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ENGINE <4D5>
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44B04
ENGINE ?7D8>
CONTENTS 4443<333;58
GENERAL INFORMATION 5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
SERVICE SPECIFICATIONS 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
SEALANTS 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
SPECIAL TOOLS 7 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
ON0VEHICLE SERVICE 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Drive Belt Tension Check and Adjustment 8 1 1 1 1 1 1
Valve Clearance Check and Adjustment ; 1 1 1 1 1 1 1 1
njection Timing Check and Adjustment < 1 1 1 1 1 1 1 1
dle Speed Check and Adjustment 45 1 1 1 1 1 1 1 1 1 1 1 1
dle0up Mechanism Check and
Adjustment0For A2C 45 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Compression Pressure Check 46 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Timing Belt Tension Adjustment 47 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Timing Belt B Tension Adjustment 48 1 1 1 1 1 1 1 1 1 1 1 1
CRANKSHAFT PULLEY 4: 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
CAMSHAFT AND CAMSHAFT OIL SEAL 4; 1 1
OIL PAN AND OIL SCREEN 54 1 1 1 1 1 1 1 1 1 1 1 1 1 1
CYLINDER HEAD GASKET 56 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
TIMING BELT AND TIMING BELT B 59 1 1 1 1 1 1
CRANKSHAFT FRONT OIL SEAL 63 1 1 1 1 1 1 1 1 1
CRANKSHAFT REAR OIL SEAL 64 1 1 1 1 1 1 1 1 1 1
ENGINE ASSEMBLY 66 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
ENGINE ?7D8> - GeneraI Information 44B05
GENERAL INFORMATION 4443334366<
tems 7D89
Total displacement mL 5/7::
Bore x Stroke mm <414 x <813
Compression ratio 54
Combustion chamber Vortex chamber type
Camshaft arrangement SOHC
Number of valve ntake 7
Exhaust 7
Valve timing ntake Opening BTDC 53E/ Closing ABDC 7<E
Exhaust Opening BBDC 88E/ Closing ATDC 55E
Fuel system Distribution type injection pump
Rocker arm Roller type
Adjusting screw Elephant foot type
ENGINE ?7D8> - Service Specifications2SeaIants 44B06
SERVICE SPECIFICATIONS 444333639:3
tems Standard value Limit
Alternator drive belt Tension N When checked 578 774
tension +for each
belt,
When a used belt is installed 5<7 6<5
belt,
When a new belt is installed 6<5 8;;
Deflection When checked 4513 4:13
+Reference
value, mm
When a used belt is installed 4613 4913
value, mm
When a new belt is installed 4313 4613
Power steering oil Tension N When checked 5<7 7<3
pump drive belt ten0
sion
sion
When a new belt is installed 7<3 9;9
Deflection When checked ;13 4513
+Reference
value, mm
When a used belt is installed <13 4418
value, mm
When a new belt is installed 913 ;13
A2C compressor Tension N When checked 676 774
drive
belt tension
belt tension
When a new belt is installed 7<3 88;
Deflection When checked 918 :18
+Reference
value, mm
When a used belt is installed 918 :18
value, mm
When a new belt is installed 815 913
Valve clearance +at hot, mm 3158
njection timing +Value indicated on dial gauge mm, <E ATDC +4 r 3136,
dle speed r2min :83 r 433
Compression pressure kPa 6/373 Min1 5/533
Compression pressure difference of all cylinder +at engine speed of 5;3
r2min, kPa
Max1 633
Timing belt tension mm 7 8
Timing belt B tension mm 7 8
SEALANTS 444333835:3
tems Specified sealant Remarks
Oil pan MTSUBSH GENUNE PART
MD<:36;< or equivalent
Semi0drying sealant
Semi0circular packing and rocker
cover seal/ and cylinder head seal
6M ATD Part No1 ;993 or equivalent
ENGINE ?7D8> - SpeciaI TooIs 44B07
SPECIAL TOOLS 4443339365:
Tool Number Name Use
MD<<;6;7 Prestroke measur0
ing adapter
Adjustment of the injection timing
MD<<;:54 Crankshaft pulley
holder
Holding the crankshaft pulley
MB<<3:9: End yoke holder Holding the camshaft sprocket
MD<<;:4< Crankshaft pulley
holder pin
MD<<;6;4 Camshaft oil seal
installer
nstalling the camshaft oil seal
MD<<;:5: Oil pan remover Removal of oil pan
MD<<;384 Cylinder head bolt
wrench
Removal and installation of the cylinder head
bolt
MD<<;6;5 Crankshaft front oil
seal installer
nstalling the crankshaft front oil seal
MD<<;6;6 Crankshaft front oil
seal guide
ENGINE ?7D8> - SpeciaI TooIs2On0vehicIe Service 44B08
Tool Use Name Number
MD<<;:;4 Flywheel stopper Securing the flywheel
MD<<;6:9 Crankshaft rear oil
seal installer
Press0fitting the crankshaft rear oil seal
ON0VEHICLE SERVICE 444333<3666
DRIVE BELT TENSION CHECK AND
ADJUSTMENT
ALTERNATOR DRIVE BELT TENSION CHECK
Use a belt tension gauge to check that the belt tension is
at the standard value at a point half0way between the two
pulleys as shown in the illustration1 n addition/ press this
section with a force of <; N and check that the amount of
belt deflection is at the standard value1
Standard vaIue +for each beIt,=
Tension N 578 774
Deflection +Reference value, mm 4513 4:13
Water pump
pulley
<; N
Alternator
pulley
Crankshaft
pulley
ENGINE ?7D8> - On0vehicIe Service 44B09
ALTERNATOR DRIVE BELT TENSION ADJUSTMENT
41 Loosen the nut of the alternator pivot bolt1
51 Loosen the lock bolt1
61 Use the adjusting bolt to adjust the belt tension and belt
deflection to the standard values1
Standard vaIue +for each beIt,=
tems When a used
belt is installed
When a newbelt
is installed
Tension N 5<7 6<5 6<5 8;;
Deflection +Reference
value, mm
4613 4913 4313 4613
71 Tighten the nut of the alternator pivot bolt1
Tightening torque= 77 Nm
81 Tighten the lock bolt1
91 Tighten the adjusting bolt1
POWER STEERING OIL PUMP DRIVE BELT TENSION
CHECK AND ADJUSTMENT 44433443485
41 Use a belt tention gauge to check that the belt tension
is at the standard value at a point half0way between the
two pulleys +indicated by an arrow in the illustration,1
n addition/ press this section with a force of <; N and
check that the amount of belt deflection is at the standard
value1
Standard vaIue=
tems When
checked
When a used
belt is intalled
When a new
belt is installed
Tension N 5<7 7<3 676 774 7<3 9;9
Deflection
+Reference
value, mm
;13 4513 <13 4418 913 ;13
Lock bolt
Adjusting
bolt
Pivot bolt
Power
steering
oil pump
pulley
Water pump
pulley
Crankshaft
pulley
<; N
Deflection
ENGINE ?7D8> - On0vehicIe Service 44B0:
51 f the tension or deflection is outside the standard value/
adjust by the following procedure1
+4, Loosen power steering oil pump fixing bolts A/ B and
C1
+5, Adjust the amount of belt deflection using adjusting
bolt D1
+6, Tighten fixing bolts A/ B and C1
+7, Check the belt deflection amount and tension/ and
readjust if necessary1
Caution
Check after turning the crankshaft once or more
cIockwise +right turn,1
AIR CONDITIONER COMPRESSOR DRIVE BELT
TENSION CHECK AND ADJUSTMENT 4443343358;
41 Use a belt tention gauge to check that the belt tension
is at the standard value at a point half0way between the
two pulleys +indicated by an arrow in the illustration,1
n addition/ press this section with a force of <; N and
check that the amount of belt deflection is at the standard
value1
Standard vaIue=
tems When
checked
When a used
belt is intalled
When a new
belt is installed
Tension N 676 774 676 774 7<3 8;;
Deflection
+Reference
value, mm
918 :18 918 :18 815 913
51 f the tension or deflection is outside the standard value/
adjust by the following procedure1
+4, Loosen tension pulley fixing nut1
+5, Adjust belt tension with adjusting bolt1
+6, Tighten fixing nut1
A
B
C
Tension pulley
Crankshaft
pulley
<; N
Deflec0
tion
A2C compressor pulley
Tension pulley
Crankshaft
pulley
Adjusting bolt
Fixing nut
A2C
compressor
pulley
ENGINE ?7D8> - On0vehicIe Service 44B0;
+7, Check the belt deflection amount and tension/ and
readjust if necessary1
Caution
Check after turning the crankshaft once or more
cIockwise +right turn,1
VALVE CLEARANCE CHECK AND
ADJUSTMENT 4443348343<
41 Start the engine and allow it to warm up until the engine
coolant temperature reaches ;3 to <3 EC1
51 Remove the timing belt upper cover1
61 Remove the rocker cover1
71 Align the camshaft sprocket timing marks and set the
No1 4 cylinder at top dead centre1
Caution
The crankshaft shouIdaIways be turnedina cIockwise
direction1
81 Measure the valve clearance at the places indicated by
arrows in the illustration1
Standard vaIue= 3158 mm
NOTE
nsert the thickness gauge from the centre of the cylinder
head towards the outside so that it doesn't touch the
pad1
Timing marks Timing marks
Camshaft
sprocket
Crankshaft
pulley
Adjusting
screw
Pad
Thickness gauge
ENGINE ?7D8> - On0vehicIe Service 44B0<
91 f the clearance is outside the standard value/ loosen
the lock nut of the rocker arm and adjust by turning the
adjusting screwwhile using a thickness gauge to measure
the clearance1
:1 Tighten the lock nut while holding the adjusting screw
with a screwdriver so that it doesn't turn1
;1 Turn the crankshaft 693E clockwise to bring No1 7 cylinder
to the top dead centre position1
<1 Measure the valve clearances at the places indicated
by arrows in the illustration1 f the clearance is not within
the standard value/ repeat steps : and ; above1
431 Apply specified sealant to the section of the semi0circular
packing shown in the illustration1
Specified seaIant= 6MATD Part No1 ;993 or equivaIent
441 nstall the rocker cover1
451 nstall the timing belt upper cover1
INJECTION TIMING CHECK AND
ADJUSTMENT 444334;33;8
41 Warm up the engine and then check to be sure that
the fast idle lever is separated from the accelerator lever1
51 Remove all of the glow plugs1
61 Remove the timing belt upper cover1
71 Align the timing marks of the camshaft sprocket and set
the No1 4 cylinder to the top dead centre position1
Thickness gauge
Cylinder head
43 mm
Semi circular packing
43 mm
Accelerator lever
Fast idle lever
Timing marks Timing marks
Camshaft
sprocket
Crankshaft
pulley
81 Remove the timing check plug at the rear of the injection
pump1
91 Before installation of special tool/ make sure that push
rod is protruding by 43 mm1 Protrusion of push rod can
be adjusted with an inner nut1
:1 Connect the dial gauge to the special tool1
;1 nstall the special tool to the check plug at the rear of
the injection pump1
<1 Turn the crankshaft clockwise to move the No1 4 cylinder
approximately 63E before compression top dead centre1
431 Set the needle of the dial gauge to 31
441 Check that the needle doesn't move even if the crankshaft
is turned slightly +5 6E, in both clockwise and
anti0clockwise direction1
NOTE
f the needle moves/ the notch is not positioned properly/
so once again move the No1 4 cylinder approximately
63E before compression top dead centre1
451 Turn the crankshaft clockwise to align the No1 4 cylinder
to <E ATDC1
461 Check that the value indicated on the dial gauge is at
the standard value1
Standard vaIue= 4 r 3136 mm
Timing check plug
Push rod
Nut
MD<<;6;7
43 mm
MD<<;6;7
Approx1 63E
4 r 3136 mm
Set to <E ATDC
471 f the needle is outside the standard value/ adjust the
injection timing by the following procedure1
+4, Loosen the injection pipe union nuts +7 places, on
the injection pump1 +Do not remove the union nuts1,
Caution
When Ioosening the nuts/ hoId the deIivery vaIve
hoIders with a spanner so that they don't turn
at the same time1
+5, Loosen the upper mounting nuts and the lower
mounting bolts of the injection pump1 +Do not remove
the nut and bolt1,
+6, Tilt the injection pump to the left and right and adjust
the needle on the dial gauge so that the display value
is uniform1
+7, Provisionally tighten the mounting nut and bolt of
the injection pump1
+8, Repeat steps < 46 to check if the adjustment has
been made correctly1
+9, Tighten the mounting nuts and bolts to the specified
torque1
+:, Tighten the injection pump union nuts to the specified
torque1
Caution
When tightening the nuts/ hoId the deIivery vaIve
hoIders with a spanner so that they don't turn
at the same time1
481 Remove the special tool1
491 nstall a new gasket to the timing check plug1
4:1 Tighten the timing check plug to the specified torque1
njection pipe
union nuts
+7 places,
Nuts +5 places,
Bolts +5 places,
4 r 3136 mmor more
Front
view
4 r 3136 mmof less
njection pipe
union nuts
+5< Nm,
Nuts
+4< Nm,
Bolts
+57 Nm,
Gasket
Timing
check plug
+4: Nm,
IDLE SPEED CHECK AND ADJUSTMENT
444334<367:
NOTE
Check that the injection timing is normal
41 Before inspection/ set the vehicle to the pre0inspection
condition1
51 Connect the speedometer to the injection nozzle or the
injection pipe1
Caution
When the speedometer is connected to the injection
pipe/ the pipe mountingcIamps shouIdaII be removed1
61 Start the engine and run it at idle1
71 Check the idle speed1
Standard vaIue= :83 r 433 r2min
81 f not within the standard value/ loosen idle adjusting
screw lock nut and adjust the idle speed by rotating
adjusting screw1 And tighten locking nut1
IDLE0UP MECHANISM CHECK AND
ADJUSTMENT0FOR A2C 44433563365
Refer to GROUP 88 On0vehicle Service1
njection
nozzle
Speedometer
Accelerator lever
dle speed
adjusting screw
Locking
nut
COMPRESSION PRESSURE CHECK 444335939<:
41 Before inspection/ check that the engine oil/ starter and
battery are normal1 n addition/ set the vehicle to the
pre0inspection condition1
51 Remove all of the glow plugs1
Caution
Be carefuI not to subject the gIowpIugs to any shocks1
61 Disconnect the fuel cut valve controller connector1
NOTE
Doing this will prevent carrying out fuel injection1
71 Cover the glow plug hole with a shop towel etc1/ and
after the engine has been cranked/ check that no foreign
material is adhering to the shop towel1
Caution
+4, Keep away fromthe gIowpIug hoIe when cranking
+5, If compression is measured with water/ oiI/ fueI/
etc1/ that has come fromcracks inside the cyIinder/
these materiaIs wiII become heated and wiII gush
out from gIow pIug hoIe/ which is dangerous1
Fuel cut valve
controller
81 Set compression gauge to one of the glow plug holes1
91 Crank the engine and measure the compression pressure1
Standard vaIue +at engine speed of 5;3 r2min,=
6/373 kPa
Limit +at engine speed of 5;3 r2min,= min1 5/533 kPa
:1 Measure the compression pressure for all the cylinders/
and check that the pressure differences of the cylinders
are below the limit1
Limit= max 633 kPa
;1 f 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 +9, and +:,1
+4, f the compression increses after oil is added/ the
cause of the malfunction is a worn or damaged piston
ring and2or cylinder inner surface1
+5, f the compression does not rise after oil is added/
the causeis aburnt or defective valveseat/ or pressure
is leaking from the gasket1
<1 Connect the fuel cut solenoid valve connector or fuel
cut valve controller connector1
431 nstall the glow plugs1
Tightening torque= 4; Nm
TIMING BELT TENSION ADJUSTMENT 444335;3469
41 Remove timing belt upper cover1
51 Turn the crankshaft in the clockwise direction and check
the timing belt around its entire circumference for
abnormalities1
61 Align the timing marks on the sprockets with the timing
marks on the front upper case1
Caution
When aIigning the timing mark/ be sure not to turn
the crankshaft in the countercIockwise direction as
this can cause improper beIt tension1
Compression gauge
Timing marks
Timing marks
71 Loosen the tensioner pivot side bolt 4 turn and slot side
bolt 4 or 5 turns1
81 Turn the crankshaft clockwise and stop at the second
lobe of the camshaft sprocket1
91 First tighten tensioner slot side bolt/ and then tighten
pivot side bolt to the specified torque1
:1 Turn the crankshaft anti0clockwise to align the timing
marks1
;1 Push down belt at a point halfway with a forefinger to
check that tension of belt is up to standard value1
Standard vaIue= 7 - 8 mm
<1 Mount the timing belt upper cover1
TIMING BELT B TENSION ADJUSTMENT
444335;3476
41 Remove timing belt upper cover1
51 Turn the crankshaft in the clockwise direction and check
the timing belt around its entire circumference for
abnormalities1
61 Align the timing marks on the sprockets with the timing
mark on the front upper case1
Caution
When aIigning the timing mark/ be sure not to turn
the crankshaft in the countercIockwise direction as
this can cause improper beIt tension1
Slot side
bolt
Pivot side
bolt
Camshaft sprocket
5 teeth
Timing marks
Timing marks
71 Remove the access cover1
81 Loosen the tensioner pivot side bolt 4 mm and slot side
nut 4 or 5 turns1
91 First tighten tensioner slot side nut/ and then tighten pivot
side bolt to the specified torque1
Tightening torque=
Pivot side boIt 57 Nm
SIot side nut 58 Nm
:1 nstall the access cover while sliding the front lower cover
down along the two guides1
;1 nstall the timing belt upper cover1
Access cover
Pivot
side
bolt
Slot
side
nut
Access cover
Guide
ENGINE ?7D8> - Crankshaft PuIIey 44B04:
CRANKSHAFT PULLEY 44533493759
REMOVAL AND INSTALLATION
Pre0removaI Operation
- Under Cover Removal
Post0instaIIation Operation
- Drive Belt Tension Adjustment +Refer to P144B081,
- Under Cover nstallation
49: - 4;9 Nm
4
5
6
7
8
58 Nm
RemovaI steps
41 Drive belt +for A2C,
51 Drive belt +for power steering,
61 Drive belt +for alternator,
*A A* 71 Crankshaft pulley +for power steering
or A2C,
81 Crankshaft pulley
REMOVAL SERVICE POINT
*ACRANKSHAFT PULLEY REMOVAL
INSTALLATION SERVICE POINT
A*CRANKSHAFT PULLEY INSTALLATION
MD<<;:54
ENGINE ?7D8> - Camshaft and Camshaft OiI SeaI 44B04;
CAMSHAFT AND CAMSHAFT OIL SEAL 445334<3987
Pre0removaI and Post0instaIIation Operation
- ntercooler Removal and nstallation
+Refer to GROUP 481,
67 - 6< Nm
4< - 54 Nm
<1; - 45 Nm
97 - :7 Nm
4
5
6
7
8
Lip
Cam section
and journal
section
:
43
9
:
<
;
81< Nm
67 - 6< Nm
4< - 54 Nm
<
43
<
<
8
7
SeaIant=
6MATDPart No1 ;993 or equivaIent
Engine oiI
Camshaft removaI steps
41 Timing belt upper cover assembly
51 Breather hose connection
61 Boost hose connection
71 Rocker cover
81 Semi0circular packing
*A D* 91 Camshaft sprocket
*B C* :1 Camshaft oil seal
*C B* ;1 Rocker arm and shaft assembly
A* <1 Camshaft bearing cap
431 Camshaft
Camshaft oiI seaI removaI steps
41 Timing belt upper cover assembly
*A D* 91 Camshaft sprocket
*B C* :1 Camshaft oil seal
ENGINE ?7D8> - Camshaft and Camshaft OiI SeaI 44B04<
REMOVAL SERVICE POINTS
*ACAMSHAFT SPROCKET REMOVAL
41 Rotate crankshaft clockwise +to the right, and align timing
marks1
Caution
Never turn the crankshaft anticIockwise1
51 Tie the camshaft sprocket and timing belt together with
cord so that timing mark is not maladjusted1
61 Use the special tool to stop the camshaft sprocket from
turning/ and then remove the camshaft sprocket with the
timing belt still attached1
Caution
Do not rotate crankshaft after removing camshaft
sprocket1
*BCAMSHAFT OIL SEAL REMOVAL
41 Make a notch in the oil seal lip section with a knife/ etc1
51 Cover the end of a +, screwdriver with a rag and insert
into the notched section of the oil seal/ and lever out
the oil seal to remove it1
Caution
BecarefuI not todamagethe camshaft andthecyIinder
head1
*CROCKER ARM AND SHAFT ASSEMBLY REMOVAL
Loosen the rocker arm and shaft assembly mounting bolt/
and then remove the rocker arm and shaft assembly with
the bolt still attached1
Caution
Never disassembIe the rocker arm and shaft assembIy1
Timing marks
No1 4 T1D1C
Cord
Timing belt
Camshaft
sprocket
MB<<3:9:
MD<<;:4<
Lip
section
Oil
seal
Camshaft
+, screwdriver
ENGINE ?7D8> - Camshaft and Camshaft OiI SeaI 44B053
INSTALLATION SERVICE POINTS
A*CAMSHAFT BEARING CAP INSTALLATION
The cap numbers are embossed on the top surface of the
bearing caps/ so install in the order of the numbers1 However/
no numbers are embossed on bearing caps 4 and 81
B*ROCKER ARM AND SHAFT ASSEMBLY
INSTALLATION
41 nstall the rocker arm and shaft assembly to the bearing
caps1
51 Set the washer so that it faces in the direction shown
in the illustration/ and then install the bolt1
61 Check the valve clearance and adjust if necessary1 +Refer
to P144B0;1,
C*CAMSHAFT OIL SEAL INSTALLATION
41 Apply a small amount of engine oil to the entire
circumference of the oil seal lip and camshaft1
51 Use the special tool to tap in the oil seal1
NOTE
The oil seal should be tapped in until the distance from
the end of the camshaft to the end of the oil seal is
as shown in the illustration1
D*CAMSHAFT SPROCKET INSTALLATION
41 Use the special tool in the same way as during removal
to stop the camshaft sprocket from turning/ and then
tighten the bolt to the specified torque1
Tightening torque= 97 - 9: Nm
51 Remove the cord which binds the camshaft sprocket and
timing belt1
Cap No1
Chamfer
MD<<;6;4
Camshaft
Oil seal
ENGINE ?7D8> - OiI Pan and OiI Screen 44B054
OIL PAN AND OIL SCREEN 44533583784
- Under Cover Removal and nstallation
- Crossmember Assembly Removal and nstallation
- Engine Oil Draining and Supplying
+Refer to GROUP 45 On0vehicle Service1,
- Alternator Removal and nstallation +Refer to GROUP
49 Alternator1,
- Stabilizer Bar Removal and nstallation +Refer to
GROUP 66A Stabilizer Bar1,
< Nm
Front of
engine
Groove
I 713 mm
Bolt
hole
SeaIant=
MITSUBISHI GENUINE Part No1
MD<:36;< or equivaIent
9
6< Nm
91< Nm
8
8
5
4
6
4< Nm
7
:
RemovaI steps
41 Drain plug
B* 51 Drain plug gasket
61 Oil return hose connection
71 Oil level sensor
*A A* 81 Oil pan
91 Oil screen
:1 Gasket
*AOIL PAN REMOVAL
41 Remove oil pan bolts1
51 Tap the special tool in between the oil pan and cylinder
block1
61 Slide the special tool by tapping it at an angle to remove
the oil pan1
MD<<;:5: MD<<;:5:
ENGINE ?7D8> - OiI Pan and OiI Screen 44B055
Caution
The use of a screwdriver or chiseI in pIace of the
speciaI tooI can damage the gasket seat surface and
cause oiI Ieakage1
A*OIL PAN INSTALLATION
41 Remove sealant from oil pan and cylinder block mating
surfaces1
51 Degrease the sealant0coated surface and the engine
mating surface1
61 Apply the specified sealant around the gasket surface
of oil pan1
Specified seaIant=
MITSUBISHI GENUINE PART No1 MD<:36;< or
equivaIent
NOTE
The sealant should be applied in a continuous bead
approximately 7 mm in diameter1
71 Assemble oil pan to cylinder block within 48 minutes after
applying the sealant1
Caution
After instaIIing the oiI pan/ wait at Ieast 4 hour before
starting the engine1
B*DRAIN PLUG GASKET INSTALLATION
nstall a new gasket in the direction so that it faces as shown
in the illustration1
INSPECTION 44533593374
- Check oil pan for cracks1
- Check oil pan sealant0coated surface for damage and
deformation1
- Check oil screen for cracked/ clogged or damaged wire
net and pipe1
Drain plug
gasket
Oil pan side
ENGINE ?7D8> - CyIinder Head Gasket 44B056
CYLINDER HEAD GASKET 44533734364
- ntake and Exhaust Manifold Removal
- Timing Belt Removal +Refer to P144B0591,
- Engine Coolant Draining
- Timing Belt nstallation +Refer to P144B0591,
- ntake and Exhaust Manifold nstallation
- Fuel Line Air Bleeding
+Refer to GROUP 46B On0vehicle Service1,
- Engine Coolant Filling
5< Nm
5< Nm
5< Nm
71< Nm
43 mm 43 mm
<
44
43
81< Nm
71< Nm
43
6
5
55 Nm
71< Nm
9
7
;
:
4
47
46
45
446 - 456 Nm
<
8
57 Nm
55 Nm
SeaIant=
6M ATD Part No1 ;993 or
equivaIent
RemovaI steps
41 Engine coolant temperature switch
connector +for A2C,
51 Engine coolant temperature gauge
unit and sensor connector
61 Glow plug terminal
*A C* 71 Radiator upper hose
*B D* 81 Fuel injection pipe
91 Heater hose or water by0pass hose
connection
:1 Fuel hose connection
;1 Earth cable connection
<1 Rocker cover
431 Semi0circular packing
*C 441 Power steering oil pump assembly
451 Power steering oil pump bracket
bolt
*D B* 461 Cylinder head assembly
A* 471 Cylinder head gasket
*ARADIATOR UPPER HOSE DISCONNECTION
After making mating marks on the radiator upper hose and
the hose clamp/ disconnect the radiator upper hose1
*BFUEL INJECTION PIPE REMOVAL
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 nut1
Caution
After disconnecting the injection pipe/ pIug the opening
so that no foreign particIes get inside the pump or into
the injection nozzIe1
*CPOWER STEERING OIL PUMP REMOVAL
Remove the power steering oil pump from the bracket with
the hose attached1
NOTE
Place the removed power steering oil pump in a place where
it will not be a hindrance when removing and installing the
engine assembly/ and tie it with a cord1
*DCYLINDER HEAD ASSEMBLY REMOVAL
Use the special tool to tighten each bolt 5 6 times in the
order shown in the illustration1
Delivery holder
Nut
Front
MD<<;384
A*CYLINDER HEAD GASKET INSTALLATION
41 Wipe off any oil or grease from the gasket mounting
surface1
51 Check the rank from the number of identification holes
on the cylinder head gasket that was removed/ and select
a cylinder head gasket of the same rank1
NOTE
The ranks are listed in the parts catalogue1
61 Place the cylinder head gasket on top of the cylinder
block so that the identification mark is facing upwards
as in the illustration1
B*CYLINDER HEAD INSTALLATION
Use the special tool to tighten each bolt 5 6 times in the
order shown in the illustration1
Caution
The head boIt washer shouId be instaIIed so that the
burred side is facing upwards1
C*RADIATOR UPPER HOSE CONNECTION
To reuse the radiator upper hose/ align the mating marks
that were made during removal/ and then install the hose
clamp1
D*FUEL INJECTION PIPE 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 specified torque1
dentification mark
Rank
dentifi0
cation
holes
A B C D E
MD<<;384
Head bolt
washer
Front
Burred
side
ENGINE ?7D8> - Timing BeIt and Timing B 44B059
TIMING BELT AND TIMING BELT B 44533763:<7
- Cooling Fan Removal +Refer to GROUP 471,
- Cooling Fan nstallation +Refer to GROUP 471,
- Engine Adjustment +Refer to P144B081,
<1; - 45 Nm
<1; - 45 Nm
58 Nm
58 Nm
49: - 4;9 Nm
57 Nm
4
9
49
48
47
46
45
44 43
6
7
<
;
:
58 Nm
8
5
58 Nm
RemovaI steps
41 Timing belt front upper cover
51 Tension pulley bracket +for A2C,
61 Crankshaft pulley +for power steering
and A2C,
*A C* 71 Crankshaft pulley
81 Timing belt front lower cover
*B B* 91 Timing belt
:1 Tensioner spacer
;1 Tensioner spring
<1 Timing belt tensioner assembly
431 Crankshaft sprocket
441 Flange
*C A* 451 Timing belt B
461 Gasket
471 Tensioner spacer B
481 Tensioner spring B
491 Timing belt tensioner B
ENGINE ?7D8> - Timing BeIt and Timing BeIt B 44B05:
*ACRANKSHAFT PULLEY REMOVAL
41 Position the No1 4 cylinder at compression TDC and
remove the crankshaft pulley1
NOTE
The No1 4 cylinder is at compression TDCwhen the marks
are aligned as shown in the figure1
51 Use the special tool to keep crankshaft from turning and
remove the bolts1
*BTIMING BELT REMOVAL
41 When reinstalling timing belt/ mark an arrow at the belt
to show rotation direction1
51 Loosen the tensioner mounting bolt A and B1
61 Push timing belt tensioner to water pump side and tighten
the tensioner mounting bolt A and B1 Secure so that
tensioner will not move back1
*CTIMING BELT B REMOVAL
41 When reinstalling timing belt B/ mark an arrow at the
belt to show rotation direction1
51 Loosen the tensioner mounting bolt and nut1
61 Push timing belt tensioner to water pump side and tighten
the tensioner mounting bolt and nut1 Secure so that
tensioner will not move back1
A*TIMING BELT B INSTALLATION
41 Align the timing marks of the 6 sprockets1
51 When reusing timing belt B/ make sure the arrow mark
is pointing in the same direction as when the belt was
removed1
Timing marks
MD<<;:54
Tilt to water pump side
Tensioner
mounting
bolt A
Tensioner
mounting
bolt B
Water pump
Tensioner
mounting
bolt
Tensioner
mounting nut
Timing mark
Tensioner
Timing marks
Timing belt
ENGINE ?7D8> - Timing BeIt and Timing BeIt B 44B05;
61 nstall timing belt B and make sure there is no deflection
on the tension side1
71 Press the deflection side of timing belt B +indicated by
arrow +A,, with the hand and fully stretch the tensioner
side1
81 Make sure that the timing marks are aligned1
91 Loosen the tensioner mounting bolt and nut so that only
the pressure of the spring is applied to timing belt B1
:1 Tighten the tensioner mounting bolt and nut/ tightening
the nut first1 f the bolt is tightened first/ the tensioner
will move and tension the belt1
;1 Press in the direction of the arrow in the figure with the
index finger to check the amount of deflection1
B*TIMING BELT INSTALLATION
41 Align the timing marks of the 6 sprockets1
51 When reusing timing belt/ make sure the arrow mark is
pointing in the same direction as when the belt was
removed1
61 nstall the timing belt tothe crankshaft sprocket/ toinjection
pump sprocket/ to tensioner and to camshaft sprocket
in that order1 Being careful not to allow deflection on
the tension side of the timing belt1
Caution
+4, Engage the beIt on the various sprockets whiIe
maintaining tension on the beIt of tension side1
+5, AIign the injection pump sprocket with the timing
mark/ hoId the sprocket so that is does not turn
and engage the beIt1
Timing mark
Tensioner
Timing marks
57 Nm
Tension side
58 Nm
Timing belt
A
Counterbalance
shaft sprocket
Belt deflection
Crankshaft
sprocket B
Tension
side
Water pump
Tension side
ENGINE ?7D8> - Timing BeIt and Timing BeIt B 44B05<
71 Loosen the tensioner mounting bolts and apply tension
with the spring1
81 Turn the crankshaft clockwise and stop at the second
lobe of the camshaft sprocket1
Caution
+4, When turning the crankshaft in item +8,/ strictIy
observe the specified amount of rotation +5 teeth
on the camshaft sprocket, in order to appIy a
constant force to the tension side of the beIt1
+5, Do not turn the crankshaft countercIockwise1
+6, Do not touch the beIt during adjustment1
91 Make sure that the part indicated by arrow A does not
float upward1
:1 Tighten the tensioner mounting bolts/ starting with the
bolt in the elongated hole1 f the lower bolt is tightened
first/ belt tension will become too tight1
;1 Turn the crankshaft anticlockwise and align the timing
mark1 Next/ make sure that the timing marks of all
sprockets are aligned1
<1 Press on the centre of the bolt with an index finger to
check the amount of deflection1
C*CRANKSHAFT PULLEY INSTALLATION
Using the special tool to install the crankshaft pulley as same
as removal procedure1
Camshaft sprocket
5 teeth
Belt deflection
Tensioner
A
Tensioner
mounting bolt
Tensioner
mounting bolt
Amount of belt deflection
ENGINE ?7D8> - Crankshaft Front OiI SeaI 44B063
CRANKSHAFT FRONT OIL SEAL 44533673788
- Timing Belt and Timing Belt "B Removal and
nstallation +Refer to P144B0591,
4
5
+Engine oil,
RemovaI steps
41 Crankshaft sprocket B
*A A* 51 Oil seal
*AOIL SEAL REMOVAL
41 Cut out a portion in the crankshaft oil seal lip1
51 Cover the tip of a screwdriver with a cloth and apply
it to the cutout in the oil seal to pry off the oil seal1
Caution
Be carefuI not to damage the crankshaft and front
case1
A*OIL SEAL INSTALLATION
Apply engine oil to the outside of the special tool +MD<<;6;6,
and to the oil seal lip/ and use the special tool to press0fit
the oil seal1
Lip
portion
Oil seal
Screwdriver
Camshaft
Oil seal
Crankshaft
MD<<;6;5
+Apply oil to outer
surface,
Front
lower
case
Oil
pump
drive
shaft
MD<<;6;6
ENGINE ?7D8> - Crankshaft Rear OiI SeaI 44B064
CRANKSHAFT REAR OIL SEAL 445336:3893
- Oil Pan Removal and nstallation +Refer to P1440541,
- Transmission Assembly Removal and nstallation
9
;
45: - 46: Nm
8
:
7
6
5
4
+Engine oil,
RemovaI steps
41 Adapter
*A C* 51 Flywheel assembly
61 Crankshaft adaptor
71 Ball bearimg
81 Oil seal case
91 Gasket
B* :1 Oil separator
A* ;1 Oil seal
*AFLYWHEEL ASSEMBLY REMOVAL
Use the special tool to secure the flywheel assembly and
remove the bolt1
A*OIL SEAL INSTALLATION
MD<<;:;4
MD<<;6:9
ENGINE ?7D8> - Crankshaft Rear OiI SeaI 44B065
B*OIL SEPARATOR INSTALLATION
nstall the oil separator in such a way that its oil hole come
at the case bottom +indicated by an arrow in the illustration,1
C*FLYWHEEL ASSEMBLY INSTALLATION
Use the special tool in the same way as during removal to
stop the flywheel assembly from turning/ and then tighten
the bolt to the specified torque1
Tightening torque= 45: - 46: Nm
Oil seal case Oil separator
Oil pan mounting surface
Oil hole
ENGINE ?7D8> - Engine AssembIy 44B066
ENGINE ASSEMBLY 44533433<;8
- Hood Removal +Refer to GROUP 751,
- ntercooler Removal +Refer to GROUP 481,
- Air Cleaner and Air ntake Hose Removal
- Brake Master Cylinder Heat Protector Removal
- Battery Removal
- Radiator Removal +Refer to GROUP 471,
- Transmission and Transfer Assembly Removal
- Transmission and Transfer Assembly nstallation
- Radiator nstallation +Refer to GROUP 471,
- Battery installation
- Brake Master Cylinder Heat Protector nstallation
- Air Cleaner and Air ntake Hose nstallation
- ntercooler nstallation
- Hood nstallation +Refer to GROUP 751,
- Drive Belt Tension Adjustment +Refer to P144B081,
- Accelerator Cable Adjustment
+Refer to GROUP 4: On0vehicle Service1,
;1; Nm
45 Nm
71< Nm
4
5
6
45
44
9
43
8
< ;
:
9
8
7
RemovaI steps
41 Engine coolant temperature sensor
and gauge unit connector
51 Earth cable connector
61 Glow plug terminal
71 Earth cable connector
81 Vacuum hose connection +for A2C,
91 Vacuum hose connection +for ABS,
:1 Brake booster vacuum hose
connection
;1 Accelerator cable connection
<1 Heater hose connections
431 Fuel cut solenoid valve or fuel cut
valve controller connector
441 Revolution pick0up sensor connector
451 Engine coolant temperature switch
connector +for A2C,
77 Nm
67 Nm
55 Nm
<1; Nm
56
57
56 55
48
49
53
54
47
46
55 Nm
63 Nm
47 Nm
4:
4;
55 Nm
4<
461 Drive belt +for Power steering,
*A 471 Power steering oil pump assembly
481 Drive belt +for A2C,
*A 491 A2C compressor assembly
4:1 Engine oil pressure switch
connector
4;1 Alternator connector
4<1 Engine oil cooler hose connection
531 Fuel hose connections
541 Front exhaust pipe connection
551 Heat protector
561 Engine support front insulator
attaching bolt
*B A* 571 Engine assembly
*APOWER STEERING OIL PUMP ASSEMBLY AND
A2C COMPRESSOR ASSEMBLY REMOVAL
41 Remove the oil pump and A2C compressor +with the hose
attached,1
51 Suspend the removed oil pump +by using wire or similar
material, at a place where no damage will be caused
during removal2installation of the engine assembly1
*BENGINE ASSEMBLY REMOVAL
41 Check that all cables/ hoses/ harness connectors/ etc1
are disconnected from the engine1
51 Lift the chain block slowly to remove the engine assembly
upward from the engine compartment1
A*ENGINE ASSEMBLY INSTALLATION
nstall the engine assembly1 When doing so/ check carefully
that all pipes and hoses are connected/ and that none are
twisted/ damaged/ etc1
NOTES
11B-1
ENGINE <4D5>
CONTENTS
GENERAL 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline of Changes 2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION 2 . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATION 2 . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 3 . . . . . . . . . . . . . . . . . . . . .
Injection Timing Check and Adjustment 3 . . . . . . . . .
Idle Speed Check 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PAN <4D56-Step III> 4 . . . . . . . . . . . . . . . . . .
CYLINDER HEAD GASKET
<4D56-Step III> 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIMING BELT AND TIMING BELT B
<4D56-Step III> 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE <4D5> - General/General Information/Service Specification 11B-2
GENERAL
OUTLINE OF CHANGES
Since the electronically-controlled type fuel injection pump has been adopted, injection timing check and
adjustment procedure and the idle speed check procedure have been established.
D Oil pan cover has been adopted. <4D56-Step III>
D The tightening torque of the cylinder head bolts and the cylinder head gasket have been changed.
<4D56-Step III>
GENERAL INFORMATION
Items 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
Valve timing Intake Opening BTDC 20, Closing ABDC 49
Exhaust Opening BBDC 55, Closing ATDC 22
Fuel system Electronically controlled type injection pump
Rocker arm Roller type
Adjusting screw Elephant foot type
SERVICE SPECIFICATION
Item Standard value Limit
Idle speed r/min 750 30 -
ENGINE <4D5> - Special Tools/On-vehicle Service 11B-3
SPECIAL TOOLS
Tools Number Name Use
MB991502 MUT-II sub
assembly
D Checking the ignition timing
D Checking the idle speed
MD998051 Cylinder head bolt
wrench
Removal and installation of the cylinder head
bolt
MB991614 Angle gauge Tightening of the cylinder head bolts
ON-VEHICLE SERVICE
INJECTION TIMING CHECK AND
ADJUSTMENT
Due to the adoption of the electronically-controlled injection
pump, the cold start device (wax-type) has been discontinued.
The other inspection and adjustment are the same as before.
IDLE SPEED CHECK
1. Set the vehicle to the pre-inspection condition.
2. Turn the ignition switch to LOCK (OFF) position, and
connect the diagnosis connector to the MUT-II.
If the MUT-II 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, refer
to 13E - Troubleshooting to check the electronically
controlled fuel injection system.
NOTE
The idle speed is controlled by the engine-ECU.
MUT-II
Tachometer
Injection
nozzle
ENGINE <4D5> - Oil Pan <4D56-Step III> 11B-4
OIL PAN <4D56-Step III>
9.0 1.0 Nm
Oil pan cover
ENGINE <4D5> - Cylinder Head Gasket <4D56-Step III>
11B-5
CYLINDER HEAD GASKET <4D56-Step
III>
CYLINDER HEAD GASKET AND CYLINDER HEAD
INSTALLATION
1. Wipe off any oil or grease from the gasket mounting
surface.
2. If you replace the cylinder head gasket only, check the
identification mark of the cylinder head gasket removed,
select the cylinder head gasket that has same
identification mark (size) from the table below.
Spec Identification mark (size) Parts number
A D5- 774 (Thickness on tightening:
1.45 0.04)
MD377774
B D5- 775 (Thickness on tightening:
1.50 0.04)
MD377775
C D5- 776 (Thickness on tightening:
1.55 0.04)
MD377776
Caution
The cylinder head gasket whose thickness is in size
with piston projection is attached. Soif youreplace the
piston or the connecting rod, the piston projection
changes. Measure the piston projection, select the
cylinder head gasket whose thickness is in size with
piston projection should be fitted.
3. Install the cylinder head gasket in order to fit the cylinder
head gasket bore to the cylinder head bore.
4. Clean the cylinder head assembly and the cylinder block
mating surfaces with a scraper or a wire brush.
Caution
Do not allow foreign material to enter the engine
coolant or oil passages and the cylinder.
5. Install the cylinder head bolt washer to the cylinder head
bolt so that the washer chamfered side faces as shown.
6. Apply a small amount of engine oil to the cylinder head
bolt thread and the washer.
Identification mark
A
B
C
Cylinder head
bolt washer
Chamfered
side
ENGINE <4D5> - Cylinder Head Gasket <4D56-Step III>
11B-6
7. Tighten the cylinder head bolts according to the following
procedure (angle-tightening procedure).
(1) Use the special tool to tighten the cylinder head bolts
in the order of the illustrated numbers to 29 2 Nm.
(2) Place the special tool in a wrench to tighten the
cylinder head bolt in the order of the illustrated
numbers to 120_.
16
9
MD998051
Front of engine
18
17
15
13
12
11
10 8
7
6
5
4
3
2
1
14
16
9
MD998051
Front of engine
18
17
15
13
12
11
10 8
7
6
5
4
3
2
1
14
MB991614
ENGINE <4D5> - Timing Belt and Timing Belt B <4D56-Step III> 11B-7
TIMING BELT AND TIMING BELT B <4D56-Step III>
Pre-removal Operation
D Cooling Fan Removal
Post-installation Operation
D Cooling Fan Installation
D Engine Adjustment
1
6
16
15
14
13
12
11
10
3
4
9
8
7
5
2
17
25 4 Nm
11 1 Nm
11 1 Nm
26 3 Nm
26 3 Nm
26 3 Nm
185 5 Nm
Removal steps
1. Timing belt front upper cover
2. Tension pulley bracket (for A/C)
3. Crankshaft pulley (for power steering
and A/C)
AA" "CA 4. Crankshaft pulley
5. Timing belt front lower cover
AB" "BA 6. Timing belt
7. Tensioner spacer
8. Tensioner spring
9. Timing belt tensioner assembly
10. Crankshaft sensing blade
11. Crankshaft sprocket
12. Flange
AC" "AA 13. Timing belt B
14. Gasket
15. Tensioner spacer B
16. Tensioner spring B
17. Timing belt tensioner B
NOTE
Follow the conventional procedures for removal
and installation service points.
NOTES

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