembling of injection pump gear
		assembly

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

4M41 ENGINE - Generator Assembly	11B-3-1

3. GENERATOR ASSEMBLY

REMOVAL AND INSTALLATION

1

2

4

5

3

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

"AAGENERATOR INSPECTION

Caution in Handling Generator

The following caution should be taken when servicing the generator 5.

Be sure to connect the generator 5 to the battery correctly. Reversed polarity causes an excessive current to flow from the battery to the generator 5, damaging the diodes and voltage regulator.

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

4M41 ENGINE - Glow Plug	11B-4-1

4. GLOW PLUG

REMOVAL AND INSTALLATION

13 ± 1 Nm

18 ± 1 Nm

1

4

5

Removal steps

1.Nut

2.Glow plug wiring harness

3.Connection plate

4.Glow plug

3

7

2

6

5.Coolant temperature sensor (For engine control)

6.Glow relay

7.Engine ECU

INSPECTION

GLOW PLUG

Measure resistance of the glow plug 4. Replace the glow plug if the reading deviates from the specified standard value.

Standard value: 1.1 W

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

4M41 ENGINE - Cooling Fan, V-belt and Water Pump	11B-5-1

5. COOLING FAN, V-BELT AND WATER PUMP

REMOVAL AND INSTALLATION

				8
				5
			7	*1
	24 ± 2 Nm
4		6
2				10
				9

3

24 ± 2 Nm

1

10 ± 1 Nm

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

*1: Timing gear case

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

11B-5-2 4M41 ENGINE - Cooling Fan, V-belt and Water Pump

5

A

C B

B

A

INSPECTION

1. AUTO-COOLING FAN COUPLING

Check the auto-cooling fan coupling 4, 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 5 at its midpoint with a force of approximately 98 N as shown and read the amount of deflection A.

(2)If the reading deviates from the specified standard value, accomplish the following adjustment.

(3)Loosen the bolt and nut B holding the generator, and adjust the tension of the V-belt 5 using the adjusting bolt C.

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 bimetal A using care not to apply unnecessary force to it.

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

4M41 ENGINE - Water Hoses and Pipes	11B-6-1

6. WATER HOSES AND PIPES

REMOVAL AND INSTALLATION

25 ± 2 Nm

"AA

3

4

8

6 7

9 ± 1 Nm

2		5
		1
			25 ± 2 Nm
	25 ± 2 Nm

Removal steps

1.Turbocharger water outlet pipe

2.Turbocharger water inlet pipe

3.Heater return pipe

4.O-ring

5.Harness

6.Coolant temperature sensor (For water temperature gauge)

7.Water outlet pipe

8.Gasket

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

11B-6-2	4M41 ENGINE - Water Hoses and Pipes

INSTALLATION SERVICE POINTS

"AAO-RING INSTALLATION

Caution

Engine oil swells O-rings. When installing the O-rings 4, be sure that they are free of engine oil.

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

4M41 ENGINE - Thermostat	11B-7-1

7. THERMOSTAT

REMOVAL AND INSTALLATION

3

4

5

2

6

1

Removal steps

1. Thermostat cover

"BA 2. Thermostat 3. Bypass pipe

"AA 4. O-ring

5. Thermostat case "AA 6. O-ring

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

11B-7-2 4M41 ENGINE - Thermostat

INSTALLATION SERVICE POINTS

"AAO-RING INSTALLATION

Caution

Engine oil swells O-rings. When installing the O-rings 4 and 6, be sure that they are free of engine oil.

		"BATHERMOSTAT INSTALLATION
	5
		Install the thermostat 2 with its jiggle valve A located at the
A		uppermost position.

2

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

4M41 ENGINE - EGR Valve Assembly	11B-8-1

8. EGR VALVE ASSEMBLY

REMOVAL AND INSTALLATION

*a	5

3

10

Removal steps

1.EGR pipe

2.Gasket

3.EGR pipe stay

4.EGR valve

5.Gasket

6.Insulator

7.EGR pipe

4

2

1

2

8		6

7

9

*b

8

8.Gasket

9.EGR box

10.EGR box bracket

*a: Intake manifold *b: Exhaust manifold

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

4M41 ENGINE - Intake Manifold	11B-9-1

9. INTAKE MANIFOLD

REMOVAL AND INSTALLATION

*b

18

*a

3

17 ± 1 Nm

2

12 11

3	10

16

13

17

		9		1
	8		15
				14

15 ± 1 Nm 5

4	7
	6

Removal steps
1.	Side cover	12.	Gas filter assembly
2.	EGR valve	13.	Rubber spacer A
3.	Gasket	14.	Nut
4.	Boost air temperature sensor	15.	Spring
5.	Gasket	16.	Intake manifold
6.	Air inlet fitting	17.	Rubber spacer B
7.	O-ring	"AA 18.	Gasket
8.	Throttle body assembly
9.	O-ring	*a. EGR pipe
10.	Boost pressure sensor	*b. Cylinder head
11.	Boost hose

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

11B-9-2	4M41 ENGINE - Intake Manifold

Cylinder head

Gasket

Gasket

Cylinder head

INSTALLATION SERVICE POINT

"AAGASKET INSTALLATION

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

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

4M41 ENGINE - Turbocharger Assembly	11B-10-1

10. TURBOCHARGER ASSEMBLY

REMOVAL AND INSTALLATION

11

*2

25 ± 2 Nm

*3

14

54 ± 5 Nm

10

*1

	5
20 Nm		49 ± 4 Nm

2	1	4

13

6

		8		7

3	9			12
		49	± 4 Nm

Removal steps
1.	Eyebolt	11.	Insulator B
2.	Oil feed pipe	12.	Insulator A
3.	Oil return pipe	13.	Gasket
4.	Nut	"AA 14.	Turbocharger assembly
5.	Coupler insulator
6.	Insulator	*1: Exhaust manifold
7.	Coupler	*2: Turbocharger water outlet pipe
8.	Gasket		(Refer to page 11B-6-1.)
9.	Nut	*3: Turbocharger water inlet pipe
10.	Bolt		(Refer to page 11B-6-1.)

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

11B-10-2	4M41 ENGINE - Turbocharger Assembly

A

C

B

INSTALLATION SERVICE POINT

"AATURBOCHARGER ASSEMBLY INSTALLATION

(1)Prior to installing the turbocharger assembly 14, pour engine oil into it through the oil inlet hole A to lubricate its component parts for smooth movement.

(2)Using a tester, apply pressure to the actuator B and read the pressure at which the rod C 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.

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

4M41 ENGINE - Exhaust Manifold	11B-11-1

11. EXHAUST MANIFOLD

REMOVAL AND INSTALLATION

*1	3
	2

6

1	7

*2

5

30 ± 3 Nm

*3

49 ± 4 Nm	4

Removal steps
1.	Insulator	*1: EGR pipe
2.	Insulator	*2: Cylinder head
3.	Bolt	*3: Turbocharger

4.Nut

5.Nut

6.Exhaust manifold

7.Gasket

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added

	4M41 ENGINE - Injection Pump Assembly							11B-12-1
12. INJECTION PUMP ASSEMBLY
REMOVAL AND INSTALLATION
				4
				6
				7
				5
				17	19
	2
	20				11
1			18		13
						25 ± 2 Nm
						14
		9		8			18 ± 2 Nm
								12
				10

15

16

3

Removal steps
1.	Injection pump cover B	11.	Fuel leak-off hose
2.	Injection pump cover A	12.	Fuel suction hose
3.	Rubber spacer	AA" "BA 13.	Injection pipe
4.	Rubber spacer	14.	Bolt
5.	Harness	15.	Pump stay
6.	Harness	16.	Pump stay
7.	Harness	"AA 17.	Injection pump assembly
8.	Harness	18.	O-ring
9.	Harness	19.	Rubber spacer
10.	Fuel return hose	20.	Stay

Caution

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

2.Be sure to wipe up spilt fuel completely. It could catch fire.

3.Have the injection pump assembly 17 serviced at an appropriate Zexel service station.

4.Dust particles entering the injection pump assembly 17 can seriously affect the engine performance. To prevent it, fully cover the openings left after the removal of parts such as pipes and hoses.

5.Before installing the injection pipe 13, check to ensure that the pipe seating surface is free from any damage and unevenness.

E Mitsubishi Motors Corporation

Feb. 2000

PWEE9409-D

Added