Mitsubishi Motors Automobile Parts 4d68 User Manual
11A-0-1  
ENGINE  
4D68  
CONTENTS  
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
11A-0-3  
11A-1-1  
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-1  
REWORK DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-3  
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-4  
NEW TIGHTENING METHOD - BY USE OF BOLTS  
TO BE TIGHTENED IN PLASTIC AREA . . . . . . . . . . . . . . . . 11A-1-7  
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
FORM-IN-PLACE GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-1-8  
2. SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
3. DRIVE BELT AND GLOW PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-3-1  
11A-1-7  
11A-2-1  
4. TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
11A-4-1  
5. GLOW PLUG, FUEL INJECTION PUMP  
AND INJECTION NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-5-1  
6. INTAKE AND EXHAUST MANIFOLDS . . . . . . . . . . . . . . . . . . . . 11A-6-1  
7. WATER PUMP, THERMOSTAT, HOSE AND PIPES . . . . . . 11A-7-1  
8. ROCKER ARMS, ROCKER SHAFT AND CAMSHAFT . . . 11A-8-1  
9. CYLINDER HEAD, VALVES AND VALVE SPRINGS . . . . . 11A-9-1  
10. FRONT CASE, COUNTERBALANCE SHAFTS  
AND OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-10-1  
11. PISTONS AND CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . 11A-11-1  
12. CRANKSHAFT, CYLINDER BLOCK AND FLYWHEEL . . . 11A-12-1  
Mitsubishi Motors Corporation  
Dec. 1996  
PWEE9609  
E
11A-0-3  
4D68 ENGINE (E-W) - General Information  
GENERAL INFORMATION  
SECTIONAL VIEW OF ENGINE  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-0-4  
4D68 ENGINE (E-W) - General Information  
SECTIONAL VIEW OF ENGINE  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-0-5  
4D68 ENGINE (E-W) - General Information  
GENERAL SPECIFICATIONS  
Descriptions  
Specifications  
Type  
Diesel engine  
Number of cylinders  
Combustion chamber  
Total displacement dm3  
Cylinder bore mm  
Piston stroke mm  
Compression ratio  
4 in-line  
Swirl chamber  
1.998  
82.7  
93  
22.4  
Valve timing  
Intake valve  
Opens (BTDC)  
Closes (ABDC)  
Opens (BBDC)  
Closes (ATDC)  
20°  
48°  
Exhaust valve  
54°  
22°  
Lubrication system  
Oil pump type  
Cooling system  
Water pump type  
EGR type  
Pressure feed, full-flow filtration  
External gear type  
Water-cooled  
Centrifugal impeller type  
Single type  
Fuel system  
Electronic control distributor-type injection pump  
Supercharging  
Rocker arm  
Turbocharger  
Roller type  
Adjusting screw  
Oil lever sensor  
Elephant foot type  
Provided  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-1-1  
4D68 ENGINE (E-W) - Specifications  
1. SPECIFICATIONS  
SERVICE SPECIFICATIONS  
Item  
Standard value  
0.5  
Limit  
Drive belt and glow plug  
Glow plug resistance W  
Timing belt  
-
Timing belt deflection mm  
Timing belt “B” deflection mm  
Rocker arms, rocker shaft and camshaft  
Camshaft cam height mm  
4.0-5.0  
5.0-7.0  
-
-
Intake  
41.90  
41.96  
0.25  
41.40  
Exhaust  
Intake  
41.46  
Valve clearance (on cold engine) mm  
-
-
-
Exhaust  
0.35  
Camshaft journal O.D. mm  
30.0  
Cylinder head, valves and valve springs  
Cylinder head gasket surface flatness mm  
Cylinder head overall height mm  
Valve overall length mm  
Within 0.03  
86.9-87.1  
114.05  
113.80  
1.5  
0.2  
-
Intake  
113.55  
Exhaust  
113.30  
Thickness of valve head (margin) mm  
Valve stem O.D. mm  
0.7  
6.0  
-
Valve face angle  
45°-45.5°  
0.05-0.09  
49.1  
-
Valve stem to guide clearance mm  
Valve spring free length mm  
0.15  
48.1  
Valve load/installed height N/mm  
Valve spring out-of-squareness  
240/37.9  
2° or less  
0.9-1.3  
43.45  
-
Max. 4°  
Valve seat valve contact width mm  
Valve stem projection mm  
-
43.95  
Valve guide I.D. mm  
8.0  
-
Valve guide projection from cylinder head upper surface mm  
Cylinder head bolt shank length mm  
Front case, counterbalance shafts and oil pan  
Oil cooler by-pass valve dimension (L) [Normal temperature] mm  
15  
-
-
119.7  
34.5  
-
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-1-2  
4D68 ENGINE (E-W) - Specifications  
Item  
Standard value  
Limit  
-
Oil cooler by-pass valve dimension (L) [by-pass hole closing temperature 40.0  
(97- 103°C or more)] mm  
Oil pump side clearance  
Drive gear  
0.08-0.14  
-
-
Driven gear 0.06-0.12  
Pistons and connecting rods  
Piston O.D. mm  
82.7  
-
Piston ring to piston ring groove clearance mm  
No. 1  
No. 2  
No. 1  
No. 2  
Oil ring  
0.05-0.07  
0.05-0.07  
0.20-0.32  
0.35-0.50  
0.10-0.30  
25.0  
0.15  
0.15  
0.8  
0.8  
0.8  
-
Piston ring end gap mm  
Piston pin O.D. mm  
Crankshaft pin oil clearance mm  
Connecting rod big end side clearance mm  
Connecting rod bushing I.D. mm  
0.02-0.05  
0.10-0.25  
25.015-25.025  
0.1  
0.4  
-
Connecting rod bushing bend (Parallelism between big end center line and small 0.05  
end center line) mm  
-
Connecting rod bushing twist (Deflection between big end center line and small 0.1  
end center line) mm  
-
Crankshaft, cylinder block and flywheel  
Crankshaft end play mm  
0.05-0.18  
0.25  
Crankshaft journal O.D. mm  
Crankshaft pin O.D. mm  
57.0  
-
45.0  
-
Crankshaft journal oil clearance mm  
Cylinder block gasket surface flatness mm  
Cylinder block overall height mm  
Cylinder bore I.D. mm  
0.02-0.04  
0.05  
0.1  
0.1  
235  
-
-
-
-
-
-
82.70-82.73  
0.01  
Cylinder conicity mm  
Piston to cylinder clearance mm  
Cylinder sleeve press-fitting force N  
Piston projection mm  
0.03-0.05  
2,200 or more  
0.823  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-1-3  
4D68 ENGINE (E-W) - Specifications  
REWORK DIMENSIONS  
Item  
Standard value  
Limit  
Cylinder head, valves and valve springs  
Cylinder head oversize valve guide hole  
(both intake and exhaust) mm  
0.05 O.S.  
0.25 O.S.  
0.50 O.S.  
0.3 O.S.  
0.6 O.S.  
13.050-13.068  
13.250-13.268  
13.500-13.518  
38.300-38.325  
38.600-38.625  
34.300-34.325  
34.600-34.625  
-
-
-
-
-
-
-
Cylinder head oversize intake valve seat ring hole mm  
Cylinder head oversize exhaust valve seat ring hole mm 0.3 O.S.  
0.6 O.S.  
NOTE  
O.D.: Outer diameter  
I.D.: Inner diameter  
O.S.: Oversize diameter  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-1-4  
4D68 ENGINE (E-W) - Specifications  
TORQUE SPECIFICATIONS  
Items  
Nm  
Drive belt and glow plug  
Oil level gauge guide bolt  
Pulley bolt (for power steering pump drive)  
Alternator brace bolt  
Lock bolt  
13  
9
23  
23  
10  
44  
25  
18  
1.8  
Adjusting bolt  
Alternator pivot nut  
Crankshaft pulley bolt  
Glow plug  
Glow plug nut  
Timing belt  
Timing belt cover  
Flange bolt  
Washer bolt  
11  
9
Crankshaft position sensor bolt  
Timing belt tensioner bolt  
Tensioner spring bolt  
9
48  
13  
48  
88  
9
Timing belt idler pulley bolt  
Camshaft sprocket bolt  
Injection pump sprocket flange bolt  
Injection pump sprocket nut  
Crankshaft bolt  
83  
118  
54  
18  
45  
11  
49  
Oil pump sprocket nut  
Tensioner “B” bolt  
Counterbalance shaft sprocket bolt  
Timing belt rear cover bolt  
Engine support bracket bolt and nut  
Glow plug, fuel injection pump and injection nozzle  
Injection pipe  
29  
5
Injection pipe clamp bolt  
Fuel pipe bolt  
13  
18  
23  
18  
35  
29  
Engine hanger bolt  
Fuel injection pump bolt  
Fuel injection pump nut  
Fuel injection pump stay bolt  
Fuel return pipe nut  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-1-5  
4D68 ENGINE (E-W) - Specifications  
Items  
Nm  
54  
Injection nozzle  
Fuel injection pump bracket nut  
Intake and exhaust manifold  
Air temperature sensor  
Air intake fitting bolt  
23  
14  
17  
24  
17  
13  
11  
13  
30  
10  
16  
59  
9
EGR valve bolt  
EGR pipe bolt and nut  
Turbocharger heat protector bolt  
M8  
M6  
Exhaust fitting heat protector bolt  
Water pipe “A” and “B” eye bolt  
Water pipe “A” and “B” bolt  
Oil pipe eye bolt  
Exhaust fitting bolt and nut  
Oil return pipe bolt  
Heat protector front and rear bolt  
Turbocharger assembly bolt  
Exhaust manifold bolt and nut  
Alternator brace stay bolt  
Intake manifold bolt and nut  
Water pump, thermostat, hose and pipe  
Oil pipe eye bolt  
13  
59  
29  
23  
17  
16  
17  
9
Oil return pipe eye bolt  
Oil return pipe bolt  
Engine coolant temperature sensor  
Engine coolant temperature gauge unit  
Cover bolt  
35  
11  
19  
13  
12  
22  
23  
12  
23  
Water pump bolt  
Water inlet pipe bolt  
Vacuum pump bolt  
Water inlet fitting bolt  
Water outlet fitting bolt  
Thermostat housing bolt  
Rocker arms, rocker shaft and camshaft  
Rocker cover bolt  
6
Rocker shaft bolt  
29  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-1-6  
4D68 ENGINE (E-W) - Specifications  
Items  
Nm  
15  
Adjusting nut  
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  
9
Oil level sensor bolt  
Oil pan bolt  
7
Oil screen bolt  
19  
54  
10  
44  
18  
23  
36  
24  
16  
10  
Oil cooler by-pass valve  
Oil pressure switch  
Relief plug  
Oil filter bracket bolt  
Plug  
Flange bolt  
Front case bolt  
Oil pump cover  
Bolt  
Screw  
Pistons and connection rods  
Connecting rod cap nut  
20  
¯
+90° - 100°  
Crankshaft, cylinder block and flywheel  
Flywheel bolt  
132  
11  
Rear plate bolt  
Oil seal case bolt  
11  
Bearing cap bolt  
25  
¯
+90° - 100°  
Check valve  
15  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-1-7  
4D68 ENGINE (E-W) - Specifications  
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.  
D
Areas where the bolts are in use:  
(1) Cylinder head bolts  
(2) Main bearing cap bolts  
(3) Connecting rod cap bolts  
D
Tightening method  
After tightening the bolts to the specified torque, tighten them another 90° or 180° (twice 90°). The  
tightening method varies on different areas. Observe the tightening method described in the text.  
SEALANT  
Items  
Specified sealant  
Quantity  
Thermostat housing  
Mitsubishi Genuine Part No. MD970389 or equivalent  
As required  
As required  
Engine coolant temperature 3M Nut Locking Part No. 4171 or equivalent  
gauge unit  
Oil pressure switch  
Water outlet fitting  
Oil pan  
3M ATD Part No. 8660 or equivalent  
As required  
As required  
As required  
As required  
As required  
As required  
Mitsubishi Genuine Part No. MD970389 or equivalent  
Mitsubishi Genuine Part No. MD970389 or equivalent  
Mitsubishi Genuine Part No. MD970389 or equivalent  
Mitsubishi Genuine Part No. MD970389 or equivalent  
3M ATD Part No. 8660 or equivalent  
Oil seal case  
Cover  
Camshaft bearing cap  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
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. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to  
apply the gasket evenly without a break, while observing the correct bead size.  
The FIPG used in the engine is a room temperature vulcanization (RTV) type and is supplied in a 100-gram  
tube (Part No. MD970389 or MD997110). Since the RTV hardens as it reacts with the moisture in the  
atmospheric air, it is normally used in the metallic flange areas. The FIPG, Part No. MD970389, can  
be used for sealing both engine oil and coolant, while Part No. 997110 can only be used for engine  
oil sealing.  
Disassembly  
The parts assembled with the FIPG can be easily disassembled without use of a special method. In  
some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking  
with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the  
joined surfaces. In this case, however, case must be taken to prevent damage to the joined surfaces.  
For removal of the oil pan, the special tool “Oil Pan Remover” (MD998727) is available. Be sure to use  
the special tool to remove the oil pan.  
Surface Preparation  
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper  
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure  
that there are no oils, greases and foreign substances deposited on the application surfaces. Do not  
forget to remove the old sealant remained in the bolt holes.  
Form-In-Place Gasket Application  
When assembling parts with the FIPG, you must observe some precautions, but the procedures is very  
simple as in the case of a conventional precut gasket.  
Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the  
bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is  
hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When  
the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do  
not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time  
(about one hour) has passed after installation is completed.  
The FIPG application procedure may vary on different areas. Observe the procedure described in the  
text when applying the FIPG.  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-2-1  
4D68 ENGINE (E-W) - Special Tools  
2. SPECIAL TOOLS  
Tool  
Number  
Name  
Use  
MB990767  
MB991603  
MD990938  
MB991654  
MD998115  
MD998162  
MD998285  
MD998371  
MD998372  
End yoke holder  
Holding camshaft sprocket or fuel injection  
pump when loosening or tightening bolts.  
Use with MD998719  
Bearing installer  
stopper  
A guide for removal and installation of  
counterbalance shaft left rear bearing  
Handle  
Installation of crankshaft rear oil seal  
(Use with MD998776)  
Cylinder head bolt Tightening and loosening of cylinder head bolt  
wrench  
Valve guide  
installer  
Removal and installation of valve guide  
Plug wrench  
Removal and installation of front case cap plug  
(Use with MD998783)  
Crankshaft front oil Guide for installation of crankshaft front oil seal  
seal guide  
Silent shaft bearing Removal of counterbalance shaft front bearing  
puller  
Silent shaft bearing Removal of counterbalance shaft rear bearing  
puller  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-2-2  
4D68 ENGINE (E-W) - Special Tools  
Tool  
Number  
Name  
Use  
MD998375  
Crankshaft front oil Installation of crankshaft front oil seal  
seal installer  
MD998388  
MD998702  
MD998705  
MD998713  
MD998719  
MD998727  
MD998729  
MD998772  
Injection pump  
sprocket puller  
Removal of injection pump sprocket  
Connecting-rod  
small-end bushing bushing  
replacement tool  
Replacement of connecting-rod small-end  
Silent shaft bearing Installation of counterbalance shaft bearing  
installer  
Camshaft oil seal Installation of camshaft oil seal  
installer  
Pulley holder pin Use with MB990767  
(2)  
Oil pan sealer  
cutter  
Removal of oil pan  
Valve stem seal Installation of valve stem seal  
installer  
Valve spring  
compressor  
Compression of valve spring  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-2-3  
4D68 ENGINE (E-W) - Special Tools  
Tool  
Number  
Name  
Use  
MD998776  
Crankshaft rear oil Installation of crankshaft rear oil seal  
seal installer  
(Use with MB990938)  
MD998778  
MD998781  
MD998783  
MD998785  
Crankshaft  
Removal of crankshaft sprocket  
sprocket puller  
Flywheel stopper  
Holding of flywheel and drive plate  
Plug wrench  
retainer  
Removal and installation of front case cap plug  
(Use with MD998162)  
Sprocket stopper  
Holding of counterbalance shaft sprocket  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-3-1  
4D68 ENGINE (E-W) - Drive Belt and Glow Plug  
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  
7
9
6
23 Nm  
9 Nm  
10  
5
25 Nm  
DEN0885  
Removal steps  
1. Oil level gauge  
2. O-ring  
7. Water pump pulley  
8. Alternator brace  
9. Alternator  
3. Oil level gauge guide  
4. O-ring  
10. Crankshaft pulley  
11. Glow plug plate  
5. Drive belt (V-type)  
6. Pulley (for power steering pump  
drive)  
AA" "AA 12. Glow plug  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
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.  
INSTALLATION SERVICE POINTS  
"AA GLOW PLUG INSTALLATION  
(1) When installing the glow plug, screw in one thread or  
more with fingers and then tighten with a tool.  
Caution  
D
Do not reuse a glow plug that has been dropped  
from a height of 10 cm or more.  
INSPECTION  
GLOW PLUG  
(1) Check the glow plugs for continuity between the terminal  
and the body as shown. Replace the glow plugs which  
show no continuity or too large a resistance.  
Standard value: 0.5 W  
DEL034  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-4-1  
4D68 ENGINE (E-W) - Timing Belt  
4. TIMING BELT  
REMOVAL AND INSTALLATION  
27  
11 Nm  
26  
28  
23  
21  
48 Nm  
5
6
11  
11 Nm  
45 Nm  
14  
22  
25  
88 Nm  
83 Nm  
10  
9 Nm  
9
49 Nm  
8
20  
7
48 Nm  
24  
13  
13 Nm  
17  
18 Nm  
18  
1
12  
11 Nm  
19  
54 Nm  
15  
16  
118 Nm  
3
4
2
9 Nm  
9 Nm  
DEN0886  
Removal steps  
1. Timing belt front upper cover  
2. Timing belt front center cover  
3. Timing belt front lower cover  
4. Crankshaft position sensor  
AE" "EA 15. Crankshaft bolt  
16. Special washer  
AF"  
17. Crankshaft sprocket  
18. Crankshaft sensing blade  
AA" "IA 5. Timing belt  
AG" "DA 19. Oil pump sprocket  
20. Tensioner “B”  
"HA 6. Timing belt tensioner  
7. Tensioner spacer  
8. Tensioner spring  
AH" "CA 21. Timing belt “B”  
AI" "BA 22. Counterbalance shaft sprocket  
9. Timing belt idler pulley  
"AA 23. Spacer  
AB" "GA 10. Camshaft sprocket bolt  
11. Camshaft sprocket  
AJ"  
24. Crankshaft sprocket “B”  
25. Key  
12. Flange  
26. Timing belt rear center cover  
27. Timing belt rear right cover  
28. Engine support bracket  
AC" "FA 13. Injection pump sprocket nut  
AD"  
14. Injection pump sprocket  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
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.  
Caution  
D
Use such a short bolt as would not come into  
contact with the timing belt tensioner mounting  
bolt at the rear end face when it is tightened.  
(3) Remove the timing belt.  
DEN0838  
AB" CAMSHAFT SPROCKET BOLT LOOSENING  
MB990767  
MD998719  
DEN0741  
AC" INJECTION PUMP SPROCKET NUT LOOSENING  
MB998719  
MB990767  
DEN0742  
AD" INJECTION PUMP SPROCKET REMOVAL  
(1) Do not strike the sprocket and drive shaft to remove these  
parts.  
MD998388  
DFU0625  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-4-3  
4D68 ENGINE (E-W) - Timing Belt  
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.  
Caution  
D
If the nut is loosened without removing the timing  
belt, the force produced by loosening the nut will  
be borne by the belt and can cause damage to  
the belt cogs.  
Plug  
Screwdriver  
6EN0563  
6EN0564  
AH" TIMING BELT “B” 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.  
NOTE  
(1) Water or oil on the belt shortens its life drastically,  
so the removed timing belt, sprocket, and tensioner  
must be free from oil and water. Do not immerse parts  
in cleaning solvent.  
(2) If there is oil or water on any part, check the front  
case oil seals, camshaft oil seal and water pump for  
leaks.  
DEN0745  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-4-4  
4D68 ENGINE (E-W) - Timing Belt  
AI" COUNTERBALANCE SHAFT SPROCKET  
REMOVAL  
MD998785  
DEN0746  
AJ" CRANKSHAFT SPROCKET “B” REMOVAL  
MD998778  
DEN0747  
INSTALLATION SERVICE POINTS  
"AA SPACER INSTALLATION  
Oil  
seal  
Spacer  
(1) Install the spacer with the chamfered end toward the oil  
seal.  
Silent  
shaft  
Sharp  
edge  
Chamfer  
6EN0615  
"BA COUNTERBALANCE SHAFT SPROCKET  
INSTALLATION  
MD998785  
DEN0746  
"CA TIMING BELT “B” INSTALLATION  
Timing  
mark  
(1) Align the timing marks on the crankshaft sprocket “B”  
and sprocket with the marks on the front case respectively.  
(2) Install the timing belt “B” on the crankshaft sprocket “B”  
and counterbalance shaft sprocket. There should be no  
slack on the tension side.  
Timing mark  
DEN0839  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-4-5  
4D68 ENGINE (E-W) - Timing Belt  
(3) Make sure that the pulley center and the bolt center are  
located as shown in the illustration.  
Timing belt “B”  
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. If the shaft  
is turned together, the belt will be overtensioned.  
DEN0750  
(5) Check to ensure that the timing marks on the sprockets  
and the front case are in alignment.  
(6) Press with index finger the center of span on the tension  
side of timing belt “B”. The bolt must deflect 5 to 7 mm.  
5 - 7 mm  
DEN0751  
"DA OIL PUMP SPROCKET INSTALLATION  
(1) Keep the counterbalance shaft in position in the same  
way as when it was loosened.  
(2) Install the oil pump sprocket.  
(3) Apply a minimum quantity of engine oil to the bearing  
surface of the nut.  
(4) Tighten the nuts to the specified torque.  
Phillips screwdriver  
6EN0564  
"EA CRANKSHAFT BOLT TIGHTENING  
MD998781  
DEN0743  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-4-6  
4D68 ENGINE (E-W) - Timing Belt  
"FA INJECTION PUMP SPROCKET NUT TIGHTENING  
MD998719  
MB990767  
DEN0754  
"GACAMSHAFT 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. Fit an offset wrench onto the bolt and turn the  
wrench downward as shown to tighten the tensioner  
mounting bolt temporarily.  
Caution  
D
Use such a short bolt as would not come into  
contact with the timing belt tensioner mounting  
bolt at the rear end face when it is tightened.  
DEN0838  
"IA TIMING BELT INSTALLATION  
Timing mark  
(1) Temporarily fix the tensioner at the most lower position  
in the injection pump bracket slot.  
Timing  
mark  
(2) Turn the crankshaft to bring the No. 1 piston at the top  
dead center on the compression stroke.  
(3) Align the timing marks of all sprockets with their mating  
marks as shown.  
Injection  
pump  
NOTE  
If the injection pump sprocket is released, it turns about  
one tooth in a counterclockwise direction. Therefore, the  
timing mark of the injection pump sprocket should be  
aligned when the timing belt is installed.  
sprocket  
Camshaft  
sprocket  
Oil pump sprocket  
Timing mark  
Timing  
mark  
Camshaft  
sprocket  
DEN0756  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-4-7  
4D68 ENGINE (E-W) - Timing Belt  
(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. Keep the  
screwdriver inserted until installation of the timing belt  
is finished.  
Plug  
Screwdriver  
6EN0563  
6EN0564  
(5) Install the timing belt on the sprockets in the following  
sequence while taking care so that the belt is not slack  
between sprockets or between sprocket and pulley.  
Camshaft sprocket  
Injection pump  
sprocket  
1
2
3
4
5
6
Crankshaft sprocket  
Timing belt idler  
Camshaft sprocket  
Injection pump sprocket  
Oil pump sprocket  
Timing  
belt idler  
Turn the crankshaft in the reverse direction by 1/2  
tooth of the camshaft sprocket toremove theslackenss  
of the belt on the idler side.  
Timing belt tensioner  
7
NOTE  
To install the timing belt on the injection pump sprocket,  
use an offset wrench or a similar tool and align the injection  
pump sprocket timing mark with the mark in the engine.  
Timing  
belt  
tensioner  
(6) Loosen the tensioner mounting bolt 1/4 - 1/3 turn and  
allow the spring tension to move the tensioner against  
the belt.  
Oil pump  
sprocket  
Crankshaft sprocket  
DEN0840  
(7) Turn the crankshaft counterclockwise by three teeth of  
the cam sprocket from the timing mark and hold this  
position. Check that the belt is in complete mesh with  
the sprockets.  
2-1/2  
Timing  
mark  
teeth  
(8) Fix the tensioner.  
(9) Turn the crankshaft clockwise to align the timing marks.  
1/2 teeth  
Timing mark  
DEN0732  
(10)Check that the belt deflects 4 - 5 mm when its midpoint  
is pushed by index finger.  
(11)Check that the timing marks of all sprockets are aligned.  
4 - 5 mm  
DEN0694  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
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.  
8EN0066  
(2) Cracked back surface rubber  
(3) Cracked or separated canvas  
(4) Cracked tooth bottom  
(5) Cracked side  
Crack  
Crack  
Separation  
Cracked  
side  
Tooth bottom  
8EN0044  
8EN0067  
8EN0068  
DEN0911  
(6) Abnormal wear on side  
NOTE  
Rounded edge  
Normal belt should have clear-cut sides as if cut by a  
sharp knife.  
Abnormal wear  
(loose core wire)  
(7) Abnormal wear in teeth  
Canvas worn  
exposing rubber  
Initial stage:  
Canvas on load side tooth flank worn (Fluffy canvas  
fibers, rubber gone and color changed to white, and  
unclear canvas texture)  
Stripped  
teeth  
Final stage:  
Canvas on load side tooth flank worn down and rubber  
exposed (tooth width reduced)  
(8) Missing tooth  
TENSIONER PULLER, IDLER PULLEY  
(1) Check the pulley for smooth rotation, excessive play,  
abnormal noise. Replace it if necessary.  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
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
7
10  
23 Nm  
19  
18 Nm  
8
13 Nm  
11  
23 Nm  
35 Nm  
12  
DEN0887  
Removal steps  
AA" "DA 1. Injection pipe No.1  
AA" "DA 2. Injection pipe No.2  
AA" "DA 3. Injection pipe No.3  
AA" "DA 4. Injection pipe No.4  
5. Fuel hose  
11. Key  
12. Fuel injection pump stay  
AC" "CA 13. Fuel return pipe nut  
14. Fuel return pipe  
15. Fuel return pipe gasket  
AD" "BA 16. Injection nozzle  
"AA 17. Holder gasket  
6. Fuel hose  
7. Fuel hose  
8. Fuel pipe  
"AA 18. Nozzle gasket  
9. Engine hanger  
10. Fuel injection pump  
19. Fuel injection pump bracket  
AB"  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-5-2  
4D68 ENGINE (E-W) - Glow Plug, Fuel Injection Pump And Injection Nozzle  
REMOVAL SERVICE POINTS  
AA" INJECTION PIPE REMOVAL  
Delivery  
holder  
(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  
Caution  
D
If the injection pipe has been removed, plug the  
delivery valve holder to prevent foreign matter  
from entering the injection pump.  
DEN0759  
(2) When loosening the union nuts on the injection nozzles,  
hold the hexagon nut of the fuel return pipe with a spanner  
to prevent it from rotating along with the union nut.  
AB" FUEL INJECTION PUMP REMOVAL  
(1) Do not hold the injection pump by the accelerator lever  
or the fast idle lever. These levers must not be removed.  
DEN0760  
DEN0761  
DEN0762  
AC" FUEL RETURN PIPE NUT REMOVAL  
(1) When removing the fuel return pipe nut, hold the hexagon  
nut of the fuel return pipe with a spanner.  
AD" INJECTION NOZZLE REMOVAL  
(1) Write the cylinder number on the injection nozzle that  
has been removed.  
Deep socket wrench  
Caution  
D
Cover the opening with an appropriate cap to  
prevent entry of dust, water and foreign material  
into the fuel passage and combustion chamber.  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
4D68 ENGINE (E-W) - Glow Plug, Fuel Injection Pump And Injection Nozzle 11A-5-3  
INSTALLATION SERVICE POINTS  
"AA NOZZLE GASKET / HOLDER GASKET  
INSTALLATION  
Holder gasket  
(1) Clean nozzle holder installation areas of the cylinder head.  
(2) Fit a new nozzle gasket and holder gasket into the nozzle  
Nozzle  
gasket  
holder hole in the cylinder head.  
DFU616  
"BA INJECTION NOZZLE INSTALLATION  
Deep socket wrench  
DEN0763  
DEN0761  
DEN0759  
DEN0760  
"CA FUEL RETURN PIPE NUT INSTALLATION  
(1) While holding the fuel hexagon nut of the fuel return pipe  
with a wrench, tighten the fuel return pipe nut to the  
specified torque.  
"DA INJECTION PIPE INSTALLATION  
Delivery  
(1) When tightening the injection pipe nuts, hold the delivery  
valve holder with a spanner in order to prevent it from  
rotating along with the nut.  
valve holder  
Nut  
(2) When tightening the injection pipe nuts, hold the hexagon  
nut of the return pipe with a spanner in order to prevent  
it from rotating along with the nut.  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-6-1  
4D68 ENGINE (E-W) - Intake and Exhaust Manifolds  
6. INTAKE AND EXHAUST MANIFOLDS  
REMOVAL AND INSTALLATION  
17 Nm  
3
24 Nm  
7
8
1
2
4
9
14 Nm  
11 Nm  
5
6
17 Nm  
16 Nm  
12  
10  
11  
38  
14 Nm  
16 Nm  
18  
20  
21  
10 Nm  
16  
15  
19  
17 Nm  
11 Nm  
30 Nm  
13 Nm  
39  
14  
22  
32  
17  
13  
28  
27  
30 Nm  
10 Nm  
24  
59 Nm  
23  
33  
59 Nm  
59 Nm  
25  
26  
30  
13 Nm  
59 Nm  
9 Nm  
29 Nm  
35  
36  
34  
29  
23 Nm  
37  
13 Nm  
30  
31  
13 Nm  
DEN0888  
Removal steps  
1. Air temperature sensor  
2. Air temperature sensor gasket  
3. Air intake fitting  
4. Intake fitting gasket  
5. Throttle body  
6. Intake fitting gasket  
7. EGR valve  
8. EGR valve gasket  
9. EGR pipe gasket  
10. EGR pipe  
21. Gasket  
22. Oil pipe  
23. Eyebolt  
24. Gasket  
25. Water pipe “B”  
26. Water hose  
27. Exhaust fitting  
28. Exhaust fitting gasket  
29. Oil return pipe  
"AA 30. Oil return pipe gasket  
31. Heat protector, rear  
32. Turbocharger assembly  
33. Turbocharger gasket  
34. Heat protector, front  
35. Engine hanger  
"CA 11. EGR pipe gasket  
12. Turbocharger heat protector  
13. Exhaust fitting heat protector  
14. Eyebolt  
15. Gasket  
16. Water pipe “A”  
17. Water hose  
36. Exhaust manifold  
37. Alternator brace stay  
38. Intake manifold  
"BA 18. Eyebolt  
19. Gasket  
39. Intake and exhaust manifold gasket  
"BA 20. Eyebolt  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-6-2  
4D68 ENGINE (E-W) - Intake and Exhaust Manifolds  
INSTALLATION SERVICE POINTS  
"AA OIL RETURN PIPE GASKET INSTALLATION  
Oil return pipe  
(1) Install the oil return pipe gasket in such a way that its  
projection is located at the illustrated position.  
Projection  
DEN0843  
"BA EYEBOLT INSTALLATION  
(1) Before installing the oil pipe eyebolt (at top of the  
turbocharger), fill the turbocharger with clean engine oil.  
"CA EGR PIPE GASKET INSTALLATION  
EGR pipe  
Exhaust fitting  
(1) Install the EGR pipe gasket in such a way that its projection  
is located at the illustrated position.  
Projection  
Exhaust fitting  
heat protector  
DEN0844  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-7-1  
4D68 ENGINE (E-W) - Water Pump, Thermostat, Hose and Pipes  
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  
23 Nm  
19  
5
7
20  
23 Nm  
11 Nm  
12 Nm  
10  
16  
6
22  
12 Nm  
15  
14  
21  
9
35 Nm  
11  
19 Nm  
12  
13  
DEN0889  
13 Nm  
Removal steps  
1. Eyebolt  
2. Gasket  
12. Water pump  
13. Water pump gasket  
3. Oil pipe  
4. Gasket  
"DA 14. O-ring  
"DA 15. Water inlet pipe  
"DA 16. O-ring  
5. Eyebolt  
6. Gasket  
17. Vacuum pump  
7. Oil return pipe  
18. O-ring  
8. Oil return hose  
19. Water inlet fitting  
"CA 20. Thermostat  
"BA 21. Water outlet fitting  
"AA 22. Thermostat housing  
9. Engine coolant temperature sensor  
"FA 10. Engine coolant temperature gauge  
unit  
"EA 11. Cover  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
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 Part No. MD970389 or  
equivalent.  
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 Part No. MD970389 or  
equivalent.  
DEN0769  
"CA THERMOSTAT INSTALLATION  
Jiggle valve  
(1) Install the thermostat with the jiggle valve up as shown  
in the illustration.  
DEN0770  
"DA WATER INLET PIPE / O-RING INSTALLATION  
(1) Wet the O-ring (with water) to facilitate assembly.  
Caution  
D
D
Keep the O-ring free of oil or grease.  
Secure the water pipe after the thermostat housing  
has been installed.  
"EA COVER INSTALLATION  
Back side of cover  
(1) Apply a 3 mm bead of form-in-place gasket (FIPG) to  
the mounting surface.  
Specified sealant:  
Mitsubishi Genuine Part No. MD970389 or  
equivalent.  
DEN0846  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-7-3  
4D68 ENGINE (E-W) - Water Pump, Thermostat, Hose and Pipes  
"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  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-8-1  
4D68 ENGINE (E-W) - Rocker Arms, Rocker Shaft and Camshaft  
8. ROCKER ARMS, ROCKER SHAFT AND CAMSHAFT  
REMOVAL AND INSTALLATION  
6 Nm  
29 Nm  
5
4
1
6
7
20 Nm  
2
15 Nm  
8
20 Nm  
12  
29 Nm  
29 Nm  
12  
12  
11  
13  
9
3
12  
10  
Apply engine oil to all  
moving parts before  
installation.  
DEN0891  
Removal steps  
Installation steps  
1. Breather hose  
2. Rocker cover  
13. Camshaft  
"AA 12. Camshaft bearing cap  
3. Rocker cover gasket  
4. Rocker shaft  
"BA 11. Rear camshaft bearing cap  
"BA 9. Front camshaft bearing cap  
"CA 8. Rocker arm adjusting screw  
7. Nut  
5. Rocker shaft spring  
6. Rocker arm  
7. Adjusting nut  
8. Rocker arm adjusting screw  
9. Front camshaft bearing cap  
10. Camshaft front oil seal  
11. Rear camshaft bearing cap  
12. Camshaft bearing cap  
13. Camshaft  
6. Rocker arm  
"DA 5. Rocker shaft spring  
4. Rocker shaft  
"EA 10. Camshaft oil seal  
3. Rocker cover gasket  
2. Rocker cover  
1. Breather hose  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-8-2  
4D68 ENGINE (E-W) - Rocker Arms, Rocker Shaft and Camshaft  
INSTALLATION SERVICE POINTS  
"AA CAMSHAFT BEARING CAP INSTALLATION  
Camshaft  
sprocket side  
(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  
Front  
INSTALLATION  
(1) Apply sealant to the locations shown in the illustrations.  
Specified sealant:  
3M ATD Part No. 8660 or equivalent  
DEN0905  
"CA ROCKER ARM ADJUSTING SCREW  
INSTALLATION  
Within 1 mm  
(1) Do not screw the adjusting screw so far that its flange  
may come into contact with the rocker arm. Leave some  
distance (within 1 mm) between them.  
DEN0848  
"DA ROCKER SHAFT SPRING INSTALLATION  
(1) Hook the rocker shaft spring to the depression of the  
bearing cap.  
Depression  
Bearing cap  
DEN0803  
"EA CAMSHAFT OIL SEAL INSTALLATION  
MD998713  
(1) Using the special tool, install a new camshaft oil seal  
into the front bearing cap.  
DEN0773  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-8-3  
4D68 ENGINE (E-W) - Rocker Arms, Rocker Shaft and Camshaft  
VALVE CLEARANCE ADJUSTMENT  
(1) Turn the crankshaft clockwise and align the timing mark  
on camshaft sprocket with that on the injection pump  
bracket.  
Timing mark  
Camshaft  
sprocket  
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.  
(4) Using a thickness gauge, adjust the valve clearance by  
turning the adjusting screw.  
Standard value (on cold engine):  
Intake  
Exhaust  
0.25 mm  
0.35 mm  
DEN0775  
NOTE  
Adjusting  
screw  
Before insertion of a thickness gauge, provide clearance  
for inserting the gauge by pushing the pad with a standard  
screwdriver or the like from the opposite side.  
Pad  
Standard screwdriver  
or the like  
Thickness  
gauge  
DEN0718  
If an attempt is made to insert the thickness gauge without  
providing the clearance for it in advance by pushing the  
pad with a standard screwdriver or the like, the pad will  
tilt as shown in the illustration, preventing insertion of the  
thickness gauge.  
Thickness  
gauge  
Pad  
DEN0719  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
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  
NOTE  
No.3 No.4  
No.4  
With the engine mounted on vehicle, warm up the engine.  
Then, check for valve clearance on hot engine and adjust  
if necessary.  
DEN0776  
INSPECTION  
CAMSHAFT  
(1) Measure the cam height.  
Standard value:  
Intake  
41.90 mm  
41.96 mm  
Exhaust  
Limit:  
Intake  
41.40 mm  
41.46 mm  
Exhaust  
9EN0058  
ROCKER ARM SHAFT  
(1) Check the oil holes for clogging and clean if clogged.  
(2) Check the outer circumference of the portion where the  
rocker arm is installed and replace if damage or seizure  
is evident.  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-9-1  
4D68 ENGINE (E-W) - Cylinder Head, Valves and Valve Springs  
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  
AC" "AA 9. Valve stem seal  
10. Spring seat  
11. Intake valve guide  
12. Exhaust valve guide  
13. Intake valve seat  
14. Exhaust valve seat  
15. Cylinder head  
"BA 6. Valve spring  
7. Intake valve  
8. Exhaust valve  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
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.  
DEN0793  
INSTALLATION SERVICE POINTS  
"AA VALVE STEM SEAL INSTALLATION  
(1) Install the valve spring seat.  
(2) The special tool must be used to install valve stem seals.  
MD998729  
Improper installation could result in oil leaks past the valve  
guide.  
Caution  
D
Do not reuse removed valve stem seals.  
DEN0780  
"BA VALVE SPRING INSTALLATION  
Spring retainer  
(1) Direct the valve spring end with identification color toward  
the spring retainer.  
Painted  
end  
Stem seal  
Spring seat  
6EN0437  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-9-3  
4D68 ENGINE (E-W) - Cylinder Head, Valves and Valve Springs  
"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.  
MD998772  
DEN0779  
"DA CYLINDER HEAD GASKET INSTALLATION  
(1) In case any of the cylinder block, piston, connecting rod  
and crankshaft has not been replaced, install the gasket  
of the same rank as before which can be identified by  
the mark shown in the illustration at left.  
Identification mark  
Rank A Rank B Rank C  
DEN0796  
(2) In case any of the cylinder block, piston, connecting rod  
and crankshaft have been replaced, reselect and install  
the gasket in accordance with the following procedure.  
1
2 3  
4 5  
6 7  
8
1
With each piston held at the top dead center, measure  
its protrusion from the upper block surface at the  
locations shown in the illustration at left (total of eight  
locations). Be sure to take measurements on the  
crankshaft center line.  
2
Using the average of the eight measurements, select  
the gasket rank (A, B or C) in accordance with the  
table given below. If, however, the maximum protrusion  
at any one location exceeds the protrusion tolerance  
shown for any rank in the following table, use the  
gasket one rank higher that rank.  
Reference for measurement  
Protrusion measuring locations  
(with each piston at top dead center)  
DEN0797  
mm  
Rank  
Average value  
of piston  
protrusions  
Protrusion  
tolerance for  
each rank  
Thickness of  
selected gasket  
(when tightened)  
Protrusion  
A
B
C
0.641 - 0.700  
0.700 - 0.760  
0.760 - 0.823  
0.750  
0.810  
-
1.40 ± 0.05  
1.45 ± 0.05  
1.50 ± 0.05  
DEN0798  
"EA CYLINDER HEAD BOLT INSTALLATION  
(1) When installing the cylinder head bolts, check that the  
shank length of each bolt meets the limit. If the limit is  
exceeded, replace the bolt.  
Limit: max. 119.7 mm  
(2) Apply engine oil to the bolt threads and washers.  
Shank length  
6EN0782  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
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  
Timing belt side  
torque.  
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.  
(7) Give a 90° turn to the cylinder head bolts in the specified  
tightening sequence.  
90°  
(8) Give another 90° turn to the cylinder head bolts and make  
sure that the paint mark on the head of each cylinder  
head bolt and that on the cylinder head are on the same  
straight line.  
90°  
Caution  
Paint mark  
D
If the bolt is turned less than 90°, proper fastening  
performance may not be expected. When  
tightening the bolt, therefore, be careful to give  
a sufficient turn to it.  
If the bolt is overtightened, loosen the bolt  
completely and then retighten it by repeating the  
tightening procedure from step (1).  
6AE0297  
D
INSPECTION  
CYLINDER HEAD  
(1) Before cleaning the cylinder head, check it for water leaks,  
gas leaks, cracks, and other damage.  
(2) Remove all oil, water scale, sealant, and carbon. After  
cleaning the oil passages, blow air through them to verify  
that they are not blocked.  
(3) Check for distortion in the cylinder head gasket surface  
using a straight edge and thickness gauge. If distortion  
exceeds the specified limit, replace the cylinder head.  
DEN0794  
Gasket surface distortion  
Standard value: 0.05 mm or less  
Limit: 0.2 mm  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-9-5  
4D68 ENGINE (E-W) - Cylinder Head, Valves and Valve Springs  
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.  
Valve seat  
contact  
Margin  
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.  
6EN0542  
Standard value:  
Intake  
114.05 mm  
113.80 mm  
Exhaust  
Limit:  
Intake  
113.55 mm  
113.30 mm  
Exhaust  
VALVE SPRING  
(1) Measure the free height of the spring and, if it is smaller  
than the limit, replace.  
Standard value: 49.1 mm  
Limit: 48.1 mm  
Free  
height  
(2) Measure the squareness of the spring and, if the limit  
is exceeded, replace.  
Standard value: 2° or less  
Limit: Max. 4°  
1EN0264  
6EN0279  
1EN033  
VALVE GUIDE  
(1) Measure the clearance between the valve guide and valve  
stem. If the limit is exceeded, replace the valve guide  
or valve, or both.  
Standard value: 0.05 - 0.09 mm  
Limit: 0.15 mm  
Stem O.D.  
Guide I.D.  
VALVE SEAT  
(1) Check the valve seat for trace of overheat and contact  
with valve surface.  
Standard value: 0.9 - 1.3 mm  
Valve contact  
width  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-9-6  
4D68 ENGINE (E-W) - Cylinder Head, Valves and Valve Springs  
(2) Install the valve and, while pressing the valve against  
Valve stem end  
the valve seat, measure the valve stem projection between  
the valve stem end and the valve spring seat seating  
surface.  
Valve stem  
projection  
Standard value: 43.45 mm  
Limit: 43.95 mm  
Spring seat seating  
surface  
DEN0212  
VALVE SEAT RECONDITIONING PROCEDURE  
0.9 - 1.3 mm  
0.9 - 1.3 mm  
(1) Before correcting the valve seat, check the clearance  
65°  
between the valve guide and valve. If necessary, replace  
65°  
the valve guide.  
(2) Using the appropriate special tool or seat grinder, correct  
the valve seat to achieve the specified seat width and  
angle.  
(3) After correcting the valve seat, lap the valve and valve  
44°  
seat using lapping compound. Then, check the valve stem  
15°  
44°  
15°  
projection (refer to 5. VALVE SEAT in INSPECTION).  
1EN0105  
VALVE SEAT REPLACEMENT PROCEDURE  
0.5 - 1.0 mm  
(1) Cut the valve seat to be replaced from the inside to thin  
the wall thickness. Then, remove the valve seat.  
Cut  
away  
0.5 - 1.0 mm  
1EN0274  
(2) Reborethevalveseatholeinthecylinderheadtoaselected  
oversize valve seat diameter.  
Intake valve seat hole diameter  
0.30 O.S.: 38.300 - 38.325 mm  
0.60 O.S.: 38.600 - 38.625 mm  
Height of  
seat ring  
Exhaust valve seat hole diameter  
0.30 O.S.: 34.300 - 34.325 mm  
0.60 O.S.: 34.600 - 34.625 mm  
Oversize I.D.  
(3) Before fitting the valve seat, either heat the cylinder head  
up to approximately 250°C or cool the valve seat using  
cooling spray, to prevent the cylinder head bore from  
galling.  
1EN0275  
(4) Using a valve seat cutter, correct the valve seat to the  
specified width and angle.  
See “VALVE SEAT RECONDITIONING PROCEDURE”.  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-9-7  
4D68 ENGINE (E-W) - Cylinder Head, Valves and Valve Springs  
VALVE GUIDE REPLACEMENT PROCEDURE  
Press  
Removal  
(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 - 13.518 mm  
Valve guide  
6EN0543  
NOTE  
Do not install a valve guide of the same size again.  
Press  
Installation  
(3) Using the special tool, press-fit the valve guide, working  
from the cylinder head top surface.  
(4) After installing valve guides, insert new valves in them  
to check for sliding condition.  
MD998115  
Valve guide  
(5) When valve guides have been replaced, check for valve  
contact and correct valve seats as necessary.  
6EN0543  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-10-1  
4D68 ENGINE (E-W) - Front Case, Counterbalance Shafts and Oil Pan  
10. FRONT CASE, COUNTERBALANCE SHAFTS AND OIL PAN  
REMOVAL AND INSTALLATION  
30  
29  
Apply engine oil to all  
27  
moving parts before  
installation.  
31  
20  
24 Nm  
28  
21  
19  
7
6
25  
22  
10 Nm  
10 Nm  
16 Nm  
9
15  
19 Nm  
54 Nm  
9 Nm  
24  
17  
23  
14  
4
8
26  
18  
13  
36 Nm  
16  
24 Nm  
11  
23 Nm  
12  
5
10  
2
44 Nm  
3
7 Nm  
18 Nm  
39 Nm  
1
DEN0892  
Removal steps  
1. Oil filter  
AC" "IA 18. Flange bolt  
2. Drain plug  
"HA 19. Front case  
3. Drain plug gasket  
4. Oil level sensor  
20. Front case gasket  
21. Oil pump cover  
AA" "LA 5. Oil pan  
"GA 22. Oil pump driven gear  
6. Oil screen  
"GA 23. Oil pump drive gear  
7. Oil screen gasket  
"FA 24. Crankshaft front oil seal  
8. Oil cooler bypass valve  
"KA 9. Oil pressure switch  
10. Relief plug  
"EA 25. Counterbalance shaft oil seal  
"DA 26. Oil pump oil seal  
27. Counterbalance shaft, right  
28. Counterbalance shaft, left  
11. Gasket  
12. Relief spring  
AD" "CA 29. Counterbalance shaft front bearing  
AE" "BA 30. Counterbalance shaft rear bearing,  
right  
13. Relief plunger  
14. Oil filter bracket  
15. Oil filter bracket gasket  
AE" "AA 31. Counterbalance shaft rear bearing,  
left  
AB" "JA 16. Plug  
17. O-ring  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
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  
AB" PLUG REMOVAL  
MD998162  
(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.  
MD998783  
6EN0909  
AC" FLANGE BOLT REMOVAL  
(1) When loosening the oil pump driven gear flange bolt, first  
insert a Phillips screwdriver [shank diameter 8 mm] into  
the plug hole on the left side of the cylinder block to block  
the silent shaft.  
Plug  
Screwdriver  
6EN0563  
6EN0564  
(2) Loosen the flange bolt.  
6EN0565  
AD" COUNTERBALANCE SHAFT FRONT BEARING  
REMOVAL  
(1) Using the special tool, remove the front bearing from the  
cylinder block.  
NOTE  
Be sure to remove the front bearing first. If it has not  
been removed, the Rear Bearing Puller cannot be used.  
Front  
bearing  
MD998371  
3EN0166  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-10-3  
4D68 ENGINE (E-W) - Front Case, Counterbalance Shafts and Oil Pan  
AE" RIGHT COUNTERBALANCE SHAFT REAR  
BEARING / LEFT COUNTERBALANCE SHAFT  
REAR BEARING REMOVAL  
MB991603  
(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.  
MD998732  
MB991603  
6EN0207  
6EN0208  
6EN0578  
6EN0774  
INSTALLATION SERVICE POINTS  
"AA LEFT COUNTERBALANCE SHAFT REAR  
BEARING INSTALLATION  
(1) Install the special tool in the cylinder block.  
(2) Apply engine oil to the rear bearing outer circumference  
and bearing hole in the cylinder block.  
NOTE  
The left side bearing is provided with no oil hole.  
MD998705  
MB991603  
(3) Using the special tool, install the bearing.  
MD998705  
Rear bearing  
"BA RIGHT COUNTERBALANCE SHAFT REAR  
BEARING INSTALLATION  
(1) Install the guide pin of the special tool to the threaded  
hole of the cylinder block as illustrated.  
Guide pin  
(2) Install the bearing to the special tool, aligning the ratchet  
ball of the special tool with the oil hole of the rear bearing.  
(3) Apply engine oil to the outer circumference of the bearing  
and to the bearing hole of the cylinder block.  
Rear bearing (right)  
Ratchet ball  
Oil  
hole  
6EN324  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
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.  
Guide pin  
6EN0774  
(3) Install the bearing to the special tool, aligning the ratchet  
Front bearing  
ball of the special tool with the oil hole of the front bearing.  
Ratchet ball  
(4) Apply engine oil to the outer circumference of the bearing  
Oil  
hole  
and to the bearing hole of the cylinder block.  
6EN324  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-10-5  
4D68 ENGINE (E-W) - Front Case, Counterbalance Shafts and Oil Pan  
(5) Insert the installer aligning with the guide pin and install  
the bearing.  
MD998705  
Guide pin  
6EN0775  
6EN0778  
"DA OIL PUMP OIL SEAL INSTALLATION  
Socket  
wrench  
Oil seal  
Front case  
6EN0494  
"EA COUNTERBALANCE SHAFT OIL SEAL  
INSTALLATION  
Socket wrench  
Front case  
Oil seal  
6EN0580  
"FA CRANKSHAFT FRONT OIL SEAL INSTALLATION  
(1) Using the special tool, install the crankshaft front oil seal  
into the front case.  
MD998375  
Oil seal  
Front case  
6EN0579  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-10-6  
4D68 ENGINE (E-W) - Front Case, Counterbalance Shafts and Oil Pan  
"GAOIL PUMP DRIVEN GEAR / OIL PUMP DRIVE  
GEAR INSTALLATION  
(1) Apply engine oil amply to the gears and line up the  
Alignment mark  
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.  
MD998285  
6EN0746  
(2) Install the front case assembly via a new front case gasket  
and temporarily tighten the flange bolts (other than those  
for tightening the filter bracket.)  
(3) Install the oil filter bracket via the oil filter bracket gasket  
and temporarily tighten four bolts with washers.  
(4) Tighten the front case bolts to the specified torque.  
MD998285  
6EN0747  
"IA FLANGE BOLT INSTALLATION  
(1) Insert a Phillips screwdriver [shank diameter 8 mm] into  
the plug hole on the left side of the cylinder block to block  
the counterbalance shaft then tighten the flange bolt.  
Phillips  
screwdriver  
6EN0564  
6EN0565  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-10-7  
4D68 ENGINE (E-W) - Front Case, Counterbalance Shafts and Oil Pan  
"JA PLUG INSTALLATION  
(1) Fit a new O-ring in the front case.  
MD998162  
(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
D
Keep the end of the thread portion clear or sealant.  
Avoid an overtightening.  
9EN0094  
"LA OIL PAN INSTALLATION  
(1) Clean both mating surface of oil pan and cylinder block.  
(2) Apply a 4 mm wide bead of sealant to the entire  
circumference of the oil pan flange.  
Specified sealant:  
MITSUBISHI GENUINE PART No. MD970389 or  
equivalent  
Bolt  
(3) The oil pan should be installed in 15 minutes after  
application of sealant.  
Groove  
portion  
hole  
portion  
6EN0213  
(4) Note the difference in bolt lengths at the location shown.  
Crankshaft pulley side  
8 mm bolts  
Oil pan viewed from lower side  
6EN0449  
INSPECTION  
FRONT CASE  
(1) Check the oil holes for clogging and clean if necessary.  
(2) Check the left silent shaft front bearing section for wear,  
damage and seizure. If there is anything wrong with the  
section, replace the front case.  
(3) Check the frontcase forcracks andother damage.Replace  
cracked or damaged front case.  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
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.  
Dimension L: 34.5 mm  
(3) Thedimensionmust bethe standardvalue whenmeasured  
after the valve has been dipped in 100°C oil.  
Valve  
Dimension L: 40 mm or more  
6EN0589  
OIL PUMP  
(1) Assemble the oil pump gear to the front case and rotate  
it to ensure smooth rotation with no looseness.  
(2) Ensure that there is no ridge wear on the contact surface  
between the front case and the gear surface of the oil  
pump cover.  
(3) Check the side clearance.  
Standard value:  
Drive gear  
0.08 - 0.14 mm  
0.06 - 0.12 mm  
Driven gear  
6LU0013  
OIL SEAL  
(1) Check the oil seal lip for wear and damage. Replace the  
oil seal if necessary.  
(2) Check the oil seal lip for deterioration. Replace oil seal  
if necessary.  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-11-1  
4D68 ENGINE (E-W) - Pistons and Connecting Rods  
11. PISTONS AND CONNECTING RODS  
REMOVAL AND INSTALLATION  
Apply engine oil to all  
moving parts before  
installation.  
DEN0771  
Removal steps  
"FA 1. Connecting rod cap nut  
AA" "EA 2. Connecting rod cap  
"CA 3. Connecting rod bearing  
"DA 4. Piston and connecting rod assembly  
"CA 5. Connecting rod bearing  
"BA 6. Piston ring No.1  
8. Oil ring  
9. Snap ring  
"AA 10. Piston pin  
"AA 11. Piston  
"AA 12. Connecting rod  
13. Bushing  
"BA 7. Piston ring No.2  
14. Connecting rod bolt  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-11-2  
4D68 ENGINE (E-W) - Pistons and Connecting Rods  
REMOVAL SERVICE POINTS  
AA" CONNECTING ROD CAP REMOVAL  
(1) Mark the cylinder number on the side of the connecting  
rod big end for correct reassembly.  
Cylinder No.  
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.  
Front mark  
(Identification  
mark)  
Front mark  
DEN0784  
"BA PISTON RING NO. 2 / PISTON RING NO. 1  
“T” identification mark  
“2T” identification mark  
INSTALLATION  
Side mark  
(1) Using a ring expander, fit ring No. 2 and ring No. 1 with  
their identification marks facing upward (on the piston  
crown side).  
No. 1  
No. 2  
Identification marks:  
No. 1 ring: T  
No. 2 ring: 2T  
NOTE  
9EN0524  
Piston rings are stamped with size marks as follows:  
Size  
Size mark  
None  
50  
STD  
0.50 mm O.S.  
1.00 mm O.S.  
100  
"CA CONNECTING ROD BEARING INSTALLATION  
(1) When the bearings are replaced, select and install them  
according to the identification colors on the crankshaft.  
No. 1  
Location of identification  
colors  
No. 4  
Crank pin O.D.  
identification color  
Connecting rod bearing  
identification mark  
Yellow  
None  
White  
1
2
3
No. 2  
No. 3  
E Mitsubishi Motors Corporation  
6EN0700  
Dec. 1996  
PWEE9609  
11A-11-3  
4D68 ENGINE (E-W) - Pistons and Connecting Rods  
"DA PISTON AND CONNECTING ROD ASSEMBLY  
INSTALLATION  
Coil expander joint  
No. 1  
(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.  
Timing  
belt side  
Piston pin  
(3) Rotate the crankshaft so that the crank pin is on the center  
of the cylinder bore.  
Oil ring  
No. 2  
6EN0549  
(4) Use suitable thread protectors on the connecting rod bolts  
before inserting the piston and connecting rod assembly  
into the cylinder block. Care must be taken not to nick  
the crank pin.  
(5) Using a suitable piston ring compressor tool, install the  
piston and connecting rod assembly into the cylinder block.  
Caution  
D
Direct the front mark (arrow) on the piston top  
towards the engine front (timing belt side).  
Timing belt  
side  
DEN0054  
"EA CONNECTING ROD CAP INSTALLATION  
(1) Verifying the mark made during disassembly, install the  
bearing cap to the connecting rod. If the connecting rod  
is new with no index mark, make sure that the bearing  
locking notches come on the same side as shown.  
Cylinder No.  
Notches  
DEN0051  
(2) Make sure that the connecting rod big end side clearance  
meets the specification.  
Standard value: 0.10 - 0.25 mm  
Limit: 0.4 mm  
6EN0621  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
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.  
Necking can be checked by running a nut with fingers  
to the full length of the bolt threads. If the nut does not  
run down smoothly, the bolt should be replaced.  
(2) Before installation of each nut, apply engine oil to the  
thread portion and bearing surface of the nut.  
(3) Install each nut to the bolt and tighten it with fingers. Then  
tighten the nuts alternately to install the cap properly.  
(4) Tighten the nuts to a torque of 20 Nm.  
(5) Make a paint mark on the head of each nut.  
(6) Make a paint mark on the bolt end at the position 90°  
to 100° from the paint mark made on the nut in the direction  
of tightening the nut.  
Paint mark  
90 - 100  
°
°
Paint  
mark  
(7) Give a 90° to 100° turn to the nut and make sure that  
the paint mark on the nut and that on the bolt are in  
alignment.  
Bolt  
Caution  
D
Nut  
If the nut is turned less than 90°, proper fastening  
performance may not be expected. When  
tightening the nut, therefore, be careful to give  
a sufficient turn to it.  
If the nut is overtightened (exceeding 100°), loosen  
the nut completely and then retighten it by  
repeating the tightening procedure from step (1).  
6AE0298  
D
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-11-5  
4D68 ENGINE (E-W) - Pistons and Connecting Rods  
INSPECTION  
PISTON RING  
(1) Check for side clearance.  
If the limit is exceeded, replace the ring or piston, or both.  
5EN0066  
DEN259  
6EN0548  
1EN0246  
(2) In the case of semi-keystone type piston rings, check  
the ring to ring groove clearance as illustrated.  
Thickness gauge  
Piston  
Standard value:  
No. 1  
No. 2  
0.05 - 0.07 mm  
0.05 - 0.07 mm  
Limit:  
No. 1  
No. 2  
0.15 mm  
0.15 mm  
(3) Insert the piston ring into the cylinder bore. Force it down  
with a piston, its crown being in contact with the ring,  
to correctly position it at right angles to the cylinder wall.  
Then, measure the end gap with a thickness gauge. If  
the end gap is excessively, replace the piston ring.  
Press down ring  
with piston  
Standard value:  
No. 1  
No. 2  
Oil  
0.20 - 0.32 mm  
0.35 - 0.50 mm  
0.10 - 0.30 mm  
Piston ring  
Limit: 0.8 mm  
End gap  
CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE  
METHOD)  
(1) Remove oil from the crankshaft pin and the connecting  
rod bearing.  
(2) Cut the plastic gauge to the same length as the width  
of the bearing and place it on the crankshaft pin in parallel  
with its axis.  
(3) Install the connecting rod cap carefully and tighten the  
bolts to the specified torque.  
(4) Carefully remove the connecting rod cap.  
(5) Measure the width of the plastic gauge at its widest part  
by using scale printed on the plastic gauge package.  
Standard value: 0.02 - 0.05 mm  
Limit: 0.1 mm  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
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  
Bushing  
Apply oil  
Chamfered end  
Align oil  
holes  
DEN205  
(3) Finish the bushing I.D. to the standard value.  
Bushing I.D. (d) standard value:  
d
25.015 - 25.025 mm  
Bend (Parallelism between big end center line and  
small end center line): 0.05 mm  
Twist (Deflection between big end center line and small  
end center line): 0.1 mm  
DEN206  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-12-1  
4D68 ENGINE (E-W) - Crankshaft, Cylinder Block and Flywheel  
12. CRANKSHAFT, CYLINDER BLOCK AND FLYWHEEL  
REMOVAL AND INSTALLATION  
132 Nm  
“A”  
3
1
6
5
2
17  
8
4
9
18  
11 Nm  
7
11 Nm  
14  
16  
13  
15  
32 Nm  
12  
11  
Apply engine oil to all  
moving parts before  
installation.  
10  
DEN0893  
Removal steps  
1. Flywheel bolt  
2. Adapter plate  
3. Flexible flywheel  
4. Adapter plate  
5. Crankshaft bush  
6. Rear plate  
15. Check valve  
16. Oil jet  
17. Cylinder sleeve  
18. Cylinder block  
Caution  
7. Bell housing cover  
On the flexible wheel equipped engines, do not  
remove any of the bolts “A” of the flywheel shown  
in the illustration.  
The balance of the flexible flywheel is adjusted in  
an assembled condition. Removing the bolt,  
therefore, can cause the flexible flywheel to be out  
of balance, giving damage to the flywheel.  
"DA 8. Oil seal case  
"CA 9. Oil seal  
"BA 10. Bearing cap bolt  
"BA 11. Bearing cap  
"AA 12. Crankshaft bearing, lower  
13. Crankshaft  
"AA 14. Crankshaft bearing, upper  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-12-2  
4D68 ENGINE (E-W) - Crankshaft, Cylinder Block and Flywheel  
INSTALLATION SERVICE POINTS  
No.3  
"AA CRANKSHAFT BEARING INSTALLATION  
No.2  
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. In the case of a  
crankshaft supplied as a service part, identification colors  
of its journals are painted at the positions shown in the  
illustration.  
No.4  
(2) The cylinder block bearing bore diameter identification  
marks are stamped at the position shown in the illustration  
from front to rear beginning at No. 1.  
No.1  
Location of  
identification colors  
Crankshaft journal  
Cylinder  
block  
bearing  
bore  
diameter  
identifica-  
tion mark  
Bearing  
identifica-  
tion mark  
(for ser-  
Classifi-  
cation  
Identification color  
O.D.  
mm  
vice part)  
Produc-  
tion part  
Service  
part  
1
2
3
None  
None  
None  
Yellow  
None  
White  
56.994 -  
57.000  
0
1
1
2
0
1
2
0
1
2
2
3
2
3
4
3
4
5
No.5  
6EN0705  
56.988 -  
56.994  
Timing belt side  
Cylinder block bearing  
bore identification mark  
No.3  
56.982 -  
56.988  
No.2  
No.4  
No.5  
No.1  
Cylinder bore size  
mark (reference)  
(3) Select a proper bearing from the above table on the basis  
of the identification data confirmed under items (1) and  
(2).  
6EN1184  
[Example]  
1. Ifthemeasuredvalueofa crankshaftjournal outerdiameter  
is 57.000 mm, the journal is classified as “1” in the table.  
In case the crankshaft is also replaced by a spare part,  
check the identification colors of the journals painted on  
the new crankshaft. If the color is yellow, for example,  
the journal is classified as “1”.  
2. Next, check the cylinder block bearing hole identification  
mark stamped on the cylinder block. If it is “0”, read the  
“Bearing identification mark” column to find the  
identification mark of the bearing to be used. In this case,  
it is “1”.  
(3) Install the bearings having an oil groove to the cylinder  
block. Install the grooveless bearing with thrust flanges  
in the center bearing bore in the cylinder block.  
(4) Install the bearings having no oil groove to the bearing  
caps.  
Grooved  
Grooveless  
Upper bearing  
(for No.1,2,4,5)  
Lower bearing  
(for No.1,2,4,5)  
Grooveless  
Upper and lower bearings  
(for center)  
1EN0272  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-12-3  
4D68 ENGINE (E-W) - Crankshaft, Cylinder Block and Flywheel  
"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.  
Shank length  
Limit: 71.1 mm  
9EN0477  
(3) Applyengineoiltothethreadedportionandbearingsurface  
of the bolt.  
(4) Tighten the bolts to 25 Nm in the specified tightening  
sequence.  
4
1
2
5
6
8
9
7
3
Q
Arrow  
mark  
6EN0624  
(5) Make a paint mark on the head of each bolt.  
(6) Make a paint mark on the bearing cap at the position  
90° to 100° from the paint mark made on the bolt in the  
direction of tightening the bolt.  
Paint mark  
Paint mark  
(7) According to the specified tightening sequence, give a  
90° to 100° turn to each bolt and make sure that the  
paint mark on the bolt and that on the cap are in alignment.  
Caution  
D
90 - 100  
°
°
If the bolt is turned less than 90°, proper fastening  
performance may not be expected. When  
tightening the bolt, therefore, be careful to give  
a sufficient turn to it.  
If the boltis overtightened(exceeding 100°),loosen  
the bolt completely and then retighten it by  
repeating the tightening procedure from step (1).  
6AE0299  
D
(8) After installing the bearing caps, make sure that the  
crankshaft turns smoothly and the end play is correct.  
If the end play exceeds the limit, replace the crankshaft  
bearings.  
Standard value: 0.05 - 0.18 mm  
Limit: 0.25 mm  
6EN0625  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
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 Part No. MD970389 or  
equivalent  
6EN0626  
Plastic  
gauge  
INSPECTION  
CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE  
METHOD)  
(1) Remove oil from the crankshaft journal and the crankshaft  
bearing.  
(2) Install the crankshaft.  
(3) Cut the plastic gauge to the same length as the width  
of the bearing and place it on the journal in parallel with  
its axis.  
6EN0703  
(4) Install the crankshaft bearing cap carefully and tighten  
the bolts to the specified torque.  
(5) Carefully remove the crankshaft bearing cap.  
(6) Measure the width of the plastic gauge at its widest part  
by using a scale printed on the plastic gauge package.  
Standard value: 0.02 - 0.04 mm  
Limit: 0.1 mm  
Plastic  
gauge  
6EN0623  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-12-5  
4D68 ENGINE (E-W) - Crankshaft, Cylinder Block and Flywheel  
CYLINDER BLOCK  
C
D
E
F
A
B
(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  
measurementswiththestraightedgeplacedinthedirection  
of A, B,.. and G as shown in the illustration. Before  
measurements, make sure that the top surface is free  
of gasket chips and other foreign material. If the distortion  
is excessive, replace the cylinder block.  
G
9EN0074  
Standard value: 0.05 mm  
Limit: 0.1 mm  
(3) Check the cylinder sleeve wall for scratches and seizure.  
If defects are evident, replace the cylinder sleeve. Measure  
the cylinder sleeve inner diameter at the points shown  
in the illustration. If it is badly worn, replace.  
A
B
Standard value: 82.70 - 82.73 mm  
Conicity: 0.01 mm  
12 mm  
Center  
Bottom  
6EN0553  
BORING CYLINDER  
(1) Oversize pistons to be used should be determined on  
the basis of the largest bore cylinder.  
Piston size identification  
Size  
Identification mark  
Thrust  
direction  
0.50 mm O.S.  
1.00 mm O.S.  
0.50  
1.00  
Piston O.D.  
NOTE  
6EN0554  
Size mark is stamped on the piston top.  
(2) Measure outside diameter of piston to be sued. Measure  
it in thrust direction as shown.  
(3) Based on the measured piston O.D., calculate the boring  
finish dimension.  
Boring finish dimension = Piston O.D. + (Clearance  
between piston O.D. and cylinder) - 0.02 mm  
(honing margin)  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
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 - 0.05 mm  
NOTE  
When boring cylinders, finish all of four cylinders to the  
same oversize. Do not bore only one cylinder to an  
oversize.  
CYLINDER SLEEVE CHANGE PROCEDURES  
REMOVAL  
(1) Fix the cylinder block to a boring machine and center  
it. Center at the lower portion of the cylinder sleeve where  
there is less uneven wear.  
Round this surface  
(2) Bore to the sleeve wall thickness of about 0.5 mm.  
(3) Machine the screwdriver as illustrated and insert it between  
the cylinder sleeve and cylinder block. Lightly hit it to break  
the sleeve.  
P view  
P
When doing so, be careful not to damage the cylinder  
block wall.  
DEN238  
Face round side  
toward the cylinder  
block  
Thinned cylinder  
sleeve  
DEN239  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
11A-12-7  
4D68 ENGINE (E-W) - Crankshaft, Cylinder Block and Flywheel  
INSPECTION  
Y direction  
(1) After removing the cylinder sleeve, check the cylinder block  
sleeve hole surface.  
X direction  
12 mm  
If there is damage, insufficient interference-fit-margin or  
other problems, bore the cylinder block sleeve hole to  
an oversize.  
(2) Tochecktheinterference,measureboththecylindersleeve  
O.D. and cylinder block sleeve hole I.D. at the positions  
D1, D2 and D3 in both X and Y directions.  
Center  
Lower  
(3) If the average of the differences between measured values  
is smaller than 0.12 mm, then bore the sleeve hole to  
0.5 mm oversize and install an oversize sleeve. If the  
average is larger than 0.175 mm, bore the sleeve hole  
to the extent that the difference falls within a range of  
0.12 to 0.175 mm, then install a standard cylinder sleeve.  
DEN116  
Caution  
D
If one cylinder requires oversize machining,  
oversizeitwiththeothercylinder sleevesremoved.  
Machining while the sleeves remain in the other  
cylinders may disturb roundness.  
INSTALLATION  
Hydraulic press  
When cylinder block sleeve hole has not been bored  
(1) Amply apply press oil to the cylinder block sleeve hole  
and sleeve outer circumference.  
Cylinder sleeve  
(2) Apply a disc [diameter 100 mm, thickness 20 mm or more]  
to the top of the sleeve and press fit using a hydraulic  
press.  
Installation load: 22,000 N or more  
DEN241  
(3) Install with the chamfered end first as illustrated. Continue  
until the sleeve upper end is flush with the block upper  
end.  
Top end  
Bottom end  
Chamfered  
DEN242  
(4) Cut off the top end of the cylinder block in order to make  
the cylinder block flush with the sleeve. Cut off the minimum  
top end portion of the cylinder block necessary to make  
them flush. Do not cut off more than 0.2 mm.  
To be flush  
Cylinder  
block  
Cylinder  
sleeve  
DEN243  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
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: 0.05 mm  
When boring the cylinder block sleeve hole  
(1) Prepare a cylinder sleeve of 0.5 mm oversize (identification  
color: red).  
(2) Hone the cylinder block sleeve hole to 86.13 to 86.15  
mm.  
(3) Install the cylinder sleeve and finish the I.D. The installation  
and machining procedures are the same as in the case  
when the block sleeve hole has not been bored.  
INSPECTION AFTER ASSEMBLY  
(1) After assembling the crankshaft, piston, etc., check the  
piston protrusion.  
If the protrusion exceeds the limit, change the piston and  
connecting rod in order to reduce the protrusion to within  
the limit.  
Protrusion  
(2) If the protrusion still exceeds the limit after piston  
reassembly, replace the cylinder block.  
Limit: 0.823 mm  
DEN0798  
Dec. 1996  
PWEE9609  
E Mitsubishi Motors Corporation  
NOTES  

Weed Eater Automobile Parts Hp22 User Manual
Texas Instruments Bq24351evm User Manual
Sharp Air Cleaner Fp A28u User Manual
Samsung Sh18zp0a User Manual
Radio Shack Tad 3809 User Manual
LG BG 123A User Manual
JENSEN JHD910BT User Manual
FUJITSU SPARC M4000 User Manual
EPSON C82363 User Manual
ACER ASPIRE 5251 User Manual