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

...

9. CYLINDER HEAD, VALVES AND VALVE SPRINGS 11A-9-1

.....

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

...

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

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