Mitsubishi 4D68 Instruction manual

11A
MITSUBISHI
ENGINE
4D68 (E-W)
WORKSHOP MANUAL
Engine .......................................
Pub. No. PWEE9609
FOREWORD
This Workshop Manual contains procedures for
removal, disassembly, inspection, adjustment,
reassembly and installation, etc. for service
mechanics.
All information, illustrations and product
descriptions contained in this manual are current
as at the time of publication. We, however, reserve
the right to make changes at any time without
prior notice or obligation.
FILING INSTRUCTION
Please keep these manual pages in the binder
No. BN890001.
File these pages according to the signs
“Added”, “Revised” and “Deleted” on the “List
of effective pages” which are interpreted
below.
Added:
File the pages with this sign additionally in
your manual.
Revised, Deleted:
Replace the existing pages with the
corresponding pages with this sign.
Missing sheets will be supplied upon request.
EMitsubishi Motors Corporation Dec. 1996

INTRODUCTION
Classification of Major Maintenance/Service Points
When there are major points relative to maintenance and servicing procedures
(such as essential maintenance and service points, maintenance and service stan-
dard values, information regarding the use of special tools, etc.), these are
arranged together as major maintenance and service points and explained in
detail.
AA": Indicates that there are essential points for removal or disassembly.
"AA: Indicates that there are essential points for installation or reassembly.
Maintenance and Servicing Procedures
(1) A diagram of the component parts is
provided near the front of each section in
order to give the reader a better under-
standing of the installed condition of
component parts.
(2) The numbers provided within the diagram
indicate the sequence for maintenance and
servicing procedures.
: Indicates a non-reusable part.
The tightening torque is provided where
applicable.
DRemoval steps:
The part designation number corresponds
to the number in the illustration to indicate
removal steps.
DDisassembly steps:
The part designation number corresponds
to the number in the illustration to indicate
disassembly steps.
DInstallation steps:
Specified in case installation is impossible
in reverse order of removal steps. Omitted
if installation is possible in reverse order
of removal steps.
DReassembly steps:
Specified in case reassembly is impossible
in reverse order of disassembly steps.
Omitted if reassembly is possible in reverse
order of disassembly steps.
Symbols for Lubrication, Sealants and Adhesives
Information concerning the locations for
lubrication and for application of sealants
and adhesives is provided, by using sym-
bols, in the diagram of component parts, or
on the page following the component parts
page, and explained.
: Grease (multipurpose grease unless
there is a brand or type specified)
: Sealant or adhesive
: Brake fluid, automatic transmission fluid
or air conditioner compressor oil
: Engine oil or gear oil
EXPLANATION OF MANUAL CONTENTS
PWEE9609
EDec. 1996Mitsubishi Motors Corporation

Indicates the
section num-
ber.
Indicates the
group title.
Indicates the
section title.
Indicates the
group number.
Indicates the
page number.
Issue date Publication number-Revision code
4G68 ENGINE (E - W) - Water Pump, Thermostat, Hose and Pipes 11A-7-1
Removal steps
1. Eyebolt
2. Gasket
3. Oil pipe
4. Gasket
5. Eyebolt
6. Gasket
7. Oil return pipe
8. Oil return hose
9. Engine coolant temperature sensor
"FA10. Engine coolant temperature gauge
unit
"EA11. Cover
12. Water pump
13. Water pump gasket
"DA14. O-ring
"DA15. Water inlet pipe
"DA16. O-ring
17. Vacuum pump
18. O-ring
19. Water inlet fitting
"CA20. Thermostat
"BA21. Water outlet fitting
"AA22. Thermostat housing
DEN0768
INSTALLATION SERVICE POINTS
"AATHERMOSTAT 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.
12
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
9Nm
23 Nm
23 Nm
22 Nm
16 Nm
12 Nm
35 Nm
11 Nm
45 Nm
13 Nm
19 Nm
12 Nm
7. WATER PUMP, THERMOSTAT, HOSE AND PIPES
REMOVAL AND INSTALLATION
EMitsubishi Motors Corporation Dec. 1996 PWEE9609
Operating procedures, cau-
tions, etc. on removal, installa-
tion, disassembly and reas-
sembly are described.
This number corresponds to
the number appearing in
“Removal steps”,
“Disassembly steps”,
“Installation steps” or
“Reassembly steps”.
Denotes tightening
torque.
Denotes non-reusable part.
INTRODUCTION
PWEE9609
EDec. 1996Mitsubishi Motors Corporation

NOTES
PWEE9609
EDec. 1996Mitsubishi Motors Corporation