Hunting for a Mitsubishi 4DR5 shop manual PDF that actually came from the factory? This 596-page shop manual covers the 4DR5, 6DR5, 4D30, 4D31, and 4D31-T diesel engines from teardown to final assembly. You get a full engine electrical section with wiring diagrams for the starter, alternator, and preheating system, plus troubleshooting tables, service standards, and exploded views spanning the injection pump, turbocharger, clutch, transmission, and parking brake. Step-by-step procedures fill page after page. Set cold valve clearance at 0.4 mm on the 4D3 engines (0.3 mm on the DR series), and hold connecting rod to crankshaft clearance between 0.05 and 0.09 mm. No more chasing wiring faults with a multimeter and a prayer. Bookmarked chapters jump you straight to any system; open the PDF on your tablet and get wrenching.
What's Inside This Mitsubishi 4D30, 4D31, 4D31-T, 4DR5, 6DR5 Manual
| System | Pages | Key Topics |
|---|---|---|
| Organization | 8-13 | External View, Major Specifications, Engine Outputs, Engine Numbers, Nameplate, General Bolts and Nuts Tightening Torque Table |
| General | 14-25 | External View, Major Specifications (Engine Outputs Classified by Application), Engine Numbers, Nameplate, Caution Plate |
| Engine | 26-133 | Engine Proper, Air Compressor, Flywheel PTO, Specifications, Service Standards, Troubleshooting |
| Lubrication | 134-165 | Lubrication System, Oil Pump, Oil Filter, Oil Cooler, Specifications, Troubleshooting |
| Fuel and Engine Control | 166-333 | Fuel System, Injection Pump, Injection Nozzle, Fuel Filter, Water Separator, Troubleshooting |
| Cooling | 334-365 | Cooling System, Water Pump, Thermostat, Radiator, Fan, Troubleshooting |
| Intake and Exhaust | 366-397 | Air Cleaner, Turbocharger, Manifolds, Specifications, Troubleshooting |
| Engine Electrical | 398-468 | Starter, Alternator, Vacuum Pump, Preheating System, Automatic Stop Device, Troubleshooting |
| Clutch | 469-510 | Clutch Proper, Clutch Control, Power Cylinder, Master Cylinder, Clutch Lever, Troubleshooting |
| Transmission | 511-582 | Transmission Proper, Transmission PTO, Bearing Case Assembly, Main Shaft Gears, Gearshifter Lower, Gearshifter Upper |
| Parking Brake | 583-596 | Parking Brake Proper, Brake Drum, Transmission Companion Flange, Shoe and Lining Assembly, Backing Plate |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Ring gear tooth crests | induction-heardened for greater durability | p. 36 |
| Pilot bearing | installed at its center | p. 36 |
| Valve clearance (both intake and exhaust, when cold) | NV 0.4 <D3> | p. 120 |
| Connecting rod to crankshaft clearance | BD 35 NV 0.05 to 0.09 L 0.2 | p. 122 |
| Cylinder to piston clearance Top | BD 60 NV 0.24 to 0.29 | p. 122 |
| Cylinder to piston clearance Skirt | BD 60 NV 0.09 to 0.14 | p. 122 |
| Engine oil lubrication | The engine is lubricated by a gear-type <D3>, or trochoid type <DR> oil pump that forces engine oil through the oil cooler (when the engine rotates at 2 500 rpm or higher <4DR5>2 200 rpm or higher <6DR5>) and oil filter into the engine for lubrication of various engine parts. | p. 136 |
| Injection pump plunger diameter | 9 mm | p. 197 |
| Transmission oil quantity | 4.0 lit. | p. 517 |
Mitsubishi 4D30, 4D31, 4D31-T, 4DR5, 6DR5 Common Problems This Manual Covers
Mitsubishi 4D31 crankshaft bearing wiped or scratched, low oil pressure and knocking under load
Drain the oil and cut the filter open; metal flakes confirm bearing damage. Measure connecting rod to crankshaft clearance with Plastigage against the 0.05 to 0.09 mm standard on page 122; anything past the 0.2 mm limit means new bearings. Flush the galleries before refilling, dirty oil is what wiped them in the first place.
Manual Section: Engine p. 122Cylinder bores scuffed or worn, blue smoke and heavy oil consumption at idle
Pull the pistons and measure cylinder to piston clearance: 0.24 to 0.29 mm at the top and 0.09 to 0.14 mm at the skirt, listed on page 122. Inspect bores for scuffing from air ingestion or overheating; hone light marks, replace liners that show erosion. Check the air cleaner for a torn element while you are in there.
Manual Section: Engine p. 122Engine cranks but will not start in cold weather, white smoke from exhaust
Test the glow plugs and battery voltage before touching anything else; slow cranking kills compression heat. Verify valve clearance cold, 0.4 mm on D3 engines and 0.3 mm on DR engines, per the chart on page 120. Check fuel for winter blend and confirm the oil viscosity matches the ambient temperature.
Manual Section: Engine is hard to start p. 120Engine loses power under load, black smoke and rough idle above half throttle
Bleed the fuel system and check the injection pump overflow valve and line connections for air leaks. Verify injection timing before condemning the pump. If plungers look scored on 4D31 and 4D31-T engines, compare against the 9 mm plunger diameter spec on page 197; replace worn elements as a set.
Manual Section: Loss of power output (Fuel System) p. 197Transmission slips out of gear on rough ground, gearshift lever vibrates heavily
Check shift rail poppet springs for collapse and verify the lock nuts have not backed off. Inspect the synchronizer rings, main shaft thrust washer, and main shaft bearing for wear. Drain and refill with 4.0 liters of gear oil, page 517 lists the capacity; low oil accelerates the bearing wear that lets gears jump out.
Manual Section: Transmission slips out of gear p. 517Frequently Asked Questions
What are the tightening torque specifications for 4D31-T cylinder head bolts?
The tightening torque for 4D31-T cylinder head bolts is 175 N·m (18 kgf·m) for M14 x 2.0 thread size. These bolts should be tightened in a wet condition. p. 11
What are the replacement specifications for valve guides?
Valve guides should be replaced if the valve to valve guide clearance exceeds the specified limits. For D3 models, the inlet clearance limit is 0.15 mm and the exhaust is 0.2 mm. For DR models, both inlet and exhaust clearance limits are 0.15 mm and 0.2 mm respectively. p. 11
What are the replacement specifications for tappets?
Tappets should be replaced if the tappet to crankcase tappet hole clearance exceeds the specified limits. For D3 models, the limit is 0.2 mm, and for DR models, the limit is 0.12 mm. p. 11
What is the engine oil capacity for Mitsubishi 4D3, 4DR5, and 6DR5 diesel engines?
The engine oil capacity for the 4D3 models is approximately 7 or 9 liters, for the 4DR5 model it is approximately 5 liters, and for the 6DR5 model it is approximately 8.5 liters. p. 12
What is the standard fuel injection pressure for the Mitsubishi 4D31, 4D31-T, 4D30, 4DR5, and 6DR5 diesel engines?
The standard fuel injection pressure for 4D31 and 4D31-T models is 17.7 MPa (180 kgf/cm²) or 21.6 MPa (220 kgf/cm²). For 4D30, 4DR5, and 6DR5 models, the injection pressure is 11.8 MPa (120 kgf/cm²). p. 13
What format is this Mitsubishi 4D31 & variants manual in?
Immediate download of the complete 596-page scanned Shop Manual. Access it on any device, from a laptop at your desk to a phone in the field.
Are there any print restrictions on this Mitsubishi 4D31 & variants manual?
Zero restrictions. The PDF is DRM-free. Print whatever sections you need to take out to the shop. Standard letter or A4 paper works.
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