M ITSUBISHI

ENGINE
4D5 SERIES
WORKSHOP M ANUAL

FOREWORD
This Workshop M anual contains procedures for
removal, disassembly, inspection, adjustment, reas-
Engine <1991 to 1993> …………… 11A
sembly and installation, etc. for service mechanics.
All information, illustrations and product descrip-
tions contained in this manual are current as at the
time of publication. We, how ever, reserve the right Engine
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to make changes at any time w ithout prior notice or

obligation.
<1994 and subsequent> ………… 11B

FILING INSTRUCTION
Please keep these manual pages in the binder
No. BN940001.
File t hese pages according t o t he signs
“ Added” , “ Revised” and “ Deleted” on the
“ List of effective pages” w hich are interpreted
below.
Added: File the pages w ith this label addi-
tionally in your manual.
Revised.Deleted: Replace the existing pages
w ith the corresponding pages w ith
this sign.

M issing sheets w ill be supplied upon request.

G M itsubishi M otors Corporation M ay 2001 Pub. No. PWEE9067-G

 INTRODUCTION

EXPLANATION OF M ANUAL CONTENTS

M aintenance and Servicing Procedures • Removal steps:

(1) A diagram of t he com ponent part s is
provided near the front of each section in
order t o give t he reader a bet t er
understanding of the installed condition of
component parts.
(2) The numbers provided w ithin the diagram
indicate the sequence for maintenance and
servicing procedures; the symbol N indi-
cates a non-reusable part; the tightening
torque is provided w here applicable.
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The part designation number corresponds
to the number in the illustration to indicate
removal steps.
• Disassembly steps:
The part designation number corresponds
to the number in the illustration to indicate
disassembly steps.
• Installation steps:
Specified in case installation is impossible
in reverse order of removal steps. Omitted
if installation is possible in reverse order of
removal steps.
• Reassembly steps:
Specified in case reassembly is impossible
in reverse order of disassembly steps.
Om it t ed if reassem bly is possible in
reverse order of disassembly steps.

Classification of M ajor M aintenance/ Service

Points
When there are major points relative to maintenance and
servicing procedures (such as essential maintenance and
service points, maintenance and service standard values,
information regarding the use of special tools, etc.),
these are arranged together as major maintenance and
service points and explained in detail.

cAd: Indicat es t hat t here are essent ial point s f or

removal or disassembly.
DAC: Indicat es t hat t here are essent ial point s f or
installation or reassembly.

Sym bols for Lubricat ion, Sealant s and ..... Grease

Adhesives
Information concerning the locations for lubrication
and for application of sealants and adhesives is
provided, by using sym bols, in the diagram of
component parts, or on the page follow ing the
component parts page, and explained.
(multipurpose grease unless there is a
brand or type specified)
..... Sealant or adhesive
..... Brake fluid, automatic transmission fluid
or air conditioner compressor oil

..... Engine oil or gear oil

 INTRODUCTION

Indicates Indicates Indicates Indicates Indicates

the group the section the group the section the page
title. title. number. number. number.

Denotes tightening
torque.

Nm Kgm ft.lbs.
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Denotes non-
reusable part.

This number
corresponds to the
number appearing in
"Removal steps",
"Disassembly steps",
"Installation steps" or
"Reassembly steps".

Operating proce-
dures, cautions,
etc. on removal,
installation,
disassembly and
reassembly are
described.

Issue date Publication

number-
Revision code
 List of Effective Pages

Page Revision Date Remarks Page Revision Date Remarks

code code

11A-0-1 and 11A-0-2 A Feb. 1995 11B-4-6 G M ay 2001 Revised

11A-0-3 to 11A-0-6 Dec. 1990 11B-4-7 A Feb. 1995
11A-1-1 and 11A-1-2 A Feb. 1995 11B-4-8 A Feb. 1995
11A-1-3 and 11A-1-4 B July 1995 11B-4-9 G M ay 2001 Added
11A-1-5 to 11A-1-7 A Feb. 1995 11B-5-1 F M ay 2000
11A-2-1 to 11A-2-3 Dec. 1990 11B-5-2 to 11B-5-6 A Feb. 1995
11A-3-1 to 11A-3-9 Dec. 1990 11B-5-7 G M ay 2001 Revised
11A-4-1 to 11A-4-3 Dec. 1990 11B-6-1 and 11B-6-2 A Feb. 1995
11A-5-1 to 11A-5-4 Dec. 1990 11B-7-1 G M ay 2001 Revised
11A-6-1 A Feb. 1995 11B-7-1a and 11B-7-1b G M ay 2001 Revised
11A-6-2 Dec. 1990 11B-7-2 G M ay 2001 Revised
11A-7-1 and 11A-7-2 Dec. 1990 11B-7-2a G M ay 2001 Revised
11A-7-3 and 11A-7-4 A Feb. 1995 11B-7-2b E Feb. 2000
11A-8-1 A Feb. 1995 11B-7-3 to 11B-7-4 A Feb. 1995
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11A-8-2 Dec. 1990 11B-7-4a and 11B-7-4b G M ay 2001 Revised

11A-8-3 to 11A-8-5 B July 1995 11B-7-5 A Feb. 1995
11A-9-1 and 11A-9-2 A Feb. 1995 11B-8-1 to 11B-8-3 A Feb. 1995
11A-9-3 to 11A-9-8 Dec. 1990 11B-9-1 G M ay 2001 Revised
11A-9-9 A Feb. 1995 11B-9-1a and 11B-9-1b G M ay 2001 Revised
11A-9-10 Dec. 1990 11B-9-2 G M ay 2001 Revised
11A-9-11 and 11A-9-12 A Feb. 1995 11B-9-3 A Feb. 1995
11A-10-1 Dec. 1990 11B-10-1 to 11B-10-4 A Feb. 1995
11A-10-2 B July 1995 11B-11-1 G M ay 2001 Revised
11A-10-3 A Feb. 1995 11B-11-2 A Feb. 1995
11A-10-4 and 11A-10-5 Dec. 1990 11B-11-3 to 11B-11-5 B July 1995
11A-11-1 to 11A-11-4 Dec. 1990 11B-11-6 and 11B-11-7 G M ay 2001 Revised
11A-12-1 to 11A-12-4 Dec. 1990 11B-11-8 G M ay 2001 Added
11A-12-5 A Feb. 1995 11B-12-1 G M ay 2001 Revised
11B-12-1a G M ay 2001 Revised
11B-0-1 A Feb. 1995 11B-12-1b E Feb. 2000
11B-0-3 to 11B-0-5 A Feb. 1995 11B-12-2 to 11B-12-8 A Feb. 1995
11B-1-1 and 11B-1-2 A Feb. 1995 11B-12-9 E Feb. 2000
11B-1-3 and 11B-1-4 B July 1995 11B-13-1 A Feb. 1995
11B-1-5 A Feb. 1995 11B-13-2 B July 1995
11B-1-6 to 11B-1-9 G M ay 2001 Revised 11B-13-3 A Feb. 1995
11B-2-1 to 11B-2-4 G M ay 2001 Revised 11B-13-4 C Sept. 1996
11B-3-1 G M ay 2001 Revised 11B-13-5 A Feb. 1995
11B-3-1a and 11B-3-1b G M ay 2001 Revised 11B-14-1 G M ay 2001 Revised
11B-3-2 G M ay 2001 Revised 11B-14-1a G M ay 2001 Revised
11B-3-3 A Feb. 1995 11B-14-1b E Feb. 2000
11B-4-1 G M ay 2001 Revised 11B-14-2 to 11B-14-9 A Feb. 1995
11B-4-2 to 11B-4-5 A Feb. 1995

M issing sheets w ill be supplied upon request. PWEE9067-G

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 11B-1-6 4D56 ENGINE <1994 –> – Specifications

TORQUE SPECIFICATIONS

Torque
Nm kgm ft.lbs.
Drive belt and glow plug
Cooling fan bolt …………………………………………… 11 1.1 8
Fan clutch bolt ……………………………………………… 11 1.1 8
Vacuum pipe bolt (L400) …………………………………… 10 1.0 7
Vacuum pipe bolt (1997 L200 and after) ………………… 23 2.4 17
Vacuum pipe bolt (2001 model PAJERO)
M 8 x 16 …………………………………………………… 12 1.2 9
M 8 x 20 …………………………………………………… 22 2.2 16
Eye bolt ……………………………………………………… 17 1.7 12
Auto tensioner bolt ………………………………………… 44 4.5 33
Pow er steering pump bracket bolt (Washer) …………… 22 2.2 16
Pow er steering pump bracket bolt (Flange) ……………… 24 2.4 17
Alternator pivot bolt
M 8 ………………………………………………………… 22 2.2 16
M 10 ……………………………………………………… 44 4.5 33
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Brace bolt …………………………………………………… 14 1.4 10

Lock bolt …………………………………………………… 23 2.3 17
Adjusting bolt ……………………………………………… 10 1.0 7
Crankshaft pulley bolt ……………………………………… 25 2.5 18
Crankshaft bolt ……………………………………………… 181 18.5 134
Oil level gauge guide bolt
M 6 (L400) ………………………………………………… 11 1.1 8
M 8 (Except L400) ……………………………………… 24 2.4 17
Glow plug plate nut ………………………………………… 1.8 0.18 1.3
Glow plug …………………………………………………… 9+30° to 40° 0.9+30° to 40° 7+30° to 40°
Timing belt
Timing belt cover bolt ……………………………………… 11 1.1 8
Flange bolt …………………………………………………… 10 1.0 7
Tensioner spacer nut ……………………………………… 25 2.6 19
Timing belt tensioner bolt ………………………………… 25 2.6 19
Camshaft sprocket bolt …………………………………… 67 7.0 51
Crank angle sensor bolt …………………………………… 9 0.9 7
Injection pump sprocket nut ……………………………… 83 8.5 61
Balancer shaft sprocket bolt and nut …………………… 36 3.7 27
Timing belt rear cover bolt ………………………………… 11 1.1 8
Fuel injection pump and injection nozzle
Injection pump protector bolt ……………………………… 14 1.4 10
Injection pipe clamp bolt …………………………………… 5 0.5 3.7
Injection pipe union nut …………………………………… 29 3.0 22
Injection pump nut ………………………………………… 19 1.9 14
Injection pump bolt ………………………………………… 24 2.4 17
Injection pump bracket bolt ………………………………… 22 2.2 16
Fuel return pipe nut ………………………………………… 27 2.8 20
Injection nozzle ……………………………………………… 54 5.5 40
Injection nozzle holder
Retaining nut ………………………………………………… 37 3.8 27

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

 4D56 ENGINE <1994 –> – Specifications 11B-1-7
Torque
Nm kgm ft.lbs.

Intake and exhaust manifolds

Air pipe bracket bolt ………………………………………… 22 2.2 16
Vacuum pipe and hose assembly bolt
(w ith turbocharger) ……………………………………… 11 1.1 8
(w ith variable geometry turbocharger) ………………… 10 1.0 7
Waste gate actuator bolt (tightened to intake manifold) 19 1.9 14
Waste gate actuator bolt (tightened to turbocharger) …… 12 1.2 9
EGR pipe bolt nut …………………………………………… 17 1.7 12
EGR valve bolt ……………………………………………… 25 2.5 18
Eyebolt (w ater pipe) ………………………………………… 42 4.3 31
Eyebolt (oil pipe) …………………………………………… 17 1.7 12
Heat protector bolt
M 6 ………………………………………………………… 9 0.9 7
M 8 ………………………………………………………… 14 1.4 10
Oil return pipe bolt ………………………………………… 9 0.9 7
Exhaust fitting nut ………………………………………… 59 6.0 43
Turbocharger nut …………………………………………… 59 6.0 43
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Relief valve ………………………………………………… 49 5.0 36

Air inlet fitting bolt ………………………………………… 19 1.9 14
Intake manifold bolt ………………………………………… 18 1.8 13
Intake manifold stay bolt …………………………………… 18 1.8 13
Exhaust manifold nut ……………………………………… 18 1.8 13
EGR cooler bolt …………………………………………… 22 2.2 16
Solenoid valve assembly bolt ……………………………… 24 2.4 17
Water pipe and hose bolt …………………………………… 22 2.2 16
Water pipe bolt
M 8 ………………………………………………………… 14 1.4 10
M 6 ………………………………………………………… 11 1.1 8
Air temperature sensor …………………………………… 14 1.4 10
Air intake fitting bolt ……………………………………… 19 1.9 14
Oil pipe flare nut …………………………………………… 20 2.0 14
Oil pipe bolt ………………………………………………… 9 0.9 7
VG actuator bolt ……………………………………………… 12 1.2 9
Hose clamp bolt …………………………………………… 14 1.4 10
Turbocharger
Coupling bolt ………………………………………………… 5 0.5 4
Water pump, thermostat, hose and pipe
Water pipe bolt
M 6 ………………………………………………………… 11 1.1 8
M 8 ………………………………………………………… 14 1.4 10
Coolant temperature gauge unit ………………………… 34 3.5 25
Water outlet fitting bolt …………………………………… 12 1.2 9
Water inlet fitting bolt
Bolt w ith spring w asher ………………………………… 12 1.2 9
Flange bolt ……………………………………………… 14 1.4 10
Thermostat housing bolt …………………………………… 14 1.4 10
Plate bolt ……………………………………………………… 10 1.0 7

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

 11B-1-8 4D56 ENGINE <1994 –> – Specifications

Torque
Nm kgm ft.lbs.

Water pump bolt

M 8 x 20, M 8 x 25, M 8 x 40 …………………………… 14 1.4 10
M 8 x 70, M 8 x 85 ……………………………………… 24 2.4 17
Rocker arms, rocker shaft and camshaft
Oil filler bolt ………………………………………………… 13 1.3 9
Rocker cover bolt …………………………………………… 6 0.6 4
Rocker shaft bolt …………………………………………… 37 3.8 27
Lock nut ……………………………………………………… 15 1.5 11
Camshaft bearing cap bolt ………………………………… 20 2.0 14
Cylinder head, valves and valve spring
Cylinder head bolt
Without throttle body …………………………………… 118 12.0 87
With throttle body ……………………………………… 29+120° to 124° 3.0±120° to 124° 22±120° to 124°
Front case and oil pan
Oil cooler by-pass valve …………………………………… 54 5.5 40
Oil pressure sw itch ………………………………………… 10 1.0 7
Oil filter bracket bolt (Except 2001 PAJERO) …………… 14 1.4 10
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Oil filter bracket bolt (2001 PAJERO)

M 6 ………………………………………………………… 11 1.0 7
M 8 ………………………………………………………… 23 2.3 17
Oil pan cover bolt …………………………………………… 9 0.9 7
Oil drain plug ………………………………………………… 39 4.0 29
Oil level sensor bolt ………………………………………… 9 0.9 7
Oil pan bolt ………………………………………………… 7 0.7 5
Oil screen bolt and nut …………………………………… 19 1.9 14
Front upper case bolt ……………………………………… 13 1.3 9
Plug cap ……………………………………………………… 24 2.4 17
Balancer shaft driven gear bolt …………………………… 36 3.7 27
Front low er case bolt
M 8 x 90 …………………………………………………… 24 2.4 17
Except M 8 x 90 ………………………………………… 13 1.3 9
Oil pump cover bolt ………………………………………… 12 1.2 9
Balancer shaft gear cover bolt …………………………… 24 2.4 17
Check valve ………………………………………………… 32 3.3 24
Stiffener bolt ………………………………………………… 19 1.9 13
Piston and connecting rod
Connecting rod cap nut …………………………………… 46 4.7 34
Crankshaft and cylinder block
Flyw heel bolt ……………………………………………… 132 13.5 98
Drive plate bolt ……………………………………………… 132 13.5 98
Rear plate bolt ……………………………………………… 9 0.9 7
Bell housing cover bolt …………………………………… 9 0.9 7
Oil seal case bolt …………………………………………… 11 1.1 8
Bearing cap bolt …………………………………………… 78 8.0 58
Cover bolt …………………………………………………… 6 0.6 4
Engine support bracket bolt (Except 2001 PAJERO)
Head mark “ 7” ………………………………………… 44 4.5 33
Head mark “ 8” ………………………………………… 55 5.5 40
G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised
 4D56 ENGINE <1994 –> – Specifications 11B-1-9
Torque
Nm kgm ft.lbs.

Engine support bracket bolt (2001 PAJERO)

M 8 ………………………………………………………… 22 2.2 16
M 10 ……………………………………………………… 44 4.5 33

SEALANT

Specified sealant Quantity

Semi-circular packing ……………………… 3M ATD Part No. 8660 or equivalent ………………… As required
Oil pan gasket ……………………………… M ITSUBISHI GENUINE Part No. M D970389 ………… As required
or equivalent
Oil pressure sw itch ………………………… 3M ATD Part No. 8660 or equivalent ………………… As required
Coolant temperature ……………………… 3M Nut Locking Part No. 4171 ……………………… As required
gauge unit or equivalent
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G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

 4D56 ENGINE <1994 –> – Special Tools 11B-2-1
2. SPECIAL TOOLS

Tool Number Name Use

M B990767 End yoke holder Holding camshaft sprocket or fuel injection

pump sprocket w hen loosening or
tightening bolts. (Use w ith M D998719)

M B991614 Angle gauge Tightening cylinder head bolt

M D998051 Cylinder head bolt Loosening and tightening of cylinder head

w rench bolts
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M D998115 Valve guide installer Removal and installation of valve guide

M D998148 Valve seat cutter pilot Correction of valve seat

M D998158 Valve seat cutter 45° Correction of valve seat

M D998165 Valve seat cutter 65° Correction of valve seat

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

 11B-2-2 4D56 ENGINE <1994 –> – Special Tools

Tool Number Name Use

M D998175 Valve seat cutter 30° Correction of valve seat

M D998250 Balancer shaft bearing Installation of silent shaft rear bearing

installer

M D998251 Balancer shaft bearing Removal of silent shaft rear bearing

puller
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M D998303 Valve spring Compression of valve spring

compressor

M D998376 Crankshaft rear oil Installation of crankshaft rear oil seal

seal installer

M D998380 Bearing installer Guide for removal and installation of silent

stopper shaft right rear bearing

M D998381 Camshaft oil seal Installation of camshaft oil seal

installer

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

 4D56 ENGINE <1994 –> – Special Tools 11B-2-3

Tool Number Name Use

M D998382 Crankshaft front oil Guide for installation of crankshaft front oil
seal guide seal

M D998383 Crankshaft front oil Installation of crankshaft front oil seal

seal installer

M D998384 Prestroke measuring Adjustment of injection timing

adapter
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M D998385 Balancer shaft drive gear Installation of silent shaft drive oil seal
oil seal guide

M D998386 Connecting-rod Replacement of connecting-rod small-end

small-end bushing bushing
replacement tool

M D998388 Injection pump Removal of injection pump sprocket

sprocket puller

M D998719 Pulley holder pin (2) Use w ith M B990767

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

 11B-2-4 4D56 ENGINE <1994 –> – Special Tools

Tool Number Name Use

M D998727 Oil pan sealer cutter Removal of oil pan

M D998729 Valve stem seal Installation of valve stem seal

installer

M D998772 Valve spring Compression of valve spring

compressor
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M D998778 Crankshaft sprocket Removal of crankshaft sprocket

puller

M D998781 Flyw heel stopper Holding flyw heel and drive plate

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

 4D56 ENGINE <1994 –> – Drive Belt and Glow Plug 11B-3-1
3. DRIVE BELT AND GLOW PLUG
REM OVAL AND INSTALLATION <PAJERO (Up to 2000 model), L200, L300, L400
CHALLENGER>

10 1.0 7 23 2.4 17

5
12 Except
Brace bolt type L400
17 1.7 12
5
14 1.4 10
7 N L400
6 22
10 1.0 7
12 13
1.8 0.18 1.3
10
Adjuster type
23
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9 N 9 0.9 7
8 +30° to 40°
23 2.3 17
17 1.7 12

M8 23 2.3 17 11
M 10 44 4.5 33
4
1
3 25 2.5 18
2 Except L400

24 2.4 17
18
16

20
19 N
14 18
17 L400 21 N
15
19 N 20

11 1.1 8 181 18.5 134 21 N

11 1.1 8 11 1.1 8
Removal steps
EDF 1. Drive belt 13. Alternator
2. Cooling fan 14. Crankshaft pulley (for A/C)
3. Fan clutch FAE EBF 15. Crankshaft bolt
4. Water pump pulley EBF 16. Special w asher
5. Vacuum pipe EBF 17. Crankshaft pulley
6. Eyebolt 18. Oil level gauge
7. Gasket 19. O-ring
8. Eyebolt 20. Oil level gauge guide
9. Gasket 21. O-ring
10. Oil tube 22. Glow plug plate
ECF 11. Oil hose FBE EAF 23. Glow plug
12. Alternator brace DEN0327

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

 11B-3-1a 4D56 ENGINE <1994 –> – Drive Belt and Glow Plug

REM OVAL AND INSTALLATION <PAJERO (From 2001 model)>

22 2.2 16
22 2.2 16
4 17
24 2.4 17
12 1.2 9 N 18
12
24 2.4 17
+30° to 21
9 0.9 7 40° 19
N 6
13 9 1.8 0.18 1.3
17 1.7 12 22
5 8 N 20 N
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7
22 2.2 16 10
17 1.7 12

11
44 4.5 33

44 4.5 33

3
1
2

15 16
14

11 1.1 8 181 18.5 134

11 1.1 8

Removal steps
1. Cooling fan 12. Pow er steering pump bracket
2. Fan clutch 13. Alternator
3. Water pump pulley FAE EBF 14. Crankshaft bolt
4. Vacuum pipe EBF 15. Special w asher
5. Eyebolt EBF 16. Crankshaft pulley
6. Gasket 17. Oil level gauge
7. Eyebolt 18. O-ring
8. Gasket 19. Oil level gauge guide
9. Oil pipe 20. O-ring
ECF 10. Oil hose 21. Glow plug plate
11. Auto tensioner FBE EAF 22. Glow plug
DEN0328
G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised
 4D56 ENGINE <1994 –> – Drive Belt and Glow Plug 11B-3-1b
REM OVAL SERVICE POINTS
FAE CRANKSHAFT PULLEY BOLT REM OVAL
(1) Hold t he f lyw heel or drive plat e in posit ion w it h t he
special tool before removing the crankshaft pulley bolts.

M D998781
DEN0117

FBE GLOW PLUG REM OVAL (CERAM IC TYPE ONLY)

(1) When removing the glow plug, you may loosen using a tool
up to the point w here one or more threads are left in
engagement. Beyond this point, loosen w ith fingers.
Caution
• Do not reuse a glow plug that has been dropped
from a height of 10 cm (4 in.) or more.
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INSPECTION
GLOW PLUG
(1) Check the continuity betw een the terminal and body as
illustrated. Replace if there is no continuity or if there is a
large resistance.
Standard value:
M etal type 0.9 – 1.1 Ω [at 20°C (68°F)]
Ceramic type 0.4 – 0.6 Ω [at 20°C (68°F)]
DEN034

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

 11B-3-2 4D56 ENGINE <1994 –> – Drive Belt and Glow Plug

INSTALLATION SERVICE POINTS

EAF GLOW PLUG INSTALLATION
(1) Check that the glow plugs, glow plug mounting threads
and plug seating surfaces of cylinder head are dry.
(2) When installing the glow plug, screw in one thread or
more w ith fingers and then tighten w ith a tool.<ceramic
type only>

EBF CRANKSHAFT BOLT/ SPECIAL WASHER /

CRANKSHAFT PULLEY INSTALLATION
(1) Use the special tool to hold the flyw heel or the drive
plate.

M D998781
DEN0117
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Crankshaft Pulley (2) Clean and t hen degrease t he crankshaf t sprocket

Crankshaft crankshaft contacting surface of the crankshaft pulley.
bolt
Washer Clean
NOTE
Degreasing is necessary t o prevent decrease in t he
friction betw een contacting surfaces.
(3) Clean the bolt hole in the crankshaft, the crankshaft
contacting surface and w asher contacting surface of the
crankshaft pulley, and the w asher.
Degrease (4) Apply an appropriatery small amount of oil to the threads
DEN0311 and seating surface of the crankshaft bolt.
(5) Tighten the crankshaft bolt to the specified torque of 181
N·m (18.5 kgm, 134 ft.lbs.).

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Added

ProCarManuals.com
ProCarManuals.com
NOTES
 4D56 ENGINE <1994 –> – Timing Belt 11B-4-1
4. TIM ING BELT
REM OVAL AND INSTALLATION

7
8
25 2.6 19
67 7.0 51 6
1

10 1.0 7 25 2.6 19

4
10
9
3
13 83 8.5 61
11
ProCarManuals.com

9 0.9 7

24
12
2
11 1.1 8
22
11 1.1 8 21
25 2.6 19
36 3.7 27

25 2.6 19

19
20 18
36 3.7 27 17
16

23
15
14
Removal steps
1. Timing belt upper cover EFF 12. Crankshaft sensing blade
2. Timing belt low er cover (w ith throttle body)
3. Flange FDE EFF 13. Crankshaft sprocket
FAE EJF 4. Timing belt EFF 14. Flange
5. Tensioner spacer FEE EEF 15. Timing belt “ B”
6. Tensioner spring 16. Gasket
EIF 7. Timing belt tensioner 17. Tensioner spacer “ B”
FBE EHF 8. Camshaft sprocket 18. Tensioner spring “ B”
FCE EGF 9. Injection pump sprocket EDF 19. Timing belt tensioner
EFF 10. Crank angle sensor FFE ECF 20. Balancer shaft sprocket, right
(w ith throttle body) FGE EBF 21. Balancer shaft sprocket, left
EFF 11. Front flange EAF 22. Spacer
(2001 model PAJERO) FHE EKF 23. Crankshaft sprocket “ B”
24. Timing belt rear cover
DEN0329

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

ProCarManuals.com
ProCarManuals.com
ProCarManuals.com
ProCarManuals.com
 11B-4-6 4D56 ENGINE <1994 –> – Timing Belt

EEF TIM ING BELT “B” INSTALLATION

(1) Align timing marks on the crankshaft sprocket “ B” , and
silent shaft sprockets w ith their timing marks.
(2) Install timing belt “ B” onto sprockets and ensure that its
tension side is not slack.

(3) Loosen tensioner “ B” mounting bolt and nut, one to tw o

turns.
(4) Tighten the tensioner “ B” attaching nut.
(5) Tighten the tensioner “ B” attaching bolt.
NOTE
If the bolt is tightened first, the tensioner “ B” should be
turned together, resulting in reduced tim ing belt “ B ”
tension.
ProCarManuals.com

Balancer shaft (6) Ensure that the deflection is as specified w hen the belt is
sprocket pushed by the index finger at the position indicated by an
arrow.
Belt deflection:
4 – 5 mm (0.16 – 0.20 in.)

Crankshaft sensing blade EFF CRANKSHAFT SENSING BLADE / FRONT FLANGE

or front flange / FLANGE / CRANKSHAFT SPROCKET
Flange
Crankshaft INSTALLATION
Clean
(1) Clean and then degrease the follow ing surfaces and parts:
Sprocket m ount ing surf ace of crankshaf t , crankshaf t
sensing blade or front flange, flange, and crankshaft
sprocket.
NOTE
Crankshaft
Degreasing is necessary t o prevent decrease in t he
Degrease
sprocket DEN0312 friction betw een contacting surfaces.
(2) Clean the crankshaft contacting surface of the crankshaft
M D998719 sprocket.

M B998767 EGF INJECTION PUM P SPROCKET INSTALLATION

DEN0129

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

ProCarManuals.com
ProCarManuals.com
 4D56 ENGINE <1994 –> – Timing Belt 11B-4-9
Crankshaft EKF CRANKSHAFT SPROCKET “B” INSTALLATION
sprocket “ B” Crankshaft
Oil pump gear
Clean and then degrease the front face of the Oil pump gear
drive shaft drive shaft, crankshaft sprocket “ B” and crankshaft surface
on w hich sprocket “ B” is attached.
NOTE
Degreasing is necessary to prevent decrease in the friction
betw een contacting surfaces.

Degrease
DEN0313
ProCarManuals.com

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Added

ProCarManuals.com
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 4D56 ENGINE <1994 –> – Fuel Injection Pump and Injection Nozzle 11B-5-7
Identification mark NOTE
The injection timing can be know n from the identification
mark stamped on the cylinder head at the position show n
in the illustration.

Identification mark Injection timing

A or B 7° ATDC
C , D, E or H 9° ATDC

DEN0175

When higher than (7) If dial indicator reading is not w ithin the standard value
the standard value range, tilt the injection pump body to the right or left until
the reading is w ithin the standard value range. Then, tem-
porarily tighten the injection pump nuts and bolts.
(8) Repeat Steps (5) and (6) to make sure that the adjust-
ment has been correctly performed.
(9) Tighten the injection pump mounting bolts and nuts to
the specified torque.
Front When low er than (10)Remove the dial indicator and the special tool.
view the standard value
DEN0107
ProCarManuals.com

(11)install new copper gasket and plug, then tighten the plug
to specified torque.

Copper gasket

Plug

DFU0013

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

ProCarManuals.com
NOTES
ProCarManuals.com
ProCarManuals.com
 4D56 ENGINE <1994 –> – Intake and Exhaust M anifolds 11B-7-1
7. INTAKE AND EXHAUST M ANIFOLDS
REM OVAL AND INSTALLATION
Engines w ithout turbocharger (Up to 1998 models for L200)

18 1.8 13

14 1.4 10
3 4

5 N
18 1.8 13
ProCarManuals.com

Removal steps
1. Engine hanger
2. Intake manifold
3. Heat protector
4. Exhaust manifold
5. M anifold gasket

DEN0308

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

 11B-7-1a 4D56 ENGINE <1994 –> – Intake and Exhaust M anifolds

Engines w ithout turbocharger (From 1999 model L200)

25 2.5 18
5 7

N 6 8 N
11 1.1 8 11
18 1.8 13

2 19 1.9 14
N 4 1
10
3 18 1.8 13
18 1.8 13
17 1.7 12 18 1.8 13
13
17 1.7 12
4 N 9

N 12
ProCarManuals.com

14 1.4 10 15

14

18 1.8 13

16
17 N

Removal steps
1. Vacuum pipe and 9. Intake manifold stay front
hose assembly 10. Intake manifold stay rear
2. Vacuum pipe and 11. Intake manifold upper
hose assembly Engines w ith 12. Intake manifold gasket
3. EGR pipe EGR system 13. Engine hanger
4. Gasket 14. Intake manifold low er
5. EGR valve 15. Heat protector
6. Gasket 16. Exhaust manifold
7. Air intake fitting 17. M anifold gasket
8. Gasket

DEN0331

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

 4D56 ENGINE <1994 –> – Intake and Exhaust M anifolds 11B-7-1b
Engines w ith turbocharger <PAJERO (Up to 2000 model) L200 (w ithout throttle
body), L300 (except P15T)>
11 1.1 8 8 25 2.5 18
29
N 9 49 5.0 36
30
18 1.8 13
12 1.2 9 31
32 N 33
42 4.3 31 N 28 27 34 10 1.0 7
10 11 N 42 4.3 31
2
18 1.8 13 1

12 9 0.9 7 7 N
19 1.9 14 6
9 0.9 7 13 17 1.7 12
5 18 1.8 13
23 36
3 35
N 7 37 N
14 1.4 10 9 0.9 7
17 1.7 12
9 0.9 7
ProCarManuals.com

15
17
4
N 16 18 1.8 13
20 2.0 14
N 23
21 59 6.0 43
25
22

59 6.0 43
14
N 19 18 14 1.4 10
9 0.9 7 26 N

20
Disassembly steps
1. Vacuum pipe and hose assembly 19. Gasket
(L200) 20. Oil hose
2. Vacuum pipe and hose assembly 21. Air hose (Engines w ithout intercooler)
(L200) 22. Exhaust fitting
3. Boost hose 23. Stay
4. Snap ring 24. Gasket
5. Waste gate actuator 25. Turbocharger assembly
6. EGR pipe 26. Gasket
7. Gasket Engines w ith 27. Eyebolt
8. EGR valve EGR system 28. Gasket
9. Gasket 29. Water pipe
10. Eyebolt 30. Relief valve
11. Gasket 31. Air inlet fitting
12. Water pipe 32. Gasket Engines w ithout
13. Heat protector A 33. Engine hanger intercooler
14. Heat protector C 34. Intake manifold
EAF 15. Eyebolt 35. Heat protector
16. Gasket 36. Exhaust manifold
17. Oil pipe 37. M anifold gasket
18. Oil return pipe DEN0332

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

 11B-7-2 4D56 ENGINE <1994 –> – Intake and Exhaust M anifolds

Engines w ith turbocharger <PAJERO (From 2001 model)>

49 5.0 36
19 1.9 14 30
29 18 1.8 13
9 N 31 32
28

25 2.5 18 3
42 4.3 31
N 10 1
33
11 N 27 26
12 N 42 4.3 31 N 8 17 1.7 12 22 2.2 16
18 1.8 13
7
20 2.0 14 17 1.7 12 8 N

9 0.9 7 9 0.9 7 34 35
13 2
18
17 1.7 12 14 36 N
16

59 6.0 43
ProCarManuals.com

N 17 9 0.9 7
22
59 6.0 43 N 23 18 1.8 13
24
59 6.0 43
4
5
6
15

N 20
19 25 N 14 1.4 10
12 1.2 9
9 0.9 7 21

Disassembly steps
1. Air pipe 19. Oil return pipe
2. Air pipe bracket 20. Gasket
3. Air intake hose 21. Oil hose
4. Boost hose 22. Exhaust fitting
5. Snap pin 23. Gasket
6. Waste gate actuator 24. Turbocharger assembly
7. EGR pipe 25. Gasket
8. Gasket 26. Eyebolt
9. EGR valve 27. Gasket
10. Gasket 28. Water pipe
11. Eyebolt 29. Relief valve
12. Gasket 30. Air intake fitting
13. Water pipe 31. Gasket
14. Turbochargr heat protector 32. Engine hanger
15. Exhaust fitting heat protector 33. Intake manifold
EAF 16. Eyebolt 34. Heat protector
17. Gasket 35. Exhaust manifold
18. Oil pipe 36. M anifold gasket

DEN0330

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

 4D56 ENGINE <1994 –> – Intake and Exhaust M anifolds 11B-7-2a
Engines w ith turbocharger <L200 (w ith throttle body)>

19 1.9 14
11 1.1 8 37
25 2.5 18 14 1.4 10
1
24 2.4 17
11 1.1 8 17 17 1.7 12 38 N
16 N 11
22 2.2 16 15 18 1.8 13 N 2
20 N 39
42 4.3 31 12 N
4
19 22 2.2 16 41 40 N
17 1.7 12 10 1.0 7
9 8
42 4.3 31 N 12 17 1.7 12 43
21 13
20 N N 14
18
36 35 N N 35
9 0.9 7 3
N 10 9 0.9 7
22 17 1.7 12 34 44
18 1.8 13 45 N
24
17 1.7 12 26
42
ProCarManuals.com

N 25 20 2.0 14
59 6.0 43 9 0.9 7

59 6.0 43 N 31 30 18 1.8 13
32

5 59 6.0 43
6
7 23

N 28
27
33 N 14 1.4 10
12 1.2 9
9 0.9 7 29

Disassembly steps
1. Air temperature sensor EAF 24. Eyebolt
2. Gasket 25. Gasket
3. Vacuum pipe and hose assembly 26. Oil pipe
4. Solenoid valve assembly 27. Oil return pipe
5. Boost hose 28. Gasket
6. Snap pin 29. Oil hose
7. Waste gate actuator 30. Exhaust fitting
8. Water hose 31. Gasket
9. Water pipe and hose 32. Turbocharger assembly
10. O-ring 33. Gasket
11. EGR upper pipe 34. EGR low er pipe
12. Gasket 35. Gasket
13. EGR valve 36. EGR cooler
14. Gasket 37. Air intake fitting
15. Eyebolt 38. Gasket
16. Gasket 39. Throttle body
17. Water pipe A 40. Gasket
18. Water hose 41. Engine hanger
19. Eyebolt 42. Heat protector
20 Gasket 43. Intake manifold
21. Water pipe B 44. Exhaust manifold
22. Turbocharger heat protector 45. M anifold gasket
23. Heat protector C
DEN0333

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

 11B-7-2b 4D56 ENGINE <1994 –> – Intake and Exhaust M anifolds
ProCarManuals.com

Intensionally blank

G M itsubishi M otors Corporation Feb. 2000 PWEE9067-E Added

ProCarManuals.com
ProCarManuals.com
 4D56 ENGINE <1994 –> – Intake and Exhaust M anifolds 11B-7-4a
Engines w ith variable geometry turbocharger <PAJERO>
11 1.1 8 19 1.9 14
39
25 2.5 18 19 1.9 14 24 2.4 17
14 1.4 10 17 4
17 1.7 12
22 2.2 16 N 16 11 40 N
15 18 1.8 13 N 5 7
21 41
N 20 42 4.3 31 12 N 10 1.0 7
9 8 17 1.7 12 22 2.2 16 43 42 N
N 12 44
19 17 1.7 12
18 N 20 13
42 4.3 31 N 14 6
N 10 38 37 N N 37
3
14 1.4 10
9 0.9 7 22 2.2 16
22 36 46
17 1.7 12 47
24 18 1.8 13
17 1.7 12 26 1
45
N 25 20 2.0 14
32
34 9 0.9 7
33 2
ProCarManuals.com

18 1.8 13
12 1.2 9 35 N

59 6.0 43 28 N
27
19 1.9 14
N 31
30
9 0.9 7 29
23
14 1.4 10

Disassembly steps
1. Air pipe 25. Gasket
2. Air pipe bracket 26. Oil pipe
3. Air hose 27. Oil return pipe
4. Air temperature sensor 28. Gasket
5. Gasket 29. Oil return hose
6. Vacuum pipe and hose assembly 30. Air inlet fitting
7. Solenoid valve assembly 31. Gasket
8. Water hose 32. Snap pin
9. Water pipe and hose 33. VG actuator
ECF 10. O-ring 34. Turbocharger assembly
11. EGR upper pipe 35. Gasket
12. Gasket 36. EGR low er pipe
13. EGR valve 37. Gasket
14. Gasket 38. EGR cooler
15. Eyebolt 39. Air intake fitting
16. Gasket 40. Gasket
17. Water pipe A 41. Throttle body
18. Water hose 42. Gasket
19. Eyebolt 43. Engine hanger
20. Gasket 44. Heat protector
21. Water pipe B 45. Intake manifold
22. Turbochargr heat protector 46. Exhaust manifold
23. Exhaust fitting heat protector 47. M anifold gasket
EAF 24. Eyebolt DEN0334

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

 11B-7-4b 4D56 ENGINE <1994 –> – Intake and Exhaust M anifolds

Engines w ith turbocharger <L200, CHALLENGER>

5 0.5 4 1 19 1.9 14
11 1.1 8
25 2.5 18 35
14 1.4 10
14 1.4 10 15 24 2.4 17
17 1.7 12 2
22 2.2 16 14 N 36 N
13 9 18 1.8 13 N 3
N 18 19 42 4.3 31 10 N 37
6 5
7 17 1.7 12 22 2.2 16 38 N
39 10 1.0 7
16 N 18 17 N 10 17 1.7 12 41
11
42 4.3 31 N 12
8 N 34 33 N N 33
14 1.4 10 9 0.9 7 4

20 17 1.7 12 32 42
43 N
22 18 1.8 13
17 1.7 12 24
ProCarManuals.com

40
N 23 20 2.0 14
28 30 9 0.9 7
29
18 1.8 13
12 1.2 9 31 N

59 6.0 4.3 26 N
25
9 0.9 7
27
21
14 1.4 10

Disassembly steps
1. Boost sensor 23. Gasket
2. Air temperature sensor 24. Oil pipe
3. Gasket 25. Oil return pipe
4. Vacuum pipe and hose assembly 26. Gasket
5. Solenoid valve assembly 27. Oil return hose
6. Water hose 28. Snap pin
7. Water pipe and hose 29. VG actuator
ECF 8. O-ring 30. Turbocharger assembly
9. EGR upper pipe 31. Gasket
10. Gasket 32. EGR low er pipe
11. EGR valve 33. Gasket
12. Gasket 34. EGR cooler
13. Eyebolt 35. Air intake fitting
14. Gasket 36. Gasket
15. Water pipe A 37. Throttle body
16. Water hose 38. Gasket
17. Eyebolt 39. Engine hanger
18. Gasket 40. Heat protector
19. Water pipe B 41. Intake manifold
20. Turbocharger upper heat protector 42. Exhaust manifold
21. Turbocharger low er heat protector 43. M anifold gasket
EAF 22. Eyebolt
DEN0335

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

ProCarManuals.com
ProCarManuals.com
NOTES
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NOTES
 4D56 ENGINE <1994 –> – Water Pump, Thermostat, Hose and Pipe 11B-9-1
9. WATER PUM P, THERM OSTAT, HOSE AND PIPE
REM OVAL AND INSTALLATION
Engines w ithout throttle body
<PAJERO (Up to 2000 model), L200, L300, L400 CHALLENGER>
1

14 1.4 10
2

11 1.1 8
ProCarManuals.com

N 6
5
14 1.4 10

14 1.4 10 7 34 3.5 25
13
14 N

16 N
11
12

15
24 2.4 17 N 10
14 1.4 10 9

12 1.2 9

Removal steps
1. Water hose 9. Water outlet fitting
2. Water pipe w ith 10. Gasket
3. Water hose turbocharger 11. Water inlet fitting
4. Water hose EAF 12. Thermostat
5. Water pipe 13. Thermostat housing
ECF 6. O-ring 14. Gasket
EDF 7. Coolant temperature gauge unit 15. Water pump
8. Engine hanger 16. Gasket

DEN0142

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

 11B-9-1a 4D56 ENGINE <1994 –> – Water Pump, Thermostat, Hose and Pipe

Except engines w ithout throttle body

<PAJERO (From 2001 model)>

4 3

5
6 14 1.4 10

N 7 11 1.1 8
ProCarManuals.com

8
12 34 3.5 25
13
14
15 N 17 N

12 1.2 9
10 1.0 7 12 1.2 9

16 10
24 2.4 17
14 1.4 10

11 N

Removal steps
1. Hose protector 10. Water outlet fitting
2. Water hose 11. Gasket
3. Water pipe 12. Water inlet fitting
4. Water hose EBF 13. Thermostat
5. Water hose 14. Plate
6. Water pipe 15. Gasket
EDF 7. O-ring 16. Water pump
ECF 8. Coolant temperature gauge unit 17. Gasket
9. Engine hanger

DEN0304

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

 4D56 ENGINE <1994 –> – Water Pump, Thermostat, Hose and Pipe 11B-9-1b
Except engines w ith throttle body <PAJERO>

2
14 1.4 10

4
3

5
11 1.1 8
ProCarManuals.com

6
34 3.5 25
10
11
12
13 N 15 N

12 1.2 9

12 1.2 9
10 1.0 7
8
14
24 2.4 17
14 1.4 10

9 N
7

Removal steps
1. Hose protector 9. Gasket
2. Water hose 10. Water inlet fitting
3. Water pipe EBF 11. Thermostat
4. Water hose 12. Plate
5. Water pipe and hose 13. Gasket
EDF 6. Coolant temperature gauge unit 14. Water pump
7. Engine hanger 15. Gasket
8. Water outlet fitting

DEN0336

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

 11B-9-2 4D56 ENGINE <1994 –> – Water Pump, Thermostat, Hose and Pipe

Engines w ith throttle body

<L200, CHALLENGER>

14 1.4 10
2

3
4

14 1.4 10

5
11 1.1 8
14 1.4 10
ProCarManuals.com

14 1.4 10 6 34 3.5 25
12
13
15 N

10
11

12 1.2 9
14
24 2.4 17 8
14 1.4 10

9 N

Removal steps
1. Hose protector 9. Gasket
2. Water hose 10. Water inlet fitting
3. Water pipe EAF 11. Thermostat
4. Water hose 12. Thermostat housing
5. Water pipe and hose 13. Gasket
EDF 6. Coolant temperature gauge unit 14. Water pump
7. Engine hanger 15. Gasket
8. Water outlet fitting

DEN0337

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

ProCarManuals.com
ProCarManuals.com
NOTES
ProCarManuals.com
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 4D56 ENGINE <1994 –> – Cylinder Head and Valves 11B-11-1
11. CYLINDER HEAD AND VALVES
REM OVAL AND INSTALLATION
<W ithout
throttle body>
118 12.0 87

5 <W ith
6 throttle body>
1 29 3.0 22
7
11 2 +
N 10 120° to 124°

12 N
N 13

3
16
ProCarManuals.com

14 N

N 15
8
4 N
9

Removal steps
FAE EEF 1. Cylinder head bolt
2. Cylinder head bolt w asher
3. Cylinder head assembly
EDF 4. Cylinder head gasket
FBE ECF 5. Valve spring retainer lock
6. Valve spring retainer
EBF 7. Valve spring
8. Intake valve
9. Exhaust valve
FCE EAF 10. Valve stem seal
11. Spring seat Lubricate all
12. Intake valve guide internal parts w ith
13. Exhaust valve guide engine oil during
14. Exhaust valve seat reassembly.
15. Cylinder head

DEN0151

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

ProCarManuals.com
ProCarManuals.com
ProCarManuals.com
ProCarManuals.com
 11B-11-6 4D56 ENGINE <1994 –> – Cylinder Head and Valves

M D998772

DEN0152

ECF RETAINER LOCK INSTALLATION

Caution
• The valve spring, if excessively com pressed,
M D998303 causes the bottom end of the retainer to be in
contact w ith, and damage, the stem seal.

DEN092
ProCarManuals.com

EDF CYLINDER HEAD GASKET INSTALLATION

Identification mark of cylinder head gasket
(1) In case any of the cylinder block, piston, connecting rod
and crankshaft has not been replaced, install the gasket
of the same rank as before w hich can be identified by the
mark show n in the illustration at left.

Identification
hole
Rank A Rank B Rank C Rank D Rank E

DEN0061

Timing belt side (2) In case any of the cylinder block, piston, connecting rod
Identification mark of cylinder head gasket and crankshaft have been replaced, reselect and install
the gasket in accordance w ith the follow ing procedure.
1) With each piston held at the top dead center, mea-
sure its protrusion from the upper block surface at the
locations show n in the illustration at left (total of eight
locations). Be sure to take measurements on the
crankshaft center line.
2) Using the average of the eight measurements, select
Rank C Rank D Rank E the gasket rank (A, B, C, D or E) in accordance w ith
Identification mark DEN0341 the table given below. If, how ever, the maximum pro-
trusion at any one location exceeds the protrusion tol-
1 2 3 45 67 8 erance show n for any rank in the follow ing table, use
the gasket one rank higher that rank.

Reference for measurement

Protrusion measuring locations
(w ith each piston at top dead center) DEN0156

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

 4D56 ENGINE <1994 –> – Cylinder Head and Valves 11B-11-7
Engines w ithout turbocharger mm (in.)
Average value of Protrusion Thickness of
Rank piston protrusions tolerance selected gasket
for each rank (w hen tightened)
A 0.562 – 0.620 0.670 1.35 ± 0.05
(0.0221 – 0.0244) (0.0264) (0.0531 ± 0.0020)
Protrusion
B 0.620 – 0.680 0.730 1.40 ± 0.05
(0.0244 – 0.0268) (0.0287) (0.0551 ±0.0020)

DEN0798 C 0.680 – 0.744 0.794 1.45 ± 0.05

(0.0268 – 0.0293) (0.0313) (0.0571 ±0.0020)

Engines w ith turbocharger mm (in.)

Average value of Protrusion Thickness of
Rank piston protrusions tolerance selected gasket
for each rank (w hen tightened)
C 0.562 – 0.620 0.670 1.45 ± 0.05
(0.0221 – 0.0244) (0.0264) (0.0571 ± 0.0020)
D 0.620 – 0.680 0.730 1.50 ± 0.05
(0.0244 – 0.0268) (0.0287) (0.0590 ±0.0020)
ProCarManuals.com

E 0.680 – 0.744 0.794 1.55 ± 0.05

(0.0268 – 0.0293) (0.0313) (0.0610 ±0.0020)

NOTE
If the piston projection exceeds the tolerance, replace the
piston, connecting rod, crankshaft or cylinder block and check
again.

EEF CYLINDER HEAD BOLT INSTALLATION

<Without throttle body>
(1) Set the cylinder head bolt w asher w ith its shear droop
tow ard the bolt head.
(2) Apply engine oil to the bolt threads and w asher.

(3) Using the special tool and torque w rench, tighten bolts in
the show n sequence.

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

 11B-11-8 4D56 ENGINE <1994 –> – Cylinder Head and Valves

(4) Repeat t he t ight ening sequence several t im es, and

tighten the bolts to 118 Nm (12.0 kgm, 87 ft.lbs.) in the
final sequence.

<With throttle body>

(1) Set the cylinder head bolt w asher w ith its shear droop
tow ard the bolt head.
(2) Apply engine oil to the bolt threads and w ashers.
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(3) Retighten the loosened bolts to a torque of 29 Nm (3.0

kgm, 22 ft.lbs.) in the specified tightening sequence.

M B991614 (4) Give a 120° turn to the bolts in the specified tightening
sequence.
Caution
• If the bolts are tightened by an angle of less than
120°, they may not hold the cylinder head w ith
120° sufficient strength.
• If a bolt is overtightened, completely remove all
the bolts and carry out the installation procedure
again from step (1).
6AE0339

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Added

 4D56 ENGINE <1994 –> – Front Case and Oil Pan 11B-12-1
12. FRONT CASE AND OIL PAN
REM OVAL AND INSTALLATION <PAJERO (Up to 2000 model), L200, L300, L400,
CHALLENGER> 14 1.4 10
5 N 37 N
1
36
Apply engine oil to 2
all moving parts 54 5.5 40
before installation.
3
4
10 1.0 7
21 N 35

24 2.4 17
36 3.7 27
30
31
32 19
20 14 13
34 19 1.9 13
24 2.4 17
12 1.2 9
40 N
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27
18 N 29 13 1.3 9 39
17 28
38
9 0.9 7 16 32 3.3 24
15 N
33 26
N 10
22 N 24 N 9
24 2.4 17
25
N 8
13 1.3 9 23 11
7 0.7 5
37 3.8 27
7
6
N 12 39 4.0 29

9 0.9 7
19 1.9 14

Removal steps
EKF 1. Oil filter 21. Front low er case gasket
2. Oil cooler by-pass valve EFF 22. Crankshaft front oil seal
EJF 3. Oil pressure sw itch 23. Plug
4. Oil filter bracket 24. Gasket
5. Oil filter bracket gasket 25. Relief spring
6. Oil pan cover 26. Relief plunger
<w ith variable geometry turbocharger> 27. Oil pump cover
7. Oil drain plug FCE EEF 28. Inner rotor
E I F 8. Oil drain plug gasket FCE EEF 29. Outer rotor
9. Oil level sensor <PAJERO> 30. Balancer shaft gear cover
FAE EHF 10. Oil pan EDF 31. Balancer shaft driven gear
11. Oil screen EDF 32. Balancer shaft drive gear
12. Oil screen gasket ECF 33. Oil seal
13. Stiffener 34. Oil pump gear drive shaft
14. Front upper case 35. Balancer shaft, left
15. Front upper case gasket 36. Balancer shaft, right
16. Oil seal FDE EBF 37. Balancer shaft bearing
17. Plug cap 38. Check valve
18. O-ring EAF 39. Oil jet
FBE EGF 19. Flange bolt 40. Gasket
20. Front low er case
DEN0338

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

 11B-12-1a 4D56 ENGINE <1994 –> – Front Case and Oil Pan

REM OVAL AND INSTALLATION <PAJERO (From 2001 model)>

10 1.0 7 11 1.0 7 37 N
3
36
2 4
54 5.5 40
5 N

Apply engine oil to 37 N

all moving parts 23 2.3 1.7
before installation. 35
1
36 3.7 27 24 2.4 17
30
34
19 31
20
32 13
24 2.4 17 21 N 19 1.9 13
18 N 12 1.2 9
33 N N 40 39
27
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17
29 N 15
28 38
13 1.3 9 32 3.3 24
15 N
26 14
25 9 10
22 N 24 N
24 2.4 17 9 0.9 7
23
13 1.3 9 37 3.8 27

7 0.7 5
N 12 11
8 N
6
7
19 1.9 14 39 4.0 29
9 0.9 7

Removal steps
EKF 1. Oil filter 21. Front low er case gasket
2. Oil cooler by-pass valve EFF 22. Crankshaft front oil seal
EJF 3. Oil pressure sw itch 23. Plug
4. Oil filter bracket 24. Gasket
5. Oil filter bracket gasket 25. Relief spring
6. Oil pan cover 26. Relief plunger
(from 2002 model) 27. Oil pump cover
7. Oil drain plug FCE EEF 28. Inner rotor
E I F 8. Oil drain plug gasket FCE EEF 29. Outer rotor
9. Oil level sensor 30. Balancer shaft gear cover
FAE EHF 10. Oil pan EDF 31. Balancer shaft driven gear
11. Oil screen EDF 32. Balancer shaft drive gear
12. Oil screen gasket ECF 33. Oil seal
13. Stiffener 34. Oil pump gear drive shaft
14. Front upper case 35. Balancer shaft, left
15. Front upper case gasket 36. Balancer shaft, right
16. Oil seal FDE EBF 37. Balancer shaft bearing
17. Plug cap 38. Check valve
18. O-ring EAF 39. Oil jet
FBE EGF 19. Flange bolt 40. Gasket
20 Front low er case DEN0339

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

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NOTES
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NOTES
 4D56 ENGINE <1994 –> – Crankshaft and Cylinder Block 11B-14-1
14. CRANKSHAFT AND CYLINDER BLOCK
REM OVAL AND INSTALLATION <PAJERO (Up to 2000 model), L200, L300, L400>

Apply engine oil to 1 132 13.5 98

all moving parts
before installation. 3

9 0.9 7
Head mark “7”
44 4.5 33 8 4
2
Head mark “ 8”
54 5.5 40 11 1.1 8

11
24
N 12
13 10
6 132 13.5 98
5
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22

14 N 7
9
9 0.9 7

18

25
20
17 N 21

19 N

16
6 0.6 4
23
15
Head mark “7”
78 8.8 58 44 4.5 33
Head mark “8”
54 5.5 40

Removal steps
1. Flyw heel ECF 14. Rear oil seal
2. Ball bearing For variable EBF 15. Bearing cap
3. Adapter plate geometry M /T EAF 16. Crankshaft bearing, low er
4. Crankshaft adapter turbocharger 17. Crankshaft
5. Adapter plate EAF 18. Crankshaft bearing, upper
6. Drive plate A/T 19. O-ring
7. Crankshaft adapter 20. Cover
8. Rear plate 21. Packing
9. Space rubber <PAJERO> 22. Engine bracket, right
10. Bell housing cover 23. Engine bracket, left
11. Oil seal case 24. Cylinder sleeve
12. Gasket 25. Cylinder block
EDF 13. Oil separator
DEN0340

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

 11B-14-1a 4D56 ENGINE <1994 –> – Crankshaft and Cylinder Block

REM OVAL AND INSTALLATION <PAJERO (From 2001 model) CHALLENGER>

132 13.5 98
Apply engine oil to
all moving parts
before installation.
9 0.9 7
4
21 N
2
M 10 44 4.5 33
11 1.1 8
M8 22 2.2 16 3

N 9
19 1
10
5

8
7
N 11
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15 6 9 0.9 7

22 N 18
17
14

20
13

16 N
12
6 0.6 4

78 88.0 58

44 4.5 33

Removal steps
1. Flyw hee EAF 13. Crankshaft bearing, low er
2. Ball bearing 14. Crankshaft
3. Adapter plate EAF 15. Crankshaft bearing, upper
4. Crankshaft adapter 16. O-ring
5. Rear plate 17. Cover
6. Space rubber <PAJERO> 18. Packing
7. Bell housing cover 19. Engine bracket, right
8. Oil seal case 20. Engine bracket, left
9. Gasket 21. Cylinder sleeve
EDF 10. Oil separator 22. Cylinder block
ECF 11. Rear oil seal
EBF 12. Bearing cap

DEN0307

G M itsubishi M otors Corporation M ay 2001 PWEE9067-G Revised

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NOTES
 Service Bulletins
Click on the applicable bookmark to select the Service Bulletin.
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 SERVICE BULLETIN
QUALITY INFORMATION ANALYSIS
OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION

SERVICE BULLETIN No.: MSB-00E11-509

Date: 2001-04-09 <Model> <M/Y>

Subject: OMISSION OF INJECTION TIMING ALL 01-10
IDENTIFICATION MARK
Group: ENGINE Draft No.: 00EN600614

CORRECTION INTERNATIONAL
CAR
ADMINISTRATION T. MASAKI-MANAGER
OFFICE TECHNICAL SERVICE PLANNING

1. Description:
Omission of a 4D5 engine injection timing identification mark from the following Workshop
Manual, has been rectified.
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2. Applicable Manuals:
Manual Pub. No. Language Page(s)
ENGINE 4D5 PWEE9067 (English) 11B-5-7
Workshop Manual PWES9068 (Spanish)
PWEF9069 (French)
PWEG9070 (German)
PWED9071 (Dutch)
PWEW9072 (Swedish)
 3. Details:
4D56 ENGINE <1994-> - Fuel Injection Pump and Injection Nozzle 11B-5-7
NOTE
Identification mark
The injection timing can be known from the
identification mark stamped on the cylinder head at
the position shown in the illustration.

Identification mark Injection timing

A or B 7° ATDC
C or D 9° ATDC

or E or G
DEN0175
<Added>
(7) If dial indicator reading is not within the standard
When higher than value range, tilt the injection pump body to the right
the standard value
or left until the reading is within the standard value
range. Then, temporarily tighten the injection pump
nuts and bolts.
(8) Repeat Steps (5) and (6) to make sure that the
adjustment has been correctly performed.
(9) Tighten the injection pump mounting bolts and nuts
Front
When lower than to the specified torque.
view
(10) Remove the dial indicator and the special tool
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the standard value

DEN0107

(11) Install new copper gasket and plug, then tighten the
plug to specified torque.

Copper gasket

Plug

DFU0013