Mitsubishi S12A2 - OVERHAUL INSTRUCTIONS

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4-1

Chapter 4 OVERHAUL INSTRUCTIONS

1. Determining Overhaul Timing ................................................................................4-3

2. Compression Pressure - Measure..........................................................................4-4

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Default Chapter4
- Description Format4
- How to Use this Manual4
- Abbreviations and Standards5
- Terms Used in this Manual5
- Unit of Measurement5
- Fire and Explosion Precautions6
- Safety Cautions6
- Stay Away from Rotating and Moving Parts7
- Be Careful of Exhaust Gas Poisoning8
- Be Careful of Falling8
- Be Careful of Hearing Loss8
- Be Careful of Burns9
- Be Careful When Handling Fuel, Engine Oil or LLC9
- Be Careful with Battery10
- When Abnormality Occurs10
- Other Cautions11
- Cool down the Engine before Stop12
- Do Not Operate the Engine in an Overloaded Condition12
- Use Care to Protect Engine from Water12
- Warm-Up the Engine before Use12
- Be Careful of Engine Room Ventilation13
- Do Not Operate Starter for a Long Time13
- Do Not Touch High Pressure Fuel Jet13
- Do Not Turn off the Battery Switch During Operation13
- Warning Labels14
- Points on Disassembling and Assembling15
- General Contents17
- Table of Contents19
- General Information19
- Engine Front View - S12A2-PTA21
- Engine Rear View - S12A2-PTA21
External View21
- Left Side View - S12A2-PTA22
- Right Side View - S12A2-PTA22
- Engine Front View - S12A2-PTA223
- Engine Rear View - S12A2-PTA223
- Left Side View - S12A2-PTA224
- Right Side View - S12A2-PTA224
- Engine Front View - S12A2-Y1PTA225
- Engine Rear View - S12A2-Y1PTA225
- Left Side View - S12A2-Y1PTA226
- Right Side View - S12A2-Y1PTA226
- Engine Front View - S12A2-PTK27
- Engine Rear View - S12A2-PTK27
- Left Side View - S12A2-PTK28
- Right Side View - S12A2-PTK28
- Engine Front View - S12A2-PTAW29
- Engine Rear View - S12A2-PTAW29
- Left Side View - S12A2-PTAW30
- Right Side View - S12A2-PTAW30
- Engine Front View - S12A2-Y2PTAW31
- Engine Rear View - S12A2-Y2PTAW31
- Left Side View - S12A2-Y2PTAW32
- Right Side View - S12A2-Y2PTAW32
Chapter 1 GENERAL33
- Outline of Fuel System33
- Outline of Lubrication System33
- Outline of Cooling System34
- Outline of Inlet and Exhaust System36
Contents of Plate and Label37
- Name Plate37
- Caution Plate37
- Emissions Certification Label37
Specifications38
- Service Data43
Chapter 2 SERVICE DATA45
- Maintenance Service Data of Engine General45
- Maintenance Service Data of Basic Engine46
- Maintenance Service Data of Fuel System51
- Maintenance Service Data of Lubrication System55
- Maintenance Service Data of Cooling System56
- Maintenance Service Data of Electrical System59
Chapter 5 DISASSEMBLY of BASIC ENGINE83
Cylinder Heads and Valve Mechanisms - Disassemble and Inspect83
- Fuel Pipe - Remove84
- Nozzle Assembly - Remove84
- Valve Clearance - Inspect84
- Fuel Injection Timing - Inspect85
- Rocker Shaft Assembly - Remove85
- Clearance between Bottom Face of Valve Bridge and Top Face of Valve Rotator - Inspect85
- Valve Bridge - Remove86
- Cylinder Head Assembly - Remove86
- Valve Sinkage - Measure86
- Valve and Valve Spring - Remove87
- Nozzle Gland Stud Bolt and Bridge Guide - Remove87
- Fuel Connector - Remove87
Rear Mechanism - Disassemble and Inspect88
- Flywheel Face and Radial Runout - Measure89
- Flywheel - Remove89
- Timing Gear Case - Remove89
- Timing Gear Backlash - Measure90
- Idler Gear End Play - Measure90
- Camshaft End Play - Measure90
- Idler Gear - Remove91
- Fuel Injection Pump Gear - Remove91
- Governor Drive and Fuel Injection Pump Accessory Drive - Remove91
- Camshaft Gear - Remove92
- Idler Shaft - Remove92
- Rear Plate - Remove93
Front Mechanism - Disassemble and Inspect94
- Fan, Fan Bracket Assembly and Belt - Remove95
- Damper Face and Radial Runout - Measure95
- Front Pulley, Damper and Crankshaft Pulley - Remove95
- Front Cover - Remove96
Cylinder Liner, Piston and Connecting Rod - Disassemble and Inspect97
- Piston Protrusion - Measure98
- Connecting Rod End Play - Measure98
- Hard Carbon Deposits on the Upper Part of Cylinder Liner - Remove98
- Connecting Rod Cap - Remove98
- Piston - Remove99
Crankcase, Crankshaft and Main Bearing - Disassemble and Inspect102
- Crankcase - Turn over (Upend)103
- Crankshaft End Play - Measure103
- Main Bearing Cap - Remove103
- Piston Cooling Nozzle - Remove103
- Crankshaft - Remove104
- Inspection and Repair of Basic Engine105
Chapter 6 INSPECTION and REPAIR of BASIC ENGINE107
Cylinder Head and Valve Mechanism - Inspect and Repair107
- Bushing Inside Diameter and Shaft Outside Diameter of Rocker - Measure107
- Rocker Bushing - Replace107
- Valve Stem Outside Diameter and Valve Guide Inside Diameter - Measure108
- Valve Guide - Replace108
- Valve Face - Inspect109
Rear Mechanism - Inspect and Repair115
- Cam Lift of Cam Shaft Lobe - Measure115
- Idler Bushing - Replace115
- Idler Bushing Inside Diameter and Idler Shaft Outside Diameter - Measure115
- Camshaft Bushing - Inspect116
- Camshaft Journal Outside Diameter - Measure116
- Camshaft Runout - Measure116
- Camshaft Bushing - Replace117
- Damper - Inspect Visually118
Front Mechanism - Inspect and Repair118
- Pulley - Inspect118
- Piston - Inspect Visually119
Piston and Connecting Rod - Inspect and Repair119
- Piston Outside Diameter - Measure119
- Piston Ring Groove - Inspect119
- Piston Weight119
- Piston Pin Bore Inside Diameter - Measure120
- Piston Ring - Inspect Visually120
- Piston Ring End Gap - Measure120
- Connecting Rod Bushing Inside Diameter - Measure121
- Deflection of Connecting Rod - Measure126
Crankcase and Crankshaft - Inspect and Repair127
- Crankcase Top Surface Distortion - Measure127
- Inside Diameter of Main Bearing Housing Bore - Measure127
- Counterbore in Crankcase - Repair128
- Crankpin and Journal Outside Diameters - Measure128
- Cylinder Liner Fitting Bore in Crankcase - Inspect128
Chapter 7 ASSEMBLY of BASIC ENGINE139
- Crankcase - Turn over (Upend)139
- Upper Main Bearing - Install140
- Crankshaft - Install141
- Upper Thrust Plates - Install141
- Lower Main Bearing Shell and Lower Thrust Plate - Install141
- Main Bearing Cap - Install142
- Crankshaft End Play - Measure143
- Crankcase - Turn over143
Crankshaft and Main Bearing - Install139
- Piston Cooling Nozzle - Install139
Cylinder Liner, Piston and Connecting Rod - Assemble144
- Cylinder Liner Protrusion - Measure144
- Cylinder Liner Flange Protrusion - Calculate (When Cylinder Liner Not Installed)144
- Cylinder Liner - Install146
- Cylinder Liner Flange Protrusion - Measure (When Cylinder Liner Installed)146
- Piston and Connecting Rod - Assemble147
- Cylinder Liner Inside Diameter - Measure147
- Piston Ring - Install148
- Crankshaft - Turn148
- Piston Installation - Prepare149
- Upper Connecting Rod Bearing - Install149
- Piston - Install150
- Connecting Rod Cap - Install152
  - Connecting Rod End Play - Measure153
  - Piston Protrusion - Measuring153
Front Mechanism - Assemble154
- Front Oil Seal - Install154
- Crankshaft Pulley, Damper and Front Pulley - Install155
  - Damper Face and Radial Runout - Measuring155
  - Pointer - Install and Adjust155
Rear Mechanism - Assemble156
- Idler Shaft - Install156
- Rear Plate - Install156
- Camshaft Gear - Install157
Cylinder Head and Valve Mechanism - Assemble163
- Cylinder Head - Assemble163
- Fuel System173
Chapter 8 FUEL SYSTEM175
- Fuel Injection Pipe - Remove and Inspect175
- Fuel Leak-Off Pipe and Fuel Pipe - Remove and Inspect176
- Tamper Proof Attachment Spec185
Fuel System - Remove and Inspect175
Fuel System - Disassemble, Inspect and Assemble186
- Fuel Filter (Wire Element) - Disassemble, Inspect and Assemble186
- Fuel Filter (Paper Element) - Disassemble, Inspect and Assemble187
Fuel System - Install205
- Rubber - Install204
- Fuel Injection Pump - Install205
Chapter 9 LUBRICATION SYSTEM221
- Oil Pipe - Remove221
- Oil Pipe for Fan Drive - Remove222
- Oil Cooler and Oil Filter - Remove and Inspect223
- Breather - Remove and Inspect226
- Oil Level Gauge and Oil Filler - Remove and Inspect227
- Oil Filter for Governor - Remove and Inspect228
- Oil Pan, Oil Strainer and Oil Pump - Remove and Inspect229
Lubrication System - Remove and Inspect221
Lubrication System - Disassemble, Inspect and Assemble231
- Oil Strainer - Disassemble and Inspect231
- Oil Pump and Safety Valve - Disassemble and Inspect232
- Oil Pump and Safety Valve - Inspect233
Lubrication System - Install241
- Backlash When Installing Oil Pump - Adjust241
- Oil Pan - Install241
- Oil Pump, Oil Strainer and Oil Pan - Install241
- Cooling System243
Chapter 10 COOLING SYSTEM245
- Tension Pulley - Remove and Inspect (Water Pump Side)245
- Tension Pulley - Remove and Inspect (Fan Side)246
- Thermostat Case and Water Pipe - Remove and Inspect247
Cooling System - Remove and Inspect245
Cooling System - Disassemble, Inspect and Assemble257
- Tension Pulley - Disassemble and Inspect (Water Pump Side)257
Cooling System - Install292
- Fan Pulley - Lock291
- Tension Pulley - Install292
- Water Outlet Pipe - Install292
- Water Pipe (Air Cooler) - Install292
- Inlet and Exhaust Systems293
Chapter 11 INLET and EXHAUST SYSTEMS295
Inlet and Exhaust Systems - Remove and Inspect295
- Air Duct and Air Cooler - Remove and Inspect (PTA,PTK,MPTA Spec)295
- Air Duct and Air Cooler - Remove and Inspect (PTA2 Spec)296
- Air Duct and Air Cooler - Remove and Inspect (MTK,MPTK Spec)297
- Pre-Cleaner and Paper Type Air Cleaner - Remove and Inspect298
Inlet and Exhaust Systems - Disassemble, Inspect and Assemble303
- Air Cooler - Disassemble, Inspect and Assemble (PTA,PTK,PTAW,MPTA Spec)303
- Air Cooler - Disassemble, Inspect and Assemble (PTA2 Spec)304
- Air Cooler - Disassemble, Inspect and Assemble (MTK,MPTK Spec)305
- Air Cooler - Clean306
- Air Cooler - Inspect306
- Air Cooler - Assemble307
- Pre-Cleaner - Clean307
Inlet and Exhaust Systems - Install308
- Air Cooler - Inspect for Leakage307
- Exhaust Manifold - Install308
  - Exhaust Manifold Coupling - Tighten308
  - Air Start System309
Air Start System - Remove and Inspect311
Chapter 12 AIR START SYSTEM311
- Magnetic Valve - Remove and Inspect311
- Air Pipe, Starter Valve and Distributor Valve - Inspect312
- Air Starter - Remove and Inspect313
Air Start System - Disassemble, Inspect and Assemble314
- Starter Valve - Disassemble and Inspect314
- Starter Valve - Inspect315
Air Start System - Install319
- Adjustment and Operation321
Chapter 13 ADJUSTMENT and OPERATION323
Engine - Adjust323
- Valve Bridge and Adjusting Screw - Check323
- Fuel System - Bleed Air323
Break-In Operation330
- Break-In Operation Load and Time330
- Engine Start-Up330
- Preparation before Engine Starting330
- Inspection and Adjustment after Break-In Operation331
Engine-Test and Adjustment332
- Inspection While the Engine Is Running331
- Alarm Action and Emergency Stop Tests332
- Emission Gas Test332
- Engine Performance Test332
- Maximum Fuel Injection Volume - Set332

Mitsubishi S12A2 - OVERHAUL INSTRUCTIONS

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