Mitsubishi L200 User Manual

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GROUP 00

GENERAL

CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00

GENERAL<ELECTRICAL> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00E

00-1

NOTES

GROUP 00

GENERAL

CONTENTS

00-1

HOW TO USE THIS MANUAL. . . . . . 00-2

HOW TO USE TROUBLESHOOTING/INSPECTION

SERVICE POINTS . . . . . . . . . . . . . . . 00-5

CONTENTS OF TROUBLESHOOTING . . . 00-5

DIAGNOSIS FUNCTION. . . . . . . . . . . . . . . 00-7

HOW TO USE THE INSPECTION

PROCEDURES. . . . . . . . . . . . . . . . . . . . . . 00-8

CONNECTOR MEASUREMENT SERVICE

POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-10

CONNECTOR INSPECTION SERVICE

POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-11

INSPECTION SERVICE POINTS FOR A

BLOWN FUSE . . . . . . . . . . . . . . . . . . . . . . 00-12

HOW TO COPE WITH INTERMITTENT

MALFUNCTIONS . . . . . . . . . . . . . . . . . . . . 00-12

HOW TO TREAT PAST TROUBLE . . . . . . 00-13

VEHICLE IDENTIFICATION . . . . . . . 00-13

INJECTOR IDENTIFICATION CODE

REGISTRATION PROCEDURE . . . . . . . . . 00-24

SMALL INJECTION QUANTITY LEARNING

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 00-25

SUPPLY PUMP CORRECTION LEARNING

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 00-26

LEARNING PROCEDURE FOR IDLING. . . 00-27

SERVICING ELECTRICAL SYSTEM . . . . . 00-27

VEHICLES WITH SEMI AUTOMATIC AIR

CONDITIONER . . . . . . . . . . . . . . . . . . . . . . 00-27

APPLICATION OF ANTI-CORROSION

AGENTS AND UNDERCOATS . . . . . . . . . . 00-27

VEHICLE WASHING . . . . . . . . . . . . . . . . . . 00-27

PRE-INSPECTION CONDITION . . . . . . . . . 00-27

MULTI USE TESTER (M.U.T.-III) SUB

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 00-28

HOW TO USE THE THROTTLE CONTROLLER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-28

IN ORDER TO PREVENT VEHICLES FROM

FIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-29

ENGINE OILS . . . . . . . . . . . . . . . . . . . . . . . 00-29

GENERAL DATA AND SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-17

PRECAUTIONS BEFORE SERVICE. 00-23

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH PRE-

TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . 00-23

WHAT THE COMMON RAIL ENGINE LEARNS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-24

SUPPLEMENTAL RESTRAINT SYSTEM

(SRS). . . . . . . . . . . . . . . . . . . . . . . . . . 00-30

SRS SERVICE PRECAUTIONS . . . . . 00-31

SUPPORT LOCATIONS FOR LIFTING

AND JACKING . . . . . . . . . . . . . . . . . . 00-33

STANDARD PART/TIGHTENING-

TORQUE TABLE . . . . . . . . . . . . . . . . 00-37

00-2

HOW TO USE THIS MANUAL

SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS

This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair and servicing of the subject model. Note, however, that for engine and transmission-related component parts, this manual covers only on-vehicle inspec tions, adjustments, and the removal and installation procedures for major components. For detailed infor mation concerning the inspection, checking, adjustment, disassembly and reassembly of the engine, transmission and major components after they have been removed from the vehicle, please refer to sepa rate manuals covering the engine and the transmission.

ON-VEHICLE SERVICE

"On-vehicle Service" is procedures for performing inspections and adjustments of particularly important locations with regard to the construction and for maintenance and servicing, but other inspection (for looseness, play, cracking, damage, etc.) must also be performed.

INSPECTION

Under this title are presented inspection and checking procedures to be performed by using special tools and measuring instruments and by feeling, but, for actual maintenance and servicing procedures, visual inspections should always be performed as well.

DEFINITION OF TERMS STANDARD VALUE

Indicates the value used as the standard for judging the quality of a part or assembly on inspection or the value to which the part or assembly is corrected and adjusted. It is given by tolerance.

LIMIT

Shows the standard for judging the quality of a part or assembly on inspection and means the maximum or minimum value within which the part or assembly must be kept functionally or in strength. It is a value established outside the range of standard value.

GENERAL

M1001000101016

REFERENCE VALUE

Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly and adjustment procedures, and so they can be com pleted in a shorter time).

DANGER, WARNING, AND CAUTION

DANGER, WARNING, and CAUTION call special attention to a necessary action or to an action that

must be avoided. The differences among DANGER,

WARNING, and CAUTION are as follows:

• If a DANGER is not followed, the result is severe

bodily harm or even death.

• If a WARNING is not followed, the result could be

bodily injury.

• If a CAUTION is not followed, the result could be

damage to the vehicle, vehicle components or service equipment.

INDICATION OF TIGHTENING TORQUE

Tightening torques (units: N⋅ m) are set to take into account the central value and the allowable toler ance. The central value is the target value, and the allowable tolerance provides the checking range for tightening torques. If bolts and nuts are not provided with tightening torques, refer to

P.00-37.

MODEL INDICATIONS

The following abbreviations are used in this manual for identification of model types. 2500:Indicates an engine with the 2,477mL <4D56>

diesel engine.

3200:Indicates an engine with the 3,200mL <4M41>

diesel engine.

DOHC: Indicates an engine with the double over-

head camshaft. M/T:Indicates the manual transmission. A/T:Indicates the automatic transmission. A/C:Indicates the air conditioner.

GENERAL

HOW TO USE THIS MANUAL

EXPLANATION OF MANUAL CONTENTS

Indicates the

Denotes tightening torque. For bolts and nuts which do not have a tightening torque listed, refer to the "Standard Parts tightening-torque Table"

section title.

Indicates the group title.

00-3

Indicates the group number.

Indicates the page number.

Indicates procedures to be performed before the work in that section is started, and procedures to be performed after the work in that section is finished.

Component diagram

A diagram of the component parts is provided near the front of each section in order to give the reader a better understanding of the installed condition of component parts.

Maintenance and servicing procedures

The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures.

Removal steps : The part designation number corresponds to the number in the illustration to indicate remov al steps.

Disassembly steps : The part designation number corresponds to the number in the illustration to indicate disas sembly steps.

Mark denotes nonreusable part.

Repair kit or parts sets are shown. (Only very frequently used parts are shown.)

Installation steps : Specified in case installation is impossible in reverse order of removal steps. Omitted if installation is possible in reverse order of re moval steps.

Reassembly steps : Specified in case installation is impossible in reverse order of removal steps. Omitted if reassembly is possible in reverse order of dis assembly steps.

AC311238

00-4

GENERAL

HOW TO USE THIS MANUAL

Classifications of major maintenance / service points

When there are major points relative to maintenance and servicing procedures (such as essential maintenance and service points, maintenance and service standard values, information regarding the use of special tools, etc.). These are arranged together as major maintenance and service points and explained in detail.

<<A>> : Indicates that there are essential points for removal or disassembly. >>A<< : Indicates that there are essential points for installation or reassembly.

35A-21

Operating procedures, cautions, etc. on removal, installation, disassembly and reassembly are described

The title of the page (following the page on which the diagram of component parts is presented) indicating the locations of lubrication and sealing procedures.

Indicates (by symbols) where lubrication is necessary.

Symbols for lubrication, sealants and adhesives

Symbols are used to show the locations for lubrication and for application of sealants and adhesives. These symbols are included in the diagram of component parts or on the page following the component parts page. The symbols do not always have accompanying text to support that symbol.

Grease (Multi-purpose grease unless there is a brand or type specified)

Sealant or adhesive Brake fluid or automatic transmission fluid

Engine oil, gear oil or air conditioning compressor oil

Adhesive tape or butyl rubber tape

AC311239

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

00-5

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE

POINTS

CONTENTS OF TROUBLESHOOTING

M1001013300211

CAUTION

During diagnosis, a diagnosis code associated with other system may be set when the ignition switch is turned on with connector(s) discon nected. On completion, confirm all systems for diagnosis code(s). If diagnosis code(s) are set, erase them all.

WARNING

Since the radiator fan rotates during CAN bus line diagnostics, make sure that no one is servicing the engine compartment before diagnosing the CAN bus line. Since the CAN communication stops when diagnosing the CAN bus line, the ETACS-ECU detects the time-out of the engine-ECU, and activates the radiator fan to prevent overheating as fail-safe.

Troubleshooting of electronic control systems for which the M.U.T.-III can be used follows the basic outline described below. Even in systems for which the M.U.T.-III cannot be used, some of these sys tems still follow this outline.

1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING

Troubleshooting sections are based on the diagnostic flow as below. If the diagnostic flow is different from that given below, or if additional explanation is required, the details of such differences or additions will also be listed.

00-6

Diagnosis method

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

Gathering information from the customer.

Reoccurs

CAN bus diagnosis*

Read the diagnosis code. Read the diagnosis code.

No diagnosis code or communication with M.U.T.-III not possible

Refer to the INSPECTION CHART FOR TROUBLE SYMPTOMS (Refer to applicable group).

Diagnosis code displayed. (Past trouble)*

How to treat past trouble*

Diagnosis code displayed. (Current trouble)*

Check trouble symptom.

CAN bus diagnosis chart*

After taking note of the malfunction code, erase the diagnosis code memory.

Recheck trouble symptom.

Read the diagnosis codes.

Diagnosis code displayed.

Refer to the INSPECTION CHART FOR DIAGNOSIS CODES (Refer to applicable group).

Diagnosis code displayed. (Current trouble)*

Does not reoccur

Diagnosis code displayed. (Past trouble)*

How to treat past trouble*

No diagnosis code.

INTERMITTENT MALFUNCTIONS*

No diagnosis code.

AC501888

• *1: For how to diagnose CAN bus lines, refer to GROUP 54C .

• *2: For the CAN bus diagnosis chart, refer to GROUP 54C .

• *3: When the M.U.T.-III detects a diagnosis code, its display informs users whether a mechanical problem

currently exists or whether it existed before. The message for the former state identifies it as a "Active" and the message for the latter identifies it as a "Stored".

• *4: For how to treat past trouble, refer to P.00-13.

• *5: For how to cope with intermittent malfunctions, refer to P.00-12.

2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS

If verification of the symptom(s) is difficult, procedures for checking operation and verifying symptoms

5. DIAGNOSIS CODE PROCEDURES

Indicates the inspection procedures corresponding to each diagnosis code (Refer to How to Use Inspection Procedures

P.00-8).

are shown.

6. TROUBLE SYMPTOM CHART

3. DIAGNOSIS FUNCTION

Details which are different from those in the "Diagnosis Function P.00-7" section are described.

If there are trouble symptoms even though the M.U.T.-III does not find any diagnosis codes, Inspec tion procedures for each trouble symptom will be found by means of this chart.

4. DIAGNOSIS CODE CHART

Diagnostic trouble codes and diagnostic items are shown.

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

00-7

7. SYMPTOM PROCEDURES

Indicates the inspection procedures corresponding to each symptoms classified in the Symptom Chart (Refer to How to Use Inspection Procedures

P.00-8).

8. SERVICE DATA REFERENCE TABLE

Inspection items and normal judgment values have been provided in this chart as reference information.

9. ACTUATOR TEST TABLE

The Actuator Test item numbers, inspection items, and judgment values have been provided in this chart as reference information.

10. CHECK AT ECU TERMINALS

Terminal numbers for the ECU connectors, inspection items, and judgment values have been provided in this chart as reference information.

11. INSPECTION PROCEDURE BY USING AN OSCILLOSCOPE

When there are inspection procedures using an oscilloscope, these are described here.

DIAGNOSIS FUNCTION

M1001013400100

HOW TO READ DIAGNOSIS CODE

Connect the M.U.T.-III to the 16-pin diagnosis connector, and read the diagnosis code.

NOTE: For details on how to use the M.U.T.-III, refer to the "M.U.T.-III operation manual."

1. Ensure that the ignition switch is at the "LOCK"

(OFF).

2. Start up the personal computer.

3. Connect M.U.T.-III USB cable MB991827 to

special tool Vehicle Communication Interface (V.C.I.) MB991824 and the personal computer.

4. Connect M.U.T.-III main harness A MB991910 to

the V.C.I.

5. Connect the M.U.T.-III main harness A to the

diagnosis connector.

6. Turn the V.C.I. power switch to the "ON" position.

NOTE: When the V.C.I. is energized, the V.C.I. indicator lamp will be illuminated in a green col

our.

7. Start the M.U.T.-III system on the personal

computer and turn the ignition switch to the "ON" position.

8. Read the diagnosis code.

9. Disconnecting the M.U.T.-III is the reverse of the

connecting sequence, making sure that the ignition switch is at the "LOCK" (OFF).

CAUTION

Before connecting or disconnecting the M.U.T.-III, turn the ignition switch to the "LOCK" (OFF) position.

Diagnosis connector

MB991910

MB991824

ERASING DIAGNOSIS CODE

CAUTION

Before connecting or disconnecting the M.U.T.-III, turn the ignition switch to the "LOCK" (OFF) position.

Diagnosis connector

MB991910

MB991824

MB991827

AC501413

MB991827

AC501413

00-8

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

GENERAL

Connect the M.U.T.-III to the diagnosis connector, and erase the diagnosis code. The procedure is the same as "How to Read Diagnosis Code

HOW TO USE THE INSPECTION PROCEDURES

M1001013500237

The causes of many of the problems occurring in electric circuitry are generally the connectors, components, the ECU, the wiring harnesses between connectors, in that order. These inspection procedures follow this order. They first try to discover a problem with a connector or a defective component.

Relevant circuit(s) of the component which the Code No. indicates are described.

AC301964

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

00-9

Explains about the basic operation of the components.

Explains about technical details.

Describes the conditions for that diagnosis code being set.

Start of diagnosis procedure

Describes inspection procedure.

M.U.T.-III data list

Describes possible causes(s) for that diagnosis code.

CURRENT TROUBLE

Indicates that the status is "Active" and the trouble is currently present. Carry out troubleshooting as described in the applicable inspection procedure.

PAST TROUBLE

Indicates that the status is "Stored" and the trouble is historic. Since the trouble may still be present, set the vehicle to the diagnosis code detection condition and check that the status changes to "Active". If the status does not change from "Stored", observe the applicable inspection procedure with particular emphasis on connector(s) and wiring harness.

AC313955

HARNESS CHECK

Check for an open or short circuit in the harness between the terminals which are faulty according to the connector measurements. Carry out this inspec

tion while referring to the Electrical Wiring Manual. Here, "Check the wiring harness between the power supply and terminal xx" also includes checking for blown fuse. For inspection service points when there is a blown fuse, refer to "Inspection Service Points for a Blown Fuse

P.00-12."

MEASURES TO TAKE AFTER REPLACING THE ECU

If the trouble symptoms have not disappeared even after replacing the ECU, repeat the inspection proce dure from the beginning.

00-10

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

CONNECTOR MEASUREMENT SERVICE POINTS

M1001013600223

CAUTION

During diagnosis, a diagnosis code associated with other system may be set when the ignition switch is turned on with connector(s) discon

nected. On completion, confirm all systems for diagnosis code(s). If diagnosis code(s) are set, erase them all.

Turn the ignition switch to the "LOCK" (OFF) position when connecting and disconnecting the connectors. Turn the ignition switch to "ON" when measuring, unless there are instructions to the contrary.

IF INSPECTING WITH THE CONNECTOR CONNECTED <WATERPROOF CONNECTORS>

CAUTION

Never insert a test probe from the harness side, as this will reduce the waterproof performance and result in corrosion.

Inspect by inserting a test probe from the harness side. If the connector is too small to insert a test probe (e.g. control unit connector), do not insert it forcibly. Use special tool extra fine probe (MB992006).

IF INSPECTING WITH THE CONNECTOR DISCONNECTED <WHEN INSPECTING A FEMALE PIN>

CAUTION

• Use special tool check harness (MB991219). If

the test bar is inserted forcibly, it will cause a poor contact.

•

If the connector is disconnected, a diagnosis code may be stored for the system to be checked or other systems.

MB991219

Special tool

AC105597

Use the special tools such as test harness, harness connector or check harness.

IF INSPECTING WITH THE CONNECTOR CONNECTED <ORDINARY (NON-WATERPROOF) CONNECTORS>

MB992006

AC105598

AC105599

Use check harness (MB991219) of special tool harness set (MB991223).

IF INSPECTING WITH THE CONNECTOR DISCONNECTED <WHEN INSPECTING A MALE PIN>

CAUTION

• Be careful not to short the connector pins

with the test bars. To do so may damage the circuits inside the ECU.

•

If the connector is disconnected, a diagnosis code may be stored for the system to be checked or other systems.

AC105600

Touch the pin directly with the test bar.

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

00-11

CONNECTOR INSPECTION SERVICE POINTS

M1001013700189

VISUAL INSPECTION

•

Connector disconnected or improperly connected

Stretched or broken wires

• Low contact pressure between male and female

terminals

• Low connection pressure due to rusted terminals

or foreign matter lodged in terminals

CONNECTOR PIN INSPECTION

AC300898

If the connector pin stopper is damaged, the terminal connections (male and female pins) will not be per fect even if the connector body is connected, and the pins may pull out of the reverse side of the connec tor. Therefore, gently pull the harnesses one by one to make sure that no pins pull out of the connector.

Harness wire breakage at terminal section

Low contact pressure

Good

Bad

AC300896

Connector is disconnected or improperly connected

• Connector pins are pulled out

• Due to harness tension at terminal section

CONNECTOR ENGAGEMENT INSPECTION

MB991219

AC300899

Use special tool inspection harness (MB991219) (connector pin connection pressure inspection har ness of the inspection harness set) to inspect the engagement of the male pins and female pins. (Pin drawing force: 1 N or more)

00-12

GENERAL

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

INSPECTION SERVICE POINTS FOR A BLOWN FUSE

M1001013800186

CAUTION

A diagnosis code may be stored due to a blown fuse.

Battery

Fuse

Short-circuit Load switch

occurrence

section

HOW TO COPE WITH INTERMITTENT MALFUNCTIONS

M1001013900183

Load

AC300900

Remove the blown fuse and measure the resistance between the load side of the blown fuse and the earth. Close the switches of all circuits which are connected to this fuse. If the resistance is almost 0

Ω

at this time, there is a short somewhere between these switches and the load. If the resistance is not 0

Ω, there is no short at the present time, but a momentary short has probably caused the fuse to blow. The main causes of a short circuit are the following.

• Harness being clamped by the vehicle body

• Damage to the outer casing of the harness due to

wear or heat

• Water getting into the connector or circuitry

• Human error (mistakenly shorting a circuit, etc.)

AC300901

Intermittent malfunctions often occur under certain conditions, and if these conditions can be ascer

tained, determining the cause becomes simple. In order to ascertain the conditions under which an intermittent malfunction occurs, first ask the cus

tomer for details about the driving conditions, weather conditions, frequency of occurrence and trouble symptoms, and then try to recreate the trou

ble symptoms. Next, ascertain whether the reason why the trouble symptom occurred under these con ditions is due to vibration, temperature or some other factor. If vibration is thought to be the cause, carry out the following checks with the connectors and components to confirm whether the trouble symptom occurs. The objects to be checked are connectors and components which are indicated by inspection procedures or given as probable causes (which gen erates diagnosis codes or trouble symptoms).

GENERAL

VEHICLE IDENTIFICATION

00-13

• Gently shake the connector up, down and to the

left and right.

• Gently shake the wiring harness up, down and to

the left and right.

• Gently rock each sensor and relay, etc. by hand.

• Gently shake the wiring harness at suspensions

and other moving parts.

NOTE: If determining the cause is difficult, the drive recorder function of the M.U.T.-III can also be used. (For details on how to use the M.U.T.-III, refer to the "M.U.T.-III operation manual).

VEHICLE IDENTIFICATION

VEHICLE NAME PLATE

HOW TO TREAT PAST TROUBLE

M1001014100157

Since the trouble may still be present even the status is "Stored", set the vehicle to the diagnosis code detection condition and check that the status changes to "Active". If the status does not change from "Stored", carry out the following procedure.

1. Establish from the customer whether a fuse or

connector has been replaced or disconnected.

2. If yes, erase the diagnosis code, and then check

that no diagnostic code is reset. If no diagnosis code is reset, the diagnosis is complete.

3. If no, follow the applicable Diagnostic Trouble

Code Chart. Then check the wiring harness and connector, and refer to "How to Cope with Intermittent Malfunction

P.00-12 ."

M1001000401255

AC501406

The name plate is riveted to the cowl top outer panel in the engine compartment.

AC501266

No. Item Content

1 MODEL KA4 Vehicle model

KB4

KB8

2 ENGINE 4D56 Engine model

4M41

00-14

VEHICLE IDENTIFICATION

GENERAL

MODELS

Model code Engine model Transmission model Fuel supply system

KA4T NCNMFRU 4D56 IDI (Indirect

Diesel Injection) SOHC engine with Turbo charger (2,477 mL)

NCNUZRU 4D56 DI-D (Direct

Injection-Diesel) DOHC engine with Turbo

NCRUZRU R4AW4

charger (2,477 mL)

2WD (rear axle drive)

R5M21 (5-speed manual transmission)

R5MB1 (5-speed manual transmission)

(4-speed automatic transmission)

Electrical fuel injection (distribution type injection pump system)

Electrical fuel injection (common rail engine control system)

KB4T GCNHZRU 4D56 DI-D (Direct

Injection-Diesel) DOHC engine with Inter cooler, Turbo charger (2,477 mL)

KB8T GCNHZRU 4M41 DI-D (Direct

Injection-Diesel) engine with Inter cooler, Turbo charger (3,200 mL)

Model code Engine model Transmission model Fuel supply system

KA4T NJNMZRU 4D56 DI-D (Direct

Injection-Diesel) DOHC engine with Turbo

NJNUZRU

NJRUZRU R4AW4

charger (2,477 mL)

4WD (easy select 4WD)

2WD (rear axle drive)

V5MB1 (5-speed manual transmission)

R5MB1 (5-speed manual transmission)

(4-speed automatic transmission)

Electrical fuel injection (common rail engine control system)

KB4T GJNHZRU 4D56 DI-D (Direct

Injection-Diesel) DOHC engine with Inter cooler, Turbo charger (2,477 mL)

KB8T GJNHZRU 4M41 DI-D (Direct

Injection-Diesel) engine with Inter cooler, Turbo

GJNXZRU

GJRXZRU V4A5A

charger (3,200 mL)

4WD (easy select 4WD)

V5MB1 (5-speed manual transmission)

(4-speed automatic transmission)

GENERAL

VEHICLE IDENTIFICATION

MODEL CODE

1 2 3 4 5 6 7 8 9 10 11

No. Item Content

1 Development K TRITON

2 Drive system A 2WD

B 4WD

3 Engine type 4 2,477 mL

8 3,200 mL

4 Sort T Truck

5 Vehicle width N Standard

G Wide fender

6 Body style C Club cab

00-15

AC407365

J Double cab

7 Transmission type N 5-speed manual transmission

R 4-speed automatic transmission

8 Vehicle grade M GL

U GLX

H GLS

X GLS-S

9 Specification engine feature F Turbo charger

9 Specification engine feature Z Inter cooler, turbo charger

10 Steering wheel location R Right hand

11 Destination U For Thailand

00-16

GENERAL

VEHICLE IDENTIFICATION

CHASSIS NUMBER

The chassis number is stamped on the side wall of the frame near the rear wheel (RH).

Frame

AC501503

1234567891011 12

No. Item Content

1 Country of manufacture M Asia

2 Maker

(distribution channel)

M MMC Sittipol Co., Ltd.

(Thailand)

AC501425

3 Destination and steering wheel

T For Thailand, right hand

location

4 Body style C Club cab

J Double cab

5 Transmission type N 5-speed manual transmission

R 4-speed automatic transmission

6 Vehicle line K MITSUBISHI TRITON

7 Development order A 2-wheel drive

B 4-wheel drive

8 Engine type 4 2,477mL diesel engine

8 3,200mL diesel engine

9 MSC internal purpose 0 No meaning

10 Model year 7 2006

11 Plant D MMC Sittipol Co., Ltd.

12 Serial number

− −

GENERAL

GENERAL DATA AND SPECIFICATIONS

00-17

ENGINE MODEL STAMPING

<4D5-SOHC>

<4D5-DOHC, 4M4>

AC502319

AC502538

The engine model is stamped on the cylinder block. This engine model numbers is as shown as follow.

Engine model Engine displacement

4D56 2,477 mL

4M41 3,200 mL

The engine serial number is stamped near the engine model number.

Engine serial number AA0201 to YY9999

CLUB CAB

<2WD>

GENERAL DATA AND SPECIFICATIONS

M1001000900945

AC502183

00-18

Items KA4T

GENERAL DATA AND SPECIFICATIONS

GENERAL

NCNMFRU NCNUZRU NCRUZRU

Vehicle dimensions mm

Vehicle weight kgKerb weight 1,565 1,600 1,600

Seating capacity 2 2 2

Front track 1 1,505 1,505 1,505

Overall width 2 1,750 1,750 1,750

Front overhang 3 785 785 785

Wheel base 4 3,000 3,000 3,000

Rear overhang 5 1,325 1,325 1,325

Overall length 6 5,110 5,110 5,110

Ground clearance (unladen) 7 200 195 195

Overall height (unladen) 8 1,660 1,655 1,655

Rear track 9 1,500 1,500 1,500

BED interior length 10 1,805 1,805 1,805

BED interior width 11 1,470 1,470 1,470

BED interior height 12 405 405 405

Cargo floor height (unladen) 13 725 720 720

Max. gross vehicle weight 2,285 2,330 2,330

Max. axle weight rating-front 1,030 1,030 1,030

Max. axle weight rating-rear 1,500 1,500 1,500

Engine Model No. 4D56 IDI (Indirect

Diesel Injection) engine with Turbo charger

Total displacement mL 2,477 2,477 2,477

Max. output kW (SP)/rpm 66 (90)/4,000 81 (110)/4,000 81 (110)/4,000 Max. torque N⋅ m/rpm 196 (20)/2,000 240 (24.5)/2,000 240 (24.5)/2,000

Transmission Model No. R5M21 R5MB1 R4AW4

Type 5-speed manual 5-speed manual 4-speed

Fuel system Fuel supply system Electrical fuel

injection (distribution type injection pump system)

Max speed km/h 150 160 158

Turning radius m 5.7 5.7 5.7

4D56 DI-D (Direct Injection-Diesel) engine with Turbo charger

Electrical fuel injection (common rail engine control system)

4D56 DI-D (Direct Injection-Diesel) engine with Turbo charger

automatic

Electrical fuel injection (common rail engine control system)

<4WD>

GENERAL

GENERAL DATA AND SPECIFICATIONS

00-19

1 2

Items KB4T KB8T

GCNHZRU GCNHZRU

Vehicle dimensions mm

Front track 1 1,520 1,520

Overall width 2 1,800 1,800

Front overhang 3 785 785

Wheel base 4 3,000 3,000

Rear overhang 5 1,325 1,325

Overall length 6 5,110 5,110

Ground clearance (unladen) 7 205 205

AC502184

Overall height (unladen) 8 1,780 1,780

Rear track 9 1,515 1,515

BED interior length 10 1,805 1,805

BED interior width 11 1,470 1,470

BED interior height 12 405 405

Cargo floor height (unladen) 13 860 860

Vehicle weight kgKerb weight 1,795 1,840

Max. gross vehicle weight 2,535 2,605

Max. axle weight rating-front 1,250 1,250

Max. axle weight rating-rear 1,600 1,600

Seating capacity 2 2

Engine Model No. 4D56 DI-D (Direct

Injection-Diesel) engine with Inter cooler, Turbo charger

4M41 DI-D (Direct Injection-Diesel) engine with Inter cooler, Turbo charger

Total displacement mL 2,477 3,200

Max. output kW (PS)/rpm 100 (136)/4,000 118 (136)/3,800 Max. torque N⋅ m/rpm 314 (32)/2,000 343 (35)/2,000

Transmission Model No. V5MB1

Type 5-speed manual

00-20

GENERAL DATA AND SPECIFICATIONS

GENERAL

Items KB4T KB8T

GCNHZRU GCNHZRU

Fuel system Fuel supply system Electrical fuel injection

(common rail engine control system)

Electrical fuel injection (common rail engine control system)

Max speed km/h 175 175

Turning radius m 5.9 5.9

DOUBLE CAB

<2WD>

1 2

AC502185

Items KA4T

NJNMZRU NJNUZRU NJRUZRU

Vehicle dimensions

Front track 1 1,505 1,505 1,505

Overall width 2 1,750 1,750 1,750

Front overhang 3 785 785 785

Wheel base 4 3,000 3,000 3,000

Rear overhang 5 1,210 1,210 1,210

Overall length 6 4,995 4,995 4,995

Ground clearance (unladen) 7 200 195 195

Overall height (unladen) 8 1,655 1,650 1,650

Rear track 9 1,500 1,500 1,500

BED interior length 10 1,325 1,325 1,325

BED interior width 11 1,470 1,470 1,470

BED interior height 12 405 405 405

Cargo floor height (unladen) 13 715 710 710

Vehicle weight kg

Kerb weight 1,640 1,640 1,640

Max. gross vehicle weight 2,330 2,330 2,330

Max. axle weight rating-front 1,030 1,030 1,030

Max. axle weight rating-rear 1,500 1,500 1,500

Seating capacity 5 5 5

GENERAL

GENERAL DATA AND SPECIFICATIONS

Items KA4T

NJNMZRU NJNUZRU NJRUZRU

00-21

Engine Model No. 4D56 DI-D

(Direct Injection-Diesel) engine with Turbo charger

Total displacement mL 2,477 2,477 2,477

Max. output kW (PS)/rpm 81 (110)/4,000 81 (110)/4,000 81 (110)/4,000 Max. torque N⋅ m/rpm 240 (24.5)/2,000 240 (24.5)/2,000 240 (24.5)/2,000

Transmission Model No. R5MB1 R5MB1 R4AW4

Type 5-speed manual 5-speed manual 4-speed

Fuel system Fuel supply system Electrical fuel

injection (common rail engine control system)

Max speed km/h 160 160 158

Turning radius m 5.7 5.7 5.7

4D56 DI-D (Direct Injection-Diesel) engine with Turbo charger

Electrical fuel injection (common rail engine control system)

4D56 DI-D (Direct Injection-Diesel) engine with Turbo charger

automatic

Electrical fuel injection (common rail engine control system)

00-22

<4WD>

GENERAL

GENERAL DATA AND SPECIFICATIONS

1 2

Items KB4T KB8T

GJNHZRU GJNHZRU GJNXZRU GJRXZRU

Vehicle dimensions

Front track 1 1,520 1,520 1,520 1,520

Overall width 2 1,800 1,800 1,800 1,800

Front overhang 3 785 785 785 785

Wheel base 4 3,000 3,000 3,000 3,000

Rear overhang 5 1,210 1,210 1,210 1,210

Overall length 6 4,995 4,995 4,995 4,995

Ground clearance (unladen) 7 205 205 205 205

Overall height (unladen) 8 1,780 1,780 1,780 1,780

AC502186

Rear track 9 1,515 1,515 1,515 1,515

BED interior length 10 1,325 1,325 1,325 1,325

BED interior width 11 1,470 1,470 1,470 1,470

BED interior height 12 405 405 405 405

Cargo floor height (unladen) 13 850 850 850 850

Vehicle weight kg

Kerb weight 1,860 1,920 1,930 1,940

Max. gross vehicle weight 2,535 2,605 2,605 2,605

Max. axle weight rating-front 1,250 1,250 1,250 1,250

Max. axle weight rating-rear 1,600 1,600 1,600 1,600

Seating capacity 5 5 5 5

Engine Model No. 4D56 DI-D

(Direct Injection-Dies el) engine with Inter cooler, Turbo charger

4M41 DI-D (Direct Injection-Die sel) engine with Inter cooler, Turbo charger

Total displacement mL 2,477 3,200 3,200 3,200

Max. output kW (PS)/rpm 100

(136)/4,000

Max. torque N⋅ m/rpm 314

(32)/2,000

118 (160)/3,800

343 (35)/2,000

118 (160)/3,800

343 (35)/2,000

4M41 DI-D (Direct Injection-Die sel) engine with Inter cooler, Turbo charger

118 (160)/3,800

343 (35)/2,000

GENERAL

PRECAUTIONS BEFORE SERVICE

Items KB4T KB8T

GJNHZRU GJNHZRU GJNXZRU GJRXZRU

Transmission Model No. V5MB1 V5MB1 V5MB1 V4A5A

Type 5-speed

manual

Fuel system Fuel supply system Electrical fuel

injection (common rail engine control system)

Max speed km/h 175 175 175 175

Turning radius m 5.9 5.9 5.9 5.9

5-speed manual

Electrical fuel injection (common rail engine control system)

5-speed manual

Electrical fuel injection (common rail engine control system)

00-23

4-speed automatic

Electrical fuel injection (common rail engine control system)

PRECAUTIONS BEFORE SERVICE

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH PRE-TENSIONER

M1001011600238

CAUTION

Items to review when servicing SRS:

1. Be sure to read GROUP 52B − Supplemental

Restraint System (SRS). For safe operation, please follow the directions and heed all warnings.

2. Wait at least 60 seconds after disconnecting

the battery cable before doing any further work. The SRS system is designed to retain enough voltage to deploy the air bag even after the battery has been disconnected. Seri ous injury may result from unintended air bag deployment if work is done on the SRS sys tem immediately after the battery cable is disconnected.

3. Warning labels must be heeded when servic-

ing or handling SRS components. Warning labels can be found in the following locations.

• SRS air bag control unit (SRS-ECU)

• Front impact sensor

• Clock spring

• Driver's and front passenger's air bag

modules

• Seat belt with pre-tensioner

4. Always use the designated special tools and

test equipment.

5. Store components removed from the SRS in a

clean and dry place. The air bag module should be stored on a flat surface and placed

so that the pad surface is facing upward. Do not place anything on top of it.

6. Never attempt to disassemble or repair the

SRS components (SRS-ECU, air bag module and clock spring).

7. Whenever you finish servicing the SRS, check

the SRS warning lamp operation to make sure that the system functions properly.

8. Be sure to deploy the air bag before dispos-

ing of the air bag module or disposing of a vehicle equipped with an air bag (Refer to GROUP 52B dures).

Observe the following when carrying out operations on places where SRS components are

installed, including operations not directly

related to the SRS air bag.

1. When removing or installing parts, do not

allow any impact or shock to the SRS compo nents.

2. If heat damage may occur during paint work,

remove the SRS-ECU, the air bag module, clock spring, the front impact sensor, and the seat belt pre-tensioner.

• SRS-ECU, air bag module, clock spring,

front impact sensor: 93

• Seat belt pre-tensioner: 90 ° C or more

− Air Bag Module Disposal Proce-

° C or more

00-24

PRECAUTIONS BEFORE SERVICE

GENERAL

WHAT THE COMMON RAIL ENGINE LEARNS

After fuel-related parts are replaced, the common rail engine must register their identification codes with the engine-ECU and execute learning. The table below shows what should be registered and learned after each type of operation.

Correspondence table

Registration and learning item

Injector identification code registration

Small injection quantity learning

Supply pump correction learning

Operation type

Injector replacement Supply pump

replacement

appricable

−

appricable

M1001012500018

NOTE: When the engine-ECU is replaced, collect in advance the injector identification code from the cur rent engine-ECU. Doing it makes registration easy.

Engine-ECU replacement

appricable

−

REGISTRATION AND LEARNING PROCEDURE

Injector identification code registration

Refer to P.00-24, INJECTOR IDENTIFICATION CODE REGISTRATION PROCEDURE.

Small injection quantity learning

Refer to P.00-25, SMALL INJECTION QUANTITY LEARNING PROCEDURE.

Supply pump correction learning

Refer to P.00-26, SUPPLY PUMP CORRECTION LEARNING PROCEDURE.

INJECTOR IDENTIFICATION CODE REGISTRATION PROCEDURE

CAUTION

1. If the injector identification code is not regis-

tered, the engine warning lamp goes on and diagnosis code No. P1626 is logged.

2. Failure to register the injector identification

code correctly will cause rough idling, abnor mal noise, and emission deterioration.

PURPOSE

Identification code

Because individual injectors have different injection characteristics, the engine-ECU corrects injection time for each cylinder to improve injection accuracy. For this reason, when the injector or engine-ECU is replaced, injector correction data must be registered afterwards in the engine-ECU using the Multi Use Tester III (M.U.T.-III). Correction data is converted into an identification code consisting of 30 alphanumeric characters and printed on the injector connector.

AK501491

M1001012600015

GENERAL

PRECAUTIONS BEFORE SERVICE

00-25

REGISTRATION PROCEDURE

1. When replacing the engine-ECU, connect the current engine-ECU to the body harness.

NOTE: This operation is purposed to read the injector identification code stored in the engine-ECU. Reading the identification code in this way before replacement can eliminate manual input of the identi fication code after replacement.

2. After the ignition switch is in "LOCK" (OFF) position, connect the M.U.T.-III to the diagnosis connector.

3. Turn the ignition switch to "ON" position.

4. Select SPECIAL FUNCTION from the function menu.

5. When the current engine-ECU is still mounted, read and register the injector identification code as follows:

(1) Select Read Injector ID Code (for engine-ECU

replacement) from the SPECIAL FUNCTION menu.

(2) Select Write and Save Injector ID Code from

the menu to read data from the current engine-ECU and save the data if it could be

read normally. (3) Mount the new engine-ECU on the vehicle. (4) Select SPECIAL FUNCTION from the function

menu. (5) Select Write Injector ID Code (for engine-ECU

replacement) from the SPECIAL FUNCTION

menu. (6) Select SAVED INJECTOR ID WRITING from

the Write Injector ID Code menu to write the

data, which was saved previously, to the

engine-ECU.

6. If the injector has been replaced or data has not been read from the current engine-ECU, register the injector identification code as follows:

(1) Select Write Injector ID Code from the

SPECIAL FUNCTION menu.

(2) If the injector was replaced, specify whether to

write to every cylinder or a specific cylinder.

Frame 1 (4 digits)

Frame 2 (4 digits)

Frame 3 (4 digits)

Frame 5 (4 digits)

Frame 7 (4 digits)

Frame 4 (4 digits)

Frame 6 (4 digits)

Frame 8 (2 digits)

AK501492

(3) Select the write mode from the menu, enter

the identification code printed on the injector, and execute writing.

CAUTION

Even if the number of the cylinder to be registered does not match the actual injector mounting location, registration ends normally. Specify the cylinder number correctly.

NOTE: The identification code is displayed in order of the frame numbers when it is read.

7. Makes sure that the engine warning lamp that is on changes to blinking, indicating the registration is complete.

NOTE: When the injector is replaced, executing the write operation also clears the values of small injec tion quantity learning.

8. Execute small injection quantity learning.

Refer to P.00-25, the SMALL INJECTION QUANTITY LEARNING PROCEDURE for the learning procedure.

9. Confirm that the engine warning lamp is off.

Confirm also that the diagnosis code is not stored.

SMALL INJECTION QUANTITY LEARNING PROCEDURE

CAUTION

1. If small injection quantity learning has not

been executed, the engine warning lamp blinks.

2. When the requirements for learning are satis-

fied by operation after replacement of the engine-ECU, learning is automatically exe

cuted even if no instruction is given from the M.U.T.-III. Accordingly, the malfunction indica tor lamp goes off. However, the learning thus executed is tentative and limited. Be sure to complete leaning using the M.U.T.-III.

PURPOSE

To keep emission and noise level at adequate levels, the engine-ECU must learn injector fuel injection in idle mode. During learning, the engine-ECU calculates actual injection from each cylinder based on changes in engine speeds and corrects pilot injection control. It then keeps records of this amount of correction as a learned value.

For this reason, after the engine-ECU or injector is replaced, learning must be executed using the M.U.T.-III.

M1001014300010

00-26

GENERAL

PRECAUTIONS BEFORE SERVICE

NOTE: Engine friction changes or injector deterioration over time may cause fluctuation in pilot injection. After use over time, it may prevent injection of an accurate amount of fuel according to the indication by the engine-ECU. This is why learning must be executed again periodically. For this reason, the engine-ECU periodically leans injection according to the cumulative mileage. Note that making the M.U.T.-III learn again resets the cumulative mileage.

NOTE: The engine sound may change or idling engine speeds may increase during injection learn ing. These are not abnormalities.

LEARNING PROCEDURE

1. After the ignition switch is in "LOCK" (OFF) position, connect the M.U.T.-III to the diagnosis connector.

2. Put the vehicle in the following idling stable conditions:

• Engine coolant temperature: 80 − 90°C

• Automatic transmission fluid temperature: 60° C

or higher

• Lamps, A/C condenser fan and all accessories:

OFF

• Transmission: Neutral <M/T>, "P" range <A/T>

• Power steering: Static state

3. Select SPECIAL FUNCTION from the function menu.

4. Select SMALL INJECTION QUANTITY LEARNING from the SPECIAL FUNCTION menu to execute learning.

CAUTION

If the vehicle conditions go out of the learning

conditions during idling, learning is interrupted.

To reexecute learning, the ignition switch

must once be turned off.

5. Continue idling for about 3 minutes before learning is completed.

6. Confirm that the engine warning lamp is off. If it still blinks, reexecute learning.

SUPPLY PUMP CORRECTION LEARNING PROCEDURE

PURPOSE

The engine-ECU learns the relation between the suction control valve (linear solenoid valve) of the supply pump drive current and the fuel injection vol ume.

The learning value is calculated from the suction control valve drive current and the rail pressure sen sor output voltage. When the supply pump is replaced, therefore, this

learning must be executed.

Re-learning is executed when the engine is idling after the learning value in the engine-ECU has been reset by the M.U.T.-III.

M1001014400017

GENERAL

PRECAUTIONS BEFORE SERVICE

LEARNING PROCEDURE FOR IDLING

After the ignition switch is in "LOCK" (OFF) position,

connect the M.U.T.-III to the diagnosis connector.

1. Turn the ignition switch to "ON" position. (Do not start the engine.)

2. Select SPECIAL FUNCTION from the function menu.

3. Select SUPPLY PUMP CORRECTION LEARNING from the SPECIAL FUNCTION menu and execute the initializing of the learning value.

4. After initializing, run the engine at idle in the following conditions.

• Accelerator pedal: OFF

• Engine coolant temperature: 60° C or higher

• Fuel temperature: 30° C or higher

5. Confirm that the item No. 65 High pressure pump learned status on M.U.T.-III Service Data is "2".

NOTE: "2" indicates that the learning has completed.

00-27

M1001014500014

APPLICATION OF ANTI-CORROSION AGENTS AND UNDERCOATS

M1001011000173

If oil or grease gets onto the oxygen sensor, it will cause a drop in the performance of the sensor. Cover the oxygen sensor with a protective cover when applying anti-corrosion agents and undercoats.

VEHICLE WASHING

M1001012000206

Approximately 40 cm

SERVICING ELECTRICAL SYSTEM

M1001011900217

CAUTION

Before connecting or disconnecting the negative (

−) cable, be sure to turn off the ignition switch

and the lighting switch (If this is not done, there is the possibility of semiconductor parts being damaged).

AC300693

Before replacing a component related to the electrical system and before undertaking any repair procedures involving the electrical system, be sure to first disconnect the negative (

−) cable from the battery in

order to avoid damage caused by short-circuiting.

VEHICLES WITH SEMI AUTOMATIC AIR CONDITIONER

M1001011300055

CAUTION

Never start the engine with the refrigerant system empty as it will damage the A/C compressor.

AC300832

If high-pressure car-washing equipment or steam car-washing equipment is used to wash the vehicle, be sure to note the following information in order to avoid damage to plastic components, etc.

• Spray nozzle distance: Approximately 40 cm or

• Spray pressure: 3,900 kPa or less

• Spray temperature: 82°C or less

• Time of concentrated spray to one point: within

30 sec.

PRE-INSPECTION CONDITION

M1001012100117

"Pre-inspection condition" refers to the condition that the vehicle must be in before proper engine inspec tion can be carried out. If you see the words "Set the vehicle to the pre-inspection condition" in this man ual. It means to set the vehicle to the following condition.

• Engine coolant temperature 80 to 90° C

• Lamps, electric cooling fan and all accessories:

OFF

• M/T: Neutral

• A/T: N range

00-28

GENERAL

PRECAUTIONS BEFORE SERVICE

MULTI USE TESTER (M.U.T.-III) SUB ASSEMBLY

M1001012400011

MULTI USE TESTER (M.U.T.-III) sub assembly

Vehicle communication interface (V.C.I.)

MB991824

M.U.T.-III USB cable

MB991827

M.U.T.-III main harness A

MB991910

M.U.T.-III main harness B

CAUTION

Diagnosis connector

MB991910

MB991824

MB991827

AC501413

Turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting the M.U.T.-III.

Connect the M.U.T.-III to the diagnosis connector as shown in the illustration.

Do not use

MB991911

M.U.T.-III measurement adapter

MB991825

M.U.T.-III trigger harness

MB991826

AC305090

Refer to the "M.U.T.-III OPERATION MANUAL" for instructions on handling the M.U.T.-III.

HOW TO USE THE THROTTLE CONTROLLER

M1001009300014

As for a vehicle with the electronic control throttle

, engine operations such as racing can not be

valve performed from outside the vehicle. Thus, the throttle valve controller (MB991791) is provided as a special tool to enable the engine operation from outside the vehicle.

NOTE: *: A vehicle with the accelerator pedal position sensor (APS) installed to the accelerator pedal

THE THROTTLE CONTROLLER CONNECTION

APS harness side connector

MB991894

MB991791

AC103781

GENERAL

PRECAUTIONS BEFORE SERVICE

00-29

1. Disconnect the accelerator pedal position sensor (APS) connector installed to the accelerator pedal, and connect the 6-pin connector of throttle controller adaptor (MB991894) to the vehicle harness-side connector.

2. Connect the throttle controller (MB991791) to the 8-pin connector of throttle controller adaptor (MB991894).

IN ORDER TO PREVENT VEHICLES FROM FIRE

M1001011100073

"Improper installation of electrical or fuel related parts could cause a fire. In order to retain the high quality and safety of the vehicle, it is important that any accessories that may be fitted or modifica tions/repairs that may be carried out which involve the electrical or fuel systems, MUST be carried out in accordance with MMC's information/Instructions".

ENGINE OILS

M1001011200081

HEALTH WARNING

Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addi tion, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities must be provided.

RECOMMENDED PRECAUTIONS

The most effective precaution is to adapt working practices which prevent, as far as practicable, the risk of skin contact with mineral oils, for example by using enclosed systems for handling used engine oil and by degreasing components, where practicable, before handling them.

Other precautions:

• Avoid prolonged and repeated contact with oils,

particularly used engine oils.

• Wear protective clothing, including impervious

gloves where practicable.

• Avoid contaminating clothes, particularly under-

pants, with oil.

• Do not put oily rags in pockets, the use of overalls

without pockets will avoid this.

• Do not wear heavily soiled clothing and

oil-impregnated foot-wear. Overalls must be cleaned regularly and kept separately from per sonal clothing.

• Where there is a risk of eye contact, eye protec-

tion should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided.

• Obtain First Aid treatment immediately for open

cuts and wounds.

• Wash regularly with soap and water to ensure all

oil is removed, especially before meals (skin cleansers and nail brushes will help). After clean ing, the application of preparations containing lanolin to replace the natural skin oils is advised.

• Do not use petrol, kerosine, diesel fuel, gas oil,

thinners or solvents for cleaning skin.

• Use barrier creams, applying them before each

work period, to help the removal of oil from the skin after work.

• If skin disorders develop, obtain medical advice

without delay.

00-30

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

The Supplemental Restraint System (SRS) and seat belt with pre-tensioner is designed to supplement the driver's and front passenger's seat belts to help reduce the risk or severity of injury to the driver and front passenger by activating and deploying both front air bags in certain frontal collisions. The SRS consist of two air bag modules, SRS air bag control unit (SRS-ECU), front impact sensors, SRS warning lamp, clock spring and seat belt pre-tensioner. Front air bags are located in the centre of the steering wheel and above the glove box. Each air bag is made up of a folded air bag and an inflator unit. The SRS-ECU is located for front the floor con

<A/T>

SRS warning lamp

GENERAL

M1001009800150

sole and has a front air bag safing G-sensor, front air bag analogue G-sensor The front impact sensor is installed outside of the readlamp sopport panel. The warning lamp on the instrument panel indicates the operational status of the SRS. The clock spring is installed in the steering column. The seat belt pre-tensioner is built into the driver's and passen ger's front seat belt retractor. Only authorized service personnel should do work on or around the SRS components. Those service per sonnel should read this manual carefully before starting any such work.

Passenger's (front) air bag module

Driver's air bag module

<M/T>

Front impact sensor

AC502001

SRS warning lamp

AC502000

SRS-ECU

Seat belt pre-tensioner

AC500480

Clock spring

AC501190

AC500479

GENERAL

SRS SERVICE PRECAUTIONS

DANGER

In order to avoid injury to yourself or others from accidental deployment of the air bag during servicing, read and carefully follow all the precautions and procedures described in this manual.

CAUTION

Do not use any electrical test equipment on or near SRS components, except those specified on .

CAUTION

Never Attempt to Repair the Following Components:

• SRS air bag control unit (SRS-ECU)

• Front impact sensor

• Clock spring

• Driver's and passenger's (front) air bag mod-

ules

• Seat belt with pre-tensioner

NOTE: If any of these components are diagnosed as faulty, they should only be replaced, in accordance with the INDIVIDUAL COMPONENTS SERVICE pro cedures in this manual, starting at page .

SRS-ECU terminal No. Destination of harness Remedy

CAUTION

SRS-ECU connector

Do not attempt to repair the wiring harness connectors of the SRS. If a defective wiring harness is found, repair or replace it by referring to the table below.

AC103220

00-31

M1001006000155

1, 2 Instrument panel wiring harness →

Front wiring harness sensor (RH)

3, 4 Instrument panel wiring harness →

Front wiring harness sensor (LH)

27, 28 Instrument panel wiring harness →

Front wiring harness pre-tensioner (LH)

29, 30 Instrument panel wiring harness →

Front wiring harness pre-tensioner (RH)

9, 10 Instrument panel wiring harness →

passenger's (Front) side air bag module

11, 12 Instrument panel wiring harness →

Clock spring module

13 Instrument panel wiring harness →

Junction block (fuse No.8)

→ Driver's side air bag

→ Front impact

→ Seat belt

Correct or replace each wiring harness.

Correct or replace the instrument panel wiring harness.

Correct or replace instrument panel wiring harness. Replace the clock spring.

Correct or replace the instrument panel wiring harness.

16 Instrument panel wiring harness →

Junction block (fuse No.15)

Correct or replace the instrument panel wiring harness.

00-32

SRS SERVICE PRECAUTIONS

GENERAL

SRS-ECU terminal No. Destination of harness Remedy

8 Instrument panel wiring harness

→SRS wiring lamp

18 Instrument panel wiring harness→

Earth

20 Instrument panel wiring harness →

Diagnosis connector

DANGER

Insulating tape

Battery cable

Battery

AC300580

CAUTION

After disconnecting the battery cable, wait 60 seconds or more before proceeding with the following work. In addition, insulate the neg

ative battery terminal with a tape. The condenser inside the SRS-ECU is designed to retain enough voltage to deploy the air bag for a short time even after the battery has been disconnected, so serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cables are disconnected.

CAUTION

The SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the SRS-ECU, driver’s and front passen ger’s air bag modules, clock spring, front impact sensor, seat belt pre-tensioner before drying or baking the vehicle after painting.

• Air bag modules: 93° C or more

CAUTION

Whenever you finish servicing the SRS, always erase the diagnosis code and check warning lamp operation to make sure that the system functions properly.

If checks are carried out by using the SRS-ECU harness connector, observe the following proce dures: Insert the special tool extra fine probe (MB992006) into connector from harness side

(rear side), and connect the tester to this probe. If any tool than special tool is used, damage to the harness and other components will result. Never insert the probe directly to the terminals from the front of the connector. The terminals are plated to increase their conductivity, so that if they are touched directly by the probe, the plating may break, which will cause drops in reliability.

Correct or replace the Instrument panel wiring harness.

Correct or replace the instrument panel wiring harness.

SRS-Harness connector

SRS-ECU harness connector (rear side)

AC006195

GENERAL

SUPPORT LOCATIONS FOR LIFTING AND JACKING

00-33

SUPPORT LOCATIONS FOR LIFTING AND JACKING

M1001000700286

SUPPORT POSITIONS FOR A GARAGE JACK AND AXLE STANDS

CAUTION

Do not support the vehicles at locations other than specified supporting points. Doing so will cause damage, etc.

<2WD>

AXLE STANDS

GARAGE JACK

<Front>

AC502650

AC502651

<Rear>

AC502647

AC502074

AC502069

AC502070

AC502562

00-34

<4WD>

AXLE STANDS

GENERAL

SUPPORT LOCATIONS FOR LIFTING AND JACKING

GARAGE JACK

<Front>

AC502650

AC502651

<Rear>

AC502647

AC502069

AC502070

AC502553

GENERAL

SUPPORT LOCATIONS FOR LIFTING AND JACKING

00-35

SUPPORT POSITIONS FOR A SINGLE-POST LIFT OR DOUBLE-POST LIFT

CAUTION

When service procedures require removing rear suspension, spare tyre and rear bumper, place additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of centre of gravity changes.

<2WD>

AC502652

AC502653

AC502571

00-36

<4WD>

GENERAL

SUPPORT LOCATIONS FOR LIFTING AND JACKING

AC502652

AC502653

AC502572

GENERAL

STANDARD PART/TIGHTENING-TORQUE TABLE

Each torque value in the table is a standard value for tightening under the following conditions.

1. Bolts, nuts and washers are all made of steel and plated with zinc.

2. The threads and bearing surface of bolts and nuts are all in dry condition.

The values in the table are not applicable:

STANDARD BOLT AND NUT TIGHTENING TORQUE

Thread size Torque N⋅ m

Bolt nominal diameter (mm)

M5 0.8 2.5 ± 0.5 5.0 ± 1.0 6.0 ± 1.0 M6 1.0 5.0 ± 1.0 8.5 ± 1.5 10 ± 2 M8 1.25 11 ± 2 20 ± 4 24 ± 4 M10 1.25 23 ± 4 42 ± 8 53 ± 7

Pitch (mm)

Head mark "4" Head mark "7" Head mark "8"

1. If toothed washers are inserted.

2. If plastic parts are fastened.

3. If bolts are tightened to plastic or die-cast inserted nuts.

4. If self-tapping screws or self-locking nuts are used.

00-37

M1001001100715

M12 1.25 42 ± 8 80 ± 10 93 ± 12 M14 1.5 70 ± 10 130 ± 20 150 ± 20 M16 1.5 105 ± 15 195 ± 25 230 ± 30 M18 1.5 150 ± 20 290 ± 40 335 ± 45 M20 1.5 210 ± 30 400 ± 60 465 ± 65 M22 1.5 290 ± 40 540 ± 80 630 ± 90 M24 1.5 375 ± 55 705 ± 105 820 ± 120

FLANGE BOLT AND NUT TIGHTENING TORQUE

Thread size Torque N⋅ m

Bolt nominal diameter (mm)

M6 1.0 5.0 ± 1.0 10 ± 2 12 ± 2 M8 1.25 13 ± 2 24 ± 4 28 ± 5 M10 1.25 26 ± 5 50 ± 5 58 ± 7 M10 1.5 25 ± 4 46 ± 8 55 ± 5 M12 1.25 47 ± 9 93 ± 12 105 ± 15 M12 1.75 43 ± 8 83 ± 12 98 ± 12

Pitch (mm)

Head mark "4" Head mark "7" Head mark "8"

NOTE: .

•

Be sure to use only the specified bolts and nuts, and always tighten them to the specified torques.

•

Bolts marked with indications such as 4T or 7T are reinforced bolts. The larger the number, the greater the bolt strength.

NOTES

GROUP 11

ENGINE

CONTENTS

ENGINE MECHANICAL <4D5-SOHC>. . . . . . . . . . . . . . . . . . . . 11A

ENGINE OVERHAUL <4D5-SOHC>. . . . . . . . . . . . . . . . . . . . . . 11B

11-1

ENGINE MECHANICAL <4D5-DOHC> . . . . . . . . . . . . . . . . . . . 11C

ENGINE OVERHAUL <4D5-DOHC> . . . . . . . . . . . . . . . . . . . . . 11D

ENGINE MECHANICAL <4M4> . . . . . . . . . . . . . . . . . . . . . . . . . 11E

ENGINE OVERHAUL <4M4> . . . . . . . . . . . . . . . . . . . . . . . . . . . 11F

NOTES

GROUP 11A

ENGINE

MECHANICAL

<4D5-SOHC>

CONTENTS

11A-1

GENERAL INFORMATION . . . . . . . . 11A-2

SERVICE SPECIFICATIONS. . . . . . . 11A-2

SEALANTS . . . . . . . . . . . . . . . . . . . . 11A-3

SPECIAL TOOLS. . . . . . . . . . . . . . . . 11A-4

ON-VEHICLE SERVICE. . . . . . . . . . . 11A-6

DRIVE BELT TENSION CHECK AND

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 11A-6

VALVE CLEARANCE CHECK AND

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 11A-8

INJECTION TIMING CHECK AND

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 11A-10

IDLE SPEED CHECK . . . . . . . . . . . . . . . . . 11A-12

COMPRESSION PRESSURE CHECK. . . . 11A-12

TIMING BELT TENSION ADJUSTMENT . . 11A-13

TIMING BELT B TENSION ADJUSTMENT 11A-14

CRANKSHAFT PULLEY . . . . . . . . . . 11A-15

REMOVAL AND INSTALLATION . . . . . . . . 11A-15

CAMSHAFT AND VALVE STEM

SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-18

REMOVAL AND INSTALLATION . . . . . . . . 11A-18

OIL PAN AND OIL SCREEN . . . . . . . 11A-22

REMOVAL AND INSTALLATION . . . . . . . . 11A-22

CRANKSHAFT OIL SEAL . . . . . . . . . 11A-25

REMOVAL AND INSTALLATION . . . . . . . . 11A-25

CYLINDER HEAD GASKET . . . . . . . . 11A-27

REMOVAL AND INSTALLATION . . . . . . . . 11A-27

TIMING BELT . . . . . . . . . . . . . . . . . . . 11A-31

REMOVAL AND INSTALLATION . . . . . . . . 11A-31

TIMING BELT B . . . . . . . . . . . . . . . . . 11A-34

REMOVAL AND INSTALLATION . . . . . . . . 11A-34

ENGINE ASSEMBLY . . . . . . . . . . . . . 11A-36

REMOVAL AND INSTALLATION . . . . . . . . 11A-36

11A-2

ENGINE MECHANICAL <4D5-SOHC>

GENERAL INFORMATION

Item 4D56

Total displacement mL 2,477 Bore × Stroke mm 91.1 × 95.0

Compression ratio 21

Combustion chamber Vortex chamber type

Camshaft arrangement SOHC

Number of valve Intake 4

Exhaust 4

Valv e timi ng Intake Opening BTDC 20°

Closing ABDC 49°

Exhaust Opening BBDC 55°

Closing ATDC 2 2 °

Fuel system Distribution type injection pump

Rocker arm Double roller type

M1111000100839

Adjusting screw Elephant foot type

SERVICE SPECIFICATIONS

Items Standard value Limit

Alternator drive belt (When checked)

Alternator drive belt (When adjusted)

Alternator drive belt (When replaced)

Power steering oil pump drive belt tension (When checked)

Power steering oil pump drive belt tension (When adjusted)

Power steering oil pump drive belt tension (When replaced)

Ten s i on N 245 − 441 Deflection mm (Reference) 12.0 −17.0 Ten s i on N 294 − 392 Deflection mm (Reference) 13.0 − 16.0 Ten s i on N 392 − 588 Deflection mm (Reference) 10.0 − 13.0 Ten s i on N 294 − 490 Deflection mm (Reference) 8.0 − 12.0 Ten s i on N 343 − 441 Deflection mm (Reference) 9.0 − 11.5 Ten s i on N 490 − 686 Deflection mm (Reference) 6.0 − 8.0

−

M1111000300899

A/C compressor drive belt tension (When checked)

A/C compressor drive belt tension (When adjusted)

A/C compressor drive belt tension (When replaced)

Ten s i on N 338 − 430 Deflection mm (Reference) 7.2 − 8.4 Ten s i on N 338 − 430 Deflection mm (Reference) 7.2 − 8.4 Ten s i on N 461 − 614 Deflection mm (Reference) 5.5 − 6.9

−

ENGINE MECHANICAL <4D5-SOHC>

SEALANTS

Items Standard value Limit

Valve clearance (at hot) mm 0.25 Injection timing (Value indicated on dial gauge mm) 9° ATDC (1 ± 0.03)

−

11A-3

Idle speed r/min 750 ± 30

Compression pressure kPa (at engine speed of 280 r/min) 3,100 Min. 2,800

Compression pressure difference of all cylinder (at engine speed of 280 r/min) kPa

Timing belt tension mm 4 − 5 Timing belt B tension mm 4 − 5

−

Max. 294

−

SEALANTS

M1111000500440

Item Specified Sealant Remark

Semi-circular packing 3M ATD Part No. 8660 or equivalent Semi-drying sealant

Engine oil pan MITSUBISHI GENUINE PART MD970389

or equivalent

Semi-drying sealant

11A-4

ENGINE MECHANICAL <4D5-SOHC>

SPECIAL TOOLS

Tool Number Name Use

A: MB991824 B: MB991827 C: MB991910 D: MB991911

MB991955

MB991824

MB991827

MB991910

E: MB991825 F: MB991826

M.U.T.-III sub assembly

A: Vehicle communication

interface (V.C.I.) B: M.U.T.-III USB cable C: M.U.T.-III main harness A

(Vehicles with CAN

communication system) D: M.U.T.-III main harness B

(Vehicles without CAN

communication system) E: M.U.T.-III measurement

adapter F: M.U.T.-III trigger harness

• Checking the ignition timing

• Checking the idle speed

For vehicles with CAN communication, use M.U.T.-III main harness A to send simulated vehicle speed. If you connect M.U.T.-III main harness B instead, the CAN communication does not function correctly.

M1111000601150

CAUTION

DO NOT USE

MB991911

MB991825

MB991826

MB991955

MD998384 Prestroke measuring adapter Adjustment of the injection

timing

D998384

B992040

MB992040 Crank pulley holder Holding the crankshaft sprocket

ENGINE MECHANICAL <4D5-SOHC>

SPECIAL TOOLS

Tool Number Name Use

MB990767 Front hub and flange yoke

Holding the camshaft sprocket

holder

B990767

MD998719 Crankshaft pulley holder pin

D998719

MD998381 Camshaft oil seal installer Camshaft oil seal installation

D998381

MD998772 Valve spring compressor Compressing valve spring

11A-5

MD998772

MD998729

D998727

D998781

MD998729 Valve stem seal installer Valve stem seal installation

MD998727 Oil pan FIPG cutter Oil pan removal

MD998781 Flywheel stopper Supporting the flywheel

assembly

MD998376 Crankshaft rear oil seal

installer

Crankshaft rear oil seal installation

11A-6

ENGINE MECHANICAL <4D5-SOHC>

ON-VEHICLE SERVICE

Tool Number Name Use

MD998383 Crankshaft front oil seal

guide

D998383

Crankshaft front oil seal installation

MD998382 Crankshaft front oil seal

installer

D998382

MD998051 Cylinder head bolt wrench Removal and installation of

cylinder head bolt

MB991614 Angle gauge Tightening cylinder head bolt

MB991614

MB991683 Sling chain set Removal and installation of

B991683

ON-VEHICLE SERVICE

DRIVE BELT TENSION CHECK AND ADJUSTMENT

ALTERNATOR DRIVE BELT TENSION CHECK AND ADJUSTMENT

Check the drive belt tension in the following procedure.

Standard value:

Item When

checked

Tension N 245 − 441 294 − 392 392 − 588

Deflection mm (Reference)

12.0 −

17.0

When adjusted

13.0 −

16.0

M1111003100991

When replaced

10.0 −

13.0

engine assembly

Tension gauge

Alternator pulley

Use a belt tension gauge to check that the belt tension is within the standard value.

Water pump pulley

Crankshaft pulley

AK403465

ENGINE MECHANICAL <4D5-SOHC>

ON-VEHICLE SERVICE

11A-7

Water pump

Approximately 100 N

Deflection

Alternator pulley

Apply approximately 100 N of force to the middle of the drive belt between the pulleys (at the place indi cated by the arrow) and check that the amount of deflection is within the standard value.

Adjusting bolt

Alternator fixing nut

Nut for alternator pivot bolt

If not within the standard value, adjust the belt tension by the following procedure.

1. Loosen the nut of the nut for alternator pivot bolt.

2. Loosen the alternator fixing nut.

3. Use the adjusting bolt to adjust the belt tension and belt deflection to the standard values.

4. Tighten the nut of the nut for alternator pivot bolt.

Tightening torque: 44 ± 10 N⋅ m

pulley

Crankshaft pulley

AK403466

AK403467

POWER STEERING OIL PUMP DRIVE BELT TENSION CHECK

Water pump pulley

Power steering pump pulley

Check the drive belt tension in the following proce-

Crankshaft pulley

AC501167

dure.

Standard value:

Item When

checked

When adjusted

When replaced

Tension N 294 − 490 343 − 441 490 − 686

Deflection mm

8.0 − 12.0 9.0 − 11.5 6.0 − 8.0

(Reference)

Place a belt tension gauge at the centre of the belt between the pulleys (arrow), and check that the belt tension is within the standard value.

Apply approximately 100 N of pressure against the location between the pulleys shown by the arrow in the illustration and then measure the deflection.

If not within the standard value, adjust the belt tension by the following procedure.

5. Tighten the alternator fixing nut.

Tightening torque: 23 ± 2 N⋅ m

6. Tighten the adjusting bolt.

Tightening torque: 5.0 ± 1.0 N⋅ m

CAUTION

Always replace the two V-belts together as a

set, and do not apply any oil to the belts.

AC503534

1. Loosen the power steering oil pump fixing bolts A,

B, and C.

2. Adjust the belt tension by placing a bar or others

to the body of the power steering oil pump, giving an appropriate tension to the belt by hands.

11A-8

ENGINE MECHANICAL <4D5-SOHC>

ON-VEHICLE SERVICE

3. Tighten the fixing bolts in the order of A, B, and C to the specified torque.

Tightening torque: 23 ± 3 N⋅ m

CAUTION

When checking the belt tension, turn the crankshaft clockwise one turn or more.

4. Check the belt tension, and readjust if necessary.

A/C COMPRESSOR DRIVE BELT TENSION CHECK AND ADJUSTMENT

Tension pulley

Crankshaft pulley

Check the drive belt tension by the following procedures.

Standard value:

Item When

checked

Tension N 338 − 430 338 − 430 461 − 614

Deflection mm

7.2 − 8.4 7.2 − 8.4 5.5 − 6.9

(Reference)

A/C compressor pulley

AC501168

When adjusted

When replaced

If not within the standard value, adjust the belt tension by the following procedure.

Tension pulley

Adjusting bolt

AC501168

1. Use the adjusting bolt to adjust the belt tension. The tension will increase when turning the adjusting bolt clockwise, and decrease when turning anti-clockwise.

CAUTION

When checking the belt tension, turn the crankshaft clockwise one turn or more.

2. Check the belt tension, and readjust if necessary.

VALVE CLEARANCE CHECK AND ADJUSTMENT

M1111001500380

1. Start the engine and allow it to warm up until the engine coolant temperature reaches 80 to 90

2. Remove the timing belt upper cover.

3. Remove the rocker cover.

Timing marks

° C

Place a belt tension gauge at the centre of the belt between the pulleys (arrow), and check that the belt tension is within the standard value.

Apply approximately 100 N of pressure against the location between the pulleys shown by the arrow in the illustration and then measure the deflection.

Camshaft sprocket

Crankshaft pulley

AK403468

4. Align the camshaft sprocket timing marks and set the No. 1 cylinder at top dead centre.

ENGINE MECHANICAL <4D5-SOHC>

ON-VEHICLE SERVICE

11A-9

CAUTION

The crankshaft should always be turned in a clockwise direction.

AK403469 AB

5. Measure the valve clearance at the places indicated by arrows in the illustration according to the methods shown below.

Standard value: 0.25 mm

Adjusting screw

pad

6. If the clearance is outside the standard value, loosen the lock nut of the rocker arm and adjust by turning the adjusting screw while using a thickness gauge to measure the clearance.

7. Tighten the lock nut while holding the adjusting screw with a screwdriver so that it doesn't turn.

8. Turn the crankshaft 360° clockwise to bring No. 4 cylinder to the top dead centre position.

AK403469 AC

9. Measure the valve clearances at the places indicated by arrows in the illustration. If the clearance is not within the standard value, repeat steps 7 and 8 above.

Thickness

Flat-tipped screwdriver

gauge

AK403470

a. Give a clearance, pushing the pad by a

flat-tipped screwdriver in the opposite direction of the thickness gauge insertion as shown in the illustration.

NOTE: Do not damage the pad retainer and

so on when pushing the pad by a flat-tipped screwdriver.

b. Insert the thickness gauge into the clear-

ance.

AK402925

AK202860AB

10 mm

Semicircular packing

Cylinder head

AK304411

10.Apply specified sealant to the section of the semi-circular packing shown in the illustration.

Specified sealant: 3M ATD Part No. 8660 or equivalent

11.Install the rocker cover.

12.Install the timing belt upper cover.

11A-10

ENGINE MECHANICAL <4D5-SOHC>

INJECTION TIMING CHECK AND ADJUSTMENT

1. Remove all of the glow plugs.

2. Remove the timing belt upper cover.

ON-VEHICLE SERVICE

M1111001800024

Timing marks

Camshaft sprocket

Timing marks

Crankshaft pulley

AK403468

3. Align the timing marks of the camshaft sprocket and set the No. 1 cylinder to the top dead centre position.

Timing check plug

AK403474 AB

4. Remove the timing check plug at the rear of the injection pump.

Nut

Push rod

MD998384

AK403476

7. Install the special tool prestroke measuring adapter (MD998384) to the check plug at the rear of the injection pump.

Approximately 30˚

AK403477

8. Turn the crankshaft clockwise to move the No. 1 cylinder approximately 30

° before compression

top dead centre.

9. Set the needle of the dial gauge to 0.

10.Check that the needle doesn't move even if the crankshaft is turned slightly (2

− 3°) in both

clockwise and counterclockwise direction.

NOTE: If the needle moves, the notch is not positioned properly, so once again move the No. 1 cylinder approximately 30° before compression top dead centre.

10mm

AK403475

5. Before installation of special tool prestroke measuring adapter (MD998384), make sure that push rod is protruding by 10 mm. Protrusion of push rod can be adjusted with an inner nut.

6. Connect the dial gauge to the special tool.

1±0.003mm

Set to 9˚ ATDC

AK403478

11.Turn the crankshaft clockwise to align the No. 1 cylinder to 9

° ATDC.

12.Check that the value indicated on the dial gauge is at the standard value.

Standard value: 1 ± 0.03 mm

ENGINE MECHANICAL <4D5-SOHC>

ON-VEHICLE SERVICE

11A-11

Injection pipe

Nuts

union nuts

Bolts

AK408479

13.If the needle is outside the standard value, adjust the injection timing by the following procedure.

(1) Loosen the injection pipe union nuts (4 places)

on the injection pump. (Do not remove the union nuts.)

CAUTION

When loosening the nuts, hold the delivery valve holders with a spanner so that they don't turn at the same time.

(2) Loosen the upper mounting nuts and the lower

mounting bolts of the injection pump. (Do not remove the nut and bolt.)

1±0.03mm or more

1±0.03mm or less

Injection pipe

Nuts

union nuts

Bolts

AK408479

(6) Tighten the mounting nuts to the specified

torque.

Tightening torque: 19 ± 3 N⋅ m

(7) Tighten the mounting bolts to the specified

torque.

Tightening torque: 24 ± 3 N⋅ m

(8) Tighten the injection pump union nuts to the

specified torque.

Tightening torque: 30 ± 7 N⋅ m

CAUTION

When tightening the nuts, hold the delivery valve holders with a spanner so that they don't turn at the same time.

14.Remove the special tool prestroke measuring adapter (MD998384).

Front View

AK403480

(3) Tilt the injection pump to the left and right and

adjust the needle on the dial gauge so that the display value is uniform.

(4) Provisionally tighten the mounting nut and bolt

of the injection pump.

(5) Repeat steps 8 − 12 to check if the adjustment

has been made correctly.

Gasket

Timing check plug

AK403482 AB

15.Install a new gasket to the timing check plug.

16.Tighten the timing check plug to the specified torque.

Tightening torque: 17 ± 2 N⋅ m

17.Install the timing belt upper cover.

18.Install all of the glow plugs

Tightening torque: 17 ± 2 N⋅ m

11A-12

ENGINE MECHANICAL <4D5-SOHC>

ON-VEHICLE SERVICE

IDLE SPEED CHECK

M1111003501141

1. Set the vehicle to the pre-inspection condition.

Diagnosis connector

MB991910

MB991824

MB991827

Tachometer

AC501413

2. Remove all of the glow plugs.

Injection pump assembly connector (

12 pin

)

AK403485AB

3. Disconnect the injection pump assembly connector (12 pin).

NOTE: Doing this will prevent carrying out fuel injection.

4. Cover the glow plug hole with a shop towel etc., and after the engine has been cranked, check that no foreign material is adhering to the shop towel.

CAUTION

• Keep away from the glow plug hole when

cranking.

•

If compression is measured with water, oil, fuel, etc., that has come from cracks inside the cylinder, these materials will become heated and will gush out from glow plug hole, which is dangerous.

Compression gauge

Injection nozzle

AK403483

2. Turn the ignition switch to "LOOK" (OFF) position, and connect the diagnosis connector to the M.U.T.-III.

If the M.U.T.-III is not used, connect a tachometer to the injection nozzle or the pipe.

3. Start the engine, and let it run at idle.

4. Check the idle speed.

Standard value: 750 ± 30 r/min

5. If the idle speed is not within the standard value, inspect the diesel system (Refer to GROUP 13A Troubleshooting

Code

− Inspection Chart for Diagnosis

COMPRESSION PRESSURE CHECK

M1111002601327

1. Before inspection, check that the engine oil, starter and battery are normal. In addition, set the vehicle to the pre-inspection condition.

AK403486

5. Set compression gauge to one of the glow plug holes.

6. Crank the engine and measure the compression pressure.

Standard value (at engine speed of 280

−

r/min): 3,100 kPa Limit (at engine speed of 280 r/min): min. 2,800 kPa

7. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit.

Limit: max 294 kPa

ENGINE MECHANICAL <4D5-SOHC>

ON-VEHICLE SERVICE

11A-13

8. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the glow plug hole, and repeat the operations in steps (6) and (7).

(1) If the compression increases after oil is added,

the cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface.

(2) If the compression does not rise after oil is

added, the cause is a burnt or defective valve seat, or pressure is leaking from the gasket.

9. Connect the injection pump assembly connector (12 pin).

10.Install the glow plugs.

Tightening torque: 17 ± 2 N⋅ m

TIMING BELT TENSION ADJUSTMENT

M1111002800094

1. Remove the timing belt upper cover.

2. Turn the crankshaft in the clockwise direction and check the timing belt around its entire circumference for abnormalities.

4. Loosen the two tensioner mounting bolts 1 or 2 turns.

NOTE: This will allow the tensioner spring to tension the timing belt automatically.

Camshaft spocket

AK403489

5. Turn the crankshaft clockwise and stop at the second teeth of the camshaft sprocket.

CAUTION

• This will allow the timing belt to be tensioned

by a specified amount, so never overturn the crankshaft.

•

Never turn the crankshaft counterclockwise.

Timing marks

AK403487

3. Align the timing marks on the sprockets with the timing mark on the front upper case.

CAUTION

When aligning the timing mark, be sure not to turn the crankshaft in the counterclockwise direction as this can cause improper belt ten

sion.

Tension side

Bolt A (slot side)

Bolt B

AK403488

6. To prevent the tensioner bracket from be turned together with the crankshaft, first tighten slot-side bolt A to the specified torque, and then tighten bolt B to the specified torque.

Tightening torque: 26 ± 3 N⋅ m

Bolt B

AK403488

11A-14

Deflection

ENGINE MECHANICAL <4D5-SOHC>

ON-VEHICLE SERVICE

CAUTION

When aligning the timing mark, be sure not to turn the crankshaft in the counterclockwise direction as this can cause improper belt ten sion.

AK403491

7. Turn the crankshaft counterclockwise to align the timing marks. Push down belt at a point halfway with a forefinger to check that defection of belt is up to standard value.

Standard value: 4.0 − 5.0 mm

8. Mount the timing belt upper cover.

TIMING BELT B TENSION ADJUSTMENT

M1111004900019

1. Remove timing belt upper cover.

2. Turn the crankshaft in the clockwise direction and check the timing belt around its entire circumference for abnormalities.

Timing marks

AK403487

3. Align the timing marks on the sprockets with the timing mark on the front upper case.

Access cover

AK403492

4. Remove the access cover.

Pivot side bolt

Slot side nut

AK403493

5. Loosen the tensioner pivot side bolt 1 turn and slot side nut 1 or 2 turns.

NOTE: These works will allow the tensioner spring to tension timing belt B automatically.

6. First tighten tensioner slot side nut, and then tighten pivot side bolt to the specified torque.

Tightening torque: Pivot side bolt 23 ± 3 N⋅ m Slot side nut 26 ± 3 N⋅ m

Access cover

Guide

AK403494

7. Install the access cover while sliding the front lower cover down along the two guides.

8. Install the timing belt upper cover.

ENGINE MECHANICAL <4D5-SOHC>

CRANKSHAFT PULLEY

11A-15

REMOVAL AND INSTALLATION

M1112001600959

Pre-removal Operation

• Engine Room Under Cover Removal (Refer to GROUP 51

− Under Cover ).

25 ± 4 N·m

185 ± 5 N·m

Post-installation Operation

• Drive Belt Tension Check and Adjustment (Refer to

P.11A-6).

• Engine Room Under Cover Installation (Refer to GROUP

− Under Cover ).

<<A>> <> <<C>>

(Engine oil)

Removal steps

1. A/C compressor drive belt

2. Power steering oil pump drive belt

3. Alternator drive belts

4. Crankshaft pulley (for A/C)

<<D>> >>A<<

>>A<< >>A<<

AC501887

Removal steps (Continued)

5. Crankshaft pulley centre bolt

6. Special washer

7. Crankshaft pulley

11A-16

ENGINE MECHANICAL <4D5-SOHC>

CRANKSHAFT PULLEY

REMOVAL SERVICE POINTS <<A>> A/C COMPRESSOR DRIVE BELT

REMOVAL

<<C>> ALTERNATOR DRIVE BELTS REMOVAL

CAUTION

To reuse the drive belt, draw an arrow indicating the rotating direction (to the right) on the back of the belt using chalk, etc.

Adjusting bolt

A/C compressorCrankshaft pulley

AC503581

Turn the adjusting bolt anti-clockwise (in the left turn), and remove the drive belt.

<> POWER STEERING OIL PUMP DRIVE BELT REMOVAL

CAUTION

To reuse the drive belt, draw an arrow indicating the rotating direction (to the right) on the back of the belt using chalk, etc.

Adjusting bolt

Alternator fixing nut

Nut for alternator pivot bolt

AC503982

1. Loosen the nut for alternator pivot bolt and locking bolt.

CAUTION

To reuse the drive belt, draw an arrow indicating the rotating direction (to the right) on the back of the belt using chalk, etc.

2. Turn the adjusting bolt anti-clockwise (in left turn), and remove the drive belt.

<<D>> CRANKSHAFT PULLEY CENTRE BOLT REMOVAL

AC503534

Loosen the mounting bolts shown in the figure to remove the drive belt.

MB992040

AC502472

1. Use special tool crank pulley holder (MB992040), hold the crankshaft pulley.

2. Remove the crankshaft pulley centre bolt.

ENGINE MECHANICAL <4D5-SOHC>

CRANKSHAFT PULLEY

11A-17

INSTALLATION SERVICE POINT >>A<< CRANKSHAFT PULLEY/SPECIAL

WASHER/CRANKSHAFT PULLEY CEN

TRE BOLT INSTALLATION

Crankshaft pulley centre bolt

Special washer

1. Clean and then degrease the crankshaft sprocket contacting surface of the crankshaft pulley.

NOTE: Degreasing is necessary to prevent decrease in the friction between contacting sur faces.

Crankshaft pulley

Clean

Degrease

Crankshaft

AC503579

2. Clean the bolt hole in the crankshaft, the crankshaft contacting surface and special washer contacting surface of the crankshaft pulley, and the special washer.

3. Apply an appropriately small amount of oil to the threads and seating surface of the crankshaft pulley centre bolt.

MB992040

AC502472

4. Use special tool crank pulley holder (MB992040) as in the removal procedure to retain crankshaft pulley, and tighten crankshaft pulley centre bolt to the specified torque.

Tightening torque: 185 ± 5 N⋅ m

11A-18

ENGINE MECHANICAL <4D5-SOHC>

CAMSHAFT AND VALVE STEM SEAL

REMOVAL AND INSTALLATION

M1112006600987

CAUTION

*Remove and assemble the marked parts in each cylinder unit.

Apply engine oil to all moving parts before installation.

10 mm

Sealant: 3M ATD Part No. 8660 or equivalent

10 mm

AC503599

37 ± 2 N·m

20 ± 1 N·m

5.9 ± 1.0 N·m

11 ± 1 N·m

37 ± 2 N·m

11 ± 1 N·m

>>E<<

69 ± 5 N·m

Camshaft removal steps

1. Control wiring harness connector

2. Battery wiring harness connector

3. Crank angle position sensor connector

4. Crank angle position sensor connector clamp

5. Timing belt front upper cover

6. Breather hose connection

7. Rocker cover

8. Oil filler cap

<<A>> >>H<<

>>G<<

<> >>D<<

>>F<<

16*

17*

18* 19*

20*

AC502018

Camshaft removal steps

9. Rocker cover gasket

10. Semi-circular packing Valve clearance adjustment

•

(Refer to

11. Camshaft sprocket

12. Camshaft oil seal

13. Rocker arm and shaft assembly

14. Camshaft bearing caps

15. Camshaft

P.11A-8).

Valve stem seal removal steps

1. Control wiring harness connector

2. Battery wiring harness connector

3. Crank angle position sensor connector

4. Crank angle position sensor connector clamp

>>E<<

<> >>D<<

<<C>> >>C<<

>>B<< >>A<<

5. Timing belt front upper cover

6. Breather hose connection

7. Rocker cover

9. Rocker cover gasket

13. Rocker arm and shaft assembly Windshield wiper (Refer to

•

GROUP 51 Cowl top panel

•

16. Valve spring retainer locks

17. Valve spring retainers

18. Valve springs

19. Valve stem seals

20. Valve spring seats

− Windshield wiper ).

REMOVAL SERVICE POINTS

ENGINE MECHANICAL <4D5-SOHC>

CAMSHAFT AND VALVE STEM SEAL

2. Secure the camshaft sprocket and the valve timing belt with cable bands to prevent deviation from the relative positions between the camshaft sprocket and the valve timing belt.

MB990767

Cable tie wrap

Camshaft sprocket

11A-19

AC502476

<<A>> CAMSHAFT SPROCKET REMOVAL

CAUTION

Always turn the crankshaft in the forward direction (clockwise).

Timing marks

AC503587

1. Turn the crankshaft in the forward direction (clockwise) to align the timing mark so that No.1 cylinder is at the compression TDC (Top Dead Centre) position.

MD998719

AC503762

3. Use the following special tools to stop the camshaft sprocket from turning.

• Front hub and flange yoke holder (MB990767)

• Crankshaft pulley holder pin (MD998719)

CAUTION

Do not turn the crankshaft after the camshaft sprocket is removed.

4. Remove the camshaft sprocket with the valve timing belt attached.

<> ROCKER ARM AND SHAFT ASSEMBLY REMOVAL

CAUTION

Never disassemble the rocker arm and shaft assembly.

Loosen the rocker arm and shaft assembly mounting bolt, and then remove the rocker arm and shaft assembly with the bolt still attached.

11A-20

ENGINE MECHANICAL <4D5-SOHC>

CAMSHAFT AND VALVE STEM SEAL

<<C>> VALVE SPRING RETAINER LOCKS REMOVAL

CAUTION

When removing valve spring retainer lock, leave the piston of each cylinder in the TDC position. The valve may fall into the cylinder if the piston is not properly in the TDC position.

MD998772

AC502475

Use special tool valve spring compressor (MD998772) to compress the valve spring, remove the valve spring retainer lock.

>>B<< VALVE SPRINGS INSTALLATION

Rocker arm side

Identification colour

AC201453

Install the valve spring with its identification colour painted end facing the rocker arm.

>>C<< VALVE SPRING RETAINER LOCKS INSTALLATION

INSTALLATION SERVICE POINTS >>A<< VALVE STEM SEALS INSTALLA-

TION

1. Apply a small amount of engine oil to the valve stem seal.

CAUTION

Valve

Valve spring seat

Valve guide

• Valve stem seal cannot be reused.

• Special tool valve stem seal installer

(MD998729) must be used to install the valve stem seal. Improper installation could result in oil leaking past the valve guide.

2. Use special tool to fill a new valve stem seal in the valve guide using the valve stem area as a guide.

MD998729

Valve stem seal

AC308920

MD998772

AC502475

Use special tool valve spring compressor (MD998772) to compress the valve spring in the same manner as removal, and install the valve spring retainer lock.

>>D<< ROCKER ARM AND SHAFT ASSEMBLY INSTALLATION

1. Install the rocker arm and shaft assembly to the bearing caps.

Chamfer

AC503766

2. Set the washer so that it faces in the direction shown in the illustration, and then install the bolt.

ENGINE MECHANICAL <4D5-SOHC>

CAMSHAFT AND VALVE STEM SEAL

11A-21

>>E<< TIMING BELT FRONT UPPER COVER INSTALLATION

AC503597

Install the bolts to the timing belt front upper cover at the shown position.

No. Bolt diameter × length mm 1 6 × 22 2 6 × 50 3 6 × 60

>>F<< CAMSHAFT BEARING CAPS INSTALLATION

>>G<< CAMSHAFT OIL SEAL INSTALLATION

MD998381

Oil seal

1. Apply new engine oil to the camshaft oil seal lip.

2. Use special tool camshaft oil seal installer (MD998381) to press-fit the camshaft oil seal.

Camshaft

AC502587

>>H<< CAMSHAFT SPROCKET INSTALLATION

MB990767

Cap numbers

Front of engine

AC503779

The cap numbers are embossed on the top surface of the bearing caps, so install in the order of the num bers. However, no numbers are embossed on bearing caps 1 and 5.

MD998719

AC503762

1. Use the following special tools to stop the camshaft sprocket from turning in the same way as was done during removal.

• Front hub and flange yoke holder (MB990767)

• Crankshaft pulley holder pin (MD998719)

2. Tighten the timing belt train bolt to the specified torque.

Tightening torque: 69 ± 5 N⋅ m

11A-22

ENGINE MECHANICAL <4D5-SOHC>

OIL PAN AND OIL SCREEN

REMOVAL AND INSTALLATION

M1112002500319

Pre-removal Operation

• Engine Room Under Cover Removal (Refer to GROUP 51

− Under Cover ).

• Engine Oil Draining (Refer to GROUP 12 − On-vehicle

Service, Engine Oil Replacement

Post-installation Operation

• Engine Oil Refilling (Refer to GROUP 12 − On-vehicle

Service, Engine Oil Replacement

• Engine Room Under Cover Installation (Refer to GROUP

− Under Cover ).

39 ± 5 N·m

>B<<

19 ± 3 N·m

9.0 ± 3.0 N·m

9.0 ± 1.0 N·m

Removal steps

1. Engine oil pan drain plug

2. Engine oil pan drain plug gasket

3. Alternator vacuum pump oil return hose connection

4. Flywheel housing front lower cover

5. Engine oil level gauge

9.0 ± 1.0 N·m

<<A>>

<>

<> <> <<C>> >>A<<

19 ± 3 N·m

AC501853

Removal steps (Continued)

Steering column shaft assembly

•

and shaft assembly connecting bolt Power steering gear box

•

connecting bolts Return tube clamp

•

Pressure tube clamp

•

6. Engine oil pan and engine oil pan strainer assembly

ENGINE MECHANICAL <4D5-SOHC>

OIL PAN AND OIL SCREEN

11A-23

Removal steps (Continued)

7. Engine oil pan

8. Engine oil pan strainer

9. Engine oil pan strainer gasket

REMOVAL SERVICE POINTS <<A>> STEERING COLUMN SHAFT

ASSEMBLY AND SHAFT ASSEMBLY CONNECTING BOLT DISCONNECTION

<R.H. fender side>

Shaft assembly connecting bolt

18 ± 2 N·m

Upper arm (R.H.)

Disconnect the steering column shaft and the shaft assembly.

AC502232

CAUTION

MD998727

AC504256AB

MD998727

AC104547

<> POWER STEERING GEAR BOX CONNECTING BOLTS/RETURN TUBE CLAMP/PRESSURE TUBE CLAMP REMOVAL

AC502231

Remove the mounting bolts of the power steering gear box and of the tube clamp, and hung the power steering gear box using a wire or other similar mate rial.

<<C>> ENGINE OIL PAN AND ENGINE OIL PAN STRAINER ASSEMBLY REMOVAL

1. Remove the engine oil pan mounting bolts.

Do not use special tool oil pan FIPG cutter (MD998727) in area A of the oil pan. Using the special tool in area A may cause deformation of the front case because the front case is made of aluminium.

2. Tap special tool MD998727 into the range (B) between the cylinder block and the oil pan, and then slide the tool sideways.

NOTE: If any sounding parts interfere with the removal, there is no need to use special tool MD998727.

3. With the oil pan separated from the cylinder block, remove the oil screen assembly mounting bolts, and then remove the oil pan together with the oil screen assembly.

INSTALLATION SERVICE POINTS >>A<< ENGINE OIL PAN AND ENGINE

OIL PAN STRAINER ASSEMBLY INSTAL LATION

1. Remove sealant from the engine oil pan and cylinder block surfaces.

11A-24

Ø4 mm

ENGINE MECHANICAL <4D5-SOHC>

OIL PAN AND OIL SCREEN

CAUTION

Then wait at least one hour. Never start the engine or let engine oil or coolant touch the seal ant surface during that time.

4. Tighten the engine oil pan bolts to the specified torque.

Tightening torque: 9.0 ± 3.0 N⋅ m

Groove

Bolt hole

AC503481

2. Apply a bead of the sealant to the cylinder block mating surface of the engine oil pan as shown.

Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

NOTE: Install the engine oil pan within 15 minutes after applying sealant.

3. Assemble the engine oil pan to the cylinder block.

>>B<< ENGINE OIL PAN DRAIN PLUG GASKET INSTALLATION

Engine oil pan side

AC102325

Replace the gasket with a new gasket. Install the new gasket in the direction shown in the illustration.

ENGINE MECHANICAL <4D5-SOHC>

CRANKSHAFT OIL SEAL

11A-25

REMOVAL AND INSTALLATION

M1112003101094

132 ± 5 N·m

11 ± 1 N·m

>>D<<

Crankshaft front oil removal steps

Timing belt B (Refer to P.11A-34).

•

1. Crankshaft sprocket B

2. Crankshaft front oil seal

Crankshaft rear oil seal removal steps

Transmission assembly (Refer to

•

GROUP 22A assembly

− Transmission

(Lip section) (Lip section)

<<A>> >>C<<

>>B<< >>A<<

Engine oil

AC502585

Crankshaft rear oil seal removal steps (Continued)

3. Flywheel assembly

4. Ball bearing

5. Oil seal case

6. Gasket

7. Oil separator

8. Crankshaft rear oil seal

11A-26

ENGINE MECHANICAL <4D5-SOHC>

CRANKSHAFT OIL SEAL

REMOVAL SERVICE POINT <<A>> FRYWHEEL ASSEMBLY

REMOVAL

MD998781

AC503817

1. Use the special tool flywheel stopper (MD998781), hold the flywheel.

2. Remove the flywheel assembly.

INSTALLATION SERVICE POINTS >>A<< CRANKSHAFT REAR OIL SEAL

INSTALLATION

Push the oil separator into the oil seal case, with its oil hole at the case bottom (indicated by an arrow in illustration).

>>C<< FLYWHEEL ASSEMBLY INSTALLATION

MD998781

AC503817

1. Use special tool flywheel stopper (MD998781) to secure the flywheel assembly in the same manner as removal.

2. Tighten the flywheel bolts to the specified torque.

Tightening torque: 132 ± 5 N⋅ m

MD998376

AC503776

Use the special tool crankshaft rear oil seal installer (MD998376), press-fit the rear oil seal in the oil seal case.

>>B<< OIL SEPARATOR INSTALLATION

Oil seal case Oil separator

>>D<< CRANKSHAFT FRONT OIL SEAL INSTALLATION

Crankshaft

MD998382

Oil seal

MD998383 (Apply oil to outer surface)

1. Attach special tool crankshaft front oil seal guide (MD998383) to the crankshaft and apply engine oil to the outer surface of the tool.

2. Using special tool crankshaft front oil seal installer (MD998382), press-fit the front oil seal into the front lower case.

Front lower case

Oil pump drive shaft

AC503778

Oil pan mounting surface

Oil hole

AC503777

ENGINE MECHANICAL <4D5-SOHC>

CYLINDER HEAD GASKET

11A-27

REMOVAL AND INSTALLATION

29 ± 2 N·m to 122˚ - +124˚ (During cold engine)

(Engine oil)

23 ± 3 N·m

M1112004001692

5.0 ± 1.0 N·m

30 ± 7 N·m

12 ± 1 N·m

<<A>> >>D<<

Removal steps

1. Oil level gauge and guide assembly

2. O-ring

3. Radiator upper hose Rocker cover (Refer to

•

P.11A-18).

4. Engine coolant temperature gauge unit connector

5. Engine coolant temperature sensor connector

6. Glow plug terminal

<> >>C<<

<<C>>

<<D>> >>B<<

>>A<<

Removal steps (Continued)

7. Fuel injection pipes

8. By-pass hose connection

9. Fuel hose Water pipe C (Refer to GROUP

•

− Water hose and water pipe ).

10. Power steering oil pump assembly

11. Power steering oil pump bracket

12. Cylinder head assembly

13. Cylinder head gasket

(Engine oil)

AC502586

11A-28

ENGINE MECHANICAL <4D5-SOHC>

CYLINDER HEAD GASKET

REMOVAL SERVICE POINTS <<A>> RADIATOR UPPER HOSE DISCON-

NECTION

After making mating marks on the radiator upper hose and the hose clamp, disconnect the radiator upper hose.

<> FUEL INJECTION PIPES REMOVAL

CAUTION

After disconnecting the injection pipe, plug the opening so that no foreign particles get inside the pump or into the injection nozzle.

Nut

Delivery holder

AC503283

<<C>> POWER STEERING OIL PUMP ASSEMBLY REMOVAL

1. Remove the power steering oil pump assembly from the bracket with the hose attached.

2. Place the removed power steering oil pump assembly in a place where it will not be a hindrance when removing and installing the engine assembly, and tie it with cord.

<<D>> CYLINDER HEAD ASSEMBLY REMOVAL

MD998051

AC502540

When loosening nuts at both ends of injection pipe, hold the delivery holder (for pump side) and the injection nozzle assembly (for nozzle side) with wrench and loosen nut.

Front of engine

AC503868

AC503912

Using special tool cylinder head bolt wrench (MD998051), loosen the cylinder head bolts in two or three steps in the order of the numbers shown in the illustration.

ENGINE MECHANICAL <4D5-SOHC>

INSTALLATION SERVICE POINTS

CYLINDER HEAD GASKET

11A-29

>>A<< CYLINDER HEAD GASKET INSTALLATION

CAUTION

The thickness of the original cylinder head gasket is selected according to the protrusion amount of the piston. Therefore, if the piston or the connecting rod is replaced, the protrusion amount may be changed. Always select a correct gasket by measuring the protrusion amount. (Refer to GROUP 11B> Valves

− Cylinder Head and

Identification mark

CAUTION

Do not allow foreign material to enter the engine coolant or oil passages and the cylinder.

2. Clean the cylinder head assembly and the cylinder block mating surfaces with a scraper or a wire brush.

Cylinder head bolt washer

Chamfered side

AC503931AB

3. Install the cylinder head bolt washer to the cylinder head bolt so that the washer chamfered side faces as shown.

4. Apply a small amount of engine oil to the cylinder head bolt thread and the washer.

AC503769

When replacing the cylinder head gasket only, confirm the gasket identification mark, and then select a replacement part according to the following table.

Spec Identification mark (size) Part number A D5-774 (fitted thickness 1.45 ±

MD377774

0.04)

B D5-774 (fitted thickness 1.50 ±

MD377775

0.04)

C D5-774 (fitted thickness 1.55 ±

MD377776

0.04)

>>B<< CYLINDER HEAD ASSEMBLY INSTALLATION

1. Select a cylinder head gasket of correct specification.

MD998051

AC502540

Front of engine

AC503868

AC503912

5. Tighten the cylinder head bolts according to the following procedure (angle-tightening procedure).

(1) Use special tool cylinder head bolt wrench

(MD998051) to tighten the cylinder head bolts in the order of illustrated numbers to 29

⋅ m.

± 2

11A-30

ENGINE MECHANICAL <4D5-SOHC>

CYLINDER HEAD GASKET

CAUTION

• If the cylinder head bolt is tightened less than

the specified lower limit of 120 degree angle, the bolt may become loose. Be sure to tighten correctly.

•

If the cylinder head bolt is tightened in excess of the specified upper limit of 124 degree angle, loosen the bolt completely and repeat the entire procedures.

>>C<< FUEL INJECTION PIPES INSTALLATION

When tightening the nuts at both ends of the fuel injection pipe, hold the delivery holder (for pump side) and the injection nozzle assembly (for nozzle side) with a wrench, and tighten the nuts to the spec ified torque.

Tightening torque: 30 ± 7 N⋅ m

MB991614

MD998051

AC502541

Front of engine

AC503868

AC503913

(2) Using special tool angle gauge (MB991614),

tighten the cylinder head bolts in the illustrated sequence by a further 120 to 124 degree angle.

>>D<< RADIATOR UPPER HOSE CONNECTION

To reuse the radiator upper hose, align the mating marks that were made during removal, and then install the hose clamp.

ENGINE MECHANICAL <4D5-SOHC>

TIMING BELT

11A-31

REMOVAL AND INSTALLATION

M1112004301358

Pre-removal Operation

• Cooling Fan Removal (Refer to GROUP 14 − Radiator Fan

26 ± 3 N·m

11 ±1 N·m

Post-installation Operation

• Cooling Fan Installation (Refer to GROUP 14 − Radiator

Fan

• Drive Belt Tension Check and Adjustment (Refer to

P.11A-6).

26 ± 3 N·m

11 ±1 N·m

>>B<<

9.0 ± 1.0 N·m

11 ±1 N·m

Removal steps

1. Crank angle sensor connector

2. Battery wiring harness connector

3. Timing belt front upper cover

4. Tension pulley and tension pulley bracket assembly

5. Timing belt front lower cover

22 ± 4 N·m

<<A>>

>>A<<

AC502129

Removal steps (Continued)

6. Crank angle sensor

7. Crankshaft sensing blade

8. Timing belt

9. Tensioner spacer

10. Tensioner spring

11. Timing belt tensioner

11A-32

ENGINE MECHANICAL <4D5-SOHC>

TIMING BELT

REMOVAL SERVICE POINT <<A>> TIMING BELT REMOVAL

1. When reinstalling timing belt, mark an arrow at the belt to show rotation direction.

Tilt to water pump side

AC503588

2. Loosen the timing belt tensioner mounting bolt A and B.

3. Push timing belt tensioner to water pump side and tighten the timing belt tensioner mounting bolt A and B. Secure so that timing tensioner will not move back.

1. Align the timing marks of the 3 sprocket.

2. When reusing timing belt, make sure the arrow mark is pointing in the same direction as when the belt was removed.

CAUTION

1. Engage the belt on the various sprockets

while maintaining tension on the belt of ten sion side.

2. Align the injection pump sprocket with the

timing mark, hold the sprocket so that is does not turn and engage the belt.

Timing marks

Camshaft sprocket

Tension side

Timing marks

INSTALLATION SERVICE POINTS >>A<< TIMING BELT INSTALLATION

Timing marks

Camshaft sprocket

Fuel injection pump sprocket

Timing marks

Crankshaft sprocket

AC504264

Fuel injection pump sprocket

Timing marks

Crankshaft sprocket

AC501169

3. Install the timing belt to the crankshaft sprocket, to injection pump sprocket, to tensioner and to camshaft sprocket in that order. Being careful not to allow deflection on the tension side of the timing belt.

4. Loosen the tensioner mounting bolts and apply tension with the spring.

ENGINE MECHANICAL <4D5-SOHC>

TIMING BELT

11A-33

CAUTION

1. When turning the crankshaft in step 5, strictly

observe the specified amount of rotation (2 teeth on the camshaft sprocket) in order to apply a constant force to the tension side of the belt.

2. Do not turn the crankshaft anti-clockwise.

3. Do not touch the belt buring adjustment.

Camshaft sprocket

2 teeth

AC503593

5. Turn the crankshaft clockwise and stop at the second lobe of the camshaft sprocket.

Tensioner mounting bolt

Amount of belt deflection

AC503595

9. Press on the centre of the bolt with an index finger to check the amount of deflection.

Standard value: 4 − 5 mm

>>B<< TIMING BELT FRONT LOWER COVER/TIMING BELT FRONT UPPER COVER INSTALLATION

Tensioner

Tensioner mounting bolt

AC503594

6. Make sure that the part indicated by arrow A does not float upward.

7. Tighten the tensioner mounting bolts, starting with the bolt in the elongated hole. If the lower bolt is tightened first, belt tension will become too tight.

8. Turn the crankshaft anti-clockwise and align the timing mark. Next, make sure that the timing marks of all sprockets are aligned.

AC503596

Install the bolts to the timing belt front lower cover and timing belt front upper cover at the shown posi tion.

No. Bolt diameter × length mm 1 6 × 22 2 6 × 50 3 6 × 60

11A-34

ENGINE MECHANICAL <4D5-SOHC>

TIMING BELT B

REMOVAL AND INSTALLATION

26 ± 3 N·m

M1112004600185

Removal steps

Timing belt (Refer to P.11A-31).

•

1. Crankshaft sprocket

2. Flange

<<A>> >>A<<

3. Timing belt B

REMOVAL SERVICE POINT <<A>> TIMING BELT B REMOVAL

1. When reinstalling timing belt B, mark an arrow at the belt to show rotation direction.

Water pump

AC502130

Removal steps (Continued)

4. Gasket

5. Tensioner spacer B

6. Tensioner spring B

7. Timing belt tensioner B

3. Push timing belt tensioner to water pump side and tighten the timing belt tensioner mounting bolt A and nut B. Secure so that timing belt tensioner will not move back.

AC503589

2. Loosen the timing belt tensioner mounting bolt A and nut B.

ENGINE MECHANICAL <4D5-SOHC>

TIMING BELT B

11A-35

INSTALLATION SERVICE POINT >>A<< TIMING BELT B INSTALLATION

Timing marks

Timing belt tensioner B

Timing marks

1. Align the timing marks of the 3 sprocket.

2. When reusing timing belt B, make sure the arrow mark is pointing in the same direction as when the belt was removed.

AC504265

3. Install timing belt B and make sure there is no deflection on the tension side.

4. Press the deflection side of timing belt B with the hand and fully stretch the tensioner side.

5. Make sure that the timing marks are aligned.

6. Loosen the tensioner mounting bolt and nut so that only the pressure of the spring is applied to timing belt B.

7. Tighten the tensioner mounting bolt A and nut B, tightening the nut first. If the bolt is tightened first, the tensioner will move and tension the belt.

Tightening torque: 26 ± 3 N⋅ m

Countrebalance shaft sprocket

Belt deflection

Crankshaft sprocket B

AC503591

8. Press in the direction of the arrow in the figure with the index finger to check the amount of deflection.

Standard value: 4 − 5 mm

Timing marks

Deflection side

Tension side

AC503590

11A-36

ENGINE MECHANICAL <4D5-SOHC>

ENGINE ASSEMBLY

REMOVAL AND INSTALLATION

M1112001002221

Pre-removal Operation

• Engine Oil Draining (Refer to GROUP 12 − On-vehicle Service,

Engine Oil Replacement

• Engine Coolant Draining (Refer to GROUP 14 - On-vehicle Serv-

ice, Engine Coolant Replacement ).

• Engine Room Under Cover Removal (Refer to GROUP 51 −

Under Cover

• Hood Removal (Refer to GROUP 42 − Hood ).

• Air Cleaner Removal (Refer to GROUP 15 − Air Cleaner ).

• Battery and Battery Tray Removal

• Radiator Removal (Refer to GROUP 14 − Radiator ).

• Windshield Wiper assembly Removal (Refer to GROUP 51 −

Windshield Wiper

• Cowl Top Panel Front Removal

• Front Exhaust Pipe Removal (Refer to GROUP 15 − Exhaust

Pipe, Main Muffler and Catalytic Converter

Post-installation Operation

• Front Exhaust Pipe Installation (Refer to GROUP 15 − Exhaust

Pipe, Main Muffler and Catalytic Converter

• Cowl Top Panel Front Installation

• Windshield Wiper assembly Installation (Refer to GROUP 51 −

Windshield Wiper

• Radiator Installation (Refer to GROUP 14 − Radiator ).

• Battery and Battery Tray Installation

• Air Cleaner Installation (Refer to GROUP 15 − Air Cleaner ).

• Hood Installation (Refer to GROUP 42 − Hood ).

• Engine Coolant Refilling (Refer to GROUP 14 - On-vehicle Serv-

ice, Engine Coolant Replacement ).

• Engine Oil Refilling (Refer to GROUP 12 − On-vehicle Service,

Engine Oil Replacement

• Engine Room Under Cover Installation (Refer to GROUP 51 −

Under Cover

• Fuel Line Air-bleeding (Refer to GROUP 13A − On-vehicle Serv-

ice, Evacuation of Water from Fuel Filter ).

• Drive Belt Tension Check and Adjustment (Refer to P.11A-6).

20 ± 2 N·m

5.0 ± 1.0 N·m

12 ± 2 N·m

Removal steps

1. Control wiring harness connection

22 ± 4 N·m

AC501848

Removal steps (Continued)

2. Battery wiring harness connection

3. Earth cable connection

23 ± 3 N·m

45 ± 5 N·m

5.0 ± 1.0 N·m

ENGINE MECHANICAL <4D5-SOHC>

ENGINE ASSEMBLY

23 ± 3 N·m

11A-37

47 ± 7 N·m

<<A>>

Cooling fan (Refer to GROUP 14 −

•

Radiator fan

4. Power steering oil pump assembly

5. Engine oil cooler feed hose connection

6. Engine oil cooler return hose connection

7. Fuel hoses connection

<>

<<C>> >>A<<

22 ± 4 N·m

AC502602

8. Brake booster vacuum hose connection

9. A/C compressor assembly Transmission assembly (Refer to

•

GROUP 22A assembly Starter motor (Refer to GROUP

•

− Starter motor ).

10. Engine mounting bolts

11. Engine assembly

− Transmission

11A-38

REMOVAL SERVICE POINTS

ENGINE MECHANICAL <4D5-SOHC>

ENGINE ASSEMBLY

<<A>> POWER STEERING OIL PUMP ASSEMBLY REMOVAL

1. With the hose installed, remove the power steering oil pump assembly from the engine assembly.

2. After removing the power steering oil pump assembly, secure it with a cord in the location where the removal and installation of the engine assembly cannot be hindered.

<> A/C COMPRESSOR ASSEMBLY REMOVAL

1. With the hose installed, remove the A/C compressor assembly from the bracket.

2. After removing the A/C compressor assembly, secure it with a cord in the location where the removal and installation of the engine assembly cannot be hindered.

<<C>> ENGINE ASSEMBLY REMOVAL

1. Check that all cables, hoses and wiring harness connectors are disconnected from the engine

2. Lift special tool sling chain set (MB991683) and chain block slowly to remove the engine assembly upwards from the engine compartment.

INSTALLATION SERVICE POINT >>A<< ENGINE ASSEMBLY INSTALLA-

TION

MB991683

AC502542

1. Use special tool sling chain set (MB991683) and chain block to lift the engine assembly in the same manner as removal.

2. Install the engine assembly, being careful not to pinch the cables, hoses or wiring harness connectors.

MB991683

AC502542

GROUP 12

ENGINE

LUBRICATION

CONTENTS

12-1

GENERAL INFORMATION . . . . . . . . 12-2

SERVICE SPECIFICATION . . . . . . . . 12-2

SEALANTS . . . . . . . . . . . . . . . . . . . . 12-2

LUBRICANTS . . . . . . . . . . . . . . . . . . 12-3

SPECIAL TOOLS. . . . . . . . . . . . . . . . 12-3

ON-VEHICLE SERVICE. . . . . . . . . . . 12-3

ENGINE OIL CHECK . . . . . . . . . . . . . . . . . 12-3

ENGINE OIL REPLACEMENT . . . . . . . . . . 12-3

ENGINE OIL FILTER REPLACEMENT. . . . 12-4

OIL PRESSURE CHECK . . . . . . . . . . . . . . 12-6

ENGINE OIL COOLER . . . . . . . . . . . . 12-7

REMOVAL AND INSTALLATION

<4D5-SOHC> . . . . . . . . . . . . . . . . . . . . . . . 12-7

REMOVAL AND INSTALLATION

<4D5-DOHC> . . . . . . . . . . . . . . . . . . . . . . . 12-8

REMOVAL AND INSTALLATION <4M4> . . 12-9

12-2

ENGINE LUBRICATION

GENERAL INFORMATION

The lubrication method is a fully force-fed, full-flow filtration type.

• Air-cooled engine oil cooler have been adopted,

and installed forward of the radiator. <4D5-SOHC>

• Water-cooled oil cooler have been adopted, and

which is buit into the oil filter bracket has been adopted . <4D5-DOHC>

• Water-cooled oil cooler have been adopted, and

which is buit into the crankcase has been adopted . <4M4>

ENGINE OILS HEALTH WARNING

RECOMMENDED PRECAUTIONS

M1121000100625

• Avoid prolonged and repeated contact with oils,

particularly used engine oils.

• Wear protective clothing, including impervious

gloves where practicable.

• Avoid contaminating clothes, particularly under-

pants, with oil.

• Do not put oily rags in pockets, the use of overalls

without pockets will avoid this.

• Do not wear heavily soiled clothing and

oil-impregnated foot-wear. Overalls must be cleaned regularly and kept separate from per sonal clothing.

• Where there is a risk of eye contact, eye protec-

tion should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided.

• Obtain First Aid treatment immediately for open

cuts and wounds.

• Wash regularly with soap and water to ensure all

oil is removed, especially before meals (skin cleansers and nail brushes will help). After clean ing, the application of preparations containing lanolin to replace the natural skin oils is advised.

• Do not use petrol, kerosine, diesel fuel, gas oil,

thinners or solvents for cleaning skin.

• Use barrier creams, applying them before each

work period, to help the removal of oil from the skin after work.

• If skin disorders develop, obtain medical advice

without delay.

SERVICE SPECIFICATION

M1121000300328

Item Standard value

Oil pressure kPa at idle 29 or more

at 3,500 r/min 294 − 686

SEALANTS

M1121000500366

Item Specified sealant Remark

Oil pressure switch 3M ATD Part No. 8660 or equivalent Semi-drying sealant

Engine oil cooler taper plug 3M Nut Locking Part No.4171 or equivalent Drying sealant

Engine oil filter bracket taper plug

ENGINE LUBRICATION

LUBRICANTS

Item 4D5-SOHC 4D5-DOHC 4M4

Engine oil ACEA classification B1, B2, B3 or B4

Engine oil API classification CD or higher

Engine oil quantity L Oil pan 6.5 6.5 7.0

Oil filter 0.8 0.8 1.0

Oil cooler 0.3 0.1 1.3

Tot al 7.6 7.4 9.3

SPECIAL TOOLS

Tool Number Name Use

MH061590 Oil filter wrench Removal and installation of engine

oil filter [When using the oil filter of MD069782 <4D5-SOHC>, MD326489 <4D5-SOHC> or 1230A045 <4D5-DOHC>]

MH061590

12-3

M1121000400842

M1121000600578

ENGINE OIL CHECK

Maximum Minimum

MD998012 Oil pressure switch wrench Removal and installation of oil

pressure switch

ON-VEHICLE SERVICE

2. Check that the oil is not excessively dirty, that there is no coolant or petrol mixed in, and that it has sufficient viscosity.

ENGINE OIL REPLACEMENT

M1121001000847

1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80

° C.

2. Remove the engine oil filler cap.

CAUTION

Use care as oil could be hot.

° C to 90

Good

M1121000900579

AC205268

1. Pull out the engine oil level gauge slowly and check that the oil level is in the illustrated range.

3. Remove the drain plug to drain oil.

12-4

ENGINE LUBRICATION

ON-VEHICLE SERVICE

<2WD>

Engine oil pan drain plug

Engine oil pan side

AC502276

<4WD>

Engine oil pan drain plug

Engine oil pan side

AC502277

4. Install a new drain plug gasket so that it faces in the direction shown in the illustration, and then tighten the drain plug to the specified torque.

Tightening torque: 39 ± 5 N⋅ m

NOTE: Install the drain plug gasket so it faces in the direction shown in the illustration.

7. Check oil level.

ENGINE OIL FILTER REPLACEMENT

M1121001100640

1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80

° C.

2. Remove the engine oil filler cap.

CAUTION

Use care as oil could be hot.

3. Remove the drain plug to drain oil.

4. Remove the under cover.

MH061590 or commerciallyavailable tool

5. Use the respective tool in the following table to remove the engine oil filter.

6. Clean the filter bracket side mounting surface.

AC000093

° C to 90

AC503612

5. Refill with specified quantity of oil.

Specified Engine Oil (ACEA and API classifica-

tion): ACEA B1, B2, B3 or B4/API CD or higher

Total quantity (Includes volume inside oil filter

and oil cooler):

<4D5-SOHC> 7.6 L <4D5-DOHC> 7.4 L <4M4> 9.3 L

6. Install the engine oil filler cap.

O-ring

AC103250

7. Apply a small amount of engine oil to the O-ring of the new oil filter.

8. Once the O-ring of the oil filter is touching the flange, use the respective tool in the following table to tighten to the specified torque.

9. Install the drain plug and refill the engine oil (Refer to

P.12-3).

10.Race the engine 2−3 times, and check to be sure that no engine oil leaks from installation section of the oil filter.

ENGINE LUBRICATION

ON-VEHICLE SERVICE

Engine model Oil filter number Special tool Tightening torque

4D5-SOHC MD069782 Oil filter wrench (MH061590) or

equivalent

MD326489 Oil filter wrench (MH061590) or

equivalent

4D5-DOHC 1230A045 Oil filter wrench (MH061590) or

equivalent

4M4 1230A046 Commercially available tool Approximately 3/4 turn (22 ± 2 N⋅ m)

Approximately 5/8 turn (20 ± 2 N⋅ m)

Approximately 3/4 turn (22 ± 2 N⋅ m)

12-5

12-6

ENGINE LUBRICATION

ON-VEHICLE SERVICE

OIL PRESSURE CHECK

1. Check engine oil quantity.

CAUTION

<4D5-SOHC>

Oil pressure switch

<4D5-DOHC>

Oil pressure switch

AK403472

M1121002300711

NOTE: Remove the terminal of oil pressure switch where the special tool Oil pressure switch wrench (MD998012) is not fitted.

3. Install the oil pressure gauge.

NOTE: Use an adapter of PT 1/8 thread.

4. Run the engine to warm it.

5. After the engine has been warmed up, check that oil pressure is within the standard value.

Standard value:

At idle: 29 kPa or more At 3,500 r/min: 294 − 686 kPa

6. Remove the oil pressure gauge.

AK403473

<4M4>

Oil pressure switch

AK403481

MD998012

AKX00294

Since sealant is applied to the thread of oil pressure switch, take care not to damage the oil pressure switch when removing it.

AKX00295

7. Apply the specified sealant to the thread of oil pressure switch.

Specified sealant: 3M ATD Part No. 8660 or equivalent

CAUTION

MD998012

AKX00294

Do not start the engine within one hour after the oil pressure switch has been installed.

8. Use the special tool Oil pressure switch wrench (MD998012) to tighten the oil pressure switch to the specified torque.

<4D5> Tightening torque: 10 ± 2 N⋅ m <4M4> Tightening torque: 19 ± 3 N⋅ m

2. Use the special tool Oil pressure switch wrench (MD998012) to remove the oil pressure switch.

ENGINE LUBRICATION

ENGINE OIL COOLER

12-7

REMOVAL AND INSTALLATION <4D5-SOHC>

Pre-removal Operation

• Engine Oil Draining (Refer to P.12-3).

• Engine Room Under Cover Removal (Refer to GROUP 51

− Under Cover ).

45 ± 5 N·m

5.0 ± 1.0 N·m

M1121001300246

Post-installation Operation

• Engine Room Under Cover Installation (Refer to GROUP

− Under Cover ).

• Engine Oil Refilling (Refer to P.12-3).

5.0 ± 1.0 N·m

48 ± 7 N·m

33 ± 2 N·m

48 ± 7 N·m

33 ± 2 N·m

11 ± 2 N·m

Removal steps

1. Engine oil cooler hose gaskets

2. Engine oil cooler feed tube connection

3. Engine oil cooler feed hose

4. Engine oil cooler hose gaskets

5. Engine oil cooler return tube connection

AC501401

Removal steps (Continued)

6. Engine oil cooler return hose

7. Engine oil cooler tube gaskets

8. Engine oil cooler feed tube

9. Engine oil cooler tube gaskets

10. Engine oil cooler return tube

11. Engine oil cooler

12-8

ENGINE LUBRICATION

ENGINE OIL COOLER

REMOVAL AND INSTALLATION <4D5-DOHC>

M1121001300235

Pre-removal Operation

• Engine Room Under Cover Removal (Refer to GROUP 51

− Under Cover ) <2WD>.

• Under Skid Plate and Engine Room Under Cover

Removal (Refer to GROUP 51

• Engine Coolant Draining (Refer to GROUP 14 − On-vehi-

cle Service, Engine Coolant Replacement ).

• Engine Oil Draining (Refer to P.12-3).

• Alternator Removal (Refer to GROUP 16 − Alternator).

− Under Cover ) <4WD>.

Post-installation Operation

• Alternator Installation (Refer to GROUP 16 − Alternator).

• Engine Coolant Refilling (Refer to GROUP 14 − On-vehi-

cle Service, Engine Coolant Replacement ).

• Engine Oil Refilling (Refer to P.12-3).

• Engine Room Under Cover Installation (Refer to GROUP

− Under Cover ) <2WD>.

• Under Skid Plate and Engine Room Under Cover Installa-

tion (Refer to GROUP 51 − Under Cover ) <4WD>.

>>A<<

Removal steps

1. Water hose

2. Water hose

3. Engine oil cooler bolt

4. Engine oil cooler

39 ± 5 N·m

AC502934

INSTALLATION SERVICE POINT >>A<< ENGINE OIL COOLER INSTALLA-

TION

Ta b

Engine oil cooler

AC502935

Position the tab as shown in the illustration.

ENGINE LUBRICATION

ENGINE OIL COOLER

REMOVAL AND INSTALLATION <4M4>

12-9

M1121001300213

Pre-removal Operation

• Under Skid Plate and Engine Room Under Cover

Removal (Refer to GROUP 51

• Engine Oil Draining (Refer to P.12-3).

• Exhaust Manifold Removal (Refer to GROUP 15 −

Exhaust Manifold and Turbocharger

Apply engine oil to all O-ring parts before installation.

45 ± 3 N·m

− Under Cover ).

37 ± 7 N·m

24 ± 3 N·m

Post-installation Operation

• Exhaust Manifold Installation (Refer to GROUP 15 −

Exhaust Manifold and Turbocharger

• Engine Oil Refilling (Refer to P.12-3).

• Under Skid Plate and Engine Room Under Cover Installation (Refer to GROUP 51 − Under Cover ).

24 ± 3 N·m

22 ± 2 N·m

>>B<<

>>A<<

20 ± 4 N·m

44 ± 10 N·m

10 ± 2 N·m

Removal steps

1. Engine oil filter assembly

2. Engine oil filter bracket assembly

3. Engine oil filter bracket taper plugs

4. O-ring

5. Engine oil cooler gaskets

6. Engine oil cooler water drain plug

7. Engine oil cooler water drain gasket

8. Engine oil cooler assembly

9. Engine oil cooler cover

10. Engine oil cooler core

45 ± 3 N·m

25 ± 4 N·m

31 ± 2 N·m

20 ± 4 N·m

3, 16

Specified sealant: 3M Nut Locking Part No.4171 or equivalent

AC503265

Removal steps (Continued)

11. Engine oil cooler gaskets

12. Engine oil cooler plugs

13. Engine oil cooler gaskets

14. Engine oil cooler relief springs

15. Engine oil cooler relief plungers

16. Engine oil cooler taper plugs

17. Engine oil cooler gasket

18. O-rings

19. Engine oil cooler water separate lip

12-10

ENGINE LUBRICATION

ENGINE OIL COOLER

INSTALLATION SERVICE POINTS >>A<< ENGINE OIL COOLER ASSEMBLY

INSTALLATION

Flange bolt

Engine oil cooler assembly

Symbol No. Part name

(head mark)

1 Flange bolt

(7T)

2 Flange bolt

(7T)

3 Flange bolt

(7T)

D× L mm Tightening

8 × 32 24 ± 3

8 × 55 24 ± 3

10 × 55 44 ± 10

AC504005

torque N

⋅ m

>>B<< ENGINE OIL FILTER BRACKET ASSEMBLY INSTALLATION

Flange bolt

Engine oil filter bracket

Symbol No. Part name

(head mark)

1 Flange bolt

(7T)

2 Flange bolt

(7T)

3 Flange bolt

(7T)

AC504095

D× L mm Tightening

torque N

⋅ m

8 × 40 24 ± 3

8 × 55 24 ± 3

8 × 75 24 ± 3

4 Flange bolt

(7T)

10 × 80 44 ± 10

GROUP 15

INTAKE AND

EXHAUST

CONTENTS

15-1

SERVICE SPECIFICATIONS. . . . . . . 15-2

SPECIAL TOOL . . . . . . . . . . . . . . . . . 15-3

ON-VEHICLE SERVICE. . . . . . . . . . . 15-4

TURBOCHARGER SUPERCHARGING

PRESSURE CHECK. . . . . . . . . . . . . . . . . . 15-4

WASTE GATE ACTUATOR CHECK . . . . . 15-5

AIR CLEANER . . . . . . . . . . . . . . . . . . 15-6

REMOVAL AND INSTALLATION

<4D5-SOHC> . . . . . . . . . . . . . . . . . . . . . . . 15-6

REMOVAL AND INSTALLATION

<4D5-DOHC, 4M4>. . . . . . . . . . . . . . . . . . . 15-7

INTERCOOLER <4D5-DOHC,4M4> . 15-8

REMOVAL AND INSTALLATION . . . . . . . . 15-8

INLET AND EXHAUST MANIFOLDS

<4D5-SOHC> . . . . . . . . . . . . . . . . . . . 15-9

REMOVAL AND INSTALLATION

<4D5-SOHC> . . . . . . . . . . . . . . . . . . . . . . . 15-9

INLET MANIFOLD . . . . . . . . . . . . . . . 15-11

REMOVAL AND INSTALLATION

<4D5-DOHC> . . . . . . . . . . . . . . . . . . . . . . . 15-11

REMOVAL AND INSTALLATION <4M4> . . 15-13

EXHAUST MANIFOLD AND

TURBOCHARGER . . . . . . . . . . . . . . . 15-14

REMOVAL AND INSTALLATION

<4D5-DOHC> . . . . . . . . . . . . . . . . . . . . . . . 15-14

REMOVAL AND INSTALLATION <4M4> . . 15-16

TURBOCHARGER ASSEMBLY

<4D5-SOHC> . . . . . . . . . . . . . . . . . . . 15-18

REMOVAL AND INSTALLATION

<4D5-SOHC> . . . . . . . . . . . . . . . . . . . . . . . 15-18

EXHAUST PIPE, MAIN MUFFLER AND CATALYTIC CONVERTER

<4D5-SOHC> . . . . . . . . . . . . . . . . . . . 15-19

REMOVAL AND INSTALLATION

<4D5-SOHC> . . . . . . . . . . . . . . . . . . . . . . . 15-19

EXHAUST PIPE AND MAIN MUFFLER

<4D5-DOHC, 4M4> . . . . . . . . . . . . . . . 15-20

REMOVAL AND INSTALLATION . . . . . . . . 15-20

15-2

INTAKE AND EXHAUST

SERVICE SPECIFICATIONS

Item Standard value Limit

Turbocharger supercharging pressure (waste gate solenoid valve not operating) kPa

4D5-SOHC 144.3 − 174.9

4D5-DOHC-2WD181.6 − 215.0

−

M1151000300677

Initial activation pressure of waste gate actuator (at the stroke of approximately 1 mm) kPa

4D5-DOHC-4WD178.9 − 215.0

4M4 178.9 − 188.2 4D5-SOHC 90 − 94 4D5-DOHC 125.3 − 135.7 4M4 126.0 − 131.4

−

INTAKE AND EXHAUST

SPECIAL TOOL

Tool Number Name Use

DO NOT USE

MB991824

MB991827

MB991910

MB991955 A: MB991824 B: MB991827 C: MB991910 D: MB991911 E: MB991825 F: MB991826

M.U.T.-III sub assembly

A: Vehicle

communication

interface (V.C.I.) B: M.U.T.-III USB cable C: M.U.T.-III main

harness A (Vehicles

with CAN

communication

system) D: M.U.T.-III main

harness B (Vehicles

without CAN

communication

system) E: M.U.T.-III

measurement

adapter F: M.U.T.-III trigger

harness

Measurement of turbocharger supercharging pressure

15-3

M1151000600582

CAUTION

MB991911

MB991825

MB991826

MB991955

15-4

INTAKE AND EXHAUST

ON-VEHICLE SERVICE

TURBOCHARGER SUPERCHARGING PRESSURE CHECK

M1151001000260

CAUTION

Conduct the driving test in a location where driving at full acceleration can be done with safety. Two person should be in the vehicle when the test is conducted; the person in the passenger seat should read the indications shown by the M.U.T.-III.

1. Set the vehicle to the pre-inspection condition.

Diagnosis connector

MB991910

MB991824

2. Turn the ignition switch to "LOOK" (OFF) position, and connect the diagnosis connector to the M.U.T.-III.

3. Use the data list function named "Item No. 6" boost pressure sensor of the M.U.T.-III to check the supercharging pressure when the engine speed increases to approximately 3,000 r/min or more by driving at full acceleration in 2nd.

Standard value:

144.3 − 174.9 kPa <4D5-SOHC>,

181.6 − 215.0 kPa <4D5-DOHC-2WD>,

178.9 − 215.0 kPa <4D5-DOHC-4WD>,

178.9 − 188.2 kPa <4M4>

4. If the supercharging pressure deviates from the standard value, check the following items for possible cause.

• Malfunction of the waste gate actuator

• Malfunction of the boost pressure sensor

• Leakage of supercharging pressure

• Malfunction of the turbocharger

5. When the indicated supercharging is more than standard value, supercharging control may be faulty, therefore check the followings.

• Disconnection or cracks of the waste gate actua-

tor rubber hose

• Malfunction of the waste gate actuator

• Malfunction of the waste gate valve

• Malfunction of the manifold absolute pressure

sensor

MB991827

AC501413

INTAKE AND EXHAUST

ON-VEHICLE SERVICE

15-5

WASTE GATE ACTUATOR CHECK

M1151001200220

<4D5-SOHC>

AK403490

<4D5-DOHC>

AK403495

2. While gradually applying pressure, check the pressure that begins to activate (approximately 1 mm stroke) the waste gate actuator rod.

Standard value:

90 − 94 kPa <4D5-SOHC>

125.3 − 135.7 kPa <4D5-DOHC>

126.0 − 131.4 kPa <4M4>

3. If there is a significant deviation from the standard value, check the actuator or the waste gate valve: replace actuator or turbocharger assembly if necessary.

<4M4>

AK403496

1. Connect a manual pump (pressure-application type) to nipple.

CAUTION

In order to avoid damage to the diaphragm, do not apply a pressure of 109 kPa <4D5-SOHC>, 159 kPa <4D5-DOHC>, 153 kPa <4M4> or higher.

15-6

INTAKE AND EXHAUST

AIR CLEANER

REMOVAL AND INSTALLATION <4D5-SOHC>

9.0 ± 1.0 N·m

M1151002101036

4.0 ± 1.0 N·m

9.0 ± 1.0 N·m

Removal steps

1. Air duct

2. Breather hose connection

3. Air cleaner cover

9.0 ± 1.0 N·m

Removal steps (Continued)

4. Air cleaner element

5. Air cleaner body

6. Air intake hose

AC501353

INTAKE AND EXHAUST

AIR CLEANER

REMOVAL AND INSTALLATION <4D5-DOHC, 4M4>

0.7 ± 0.1 N·m

15-7

M1151002100947

9.0 ± 1.0 N·m

4.0 ± 1.0 N·m

9.0 ± 1.0 N·m

Removal steps

1. Air cleaner element

2. Intake air flow sensor connector

3. Intake air flow sensor

4. Harness clamp

5. Air cleaner cover

6. Breather hose connection

9.0 ± 1.0 N·m

Removal steps (Continued)

7. Air intake hose

8. Radiator condenser tank hose connection

9. Air duct

10. Air cleaner body

AC501396

15-8

INTAKE AND EXHAUST

INTERCOOLER <4D5-DOHC,4M4>

REMOVAL AND INSTALLATION

12 ± 2 N·m

M1151002400131

9.0 ± 1.0 N·m

>>A<<

Removal steps

Air Duct (Refer to P.15-7).

•

1. Air A1 hose

2. Air B2 hose

3. Intercooler assembly, intercooler gasket, intercooler pipe Front bumper assembly (Refer to

•

GROUP 51 Assembly

4. Intercooler pipe

5. Intercooler gasket

6. Intercooler assembly

7. Air B1 hose Oil reservoir bolt (Refer to

•

GROUP 37 Hose

8. Air B1 pipe

− Front Bumper

− Power Steering

). <4M4>

AC501310

INSTALLATION SERVICE POINT >>A<< INTERCOOLER GASKET INSTAL-

LATION

AC504286

The tab on the intercooler gasket should be position as shown.

INTAKE AND EXHAUST

INLET AND EXHAUST MANIFOLDS <4D5-SOHC>

15-9

REMOVAL AND INSTALLATION <4D5-SOHC>

Pre-removal Operation

• Engine Oil Draining (Refer to GROUP 12 − On-vehicle

Service, Engine Oil Replacement

• Engine Coolant Draining (Refer to GROUP 14 − On-vehi-

cle Service, Engine Coolant Replacement ).

• Engine Room Under Cover Removal (Refer to GROUP 51

− Under Cover ).

• Air Cleaner Removal (Refer to P.15-6).

• Throttle Body Removal (Refer to GROUP 13A − Throttle

• EGR Cooler Removal (Refer to GROUP 17 − EGR Valve

Body

and EGR Cooler

18 ± 2 N·m

24 ± 4 N·m

M1151003600031

Post-installation Operation

• EGR Cooler Installation (Refer to GROUP 17 − EGR Valve

and EGR Cooler

• Throttle Body Installation (Refer to GROUP 13A − Throttle

Body

• Air Cleaner Installation (Refer to P.15-6).

• Engine Coolant Refilling (Refer to GROUP 14 − On-vehi-

cle Service, Engine Coolant Replacement ).

• Engine Oil Refilling (Refer to GROUP 12 − On-vehicle

Service, Engine Oil Replacement

• Engine Room Under Cover Installation (Refer to GROUP

− Under Cover ).

6.0 ± 1.0 N·m

9.0 ± 1.0 N·m

20 ± 2 N·m

Removal steps

1. Manifold absolute pressure sensor connector

2. Vacuum hose assembly

3. Manifold absolute pressure sensor

20 ± 2 N·m

AC501902

Removal steps (Continued)

4. Manifold absolute pressure sensor bracket

5. EGR solenoid valve No.1 connector

15-10

INTAKE AND EXHAUST

INLET AND EXHAUST MANIFOLDS <4D5-SOHC>

Removal steps (Continued)

6. EGR solenoid valve No.2 connector

7. Throttle solenoid valve connector

8. Vacuum hose connection

9. Vacuum hose assembly

10. Vacuum hose connection

11. Solenoid valve assembly

12. Engine hanger

13. Inlet manifold Turbocharger assembly (Refer to

•

P.15-18).

14. Exhaust manifold heat protector

15. Exhaust manifold

16. Inlet and Exhaust manifold gasket

Mitsubishi L200 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

GENERAL

GENERAL

HOW TO USE THIS MANUAL

SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS

INDICATION OF TIGHTENING TORQUE

MODEL INDICATIONS

EXPLANATION OF MANUAL CONTENTS

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

CONTENTS OF TROUBLESHOOTING

Diagnosis method

2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS

5. DIAGNOSIS CODE PROCEDURES

6. TROUBLE SYMPTOM CHART

3. DIAGNOSIS FUNCTION

4. DIAGNOSIS CODE CHART

7. SYMPTOM PROCEDURES

8. SERVICE DATA REFERENCE TABLE

9. ACTUATOR TEST TABLE

10. CHECK AT ECU TERMINALS

11. INSPECTION PROCEDURE BY USING AN OSCILLOSCOPE

DIAGNOSIS FUNCTION

HOW TO READ DIAGNOSIS CODE

ERASING DIAGNOSIS CODE

HOW TO USE THE INSPECTION PROCEDURES

CURRENT TROUBLE

PAST TROUBLE

HARNESS CHECK

CONNECTOR MEASUREMENT SERVICE POINTS

CONNECTOR INSPECTION SERVICE POINTS

INSPECTION SERVICE POINTS FOR A BLOWN FUSE

HOW TO COPE WITH INTERMITTENT MALFUNCTIONS

VEHICLE IDENTIFICATION

VEHICLE NAME PLATE

HOW TO TREAT PAST TROUBLE

MODEL CODE

CHASSIS NUMBER

GENERAL DATA AND SPECIFICATIONS

ENGINE MODEL STAMPING

CLUB CAB

<2WD>

<4WD>

DOUBLE CAB

<2WD>

<4WD>

PRECAUTIONS BEFORE SERVICE

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH PRE-TENSIONER

WHAT THE COMMON RAIL ENGINE LEARNS

INJECTOR IDENTIFICATION CODE REGISTRATION PROCEDURE

PURPOSE

REGISTRATION PROCEDURE

SMALL INJECTION QUANTITY LEARNING PROCEDURE

PURPOSE

LEARNING PROCEDURE

SUPPLY PUMP CORRECTION LEARNING PROCEDURE

PURPOSE

LEARNING PROCEDURE FOR IDLING

APPLICATION OF ANTI-CORROSION AGENTS AND UNDERCOATS

VEHICLE WASHING

SERVICING ELECTRICAL SYSTEM

VEHICLES WITH SEMI AUTOMATIC AIR CONDITIONER

PRE-INSPECTION CONDITION

MULTI USE TESTER (M.U.T.-III) SUB ASSEMBLY

HOW TO USE THE THROTTLE CONTROLLER

IN ORDER TO PREVENT VEHICLES FROM FIRE

ENGINE OILS

HEALTH WARNING

RECOMMENDED PRECAUTIONS

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

SRS SERVICE PRECAUTIONS

SUPPORT LOCATIONS FOR LIFTING AND JACKING

<2WD>

<4WD>

<2WD>

<4WD>

STANDARD PART/TIGHTENING-TORQUE TABLE

ENGINE