1A-0-1 ENGINE 4D68 CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-0-3 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1 REWORK DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-3 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11A-0-2 NOTES E Mitsubishi Motors Corporation Dec.
4D68 ENGINE (E - W) - General Information GENERAL INFORMATION SECTIONAL VIEW OF ENGINE E Mitsubishi Motors Corporation Dec.
11A-0-4 4D68 ENGINE (E - W) - General Information SECTIONAL VIEW OF ENGINE E Mitsubishi Motors Corporation Dec.
4D68 ENGINE (E - W) - General Information 11A-0-5 GENERAL SPECIFICATIONS Descriptions Specifications Type Diesel engine Number of cylinders 4 in-line Combustion chamber Swirl chamber Total displacement dm3 1.998 Cylinder bore mm 82.7 Piston stroke mm 93 Compression ratio 22.
11A-1-1 4D68 ENGINE (E - W) - Specifications 1. SPECIFICATIONS SERVICE SPECIFICATIONS Item Standard value Limit 0.5 - Timing belt deflection mm 4.0 - 5.0 - Timing belt “B” deflection mm 5.0 - 7.0 - Intake 41.90 41.40 Exhaust 41.96 41.46 Intake 0.25 - Exhaust 0.35 - 30.0 - Cylinder head gasket surface flatness mm Within 0.03 0.2 Cylinder head overall height mm 86.9 - 87.1 - Intake 114.05 113.55 Exhaust 113.80 113.30 Thickness of valve head (margin) mm 1.5 0.
11A-1-2 4D68 ENGINE (E - W) - Specifications Item Standard value Limit Oil cooler by-pass valve dimension (L) [by-pass hole closing temperature (97 - 103°C or more)] mm 40.0 - Oil pump side clearance Drive gear 0.08 - 0.14 - Driven gear 0.06 - 0.12 - 82.7 - No. 1 0.05 - 0.07 0.15 No. 2 0.05 - 0.07 0.15 No. 1 0.20 - 0.32 0.8 No. 2 0.35 - 0.50 0.8 Oil ring 0.10 - 0.30 0.8 Piston pin O.D. mm 25.0 - Crankshaft pin oil clearance mm 0.02 - 0.05 0.
11A-1-3 4D68 ENGINE (E - W) - Specifications REWORK DIMENSIONS Item Standard value Limit 0.05 O.S. 13.050 - 13.068 - 0.25 O.S. 13.250 - 13.268 - 0.50 O.S. 13.500 - 13.518 - 0.3 O.S. 38.300 - 38.325 - 0.6 O.S. 38.600 - 38.625 - 0.3 O.S. 34.300 - 34.325 - 0.6 O.S. 34.600 - 34.
11A-1-4 4D68 ENGINE (E - W) - Specifications TORQUE SPECIFICATIONS Items Nm Drive belt and glow plug Oil level gauge guide bolt 13 Pulley bolt (for power steering pump drive) 9 Alternator brace bolt 23 Lock bolt 23 Adjusting bolt 10 Alternator pivot nut 44 Crankshaft pulley bolt 25 Glow plug 18 Glow plug nut 1.
11A-1-5 4D68 ENGINE (E - W) - Specifications Items Nm Injection nozzle 54 Fuel injection pump bracket nut 23 Intake and exhaust manifold Air temperature sensor 14 Air intake fitting bolt 17 EGR valve bolt 24 EGR pipe bolt and nut 17 Turbocharger heat protector bolt M8 13 M6 11 Exhaust fitting heat protector bolt 13 Water pipe “A” and “B” eye bolt 30 Water pipe “A” and “B” bolt 10 Oil pipe eye bolt 16 Exhaust fitting bolt and nut 59 Oil return pipe bolt 9 Heat protector front
A-1-6 4D68 ENGINE (E - W) - Specifications Items Nm Adjusting nut 15 Camshaft bearing cap bolt M8 ¢ 25, M8 ¢ 40 20 M8 ¢ 55 29 Cylinder head, valves and valve springs Cylinder head bolt 90 ¯ Fully loosen ¯ 40 + 90° + 90° Front case, counterbalance shafts and oil pan Drain plug 39 Oil level sensor bolt 9 Oil pan bolt 7 Oil screen bolt 19 Oil cooler by-pass valve 54 Oil pressure switch 10 Relief plug 44 Oil filter bracket bolt 18 Plug 23 Flange bolt 36 Front case bolt 24 Oi
4D68 ENGINE (E - W) - Specifications 11A-1-7 NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA A new type of bolts, to be tightened in plastic area, is currently used some parts of the engine. The tightening method for the bolts is different from the conventional one. Be sure to observe the method described in the text when tightening the bolts. Service limits are provided for the bolts. Make sure that the service limits described in the text are strictly observed.
11A-1-8 4D68 ENGINE (E - W) - Specifications FORM-IN-PLACE GASKET The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the fluid feed line.
4D68 ENGINE (E - W) - Special Tools 11A-2-1 2. SPECIAL TOOLS Tool E Mitsubishi Motors Corporation Number Name Use MB990767 End yoke holder Holding camshaft sprocket or fuel injection pump when loosening or tightening bolts.
11A-2-2 Tool E Mitsubishi Motors Corporation 4D68 ENGINE (E - W) - Special Tools Number Name Use MD998375 Crankshaft front oil seal installer Installation of crankshaft front oil seal MD998388 Injection pump sprocket puller Removal of injection pump sprocket MD998702 Connecting-rod small-end bushing replacement tool Replacement of connecting-rod small-end bushing MD998705 Silent shaft bearing installer Installation of counterbalance shaft bearing MD998713 Camshaft oil seal installer Insta
4D68 ENGINE (E - W) - Special Tools Tool E Mitsubishi Motors Corporation 11A-2-3 Number Name Use MD998776 Crankshaft rear oil seal installer Installation of crankshaft rear oil seal (Use with MB990938) MD998778 Crankshaft sprocket puller Removal of crankshaft sprocket MD998781 Flywheel stopper Holding of flywheel and drive plate MD998783 Plug wrench retainer Removal and installation of front case cap plug (Use with MD998162) MD998785 Sprocket stopper Holding of counterbalance shaft sproc
4D68 ENGINE (E - W) - Drive Belt and Glow Plug 11A-3-1 3. DRIVE BELT AND GLOW PLUG REMOVAL AND INSTALLATION 1 11 2 13 Nm 1.8 Nm 12 18 Nm 3 4 8 10 Nm 44 Nm 9 23 Nm 7 6 9 Nm 5 10 25 Nm DEN0885 Removal steps 1. Oil level gauge 2. O-ring 3. Oil level gauge guide 4. O-ring 5. Drive belt (V-type) 6. Pulley (for power steering pump drive) E Mitsubishi Motors Corporation Dec. 1996 7. 8. 9. 10. 11. AA" "AA 12.
11A-3-2 4D68 ENGINE (E - W) - Drive Belt and Glow Plug REMOVAL SERVICE POINTS AA" GLOW PLUG REMOVAL (1) When removing the glow plug, you may loosen using a tool up to the point where one or more threads are left in engagement. Beyond this point, loosen with fingers. Caution D Do not reuse a glow plug that has been dropped from a height of 10 cm or more.
11A-4-1 4D68 ENGINE (E - W) - Timing Belt 4. TIMING BELT REMOVAL AND INSTALLATION 27 11 Nm 26 28 21 45 Nm 23 5 11 Nm 22 25 10 88 Nm 49 Nm 20 11 83 Nm 24 18 Nm 18 1 6 14 9 Nm 48 Nm 13 48 Nm 9 7 8 13 Nm 17 12 11 Nm 15 16 19 54 Nm 118 Nm 3 4 2 9 Nm 9 Nm DEN0886 AA" "IA "HA AB" "GA AC" "FA AD" Removal steps 1. Timing belt front upper cover 2. Timing belt front center cover 3. Timing belt front lower cover 4. Crankshaft position sensor 5. Timing belt 6.
11A-4-2 4D68 ENGINE (E - W) - Timing Belt REMOVAL SERVICE POINTS AA" TIMING BELT REMOVAL (1) Using chalk, etc., mark an arrow on the back of the timing belt to indicate the direction of rotation. This is to ensure correct installation of the belt in case it is reused. DEN0739 (2) Attach a bolt to the front end face of the timing belt tensioner. Fit an offset wrench onto the bolt and turn the wrench downward as shown to tighten the tensioner mounting bolt temporarily.
4D68 ENGINE (E - W) - Timing Belt 11A-4-3 AE" CRANKSHAFT BOLT LOOSENING MD998781 DEN0743 AF" CRANKSHAFT SPROCKET REMOVAL MD998778 DEN0744 AG" OIL PUMP SPROCKET REMOVAL (1) Before loosening the oil pump sprocket nut (flange nut), remove the timing belt and then the plug at the left side of the cylinder block and insert a Phillips screwdriver [shank diameter 8 mm] through the plug hole to keep the left counterbalance shaft in position.
11A-4-4 4D68 ENGINE (E - W) - Timing Belt AI" COUNTERBALANCE SHAFT SPROCKET REMOVAL MD998785 DEN0746 AJ" CRANKSHAFT SPROCKET “B” REMOVAL MD998778 DEN0747 Oil seal Spacer Sharp edge INSTALLATION SERVICE POINTS "AA SPACER INSTALLATION (1) Install the spacer with the chamfered end toward the oil seal.
4D68 ENGINE (E - W) - Timing Belt Timing belt “B” 11A-4-5 (3) Make sure that the pulley center and the bolt center are located as shown in the illustration. Tensioner “B” Tensioner pulley center DEN0749 (4) More the tensioner “B” in the direction of arrow while lifting with a finger to give a sufficient tension to the tension side of the timing belt. In this condition, tighten the bolt to secure tensioner “B”. When the bolt is tightened, use care to prevent the shaft from turning together.
11A-4-6 4D68 ENGINE (E - W) - Timing Belt "FA INJECTION PUMP SPROCKET NUT TIGHTENING MD998719 MB990767 DEN0754 "GA CAMSHAFT SPROCKET BOLT TIGHTENING MB990767 MD998719 DEN0755 "HA TIMING BELT TENSIONER INSTALLATION (1) Set the tensioner spring ends against the tensioner bracket and the projection of the injection pump bracket. (2) Attach a bolt to the front end face of the timing belt tensioner.
4D68 ENGINE (E - W) - Timing Belt Plug Screwdriver 6EN0563 11A-4-7 (4) Remove the plug on the cylinder block and insert a Phillips screwdriver [shank diameter 8 mm] through the hole. If it can be inserted as deep as 60 mm or more, the timing marks are correctly aligned. If the inserted depth is only 20 - 25 mm, turn the oil pump sprocket one turn and realign the timing marks. Then check to ensure that the screwdriver can be inserted 60 mm or more.
11A-4-8 4D68 ENGINE (E - W) - Timing Belt INSPECTION TIMING BELTS The timing belts must be checked closely. Should the following defects be evident, replace the belt with a new one. (1) Hardened back surface rubber Glossy, non-elastic, and so hard that no mark is produced even when scratched by fingernails.
4D68 ENGINE (E - W) - Glow Plug, Fuel Injection Pump And Injection Nozzle 11A-5-1 5. GLOW PLUG, FUEL INJECTION PUMP AND INJECTION NOZZLE REMOVAL AND INSTALLATION 5 Nm 5 Nm 4 1 3 29 Nm 29 Nm 2 13 29 Nm 14 54 Nm 16 15 17 18 5 18 Nm 13 Nm 9 6 10 7 23 Nm 19 18 Nm 8 13 Nm 11 23 Nm 35 Nm 12 AA" AA" AA" AA" AB" "DA "DA "DA "DA Removal steps 1. Injection pipe No.1 2. Injection pipe No.2 3. Injection pipe No.3 4. Injection pipe No.4 5. Fuel hose 6. Fuel hose 7. Fuel hose 8.
11A-5-2 4D68 ENGINE (E - W) - Glow Plug, Fuel Injection Pump And Injection Nozzle REMOVAL SERVICE POINTS Delivery holder AA" INJECTION PIPE REMOVAL (1) When loosening the union nuts on the injection pump, hold the delivery valve holder on the fuel injection pump head with a spanner to prevent it from rotating along with the union nut. Nut DEN0759 Caution D If the injection pipe has been removed, plug the delivery valve holder to prevent foreign matter from entering the injection pump.
4D68 ENGINE (E - W) - Glow Plug, Fuel Injection Pump And Injection Nozzle 11A-5-3 INSTALLATION SERVICE POINTS Holder gasket Nozzle gasket "AA NOZZLE GASKET / HOLDER GASKET INSTALLATION (1) Clean nozzle holder installation areas of the cylinder head. (2) Fit a new nozzle gasket and holder gasket into the nozzle holder hole in the cylinder head.
11A-6-1 4D68 ENGINE (E - W) - Intake and Exhaust Manifolds 6. INTAKE AND EXHAUST MANIFOLDS REMOVAL AND INSTALLATION 17 Nm 24 Nm 3 7 8 11 Nm 17 Nm 12 14 Nm 16 14 30 Nm 13 Nm 15 13 27 28 19 17 Nm 22 32 17 59 Nm 59 Nm 29 Nm 59 Nm 35 34 23 Nm 59 Nm 24 37 14 Nm 38 25 39 30 Nm 23 10 Nm 26 9 Nm 36 1 20 21 33 13 Nm 6 2 16 Nm 18 10 Nm 5 10 11 16 Nm 11 Nm 4 9 30 29 13 Nm 30 31 13 Nm DEN0888 Removal steps 1. Air temperature sensor 2. Air temperature sensor gasket 3.
11A-6-2 4D68 ENGINE (E - W) - Intake and Exhaust Manifolds INSTALLATION SERVICE POINTS "AA OIL RETURN PIPE GASKET INSTALLATION (1) Install the oil return pipe gasket in such a way that its projection is located at the illustrated position. Oil return pipe Projection DEN0843 "BA EYEBOLT INSTALLATION (1) Before installing the oil pipe eyebolt (at top of the turbocharger), fill the turbocharger with clean engine oil.
4D68 ENGINE (E - W) - Water Pump, Thermostat, Hose and Pipes 11A-7-1 7. WATER PUMP, THERMOSTAT, HOSE AND PIPES REMOVAL AND INSTALLATION 16 Nm 1 2 17 3 4 18 22 Nm 8 9 Nm 45 Nm 19 5 7 23 Nm 23 Nm 20 11 Nm 16 12 Nm 10 6 22 15 12 Nm 9 35 Nm 21 11 14 19 Nm 12 13 13 Nm DEN0889 Removal steps 1. Eyebolt 2. Gasket 3. Oil pipe 4. Gasket 5. Eyebolt 6. Gasket 7. Oil return pipe 8. Oil return hose 9. Engine coolant temperature sensor "FA 10. Engine coolant temperature gauge unit "EA 11.
11A-7-2 4D68 ENGINE (E - W) - Water Pump, Thermostat, Hose and Pipes INSTALLATION SERVICE POINTS "AA THERMOSTAT HOUSING INSTALLATION (1) Apply a 3 mm bead of form-in-place gasket (FIPG) to the mounting surface. Specified sealant: Mitsubishi Genuine equivalent. Part No. MD970389 or DEN0768 "BA WATER OUTLET FITTING INSTALLATION (1) Apply a 3 mm bead of form-in-place gasket (FIPG) to the mounting surface. Specified sealant: Mitsubishi Genuine equivalent. Part No.
4D68 ENGINE (E - W) - Water Pump, Thermostat, Hose and Pipes 11A-7-3 "FA ENGINE COOLANT TEMPERATURE GAUGE UNIT INSTALLATION (1) If the water temperature sensor is to be reused, apply the specified sealant to its thread. Specified sealant: 3M Nut Locking Part No. 4171 or equivalent. DEN0890 E Mitsubishi Motors Corporation Dec.
4D68 ENGINE (E - W) - Rocker Arms, Rocker Shaft and Camshaft 11A-8-1 8. ROCKER ARMS, ROCKER SHAFT AND CAMSHAFT REMOVAL AND INSTALLATION 6 Nm 29 Nm 15 Nm 20 Nm 5 4 1 6 7 2 20 Nm 8 29 Nm 12 12 29 Nm 12 11 13 9 3 12 10 Apply engine oil to all moving parts before installation. DEN0891 Removal steps 1. Breather hose 2. Rocker cover 3. Rocker cover gasket 4. Rocker shaft 5. Rocker shaft spring 6. Rocker arm 7. Adjusting nut 8. Rocker arm adjusting screw 9. Front camshaft bearing cap 10.
11A-8-2 4D68 ENGINE (E - W) - Rocker Arms, Rocker Shaft and Camshaft INSTALLATION SERVICE POINTS Camshaft sprocket side "AA CAMSHAFT BEARING CAP INSTALLATION (1) Install the bearing caps in the designated position confirming the identification numbers stamped on the cap front. The No.5 cap has no identification number stamped. Identification number DEN658 "BA FRONT, REAR CAMSHAFT BEARING CAP INSTALLATION (1) Apply sealant to the locations shown in the illustrations.
4D68 ENGINE (E - W) - Rocker Arms, Rocker Shaft and Camshaft 11A-8-3 VALVE CLEARANCE ADJUSTMENT Camshaft sprocket Timing mark (1) Turn the crankshaft clockwise and align the timing mark on camshaft sprocket with that on the injection pump bracket. DEN0605 (2) Adjust the valve clearance at the points shown in the illustration. Exhaust Intake Intake Exhaust No.1 No.1 No.2 No.3 DEN0774 (3) Loosen the adjusting screw lock nut.
11A-8-4 4D68 ENGINE (E - W) - Rocker Arms, Rocker Shaft and Camshaft (5) While holding the adjusting screw with a screwdriver, tighten the lock nut. (6) Rotate clockwise the crankshaft one complete turn (360 degrees). (7) Adjust the valve clearance at the points shown in the illustration. (8) Repeat steps (3) to (5) to adjust the valve clearance of the remaining valves. Exhaust No.2 Intake Exhaust Intake No.3 No.4 No.4 DEN0776 NOTE With the engine mounted on vehicle, warm up the engine.
4D68 ENGINE (E - W) - Cylinder Head, Valves and Valve Springs 11A-9-1 9. CYLINDER HEAD, VALVES AND VALVE SPRINGS REMOVAL AND INSTALLATION Apply engine oil to all moving parts before installation. DEN0777 Removal steps AA" "EA 1. Cylinder head bolt 2. Cylinder head assembly "DA 3. Cylinder head gasket AB" "CA 4. Valve spring retainer lock 5. Valve spring retainer "BA 6. Valve spring 7. Intake valve 8. Exhaust valve E Mitsubishi Motors Corporation Dec. 1996 AC" "AA 9. 10. 11. 12. 13. 14. 15.
11A-9-2 4D68 ENGINE (E - W) - Cylinder Head, Valves and Valve Springs REMOVAL SERVICE POINTS AA" CYLINDER HEAD BOLT REMOVAL (1) Using a 12 mm - 12 points socket wrench, loosen the cylinder head bolts. MB991654 DEN0778 AB" RETAINER LOCK REMOVAL (1) Store removed valves, springs and other parts, tagged to indicate their cylinder No. and location for reassembly. MD998772 DEN0779 AC" VALVE STEM SEAL REMOVAL (1) Do not reuse removed stem seals.
4D68 ENGINE (E - W) - Cylinder Head, Valves and Valve Springs 11A-9-3 "CA RETAINER LOCK INSTALLATION (1) The valve spring, if excessively compressed, causes the bottom end of the retainer to be in contact with, and damage, the stem seal.
11A-9-4 4D68 ENGINE (E - W) - Cylinder Head, Valves and Valve Springs (3) Using the special tool (MB991654) and according to the tightening sequence, tighten the bolts to the specified torque. Timing belt side Tightening torque: 90 Nm (4) Loosen all bolts fully. (5) Retighten the loosened bolts to a torque of 40 Nm in the specified tightening sequence. DEN0781 (6) Make paint marks on the cylinder head bolt heads and cylinder head.
4D68 ENGINE (E - W) - Cylinder Head, Valves and Valve Springs Valve seat contact Margin 6EN0542 11A-9-5 VALVE (1) Check the valve face for correct contact. If incorrect, reface using a valve refacer. Valve seat contact should be maintained uniform at the center of valve face. (2) If the margin is smaller than the service limit, replace the valve. Standard value: 1.5 mm Limit: 0.7 mm (3) Measure the overall height of the valve. If the specified limit is exceeded, replace the valve.
11A-9-6 4D68 ENGINE (E - W) - Cylinder Head, Valves and Valve Springs (2) Install the valve and, while pressing the valve against the valve seat, measure the valve stem projection between the valve stem end and the valve spring seat seating surface. Valve stem end Valve stem projection Spring seat seating surface Standard value: 43.45 mm Limit: 43.95 mm DEN0212 VALVE SEAT RECONDITIONING PROCEDURE 0.9 - 1.3 mm 0.9 - 1.
4D68 ENGINE (E - W) - Cylinder Head, Valves and Valve Springs Removal VALVE GUIDE REPLACEMENT PROCEDURE Press (1) Using the special tool and a press, remove the valve guide toward the cylinder head gasket surface. (2) Rebore the valve guide hole to the new oversize valve guide outside diameter. Push rod contained in MD998115 Valve guide hole diameter 0.05 O.S.: 13.050 - 13.068 mm 0.25 O.S.: 13.250 - 13.268 mm 0.50 O.S.: 13.500 - 13.
4D68 ENGINE (E - W) - 11A-10-1 Front Case, Counterbalance Shafts and Oil Pan 10. FRONT CASE, COUNTERBALANCE SHAFTS AND OIL PAN REMOVAL AND INSTALLATION 29 Apply engine oil to all moving parts before installation. 30 27 31 20 24 Nm 19 25 7 6 22 10 Nm 10 Nm 9 16 Nm 15 54 Nm 8 28 21 24 17 14 23 4 18 26 13 11 16 36 Nm 19 Nm 9 Nm 24 Nm 23 Nm 12 5 10 2 44 Nm 18 Nm 39 Nm 3 7 Nm 1 DEN0892 Removal steps 1. Oil filter 2. Drain plug 3. Drain plug gasket 4.
11A-10-2 4D68 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan REMOVAL SERVICE POINTS AA" OIL PAN REMOVAL (1) Knock the special tool deeply between the oil pan and the cylinder block. (2) Hitting the side of the special tool, slide the special tool along the oil pan to remove it. MD998727 6EN0698 MD998162 AB" PLUG REMOVAL (1) If the plug is too hard to loosen, tap on the plug several times with a plastic hammer, then remove it using the special tool.
4D68 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan 11A-10-3 AE" RIGHT COUNTERBALANCE SHAFT REAR BEARING / LEFT COUNTERBALANCE SHAFT REAR BEARING REMOVAL (1) Using the special tool, remove two rear bearings from the cylinder block. (2) To remove the left rear bearing, install the special tool, Silent Shaft Bearing Installer Stopper, to the front of the cylinder block, then remove the bearing using the special tool, Silent Shaft Bearing Puller.
11A-10-4 4D68 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan (4) Insert the installer aligning with the guide pin and install the bearing. MD998705 Guide pin 6EN0775 MD998705 6EN0776 "CA COUNTERBALANCE SHAFT FRONT BEARING INSTALLATION (1) Remove the rear bearing installing portion from the special tool. Rear bearing installer 6EN0777 (2) Install the guide pin of the special tool to the threaded hole of the cylinder block as illustrated.
4D68 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan 11A-10-5 (5) Insert the installer aligning with the guide pin and install the bearing. MD998705 Guide pin 6EN0775 6EN0778 "DA OIL PUMP OIL SEAL INSTALLATION Oil seal Socket wrench Front case 6EN0494 "EA COUNTERBALANCE SHAFT OIL SEAL INSTALLATION Socket wrench Oil seal Front case 6EN0580 "FA CRANKSHAFT FRONT OIL SEAL INSTALLATION (1) Using the special tool, install the crankshaft front oil seal into the front case.
11A-10-6 4D68 ENGINE (E - W) - Alignment mark Front Case, Counterbalance Shafts and Oil Pan "GA OIL PUMP DRIVEN GEAR / OIL PUMP DRIVE GEAR INSTALLATION (1) Apply engine oil amply to the gears and line up the alignment marks. 6LU0015 "HA FRONT CASE INSTALLATION (1) Install the special tool at the front end of the crankshaft and apply a thin coat of engine oil to the outer circumference. In case an oil seal has been installed to the front case, be sure to use the guide.
4D68 ENGINE (E - W) MD998162 Front Case, Counterbalance Shafts and Oil Pan 11A-10-7 "JA PLUG INSTALLATION (1) Fit a new O-ring in the front case. (2) Tighten the plug to the specified torque using the special tool. MD998783 6EN0909 "KA OIL PRESSURE SWITCH INSTALLATION Specified sealant: 3M ATD Part No. 8660 or equivalent Caution D Keep the end of the thread portion clear or sealant. D Avoid an overtightening.
11A-10-8 4D68 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan COUNTERBALANCE SHAFT (1) Check the oil holes for clogging. (2) Check the journals for seizure, damage, and contact with bearing. If there is anything wrong with the journal, replace the counterbalance shaft, bearing or front case assembly. DEN0711 OIL COOLER BYPASS VALVE (1) Make sure that the valve moves smoothly. (2) Ensure that the dimension L measures the standard value under normal temperature and humidity.
4D68 ENGINE (E - W) - Pistons and Connecting Rods 11A-11-1 11. PISTONS AND CONNECTING RODS REMOVAL AND INSTALLATION Apply engine oil to all moving parts before installation. DEN0771 "FA AA" "EA "CA "DA "CA "BA "BA Removal steps 1. Connecting rod cap nut 2. Connecting rod cap 3. Connecting rod bearing 4. Piston and connecting rod assembly 5. Connecting rod bearing 6. Piston ring No.1 7. Piston ring No.2 E Mitsubishi Motors Corporation Dec. 1996 PWEE9609 8. 9. "AA 10. "AA 11. "AA 12. 13. 14.
11A-11-2 4D68 ENGINE (E - W) - Pistons and Connecting Rods REMOVAL SERVICE POINTS Cylinder No. AA" CONNECTING ROD CAP REMOVAL (1) Mark the cylinder number on the side of the connecting rod big end for correct reassembly. DEN0050 INSTALLATION SERVICE POINTS "AA PISTON PIN / PISTON / CONNECTING ROD INSTALLATION (1) Assemble the piston and connecting rod, directing the front marks in the same direction. (2) Insert the piston pin. The pin should be inserted by hand. Replace if there is a play.
4D68 ENGINE (E - W) - Pistons and Connecting Rods Coil expander joint Timing belt side "DA PISTON AND CONNECTING ROD ASSEMBLY 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 as shown in the illustration. (3) Rotate the crankshaft so that the crank pin is on the center of the cylinder bore. No. 1 Piston pin No.
11A-11-4 4D68 ENGINE (E - W) - Pistons and Connecting Rods "FA CONNECTING ROD CAP NUT INSTALLATION Caution D If the cylinder head has been installed before installing the connecting rod cap nut, be sure to remove the spark plugs. (1) Since the connecting rod cap bolts and nuts are torqued using the plastic area tightening method, the bolts should be examined BEFORE reuse. If the bolt threads are “necked down”, the bolt should be replaced.
4D68 ENGINE (E - W) - Pistons and Connecting Rods 11A-11-5 INSPECTION PISTON RING (1) Check for side clearance. If the limit is exceeded, replace the ring or piston, or both. 5EN0066 Piston (2) In the case of semi-keystone type piston rings, check the ring to ring groove clearance as illustrated. Thickness gauge Standard value: No. 1 0.05 - 0.07 mm No. 2 0.05 - 0.07 mm Limit: No. 1 No. 2 0.15 mm 0.15 mm DEN259 (3) Insert the piston ring into the cylinder bore.
11A-11-6 4D68 ENGINE (E - W) - Pistons and Connecting Rods CONNECTING ROD BUSHING REPLACEMENT Removal (1) Using the special tool, remove the bushing. MD998702 Bushing DEN204 (2) Using the special tool, install the bushing, aligning the oil hole of the bushing with the oil hole at the small end of the connecting rod. Installation MD998702 Apply oil Bushing Chamfered end Align oil holes DEN205 (3) Finish the bushing I.D. to the standard value. Bushing I.D. (d) standard value: 25.015 - 25.
11A-12-1 4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel 12. CRANKSHAFT, CYLINDER BLOCK AND FLYWHEEL REMOVAL AND INSTALLATION 132 Nm “A” 6 3 5 2 17 8 18 1 4 9 11 Nm 7 11 Nm 14 16 13 15 12 32 Nm 11 Apply engine oil to all moving parts before installation. 10 DEN0893 "DA "CA "BA "BA "AA "AA Removal steps 1. Flywheel bolt 2. Adapter plate 3. Flexible flywheel 4. Adapter plate 5. Crankshaft bush 6. Rear plate 7. Bell housing cover 8. Oil seal case 9. Oil seal 10.
11A-12-2 4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel INSTALLATION SERVICE POINTS No.3 No.2 No.4 No.1 Location of identification colors "AA CRANKSHAFT BEARING INSTALLATION When the bearing needs replacing, select and install a proper bearing by the following procedure. (1) Measure the crankshaft journal diameter and confirm its classification from the following table.
4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel 11A-12-3 "BA BEARING CAP / BEARING CAP BOLT INSTALLATION (1) Install the bearing caps so that their arrows are directed to the timing belt side. (2) Before installing the bearing cap bolts, check that the shank length of each bolt meets the limit. If the limit is exceeded, replace the bolt. Limit: 71.1 mm Shank length 9EN0477 8 Arrow mark 7 4 1 5 3 2 6 9 (3) Apply engine oil to the threaded portion and bearing surface of the bolt.
11A-12-4 4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel "CA OIL SEAL INSTALLATION MB990938 MD998776 6EN0709 "DA OIL SEAL CASE INSTALLATION Specified sealant: Mitsubishi Genuine equivalent Part No. MD970389 or 6EN0626 INSPECTION Plastic gauge CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE METHOD) (1) Remove oil from the crankshaft journal and the crankshaft bearing. (2) Install the crankshaft.
4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel A C D E F G B 9EN0074 11A-12-5 CYLINDER BLOCK (1) Visually check for cracks, rust, and corrosion, and inspect the cylinder block using a flaw detecting agent. Rectify defects where possible or replace the cylinder block. (2) Check the cylinder block’s top surface for distortion using a straight edge and thickness gauge. Be sure to make measurements with the straight edge placed in the direction of A, B,..
11A-12-6 4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel (4) Bore all cylinders to the calculated boring finish dimension. Caution To prevent distortion that may result from temperature rise during honing, bore cylinders, in the order of No. 2, No. 4, No. 1 and No. 3. (5) Hone to the final finish dimension (Piston O.D. + clearance between piston O.D. and cylinder.) (6) Check the clearance between piston and cylinder. Clearance between piston and cylinder: 0.03 - 0.
4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel Y direction X direction 12 mm Center Lower DEN116 11A-12-7 INSPECTION (1) After removing the cylinder sleeve, check the cylinder block sleeve hole surface. If there is damage, insufficient interference-fit-margin or other problems, bore the cylinder block sleeve hole to an oversize. (2) To check the interference, measure both the cylinder sleeve O.D. and cylinder block sleeve hole I.D. at the positions D1, D2 and D3 in both X and Y directions.
11A-12-8 4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel (5) Chamfer the cylinder sleeve top end as illustrated. 0.5 mm Cylinder sleeve 30° DEN244 (6) The service cylinder sleeve has the I.D. machined to 81.5 to 81.7 mm. After installation of the sleeve, therefore, hone the I.D. to the standard value. Cylinder I.D.: 82.70 - 82.73 mm Honing finished surface roughness: 2 - 4 m Honing cross hatch angle: 15 - 25° Cylinder bore squareness: 0.
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