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Mitsubishi L2A Service Manual
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INLET AND EXHAUST SYSTEMS
11-2
1.
Removing inlet and exhaust systems
1.1
Removing inlet co
ver and exhaust manifold
Removing inlet cover and exhaust manifold
Removing sequence
1
Inlet pipe
2
Inlet cover
3
Exhaust manifold
4
Exhau
st elbow
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
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163
165
Table of Contents
General Contents
15
Table of Contents
15
General
17
External View
18
External View of L2A, L2C and L2E
18
External View of L3A, L3C and L3E
19
System Flow Diagrams
20
Fuel System - Flow Diagram
20
Lubrication System - Flow Diagram
20
Cooling System - Flow Diagram
21
Inlet and Exhaust System - Flow Diagram
21
Engine Serial Number Location
22
Indication of Engine Model and Total Displacement
22
Specifications
23
Specifications of L2A, L2C and L2E
23
Specifications of L3A, L3C and L3E
27
Tips on Disassembling and Reassembling
31
Disassembling
31
Reassembling
31
Service Data
33
1 Maintenance Service Data
34
Basic Engine
34
Fuel System
37
Cooling System
38
Inlet/Exhaust System
38
Lubrication System
38
Electrical System
39
Basic Engines
42
Fuel System
42
2 List of Tightening Torque
42
Major Bolts and Nuts Tightening Torque
42
Cooling System
43
Electrical System
43
Inlet and Exhaust Systems
43
Lubrication System
43
Standard Bolt and Nut Tightening Torque
44
High-Pressure Fuel Injection Pipe Tightening Torque
45
Standard Eyebolt Tightening Torque
45
Standard Union Nut Tightening Torque
45
Service Tools
47
Determination of Overhaul
51
Determining Overhaul Timing
52
Disassembly of Basic Engine
55
1 Disassembling and Inspecting Cylinder Head and Valve Mechanism
56
Disassembling Rocker Shaft Assembly
57
Removing Rocker Shaft Assembly
57
Removing Cylinder Head Assembly
58
Removing Cylinder Head Bolt
58
Removing Valve Stem Seal
59
Removing Valves and Valve Spring
59
2 Disassembling and Inspecting Flywheel
60
Removing Flywheel
61
Removing Flywheel Housing
61
Removing Oil Seal Case
61
Disassembling and Inspecting Gear Case, Timing Gear and Camshaft
62
3 Disassembling and Inspecting Gear Case, Timing Gears and Camshaft
62
Removing Crankshaft Pulley
63
Removing Gear Pump Housing
63
Removing Tappet
63
Removing Timing Gear Case
63
Removing Governor Shaft and Speed Control Lever
64
Removing Oil Pump
64
Removing PTO Gear
64
Removing Relief Valve
64
Measuring Timing Gear Backlash
65
Removing Idler Gear
65
Removing Camshaft
66
Removing Fuel Injection Pump Camshaft
67
Removing Front Plate
68
4 Disassembling and Inspecting Cylinder Block, Crankshaft, Piston and Oil Pan
69
Removing Oil Pan
70
Removing Oil Screen
70
Removing Connecting Rod Cap
70
Pulling out Piston
71
Removing Piston Ring
71
Removing Piston Pin
71
Measuring Crankshaft End Play
72
Removing Main Bearing Cap
72
Removing Crankshaft
72
Inspection and Repair of Basic Engine
73
1 Inspecting and Repairing Cylinder Head and Valve Mechanism
74
Measuring Clearance between Rocker Arm and Rocker Shaft
74
Measuring Valve Stem Outside Diameter and Valve Guide Inside Diameter
74
Replacing Valve Guide
75
Inspecting Valve Face
76
Refacing Valve Face
76
Measuring Perpendicularity and Free Length of Valve Spring
77
Lapping Valve and Valve Seat
77
Measuring Distortion of the Bottom Surface of the Cylinder Head
78
Measuring Push Rod Runout
78
2 Inspecting and Repairing Flywheel
79
Measuring Flatness of Flywheel
79
Inspecting Ring Gear
79
Replacing Ring Gear
79
Removing Ring Gear
79
Installing Ring Gear
79
3 Inspecting and Repairing Gear Case, Timing Gear and Camshaft
80
Measuring Timing Gear Backlash
80
Measuring Clearance between Idler Gear and Idler Shaft
80
Replacing Idler Shaft
80
Measuring Clearance between
80
Measuring Cam Lift
81
Measuring Cam Height of Fuel Injection Pump Camshaft
81
Inspecting Tappet
82
Measuring Clearance between Tappet and Tappet Guide Hole
82
4 Inspecting and Repairing Cylinder Block, Crankshaft, Piston and Oil Pan
83
Measuring Cylinder Inside Diameter
83
Reboring Cylinder
84
Measuring Piston Outside Diameter
84
Boring Finish Dimension
84
Measuring Piston Ring End Gap
85
Measuring Clearance between Piston Ring Groove and Piston Ring
85
Measuring Piston Pin Bore Diameter and Piston Pin Outside Diameter
86
Measuring Connecting Rod End Play
86
Inspecting Connecting Rod Bend and Twist6-15
87
Measuring Clearance between Connecting Rod Bearing and Crankpin
88
Measuring Clearance between Main Bearing and Crankshaft Journal
89
Measuring Crankshaft Runout
90
Replacing Crankshaft Gear
90
Removing Crankshaft Gear
90
Installing Crankshaft Gear
90
Measuring Distortion Cylinder Block Top Surface
91
Reassembly of Basic Engine
93
1 Reassembling Cylinder Block, Crankshaft, Piston and Oil Pan
94
Installing Main Bearing
94
Installing Crankshaft
94
Installing Main Bearing Cap
95
Inserting Side Seal
95
Installing Main Bearing Cap Bolt
96
Measuring Crankshaft End Play
96
Reassembling Piston and Connecting Rod
97
Installing Piston
98
Installing Piston and Connecting Rod
98
Installing Connecting Rod Cap
99
Installing Oil Screen
100
Installing Oil Pan
100
Reassembling Gear Case, Timing Gears and Camshaft
101
2 Reassembling Gear Case, Timing Gear and Camshaft
101
Installing Front Plate
101
Installing Fuel Injection Pump Camshaft
101
Rotating Crankshaft
101
Installing Camshaft
102
Installing Idler Gear
102
Inspecting and Adjusting Timing Gear after Installation
103
Inspecting Backlash
103
Installing Governor Weights and Sliding Shaft
103
Installing Oil Pump
104
Installing Relief Valve
104
Installing Speed Control Lever and Governor Shaft
104
Installing Crankshaft Pulley
105
Installing PTO Gear
105
Installing Timing Gear Case
105
Installing Gear Pump Housing
106
Installing Tappet
106
3 Reassembling Flywheel
107
Installing Oil Seal Case
107
Installing Flywheel Housing
107
Installing Flywheel
108
4 Reassembling Cylinder Head and Valve Mechanism
109
Cleaning Cylinder Head Bottom Surface
109
Installing Valve Stem Seal
109
Installing Valve Spring
109
Installing Valve Lock
110
Installing Cylinder Head Gasket
110
Installing Cylinder Head Assembly
110
Tightening Cylinder Head Bolts
111
Inserting Push Rod
111
Reassembling Rocker Shaft Assembly
112
Installing Rocker Shaft Assembly
112
Adjusting Valve Clearance
113
Installing Rocker Cover
113
Installing Torque Spring Set
113
Fuel System
115
1 Removing Fuel System
116
Removing Fuel Pipe and Fuel Injection Nozzle
116
Removing Fuel Injection Pipe
117
Removing Fuel Injection Nozzle
117
Removing Fuel Filter
118
Removing Governor
119
Disconnecting Tie Rod from Control Rack
120
Removing Governor Shaft and Speed Control Lever
120
Removing Fuel Injection Pump
121
2 Disassembling, Inspecting and Reassembling Fuel System
122
Disassembling and Inspecting Fuel Injection Nozzles
122
Inspecting and Adjusting Fuel Injection Valve Opening Pressure
123
Inspecting Fuel Spray Pattern of Fuel Injection Nozzle
124
Cleaning and Replacing Faulty Nozzle
124
Reassembling Fuel Injection Nozzles
125
Inspecting Fuel Injection Pump on Engine8-12
126
Disassembling and Inspecting Fuel Injection Pump
126
Removing Swivel Nipple
127
Removing Tappets
127
Removing Plunger
127
Removing Delivery Valve
128
Reassembling Fuel Injection Pump
129
Installing Plunger Barrel
129
Assembling Delivery Valve
130
Assembling Control Sleeve
130
Assembling Plunger
130
Installing Tappet
131
Installing Control Rack
131
Tightening Delivery Valve Holder
132
Inspecting Control Rack for Smooth Operation
132
Installing Lock Plate
132
Installing Swivel Nipple
132
Disassembling and Inspecting Governor Cover
133
Reassembling Governor Cover
133
Disassembling and Inspecting Torque Spring Set
134
Reassembling Torque Spring Set
134
Reassembling Torque Spring Set, Double Spring Type
136
Inspecting Fuel Pump
137
Disassembling, Inspecting and Reassembling Fuel Filter (Cock Switch Type, Push Botton)
138
Disassembling, Inspecting and Reassembling Fuel Filter (Cock Switch Type, Changover)
139
3 Installing Fuel System
140
Installing Fuel Injection Pump
140
Installing Governor
141
Installing Speed Control Lever and Governor Shaft
142
Connecting Tie Rod
142
Installing Torque Spring Set (Single Spring, Double Spring)
143
Installing Torque Set Spring (Double Spring, Two Point Control)
143
Installing Rack Set Screw
144
Installing Fuel Filter
145
Installing Fuel Pipe and Fuel Injection Nozzles
146
Installing Fuel Injection Nozzle
146
Installing Fuel Return Pipe and Fuel Injection Pipe
146
Lubrication System
147
1 Removing Lubrication System
148
Removing Oil Filter, Relief Valve and Oil Pressure Switch
148
Removing Oil Filter
149
Removing Relief Valve
149
Removing Oil Pressure Switch
149
Removing Oil Pump, Oil Pan and Oil Screen9-4
150
Removing Oil Pump
150
2 Disassembling, Inspecting and Reassembling Lubrication System
151
Inspecting Oil Pump
151
Measuring Clearance between Oil Pump Housing Inside Diameter and Oil Pump Outer Gear Outside Diameter
151
Measuring the End Clearance between Oil Pump Outer Gear Width and Oil Pump Housing Depth
151
Inspecting Relief Valve
152
Inspecting Oil Pressure Switch
152
3 Installing Lubrication System
153
Installing Oil Pump, Oil Pan and Oil Screen
153
Installing Oil Pump
153
Installing Oil Filter, Relief Valve and Oil Pressure
154
Installing Oil Pressure Switch
154
Installing Relief Valve
154
Installing Oil Filter
155
Cooling System
157
1 Removing Cooling System
158
Removing Cooling Fan, Fan Pulley, V-Belt, Thermostat, Thermoswitch and Water Pump
158
2 Disassembling, Inspecting and Reassembling Cooling System
159
Disassembling and Inspecting Thermostat10-3
159
Inspecting Thermostat
159
Reassembling Thermostat
160
Inspecting Thermoswitch
160
Inspecting Water Pump
160
Checking Water Pump for Smooth Rotation10-4
160
3 Installing Cooling System
161
Installing Cooling Fan, Fan Pulley, V-Belt, Thermostat, Thermoswitchand Water Pump
161
Inlet and Exhaust Systems
163
1 Removing Inlet and Exhaust Systems
164
Removing Inlet and Exhaust Sysytems
164
Removing Inlet Cover and Exhaust Manifold
164
2 Disassembling, Inspecting and Reassembling Inlet and Exhaust Systems
165
Inspecting Inlet Cover and Exhaust Manifold
165
Measuring Distortion of Inlet and Exhaust Manifold
165
3 Installing Inlet and Exhaust Systems
166
Installing Inlet Cover and Exhaust Manifold
166
Table of Contents
167
1 Removing Electrical System
169
Removing Starter
169
Inspection before Removing Alternator (A007TA0171B (12V-40A), A007TA8271A (24V-25A))
170
Inspecting Alternator Operation
170
Handling Precaution
170
Inspecting Regulated Voltage
171
Inspecting Output
171
Removing Alternator
172
Removing Stop Solenoid
172
Removing Glow Plug
173
2 Disassembling, Inspecting and Reassembling Electrical System
174
Inspection before Disassembling Starter (M000T60481 (12V-1.2Kw), M001T68381 (12V-1.7Kw))
174
Inspecting Pinion Clearance
174
No Load Test
176
Disassembling and Inspecting Starter (M000T60481 (12V-1.2Kw), M001T68381 (12V-1.7Kw))
177
Preparation before Disassembling
178
Removing Pinion Set
178
Removing Magnetic Switch
178
Removing Rear Bracket
179
Removing Brush Holder and Brush Assembly
179
Removing Armature and Yoke
179
Removing Overrunning Clutch
180
Removing Gear Shaft
180
Inspecting and Repairing Starter (M000T60481 (12V-1.2Kw), M001T68381 (12V-1.7Kw))
181
Inspecting Brushes for Wear
181
Measuring Brush Spring Load
181
Inspecting Brush Holder for Insulation
181
Measuring Commutator Radial Runout
182
Measuring Commutator Outside Diameter12-15
182
Measuring Undercut Depth
182
Checking Armature Coil
183
Inspecting Rear Bracket
183
Inspecting Overrunning Clutch
184
Inspecting Pinion
184
Inspecting Front Bracket
184
Inspecting Gears of Starter
184
Inspecting Continuity of Magnetic Switch (between M Terminal and Case)
184
Inspecting Insulation of Magnetic Switch
184
(Between M Terminal and B Terminal)
184
Reassembling Starter (M000T60481 (12V-1.2Kw), M001T68381 (12V-1.7Kw))
185
Applying Grease
185
Installing Pinion
186
Installing Gear Shaft
186
Installing Yoke and Armature
187
Installing Brush Holder and Brush Assembly
187
Installing Rear Bracket
187
Installing Magnetic Switch
187
Inspecting Pinion Clearance
189
Inspection before Disassembling Starter (M002T66071 (24V-3.2Kw))
189
No Load Test
191
Disassembling and Inspecting Starter (M002T66071 (24V-3.2Kw))
192
Preparation before Disassembling
193
Removing Magnetic Switch
193
Removing Rear Bracket
193
Removing Brushes, Brush Holder, Yoke and Armature
194
Removing Ball Bearing
194
Removing Cover Set
194
Removing Center Bracket
195
Removing Reduction Gear and Spring Set
195
Removing Pinion Set
195
Removing Lever and Pinion Shaft
195
Inspecting and Repairing Starter (M002T66071 (24V-3.2Kw))
196
Inspecting Brushes for Wear
196
Measuring Brush Spring Load
196
Inspecting Brush Holder for Insulation
196
Measuring Commutator Radial Runout
197
Measuring Commutator Outside Diameter12-30
197
Measuring Undercut Depth
197
Checking Armature Coil
198
Inspecting Continuity of Yoke Assembly
199
Inspecting Insulation between Yoke Body and Brush
199
Inspecting Center Bracket
199
Inspecting Overrunning Clutch
200
Inspecting Pinion
200
Inspecting Front Bracket
200
Inspecting Gears of Starter
200
(Between M Terminal and Case)
200
Inspecting Insulation of Magnetic Switch (ETS Type)
200
(Between M Terminal and B Terminal)
200
(M002T66071 (24V-3.2Kw))
201
Applying Grease
201
Installing Lever and Pinion Shaft
202
Installing Pinion
202
Installing Spring Set and Reduction Gear
202
Installing Center Bracket
202
Adjusting Pinion Shaft End Play
203
Installing Bearing
203
Installing Armature, Yoke, Brush and Brush Holder
203
Installing Rear Bracket
204
Installing Magnetic Switch
204
Inspecting Pinion Clearance
204
Disassembling and Inspecting Alternator12-38
205
Separating Front Bracket from Stator
206
Removing Pulley
206
Removing Rear Bearing
206
Removing Front Bearing
206
Removing Stator
207
Removing Regulator Assembly
207
Removing Rectifier Assembly
207
Inspecting and Repairing Alternator
208
Inspecting Rectifier
208
Inspecting Rotor
208
Inspecting Stator
209
Inspecting Brushes for Wear
209
Replacing Brushes
210
Reassembling Alternator
211
Installing Rectifier Assembly and Regulator Assembly
212
Installing Stator
212
Installing Front Bearing
212
Installing Rear Bearing
213
Installing Pulley
213
Assembling Stator and Front Bracket
213
Inspecting Glow Plug
214
3 Installing Electrical System
215
Installing Glow Plug
215
Installing Stop Solenoid
216
Installing Stop Solenoid (ETR Type)
216
Procedure for Installing Stop Solenoid (ETR Type)
216
Verification after Reassembling (ETR Type)
216
Adjustment and Operation
221
1 Inspection and Adjustment of Engine
222
Inspecting and Adjusting Valve Clearance13-2
222
Preparation for Valve Clearance Inspection13-2
222
Inspecting Valve Clearance
223
Inspecting Fuel Injection Timing
224
Adjusting Fuel Injection Timing
225
Inspecting and Adjusting Low Idle Speed and High Idle Speed
226
Preparation
226
Adjusting Low Idle Speed
226
Adjusting High Idle Speed
226
Bleeding Fuel System
227
Bleeding Air from Fuel Filter
227
Bleeding Air from Fuel Injection Pump
228
Adjusting V-Belt Tension
229
2 Break-In Operation
230
Starting up
230
Inspecting Engine Condition after Starting up
230
Break-In Operation Time
230
Inspection and Adjustment after Break-In Operation
230
3 Performance Test (JIS Standard)
231
Engine Equipment Condition
231
Test Items and Purposes
231
Operation Load Test
231
Continuous Load Test
231
Low Idle Test
231
Other Inspections
231
Engine Output Adjustment
231
Standard Atmospheric Conditions
231
Calculation of Corrected Power
232
Troubleshooting
233
Troubleshooting
234
Before Troubleshooting
234
Check Items before Troubleshooting
235
Problem: Starting Trouble
235
Starting Trouble
235
Check Items before Troubleshooting
236
Knocking
236
Problem: Knocking
236
Check Items before Troubleshooting
237
Overheating
237
Problem: Overheating
237
Check Items before Troubleshooting
238
Excessive Black Smoke
238
Problem: Excessive Black Smoke
238
Check Items before Troubleshooting
239
Idling Malfunction
239
Problem: Unstable Idling
239
Check Items before Troublshooting
240
Low Output
240
Problem: Low Output
240
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Mitsubishi L2A Specifications
General
Brand
Mitsubishi
Model
L2A
Category
Engine
Language
English
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