Mitsubishi 4D56 engine factory workshop and repair manual 1991 onwards

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Manual Contents
Specifications
Special Tools
Drive Belt and Timing Belt
Intake and Exhaust Manifolds
Turbocharger
Water pump Thermostat hose and pipe
Procker Arms Rocker shaft and Camshaft
Cylinder Head Valves and Valve Spring
Front Case, Silent Shaft and Oil Pan
Piston and connecting rod
Crankshaft Flywheel and Drive Plate
Cylinder Block

About the 4D5 engine

The 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passenger car, it proved popular in the emerging SUV and minivan markets where Mitsubishi was highly successful, until superseded by the 4M4 range in 1993.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)
Bore - 91.1 mm
Stroke - 95.0 mm
Fuel type - Diesel
Non-Turbo

Power - 55 kW (74 hp) at 4,200 rpm
Torque - 142 N·m (105 lb·ft) at 2,500 rpm
Engine type - Inline 4-cylinder SOHC
Fuel system - Distribution type jet pump
Compression ratio - 21:1

Non-intercooled Turbo

Power - 84 PS (62 kW) at 4,200 rpm
Torque - 201 N·m (148 lb·ft) at 2,000 rpm
Engine type - Inline 4-cylinder SOHC

Non-intercooled Turbo (TD04 Turbo)

Power - 90 hp (67 kW) at 4,200 rpm
Torque - 197 N·m (145 lb·ft) at 2,000 rpm
Engine type - Inline 4-cylinder SOHC
Fuel system - Distribution type jet pump
Compression ratio - 21:1

Intercooled Turbo (TD04 watercooled Turbo)

Power - 78 kW (104 hp) at 4,300 rpm
Torque - 240 N·m (177 lb·ft) at 2,000 rpm
Engine type - Inline 4-cylinder SOHC
Rocker arm - Roller Follower type
Fuel system - Distribution type jet pump (indirect injection)
Combustion chamber - Swirl type
Bore x Stroke - 91.1 x 95mm
Compression ratio - 21:1
Lubrication System - Pressure feed, full flow filtration

Intercooled Turbo (1st Generation DI-D)

Power - 85 kW (114 hp) at 4,000 rpm
Torque - 247 N·m (182 lb·ft) at 2,000 rpm
Engine type - Inline 4-cylinder
Fuel system - 1st Generation Common Rail Direct Injection (CRDi)
Compression ratio - 17:1

Intercooled Turbo (2nd Generation DI-D)

Power - 100 kW (134 hp) at 4,000 rpm
Torque - 320 N·m (236 lb·ft) at 2,000 rpm
Engine type - Inline 4-cylinder
Fuel system - 2nd Generation Common Rail Direct Injection (CRDi)
Compression ratio - 17:1

Intercooled Turbo (3rd Generation DI-D with variable geometry turbo)

With manual transmission

Power - 131 kW (178 PS) at 4,000 rpm
Torque - 400 N·m (295 lb·ft) at 2,000 rpm
Engine type - Inline 4-cylinder
Fuel system - 2nd Generation Common Rail Direct Injection (CRDi)
Compression ratio - 16.5:1

With automatic transmission

Power - 131 kW (178 PS) at 4,000 rpm
Torque - 350 N·m (258 lb·ft) at 1,800 rpm
Engine type - Inline 4-cylinder
Fuel system - 2nd Generation Common Rail Direct Injection (CRDi)
Compression ratio - 16.5:1

Mitsubishi Hilux 4D56 engine factory workshop and repair manual 1991 onwards Download