Mitsubishi Fuso 4M5 EPA04 Diesel Engine Shop Manual (TWDE0926) – Australia & New Zealand

Description

File Details

• Manual Type: Shop Manual
• Brand: Mitsubishi Fuso
• Models Covered: 4M50T7, 4M50T8
• Document Number: TWDE0926
• Publication Date: November 2009
• Language: English
• Page Count: 352
• File Format: PDF

Chapters Covered

• General (00)
• Engine (11)
• Lubrication (12)
• Fuel and Engine Control (13)
• Cooling (14)
• Intake and Exhaust (15)
• Emission Control (17)

General (00)

This opening chapter lays the foundation for all maintenance and repair work on the 4M5 (EPA04) engine. It provides detailed information on the equipment type coding system, allowing you to accurately identify specific vehicle configurations. The power train tables and vehicle identification number (VIN) / engine number locations are crucial for ordering the correct parts and verifying the exact model you are working on. Additionally, it covers essential safety and procedural precautions, such as the proper jacking up of the vehicle, how to read and erase diagnostic codes, and a comprehensive table of standard tightening torques for various bolt and nut sizes.

Engine (11)

The Engine chapter is the mechanical core of this Mitsubishi Fuso 4M5 shop manual, offering exhaustive specifications, structure and operation details, and troubleshooting guidance. It covers the complete disassembly, inspection, and reassembly of the major engine components. You will find detailed procedures for measuring compression pressure, adjusting valve clearances, and removing the engine from both tilt cab and fixed cab models. The chapter breaks down the rocker cover, rockers and camshafts, cylinder head and valve mechanism, pistons, connecting rods, cylinder liners, flywheel, front case, timing gears, balance shafts, and the crankshaft and crankcase. Each section includes service standards, limits, and remedies to ensure precise engine rebuilding.

Lubrication (12)

This chapter details the forced lubrication system that keeps the 4M5 diesel engine running smoothly. It includes the specifications for engine oil, the oil pump, oil cooler, and the spin-on paper type oil filter. The troubleshooting section helps diagnose low oil pressure, excessive oil consumption, and other lubrication-related issues. On-vehicle inspection and adjustment procedures are provided for replacing the oil filter and engine oil, as well as measuring oil pressure. The chapter also covers the removal and installation of the oil pan, oil strainer, oil jets, oil pump, and oil cooler, complete with structural diagrams and exploded views.

Fuel and Engine Control (13)

This is a critical chapter for understanding the advanced common rail fuel system used in the 4M50T7 and 4M50T8 engines. It provides an in-depth look at the common rail system, electronic engine control, and the fuel filter. A major portion of this section is dedicated to troubleshooting using the Multi-Use Tester, including a full list of diagnosis codes, diagnostic precautions, service data, and actuator tests. Detailed procedures are provided for the removal, installation, and inspection of the common rail, supply pump, injectors, fuel tank, and fuel filter. The chapter also includes electrical equipment inspections, installed locations of parts, and comprehensive electric circuit diagrams for both manual and automatic transmission models.

Cooling (14)

Keep your engine operating at the optimal temperature with the detailed cooling system information in this manual. It explains the flow of coolant, the operation of the wax pellet bottom bypass thermostat, and the belt-driven water pump. Troubleshooting tables assist in diagnosing overheating, overcooling, abnormal noise, and coolant loss. The on-vehicle inspection and adjustment section covers belt tension measurement using both a belt tension gauge and a sonic belt tension gauge, inspection of cracks or damage, coolant replacement, system cleaning, air bleeding, and air/gas leakage tests. Service procedures for the radiator, cooling fan, water pump, tension pulley, thermostat, and pressure cap are also included.

Intake and Exhaust (15)

This chapter covers the air intake and exhaust systems, including the air cleaner, turbocharger, muffler, and exhaust brake system. It provides structure and operation details for the waste gate mechanism of the turbocharger and the operation of the exhaust brake. Troubleshooting tables help diagnose issues such as black or white exhaust gas, insufficient engine output, and turbocharger noise. The on-vehicle inspection and adjustment procedures include measuring turbocharger boost pressure, cleaning the air cleaner element, and checking for looseness, cracks, or gas leakage in the intake manifold, exhaust manifold, and turbocharger. Detailed removal and installation guides are provided for the air duct, air cleaner, turbocharger, intercooler, and exhaust pipe.

Emission Control (17)

The final chapter focuses on the systems designed to minimize harmful emissions from the 4M5 diesel engine. It provides an overview of the exhaust gas recirculation (EGR) system, including the electronic control system block diagram, the EGR valve control function, and the fault diagnosis function. It also covers the crankcase emission control system and the positive crankcase ventilation valve. Detailed troubleshooting and diagnostic procedures, including diagnosis codes, Multi-Use Tester service data, and inspections at the electronic control unit connectors, are provided for the EGR system. The chapter concludes with service procedures for the EGR valve, pipe, cooler, and the crankcase emission control system.

Why This Manual is Essential for Your Workshop

Modern diesel engines, especially those equipped with common rail fuel systems like the Mitsubishi Fuso 4M50T7 and 4M50T8, require precise diagnostics and meticulous repair procedures. This official shop manual provides the exact specifications, tightening torques, and step-by-step instructions that technicians need to perform these jobs correctly. Whether you are overhauling the engine, replacing a supply pump, or tracking down a persistent diagnostic trouble code, this manual gives you the data to do it right the first time. It includes crucial torque-turn tightening methods for cylinder head and main cap bolts, ensuring the structural integrity of the engine, and detailed diagnostic flowcharts that save hours of guesswork.

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