Mitsubishiメーカー4D68の使用説明書/サービス説明書
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GENERAL INFORMA TION 1 1A-0-3 ..................................... 1. SPECIFICA TIONS 1 1A-1-1 .......................................... SERVICE SPECIFICA TIONS 1 1A-1-1 ............................ REWORK DIMENSIONS 1 1A-1-3 .......................
1 1A-0-2 PWEE9609 E Dec. 1996 Mitsubishi Motors Corporation NOTES.
4D68 ENGINE (E - W) - General Information 1 1A-0-3 GENERAL INFORMA TION SECTIONAL VIEW OF ENGINE PWEE9609 E Dec. 1996 Mitsubishi Motors Corporation.
4D68 ENGINE (E - W) - General Information 1 1A-0-4 SECTIONAL VIEW OF ENGINE PWEE9609 E Dec. 1996 Mitsubishi Motors Corporation.
4D68 ENGINE (E - W) - General Information 1 1A-0-5 GENERAL SPECIFICA TIONS Descriptions Specifications T ype Diesel engine Number of cylinders 4 in-line Combustion chamber Swirl chamber T otal displacement dm 3 1.998 Cylinder bore mm 82.7 Piston stroke mm 93 Compression ratio 22.
4D68 ENGINE (E - W) - Specifications 1 1A-1-1 1. SPECIFICA TIONS SERVICE SPECIFICA TIONS Item Standard value Limit Drive belt and glow plug Glow plug resistance W 0.5 - Timing belt T iming belt deflection mm 4.0 - 5.0 - T iming belt “B” deflection mm 5.
4D68 ENGINE (E - W) - Specifications 1 1A-1-2 Item Limit Standard 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.
4D68 ENGINE (E - W) - Specifications 1 1A-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.
4D68 ENGINE (E - W) - Specifications 1 1A-1-4 TORQUE SPECIFICA TIONS 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.
4D68 ENGINE (E - W) - Specifications 1 1A-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.
4D68 ENGINE (E - W) - Specifications 1 1A-1-6 Items Nm Adjusting nut 15 Camshaft bearing cap bolt M8 ¢ 25, M8 ¢ 40 20 M8 ¢ 55 29 Cylinder head, valves and valve springs Cylinder head bolt 90 ¯ Ful.
4D68 ENGINE (E - W) - Specifications 1 1A-1-7 NEW TIGHTENING METHOD - BY USE OF BOL TS 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 dif ferent from the conventional one.
4D68 ENGINE (E - W) - Specifications 1 1A-1-8 FORM-IN-PLACE GASKET The engine has several areas where the form-in-place gasket (FIPG) is in use. T o ensure that the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket.
4D68 ENGINE (E - W) - Special T ools 1 1A-2-1 2. SPECIAL TOOLS T ool Number Name Use MB990767 End yoke holder Holding camshaft sprocket or fuel injection pump when loosening or tightening bolts.
4D68 ENGINE (E - W) - Special T ools 1 1A-2-2 T ool Use Name Number MD998375 Crankshaft front oil seal installer Installation of crankshaft front oil seal MD998388 Injection pump sprocket puller Remov.
4D68 ENGINE (E - W) - Special T ools 1 1A-2-3 T ool Use Name Number MD998776 Crankshaft rear oil seal installer Installation of crankshaft rear oil seal (Use with MB990938) MD998778 Crankshaft sprocke.
4D68 ENGINE (E - W) - Drive Belt and Glow Plug 1 1A-3-1 3. DRIVE BEL T A ND GLOW PLUG REMOV AL AND INST ALLA TION DEN0885 1 2 3 4 5 6 7 8 9 10 11 12 13 Nm 18 Nm 1.8 Nm 44 Nm 10 Nm 23 Nm 9N m 25 Nm Removal steps 1. Oil level gauge 2. O-ring 3. Oil level gauge guide 4.
4D68 ENGINE (E - W) - Drive Belt and Glow Plug 1 1A-3-2 REMOV AL SERVICE POINTS A A " GLOW PLUG REMOV AL (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.
4D68 ENGINE (E - W) - Timing Belt 1 1A-4-1 4. TIMING BEL T REMOV AL AND INST ALLA TION DEN0886 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 11 N m 45 Nm 18 Nm 11 N m 11 N m 9N m 9N m 9N m 49 Nm 48 Nm 48 Nm 83 Nm 88 Nm 54 Nm 11 8 N m 13 Nm 28 Removal steps 1.
4D68 ENGINE (E - W) - Timing Belt 1 1A-4-2 REMOV AL SERVICE POINTS A A " TIMING BEL T REMOV AL (1) Using chalk, etc., mark an arrow on the back of t he timing belt to indicate the direction of rotation. This is to ensure correct installation of the belt in case it is reused.
4D68 ENGINE (E - W) - Timing Belt 1 1A-4-3 A E " CRANKSHAFT BOL T LOOSENING A F " CRANKSHAFT SPROCKET REMOV AL A G " OIL PUMP SPROCKET REMOV AL (1) Before loosening the oil pump sprocke.
4D68 ENGINE (E - W) - Timing Belt 1 1A-4-4 A I " COUNTERBALANCE SHAFT SPROCKET REMOV AL A J " CRANKSHAFT SPROCKET “B” REMOV AL INST ALLA TION SERVICE POINTS " A A SP ACER INST ALLA TION (1) Install t he spacer with t he chamfered e nd toward t he oil seal.
4D68 ENGINE (E - W) - Timing Belt 1 1A-4-5 (3) Make sure that the pulley center and the bolt center are located as shown in the illustration. (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.
4D68 ENGINE (E - W) - Timing Belt 1 1A-4-6 " F A INJECTION PUMP SPROCKET NUT TIGHTENING " G A CAMSHAFT SPROCKET BOL T TIGHTENING " H A TIMING BEL T TENSIONER INST ALLA TION (1) Set the tensioner spring ends against the tensioner bracket and the projection of the injection pump bracket.
4D68 ENGINE (E - W) - Timing Belt 1 1A-4-7 (4) Remove the plug on the cylinder block and insert a Phillips screwdriver [shank diameter 8 mm] through the hole.
4D68 ENGINE (E - W) - Timing Belt 1 1A-4-8 INSPECTION TIMING BEL TS 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 n o mark is produced even when scratched by fingernails.
4D68 ENGINE (E - W) - Glow Plug, Fue l Injec tion Pum p And Inje ct ion Noz zle 1 1A-5-1 5. GLOW PLUG, FUEL INJECTION PUMP AND INJECTION NOZZLE REMOV AL AND INST ALLA TION DEN0887 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 18 Nm 18 Nm 13 Nm 13 Nm 23 Nm 23 Nm 35 Nm 54 Nm 29 Nm 29 Nm 29 Nm 5N m 5N m Removal steps A A "" D A 1.
4D68 ENGINE (E - W) - Glow Plug, Fue l Injec tion Pum p And Inje ct ion Noz zle 1 1A-5-2 REMOV AL SERVICE POINTS A A " INJECTION PIPE REMOV AL (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.
4D68 ENGINE (E - W) - Glow Plug, Fue l Injec tion Pum p And Inje ct ion Noz zle 1 1A-5-3 INST ALLA TION SERVICE POINTS " A A NOZZLE GASKET / HOLDER GASKET INST ALLA TION (1) Clean nozzle holder installation areas of the cylinder head. (2) Fit a new nozzle gasket and holder gasket into the nozzle holder hole in the cylinder head.
4D68 ENGINE (E - W) - Intake and Exhaust Manifolds 1 1A-6-1 6. INT AKE AND EXHAUST MANIFOLDS REMOV AL AND INST ALLA TION DEN0888 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 26 27 28 29 30 23.
4D68 ENGINE (E - W) - Intake and Exhaust Manifolds 1 1A-6-2 INST ALLA TION SERVICE POINTS " A A OIL RETURN PIPE GASKET INST ALLA TION (1) Install the oil return pipe gasket in such a way that its projection is located at the illustrated position.
4D68 ENGINE (E - W) - W ater Pump, Thermostat, Hose and Pipes 1 1A-7-1 7. W A TER PUMP , THERMOST A T , HOSE AND PIPES REMOV AL AND INST ALLA TION DEN0889 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 9N m 23 Nm 23 Nm 22 Nm 16 Nm 12 Nm 35 Nm 11 N m 45 Nm 13 Nm 19 Nm 12 Nm Removal steps 1.
4D68 ENGINE (E - W) - W ater Pump, Thermostat, Hose and Pipes 1 1A-7-2 INST ALLA TION SERVICE POINTS " A A THERMOST A T HOUSING INST ALLA TION (1) Apply a 3 mm bead of form-in-place gasket (FIPG) to the mounting surface. Specified sealant: Mitsubishi Genuine Part No.
4D68 ENGINE (E - W) - W ater Pump, Thermostat, Hose and Pipes 1 1A-7-3 " F A ENGINE COOLANT TEMPERA TURE GAUGE UNIT INST ALLA TION (1) If the water temperature sensor is to be reused, apply the specified sealant to its thread. Specified sealant: 3M Nut Locking Part No.
4D68 ENGINE (E - W) - Rocker Arms, Rocker Shaft and Camshaft 1 1A-8-1 8. ROCKER ARMS, ROCKER SHAFT AND CAMSHAFT REMOV AL AND INST ALLA TION DEN0891 1 2 3 4 5 6 7 8 9 10 11 12 13 29 Nm 29 Nm 20 Nm 20 Nm 15 Nm 6N m 29 Nm 12 12 12 Apply engine oil to all moving parts before installation.
4D68 ENGINE (E - W) - Rocker Arms, Rocker Shaft and Camshaft 1 1A-8-2 INST ALLA TION SERVICE POINTS " A A CAMSHAFT BEARING CAP INST ALLA TION (1) Install the bearing caps in the designated position confirming the identification numbers stamped on the cap front.
4D68 ENGINE (E - W) - Rocker Arms, Rocker Shaft and Camshaft 1 1A-8-3 V AL VE CLEARANCE ADJUSTMENT (1) T urn the crankshaft clockwise an d align the timing mark on camshaft sprocket with that on the injection pump bracket. (2) Adjust the valve clearance at the points shown in the illustration.
4D68 ENGINE (E - W) - Rocker Arms, Rocker Shaft and Camshaft 1 1A-8-4 (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.
4D68 ENGINE (E - W) - Cylinder Head, V alves and V alve Springs 1 1A-9-1 9. CYLINDER HEAD, V AL VES AN D V AL VE SPRINGS REMOV AL AND INST ALLA TION DEN0777 Apply engine oil to all moving parts before installation. Removal steps A A "" E A 1.
4D68 ENGINE (E - W) - Cylinder Head, V alves and V alve Springs 1 1A-9-2 REMOV AL SERVICE POINTS A A " CYLINDER HEAD BOL T REMOV AL (1) Using a 12 mm - 12 points socket wrench, loosen the cylinder head bolts. A B " RET AINER LOCK REMOV AL (1) Store removed valves, springs and other parts, tagged to indicate their cylinder No.
4D68 ENGINE (E - W) - Cylinder Head, V alves and V alve Springs 1 1A-9-3 " C A RET AINER LOCK INST ALLA TION (1) The valve spring, if excessively compressed, causes the bottom end of the retainer to be in contact with, and damage, the stem seal.
4D68 ENGINE (E - W) - Cylinder Head, V alves and V alve Springs 1 1A-9-4 (3) Using the special tool (MB991654) a nd according to the tightening sequence, tighten the bolts to the specified torque. T ightening torque: 90 Nm (4) Loosen all bolts fully .
4D68 ENGINE (E - W) - Cylinder Head, V alves and V alve Springs 1 1A-9-5 VA LV E (1) Check the valve face for correct contact. If incorrect, reface using a valve refacer . V alve 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.
4D68 ENGINE (E - W) - Cylinder Head, V alves and V alve Springs 1 1A-9-6 (2) Install the valve and, while pressing the valve against the valve seat, measure the valve stem projection between the valve stem end and the valve spring seat seating surface.
4D68 ENGINE (E - W) - Cylinder Head, V alves and V alve Springs 1 1A-9-7 V AL VE GUIDE REPLACEMENT PROCEDURE (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 .
4D68 ENGINE (E - W) - Fro nt Case, C ounterba lanc e Sha fts a nd Oil Pan 1 1A-10-1 10. FRONT CASE, COUNTERBALANCE SHAFTS AND OIL P AN REMOV AL AND INST ALLA TION DEN0892 5 1 3 4 6 7 11 12 13 14 15 16.
4D68 ENGINE (E - W) - Fro nt Case, C ounterba lanc e Sha fts a nd Oil Pan 1 1A-10-2 REMOV AL SERVICE POINTS A A " OIL P AN REMOV AL (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.
4D68 ENGINE (E - W) - Fro nt Case, C ounterba lanc e Sha fts a nd Oil Pan 1 1A-10-3 A E " RIGHT COUNTERBALANCE SHAFT REAR BEARING / LEFT COUNTERBALANCE SHAFT REAR BEARING REMOV AL (1) Using the special tool, remove two rear bearings from the cylinder block.
4D68 ENGINE (E - W) - Fro nt Case, C ounterba lanc e Sha fts a nd Oil Pan 1 1A-10-4 (4) Insert the installer aligning with the guide pin and install the bearing. " C A COUNTERBALANCE SHAFT FRONT BEARING INST ALLA TION (1) Remove the rear bearing installing portion from the special tool.
4D68 ENGINE (E - W) - Fro nt Case, C ounterba lanc e Sha fts a nd Oil Pan 1 1A-10-5 (5) Insert the installer aligning with the guide pin and install the bearing.
4D68 ENGINE (E - W) - Fro nt Case, C ounterba lanc e Sha fts a nd Oil Pan 1 1A-10-6 " G A OIL PUMP DRIVEN GEAR / OIL PUMP DRIVE GEAR INST ALLA TION (1) Apply engine oil amply to the gears and line up the alignment marks.
4D68 ENGINE (E - W) - Fro nt Case, C ounterba lanc e Sha fts a nd Oil Pan 1 1A-10-7 " J A PLUG INST ALLA TION (1) Fit a new O-ring in the front case. (2) T ighten the plug to the specified torque using the special tool. " K A OIL PRESSURE SWITCH INST ALLA TION Specified sealant: 3M A TD Part No.
4D68 ENGINE (E - W) - Fro nt Case, C ounterba lanc e Sha fts a nd Oil Pan 1 1A-10-8 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 .
4D68 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-1 1 1. PISTONS AND CONNECTING RODS REMOV AL AND INST ALLA TION DEN0771 Apply engine oil to all moving parts before installation. Removal steps " F A 1. Connecting rod cap nut A A "" E A 2.
4D68 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-2 REMOV AL SERVICE POINTS A A " CONNECTING ROD CAP REMOV AL (1) Mark the cylinder number on the side of t he connecting rod big end for correct reassembly .
4D68 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-3 " D A PIST ON AND CONNECTING ROD ASSEMBL Y INST ALLA TION (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.
4D68 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-4 " F A CONNECTING ROD CAP NUT INST ALLA TION Caution D If the cylinder head has been installed before installing the connecting rod cap nut, be sure to remove the spark plugs.
4D68 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-5 INSPECTION PISTON RING (1) Check for side clearance. If the limit is exceeded, replace the ring or piston, or both. (2) In the case of semi-keystone type piston rings, check the ring to ring groove clearance as illustrated.
4D68 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-6 CONNECTING ROD BUSHING REPLACEMENT (1) Using the special tool, remove the bushing. (2) Using the special tool, install the bushing, aligning the oil hole of t he bushing with t he oil hole at the small end of the connecting rod.
4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel 1 1A-12-1 12. CRANKSHAFT , CYLINDER BLOCK AND FL YWHEEL REMOV AL AND INST ALLA TION DEN0893 1 2 3 4 5 6 7 89 10 11 12 13 14 15 16 17 18 “A” 11 N m 32 Nm 132 Nm 11 N m Apply engine oil to all moving parts before installation.
4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel 1 1A-12-2 INST ALLA TION SERVICE POINTS " A A CRANKSHAFT BEARING INST ALLA TION When the bearing needs replacing, select and install a proper bearing by the following procedure. (1) Measure the crankshaft journal diameter a nd confirm its classification from the following table.
4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel 1 1A-12-3 " B A BEARING CAP / BEARING CAP BOL T INST ALLA TION (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.
4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel 1 1A-12-4 " C A OIL SEAL INST ALLA TION " D A OIL SEAL CASE INST ALLA TION Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent INSPECTION CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE METHOD) (1) Remove oil from t he crankshaft journal and the crankshaft bearing.
4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel 1 1A-12-5 CYLINDER BLOCK (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.
4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel 1 1A-12-6 (4) Bore all cylinders to the calculated boring finish dimension. Caution T o prevent distortion that may result from temperature rise during honing, bore cylinders, in the order of No.
4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel 1 1A-12-7 INSPECTION (1) After removing the cylinder sleeve, check th e cylinder block sleeve hole surface. If there is damage, insufficient interference-fit-margin or other problems, bore the cylinder block sleeve hole to an oversize.
4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel 1 1A-12-8 (5) Chamfer the cylinder sleeve top en d as illustrated. (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.
NOTES.
デバイスMitsubishi 4D68の購入後に（又は購入する前であっても）重要なポイントは、説明書をよく読むことです。その単純な理由はいくつかあります：
Mitsubishi 4D68をまだ購入していないなら、この製品の基本情報を理解する良い機会です。まずは上にある説明書の最初のページをご覧ください。そこにはMitsubishi 4D68の技術情報の概要が記載されているはずです。デバイスがあなたのニーズを満たすかどうかは、ここで確認しましょう。Mitsubishi 4D68の取扱説明書の次のページをよく読むことにより、製品の全機能やその取り扱いに関する情報を知ることができます。Mitsubishi 4D68で得られた情報は、きっとあなたの購入の決断を手助けしてくれることでしょう。
Mitsubishi 4D68を既にお持ちだが、まだ読んでいない場合は、上記の理由によりそれを行うべきです。そうすることにより機能を適切に使用しているか、又はMitsubishi 4D68の不適切な取り扱いによりその寿命を短くする危険を犯していないかどうかを知ることができます。
ですが、ユーザガイドが果たす重要な役割の一つは、Mitsubishi 4D68に関する問題の解決を支援することです。そこにはほとんどの場合、トラブルシューティング、すなわちMitsubishi 4D68デバイスで最もよく起こりうる故障・不良とそれらの対処法についてのアドバイスを見つけることができるはずです。たとえ問題を解決できなかった場合でも、説明書にはカスタマー・サービスセンター又は最寄りのサービスセンターへの問い合わせ先等、次の対処法についての指示があるはずです。
