Professional Documents
Culture Documents
11B-1-6
TORQUE SPECIFICATIONS
Nm
Drive belt and glow plug
Cooling fan bolt 11
Fan clutch bolt 11
Vacuum pipe bolt (L400) 10
Vacuum pipe bolt (1997 L200 and after) 23
Vacuum pipe bolt (2001 model PAJERO)
M8 x 16 12
M8 x 20 22
Eye bolt 17
Auto tensioner bolt 44
Power steering pump bracket bolt (Washer) 22
Power steering pump bracket bolt (Flange) 24
Alternator pivot bolt
M8 22
M10 44
Brace bolt 14
Lock bolt 23
Adjusting bolt 10
Crankshaft pulley bolt 25
Crankshaft bolt 181
Oil level gauge guide bolt
M6 (L400) 11
M8 (Except L400) 24
Glow plug plate nut 1.8
Glow plug 9+30 to 40
Timing belt
Timing belt cover bolt 11
Flange bolt 10
Tensioner spacer nut 25
Timing belt tensioner bolt 25
Camshaft sprocket bolt 67
Crank angle sensor bolt 9
Injection pump sprocket nut 83
Balancer shaft sprocket bolt and nut 36
Timing belt rear cover bolt 11
Fuel injection pump and injection nozzle
Injection pump protector bolt 14
Injection pipe clamp bolt 5
Injection pipe union nut 29
Injection pump nut 19
Injection pump bolt 24
Injection pump bracket bolt 22
Fuel return pipe nut 27
Injection nozzle 54
Injection nozzle holder
Retaining nut 37
G Mitsubishi Motors Corporation May 2001
PWEE9067-G
Torque
kgm
ft.lbs.
1.1
1.1
1.0
2.4
8
8
7
17
1.2
2.2
1.7
4.5
2.2
2.4
9
16
12
33
16
17
2.2
4.5
1.4
2.3
1.0
2.5
18.5
16
33
10
17
7
18
134
1.1
2.4
0.18
0.9+30 to 40
8
17
1.3
7+30 to 40
1.1
1.0
2.6
2.6
7.0
0.9
8.5
3.7
1.1
8
7
19
19
51
7
61
27
8
1.4
0.5
3.0
1.9
2.4
2.2
2.8
5.5
10
3.7
22
14
17
16
20
40
3.8
27
Revised
11B-1-7
Nm
Intake and exhaust manifolds
Air pipe bracket bolt 22
Vacuum pipe and hose assembly bolt
(with turbocharger) 11
(with variable geometry turbocharger) 10
Waste gate actuator bolt (tightened to intake manifold) 19
Waste gate actuator bolt (tightened to turbocharger) 12
EGR pipe bolt nut 17
EGR valve bolt 25
Eyebolt (water pipe) 42
Eyebolt (oil pipe) 17
Heat protector bolt
M6 9
M8 14
Oil return pipe bolt 9
Exhaust fitting nut 59
Turbocharger nut 59
Relief valve 49
Air inlet fitting bolt 19
Intake manifold bolt 18
Intake manifold stay bolt 18
Exhaust manifold nut 18
EGR cooler bolt 22
Solenoid valve assembly bolt 24
Water pipe and hose bolt 22
Water pipe bolt 11
Air temperature sensor 14
Air intake fitting bolt 18
Oil pipe flare nut 20
Oil pipe bolt 9
Hose clamp bolt 14
Turbocharger
Coupling bolt 5
Water pump, thermostat, hose and pipe
Water pipe bolt
M6 11
M8 14
Engine coolant temperature gauge unit 34
Engine coolant temperature sensor 11
Water outlet fitting bolt 12
Water inlet fitting bolt
Bolt with spring washer 12
Flange bolt 14
Thermostat housing bolt 14
Plate bolt 10
PWEE9067-H
Torque
kgm
ft.lbs.
2.2
16
1.1
1.0
1.9
1.2
1.7
2.5
4.3
1.7
8
7
14
9
12
18
31
12
0.9
1.4
0.9
6.0
6.0
5.0
1.9
1.8
1.8
1.8
2.2
2.4
2.2
1.1
1.4
1.8
2.0
0.9
1.4
7
10
7
43
43
36
14
13
13
13
16
17
16
8
10
13
14
7
10
0.5
1.1
1.4
3.5
1.1
1.2
8
10
25
8
9
1.2
1.4
1.4
1.0
9
10
10
7
Revised
11B-1-8
Nm
Water pump bolt
M8 x 20, M8 x 25, M8 x 40 14
M8 x 70, M8 x 85 24
Rocker arms, rocker shaft and camshaft
Oil filler bolt 13
Rocker cover bolt 6
Rocker shaft bolt 37
Lock nut 15
Camshaft bearing cap bolt 20
Cylinder head, valves and valve spring
Cylinder head bolt
Without throttle body 118
With throttle body 29+120 to 124
Front case and oil pan
Oil cooler by-pass valve 54
Oil pressure switch 10
Oil filter bracket bolt (Except 2001 PAJERO) 14
Oil filter bracket bolt (2001 PAJERO)
M6 11
M8 23
Oil pan cover bolt 9
Oil drain plug 39
Oil level sensor bolt 9
Oil pan bolt 7
Oil screen bolt and nut 19
Front upper case bolt 13
Plug cap 24
Balancer shaft driven gear bolt 36
Front lower case bolt
M8 x 90 24
Except M8 x 90 13
Oil pump cover bolt 12
Balancer shaft gear cover bolt 24
Check valve 32
Stiffener bolt 19
Piston and connecting rod
Connecting rod cap nut
Without variable geometry turbocharger 46
With variable geometric turbocharger 27+90 to 94
Crankshaft and cylinder block
Flywheel bolt 132
Drive plate bolt 132
Rear plate bolt 9
Bell housing cover bolt 9
Oil seal case bolt 11
Bearing cap bolt 78
Cover bolt 6
G Mitsubishi Motors Corporation Apr. 2002
PWEE9067-H
Torque
kgm
ft.lbs.
1.4
2.4
10
17
1.3
0.6
3.8
1.5
2.0
9
4
27
11
14
12.0
87
3.0+120 to 124 22+120 to 124
5.5
1.0
1.4
40
7
10
1.0
2.3
0.9
4.0
0.9
0.7
1.9
1.3
2.4
3.7
7
17
7
29
7
5
14
9
17
27
2.4
1.3
1.2
2.4
3.3
1.9
17
9
9
17
24
13
4.7
2.8+90 to 94
34
20+90 to 94
13.5
13.5
0.9
0.9
1.1
8.0
0.6
98
98
7
7
8
58
4
Revised
11B-1-9
Nm
Engine support bracket bolt (Except 2001 PAJERO)
Head mark 7 44
Head mark 8 55
Engine support bracket bolt (2001 PAJERO)
M8 22
M10 44
Torque
kgm
ft.lbs.
4.5
5.5
33
40
2.2
4.5
16
33
SEALANT
Specified sealant
Quantity
PWEE9067-H
Revised
11B-2-1
2. SPECIAL TOOLS
Tool
Number
Name
Use
MB990767
MB991614
Angle gauge
MD998051
MD998115
MD998148
MD998158
MD998165
PWEE9067-G
Revised
11B-2-2
Tool
Name
Use
MD998175
MD998250
MD998251
MD998303
Valve spring
compressor
MD998376
MD998380
Bearing installer
stopper
MD998381
PWEE9067-G
Revised
Number
Name
11B-2-3
Use
MD998382
MD998383
MD998384
Prestroke measuring
adapter
MD998385
Balancer shaft drive gear Installation of silent shaft drive oil seal
oil seal guide
MD998386
Connecting-rod
small-end bushing
replacement tool
MD998388
Injection pump
sprocket puller
MD998719
PWEE9067-G
Revised
11B-2-4
Tool
Name
Use
MD998729
MD998772
Valve spring
compressor
MD998778
Crankshaft sprocket
puller
MD998781
Flywheel stopper
PWEE9067-G
Revised
11B-3-1
23 2.4 17
5
Except
L400
12
17 1.7 12
5
L400
14 1.4 10
7 N
22
10 1.0 7
12
13
10
Adjuster type
23
9 0.9 7
9 N
8
23 2.3 17
+30 to 40
17 1.7 12
M8
23 2.3 17
M10
44 4.5 33
11
4
1
25 2.5 18
Except L400
24 2.4 17
18
16
20
14
18
17
L400
19 N
15
11 1.1 8
11 1.1 8
Removal steps
EDF 1. Drive belt
2. Cooling fan
3. Fan clutch
4. Water pump pulley
5. Vacuum pipe
6. Eyebolt
7. Gasket
8. Eyebolt
9. Gasket
10. Oil tube
ECF 11. Oil hose
12. Alternator brace
G Mitsubishi Motors Corporation May 2001
19 N
21 N
20
21 N
11 1.1 8
FAE EBF
EBF
EBF
FBE EAF
13. Alternator
14. Crankshaft pulley (for A/C)
15. Crankshaft bolt
16. Special washer
17. Crankshaft pulley
18. Oil level gauge
19. O-ring
20. Oil level gauge guide
21. O-ring
22. Glow plug plate
23. Glow plug
DEN0327
PWEE9067-G
Revised
11B-3-1a
22 2.2 16
22 2.2 16
17
24 2.4 17
12 1.2 9
12
24 2.4 17
N 6
13
+30 to
40
9 0.9 7
9
17 1.7 12
5
22
N 18
21
19
8 N
7
10
22 2.2 16
17 1.7 12
11
44 4.5 33
44 4.5 33
3
1
2
15
16
14
11 1.1 8
11 1.1 8
Removal steps
1. Cooling fan
2. Fan clutch
3. Water pump pulley
4. Vacuum pipe
5. Eyebolt
6. Gasket
7. Eyebolt
8. Gasket
9. Oil pipe
ECF 10. Oil hose
11. Auto tensioner
FAE EBF
EBF
EBF
FBE EAF
PWEE9067-G
Revised
11B-3-1b
MD998781
DEN0117
INSPECTION
GLOW PLUG
(1) Check the continuity between the terminal and body as
illustrated. Replace if there is no continuity or if there is a
large resistance.
Standard value:
Metal type
0.9 1.1 [at 20C (68F)]
Ceramic type
0.4 0.6 [at 20C (68F)]
DEN034
PWEE9067-G
Revised
11B-3-2
30 to 40
DEN0343
MD998781
Crankshaft
bolt
Washer
DEN0117
Crankshaft
Pulley
crankshaft
Clean
Degrease
DEN0311
PWEE9067-H
Revised
NOTES
11B-4-1
4. TIMING BELT
REMOVAL AND INSTALLATION
7
8
25 2.6 19
67 7.0 51
10 1.0 7
25 2.6 19
4
10
9
3
83 8.5 61
13
11
9 0.9 7
24
12
11 1.1 8
22
11 1.1 8
21
25 2.6 19
36 3.7 27
25 2.6 19
20
18
36 3.7 27
16
19
17
23
15
14
Removal steps
1. Timing belt upper cover
2. Timing belt lower cover
3. Flange
FAE EJF 4. Timing belt
5. Tensioner spacer
6. Tensioner spring
EIF 7. Timing belt tensioner
FBE EHF 8. Camshaft sprocket
FCE EGF 9. Injection pump sprocket
EFF 10. Crank angle sensor
(with throttle body)
EFF 11. Front flange
(2001 model PAJERO)
FDE
FEE
FFE
FGE
FHE
PWEE9067-G
Revised
11B-4-6
Balancer shaft
sprocket
Clean
Crankshaft
sprocket
Degrease
DEN0312
MD998719
MB998767
DEN0129
G Mitsubishi Motors Corporation May 2001
PWEE9067-G
Revised
11B-4-9
Clean and then degrease the front face of the Oil pump gear
drive shaft, crankshaft sprocket B and crankshaft surface
on which sprocket B is attached.
NOTE
Degreasing is necessary to prevent decrease in the friction
between contacting surfaces.
Degrease
DEN0313
PWEE9067-G
Added
4D56 ENGINE <1994 > Fuel Injection Pump and Injection Nozzle
11B-5-7
NOTE
The injection timing can be known from the identification
mark stamped on the cylinder head at the position shown
in the illustration.
Identification mark
Identification mark
Injection timing
A or B
7 ATDC
C , D, E, G or H
9 ATDC
DEN0175
Front
view
DEN0107
(11)install new copper gasket and plug, then tighten the plug
to specified torque.
Copper gasket
Plug
DFU0013
PWEE9067-H
Revised
NOTES
11B-7-1
18 1.8 13
14 1.4 10
3
4
5 N
18 1.8 13
Removal steps
1. Engine hanger
2. Intake manifold
3. Heat protector
4. Exhaust manifold
5. Manifold gasket
DEN0308
G Mitsubishi Motors Corporation May 2001
PWEE9067-G
Revised
11B-7-1a
25 2.5 18
7
8 N
N 6
11 1.1 8
18 1.8 13
2
1
N 4
11
19 1.9 14
10
18 1.8 13
18 1.8 13
17 1.7 12
18 1.8 13
13
17 1.7 12
4 N
9
N 12
15
14 1.4 10
14
18 1.8 13
16
17 N
Removal steps
1. Vacuum pipe and
hose assembly
2. Vacuum pipe and
hose assembly
3. EGR pipe
4. Gasket
5. EGR valve
6. Gasket
7. Air intake fitting
8. Gasket
Engines with
EGR system
DEN0331
G Mitsubishi Motors Corporation May 2001
PWEE9067-G
Revised
11B-7-1b
Engines with turbocharger <PAJERO (Up to 2000 model) L200 (without throttle
body), L300 (except P15T)>
11 1.1 8
29
25 2.5 18
N 9
49 5.0 36
30
42 4.3 31
10
31
12 1.2 9
32 N
27
N 28
11 N
18 1.8 13
33
34
10 1.0 7
42 4.3 31
18 1.8 13
9 0.9 7
12
7 N
19 1.9 14
9 0.9 7
13
17 1.7 12
18 1.8 13
23
36
35
N 7
9 0.9 7
14 1.4 10
37 N
17 1.7 12
9 0.9 7
15
17
N 16
18 1.8 13
20 2.0 14
N 23
21
59 6.0 43
25
22
59 6.0 43
14
N 19
9 0.9 7
18
14 1.4 10
26 N
20
Disassembly steps
1. Vacuum pipe and hose assembly
(L200)
2. Vacuum pipe and hose assembly
(L200)
3. Boost hose
4. Snap ring
5. Waste gate actuator
6. EGR pipe
Engines with
7. Gasket
8. EGR valve EGR system
9. Gasket
10. Eyebolt
11. Gasket
12. Water pipe
13. Heat protector A
14. Heat protector C
EAF 15. Eyebolt
16. Gasket
17. Oil pipe
18. Oil return pipe
G Mitsubishi Motors Corporation May 2001
19. Gasket
20. Oil hose
21. Air hose (Engines without intercooler)
22. Exhaust fitting
23. Stay
24. Gasket
25. Turbocharger assembly
26. Gasket
27. Eyebolt
28. Gasket
29. Water pipe
30. Relief valve
31. Air inlet fitting
Engines without
32. Gasket
33. Engine hanger intercooler
34. Intake manifold
35. Heat protector
36. Exhaust manifold
37. Manifold gasket
DEN0332
PWEE9067-G
Revised
11B-7-2
49 5.0 36
30
19 1.9 14
29 18 1.8 13
32
N 31
28
11
25 2.5 18
42 4.3 31
N 10
N 27
12 N
42 4.3 31
17 1.7 12
N 8
18 1.8 13
9 0.9 7
9 0.9 7
18
17 1.7 12
17 1.7 12
20 2.0 14
13
33
26
34
22 2.2 16
8 N
35
2
36 N
14
16
59 6.0 43
N 17
9 0.9 7
22
N 23
59 6.0 43
18 1.8 13
24
59 6.0 43
4
6
5
15
N 20
19
12 1.2 9
9 0.9 7
25 N
14 1.4 10
21
Disassembly steps
1. Air pipe
2. Air pipe bracket
3. Air intake hose
4. Boost hose
5. Snap pin
6. Waste gate actuator
7. EGR pipe
8. Gasket
9. EGR valve
10. Gasket
11. Eyebolt
12. Gasket
13. Water pipe
14. Turbochargr heat protector
15. Exhaust fitting heat protector
EAF 16. Eyebolt
17. Gasket
18. Oil pipe
PWEE9067-G
Revised
11B-7-2a
18 1.8 13
11 1.1 8
25 2.5 18
11 1.1 8
22 2.2 16
15 N
19 N
16
10
14
36
14 1.4 10
1
17 1.7 12
18 1.8 13 N 2
24 2.4 17
37 N
38
11 N
42 4.3 31
22 2.2 16 40
17 1.7 12
8
42 4.3 31 N 11
17 1.7 12
20
12
19 N
N 13
17
N 34
35
34 N
9 0.9 7
N 9
9 0.9 7
33
21
17 1.7 12
18
1.8 13
23
25
17 1.7 12
41
N 24
20 2.0 14
39 N
18
59 6.0 43
10 1.0 7
42
3
43
44 N
9 0.9 7
29
N 30
59 6.0 43
18 1.8 13
31
59 6.0 43
5
6
7
22
N 27
26
12 1.2 9
9 0.9 7
32 N
14 1.4 10
28
Disassembly steps
1. Air temperature sensor
2. Gasket
3. Vacuum pipe and hose assembly
4. Solenoid valve assembly
5. Boost hose
6. Snap pin
7. Waste gate actuator
8. Water pipe and hose
9. O-ring
10. EGR upper pipe
11. Gasket
12. EGR valve
13. Gasket
14. Eyebolt
15. Gasket
16. Water pipe B
17. Water hose
18. Eyebolt
19 Gasket
20. Water pipe A
21. Turbocharger heat protector
22. Heat protector C
PWEE9067-H
Revised
11B-7-2b
Intensionally blank
PWEE9067-E
Added
11B-7-4a
11 1.1 8
32
25 2.5 18
13
11 1.1 8
N 12
22 2.2 16
N 16 15
N 6
42 4.3 31
9 0.9 7
14 1.4 10
9
N 10
31
34
35 N
10 1.0 7
38
N 30
30 N
9 0.9 7
18
21
17 1.7 12
33 N
18 1.8 13 N 2
8 N
22 2.2 16
36
17 1.7 12
42 4.3 31
17 1.7 12
N 8
5
14
11
17
N 16
24 2.4 17
14 1.4 10
1
17 1.7 12
29
17 1.7 12
18 1.8 13
39
40 N
23
N 22
27
59 6.0 43
N 25
9 0.9 7
37
20 2.0 14
9 0.9 7
18 1.8 13
28 N
24
26
19
14 1.4 10
20
14 1.4 10
Disassembly steps
1. Air temperature sensor
2. Gasket
3. Vacuum pipe and hose assembly
4. Solenoid valve assembly
ECF 5. Water pipe and hose
ECF 6. O-ring
EBF 7. EGR upper pipe
8. Gasket
9. EGR valve
10. Gasket
11. Eyebolt
12. Gasket
13. Water pipe B
14. Water hose
15. Eyebolt
16. Gasket
17. Water pipe A
18. Turbocharger upper heat protector
19. Turbocharger lower heat protector
20. Heat protector
PWEE9067-H
Revised
11B-7-4b
18 1.8 13
25 2.5 18
N 15
22 2.2 16
20
N 19
8
N 19 18
17
42 4.3 31
N 9
10
14
42 4.3 31
17 1.7 12
N 11
12
22 2.2 16
34 N
24 2.4 17
36
37 N
7
38
10 1.0 7
39 N
40
42
17 1.7 12
N 13 35
14 1.4 10
N 34
3
9 0.9 7
21
17 1.7 12
14 1.4 10
4
17 1.7 12
N 5
18 1.8 13
11 N
16
11 1.1 8
33
17 1.7 12
18 1.8 13
23
25
N 24
31
41
20 2.0 14
9 0.9 7
N 30
22 2.2 16
43
44 N
1
29
32 N
18 1.8 13
27 N
19 1.9 14
59 6.0 43
26
22
9 0.9 7
28
14 1.4 10
Disassembly steps
1. Air pipe
2. Air pipe bracket
3. Air hose
4. Air temperature sensor
5. Gasket
6. Vacuum pipe and hose assembly
7. Solenoid valve assembly
ECF 8. Water pipe and hose
ECF 9. O-ring
EBF 10. EGR upper pipe
11. Gasket
12. EGR valve
13. Gasket
14. Eyebolt
15. Gasket
16. Water pipe B
17. Water hose
18. Eyebolt
19. Gasket
20. Water pipe A
21. Turbocharger heat protector
22. Exhaust fitting heat protector
PWEE9067-H
Revised
11B-7-4c
N 17
6
14 1.4 10
2
17 1.7 12
14
13 N
18
18 1.8 13
32
25 2.5 18
11 1.1 8
22 2.2 16
5 0.5 4
11 1.1 8
12
24 2.4 17
33 N
18 1.8 13 N 3
9 N
42 4.3 31
22 2.2 16
17 1.7 12
36
15 N 17 16
N 9
17 1.7 12
9 0.9 7
10
42 4.3 31
N 11
7 N
30 N N 30
31
14 1.4 10
9 0.9 7
19
29
17 1.7 12
21
18 1.8 13
17 1.7 12
23
N 22
37
20 2.0 14
27
9 0.9 7
34
35 N
10 1.0 7
38
4
39
40 N
18 1.8 13
59 6.0 4.3
28 N
25 N
24
9 0.9 7
26
20
14 1.4 10
Disassembly steps
1. Boost sensor
2. Air temperature sensor
3. Gasket
4. Vacuum pipe and hose assembly
5. Solenoid valve assembly
ECF 6. Water pipe and hose
ECF 7. O-ring
EBF 8. EGR upper pipe
9. Gasket
10. EGR valve
11. Gasket
12. Eyebolt
13. Gasket
14. Water pipe B
15. Water hose
16. Eyebolt
17. Gasket
18. Water pipe A
19. Turbocharger upper heat protector
20. Turbocharger lower heat protector
PWEE9067-H
DEN0352
Added
11B-7-4d
Intensionally blank
PWEE9067-H
Added
11B-7-5
INSPECTION
EGR VALVE
(1) Remove, the EGR valve and check it for sticking, deposit of
carbon, etc.
If such condition exists, clean with adequate solvent to
ensure correct valve seat contact.
3EM135
Vacuum
Normal condition
(5) Replace the gasket with a new one and tighten the EGR
valve to specified torque.
DIN023
G Mitsubishi Motors Corporation Feb. 1995
PWEE9067-A
Added
11B-7-6
Projection
DEN0342
Water pipe
O-ring
6EN0594
PWEE9067-H
Added
NOTES
11B-9-1
4D56 ENGINE <1994 > Water Pump, Thermostat, Hose and Pipe
14 1.4 10
2
3
11 1.1 8
N 6
5
14 1.4 10
7
14 1.4 10
34 3.5 25
13
14 N
16 N
11
12
15
24 2.4 17
N 10
14 1.4 10
12 1.2 9
Removal steps
1. Water hose
with
2. Water pipe
turbocharger
3. Water hose
4. Water hose
5. Water pipe
EDF 6. O-ring
ECF 7. Engine coolant temperature
gauge unit
8. Engine hanger
PWEE9067-H
Revised
11B-9-1a
4D56 ENGINE <1994 > Water Pump, Thermostat, Hose and Pipe
1
2
4
5
14 1.4 10
11 1.1 8
N 7
8
12
34 3.5 25
13
14
15 N
17 N
12 1.2 9
12 1.2 9
10 1.0 7
10
16
24 2.4 17
14 1.4 10
11 N
9
Removal steps
1. Hose protector
2. Water hose
3. Water pipe
4. Water hose
5. Water hose
6. Water pipe
EDF 7. O-ring
ECF 8. Coolant temperature gauge unit
9. Engine hanger
PWEE9067-G
Revised
11B-9-1b
4D56 ENGINE <1994 > Water Pump, Thermostat, Hose and Pipe
Except engines with throttle body <PAJERO>
14 1.4 10
4
3
11 1.1 8
6
10
34 3.5 25
11
12
13 N
15 N
12 1.2 9
12 1.2 9
10 1.0 7
24 2.4 17
14
14 1.4 10
9 N
7
Removal steps
1. Hose protector
2. Water hose
3. Water pipe
4. Water hose
5. Water pipe and hose
EDF 6. Coolant temperature gauge unit
7. Engine hanger
8. Water outlet fitting
9. Gasket
10. Water inlet fitting
EBF 11. Thermostat
12. Plate
13. Gasket
14. Water pump
15. Gasket
DEN0336
G Mitsubishi Motors Corporation May 2001
PWEE9067-G
Revised
11B-9-2
4D56 ENGINE <1994 > Water Pump, Thermostat, Hose and Pipe
1
2
4
5
14 1.4 10
11 1.1 8
N 7
8
12
34 3.5 25
13
14
15 N
17 N
12 1.2 9
12 1.2 9
10 1.0 7
10
16
24 2.4 17
14 1.4 10
11 N
9
Removal steps
1. Hose protector
2. Water hose
3. Water pipe
4. Water hose
5. Water hose
6. Water pipe
EDF 7. O-ring
ECF 8. Engine coolant oolant temperature
gauge unit
9. Engine hanger
10. Water outlet fitting
11. Gasket
12. Water inlet fitting
EBF 13. Thermostat
14. Plate
15. Gasket
16. Water pump
17. Gasket
DEN0304
PWEE9067-H
Revised
11B-9-3
4D56 ENGINE <1994 > Water Pump, Thermostat, Hose and Pipe
Except engines with throttle body <PAJERO>
14 1.4 10
4
3
34 3.5 25
11 1.1 8
11
12
13
14 N
16 N
12 1.2 9
11 1.1 8
10 1.0 7
24 2.4 17
15
14 1.4 10
10 N
8
12 1.2 9
Removal steps
1. Hose protector
2. Water hose
3. Water pipe
4. Water hose
5. Water pipe and hose
EFF 6. Engine coolant temperature
gauge unit
EEF 7. Engine coolant temperature sensor
8. Engine hanger
PWEE9067-H
Revised
11B-9-4
4D56 ENGINE <1994 > Water Pump, Thermostat, Hose and Pipe
14 1.4 10
2
14 1.4 10
5
14 1.4 10
34 3.5 25
6
11 1.1 8
14 1.4 10
13
14
11
16 N
12
11 1.1 8
24 2.4 17
15
14 1.4 10
10 N
8
12 1.2 9
Removal steps
1. Hose protector
2. Water hose
3. Water pipe
4. Water hose
5. Water pipe and hose
EFF 6. Engine coolant temperature
gauge unit
EEF 7. Engine coolant temperature sensor
8. Engine hanger
DEN0353
G Mitsubishi Motors Corporation Apr. 2002
PWEE9067-H
Added
4D56 ENGINE <1994 > Water Pump, Thermostat, Hose and Pipe
11B-9-5
90
Thermostat
housing
Rubber
ring
Thermostat
bridge
Thermostat
DEN0172
Marking
Thermostat
04E0010
O-ring
6CO035
EEF
6AE0070
G Mitsubishi Motors Corporation Apr. 2002
PWEE9067-H
Added
11B-9-6
4D56 ENGINE <1994 > Water Pump, Thermostat, Hose and Pipe
EFF
6AE0071
PWEE9067-H
Added
11B-11-1
7
11
N 10
N 13
<With
throttle body>
29 3.0 22
+
120 to 124
12 N
3
16
14 N
N 15
8
4 N
Removal steps
FAE EEF 1. Cylinder head bolt
2. Cylinder head bolt washer
3. Cylinder head assembly
EDF 4. Cylinder head gasket
FBE ECF 5. Valve spring retainer lock
6. Valve spring retainer
EBF 7. Valve spring
8. Intake valve
9. Exhaust valve
FCE EAF 10. Valve stem seal
11. Spring seat
12. Intake valve guide
13. Exhaust valve guide
14. Exhaust valve seat
15. Cylinder head
Lubricate all
internal parts with
engine oil during
reassembly.
DEN0151
G Mitsubishi Motors Corporation May 2001
PWEE9067-G
Revised
11B-11-6
MD998772
DEN0152
MD998303
Caution
The valve spring, if excessively compressed,
causes the bottom end of the retainer to be in
contact with, and damage, the stem seal.
DEN092
Identification mark
Rank A
Rank B
Rank C
Rank D
Rank E
Identification hole
DEN0344
Rank C
Rank D
Rank E
Identification hole
2 3
45
67
DEN0345
DEN0156
Revised
11B-11-7
Protrusion
DEN0798
mm (in.)
Rank
Average value of
piston protrusions
Protrusion tolerance
for each rank
Thickness of selected
gasket (when tightened)
Identification
mark
0.562 0.620
(0.0221 0.0244)
0.670
(0.0264)
1.35 0.05
(0.0531 0.0020)
135
0.620 0.680
(0.0244 0.0268)
0.730
(0.0287)
1.40 0.05
(0.0551 0.0020)
140
0.680 0.774
(0.0268 0.0293)
0.794
(0.0313)
1.45 0.05
(0.0571 0.0020)
145
mm (in.)
Rank
Average value of
piston protrusions
Protrusion tolerance
for each rank
Thickness of selected
gasket (when tightened)
Identification
mark
0.562 0.620
(0.0221 0.0244)
0.670
(0.0264)
1.45 0.05
(0.0571 0.0020)
145
0.620 0.680
(0.0244 0.0268)
0.730
(0.0287)
1.50 0.05
(0.0590 0.0020)
150
0.680 0.774
(0.0268 0.0293)
0.794
(0.0313)
1.55 0.05
(0.0610 0.0020)
155
NOTE
If the piston projection exceeds the tolerance, replace the piston, connecting rod, crankshaft or cylinder
block and check again.
(3) Using the special tool and torque wrench, tighten bolts in
the shown sequence.
DGE033
G Mitsubishi Motors Corporation Apr. 2002
PWEE9067-H
Revised
11B-11-8
MB991614
120
6AE0339
PWEE9067-G
Added
11B-12-1
36
37 N
54 5.5 40
3
10 1.0 7
21 N
35
24 2.4 17
36 3.7 27
20
32 19
30
31
14
24 2.4 17
17
19 1.9 13
12 1.2 9
27
18 N
28
29
33
N
26
13 1.3 9
39
16
38
32 3.3 24
15 N
10
24 N
22 N
40 N
13 1.3 9
9 0.9 7
24 2.4 17
13
34
25
23
9
N 8
11
7 0.7 5
37 3.8 27
7
6
N 12
39 4.0 29
9 0.9 7
19 1.9 14
Removal steps
EKF 1. Oil filter
2. Oil cooler by-pass valve
EJF 3. Oil pressure switch
4. Oil filter bracket
5. Oil filter bracket gasket
6. Oil pan cover
<with variable geometry turbocharger>
7. Oil drain plug
E IF 8. Oil drain plug gasket
9. Oil level sensor <PAJERO>
FAE EHF 10. Oil pan
11. Oil screen
12. Oil screen gasket
13. Stiffener
14. Front upper case
15. Front upper case gasket
16. Oil seal
17. Plug cap
18. O-ring
FBE EGF 19. Flange bolt
20. Front lower case
PWEE9067-G
Revised
11B-12-1a
10 1.0 7
37 N
36
54 5.5 40
Apply engine oil to
all moving parts
before installation.
11 1.0 7
5 N
37 N
23 2.3 1.7
35
1
36 3.7 27
24 2.4 17
30
34
19 31
20
13
32
24 2.4 17
21 N
19 1.9 13
12 1.2 9
18 N
33 N
17
28
29
N 15
38
13 1.3 9
24 2.4 17
22 N
26
25
24 N
23
13 1.3 9
39
N 40
27
32 3.3 24
15 N
14
9
10
9 0.9 7
37 3.8 27
7 0.7 5
N 12
11
6
19 1.9 14
Removal steps
EKF 1. Oil filter
2. Oil cooler by-pass valve
EJF 3. Oil pressure switch
4. Oil filter bracket
5. Oil filter bracket gasket
6. Oil pan cover
(from 2002 model)
7. Oil drain plug
E IF 8. Oil drain plug gasket
9. Oil level sensor
FAE EHF 10. Oil pan
11. Oil screen
12. Oil screen gasket
13. Stiffener
14. Front upper case
15. Front upper case gasket
16. Oil seal
17. Plug cap
18. O-ring
FBE EGF 19. Flange bolt
20 Front lower case
G Mitsubishi Motors Corporation May 2001
8 N
7
39 4.0 29
9 0.9 7
Revised
NOTES
11B-13-1
7
8
9
12
11
4
10
14
6
13
Lubricate all
internal parts with
engine oil during
reassembly.
3
2
1
46 4.7 34
<Without variable geometry turbocharger>
27 2.8 20 + 90 94
<With variable geometry turbocharger>
Removal steps
EEF 1. Nut
FAE EDF 2. Connecting rod cap
3. Connecting rod bearing
ECF 4. Piston and connecting rod assembly
5. Connecting rod bearing
6. Bolt
EBF 7. Piston ring No. 1
EBF 8. Piston ring No. 2
ECF 9. Oil ring
EBF 10. Snap ring
EAF 11. Piston pin
EAF 12. Piston
EAF 13. Connecting rod
14. Bushing
DEN0039
G Mitsubishi Motors Corporation Apr. 2002
PWEE9067-H
Revised
11B-13-4
(2) Using the special tool, press-fit the bushing into position.
At the time, make sure that the oil hole in the bushing is
aligned with that in the connecting rod small end.
No. 1
No. 2
No. 3
No. 4
AK200853AB
Piston class
A
B
C
A
None
C
NOTE
The piston size mark shows on the top of the piston.
(2) Mate the piston with the connecting rod.
(3) Line up the front marks and insert the piston pin. The
piston pin must be smoothly pressed by hand into position.
Replace the piston pin if there is an excessive play.
G Mitsubishi Motors Corporation Apr. 2002
PWEE9067-H
Revised
Identification mark
1T, T1 or 1R
Size mark
No. 1
ring
No. 2
ring
11B-13-5
9EN0524
Timing
belt side
No. 2 ring
No. 1 ring
Piston pin
INSTALLATION
(1) Liberally coat engine oil on the circumference of the piston,
piston ring, and oil ring.
(2) Arrange the piston ring and oil ring gaps (side rail and
spacer) as shown in the figure.
(3) Rotate crankshaft so that crank pin is on center of cylinder
bore.
Oil ring
6EN0549
DEN0051
(2) Make sure that connecting rod big end side clearance
meets the specification.
Standard value: 0.10 0.25 mm (0.0039 0.0098 in.)
Limit: 0.40 mm (0.0157 in.)
DEN0162
G Mitsubishi Motors Corporation Apr. 2002
PWEE9067-H
Revised
11B-13-6
(1)
(2)
Paint mark
90 94
Paint
mark
(3)
(4)
(5)
(6)
Nut
Bolt
6AE0298
PWEE9067-H
Added
11B-14-1
132 13.5 98
9 0.9 7
Head mark 7
44 4.5 33
Head mark 8
11 1.1 8
54 5.5 40
11
24
N 12
13
10
132 13.5 98
5
22
7
14 N
9 0.9 7
18
25
17
N 21
20
19 N
16
23
6 0.6 4
15
Head mark 7
78 8.8 58
44 4.5 33
Head mark 8
54 5.5 40
Removal steps
1. Flywheel
For variable
2. Ball bearing
M/T
geometry
3. Adapter plate
4. Crankshaft adapter turbocharger
5. Adapter plate
A/T
6. Drive plate
7. Crankshaft adapter
8. Rear plate
9. Space rubber <PAJERO>
10. Bell housing cover
11. Oil seal case
12. Gasket
EDF 13. Oil separator
PWEE9067-G
Revised
11B-14-1a
132 13.5 98
9 0.9 7
4
21 N
M10 44 4.5 33
M8
11 1.1 8
22 2.2 16
3
N 9
19
10
5
N 11
15
9 0.9 7
22
N 18
14
17
20
13
16 N
12
6 0.6 4
78 88.0 58
44 4.5 33
Removal steps
1. Flywhee
2. Ball bearing
3. Adapter plate
4. Crankshaft adapter
5. Rear plate
6. Space rubber <PAJERO>
7. Bell housing cover
8. Oil seal case
9. Gasket
EDF 10. Oil separator
ECF 11. Rear oil seal
EBF 12. Bearing cap
DEN0307
G Mitsubishi Motors Corporation May 2001
PWEE9067-G
Revised
11B-14-2
3EN056
CRANKSHAFT
(1) Measure the outside diameter of journal and inside diameter of crankshaft bearing. If the difference between
them (oil clearance) exceeds the limit, replace the crankshaft bearing and, if necessary, crankshaft.
When the crankshaft is to be reused by machining to
undersize, the crankshaft bearings should be changed to
undersized ones.
Standard value:
0.02 0.05 mm (0.0008 0.0020 in.)
Limit: 0.1 mm (0.0039 in.)
3EN055
2.5 mm R
(0.098 in.)
2.5 mm R
(0.098 in.)
2.5
mm R
(0.098
in.)
Plastic gauge
6EN043
(4) Gently place the crankshaft bearing cap over it and tighten
the bolts to the specified torque.
(5) Remove the bolts and gently remove the crankshaft
bearing cap.
(6) Measure the width of the smashed plastic gauge at its
widest section by using a scale printed on the plastic
gauge bag.
Standard value: 0.02 0.04 mm
Limit: 0.1 mm
1EN067
G Mitsubishi Motors Corporation Apr. 2002
PWEE9067-H
Revised
11B-14-6
1 mm
Cylinder
(0.0394 in.) sleeve
30
DEN244
(6) The service cylinder sleeve has the I.D. machined to 89.9
to 90.1 mm (3.539 to 3.547 in.). After installation of the
sleeve, therefore, hone the I.D. to the standard value.
Cylinder I.D.: 91.10 91.13 mm (3.5866 3.5878 in.)
Honing finished surface roughness: 2 4 m
Honing cross hatch angle: 15 25
Cylinder bore squareness: 0.05 mm (0.0197 in.)
Protrusion
DEN0798
PWEE9067-H
Revised
NOTES
Service Bulletins
Click on the applicable bookmark to select the Service Bulletin.
SERVICE BULLETIN
QUALITY INFORMATION ANALYSIS
OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION
SERVICE BULLETIN
Subject:
Group:
No.: MSB-00E11-509
Date: 2001-04-09
OMISSION OF INJECTION TIMING
IDENTIFICATION MARK
ENGINE
Draft No.: 00EN600614
CORRECTION
INTERNATIONAL
CAR
ADMINISTRATION
OFFICE
<Model>
ALL
<M/Y>
01-10
T. MASAKI-MANAGER
TECHNICAL SERVICE PLANNING
1. Description:
Omission of a 4D5 engine injection timing identification mark from the following Workshop
Manual, has been rectified.
2. Applicable Manuals:
Manual
ENGINE 4D5
Workshop Manual
Pub. No.
PWEE9067
PWES9068
PWEF9069
PWEG9070
PWED9071
PWEW9072
Language
Page(s)
(English) 11B-5-7
(Spanish)
(French)
(German)
(Dutch)
(Swedish)
3. Details:
11B-5-7
NOTE
The injection timing can be known from the
identification mark stamped on the cylinder head at
the position shown in the illustration.
Identification mark
Identification mark
A or B
C or D
Injection timing
7 ATDC
9 ATDC
or E or G
<Added>
DEN0175
(7)
When higher than
the standard value
Front
view
DEN0107
(11) Install new copper gasket and plug, then tighten the
plug to specified torque.
Copper gasket
Plug
DFU0013
SERVICE BULLETIN
QUALITY INFORMATION ANALYSIS
OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION
SERVICE BULLETIN
No.: MSB-01E11-003
Subject:
Date: 2002-04-05
CHANGE IN GLOW PLUG TIGHTENING
CONDITION AND ADDITION OF NOTE
Group:
ENGINE
INFORMATION
INTERNATIONAL
CAR
ADMINISTRATION
OFFICE
T.Inoue - Manager
SERVICE PUBLICATION
<Model>
(EC)PAJERO/MONTERO(V10-40,
V60-70)
(EC)MONTERO
SPORT/PAJERO
SPORT(K80W,K90W)
(EC)L200/4WD
L200(K00-K30,
K60-K70)
(EC)L300(L30,L60,
P00,P10,P40)
(EC)L400(PA,PB,PD)
(EC)GALANT(E50-80,
EA0)
(EC)GALANT
WAGON(EA0W)
(EC)SPACERUNNER/
WAGON(N10,N20,
N30,N40)
(EC)COLT LANCER/
STATION
WAGON(CA0,CB0)
<M/Y>
97-10
1. Description:
On the 4D56 and 4D68 engines, the glow plug tightening condition has been changed, and a note
added.
2. Applicable Manuals:
Manual
ENGINE 4D5
Workshop Manual
CD
Pub. No.
PWEE9067
PWES9068
PWEF9069
PWEG9070
PWED9071
PWEW9072
PWEH9903R-D
PWEH9903R-D
PWEH9903R-D
PWEK9904R-D
PWEK9904R-D
PWEK9904R-D
PWEE9073
PWES9074
PWEF9075
PWEG9076
PWED9077
PWEW9078
PWEH9903R-D
PWEH9903R-D
PWEH9903R-D
PWEK9904R-D
PWEK9904R-D
PWEK9904R-D
PWEE9609
PWES9610
PWEF9611
PWEG9612
PWED9613
PWEW9614
PWEH9903R-D
PWEH9903R-D
PWEH9903R-D
PWEK9904R-D
PWEK9904R-D
PWEK9904R-D
Language
Page(s)
(English) 11B-3-1, 3-1A, 3-2
(Spanish)
(French)
(German)
(Dutch)
(Swedish)
(English)
(Spanish)
(Swedish)
(French)
(German)
(Dutch)
(English) 11B-3-1, 3-2
(Spanish)
(French)
(German)
(Dutch)
(Swedish)
(English)
(Spanish)
(Swedish)
(French)
(German)
(Dutch)
(English) 11B-3-1, 3-2
(Spanish)
(French)
(German)
(Dutch)
(Swedish)
(English)
(Spanish)
(Swedish)
(French)
(German)
(Dutch)
3. Details:
In order to improve reliability, the glow plug tightening condition has been changed as follows.
30
to 40
DEN0343