11-1

ENGINE
CONTENTS

ENGINE <4D5-Step III> . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 4

Injection Timing Check and Adjustment . . . . . . . . . 4
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Idle Speed Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Outline of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OIL PAN AND OIL SCREEN . . . . . . . . . . . . . . . . 5
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2
TIMING BELT AND TIMING BELT B . . . . . . . . 7
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2
CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . 11
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
 General/General Information/Service
11-2 ENGINE <4D5-Step III> - Specifications

ENGINE <4D5-Step III>

GENERAL
OUTLINE OF CHANGES
Some service procedures have been revised as the following changes have been made to comply to
the Emission Regulation Step III.
D The injection timing check and adjustment procedure and the idle speed check procedure have been
changed.
D The oil pan has a cover in order to reduce noise due to an enhanced engine output.
D A crank angle sensor and crankshaft sensing blade have been added due to the introduction of
an electronic-controlled fuel injection pump. Due to this change, the timing belt front lower cover
has been reshaped.
D The tightening torque of the cylinder head bolts and the cylinder head gasket have been changed.

GENERAL INFORMATION
Items 4D56

Total displacement mL 2,477

Bore x Stroke mm 91.1 x 95.0

Compression ratio 21

Combustion chamber Vortex chamber type

Camshaft arrangement SOHC

Number of valve Intake 4

Exhaust 4

Valve timing Intake Opening BTDC 20_

Exhaust Closing ABDC 49_

Intake Opening BBDC 55_

Exhaust Closing ATDC 22_

Fuel system Electronically controlled type injection pump

Rocker arm Roller type

Adjusting screw Elephant foot type

SERVICE SPECIFICATIONS
Items Standard value
Timing belt tension mm 4-5
Timing belt B tension mm 4-5
Idle speed r/min 750 ± 30
 ENGINE <4D5-Step III> - Sealant/Special Tools 11-3
SEALANT
Items Specified sealant Remarks

Oil pan MITSUBISHI GENUINE PART Semi-drying sealant

MD970389 or equivalent

Semi-circular packing and rocker 3M ATD Part No. 8660 or equivalent

cover seal, and cylinder head seal

SPECIAL TOOLS
Tools Number Name Use
MD998727 Oil pan remover Removal of oil pan

MD998721 Crankshaft pulley Holding the crankshaft pulley

holder

MD998051 Cylinder head bolt Removal and installation of the cylinder head
wrench bolt

MB991614 Angle gauge Tightening of the cylinder head bolts

11-4 ENGINE <4D5-Step III> - On-vehicle Service

ON-VEHICLE SERVICE
INJECTION TIMING CHECK AND
ADJUSTMENT
The cold start device (wax type) has been discontinued as
an electronically controlled injection pump has been used.
The other inspection and adjustment procedures are the same
as before.

IDLE SPEED CHECK

1. Set the vehicle to the pre-inspection condition.
2. Turn the ignition switch to “LOCK” (OFF) position, and
connect the diagnosis connector to the MUT-II.
Tachometer If the MUT-II is not used, connect a tachometer to the
injection nozzle or the pipe.
3. Start the engine, and let it run at idle.
4. Check the idle speed.
Standard value: 750 ± 30 r/min
Injection nozzle
5. If the idle speed is not within the standard value, refer
to 13C - Troubleshooting to check the electronic controlled
fuel injection system.
NOTE
The idle speed is controlled by the engine-ECU.
 ENGINE <4D5-Step III> - Oil Pan and Oil Screen 11-5
OIL PAN AND OIL SCREEN
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Skid Plate and Under Cover Removal and Installation. D Engine Oil Draining and Supplying.
D Front Exhaust Pipe Removal and Installation (Refer
to GROUP 15 - Exhaust Pipe and Muffler.)

12

15
4 mm
(0.16 in.) 19 ± 3 N·m
diameter 14
Groove Hole of bolt
4
Sealant:
MITSUBISHI GENUINE Part No.
MD997110 or equivalent
9.0 ± 1.0 N·m 12 ± 1 N·m
8 9
7
(Engine oil)
12
7.0 ± 1.0
5 N·m
6
11
39 ± 5 N·m 10
35 ± 6 N·m

1
9.0 ± 1.0 N·m
13

110 ± 10 N·m 9.0 ± 1.0 N·m

3
2

110 ± 10 N·m

Removal steps
1. Vacuum hose connection 8. Oil level sensor connector
2. Bolt 9. Oil level sensor
3. Front suspension crossmember 10. Space rubber
4. Engine oil level gauge and guide 11. Bell housing cover
assembly AA" "AA. 12. Oil pan
5. Drain plug 13. Oil pan cover
"BA 6. Drain plug gasket 14. Oil screen
7. Alternator vacuum pump oil return 15. Oil screen gasket
hose connection
11-6 ENGINE <4D5-Step III> - Oil Pan and Oil Screen

MD998727 MD998727 REMOVAL SERVICE POINT

AA" OIL PAN REMOVAL

INSTALLATION SERVICE POINTS

"AA OIL PAN INSTALLATION
1. Remove sealant from oil pan and cylinder block mating
surfaces.
2. Degrease the sealant-coated surface and the engine
mating surface.
3. Apply a continuous bead of the specified sealant to the
oil pan mating surface as shown.
Specified sealant:
MITSUBISHI GENUINE PART No. MD970389 or
equivalent
NOTE
The sealant should be applied in a continuous bead
approximately 4 mm in diameter.
φ 4 mm 4. Assemble oil pan to cylinder block within 15 minutes after
applying the sealant.
Bolt hole Groove Caution
After installing the oil pan, wait at least 1 hour before
starting the engine.

"BA DRAIN PLUG GASKET INSTALLATION

Install a new gasket in the direction so that it faces as shown
in the illustration.
Oil pan
Drain plug side
gasket
 ENGINE <4D5-Step III> - Timing Belt and Timing B 11-7
TIMING BELT AND TIMING BELT B
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Intercooler Removal and Installation
(Refer to GROUP 15.)
D Cooling Fan Removal and Installation.

6
26 ± 3 N·m 8 9
1 7

26 ± 3 N·m

11 ± 1 N·m
5

(Engine oil) 4
18
3

26 ± 3 N·m
11 ± 1 N·m

17
177 ± 9 N·m 16
13 15 26 ± 3 N·m
12
26 ± 3 N·m 11 14 2

10
9.0 ± 1.0 N·m

Removal steps
"CA 1. Timing belt front upper cover 9. Timing belt tensioner
2. Tension pulley and tension pulley 10. Crank angle sensor
bracket assembly 11. Crankshaft sensing blade
3. Crankshaft pulley (for power steer- 12. Crankshaft sprocket
ing and A/C) 13. Flange
AA" "DA 4. Crankshaft pulley AC" "AA 14. Timing belt B
"CA 5. Timing belt front lower cover 15. Gasket
AB" "BA 6. Timing belt 16. Tensioner spacer B
7. Tensioner spacer 17. Tensioner spring B
8. Tensioner spring 18. Timing belt tensioner B
11-8 ENGINE <4D5-Step III> - Timing Belt and Timing B

REMOVAL SERVICE POINTS

Timing marks
AA" CRANKSHAFT PULLEY REMOVAL
1. Turn the crankshaft clockwise, align the timing marks
to set No.1 cylinder to TDC of its compression stroke.
Caution
Never turn the crankshaft anticlockwise.

2. Use the special tool to keep crankshaft from turning and

remove the bolts.

MD998721

Tilt to water pump side AB" TIMING BELT REMOVAL

1. When reinstalling timing belt, mark an arrow at the belt
A to show rotation direction.
2. Loosen the tensioner mounting bolt A and B.
3. Push timing belt tensioner to water pump side and tighten
the tensioner mounting bolt A and B. Secure so that
tensioner will not move back.

Water pump AC" TIMING BELT B REMOVAL

1. When reinstalling timing belt B, mark an arrow at the
belt to show rotation direction.
C 2. Loosen the tensioner mounting bolt C and nut D.
3. Push timing belt tensioner to water pump side and tighten
the tensioner mounting bolt C and nut D. Secure so that
tensioner will not move back.
D
 ENGINE <4D5-Step III> - Timing Belt and Timing Belt B 11-9
INSTALLATION SERVICE POINTS
Timing mark "AA TIMING BELT B INSTALLATION
1. Align the timing marks of the 3 sprockets.
2. When reusing timing belt B, make sure the arrow mark
is pointing in the same direction as when the belt was
C removed.
3. Install timing belt B and make sure there is no deflection
Timing
on the tension side.
Deflection
marks side 4. Press the deflection side of timing belt B with the hand
and fully stretch the tensioner side.
D 5. Make sure that the timing marks are aligned.
6. Loosen the tensioner mounting bolt and nut so that only
the pressure of the spring is applied to timing belt B.
7. Tighten the tensioner mounting bolt C and nut D, tightening
Tension the nut first. If the bolt is tightened first, the tensioner
side
will move and tension the belt.
Tightening torque: 26 ± 3 N·m

8. Press in the direction of the arrow in the figure with the

Counterbalance
index finger to check the amount of deflection.
shaft sprocket Standard value: 4 - 5 mm

Belt deflection

Crankshaft
sprocket B

"BA TIMING BELT INSTALLATION

Tension side 1. Align the timing marks of the 3 sprockets.
2. When reusing timing belt, make sure the arrow mark is
pointing in the same direction as when the belt was
removed.
3. Install the timing belt to the crankshaft sprocket, to injection
pump sprocket, to tensioner and to camshaft sprocket
in that order. Being careful not to allow deflection on
the tension side of the timing belt.
Caution
Timing marks (1) Engage the belt on the various sprockets while
Water pump maintaining tension on the belt of tension side.
(2) Align the injection pump sprocket with the timing
mark, hold the sprocket so that is does not turn
and engage the belt.
4. Loosen the tensioner mounting bolts and apply tension
with the spring.

Tension
side
11-10 ENGINE <4D5-Step III> - Timing Belt and Timing Belt B

5. Turn the crankshaft clockwise and stop at the second

Camshaft sprocket lobe of the camshaft sprocket.
Caution
(1) When turning the crankshaft in item (5), strictly
observe the specified amount of rotation (2 teeth
2 teeth on the camshaft sprocket) in order to apply a
constant force to the tension side of the belt.
(2) Do not turn the crankshaft counterclockwise.
(3) Do not touch the belt during adjustment.

6. Make sure that the part indicated by arrow A does not

A float upward.
Tensioner
mounting bolt 7. Tighten the tensioner mounting bolts, starting with the
bolt in the elongated hole. If the lower bolt is tightened
first, belt tension will become too tight.
Tensioner 8. Turn the crankshaft anticlockwise and align the timing
mark. Next, make sure that the timing marks of all
sprockets are aligned.
Tensioner
mounting bolt

Amount of belt 9. Press on the center of the bolt with an index finger to check
deflection the amount of deflection.
Standard value: 4 - 5 mm

"CA TIMING BELT FRONT LOWER COVER/TIMING

A BELT FRONT UPPER COVER INSTALLATION
Install the bolts to the timing belt cover at the shown positions.
A B Name Symbols Size mm (d×l)

A Flange bolt A 6×22

C B 6×50

C 6×60

d=Nominal diameter
l=Nominal length

A "DA CRANKSHAFT PULLEY INSTALLATION

A
B Using the special tool to install the crankshaft pulley as same
as removal procedure.

A
A
 ENGINE <4D5-Step III> - Cylinder Head Gasket 11-11
CYLINDER HEAD GASKET
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
D Intake and Exhaust Manifold Removal D Timing Belt Installation (Refer to P.11-4.)
(Refer to GROUP 15.) D Intake and Exhaust Manifold Installation
D Timing Belt Removal (Refer to P.11-4.) (Refer to GROUP 15.)
D Engine Coolant Draining. D Fuel Line Air Bleeding
(Refer to GROUP 13 - On-vehicle Service.)
D Engine Coolant Filling

13 ± 2 N·m
8 5.9 ± 1.0 N·m

4.9 ± 1.0 N·m

9 11 30 ± 6 N·m
10 ± 2 N·m
30 ± 6
N·m 4.9 ± 1.0 N·m
4.9 ± 1.0
N·m
10
29 ± 2 N·m → +120° 3
(During cold engine) 5
22 ± 4 N·m 2
22 ± 4 N·m
12 30 ± 6 N·m

6
7

13
14
4
10 mm 10 mm 1
24 ± 4 N·m

10
15
11

Sealant:
3M ATD Part No. 8660 or
equivalent

Removal steps
1. Engine coolant temperature switch 8.
Boost sensor and bracket assembly
connector (for A/C) 9.
Vacuum hose and pipe assembly
2. Engine coolant temperature gauge 10.
Rocker cover
unit and sensor connector 11.
Semi-circular packing
3. Glow plug terminal AC" 12.
Power steering oil pump assembly
AA" "DA 4. Radiator upper hose 13.
Power steering oil pump bracket
AB" "CA 5. Fuel injection pipe bolt
6. Heater hose or water by-pass hose AD" "BA 14. Cylinder head assembly
connection "AA 15. Cylinder head gasket
7. Fuel hose connection
11-12 ENGINE <4D5-Step III> - Cylinder Head Gasket

REMOVAL SERVICE POINTS

AA" RADIATOR UPPER HOSE DISCONNECTION
After making mating marks on the radiator upper hose and
the hose clamp, disconnect the radiator upper hose.

AB" FUEL INJECTION PIPE REMOVAL

When loosening nuts at both ends of injection pipe, hold
Delivery holder
the delivery holder (for pump side) and the injection nozzle
assembly (for nozzle side) with wrench and loosen nut.
Caution
After disconnecting the injection pipe, plug the opening
so that no foreign particles get inside the pump or into
the injection nozzle.
Nut

AC" POWER STEERING OIL PUMP REMOVAL

Remove the power steering oil pump from the bracket with
the hose attached.
NOTE
Place the removed power steering oil pump in a place where
it will not be a hindrance when removing and installing the
engine assembly, and tie it with a cord.

AD" CYLINDER HEAD ASSEMBLY REMOVAL

Use the special tool to tighten each bolt 2 - 3 times in the
order shown in the illustration.

MD998051

Front
 ENGINE <4D5-Step III> - Cylinder Head Gasket 11-13
INSTALLATION SERVICE POINTS
"AA CYLINDER HEAD GASKET INSTALLATION
When replacing the cylinder head gasket only, confirm the
gasket identification mark, and then select a replacement
part according to the table below:

Spec Identification mark (size) Parts num-

Identification mark ber

A D5 - 774 (fitted thickness 1.45 ± 0.04) MD377774

A B D5 - 775 (fitted thickness 1.50 ± 0.04) MD377775

C D5 - 776 (fitted thickness 1.55 ± 0.04) MD377776

B Caution
The thickness of the original cylinder head gasket is
selected according to the protrusion amount of the piston.
C Therefore, if the piston or the connecting rod is replaced,
the protrusion amount may be changed. Always select
a correct gasket by measuring the protrusion amount.
(For details, refer to the Engine Workshop Manual.)

"BA CYLINDER HEAD INSTALLATION

1. Select a cylinder head gasket of correct specification.
2. Clean the cylinder head assembly and the cylinder block
mating surfaces with a scraper or a wire brush.
Caution
Do not allow foreign material to enter the engine
coolant or oil passages and the cylinder.

3. Install the cylinder head bolt washer to the cylinder head

bolt so that the washer chamfered side faces as shown.
4. Apply a small amount of engine oil to the cylinder head
bolt thread and the washer.

Cylinder head Chamfered

bolt washer side
11-14 ENGINE <4D5-Step III> - Cylinder Head Gasket

5. Tighten the cylinder head bolts according to the following

procedure (angle-tightening procedure.)
(1) Use the special tool to tighten the cylinder head bolts
in the order of the illustrated numbers to 29 ± 2 N·m.

MD998051

17 13 9 5 1 3 7 11 15

14 10 6 4 12
18 2 8 16

Front of engine

(2) Place the special tool in a wrench to tighten the

MB991614 cylinder head bolt in the order of the illustrated
numbers to 120_.

"CA FUEL INJECTION PIPE INSTALLATION

When tightening the nuts at both ends of the fuel injection
pipe, hold the delivery holder (for pump side) and the injection
nozzle assembly (for nozzle side) with a wrench, and tighten
MD998051 the nuts to the specified torque.
Tightening torque: 30 ± 6 N·m

"DA RADIATOR UPPER HOSE CONNECTION

17 13 9 5 1 3 7 11 To reuse the radiator upper hose, align the mating marks
15
that were made during removal, and then install the hose
clamp.
14 10 6 4 12
18 2 8 16

Front of engine