Mitsubishi 4D68 Instruction manual

GENERAL INFORMATION 11A-0-3
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1. SPECIFICATIONS 11A-1-1
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SERVICE SPECIFICATIONS 11A-1-1
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REWORK DIMENSIONS 11A-1-3
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TORQUE SPECIFICATIONS 11A-1-4
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NEW TIGHTENING METHOD - BY USE OF BOLTS
TO BE TIGHTENED IN PLASTIC AREA 11A-1-7
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SEALANT 11A-1-7
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FORM-IN-PLACE GASKET 11A-1-8
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2. SPECIAL TOOLS 11A-2-1
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3. DRIVE BELT AND GLOW PLUG 11A-3-1
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4. TIMING BELT 11A-4-1
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5. GLOW PLUG, FUEL INJECTION PUMP
AND INJECTION NOZZLE 11A-5-1
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6. INTAKE AND EXHAUST MANIFOLDS 11A-6-1
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7. WATER PUMP, THERMOSTAT, HOSE AND PIPES 11A-7-1
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8. ROCKER ARMS, ROCKER SHAFT AND CAMSHAFT 11A-8-1
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9. CYLINDER HEAD, VALVES AND VALVE SPRINGS 11A-9-1
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10. FRONT CASE, COUNTERBALANCE SHAFTS
AND OIL PAN 11A-10-1
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11. PISTONS AND CONNECTING RODS 11A-11-1
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12. CRANKSHAFT, CYLINDER BLOCK AND FLYWHEEL 11A-12-1
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11A-0-1
PWEE9609
EDec. 1996Mitsubishi Motors Corporation
ENGINE
4D68
CONTENTS

11A-0-2
PWEE9609
EDec. 1996Mitsubishi Motors Corporation
NOTES

4D68 ENGINE (E-W) - General Information 11A-0-3
GENERAL INFORMATION
SECTIONAL VIEW OF ENGINE
PWEE9609
EDec. 1996Mitsubishi Motors Corporation

4D68 ENGINE (E-W) - General Information
11A-0-4
SECTIONAL VIEW OF ENGINE
PWEE9609
EDec. 1996Mitsubishi Motors Corporation

4D68 ENGINE (E-W) - General Information 11A-0-5
GENERAL SPECIFICATIONS
Descriptions Specifications
Type Diesel engine
Number of cylinders 4 in-line
Combustion chamber Swirl chamber
Total displacement dm31.998
Cylinder bore mm 82.7
Piston stroke mm 93
Compression ratio 22.4
Valve timing Intake valve Opens (BTDC) 20°
Closes (ABDC) 48°
Exhaust valve Opens (BBDC) 54°
Closes (ATDC) 22°
Lubrication system Pressure feed, full-flow filtration
Oil pump type External gear type
Cooling system Water-cooled
Water pump type Centrifugal impeller type
EGR type Single type
Fuel system Electronic control distributor-type injection pump
Supercharging Turbocharger
Rocker arm Roller type
Adjusting screw Elephant foot type
Oil lever sensor Provided
PWEE9609
EDec. 1996Mitsubishi Motors Corporation

4D68 ENGINE (E-W) - Specifications 11A-1-1
1. SPECIFICATIONS
SERVICE SPECIFICATIONS
Item Standard value Limit
Drive belt and glow plug
Glow plug resistance W0.5 -
Timing belt
Timing belt deflection mm 4.0- 5.0 -
Timing belt “B” deflection mm 5.0- 7.0 -
Rocker arms, rocker shaft and camshaft
Camshaft cam height mm Intake 41.90 41.40
Exhaust 41.96 41.46
Valve clearance (on cold engine) mm Intake 0.25 -
Exhaust 0.35 -
Camshaft journal O.D. mm 30.0 -
Cylinder head, valves and valve springs
Cylinder head gasket surface flatness mm Within 0.03 0.2
Cylinder head overall height mm 86.9- 87.1 -
Valve overall length mm Intake 114.05 113.55
Exhaust 113.80 113.30
Thickness of valve head (margin) mm 1.5 0.7
Valve stem O.D. mm 6.0 -
Valve face angle 45°- 45.5°-
Valve stem to guide clearance mm 0.05- 0.09 0.15
Valve spring free length mm 49.1 48.1
Valve load/installed height N/mm 240/37.9 -
Valve spring out-of-squareness 2°or less Max. 4°
Valve seat valve contact width mm 0.9- 1.3 -
Valve stem projection mm 43.45 43.95
Valve guide I.D. mm 8.0 -
Valve guide projection from cylinder head upper surface mm 15 -
Cylinder head bolt shank length mm -119.7
Front case, counterbalance shafts and oil pan
Oil cooler by-pass valve dimension (L) [Normal temperature] mm 34.5 -
PWEE9609
EDec. 1996Mitsubishi Motors Corporation

4D68 ENGINE (E-W) - Specifications
11A-1-2
Item LimitStandard value
Oil cooler by-pass valve dimension (L) [by-pass hole closing temperature
(97 - 103°C or more)] mm
40.0 -
Oil pump side clearance Drive gear 0.08 - 0.14 -
Driven gear 0.06- 0.12 -
Pistons and connecting rods
Piston O.D. mm 82.7 -
Piston ring to piston ring groove clearance mm No. 1 0.05- 0.07 0.15
No. 2 0.05- 0.07 0.15
Piston ring end gap mm No. 1 0.20 - 0.32 0.8
No. 2 0.35- 0.50 0.8
Oil ring 0.10 - 0.30 0.8
Piston pin O.D. mm 25.0 -
Crankshaft pin oil clearance mm 0.02- 0.05 0.1
Connecting rod big end side clearance mm 0.10- 0.25 0.4
Connecting rod bushing I.D. mm 25.015- 25.025 -
Connecting rod bushing bend (Parallelism between big end center line and small
end center line) mm
0.05 -
Connecting rod bushing twist (Deflection between big end center line and small
end center line) mm
0.1 -
Crankshaft, cylinder block and flywheel
Crankshaft end play mm 0.05- 0.18 0.25
Crankshaft journal O.D. mm 57.0 -
Crankshaft pin O.D. mm 45.0 -
Crankshaft journal oil clearance mm 0.02- 0.04 0.1
Cylinder block gasket surface flatness mm 0.05 0.1
Cylinder block overall height mm 235 -
Cylinder bore I.D. mm 82.70- 82.73 -
Cylinder conicity mm 0.01 -
Piston to cylinder clearance mm 0.03- 0.05 -
Cylinder sleeve press-fitting force N 2,200 or more -
Piston projection mm 0.823 -
PWEE9609
EDec. 1996Mitsubishi Motors Corporation

4D68 ENGINE (E-W) - Specifications 11A-1-3
REWORK DIMENSIONS
Item Standard value Limit
Cylinder head, valves and valve springs
Cylinder head oversize valve guide hole 0.05 O.S. 13.050- 13.068 -
(both intake and exhaust) mm
0.25 O.S. 13.250- 13.268 -
0.50 O.S. 13.500- 13.518 -
Cylinder head oversize intake valve seat ring hole mm 0.3 O.S. 38.300- 38.325 -
0.6 O.S. 38.600- 38.625 -
Cylinder head oversize exhaust valve seat ring hole mm 0.3 O.S. 34.300- 34.325 -
0.6 O.S. 34.600- 34.625 -
NOTE
O.D.: Outer diameter
I.D.: Inner diameter
O.S.: Oversize diameter
PWEE9609
EDec. 1996Mitsubishi Motors Corporation

4D68 ENGINE (E-W) - Specifications
11A-1-4
TORQUE SPECIFICATIONS
Items Nm
Drive belt and glow plug
Oil level gauge guide bolt 13
Pulley bolt (for power steering pump drive) 9
Alternator brace bolt 23
Lock bolt 23
Adjusting bolt 10
Alternator pivot nut 44
Crankshaft pulley bolt 25
Glow plug 18
Glow plug nut 1.8
Timing belt
Timing belt cover Flange bolt 11
Washer bolt 9
Crankshaft position sensor bolt 9
Timing belt tensioner bolt 48
Tensioner spring bolt 13
Timing belt idler pulley bolt 48
Camshaft sprocket bolt 88
Injection pump sprocket flange bolt 9
Injection pump sprocket nut 83
Crankshaft bolt 118
Oil pump sprocket nut 54
Tensioner “B” bolt 18
Counterbalance shaft sprocket bolt 45
Timing belt rear cover bolt 11
Engine support bracket bolt and nut 49
Glow plug, fuel injection pump and injection nozzle
Injection pipe 29
Injection pipe clamp bolt 5
Fuel pipe bolt 13
Engine hanger bolt 18
Fuel injection pump bolt 23
Fuel injection pump nut 18
Fuel injection pump stay bolt 35
Fuel return pipe nut 29
PWEE9609
EDec. 1996Mitsubishi Motors Corporation

4D68 ENGINE (E-W) - Specifications 11A-1-5
Items Nm
Injection nozzle 54
Fuel injection pump bracket nut 23
Intake and exhaust manifold
Air temperature sensor 14
Air intake fitting bolt 17
EGR valve bolt 24
EGR pipe bolt and nut 17
Turbocharger heat protector bolt M8 13
M6 11
Exhaust fitting heat protector bolt 13
Water pipe “A” and “B” eye bolt 30
Water pipe “A” and “B” bolt 10
Oil pipe eye bolt 16
Exhaust fitting bolt and nut 59
Oil return pipe bolt 9
Heat protector front and rear bolt 13
Turbocharger assembly bolt 59
Exhaust manifold bolt and nut 29
Alternator brace stay bolt 23
Intake manifold bolt and nut 17
Water pump, thermostat, hose and pipe
Oil pipe eye bolt 16
Oil return pipe eye bolt 17
Oil return pipe bolt 9
Engine coolant temperature sensor 35
Engine coolant temperature gauge unit 11
Cover bolt 19
Water pump bolt 13
Water inlet pipe bolt 12
Vacuum pump bolt 22
Water inlet fitting bolt 23
Water outlet fitting bolt 12
Thermostat housing bolt 23
Rocker arms, rocker shaft and camshaft
Rocker cover bolt 6
Rocker shaft bolt 29
PWEE9609
EDec. 1996Mitsubishi Motors Corporation