This comprehensive Service & Repair Manual provides detailed instructions and specifications for the Mitsubishi 4D68 engine, covering everything from general information and specifications to detailed repair procedures. The manual features a wide range of technical information, including:

* **General Information:** Learn about the engine's design, operation, and key components.
* **Specifications:** Find detailed technical specifications for the 4D68 engine, including dimensions, tolerances, and fluid capacities.
* **Service Specifications:** Access essential service specifications, such as tightening torques, fluid types, and maintenance schedules.
* **Rework Dimensions:** Find diagrams and dimensions for critical engine parts, assisting with repairs and rebuilds.
* **Torque Specifications:** Obtain precise torque values for all engine fasteners, ensuring proper tightening and avoiding damage.
* **New Tightening Method:** Understand the latest techniques for tightening bolts in plastic areas, ensuring a secure and reliable connection.
* **Sealant and Form-in-Place Gaskets:** Learn about the proper application and usage of sealants and form-in-place gaskets for critical engine areas.
* **Special Tools:** Identify required specialized tools for specific engine repairs and maintenance.
* **Drive Belt and Glow Plug:** Obtain detailed instructions for inspecting, adjusting, and replacing drive belts and glow plugs.
* **Timing Belt:** Learn about the timing belt system, including replacement procedures, critical alignment points, and proper tensioning.
* **Glow Plug, Fuel Injection Pump, and Injection Nozzle:** Gain comprehensive knowledge on the fuel system, covering diagnosis, repair, and replacement of glow plugs, fuel injection pumps, and injection nozzles.
* **Intake and Exhaust Manifolds:** Discover step-by-step procedures for inspecting, removing, and replacing intake and exhaust manifolds.
* **Water Pump, Thermostat, Hose, and Pipes:** Learn how to diagnose, service, and replace the water pump, thermostat, and associated hoses and pipes.
* **Rocker Arms, Rocker Shaft, and Camshaft:** Find detailed instructions for inspecting, adjusting, and replacing rocker arms, rocker shafts, and camshafts.
* **Cylinder Head, Valves, and Valve Springs:** Gain expertise on inspecting, repairing, and replacing cylinder heads, valves, and valve springs.
* **Front Case, Counterbalance Shafts, and Oil Pan:** Learn how to diagnose, service, and replace the front case, counterbalance shafts, and oil pan.
* **Pistons and Connecting Rods:** Obtain detailed procedures for inspecting, repairing, and replacing pistons and connecting rods.
* **Crankshaft, Cylinder Block, and Flywheel:** Gain comprehensive knowledge about servicing and repairing the crankshaft, cylinder block, and flywheel.

This manual provides a comprehensive and invaluable resource for anyone looking to service or repair their Mitsubishi 4D68 engine, empowering you to confidently handle a wide range of tasks.

## The Mitsubishi 4D68: A Workhorse Engine with Enduring Legacy

The Mitsubishi 4D68 engine is a robust and reliable diesel powerplant that has been a staple in Mitsubishi's vehicle lineup for over three decades. Introduced in 1989, this 4-cylinder, naturally aspirated, direct-injection engine boasts a displacement of 2.8 liters, generating power outputs ranging from 85 to 136 horsepower, depending on the application. The 4D68 engine is known for its exceptional durability and fuel efficiency, making it a popular choice for a wide range of applications, from pickup trucks and SUVs to commercial vehicles and even marine applications.

The 4D68 engine's longevity and success can be attributed to its solid construction and advanced design features. It utilizes a cast-iron engine block and cylinder head, ensuring strength and resistance to wear and tear. Other features contributing to its robust performance include a forged steel crankshaft, durable connecting rods, and a sophisticated fuel injection system. The 4D68 engine is also renowned for its simplicity and ease of maintenance, making it a cost-effective option for owners. It was widely praised for its smooth operation, quietness, and relatively low emissions, particularly when compared to other diesel engines of its era. The 4D68 engine has been continuously refined and updated throughout its production run, with improvements in fuel economy, power output, and emissions compliance, making it a true testament to Mitsubishi's engineering expertise.