Rebuilding a Mitsubishi 4D31, 4D31-T, 4D32, or 4DR5 diesel? This 444-page Mitsubishi 4D32 shop manual PDF (OEM #97811-03021 NA) covers all four engines from cylinder head to transmission. You get factory wiring diagrams for the complete engine electrical system, exploded views of every major assembly, and full teardown procedures for the injection pump, governors, and automatic timers. A dedicated troubleshooting section walks you through lubrication, cooling, and fuel faults, plus clutch and transmission service for the whole driveline. Torque tables and service standards sit up front where you can find them fast. Set tappet-to-crankcase bore clearance between 0.06 and 0.10 mm, and confirm each piston carries two compression rings and one oil ring before reassembly. Injection pumps don't forgive guesswork. This bookmarked PDF opens on any device; grab your tablet, walk out to the engine, and start wrenching.
What's Inside This Mitsubishi 4D31, 4D31-T, 4D32, 4DR5 Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 12-19 | External View, Major Specifications |
| Engine | 20-97 | Cylinder Head and Valve Mechanism, Flywheel and Rear Plate, Timing Gear and Camshaft, Crankcase and Main Moving Parts, Measurement of Compression Pressure |
| Lubrication | 98-125 | General, Specifications, Service Standards, Special Tool, Oil Pump, Oil Filter, Oil Cooler and Oil Strainer, Troubleshooting |
| Fuel and Engine Control | 126-245 | Injection Pump, Governors, Automatic Timers, Feed Pump, Injection Nozzle, Fuel Filter |
| Cooling | 246-267 | Water Pump, Thermostat, Radiator, Cooling Fan, V-Belt Tension, Cleaning the Cooling System |
| Intake and Exhaust | 268-297 | Air |
| Engine Electrical | 298-367 | - |
| Clutch | 368-387 | - |
| Transmission | 388-433 | - |
| Special Equipment | 434-444 | Brake Drum, Brake Lining, Brake Shoe Return Spring, Companion Flange, Shoe and Lining Assembly |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Fuel and Engine Control | 13 | p. 4 |
| Cooling | 14 | p. 4 |
| No. of piston rings | Compression ring: 2; Oil ring: 1 | p. 28 |
| Tappet to crankcase tappet hole clearance | [28] 0.06 to 0.10 | p. 29 |
| Oil filter type | filter paper full-flow type with a regulator valve, bypass valve and oil bypass alarm in its head | p. 104 |
| Tappet replacement | Replace | p. 238 |
| Loaded gauze filter remedy | Clean | p. 238 |
| Water pump removal and installation | 247 | p. 247 |
| Cooling system cleaning | 258 | p. 247 |
| Bleeding the cooling system | 260 | p. 247 |
| Coolant capacity (Engine proper) | Approx. 5 lit. | p. 244 |
Mitsubishi 4D31, 4D31-T, 4D32, 4DR5 Common Problems This Manual Covers
Mitsubishi 4DR5 diesel engine overheats under load, coolant disappears fast, temperature gauge climbs at highway speed
Check the water pump first; shaft play or a weeping seal means rebuild, and removal steps start on page 247. Test the thermostat opening and flush scale out of the radiator core. Refill with approximately 5 liters of coolant, the 4DR5 engine-proper capacity listed on page 244, then bleed all air from the system.
Manual Section: Cooling p. 247Engine cranks but will not start, or fires briefly then stalls right after startup
Verify battery condition and glow plug operation before touching the fuel side. Bleed the fuel system, clean the gauze filter if it is loaded, and replace a loaded fuel filter element; the troubleshooting table on page 238 walks through fuel supply failures step by step. Check feed pump delivery while cranking before suspecting the injection pump.
Manual Section: Fuel and Engine Control p. 238Loud tapping noise from the valve train, rough idle and noticeable power loss at high hours
Pull the tappets and inspect the cam contact faces for cracks or irregular wear patterns. Measure tappet to crankcase tappet hole clearance against the 0.06 to 0.10 mm standard on page 29. Replace any tappet that is worn or slides poorly; never regrind one. Reset valve clearance after reassembly and listen again at idle.
Manual Section: Engine p. 29Blue smoke on startup, oil consumption climbing, compression feels weak on a worn engine
Measure compression pressure using the Engine section procedure before condemning anything. Inspect the piston rings during teardown; each piston carries two compression rings and one oil ring, per the specification on page 28. Replace rings as a complete set, deglaze the cylinder bores, and track oil consumption after reassembly to confirm the fix.
Manual Section: Engine p. 28Frequently Asked Questions
What are the torque specs for 4D31 cylinder head bolts?
The tightening torque for 4D31 cylinder head bolts is 195 N·m (20 kgf·m). This specification is for a wet condition. p. 28
What are the torque specs for 4D32 main bearing bolts?
The tightening torque for 4D32 main bearing cap bolts is 175 N·m (18 kgf·m). This specification is for a wet condition. p. 28
What are the replacement specifications for Fuel injectors?
The injection pressure for 4D31 and 4D32 fuel injectors is 17.7 MPa (180 kgf/cm²), 21.6 MPa (220 kgf/cm²) for 4D31-T, while for 4DR5 it is 11.8 MPa (120 kgf/cm²). Specific orifice diameters and angles are also listed in the specifications. p. 147
What are the replacement specifications for Glow plugs?
The glow plug voltage-current for 4D3 engines is 23V - 3A, and for 4DR5 engines it is 20.5V - 6A. The time for the indicator to illuminate is 10 to 15 seconds for 4D3 and 20 to 30 seconds for 4DR5. p. 308
What is the oil capacity for the 4D31 engine?
The engine oil capacity for the 4D31 engine's oil pan is approximately 7 or 9 liters, and the oil filter capacity is approximately 1.2 liters. p. 109
Is this Mitsubishi 4D31, 4D31-T, 4D32, 4DR5 Shop Manual a digital download?
You get a 444-page scanned PDF that downloads instantly after checkout. Open it on your laptop, tablet, or phone, and bring it right to the shop floor.
Is this Mitsubishi 4D31, 4D31-T, 4D32, 4DR5 Shop Manual printable?
Yes. The PDF has no DRM restrictions, so print any page or section you need for your shop. Works with any standard printer.
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