Table of Contents

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1. SPECIFICATIONS
3. GENERATOR ASSEMBLY
4. GLOW PLUG
5. COOLING FAN, V-BELT AND WATER PUMP
6. WATER HOSES AND PIPES
7. THERMOSTAT
8. EGR VALVE ASSEMBLY
9. INTAKE MANIFOLD
10. TURBOCHARGER ASSEMBLY
11. EXHAUST MANIFOLD
12. INJECTION PUMP ASSEMBLY
13. INJECTION PUMP GEAR
14. ROCKER COVER, CAMSHAFT HOLDER ASSEMBLY AND CAMSHAFT
15. INJECTION NOZZLE
16. CYLINDER HEAD AND VALVE MECHANISM
17. VACUUM PUMP
18. TIMING GEAR CASE
19. TIMING GEAR AND BALANCE SHAFT
20. OIL PUMP
21. OIL COOLER AND OIL FILTER
22. OIL PAN, OIL STRAINER AND OIL JET
23. PISTON AND CONNECTING ROD
24. DRIVE PLATE
25. CRANK SHAFT AND CRANK CASE
26. BALANCE SHAFT BUSH
E
Mitsubishi Motors Corporation
ENGINE
4M41
CONTENTS
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Feb. 2000
PWEE9409-D
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11B-0-1
11B-0-3
11B-1-1
11B-1-1
11B-1-4
11B-1-8
11B-2-1
11B-3-1
11B-4-1
11B-5-1
11B-6-1
11B-7-1
11B-8-1
11B-9-1
11B-10-1
11B-11-1
11B-12-1
11B-13-1
. . . .
11B-14-1
11B-15-1
11B-16-1
11B-17-1
11B-18-1
11B-19-1
11B-20-1
11B-21-1
11B-22-1
11B-23-1
11B-24-1
11B-25-1
11B-26-1
Added

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Summary of Contents for Mitsubishi MOTORS 4M41

  • Page 1 ..........11B-26-1 Mitsubishi Motors Corporation Feb. 2000...
  • Page 2 11B-0-2 NOTES Mitsubishi Motors Corporation Feb. 2000 PWEE9409-D Added...
  • Page 3: General Information

    11B-0-3 4M41 ENGINE - General Information GENERAL INFORMATION Descriptions Specifications Total displacement dm 3200 No. and arrangement of cylinders 4 in-line Combustion chamber Direct injection No. of intake/exhaust valves (per cylinder) 2 each Valve mechanism Double overhead camshaft, 4-valve Cylinder bore x stroke mm 98.5 x 105...
  • Page 4: Specifications

    11B-1-1 4M41 ENGINE – Specifications 1. SPECIFICATIONS SERVICE SPECIFICATIONS Unit: mm Descriptions Standard Limit Glow plug Resistance Ω Glow plug – Intake manifold Resistance Ω Throttle body Throttle body temperature 12 – 20 – –10 – 50°C Throttle body temperature 15 –...
  • Page 5 11B-1-2 4M41 ENGINE – Specifications Descriptions Standard Limit Valve Intake Stem diameter 6.560 – 6.575 6.45 Sinkage from cylinder head 0.05 – 0.55 bottom Margin 45_ ± 15’ Valve seat angle – Exhaust Stem diameter 6.53 – 6.55 6.45 Sinkage from cylinder head 0.05 –...
  • Page 6 11B-1-3 4M41 ENGINE – Specifications Descriptions Standard Limit Piston and connecting rod assembly Piston Protrusion –0.20 – –0.30 – Piston pin Piston pin-to-connecting rod bush clearance 0.03 – 0.05 Piston pin-to-piston clearance 0.007 – 0.021 0.05 Piston ring Ring-to-ring No.1 compression ring 0.03 –...
  • Page 7: Torque Specifications

    11B-1-4 4M41 ENGINE – Specifications TORQUE SPECIFICATIONS Items Torque Nm Glow plug 1.3 ± 1 Connection plate 18 ± 1 Glow plug Cooling fan V-belt and water pump 10 ± 1 Cooling fan bolt 24 ± 2 Auto-cooling fan coupling nut 24 ±...
  • Page 8 11B-1-5 4M41 ENGINE - Specifications Items Torque Nm Injection nozzle Injection pipe 33 ± 3 Return pipe eyebolt 11 ± 1 Injection nozzle assembly eyebolt 13 ± 2 Leak-off pipe eye bolt 11 ± 1 Injection nozzle assembly mounting bolt 21 ±...
  • Page 9 11B-1-6 4M41 ENGINE - Specifications Items Torque Nm Oil pan, oil strainer and oil jet Drain plug 39 ± 3 Oil jet 32 ± 3 Piston and connecting rod Connecting rod cap mounting nut 29 ± 3 + 49 ± 5 + 45_ + 45_...
  • Page 10 11B-1-7 4M41 ENGINE - Specifications Hexagon flange bolts Unit: Nm Strength Code Head Mark Nominal Diameter mm 5 ± 1 10 ± 2 12 ± 2 13 ± 2 23 ± 4 27 ± 5 26 ± 4 22 ± 4 49 ±...
  • Page 11 11B-1-8 4M41 ENGINE - Specifications SEALANT Location Specified sealant Mating surface of front plate to cylinder head gasket 3M ATD Part No.8660 or equivalent Inner surface of sealing cap press-fitting hole THREEBOND TB1386, LOCTITE 962T or equivalent Mating surface of timing gear case to front plate* Mitsubishi Genuine Part No.
  • Page 12 11B-2-1 4M41 ENGINE - Special Tools 2. SPECIAL TOOLS Tool Number Name MB990767 Front Removal of crankshaft puley flange yoke holder Installation of injection pump assembly MD998754 Crankshaft pulley holder pin 157944-9520 Plate Removal and installation of retaining nut (Zexel)
  • Page 13 11B-2-2 4M41 ENGINE - Special Tools Tool Number Name MH063490 Cam sprocket Holding cam sprocket holder kit MD998772 Valve spring com- Removal and installation of valve cotter pressor MD998784 Valve spring com- pressor adaptor plate MD999597 Valve spring com- pressor...
  • Page 14 11B-2-3 4M41 ENGINE - Special Tools Tool Number Name MH063609 Valve stem seal Installation of valve stem seal f6.6 installer f15.4 MH062463 Idler gear bush Removal and installation of idler gear bush f27.5 puller f41.5 MH062462 Idler sprocket bush Removal and installation of idler sprocket...
  • Page 15 11B-2-4 4M41 ENGINE - Special Tools Tool Number Name MH062567 Gear puller Removal of injection pump gear MH063473 Pin wrench arm Assembling of injection pump gear assembly Mitsubishi Motors Corporation Feb. 2000 PWEE9409-D Added...
  • Page 16 11B-3-1 4M41 ENGINE - Generator Assembly 3. GENERATOR ASSEMBLY REMOVAL AND INSTALLATION Removal steps 1. Wiring harness 2. Adjusting bolt 3. Bolt 4. V-belt (Refer to page 11B-5-1.) "AA 5. Generator REMOVAL SERVICE POINT "AA GENERATOR INSPECTION Caution in Handling Generator The following caution should be taken when servicing the generator 5.
  • Page 17: Glow Plug

    11B-4-1 4M41 ENGINE - Glow Plug 4. GLOW PLUG REMOVAL AND INSTALLATION 13 ± 1 Nm 18 ± 1 Nm Removal steps 1. Nut 5. Coolant temperature sensor 2. Glow plug wiring harness (For engine control) 3. Connection plate 6. Glow relay 4.
  • Page 18 11B-5-1 4M41 ENGINE - Cooling Fan, V-belt and Water Pump 5. COOLING FAN, V-BELT AND WATER PUMP REMOVAL AND INSTALLATION 24 ± 2 Nm 24 ± 2 Nm 10 ± 1 Nm Removal steps 1. Bolt 2. Cooling fan 3. Nut 4.
  • Page 19 11B-5-2 4M41 ENGINE - Cooling Fan, V-belt and Water Pump INSPECTION 1. AUTO-COOLING FAN COUPLING Check the auto-cooling fan coupling 4, and replace if any of the following conditions exists: (1) Hydraulic fluid is leaking from the hermetically sealed housing.
  • Page 20 11B-6-1 4M41 ENGINE – Water Hoses and Pipes 6. WATER HOSES AND PIPES REMOVAL AND INSTALLATION 9 ± 1 Nm 25 ± 2 Nm 25 ± 2 Nm 25 ± 2 Nm Removal steps 1. Water hose *a: Thermostat case 2.
  • Page 21 11B-6-2 4M41 ENGINE - Water Hoses and Pipes INSTALLATION SERVICE POINTS "AA O-RING INSTALLATION Caution Engine oil swells O-rings. When installing the O-rings 4, be sure that they are free of engine oil. Mitsubishi Motors Corporation Feb. 2000 PWEE9409-D Added...
  • Page 22 11B-7-1 4M41 ENGINE - Thermostat 7. THERMOSTAT REMOVAL AND INSTALLATION Removal steps 1. Thermostat cover "BA 2. Thermostat 3. Bypass pipe "AA 4. O-ring 5. Thermostat case "AA 6. O-ring Mitsubishi Motors Corporation Feb. 2000 PWEE9409-D Added...
  • Page 23 11B-7-2 4M41 ENGINE - Thermostat INSTALLATION SERVICE POINTS "AA O-RING INSTALLATION Caution Engine oil swells O-rings. When installing the O-rings 4 and 6, be sure that they are free of engine oil. "BA THERMOSTAT INSTALLATION Install the thermostat 2 with its jiggle valve A located at the uppermost position.
  • Page 24 11B-8-1 4M41 ENGINE – EGR Valve Assembly 8. EGR VALVE ASSEMBLY REMOVAL AND INSTALLATION <EXCEPT 2002 MODEL PAJERO FOR EUROPE> Removal steps 1. EGR pipe 8. Gasket 2. Gasket 9. Air intake box 3. EGR pipe stay 10. Air intake box bracket 4.
  • Page 25 11B-8-2 4M41 ENGINE – EGR Valve Assembly REMOVAL AND INSTALLATION <2002 MODEL PAJERO FOR EUROPE> Removal steps 1. EGR pipe 8. EGR cooler 2. Gasket 9. EGR cooler bracket 3. EGR valve 4. Gasket *a: Air intake pipe 5. Insulator *b: Water hose 6.
  • Page 26 11B-8-3 4M41 ENGINE – EGR Valve Assembly CLEANING (1) Check the EGR valve 3 for carbon or sludge deposits. If present, remove the carbon or sludge using a wire brush. (2) Check the exhaust gas passage in the EGR cooler 8 for carbon or sludge deposits.
  • Page 27: Intake Manifold

    11B-9-1 4M41 ENGINE – Intake Manifold 9. INTAKE MANIFOLD REMOVAL AND INSTALLATION <EXCEPT 2002 MODEL PAJERO FOR EUROPE> 19.6 ± 1 Nm 15 ± 1 Nm Removal steps 1. Side cover 12. Gas filter assembly 2. EGR valve 13. Rubber spacer A 3.
  • Page 28 11B-9-2 4M41 ENGINE – Intake Manifold REMOVAL AND INSTALLATION <2002 MODEL PAJERO FOR EUROPE> 19.6 ± 1 Nm 15 ± 1 Nm Removal steps 1. Side cover 12. Gas filter assembly 2. EGR valve 13. Bracket 3. Gasket 14. Air intake pipe 4.
  • Page 29 11B-9-3 4M41 ENGINE – Intake Manifold INSTALLATION SERVICE POINT "AA GASKET INSTALLATION Gasket Fit the gasket to the cylinder head in the direction shown in the illustration. Gasket Cylinder head Cylinder head INSPECTION THROTTLE BODY ASSEMBLY (1) Move the throttle valve A by hand to check that it can be moved smoothly without getting stuck at any intermediate point.
  • Page 30 11B-10-1 4M41 ENGINE - Turbocharger Assembly 10. TURBOCHARGER ASSEMBLY REMOVAL AND INSTALLATION 54 ± 5 Nm 20 Nm 49 ± 4 Nm 25 ± 2 Nm 49 ± 4 Nm Removal steps 1. Eyebolt 11. Insulator B 2. Oil feed pipe 12.
  • Page 31 11B-10-2 4M41 ENGINE - Turbocharger Assembly INSTALLATION SERVICE POINT "AA TURBOCHARGER ASSEMBLY INSTALLATION (1) Prior to installing the turbocharger assembly 14, pour engine oil into it through the oil inlet hole A to lubricate its component parts for smooth movement.
  • Page 32: Exhaust Manifold

    11B-11-1 4M41 ENGINE - Exhaust Manifold 11. EXHAUST MANIFOLD REMOVAL AND INSTALLATION 30 ± 3 Nm 49 ± 4 Nm Removal steps 1. Insulator *1: EGR pipe 2. Insulator *2: Cylinder head 3. Bolt *3: Turbocharger 4. Nut 5. Nut 6.
  • Page 33: Injection Pump Assembly

    11B-12-1 4M41 ENGINE - Injection Pump Assembly 12. INJECTION PUMP ASSEMBLY REMOVAL AND INSTALLATION 25 ± 2 Nm 18 ± 2 Nm Removal steps 1. Injection pump cover B 11. Fuel leak-off hose 2. Injection pump cover A 12. Fuel suction hose 3.
  • Page 34 11B-12-2 4M41 ENGINE - Injection Pump Assembly REMOVAL SERVICE POINT AA" INJECTION PIPE REMOVAL Loosen the union nut B of the fuel injection pipe 13 while locking the delivery valve holder A to prevent it from rotating together. INSTALLATION SERVICE POINTS "AA INJECTION PUMP ASSEMBLY INSTALLATION...
  • Page 35 11B-12-3 4M41 ENGINE - Injection Pump Assembly (4) Confirm that the notch F on the injection pump gear E is aligned with the mating mark “H” on the flange plate G. Then push the injection pump assembly further into the front plate.
  • Page 36 11B-13-1 4M41 ENGINE - Injection Pump Gear 13. INJECTION PUMP GEAR REMOVAL AND INSTALLATION Locating pin 5 ± 1 Nm 38 ± 2 Nm 5 ± 1 Nm 5 ± 1 Nm 180 ± 10 Nm Locating pin 4ME0568 Removal steps 1.
  • Page 37 11B-13-2 4M41 ENGINE - Injection Pump Gear REMOVAL SERVICE POINT AA" INJECTION PUMP GEAR REMOVAL MH062567 Using the special tool, remove the injection pump gear 7. INSTALLATION SERVICE POINTS "AA FLANGE PLATE INSTALLATION Install the flange plate 11 while aligning the mating marks A on the flange plate and the injection pump 20.
  • Page 38 11B-13-3 4M41 ENGINE - Injection Pump Gear (5) Fit the snap ring 3 onto the injection pump gear. (6) Fit the special tool in the hole D in the sub gear 4. Turning the sub gear with the special tool counter-clockwise, align...
  • Page 39 Rocker Cover, Camshaft Holder 11B-14-1 4M41 ENGINE - Assembly and Camshaft 14. ROCKER COVER, CAMSHAFT HOLDER ASSEMBLY AND CAMSHAFT REMOVAL AND INSTALLATION Apply engine oil to all moving parts before installation. 13 ± 2 Nm 11 ± 1 Nm 20 ± 1 Nm 3.0 ±...
  • Page 40 Rocker Cover, Camshaft Holder 11B-14-2 4M41 ENGINE - Assembly and Camshaft Removal steps 1. Oil filler cap 19. No.5 camshaft cap 2. Bolt 20. Intake camshaft 3. Washer 21. Exhaust camshaft "BA 4. Rocker cover assembly 22. No.1 camshaft holder "BA 5.
  • Page 41 Rocker Cover, Camshaft Holder 11B-14-3 4M41 ENGINE - Assembly and Camshaft INSTALLATION SERVICE POINTS "AA BOLT INSTALLATION Caution The bolt 13 is inversely threaded. The arrow mark on its head B indicates its turning direction when tightened. "BA ROCKER COVER GASKET / ROCKET COVER...
  • Page 42 Rocker Cover, Camshaft Holder 11B-14-4 4M41 ENGINE - Assembly and Camshaft (3) Oil Clearance at Journals Measure the oil clearance at each journal. If the reading 15 - 19 exceeds the specified limit, replace the defective part. Standard value: 0.05 - 0.09 mm Limit: 0.15 mm...
  • Page 43: Injection Nozzle

    11B-15-1 4M41 ENGINE - Injection Nozzle 15. INJECTION NOZZLE REMOVAL AND INSTALLATION 13 ± 2 Nm 11 ± 1 Nm 21 ± 2 Nm 35 ± 5 Nm Cylinder head 11 ± 1 Nm 33 ± 3 Nm 4ME0506 Removal steps 1.
  • Page 44 11B-15-2 4M41 ENGINE - Injection Nozzle Caution 1. Fuel is highly flammable. Keep it away from flames and sources of heat. 2. Wipe up spilt fuel completely. It could catch fire. 3. Remove all deposited carbon from the injection nozzle assembly 10 before disassembling, reassembling and adjusting it.
  • Page 45 11B-15-3 4M41 ENGINE - Injection Nozzle 3. OIL TIGHTNESS CHECK (1) Slowly increase the nozzle internal pressure and maintain it at a pressure 1960 kPa lower than the specified 1st valve opening pressure. In this condition, check that the fuel injection nozzle does not start dribbling within10 seconds.
  • Page 46 11B-15-4 4M41 ENGINE - Injection Nozzle NOZZLE TIP, NEEDLE VALVE CLEANING 105789-0010 Wash the needle valve 13 and nozzle tip 12 removed in clean kerosene (cleaning oil) and remove deposited carbon from them in the following manners using the specified special tools.
  • Page 47 11B-15-5 4M41 ENGINE - Injection Nozzle INJECTION NOZZLE ASSEMBLY ADJUSTMENT While reassembling parts, adjust and check the injection nozzle assembly in the sequence shown below. Caution 1. Before starting adjustments and checks, wash all parts clean in clean kerosene (cleaning oil) to ensure that they are entirely free of dirt and other foreign matters.
  • Page 48 11B-15-6 4M41 ENGINE - Injection Nozzle (4) Attach the nozzle holder 25 to the nozzle tester A. (5) Pumping the nozzle tester B, measure the 1st valve opening pressure. Standard value: 17.60 - 18.58 MPa 4ME0519 (6) If the reading deviates from the specified standard value,...
  • Page 49 11B-15-7 4M41 ENGINE - Injection Nozzle (5) Connect the special tool Pin to the special tool Dial Gauge. 157892-7200 157954-3801 (6) Fit the special tool Dial Gauge onto the nozzle holder 25 and secure it with the special tool Nut in such a manner...
  • Page 50 11B-15-8 4M41 ENGINE - Injection Nozzle CHECKING PRELIFT (1) With the needle valve 13 fully lifted, release the handle of the nozzle tester B. This causes the pipe pressure to decrease with a concomitant drop in dial gauge reading (needle valve lift).
  • Page 51 11B-15-9 4M41 ENGINE - Injection Nozzle (3) Note the value indicated by the pressure gauge H the moment the dial gauge indicates the specified amount of needle valve lift (normally prelift E + 0.05 mm). D: Needle valve full lift E + 0.05...
  • Page 52 11B-16-1 4M41 ENGINE - Cylinder Head and Valve Mechanism 16. CYLINDER HEAD AND VALVE MECHANISM REMOVAL AND INSTALLATION Apply engine oil to all moving parts before 49 ± 5 Nm + 90_ + 90_ installation. 21 ± 2 Nm 49 ± 5 Nm + 90_ + 90_ 1.3 ±...
  • Page 53 11B-16-2 4M41 ENGINE - Cylinder Head and Valve Mechanism Apply engine oil to all moving parts before installation. 47 ± 5 Nm Removal steps 17. Valve cap AC" "BA 25. Exhaust valve guide AB" "EA 18. Valve cotter AC" "BA 26. Intake valve guide 19.
  • Page 54 11B-16-3 4M41 ENGINE - Cylinder Head and Valve Mechanism REMOVAL SERVICE POINTS AA" CYLINDER HEAD ASSEMBLY / CYLINDER HEAD GASKET REMOVAL Caution When removing the cylinder head gasket 16, use care not to scratch the cylinder head assembly 15, crankcase assembly and timing gear case assembly.
  • Page 55 11B-16-4 4M41 ENGINE - Cylinder Head and Valve Mechanism AB" VALVE COTTER REMOVAL MD998772 <Method 1> Using the special tools, remove the valve cotters 18 as follows. MD998784 Component parts of special tool MD998772 Valve Spring Compressor A: Wing bolt...
  • Page 56 11B-16-5 4M41 ENGINE - Cylinder Head and Valve Mechanism (4) Turning the handle C clockwise to depress the valve spring retainer 19, remove the valve cotters 18. <Method 2> MD999597 Using the special tool, compress the valve spring 20 to remove the valve cotters 18.
  • Page 57 11B-16-6 4M41 ENGINE - Cylinder Head and Valve Mechanism INSTALLATION SERVICE POINTS "AA INTAKE VALVE SEAT / EXHAUST VALVE SEAT INSTALLATION (1) Measure a diameter of the valve seat hole J, H in the cylinder head 32 and select an oversize valve seat which can provide proper amount of cylinder head-to-valve seat interference.
  • Page 58 11B-16-7 4M41 ENGINE - Cylinder Head and Valve Mechanism "CA VALVE STEM SEAL INSTALLATION (1) Apply a thin coat of engine oil to the lip A of the valve MH063609 stem seal 22, then press in the valve stem seal 22 by...
  • Page 59 11B-16-8 4M41 ENGINE - Cylinder Head and Valve Mechanism (2) Install the special tool MD998772 on the special tools MD998772 MD998784. MD998784 Q: Washer R: Nut (M6 x 1 mm) (3) Move the retainer B and mobile nut K into a position...
  • Page 60 11B-16-9 4M41 ENGINE - Cylinder Head and Valve Mechanism "FA CYLINDER HEAD GASKET INSTALLATION The cylinder head gasket 16 is a part that needs to be selected for use. Select the appropriate gasket in the following manner. (1) When replacing the cylinder head gasket alone-Identify;...
  • Page 61 11B-16-10 4M41 ENGINE - Cylinder Head and Valve Mechanism (1) Apply a coat of specified sealant to the upper surface H of the front plate *c that joins the cylinder head gasket Specified sealant: ThreeBond 1211 or equivalent (2) Within 3 minutes after the sealant application, install the cylinder head assembly 15 to the crankcase assembly *d together with the cylinder head gasket 16.
  • Page 62 11B-16-11 4M41 ENGINE - Cylinder Head and Valve Mechanism (2) Turn the cam A of the tensioner 9 to thrust the plunger B in and lock the plunger with the hook C. Then, install the tensioner in that state. (3) Crank the engine in the normal direction (clockwise).
  • Page 63 11B-16-12 4M41 ENGINE - Cylinder Head and Valve Mechanism 2. VALVE SEAT (1) Valve Seat Width 23, 24 Replace the valve seat 27, 28 if the specified service 27, 28 limit is exceeded. A: Valve seat width Standard value: 1.8 - 2.2 mm Limit: 2.8 mm...
  • Page 64 11B-16-13 4M41 ENGINE - Cylinder Head and Valve Mechanism 5. CYLINDER HEAD ASSEMBLY Measure the distortion of the bottom surface of the cylinder head 31. If the measured value exceeds the limit, replace the cylinder head. Standard value: 0.05 mm or less Limit: 0.2 mm...
  • Page 65 11B-16-14 4M41 ENGINE - Cylinder Head and Valve Mechanism (2)Using Valve Lapper, strike the valve 23, 24 against the valve seat 27, 28 a few times while turning little by little. B: Valve Lapper 23, 24 (3) Wash off the lapping compound in kerosene.
  • Page 66: Vacuum Pump

    11B-17-1 4M41 ENGINE - Vacuum Pump 17. VACUUM PUMP REMOVAL AND INSTALLATION <With ABS> <Without ABS, LHD> <Without ABS, RHD> 20 ± 2 Nm 5.4 ± 0.4 Nm Removal steps 1. Vacuum hose 7. Cover 2. Vacuum pipe 8. O-ring 3.
  • Page 67 11B-17-2 4M41 ENGINE - Vacuum Pump INSPECTION VACUUM PUMP ASSEMBLY (1) Connect a vacuum tank (capacity: 10 liters) to the vacuum pump assembly 5 through a vacuum gauge A. B: Engine oil inlet C: Engine oil outlet (to oil pan) (2) With the engine running, read the engine speed when the vacuum builds up to the standard value.
  • Page 68 11B-18-1 4M41 ENGINE - Timing Gear Case 18. TIMING GEAR CASE REMOVAL AND INSTALLATION Apply engine oil to all moving parts before installation. 23 ± 2 Nm 323 ± 32 Nm 23 ± 2 Nm Removal steps 1. Timing gear lower cover 8.
  • Page 69 11B-18-2 4M41 ENGINE - Timing Gear Case REMOVAL SERVICE POINT AA" CRANKSHAFT PULLY REMOVAL Holding the crankshaft pulley 4 with the special tool, remove the bolt 2. MD998754 MB990767 INSTALLATION SERVICE POINTS "AA TIMING GEAR CASE INSTALLATION Apply an even bead of sealant to the entire joint surface of the timing gear case 13 as shown.
  • Page 70 11B-19-1 4M41 ENGINE - Timing Gear and Balance Shaft 19. TIMING GEAR AND BALANCE SHAFT REMOVAL AND INSTALLATION Apply engine oil to all moving parts before installation. 36 ± 4 Nm 33 ± 3 Nm 40 ± 4 Nm 12 ± 1 Nm 36 ±...
  • Page 71 11B-19-2 4M41 ENGINE - Timing Gear and Balance Shaft Removal steps 1. Upper guide plate "EA 24. Idler gear assembly LH 2. Cam sprocket AA" "DA 25. Idler gear bush LH "GA 3. Timing chain 26. Idler gear LH 4. Bolt 27.
  • Page 72 11B-19-3 4M41 ENGINE - Timing Gear and Balance Shaft 2. END PLAY If the reading exceeds the specified service limit, replace defective part. Standard value: Balance shaft LH, RH 0.09 - 0.24 mm Idler gear and sprocket assembly 0.05 - 0.20 mm Idler gear LH assembly 0.05 - 0.20 mm...
  • Page 73 11B-19-4 4M41 ENGINE - Timing Gear and Balance Shaft "BA IDLER GEAR AND SPROCKET ASSEMBLY INSTALLATION Install the idler gear and sprocket assembly 42 onto the idler “1” shaft 45 while aligning the mark “1” with that on the crankshaft gear *c.
  • Page 74 11B-19-5 4M41 ENGINE - Timing Gear and Balance Shaft "FA BALANCE SHAFT RH ASSEMBLY INSTALLATION (1) Assemble the parts shown in the illustration to the balance shaft RH 19. Be sure to install the washer 14 and thrust spacer 16 in the direction shown in the illustration, and install the balance shaft gear RH 15 with its mating mark “0”...
  • Page 75 11B-19-6 4M41 ENGINE - Timing Gear and Balance Shaft INSPECTION 1. TIMING CHAIN (1) Aligning the stamped lines L on the adjusting plate D and nut E, set the camshaft sprocket 2 in position. (2) Push the tension lever 5 by hand to take up the slack of the timing chain 3.
  • Page 76 11B-19-7 4M41 ENGINE - Timing Gear and Balance Shaft 4. IDLER GEAR BUSH LH AND IDLER SHAFT If the idler gear bush 25 to idler shaft 27 clearance exceeds the specified limit, replace the defective part. Standard value: 0.02 - 0.05 mm Limit: 0.1 mm...
  • Page 77: Oil Pump

    11B-20-1 4M41 ENGINE - Oil Pump 20. OIL PUMP REMOVAL AND INSTALLATION 44 ± 4 Nm 10 ± 1 Nm 36 ± 3 Nm Removal steps 1. Balance shaft RH assembly 13. Relief valve spring 2. Bolt 14. Steel ball 3.
  • Page 78 11B-20-2 4M41 ENGINE - Oil Pump INSPECTION OIL PUMP (1) Shaft to Oil Pump Case and Cover Clearances In either case, if the measurement exceeds the specified service limit, replace oil pump assembly. Standard value: 0.03 - 0.05 mm Limit: 0.15 mm...
  • Page 79 11B-21-1 4M41 ENGINE - Oil Cooler and Oil Filter 21. OIL COOLER AND OIL FILTER REMOVAL AND INSTALLATION 20 ± 2 Nm 44 ± 4 Nm 44 ± 4 Nm 30 ± 3 Nm Removal steps "AA 1. Oil filter 10.
  • Page 80 11B-21-2 4M41 ENGINE - Oil Cooler and Oil Filter CLEANING (1) Check the oil cooler element 5 for deposited carbon and sludge in oil passage and bypass, and wash it clean in cleaning oil, if necessary. (2) Wash the oil cooler element 5 and the oil cooler body 13 if they are much contaminated with scale.
  • Page 81 11B-22-1 4M41 ENGINE - Oil Pan, Oil Strainer and Oil Jet 22. OIL PAN, OIL STRAINER AND OIL JET REMOVAL AND INSTALLATION 32 ± 3 Nm 39 ± 3 Nm Removal steps 1. Drain plug 10. Check valve 2. Oil pan cover LH (Refer to page 11B-25-1.)
  • Page 82 11B-22-2 4M41 ENGINE - Oil Pan, Oil Strainer and Oil Jet INSTALLATION SERVICE POINT "AA OIL PAN INSTALLATION (1) Apply sealant at the bottom B of the mating surface of lower crankcase C and timing gear case D. (2) Apply even beads of sealant A without skips to the circumferential mating surface of the oil pan 6 as shown.
  • Page 83: Piston And Connecting Rod

    11B-23-1 4M41 ENGINE - Piston and Connecting Rod 23. PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION Apply engine oil to all moving parts before installation. 29 ± 3 Nm + 49 ± 5 Nm + 45_ + 45_ 4ME0597 Mitsubishi Motors Corporation Feb.
  • Page 84 11B-23-2 4M41 ENGINE - Piston and Connecting Rod Apply engine oil to all moving parts before installation. Removal steps AA" 1. Nut AB" "DA 8. Oil ring "FA 2. Lower connecting rod bearing 9. Snap ring 3. Connecting rod cap AC"...
  • Page 85 11B-23-3 4M41 ENGINE - Piston and Connecting Rod PRE-REMOVAL INSPECTION 1. PISTON PROTRUSION FROM CRANKCASE TOP Caution Do not fail to check piston protrusions. The engine performance are directly influenced by them. (1) Position each piston at the TDC. (2) There are five reference points A on the upper crankcase *b that serve as a zero level each.
  • Page 86 11B-23-4 4M41 ENGINE - Piston and Connecting Rod AC" PISTON PIN / PISTON / CONNECTING ROD ASSEMBLY REMOVAL Remove the piston pin 10 using an appropriate push-out bar D as shown. NOTE To make the piston pin 10 easy to remove, warm the piston 11 over an appropriate heater or in hot water if necessary.
  • Page 87 11B-23-5 4M41 ENGINE - Piston and Connecting Rod "BA CONNECTING ROD BUSH INSTALLATION Use the special tool to install the connecting rod bush 13. Component Parts of Special Tool MH062574 - Connecting Rod Bush Puller Kit A: Collar B: Collar...
  • Page 88 11B-23-6 4M41 ENGINE - Piston and Connecting Rod (2) Apply a thin coat of engine oil to the piston pin 10 prior “¬” to insertion. Assemble the connecting rod 12 and piston 11 facing in the directions shown. “1”: Connecting rod identification mark “¬”: Front mark...
  • Page 89 11B-23-7 4M41 ENGINE - Piston and Connecting Rod (4) Using the special tool, install the piston and connecting “¬” rod assembly in position, with the front mark “¬” on the piston crown facing toward the engine front F. MH063484 (5) Press the piston down. Apply a thin coat of engine oil...
  • Page 90 11B-23-8 4M41 ENGINE - Piston and Connecting Rod "FA CONNECTING ROD BEARING INSTALLATION The connecting rod bearing 2, 4 to be used must have an appropriate thickness that matches the big end I.D. of the connecting rod and the pin O.D. of the crankshaft assembly.
  • Page 91 11B-23-9 4M41 ENGINE - Piston and Connecting Rod <Selection by identification color> Select appropriate connecting rod bearings through the combination of the big end I.D. identification color marked on each connecting rod and the appropriate pin O.D. identification color on the crankshaft assembly *a as shown in the table below.
  • Page 92 11B-23-10 4M41 ENGINE - Piston and Connecting Rod (2) Connecting Rod Bearing-to-Crankshaft Clearance (Oil clearance) 1) Fit the lower connecting rod bearing shell 2 and upper connecting rod bearing shell 4 in the connecting rod cap 3 and the piston and connecting rod assembly 5, respectively.
  • Page 93 11B-23-11 4M41 ENGINE - Piston and Connecting Rod (2) Piston Ring-to-Piston Ring Groove Clearance 1) If the measured clearance exceeds the specified limit, replace the defective part. 6, 7, 8 Standard value: 1st compression ring 0.03 - 0.08 mm 2nd compression ring 0.07 - 0.10 mm...
  • Page 94 11B-23-12 4M41 ENGINE - Piston and Connecting Rod 4. CONNECTING ROD (1) Fit the connecting rod bush 13 and piston pin 10 in the connecting rod 15. 100 mm (2) Measure the bend A and twist B of the connecting rod 15.
  • Page 95 11B-24-1 4M41 ENGINE - Drive Plate 24. DRIVE PLATE REMOVAL AND INSTALLATION 123 ± 12 Nm 4ME0598 Removal steps 1. Bolt "AA 2. Adaptor plate 3. Drive plate assembly AA" "BA 4. Ring gear 5. Drive plate "AA 6. Crankshaft adaptor REMOVAL SERVICE POINT AA"...
  • Page 96 11B-24-2 4M41 ENGINE - Drive Plate INSTALLATION SERVICE POINTS "AA CRANKSHAFT ADAPTOR / ADAPTOR PLATE INSTALLATION Attach the adaptor plate 2 and the crankshaft adaptor 6 to the drive plate assembly, facing in the directions A shown. A: Drive plate side "BA RING GEAR INSTALLATION...
  • Page 97 11B-25-1 4M41 ENGINE - Crank Shaft and Crank Case 25. CRANK SHAFT AND CRANK CASE REMOVAL AND INSTALLATION 32 ± 3 Nm 47 ± 5 Nm Apply engine oil to all moving parts before installation. 20 ± 2 Nm + 90_ + 90_ 25 ±...
  • Page 98 11B-25-2 4M41 ENGINE - Crank Shaft and Crank Case Removal steps 1. Bolt "AA 16. Lower main bearing "FA 2. Front plate 17. Lower crankcase 3. Stiffener "BA 18. Lower thrust plate 4. Stiffener RH 19. Crankshaft assembly 5. Stiffener LH AB"...
  • Page 99 11B-25-3 4M41 ENGINE - Crank Shaft and Crank Case INSTALLATION SERVICE POINTS "AA MAIN BEARING INSTALLATION The main bearings 16 and 25 must have a proper plate thickness that matches the difference between the bearing mounting hole I.D. of the crankcase assembly 17, 29 and the journal O.D.
  • Page 100 11B-25-4 4M41 ENGINE - Crank Shaft and Crank Case "BA THRUST PLATE INSTALLATION Install the thrust plates 18 and 23 to the crankshaft assembly 19 at No.5 journal only. Install all halves of the thrust plates with the oil groove A oriented outward.
  • Page 101 11B-25-5 4M41 ENGINE - Crank Shaft and Crank Case "EA REAR OIL SEAL / REAR OIL SEAL CASE INSTALLATION (1) Apply a thin coat of engine oil to the lip A of the rear oil seal 11. Press the rear oil seal all the way into the rear oil seal case 12 in the direction shown.
  • Page 102 11B-25-6 4M41 ENGINE - Crank Shaft and Crank Case INSPECTION 1. MAIN BEARINGS Caution 1. Be sure not to use the main bearings 16 and 25 expanded forcedly. 2. When either the main bearing 16 or 25 is defective, replace them in pairs.
  • Page 103 11B-25-7 4M41 ENGINE - Crank Shaft and Crank Case (2) Bend 1) To measure the bend of the crankshaft 22, support it at No. 1 journal C and No. 5 journal D and read the runout at No. 3 journal E.
  • Page 104 11B-25-8 4M41 ENGINE - Crank Shaft and Crank Case 4. CYLINDER BORING (1) Determine the oversize piston to be used based on the largest cylinder inside diameter. (2) There are two types of oversize pistons available (+0.50 53.5 mm mm and +1.00 mm). Bore the cylinders so that the clearance between the cylinder and the piston installed meets the specified standard value.
  • Page 105 11B-26-1 4M41 ENGINE - Balance Shaft Bush 26. BALANCE SHAFT BUSH REMOVAL AND INSTALLATION 4ME0600 Removal steps AA" "AA 1. Balance shaft bush REMOVAL SERVICE POINT AA" BALANCE SHAFT BUSH REMOVAL Using the special tool, remove the balance shaft bush 1 in...
  • Page 106 11B-26-2 4M41 ENGINE - Balance Shaft Bush (1) Set the tools as shown by passing the remover C, through the balance shaft bush 1 while tilting it as shown. (2) Pull the puller D to bring the washer B into contact with the remover C.
  • Page 107 11B-26-3 4M41 ENGINE - Balance Shaft Bush (1) Fit the balance shaft bush 1 onto the installer K from the non-chamfered side. At this time, align the oil hole with the alignment mark P “ - ” on the installer.
  • Page 108 11B-26-4 4M41 ENGINE - Balance Shaft Bush (4) Screw the nut N onto the installer K up to its alignment mark P “ - ” to predetermine the press-fitting depth of the balance shaft bush 1. (5) Strike on the installer K until the nut N positively contacts the washer M to press-fit the balance shaft bush 1 into the crankcase.

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