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.
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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 |
