<4D5> ENGINE

Click on the applicable bookmark to selected the required model year

11B-2 ENGINE <4D5> – General Information

GENERAL INFORMATION 11100010339

Items 4D56

Total displacement m
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_, Closing ABDC 49_

Exhaust Opening BBDC 55_, Closing ATDC 22_

Fuel system Distribution type injection pump

Rocker arm Roller type

Adjusting screw Elephant foot type

 ENGINE <4D5> – Service Specifications/Sealants 11B-3
SERVICE SPECIFICATIONS 11100030359

Items Standard value Limit

Alternator drive belt Tension N When checked 245 – 441 –
tension (for each
belt)) When a used belt is installed 294 – 392 –
When a new belt is installed 392 – 588 –
Deflection When checked 12.0 – 17.0 –
(Reference
value)) mm When a used belt is installed 13.0 – 16.0 –
When a new belt is installed 10.0 – 13.0 –
Power steering oil Tension N When checked 294 – 490 –
pump drive belt ten-
ten
sion When a used belt is installed 343 – 441 –
When a new belt is installed 490 – 686 –
Deflection When checked 8.0 – 12.0 –
(Reference
value)) mm When a used belt is installed 9.0 – 11.5 –
When a new belt is installed 6.0 – 8.0 –
A/C compressor Tension N When checked 320 – 400 –
drive
belt tension When a used belt is installed 320 – 400 –
When a new belt is installed 480 – 560 –
Deflection When checked 6.0 – 7.0 –
(Reference
value)) mm When a used belt is installed 6.0 – 7.0 –
When a new belt is installed 4.5 – 5.5 –
Valve clearance (at hot) mm 0.25 –
Injection timing (Value indicated on dial gauge mm) 9_ ATDC (1 ± 0.03) –
Idle speed r/min 750 ± 100 –
Idle up engine speed for ABS r/min 1,900 ± 100 –
Compression pressure kPa 3,040 Min. 2,200
Compression pressure difference of all cylinder (at engine speed of 280 – Max. 300
r/min) kPa
Timing belt tension mm 4–5 –
Timing belt B tension mm 4–5 –

SEALANTS 11100050270

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
11B-4 ENGINE <4D5> – Special Tools

SPECIAL TOOLS 11100060327

Tool Number Name Use

MD998384 Prestroke measur- Adjustment of the injection timing
ing adapter

MD998721 Crankshaft pulley Holding the crankshaft pulley

holder

MB990767 End yoke holder Holding the camshaft sprocket

MD998719 Crankshaft pulley

holder pin

MD998381 Camshaft oil seal Installing the camshaft oil seal

installer

MD998727 Oil pan remover Removal of oil pan

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

MD998382 Crankshaft front oil Installing the crankshaft front oil seal
seal installer

MD998383 Crankshaft front oil

seal guide
 ENGINE <4D5> – Special Tools/On-vehicle Service 11B-5

Tool Number Name Use

MD998781 Flywheel stopper Securing the flywheel

MD998376 Crankshaft rear oil Press-fitting the crankshaft rear oil seal
seal installer

Water pump ON-VEHICLE SERVICE 11100090333

pulley
98 N DRIVE BELT TENSION CHECK AND
ADJUSTMENT
ALTERNATOR DRIVE BELT TENSION CHECK
Use a belt tension gauge to check that the belt tension is
at the standard value at a point half-way between the two
pulleys as shown in the illustration. In addition, press this
Alternator section with a force of 98 N and check that the amount of
pulley Crankshaft
pulley belt deflection is at the standard value.
Standard value (for each belt):
Tension N 245 – 441
Deflection (Reference value) mm 12.0 – 17.0
11B-6 ENGINE <4D5> – On-vehicle Service

ALTERNATOR DRIVE BELT TENSION ADJUSTMENT

Lock bolt
1. Loosen the nut of the alternator pivot bolt.
2. Loosen the lock bolt.
3. Use the adjusting bolt to adjust the belt tension and belt
deflection to the standard values.
Adjusting
bolt Standard value (for each belt):
Items When a used When a new belt
belt is installed is installed
Pivot bolt
Tension N 294 – 392 392 – 588
Deflection (Reference 13.0 – 16.0 10.0 – 13.0
value) mm
4. Tighten the nut of the alternator pivot bolt.
Tightening torque: 44 Nm
5. Tighten the lock bolt.
Tightening torque: 22 Nm
6. Tighten the adjusting bolt.
Tightening torque: 9.8 Nm

98 N
POWER STEERING OIL PUMP DRIVE BELT TENSION
Power CHECK AND ADJUSTMENT 11100110152
steering
oil pump Deflection 1. Use a belt tention gauge to check that the belt tension
pulley is at the standard value at a point half-way between the
two pulleys (indicated by an arrow in the illustration).
In addition, press this section with a force of 98 N and
Water pump
pulley check that the amount of belt deflection is at the standard
value.
Crankshaft Standard value:
pulley
Items When When a used When a new
checked belt is intalled belt is installed

Tension N 294 – 490 343 – 441 490 – 686

Deflection 8.0 – 12.0 9.0 – 11.5 6.0 – 8.0

(Reference
value) mm
 ENGINE <4D5> – On-vehicle Service 11B-7
2. If the tension or deflection is outside the standard value,
adjust by the following procedure.
A (1) Loosen power steering oil pump fixing bolts A, B and
C.
(2) Adjust the amount of belt deflection using adjusting
C bolt D.
(3) Tighten fixing bolts A, B and C.
B Tightening torque: 22 Nm
(4) Check the belt deflection amount and tension, and
readjust if necessary.
Caution
Check after turning the crankshaft once or more
clockwise (right turn).

AIR CONDITIONER COMPRESSOR DRIVE BELT

Tension pulley
TENSION CHECK AND ADJUSTMENT 11100100142

Crankshaft 98 N 1. Use a belt tention gauge to check that the belt tension
pulley is at the standard value at a point half-way between the
two pulleys (indicated by an arrow in the illustration).
In addition, press this section with a force of 98 N and
Deflec- check that the amount of belt deflection is at the standard
tion value.
Standard value:
A/C compressor pulley
Items When When a used When a new
checked belt is intalled belt is installed

Tension N 320 – 400 320 – 400 480 – 560

Deflection 6.0 – 7.0 6.0 – 7.0 4.5 – 5.5

(Reference
value) mm

Adjusting bolt 2. If the tension or deflection is outside the standard value,

Tension pulley adjust by the following procedure.
Fixing nut (1) Loosen tension pulley fixing nut.
Crankshaft A/C (2) Adjust belt tension with adjusting bolt.
pulley compressor
pulley (3) Tighten fixing nut.
11B-8 ENGINE <4D5> – On-vehicle Service

(4) Check the belt deflection amount and tension, and

readjust if necessary.
Caution
Check after turning the crankshaft once or more
clockwise (right turn).

Timing marks Timing marks VALVE CLEARANCE CHECK AND

ADJUSTMENT 11100150109

1. Start the engine and allow it to warm up until the engine

coolant temperature reaches 80 to 90 _C.
2. Remove the timing belt upper cover.
3. Remove the rocker cover.
4. Align the camshaft sprocket timing marks and set the
No. 1 cylinder at top dead centre.
Camshaft Crankshaft Caution
sprocket pulley The crankshaft should always be turned in a clockwise
direction.

5. Measure the valve clearance at the places indicated by

arrows in the illustration.
Standard value: 0.25 mm

NOTE
Insert the thickness gauge from the centre of the cylinder
Adjusting head towards the outside so that it doesn’t touch the
screw
pad.
Pad

Thickness gauge
 ENGINE <4D5> – On-vehicle Service 11B-9
6. If the clearance is outside the standard value, loosen
the lock nut of the rocker arm and adjust by turning the
Thickness gauge adjusting screw while using a thickness gauge to measure
the clearance.
7. Tighten the lock nut while holding the adjusting screw
with a screwdriver so that it doesn’t turn.
8. Turn the crankshaft 360_ clockwise to bring No. 4 cylinder
to the top dead centre position.

9. Measure the valve clearances at the places indicated

by arrows in the illustration. If the clearance is not within
the standard value, repeat steps 7 and 8 above.

10. Apply specified sealant to the section of the semi-circular

Cylinder head packing shown in the illustration.
10 mm
Specified sealant: 3M ATD Part No. 8660 or equivalent
11. Install the rocker cover.
12. Install the timing belt upper cover.

10 mm

Semi circular packing

INJECTION TIMING CHECK AND

ADJUSTMENT 11100180023

1. Warm up the engine and then check to be sure that

the fast idle lever is separated from the throttle lever.
Accelerator lever 2. Remove all of the glow plugs.
3. Remove the timing belt upper cover.

Fast idle lever

Timing marks Timing marks 4. Align the timing marks of the camshaft sprocket and set
the No. 1 cylinder to the top dead centre position.

Camshaft Crankshaft
sprocket pulley
11B-10 ENGINE <4D5> – On-vehicle Service

5. Remove the timing check plug at the rear of the injection

pump.

Timing check plug

6. Before installation of special tool, make sure that push

rod is protruding by 10 mm. Protrusion of push rod can
be adjusted with an inner nut.
Push rod Nut MD998384 7. Connect the dial gauge to the special tool.

10 mm

8. Install the special tool to the check plug at the rear of

the injection pump.

MD998384

9. Turn the crankshaft clockwise to move the No. 1 cylinder

Approx. 30_ approximately 30_ before compression top dead centre.
10. Set the needle of the dial gauge to 0.
11. Check that the needle doesn’t move even if the crankshaft
is turned slightly (2 – 3_) in both clockwise and
anti-clockwise direction.
NOTE
If the needle moves, the notch is not positioned properly,
so once again move the No. 1 cylinder approximately
30_ before compression top dead centre.

12. Turn the crankshaft clockwise to align the No. 1 cylinder

1 ± 0.03 mm to 9_ ATDC.
13. Check that the value indicated on the dial gauge is at
the standard value.
Standard value: 1 ± 0.03 mm

Set to 9_ ATDC
 ENGINE <4D5> – On-vehicle Service 11B-11
Injection pipe 14. If the needle is outside the standard value, adjust the
union nuts injection timing by the following procedure.
(4 places) (1) Loosen the injection pipe union nuts (4 places) on
the injection pump. (Do not remove the union nuts.)
Caution
When loosening the nuts, hold the delivery valve
Nuts (2 places) holders with a spanner so that they don’t turn
Bolts (2 places) at the same time.
(2) Loosen the upper mounting nuts and the lower
mounting bolts of the injection pump. (Do not remove
the nut and bolt.)
1 ± 0.03 mm or more (3) Tilt the injection pump to the left and right and adjust
the needle on the dial gauge so that the display value
is uniform.
(4) Provisionally tighten the mounting nut and bolt of
the injection pump.
(5) Repeat steps 9 – 13 to check if the adjustment has
been made correctly.
1 ± 0.03 mm of less
Front
view

Injection pipe (6) Tighten the mounting nuts and bolts to the specified
union nuts torque.
(29 Nm) (7) Tighten the injection pump union nuts to the specified
torque.
Caution
When tightening the nuts, hold the delivery valve
Nuts holders with a spanner so that they don’t turn
(19 Nm) Bolts
(24 Nm)
at the same time.

15. Remove the special tool.

16. Install a new gasket to the timing check plug.
17. Tighten the timing check plug to the specified torque.
Gasket N

Timing
check plug
(17 Nm)

IDLE SPEED CHECK AND ADJUSTMENT

11100190347

NOTE
Check that the injection timing is normal
1. Before inspection, set the vehicle to the pre-inspection
condition.
11B-12 ENGINE <4D5> – On-vehicle Service

2. Connect the speedometer to the injection nozzle or the

injection pipe.
Caution
When the speedometer is connected to the injection
Speedometer pipe, the pipe mounting clamps should all be removed.
3. Start the engine and run it at idle.
4. Check the idle speed.
Standard value: 750 ± 100 r/min
Injection
nozzle

5. If not within the standard value, loosen idle adjusting

screw lock nut and adjust the idle speed by rotating
adjusting screw. And tighten locking nut.
Accelerator lever

Locking
nut
Idle speed
adjusting screw

IDLE-UP MECHANISM CHECK AND

ADJUSTMENT-FOR A/C 11100230032

Refer to GROUP 55 – On-vehicle Service.

IDLE-UP MECHANISM CHECK AND

ADJUSTMENT-FOR ABS 11100230025

1. Before inspection, set the vehicle to the pre-inspection

condition.

2. Inspect and adjust the idle speed.

3. Disconnect the vacuum hose (for anti-skid brakes: blue
stripe) from the idle-up actuator.
4. Connect a hand vacuum pump to the nipple of the removed
vacuum hose.
5. Connect the speedometer.
6. Start the engine and run it at idle.
 ENGINE <4D5> – On-vehicle Service 11B-13
7. Check the engine speed when a negative pressure of
87 kPa is applied.
Lock nut
Adjusting Standard value: 1,900 ± 100 r/min
screw
8. If the engine speed is outside the standard value, loosen
the lock nut on the actuator rod and adjust by turning
the adjusting screw.
9. Tighten the lock nut while making sure that the adjusting
screw doesn’t turn.

COMPRESSION PRESSURE CHECK 11100260369

1. Before inspection, check that the engine oil, starter and

battery are normal. In addition, set the vehicle to the
pre-inspection condition.
2. Remove all of the glow plugs.
Caution
Be careful not to subject the glow plugs to any shocks.

3. Disconnect the fuel cut solenoid valve connector or fuel

Fuel cut valve cut valve controller.
Fuel cut controller
solenoid valve NOTE
Doing this will prevent carrying out fuel injection.
4. Cover the glow plug hole with a shop towel etc., and
after the engine has been cranked, check that no foreign
material is adhering to the shop towel.
Caution
1. Keep away from the glow plug hole when cranking
2. If compression is measured with water, oil, fuel,
etc., that has come from cracks inside the cylinder,
these materials will become heated and will gush
out from glow plug hole, which is dangerous.
11B-14 ENGINE <4D5> – On-vehicle Service

Compression gauge 5. Set compression gauge to one of the glow plug holes.
6. Crank the engine and measure the compression pressure.
Standard value (at engine speed of 280 r/min):
3,040 kPa
Limit (at engine speed of 280 r/min): min. 2,200 kPa
7. Measure the compression pressure for all the cylinders,
and check that the pressure differences of the cylinders
are below the limit.
Limit: max 300 kPa
8. If there is a cylinder with compression or a compression
difference that is outside the limit, pour a small amount
of engine oil through the glow plug hole, and repeat the
operations in steps (6) and (7).
(1) If the compression increses after oil is added, the
cause of the malfunction is a worn or damaged piston
ring and/or cylinder inner surface.
(2) If the compression does not rise after oil is added,
the cause is a burnt or defective valve seat, or pressure
is leaking from the gasket.
9. Connect the fuel cut solenoid valve connector or fuel
cut valve controller connector.
10. Install the glow plugs.
Tightening torque: 18 Nm

TIMING BELT TENSION ADJUSTMENT 11100280136

1. Remove timing belt upper cover.

2. Turn the crankshaft in the clockwise direction and check
the timing belt around its entire circumference for
abnormalities.

Timing marks 3. Align the timing marks on the sprockets with the timing
marks on the front upper case.
Caution
When aligning the timing mark, be sure not to turn
the crankshaft in the counterclockwise direction as
this can cause improper belt tension.

Timing marks
 ENGINE <4D5> – On-vehicle Service 11B-15
4. Loosen the tensioner pivot side bolt 1 turn and slot side
bolt 1 or 2 turns.
Slot side
bolt

Pivot side
bolt

Camshaft sprocket
5. Turn the crankshaft clockwise and stop at the second
lobe of the camshaft sprocket.
6. First tighten tensioner slot side bolt, and then tighten
pivot side bolt to the specified torque.
Tightening torque: 25 Nm

2 teeth

7. Turn the crankshaft anti-clockwise to align the timing

marks.
8. Push down belt at a point halfway with a forefinger to
check that tension of belt is up to standard value.
Standard value: 4 – 5 mm
9. Mount the timing belt upper cover.

Timing marks TIMING BELT “B” TENSION ADJUSTMENT

11100280143

1. Remove timing belt upper cover.

2. Turn the crankshaft in the clockwise direction and check
the timing belt around its entire circumference for
abnormalities.
3. Align the timing marks on the sprockets with the timing
mark on the front upper case.
Caution
Timing marks When aligning the timing mark, be sure not to turn
the crankshaft in the counterclockwise direction as
this can cause improper belt tension.
11B-16 ENGINE <4D5> – On-vehicle Service

4. Remove the access cover.

Access cover

5. Loosen the tensioner pivot side bolt 1 mm and slot side

Pivot nut 1 or 2 turns.
side 6. First tighten tensioner slot side nut, and then tighten pivot
bolt side bolt to the specified torque.
Slot
side Tightening torque:
nut Pivot side bolt 24 Nm
Slot side nut 25 Nm

Access cover 7. Install the access cover while sliding the front lower cover
Guide down along the two guides.
8. Install the timing belt upper cover.
 ENGINE <4D5> – Crankshaft Pulley 11B-17
CRANKSHAFT PULLEY 11200160242

REMOVAL AND INSTALLATION

Pre-removal Operation Post-installation Operation
D Under Cover Removal D Drive Belt Tension Adjustment (Refer to P.11B-5.)
D Under Cover Installation

167 – 186 Nm

4
25 Nm

Removal steps
1. Drive belt (for A/C)
2. Drive belt (for power steering)
3. Drive belt (for alternator)
AA" "AA 4. Crankshaft pulley (for power steering
or A/C)
5. Crankshaft pulley

REMOVAL SERVICE POINT

AA" CRANKSHAFT PULLEY REMOVAL

INSTALLATION SERVICE POINT

"AA CRANKSHAFT PULLEY INSTALLATION

MD998721
11B-18 ENGINE <4D5> – Camshaft and Camshaft Oil Seal

CAMSHAFT AND CAMSHAFT OIL SEAL 11200190289

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation
D Intercooler Removal and Installation <4WD>
(Refer to GROUP 15.)

5.9 Nm
4

5
2
5
3
Sealant:
3M ATD Part No. 8660 or equivalent 4
34 – 39 Nm

Lip

7 19 – 21 Nm
8

34 – 39 Nm
9
10 9
19 – 21 Nm
9
9
Cam section 7
and journal
section
6 10
Engine oil

64 – 74 Nm

9.8 – 12 Nm

Camshaft removal steps Camshaft oil seal removal steps

1. Timing belt upper cover assembly 1. Timing belt upper cover assembly
2. Breather hose connection AA" "DA 6. Camshaft sprocket
3. Boost hose connection <4WD> AB" "CA 7. Camshaft oil seal
4. Rocker cover
5. Semi-circular packing
AA" "DA 6. Camshaft sprocket
AB" "CA 7. Camshaft oil seal
AC" "BA 8. Rocker arm and shaft assembly
"AA 9. Camshaft bearing cap
10. Camshaft
 ENGINE <4D5> – Camshaft and Camshaft Oil Seal 11B-19
Timing marks REMOVAL SERVICE POINTS
AA" CAMSHAFT SPROCKET REMOVAL
1. Rotate crankshaft clockwise (to the right) and align timing
marks.
Caution
Never turn the crankshaft anticlockwise.

No. 1 T.D.C

2. Tie the camshaft sprocket and timing belt together with

Timing belt
Cord cord so that timing mark is not maladjusted.

Camshaft
sprocket

3. Use the special tool to stop the camshaft sprocket from

MB990767 turning, and then remove the camshaft sprocket with the
timing belt still attached.
Caution
Do not rotate crankshaft after removing camshaft
sprocket.

MD998719

AB" CAMSHAFT OIL SEAL REMOVAL

1. Make a notch in the oil seal lip section with a knife, etc.
Oil 2. Cover the end of a (–) screwdriver with a rag and insert
Lip seal
section
into the notched section of the oil seal, and lever out
the oil seal to remove it.
Caution
Be careful not to damage the camshaft and the cylinder
(–) screwdriver head.
Camshaft

AC" ROCKER ARM AND SHAFT ASSEMBLY REMOVAL

Loosen the rocker arm and shaft assembly mounting bolt,
and then remove the rocker arm and shaft assembly with
the bolt still attached.
Caution
Never disassemble the rocker arm and shaft assembly.
11B-20 ENGINE <4D5> – Camshaft and Camshaft Oil Seal

INSTALLATION SERVICE POINTS

Cap No. "AA CAMSHAFT BEARING CAP INSTALLATION
The cap numbers are embossed on the top surface of the
bearing caps, so install in the order of the numbers. However,
no numbers are embossed on bearing caps 1 and 5.

"BA ROCKER ARM AND SHAFT ASSEMBLY

INSTALLATION
1. Install the rocker arm and shaft assembly to the bearing
caps.
2. Set the washer so that it faces in the direction shown
in the illustration, and then install the bolt.
3. Check the valve clearance and adjust if necessary. (Refer
to P.11B-8.)
Chamfer

MD998381 Camshaft "CA CAMSHAFT OIL SEAL INSTALLATION

1. Apply a small amount of engine oil to the entire
circumference of the oil seal lip and camshaft.
2. Use the special tool to tap in the oil seal.
NOTE
The oil seal should be tapped in until the distance from
the end of the camshaft to the end of the oil seal is
as shown in the illustration.
Oil seal

"DA CAMSHAFT SPROCKET INSTALLATION

1. Use the special tool in the same way as during removal
to stop the camshaft sprocket from turning, and then
tighten the bolt to the specified torque.
Tightening torque: 64 – 67 Nm
2. Remove the cord which binds the camshaft sprocket and
timing belt.
 ENGINE <4D5> – Oil Pan and Oil Screen 11B-21
OIL PAN AND OIL SCREEN 11200250192

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation
D Under Cover Removal and Installation
D Engine Oil Draining and Supplying
(Refer to GROUP 12 – On-vehicle Service.)

Front of
engine
6
<4WD> 5 5 <2WD>
φ 4.0 mm
4

Groove Bolt
hole

6 19 Nm
Sealant:
MITSUBISHI GENUINE Part No. 19 Nm
MD970389 or equivalent
3

39 Nm

6.9 Nm

2 4

Removal steps
1. Drain plug AA" "AA 4. Oil pan
"BA 2. Drain plug gasket 5. Oil screen
3. Oil return hose connection 6. Gasket

MD998727 MD998727 REMOVAL SERVICE POINT

AA" OIL PAN REMOVAL
1. Remove oil pan bolts.
2. Tap the special tool in between the oil pan and cylinder
block.
3. Slide the special tool by tapping it at an angle to remove
the oil pan.
11B-22 ENGINE <4D5> – Oil Pan and Oil Screen

Caution
The use of a screwdriver or chisel in place of the
special tool can damage the gasket seat surface and
cause oil leakage.

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 the specified sealant around the gasket surface
of oil pan.
Specified sealant:
MITSUBISHI GENUINE PART No. MD970389 or
equivalent
NOTE
The sealant should be applied in a continuous bead
approximately 4 mm in diameter.
4. Assemble oil pan to cylinder block within 15 minutes after
applying the sealant.
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 side
Drain plug
gasket

INSPECTION 11200260041

D Check oil pan for cracks.

D Check oil pan sealant-coated surface for damage and
deformation.
D Check oil screen for cracked, clogged or damaged wire
net and pipe.
 ENGINE <4D5> – Cylinder Head Gasket 11B-23
CYLINDER HEAD GASKET 11200400368

REMOVAL AND INSTALLATION

Pre-removal Operation Post-installation Operation
D Intake and Exhaust Manifold Removal D Timing Belt Installation (Refer to P.11B-26.)
(Refer to GROUP 15.) D Intake and Exhaust Manifold Installation
D Timing Belt Removal (Refer to P.11B-26.) (Refer to GROUP 15.)
D Engine Coolant Draining D Fuel Line Air Bleeding
(Refer to GROUP 14 – On-vehicle Service.) (Refer to GROUP 13E – On-vehicle Service.)
D Engine Coolant Filling
(Refer to GROUP 14 – On-vehicle Service.)

5.9 Nm

10

29 Nm
4.9 Nm
9
29 Nm
4.9 Nm 5
113 – 123 Nm 3

22 Nm 2
11 4.9 Nm

29 Nm

22 Nm

8
7
9 12
13
10 mm 10 mm
1
24 Nm
4

10 14
Sealant:
3M ATD Part No. 8660 or
equivalent

Removal steps
1. Engine coolant temperature switch 7.
Fuel hose connection
connector (for A/C) 8.
Earth cable connection
2. Engine coolant temperature gauge 9.
Rocker cover
unit and sensor connector 10.
Semi-circular packing
3. Glow plug terminal AC" 11.
Power steering oil pump assembly
AA" "CA 4. Radiator upper hose 12.
Power steering oil pump bracket
AB" "DA 5. Fuel injection pipe bolt
6. Heater hose or water by-pass hose AD" "BA 13. Cylinder head assembly
connection "AA 14. Cylinder head gasket
11B-24 ENGINE <4D5> – 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> – Cylinder Head Gasket 11B-25
INSTALLATION SERVICE POINTS
Identification mark
"AA CYLINDER HEAD GASKET INSTALLATION
1. Wipe off any oil or grease from the gasket mounting
surface.
2. Check the rank from the number of identification holes
on the cylinder head gasket that was removed, and select
a cylinder head gasket of the same rank.
Identifi-
Rank A B C D E cation NOTE
holes The ranks are listed in the parts catalogue.
3. Place the cylinder head gasket on top of the cylinder
block so that the identification mark is facing upwards
as in the illustration.

"BA CYLINDER HEAD INSTALLATION

Use the special tool to tighten each bolt 2 – 3 times in the
order shown in the illustration.
Caution
MD998051
The head bolt washer should be installed so that the
Head bolt
burred side is facing upwards.
washer

Burred
side

Front

"CA RADIATOR UPPER HOSE CONNECTION

To reuse the radiator upper hose, align the mating marks
that were made during removal, and then install the hose
clamp.
"DA 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
the nuts to the specified torque.
11B-26 ENGINE <4D5> – Timing Belt and Timing B

TIMING BELT AND TIMING BELT B 11200430343

REMOVAL AND INSTALLATION

Pre-removal Operation Post-installation Operation
D Cooling Fan Removal (Refer to GROUP 14.) D Cooling Fan Installation (Refer to GROUP 14.)
D Engine Adjustment (Refer to P.11B-5.)

1 6 8 9
7
25 Nm

25 Nm

9.8 – 12 Nm

4
3 5

16

9.8 – 12 Nm 25 Nm

167 – 186 Nm

25 Nm
24 Nm
15
14
13
2
12
10 11

Removal steps
1. Timing belt front upper cover 9. Timing belt tensioner assembly
2. Tension pulley bracket (for A/C) 10. Crankshaft sprocket
3. Crankshaft pulley (for power steering 11. Flange
and A/C) AC" "AA 12. Timing belt B
AA" "CA 4. Crankshaft pulley 13. Gasket
5. Timing belt front lower cover 14. Tensioner spacer B
AB" "BA 6. Timing belt 15. Tensioner spring B
7. Tensioner spacer 16. Timing belt tensioner B
8. Tensioner spring
 ENGINE <4D5> – Timing Belt and Timing Belt B 11B-27
REMOVAL SERVICE POINTS
AA" CRANKSHAFT PULLEY REMOVAL
1. Position the No. 1 cylinder at compression TDC and
remove the crankshaft pulley.
NOTE
The No. 1 cylinder is at compression TDC when the marks
Timing marks are aligned as shown in the figure.

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

remove the bolts.

MD998721

Tilt to water pump side AB" TIMING BELT REMOVAL

Tensioner
mounting 1. When reinstalling timing belt, mark an arrow at the belt
bolt 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.
Tensioner
mounting
bolt B

Water pump AC" TIMING BELT B REMOVAL

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

Timing mark INSTALLATION SERVICE POINTS

"AA TIMING BELT B INSTALLATION
Tensioner
1. Align the timing marks of the 3 sprockets.
2. When reusing timing belt ”B”, make sure the arrow mark
Timing marks is pointing in the same direction as when the belt was
removed.

Timing belt
11B-28 ENGINE <4D5> – Timing Belt and Timing Belt B

Timing mark 3. Install timing belt B and make sure there is no deflection
Tensioner on the tension side.
24 Nm 4. Press the deflection side of timing belt B (indicated by
A arrow (A)) with the hand and fully stretch the tensioner
Timing marks Tension side side.
5. Make sure that the timing marks are aligned.
25 Nm 6. Loosen the tensioner mounting bolt and nut so that only
the pressure of the spring is applied to timing belt B.
Timing belt 7. Tighten the tensioner mounting bolt and nut, tightening
the nut first. If the bolt is tightened first, the tensioner
will move and tension the belt.

Counterbalance 8. Press in the direction of the arrow in the figure with the
shaft sprocket index finger to check the amount of deflection.
Standard value: 4 – 5 mm

Belt deflection

Crankshaft
sprocket “B”

"BA TIMING BELT INSTALLATION

Tension 1. Align the timing marks of the 3 sprockets.
side 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
Water pump pump sprocket, to tensioner and to camshaft sprocket
Tension side
in that order. Being careful not to allow deflection on
the tension side of the timing belt.
Caution
1. Engage the belt on the various sprockets while
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.
 ENGINE <4D5> – Timing Belt and Timing Belt B 11B-29
4. Loosen the tensioner mounting bolts and apply tension
Camshaft sprocket with the spring.
5. Turn the crankshaft clockwise and stop at the second
lobe of the camshaft sprocket.
Caution
1. When turning the crankshaft in item (5), strictly
2 teeth
observe the specified amount of rotation (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.

Belt deflection Tensioner

6. Make sure that the part indicated by arrow A does not
mounting bolt float upward.
A 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

Tensioner
mounting bolt

8. Turn the crankshaft anticlockwise and align the timing

Amount of belt deflection
mark. Next, make sure that the timing marks of all
sprockets are aligned.
9. Press on the centre of the bolt with an index finger to
check the amount of deflection.
Standard value: 4 – 5 mm

"CA CRANKSHAFT PULLEY INSTALLATION

Using the special tool to install the crankshaft pulley as same
as removal procedure.
11B-30 ENGINE <4D5> – Crankshaft Front Oil Seal

CRANKSHAFT FRONT OIL SEAL 11200340233

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation
D Timing Belt and Timing Belt “B” Removal and
Installation (Refer to P.11B-26.)

(Engine oil)
2

Removal steps
1. Crankshaft sprocket B
AA" "AA 2. Oil seal

REMOVAL SERVICE POINT

AA" OIL SEAL REMOVAL
Oil seal
Lip 1. Cut out a portion in the crankshaft oil seal lip.
portion 2. Cover the tip of a screwdriver with a cloth and apply
it to the cutout in the oil seal to pry off the oil seal.
Caution
Be careful not to damage the crankshaft and front
Screwdriver case.
Camshaft

Oil seal
INSTALLATION SERVICE POINT
Crankshaft "AA OIL SEAL INSTALLATION
Apply engine oil to the outside of the special tool (MD998383)
and to the oil seal lip, and use the special tool to press-fit
the oil seal.

MD998382 MD998383

(Apply oil to outer surface)

 ENGINE <4D5> – Crankshaft Rear Oil Seal 11B-31
CRANKSHAFT REAR OIL SEAL 11200370249

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation
D Oil Pan Removal and Installation (Refer to P.11-21.)
D Transmission Assembly Removal and Installation
(Refer to GROUP 22, 23.)

127 – 137 Nm

6 5

127 – 137 Nm
1

8 2
7
4 3

Removal steps
AA" "CA 1. Flywheel assembly <M/T> 5. Oil seal case
AA" "CA 2. Adaptor plate <A/T> 6. Gasket
3. Drive plate <A/T> "BA 7. Oil separator
4. Crankshaft adaptor <A/T> "AA 8. Oil seal

REMOVAL SERVICE POINT

AA" FLYWHEEL <M/T>/ADAPTOR PLATE <A/T>
REMOVAL
Use the special tool to secure the flywheel or adaptor plate
and remove the bolt.

MD998781

INSTALLATION SERVICE POINTS

"AA OIL SEAL INSTALLATION

MD998376
11B-32 ENGINE <4D5> – Crankshaft Rear Oil Seal

Oil seal case Oil separator "BA OIL SEPARATOR INSTALLATION

Install the oil separator in such a way that its oil hole come
at the case bottom (indicated by an arrow in the illustration).

Oil hole

Oil pan mounting surface

"CA FLYWHEEL <M/T>/ADAPTOR PLATE <A/T>

INSTALLATION
Use the special tool in the same way as during removal to
stop the flywheel or adaptor plate assembly from turning,
and then tighten the bolt to the specified torque.
Tightening torque: 127 – 137 Nm
 ENGINE <4D5> – Engine Assembly 11B-33
ENGINE ASSEMBLY 11200100367

REMOVAL AND INSTALLATION

Pre-removal Operation Post-installation Operation
D Hood Removal (Refer to GROUP 42.) D Transmission and Transfer Assembly Installation
D Intercooler Removal <4WD> (Refer to GROUP 15.) <4WD> (Refer to GROUP 22, 23.)
D Air Cleaner and Air Intake Hose Removal D Transmission Assembly Installation <2WD>
(Refer to GROUP 15.) (Refer to GROUP 22.)
D Brake Master Cylinder Heat Protector Removal D Radiator Installation (Refer to GROUP 14.)
<4WD> D Battery installation
D Battery Removal D Brake Master Cylinder Heat Protector Installation
D Radiator Removal (Refer to GROUP 14.) <4WD>
D Transmission Assembly Removal <2WD> D Air Cleaner and Air Intake Hose Installation
(Refer to GROUP 22.) (Refer to GROUP 15.)
D Transmission and Transfer Assembly Removal D Intercooler Installation <4WD>
<4WD> (Refer to GROUP 22, 23.) (Refer to GROUP 15.)
D Hood Installation (Refer to GROUP 42.)
D Drive Belt Tension Adjustment (Refer to P.11B-5.)
D Accelerator Cable Adjustment
(Refer to GROUP 17 – On-vehicle Service.)
D Throttle Cable Adjustment <A/T>
(Refer to GROUP 23 – On-vehicle Service.)

4 5
6
4.9 Nm
8.8 Nm
7

8
3 9
2
12 Nm
1

5
10
16 Nm

14 13 12 11 6

Removal steps
1. Engine coolant temperature sensor 9. Heater hose connections
and gauge unit connector 10. Throttle cable connection <A/T>
2. Earth cable connector 11. Fuel cut solenoid valve or fuel cut
3. Glow plug terminal valve controller connector
4. Earth cable connector 12. Revolution pick-up sensor connector
5. Vacuum hose connection (for A/C) 13. Lever (throttle) position switch
6. Vacuum hose connection (for ABS) connector
7. Brake booster vacuum hose 14. Engine coolant temperature switch
connection connector (for A/C)
8. Accelerator cable connection
11B-34 ENGINE <4D5> – Engine Assembly

16
22 Nm

22 Nm
15
23

44 Nm

21
30 Nm

14 Nm

22
20 19
22 Nm

18

24 25 17
9.8 Nm 26

34 Nm

25

15. Drive belt (for Power steering) 21.

Engine oil cooler hose connection
AA" 16. Power steering oil pump assembly 22.
Fuel hose connections
17. Drive belt (for A/C) 23.
Front exhaust pipe connection
AA" 18. A/C compressor assembly 24.
Heat protector
19. Engine oil pressure switch 25.
Engine support front insulator
connector attaching bolt
20. Alternator connector AB" "AA 26. Engine assembly
ENGINE <4D5> – Engine Assembly 11B-35
REMOVAL SERVICE POINTS
AA" POWER STEERING OIL PUMP ASSEMBLY AND
A/C COMPRESSOR ASSEMBLY REMOVAL
1. Remove the oil pump and A/C compressor (with the hose
attached).
2. Suspend the removed oil pump (by using wire or similar
material) at a place where no damage will be caused
during removal/installation of the engine assembly.

AB" ENGINE ASSEMBLY REMOVAL

1. Check that all cables, hoses, harness connectors, etc.
are disconnected from the engine.
2. Lift the chain block slowly to remove the engine assembly
upward from the engine compartment.

INSTALLATION SERVICE POINT

"AA ENGINE ASSEMBLY INSTALLATION
Install the engine assembly. When doing so, check carefully
that all pipes and hoses are connected, and that none are
twisted, damaged, etc.
NOTES
 11B-1

ENGINE <4D5>
CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Injection Timing Check and Adjustment . . . . . . . . 3

Outline of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Idle Speed Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 OIL PAN <4D56-Step III> . . . . . . . . . . . . . . . . . . 4

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 CYLINDER HEAD GASKET

<4D56-Step III> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TIMING BELT AND TIMING BELT B
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 3 <4D56-Step III> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
 General/General Information/
11B-2 ENGINE <4D5> – Service Specifications/Special Tools

GENERAL
OUTLINE OF CHANGES
D The following service procedures have been established due to the introduction of the
electronic-controlled injection pump. Other service procedures are the same as before. <4D56-Step III>
D Oil pan cover has been adopted. <4D56-Step III>
D The tightening torque of the cylinder head bolts and the cylinder head gasket have been
changed.<4D56-Step III>

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_, Closing ABDC 49_

Exhaust Opening BBDC 55_, Closing ATDC 22_

Fuel system Electronic-controlled injection pump

Rocker arm Roller type

Adjusting screw Elephant foot type

SERVICE SPECIFICATIONS
Items Standard value Limit
Idle speed r/min 750 ± 30 –

SPECIAL TOOLS
Tools Number Name Use
MD998051 Cylinder head bolt Removal and installation of the cylinder head
wrench bolt

MB991614 Angle gauge Tightening of the cylinder head bolts

 ENGINE <4D5> – Service Specifications/On-vehicle Service 11B-3
ON-VEHICLE SERVICE
INJECTION TIMING CHECK AND ADJUSTMENT
Inspection and adjustment are the same as before. The
electronic-controlled injection pump does not have a cold
start device (wax-type).

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. 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
MUT-II

Tachometer

Injection
nozzle

5. If the idle speed is not within the standard value, refer

to 13I – Troubleshooting to check the electronic-controlled
fuel injection system.
NOTE
The idle speed is controlled by the engine-ECU.
11B-4 ENGINE <4D5> – Oil Pan <4D56-Step III>

OIL PAN <4D56-Step III>

REMOVAL AND INSTALLATION

Oil pan cover

9.0 ± 1.0 N·m

 ENGINE <4D5> – Cylinder Head Gasket <4D56-Step III> 11B-5
CYLINDER HEAD GASKET <4D56-Step
III>
INSTALLATION SERVICE POINT
CYLINDER HEAD GASKET AND CYLINDER HEAD
INSTALLATION
1. Wipe off any oil or grease from the gasket mounting
Identification mark surface.
2. If you replace the cylinder head gasket only, check the
identification mark of the cylinder head gasket removed,
select the cylinder head gasket that has same identification
A
mark (size) from the table below.
Spec Identification mark (size) Parts number
B A D5–774 (Thickness on tightening:1.45 ± MD377774
0.04)
B D5–775 (Thickness on tightening:1.50 ± MD377775
C 0.04)
C D5–776 (Thickness on tightening:1.55 ± MD377776
0.04)

Caution
The cylinder head gasket whose thickness is in size
with piston projection is attached. So if you replace the
piston or the connecting rod, the piston projection
changes. Measure the piston projection, select the
cylinder head gasket whose thickness is in size with
piston projection should be fitted.
3. Install the cylinder head gasket in order to fit the cylinder
head gasket bore to the cylinder head bore.
4. 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.

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

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

Cylinder head Chamfered

bolt washer side
11B-6 ENGINE <4D5> – Cylinder Head Gasket <4D56-Step III>
7. 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 8 12
18 2 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_.

MD998051

17 13 9 5 1 3 7 11 15

14 10 6 4 8 12
18 2 16

Front of engine
 ENGINE <4D5> – Timing Belt and Timing B <4D56-Step III> 11B-7
TIMING BELT AND TIMING BELT B <4D56-Step III>
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
D Cooling Fan Removal (Refer to GROUP 14.) D Cooling Fan Installation (Refer to GROUP 14.)
D Engine Adjustment

8
6 7 9
1

26 ± 3 N·m

26 ± 3 N·m

11 ± 1 N·m

4 5

3 17

11 ± 1 N·m
26 ± 3 N·m

185 ± 5 N·m

25 ± 4 N·m 11 16 2
15
14
10
13
12

Removal steps
1. Timing belt front upper cover 12. Flange
2. Tension pulley bracket (for A/C) AC" "AA 13. Timing belt B
3. Crankshaft pulley (for power steering 14. Gasket
and A/C) 15. Tensioner spacer B
AA" "CA 4. Crankshaft pulley 16. Tensioner spring B
5. Timing belt front lower cover 17. Timing belt tensioner B
AB" "BA 6. Timing belt
7. Tensioner spacer NOTE
8. Tensioner spring Follow the conventional procedures for removal
9. Timing belt tensioner assembly and installation service points.
10. Crankshaft sensing blade
11. Crankshaft sprocket
NOTES