ENGINE Workshop Manual 4M41 - mitsubishilinks.com

1 GENERAL SPECIAL GENERATOR GLOW COOLING FAN, V-BELT AND WATER WATER HOSES AND EGR VALVE INTAKE TURBOCHARGER EXHAUST INJECTION PUMP INJECTION PUMP ROCKER COVER, CAMSHAFT HOLDER ASSEMBLY AND INJECTION CYLINDER HEAD AND VALVE VACUUM TIMING GEAR TIMING GEAR AND BALANCE OIL OIL COOLER AND OIL OIL PAN, OIL STRAINER AND OIL PISTON AND CONNECTING DRIVE CRANK SHAFT AND CRANK BALANCE SHAFT 2000 mitsubishi Motors CorporationAdded11B-0-2 NOTESPWEE9409-DEFeb. 2000 mitsubishi Motors CorporationAdded4M41 ENGINE -General Information11B-0-3 GENERAL INFORMATIOND escriptionsSpecificationsTotal displacement dm33200No.

2 And arrangement of cylinders4 in-lineCombustion chamberDirect injectionNo. of intake/exhaust valves (per cylinder)2 eachValve mechanismDouble overhead camshaft, 4-valveCylinder bore x stroke x 105 Compression ratio17 SuperchargerTurbo-charging typeIntercoolerAir-cooling typeFuel supplyDistributor type electronically controlled fuel injection pumpPWEE9409-DEFeb. 2000 mitsubishi Motors CorporationAdded4M41 ENGINE -Specifications11B-1-11. SPECIFICATIONSSERVICE SPECIFICATIONSUnit: mmDescriptionsStandardLimitGlow plugGlow assemblyTurbochargerActuator operating pressure(when operating 1 mm)kPa161-Rocker cover, camshaft holder assembly, camshaft assemblyCamshaftEnd - lobe oil - roller radial - nozzleInjection nozzleInjection pressure(valve openingNo.)

3 1 valve opening - )No. 2 valve opening - - valve - head and valve mechanismValve springFree (installed height: ) N255-Out-of-squareness2_4_ValveIntakeSte m - from cylinder - seat angle45_ 15 -ExhaustStem - from cylinder - seat angle45_ 15 -Valve guideStem-to-guide - - 2000 mitsubishi Motors CorporationAdded4M41 ENGINE -Specifications11B-1-2 DescriptionsLimitStandardValve seatSeat - headBottom surface distortionLess than pumpVacuum pumpPerformanceAttained degree of vacuum93 kPa or more-Pump speed1500 r/min-Timing gears and balance shaftsBacklash between gearsBalance shaft gear RH and oil pump - pump gear and crankshaft - gear and idler.

4 Gear and idler gear - gear LH and balance shaft gear - gear and injection pump - playBalance shaft LH, - gear/sprocket - gear LH - chain elongation (minimum distance between chain spans facing eachother when pressing on tensioner lever) lever-to-tension lever shaft - gear bush LH-to-idler shaft - sprocket bush-to-idler shaft - pumpOil pumpDriven gear shaft-to-oil pump case and - - - cooler and oil filterBypass valve springValve opening pressurekPa490 30-Regulator valve springValve opening pressurekPa620 30-Piston and connecting rod - pinPiston pin-to-connecting rod bush - pin-to-piston - compression - compression - - compression - compression - - 2000 mitsubishi Motors CorporationAdded4M41 ENGINE -Specifications11B-1-3

5 DescriptionsLimitStandardConnecting rodEnd - rod bearingOil - and crankcaseCrankshaftEnd - than and journalOut-of-roundnessLess than bearingMain , 2, 4 and 5 - - crankcaseUpper surface distortionLess than - and connecting rod assembly-to-uppercrankcase cylinder - shaft bushBalance shaftClearance between balance shaft and balance - 2000 mitsubishi Motors CorporationAdded4M41 ENGINE -Specifications11B-1-4 TORQUE SPECIFICATIONSI temsTorque NmGlow plugConnection 1 Glow plug18 1 Cooling fan V-belt and water pumpCooling fan bolt10 1 Auto-cooling fan coupling nut24 2 Water pump bolt24 2 Water hoses and pipesEyebolt25 2 Coolant temperature sensor9 1 Intake manifoldBoost air temperature sensor15 1

6 Gas filter assembly17 1 Turbocharger assemblyEye bolt (for oil pipe)20 2 Eye bolt (for water pipe)25 2 Coupler nut49 4 Turbocharger nut49 4 Turbocharger bolt54 5 Exhaust manifoldExhaust manifold nut30 3 Injection pump assemblyInjection pipe25 2 Pump stay mounting bolt18 2 Injection pumpInjection pump gear mounting nut180 10 Sensor plate mounting bolt5 1 Flange plate mounting nut38 2 ENGINE speed sensor mounting bolt5 1 Rocker cover, camshaft holder assembly, camshaft assemblyRocker cover mounting leak-off pipe eyeboltInjection nozzle side13 2 Cylinder head side11 1 Cam sprocket mounting bolt88 10 Camshaft cap mounting bolt20 1 Adjust screw bolt38 8 PWEE9409-DEFeb.

7 2000 mitsubishi Motors CorporationAdded4M41 ENGINE -Specifications11B-1-5 ItemsTorque NmInjection nozzleInjection pipe33 3 Return pipe eyebolt11 1 Injection nozzle assembly eyebolt13 2 Leak-off pipe eye bolt11 1 Injection nozzle assembly mounting bolt21 2 Retaining nut34 5 Cylinder head and valve mechanismInjection nozzle mounting bolt21 2 Connecting plate mounting plug18 2 Bolt (M10)58 6 Cylinder head bolt (M12: long)49 5+90_+90_Cylinder head bolt (M12: short)49 5+90_+90_Water joint47 5 Vacuum pumpEyebolt20 2 Cover and body assembly mounting gearcaseCrankshaft pulley mounting bolt323 32 Cap nut23 2 Timing gear and balance shaftTension lever shaft mounting bolt40 4 Guide plate mounting bolt33 3 Balance shaft gear RH mounting bolt36 4 Thrust plate mounting bolt12 1 Balance shaft gear LH mounting bolt36 4 Oil PumpBalance shaft RH bolt36 3 Plug44 4 Oil pump cover screw10 1 Oil cooler and oil filterOil cooler element nut20 2 Bypass plug44 4 Regulator plug44 4 Water drain plug30 3 PWEE9409-DEFeb.

8 2000 mitsubishi Motors CorporationAdded4M41 ENGINE -Specifications11B-1-6 ItemsTorque NmOil pan, oil strainer and oil jetDrain plug39 3 Oil jet32 3 Piston and connecting rodConnecting rod cap mounting nut29 3+49 5+45_+45_Drive plateDrive plate assembly and crankshaft mounting bolt123 12 Crankshaft and crankcaseDust cover mounting bolt47 5 Lower crankcase mounting bolt25 3 Main bearing cap bolt20 2+90_+90_Check valve32 3 STANDARD BOLT AND NUT TIGHTENING TORQUE TABLE1. Fasten the parts and equipment of vehicle using the specified standard bolts and nuts. Tighten thesebolts and nuts to the torques indicated below, unless otherwise Threads and bearing surfaces must be In case nut and bolt (or stud bolt) differ in strength, tighten them to the torque specified for head bolts and stud boltsUnit: NmStrengthCode4T7T8 THead MarkNominalDiameter mm(Stud)(Stud)(Stud) 1-6 1-M65 1-9 2-10 4-25 4-M1023 422 444 1041 852 755 13M1241 838 881 1274 996 1286 12 PWEE9409-DEFeb.

9 2000 mitsubishi Motors CorporationAdded4M41 ENGINE -Specifications11B-1-7 Hexagon flange boltsUnit: NmStrengthCode4T7T8 THead MarkNominalDiameter mmM65 1-10 2-12 2-M813 2-23 4-27 5-M1026 422 449 1044 957 754 10M1246 842 993 1581 12103 1596 12 Hexagon nutsUnit: NmStrength Code4T6 THead MarkNominalDiameter mmStandardThreadCoarse ThreadStandard ThreadCoarse 1-M65 1-9 2-M812 2-21 4-M1023 422 444 1041 8M1241 838 881 1273 10 Hexagon flange nutsUnit: NmStrength Code4 THead MarkNominalDiameter mmStandardThreadCoarse ThreadM65 1-M813 2-M1026 424 4M1241 842 9 PWEE9409-DEFeb. 2000 mitsubishi Motors CorporationAdded4M41 ENGINE -Specifications11B-1-8 SEALANTL ocationSpecified sealantMating surface of front plate to cylinder head gasket3M ATD Part or equivalentInner surface of sealing cap press-fitting holeTHREEBOND TB1386, LOCTITE 962T or equivalentMating surface of timing gear case to front plate* mitsubishi Genuine Part No.

10 MD970389 or equivalentUpper crankcase assembly-to-lower crankcase assem-bly mounting surface*Rear oil seal case-to-upper or lower crankcase assemblymounting surface*Upper or lower crankcase assembly-to-front platemounting surface**: FIPG to be appliedFORM-IN-PLACE GASKETThe ENGINE has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasketfully serves its purpose, it is necessary to observe some precautions when applying the gasket. Beadsize, continuity and location are of paramount thin a bead could cause leaks. Too thick a bead, on the other hand, could be squeezed out oflocation, causing blocking or narrowing of the fluid feed line.