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Mitsubishi 4D56 engine factory workshop and repair manual download
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Mitsubishi 4D56 engine factory workshop and repair manual 1991 onwardson PDF can be viewed using free PDF reader like adobe , or foxit or nitro . It is compressed as a zip file which you can extract with 7zip File size 6 Mb Searchable PDF document with bookmarks. Manual Contents About the 4D5 engineThe Mitsubishi Astron or 4G5 engine, is a series of straight-four internal combustion engines first built by Mitsubishi Motors in 1972. Engine displacement ranged from 1.8 to 2.6 litres, making it one of the largest four-cylinder engines of its time. It employed a hemispherical cylinder head, chain-driven single overhead camshaft (SOHC) and eight valves (two per cylinder). United States passenger car versions had a small secondary intake valve referred to as the "Jet Valve". This valve induced swirl in the intake charge, enabling the use of leaner fuel/air mixtures for lower emissions. It was designed as a cartridge containing the valve spring and seat which simply screwed into a threaded hole in the head, similar to a spark plug but inside the cam cover. The rocker arms for the intake valve were widened on the valve end to accommodate the cartridge, which was equipped with a very soft valve spring in order to avoid wear on the camshaft intake lobe. Modifications to the head were thereby reduced as the Jet Valve negated the necessity for a three-valve-per-cylinder design. In 1975, the Astron 80 introduced a system dubbed "Silent Shaft": the first use of twin balance shafts in a modern engine. It followed the designs of Frederick Lanchester, whose original patents Mitsubishi had obtained, and proved influential as Fiat/Lancia, Saab and Porsche all licensed this technology. The 4D5 engine is a range of four-cylinder belt-driven overhead camshaft diesel engines which were part of the "Astron" family, and introduced in 1980 in the then new fifth generation Galant. As the first turbodiesel to be offered in a Japanese passenger car, it proved popular in the emerging SUV and minivan markets where Mitsubishi was highly successful, until superseded by the 4M4 range in 1993. However, production of the 4D5 (4D56) continued throughout the 1990s as a lower-cost option than the more modern powerplants. Until now it is still in production, but made into a modern powerplant by putting a common rail direct injection fuel system into the engine. Displacement - 2.5 L (2,476 cc) Power - 55 kW (74 hp) at 4,200 rpm Non-intercooled Turbo Power - 84 PS (62 kW) at 4,200 rpm Non-intercooled Turbo (TD04 Turbo) Power - 90 hp (67 kW) at 4,200 rpm Intercooled Turbo (TD04 watercooled Turbo) Power - 78 kW (104 hp) at 4,300 rpm Intercooled Turbo (1st Generation DI-D) Power - 85 kW (114 hp) at 4,000 rpm Intercooled Turbo (2nd Generation DI-D) Power - 100 kW (134 hp) at 4,000 rpm Intercooled Turbo (3rd Generation DI-D with variable geometry turbo) With manual transmission Power - 131 kW (178 PS) at 4,000 rpm With automatic transmission Power - 131 kW (178 PS) at 4,000 rpm Mitsubishi Hilux 4D56 engine factory workshop and repair manual 1991 onwards Download |
#### Tools Required:
- **Basic Hand Tools:**
- **Socket Wrench Set:** For removing and tightening bolts. Use the correct size to avoid stripping the fasteners.
- **Torque Wrench:** Ensures bolts are tightened to the manufacturer's specified torque. This is crucial for maintaining the integrity of the assembly.
- **Pliers:** For gripping and pulling components apart, especially when dealing with small clips or pins.
- **Hammer:** A rubber or brass hammer is recommended to avoid damaging parts when tapping them into place or removing stubborn components.
- **Specialized Tools:**
- **Bearing Puller:** Essential for removing the old pinion bearings without damaging the differential housing. The puller grips the bearing and allows you to pull it out smoothly.
- **Bearing Press or Arbor Press:** If you need to press new bearings onto the pinion shaft, this tool applies even pressure to avoid damaging the bearings.
- **Dial Indicator (optional):** For measuring backlash and ensuring proper setup of the differential gears.
- **Cleaning Tools:**
- **Degreaser/Cleaning Solvent:** To clean the differential housing and components of old grease and debris.
- **Rags or Shop Towels:** For wiping down parts and keeping the workspace clean.
- **Replacement Parts:**
- **Pinion Bearings:** Replace the old bearings as they may be worn or damaged. Ensure you get the correct size and type for the Mitsubishi 4D56.
- **Seals:** It's recommended to replace the pinion seal when you replace the bearings to prevent leaks. Look for a high-quality rubber seal to ensure a proper fit.
- **Gear Oil:** New gear oil is necessary after reassembly. Check the specifications for the correct type and amount for your differential.
#### Procedure:
- **Preparation:**
- Park the vehicle on a level surface and engage the parking brake.
- Lift the rear of the vehicle using a jack and secure it with jack stands for safety.
- **Removing the Differential Cover:**
- Use a socket wrench to remove the bolts securing the differential cover.
- Carefully pry the cover off to avoid damaging the gasket. Clean the mating surfaces thoroughly.
- **Removing the Pinion Nut:**
- Use a socket wrench to remove the pinion nut. This may require significant force, so a breaker bar might be necessary.
- Once the nut is removed, slide off the pinion gear assembly.
- **Removing Old Bearings:**
- Use a bearing puller to carefully extract the old pinion bearings from the pinion shaft and differential housing.
- Inspect the bearing surfaces for wear or damage.
- **Installing New Bearings:**
- Use a bearing press to install new pinion bearings onto the pinion shaft. Ensure they are pressed on evenly and aligned correctly.
- Install the new pinion seal into the differential housing using the proper installation tool or a flat piece of wood to avoid damage.
- **Reinstalling the Pinion Gear:**
- Slide the pinion gear assembly back into the differential housing.
- Secure it in place with a new pinion nut. Use a torque wrench to tighten it to the manufacturer's specifications.
- **Reassembling the Differential:**
- Reattach the differential cover with a new gasket or sealant as necessary.
- Refill the differential with the appropriate gear oil through the fill hole.
- **Final Steps:**
- Double-check all bolts and seals for tightness and proper installation.
- Lower the vehicle and perform a test drive to ensure everything operates smoothly.
#### Final Notes:
- Always refer to the vehicle’s service manual for specific torque settings and procedures.
- If at any point you feel unsure, consult a professional mechanic or seek further guidance.
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