Table of Content Mitsubishi 4M40 Engine 

• General
• Engine Number, Engine Name Plate
• How To Read This Manual
• Structure of This Shop Manual
• Terminology
• Tightening Torques
• Standard tightening torque table
• Units
• How To Read This Manual
• General Work
• Part Measurement Methods
• Shaft-to-hole clearance measurement, and good/bad evaluation
• Shaft deflection and bend
• Measurement of springs
• Evaluation of Oil Leakage
• Precautions For Maintenance Operation
• General Precautions
• Precautions for Electrical System
• Handling precautions for electric circuits
• Precautions for Arc Welding
• Engine
• Specifications
• Remarks
• Structure And Operation
• Exploded View
• Cylinder Head and Cylinder Head Gasket
• Cylinder head
• Cylinder head gasket
• Valve Mechanism and Timing Chain
• Valve Mechanism
• Timing Chain
• Timing Gears
• Idler Gear
• Connecting Rods
• Piston and Piston Rings
• Flywheel
• Crankcase, Crankshaft and Main Bearings
• Crankcase
• Crankshaft
• Main Bearing
• Thrust Plates
• Oil Seal
• Front Oil Seal
• Rear Oil Seal
• Troubleshooting
• General Inspection And Adjustment
• Measuring Compression Pressure
• Service Standards
• Inspection and Adjustment of Valve Clearances
• Replacement of Timing Chain
• Rocker Cover
• Installation procedure
• Cylinder Head And Valve Mechanism
• Removal procedure
• Installation procedure
• Tightening procedure for bolts 1 to 18
• Tightening procedure for bolts 19 and 20
• Cylinder Head
• Inspection before removal
• Removal procedure
• Inspection procedure
• Refacing
• Replacement of valve guides
• Lapping
• Refacing the valve seat
• Replacement of valve seat
• Installation procedure
• Piston and Connecting Rod
• Inspection before removal
• Inspection procedure
• Selection of oversize piston
• Installation procedure
• Removal procedure
• Inspection procedure
• Replacement of connecting rod bushing
• Inspection procedure
• Flywheel
• Work before removal
• Removal procedure
• Installation procedure
• Timing Gear Case
• Installation procedure
• Timing Gears
• Inspection before removal
• Inspection procedure
• Installation procedure
• Crankshaft and Crankcase
• Inspection before removal
• Removal procedure
• Inspection procedure
• Grinding of crankshaft
• Installation procedure
• Lubrication
• Specifications
• Structure and Operation
• Lubrication System
• Oil Pump
• Oil Cooler and Oil Filter
• Bypass valve
• Regulator valve
• Oil Filter <Engine-mounted Type>
• Lubrication of Engine Components
• Main bearing and connecting rod bearing
• Valve mechanism
• Check valves and oil jets
• Idler shaft
• Timing chain
• Troubleshooting
• General Inspection and Adjustment
• Oil Filter Replacement
• Engine-mounted type
• Engine separately mounted type
• Engine Oil Replacement
• Engine Oil Leak Inspection
• Oil Pan, Oil Strainer and Oil Jet
• Installation procedure
• Oil Pump
• Inspection procedure
• Oil Cooler
• Oil Filter
• Removal procedure
• Inspection procedure
• Installation procedure
• Fuel and Engine Control
• Specifications
• Structure and Operation
• Fuel System (Flow of Fuel)
• Fuel Filter
• Injection Nozzles
• Injection Pump
• Injection pump body
• Governor
• Automatic timer
• Feed pump
• Fuel-cut solenoid valve
• Troubleshooting
• General Inspection and Adjustment
• Inspecting and Adjusting Fuel Injection Timing
• Inspecting and Adjusting No-load Minimum and Maximum Speeds
• Inspection of Fuel Leakage
• Inspection of Injection Pipe and Fuel Pipe Mounting Clamp
• Air-bleeding of Fuel System
• Fuel Filter Replacement
• Fuel Filter
• Installation procedure
• Injection Pump
• Removal procedure
• Installation procedure
• Removal procedure
• Installation procedure
• Injection Nozzle
• Inspection before removal
• Removal procedure
• Cleaning procedure
• Inspection procedure
• Cooling
• Specifications
• Structure And Operation
• Cooling System (Flow of Coolant)
• Thermostat
• Water Pump
• Troubleshooting
• General Inspection And Adjustment
• Inspection And Adjustment Of Belt Tension
• Inspection of Belts
• Coolant Replacement and Cleaning of Cooling System
• Draining of Coolant
• Cleaning Procedure
• Air Bleeding of Cooling System
• Air/Gas Leakage Test
• Inspection of Coolant Leak
• Coolant Fan, Belt And Water Pump
• Water Hose And Pipe
• Thermostat
• Intake And Exhaust
• Specifications
• Structure And Operation
• Air Cleaner
• Turbocharger
• Waste Gate Mechanism
• Operating of Over-Boost Valve
• Troubleshooting
• General Inspection And Adjustment
• Cleaning And Inspection Of Air Cleaner Element
• Inspection Of Intake Manifold For Looseness
• Inspection Of Exhaust Manifold For Cracks And Gas Leaks
• Inspection Of Turbocharger For Cracks And Gas Leaks
• Looseness Of Turbocharger
• Air Cleaner
• Turbocharger
• Intake Manifold
• Exhaust Manifold
• Electrical
• Specifications
• Structure And Operation
• Starter
• Alternator
• Circuit Diagram
• Troubleshooting
• Power And Charging
• Engine Starting, Preheating and Stopping
• #180 to #249 Relay, #250 to #349 Sensor, #750 to #859 Other
• #187 Inspection of starter relay
• #231 Inspection of safety relay
• #262 Inspection of water temperature sensor
• #764 Inspection of glow plug
• #930 Starter
• #940 Alternator
• #950 Inspection Of Alternator
• #951 Inspection Of Regulator
• #955 Inspection Of Preheating System
• #959 Inspection Of SafetyRelay