Mitsubishi S3L2 Service Manual

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Service Manual Mitsubishi SL-Series diesel engines
Version 08/2004
ENGLISH
INTRODUCTION
This service manual has instructions and procedures for the Mitsubishi SL-series diesel engines.
The information, specifications and illustrations in this manual are on the basis of the information that was current at
the time this issue was written.
Correct servicing, test and repair procedures will give the engine a long service life. Before starting a test, repair or
rebuild job, the serviceman must read the respective sections of this manual to know all the component he will work
on.
Continuing improvement of product design may have caused changes to your engine which are not included in this
manual.
Whenever a question arises regarding your engine, or this manual, consult your Mitsubishi dealer for the latest
available information.
Service Manual
Mitsubishi SL-Series diesel engines
Version 08/2004
Copyright © 2004 MHI Equipment Europe B.V.

Mitsubishi S3L2 Specifications

General

Engine Model	S3L2
Aspiration	Naturally aspirated
Cooling System	Water-cooled
Displacement	1.318 L
Bore x Stroke	78 mm x 92 mm
Starting System	Electric starter
Lubrication System	Forced lubrication by trochoid pump

Summary

GENERAL INFORMATION

MODEL IDENTIFICATION AND SERIAL NUMBER LOCATION

Details how to find and interpret engine model identification and serial numbers.

Serial Number Location

Describes the location where the serial number is punched on the cylinder block.

COMPONENT LOCATION

S3L/S3L2

Identifies components of the S3L/S3L2 engine models using diagrams.

Engine S3L-T/S3L2-T

Identifies components of the S3L-T/S3L2-T engine models using diagrams.

S4L/S4L2

Identifies components of the S4L/S4L2 engine models using diagrams.

Engine S4L-T/S4L2-T

Identifies components of the S4L-T/S4L2-T engine models using diagrams.

SPECIFICATIONS

Table 1 Specifications

Provides detailed technical specifications for various engine models and systems.

OVERHAUL INSTRUCTIONS

DETERMINING WHEN TO OVERHAUL THE ENGINE

Provides guidance on when to determine if an engine requires overhauling.

COMPRESSION PRESSURE MEASUREMENT

Measurement

Details the steps for measuring the engine's compression pressure using a gauge.

TROUBLESHOOTING

General

Provides general advice and introduces common diesel engine characteristics for diagnosis.

Engine Troubleshooting

Outlines a troubleshooting process for common engine starting problems.

Problem 2: Fuel Knock

Addresses troubleshooting for fuel knock issues in diesel engines.

Problem 3: Overheating

Details troubleshooting steps for engine overheating problems.

Problem 4: Black Exhaust Smoke

Provides troubleshooting steps for diagnosing black exhaust smoke issues.

Problem 5: Erratic Idle Speeds

Outlines troubleshooting steps for engines with erratic idle speeds.

Problem 6: Low Power or Loss of Power

Details troubleshooting steps for engines experiencing low power or loss of power.

Starting System Troubleshooting

Provides troubleshooting steps for the engine's starting system.

BASIC PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

Disassembly

Lists essential precautions to be observed during the disassembly process.

Assembly

Lists essential precautions to be observed during the assembly process.

DISASSEMBLY

PREPARATION FOR DISASSEMBLY

Details steps required to prepare the engine before disassembly.

ELECTRICAL SYSTEM

Starter

Covers starter testing, removal, inspection, and assembly.

Testing Before Disassembly

Details tests to perform on the starter before disassembling it.

Alternator

Covers alternator inspection, testing, and removal.

Inspection Before Removal

Guides on inspecting the alternator on the engine before removal.

Testing Voltage Setting

Explains how to test the voltage setting of the alternator.

Testing Output Characteristics

Details testing procedures for the alternator's output characteristics.

Cooling System

Water Pump Installation

Thermostat Installation

Cooling Fan Installation

Thermoswitch and Thermounit Combination Installation

Fuel System

Fuel Injection Nozzle Installation

Fuel Injection Pump Installation

Flyweight Assembly Installation

Sliding Sleeve Installation

Governor Assembly Installation

Fuel Injection Line Installation

Lubrication System

Pressure Relief Valve Installation

Oil Filter Installation

Oil Pressure Switch Installation

AIR INLET SYSTEM AND EXHAUST SYSTEM

INSPECTION

Covers inspection of air inlet and exhaust system components.

Inspection Procedure

CYLINDER HEAD AND VALVE MECHANISM

Rocker Shaft Assembly Removal

Explains how to remove the rocker shaft assembly.

Cylinder Head Bottom Face Cleaning

Rocker Shaft Disassembly

Details how to disassemble the rocker shaft.

Valve Stem Seal Installation

Cylinder Head Bolt Removal

Describes the procedure for removing cylinder head bolts.

Valve Spring Installation

Cylinder Head Assembly Removal

Explains how to remove the cylinder head assembly.

Valve and Valve Spring Removal

Details how to remove valves and valve springs.

Cylinder Head Gasket Installation

Valve Stem Seal Removal

Explains how to remove valve stem seals.

Cylinder Head Installation

Cylinder Head Bolt Tightening

Valve Push Rod Installation

Rocker Shaft Assembling

Rocker Shaft Assembly Installation

Valve Clearance Adjustment

Rocker Cover Installation

Timing Gears and Flywheel

Flywheel Removal

Explains how to remove the flywheel.

Front Plate Installation

Rear Plate Removal

Details the procedure for removing the rear plate.

Oil Pump Installation

Oil Seal Case Removal

Explains how to remove the oil seal case.

Engine Turning

Speedometer Driven Gear Removal

Explains how to remove the speedometer driven gear.

Crankshaft Pulley Removal

Details how to remove the crankshaft pulley.

Timing Gear Case Removal

Explains how to remove the timing gear case.

Idler Gear Installation

Timing Gear Backlash Measurement

Describes how to measure timing gear backlash.

Timing Gear Case Installation

Idler Gear Removal

Explains how to remove the idler gear.

Crankshaft Pulley Nut Tightening

Camshaft Removal

Details how to remove the camshaft.

Fuel Injection Pump Camshaft Removal

Explains how to remove the fuel injection pump camshaft.

Oil Seal Case Installation

Rear Plate Installation

Flywheel Installation

Cylinder Block, Crankshaft, Pistons and Oil Pan

Oil Pan Removal

Explains how to remove the oil pan.

Oil Screen Removal

Details how to remove the oil screen.

Thrust Clearance Measurement for Connecting Rod Big End

Describes how to measure thrust clearance for the connecting rod big end.

Connecting Rod Cap Removal

Explains how to remove connecting rod caps.

Piston Removal

Details how to remove pistons.

End Play Measurement for Crankshaft

Describes how to measure crankshaft end play.

Main Bearing Cap Removal

Explains how to remove main bearing caps.

Crankshaft Removal

Details how to remove the crankshaft.

Piston Separation from Connecting Rod

INSPECTION

CYLINDER HEAD AND VALVE MECHANISM

Covers inspection of cylinder head, rocker arms, shafts, valves, and related components.

Cylinder Head

Rocker Arms and Rocker Shaft

Valve Springs

Valve Push Rods

Valves, Valve Guides and Valve Seats

Clearance Between Valve Stem and Valve Guide

Valve Guide Replacement

Valves

Valve Margin and Sinkage

Valve Refacing

Valve Seat Refacing

Valve Lapping

Combustion Jet Replacement

TIMING GEARS AND FLYWHEEL

Camshaft

Bushing Replacement

Lobe Lift

Fuel Injection Pump Camshaft

Tappets

Idler Gear

Idler Shaft Replacement

Flywheel and Ring Gear

CYLINDER BLOCK, CRANKSHAFT, PISTONS AND OIL PAN

Pistons, Piston Rings and Piston Pins

Diameter of Piston

Clearance Between Piston Ring and Groove

Clearance Between Ends of Piston Ring

Clearance Between Piston Pin and Piston

Connecting Rods

Clearance Between Crankpin and Connecting Rod Bearing

Diameter of Crankpin

Clearance Between Journal and Main Bearing

Diameter of Journal

Runout

ASSEMBLY

Cylinder Block, Crankshaft, Pistons and Oil Pan

Covers assembly of cylinder block, crankshaft, pistons, and oil pan.

Main Bearing Installation

Crankshaft Installation

Main Bearing Cap Installation

Side Seal Installation

Piston Assembling to Connecting Rod

Piston Ring Installation

Piston and Connecting Rod Installation

Connecting Rod Cap Installation

Oil Screen Installation

Oil Pan Installation

Air Inlet System and Exhaust System

Air Inlet Cover Installation

Exhaust Manifold Installation

Electrical System

Glow Plug Installation

Alternator Installation

Adjusting Alternator and Fan Belt

Wiring Diagrams

Shows wiring diagrams for the electrical system, including ETR solenoid.

STARTER

Removing Pinion

Commutator Inspection

Brushes and Brush Holders

Overrunning Clutch

Inspection and Testing After Assembly

Covers post-assembly checks for the starter.

Inspection and Adjustment of Pinion Gap

No-Load Test

Solenoid Switch

ALTERNATOR

Stator Core Separation from Front Bracket

Pulley Removal

Stator Core and Rectifier Removal

Diodes

Field Coil

Stator Core

Brushes

KEY SHUTOFF SYSTEM (ETS solenoid type)

KEY SHUTOFF SYSTEM (ETR solenoid type)

Shutoff Solenoid Installation

AUTOMATIC GLOW SYSTEM

Glow Plug Inspection

COOLING SYSTEM

Water Pump

Thermostat (Standard)

Thermoswitch (Standard)

Thermounit (Standard)

LUBRICATION SYSTEM

Specifications

Provides standard specifications for the lubrication system.

Oil Pump

Oil Pressure Switch

Pressure Relief Valve

FUEL SYSTEM

Specifications (Standard)

Provides standard specifications for fuel system components.

FUEL INJECTION NOZZLE

Covers inspection, testing, and service of fuel injection nozzles.

Disassembly and Assembly

Covers disassembly and assembly of the fuel injection nozzle.

FUEL INJECTION PUMP

Covers testing, disassembly, inspection, and assembly of the fuel injection pump.

Test on Engine

Disassembly

Details the disassembly sequence for the fuel injection pump.

Tappet Removal

Explains how to remove tappets from the injection pump.

Plunger Removal

Delivery Valve Removal

Barrel Removal

Barrel Installation

Delivery Valve Installation

Control Sleeve Installation

Tappet Installation

Delivery Valve Holder Installation

Inspection After Assembly

GOVERNOR

Disassembly and Inspection

Covers disassembly and inspection of the governor.

Assembly

Details the assembly procedure for the governor.

Torque Spring Set Installation

FUEL PUMP

Inspection

FUEL FILTER

Fuel Filter with [AIR] Valve

Cartridge (Air Vent Screw) Type Fuel Filter

MAINTENANCE

LUBRICATION AND MAINTENANCE CHART

Provides a schedule for lubrication and maintenance tasks.

ENGINE OIL AND OIL FILTER

Covers engine oil specifications, level check, and filter changes.

Engine Oil Specifications

Provides recommendations for engine oil specifications and viscosities.

Oil Level Check

Oil and Oil Filter Change

Details the procedure for changing engine oil and oil filter.

Oil Filter Change

VALVE CLEARANCE

FUEL INJECTION TIMING

Preparation

Inspection

Covers inspection of fuel injection timing.

Fuel Flow Method

Alternate Method

Adjustment

Explains how to adjust fuel injection timing using shims.

FUEL SYSTEM PRIMING

Engine with Fuel Filter with [AIR] Valve

Engine with Cartridge (Air Vent Screw) Type Fuel Filter

IDLE RPM SETTING

FUEL INJECTION NOZZLES

Injection Pressure (Valve Opening Pressure) Test

Orifice Restriction Test

Nozzle Tip Washing and Replacement

Installation

FAN BELT

SERVICE DATA

SPECIFICATIONS

Provides core technical data and specifications for the engine.

Basic Engine Components

Continues listing basic engine component specifications.

Lubrication System

Provides specifications for the lubrication system.

Fuel System

Provides specifications for the fuel system.

Air Inlet System and Exhaust System

Provides specifications for air inlet and exhaust systems.

Cooling System (Standard)

Lists standard specifications for the cooling system.

Electrical System

Provides specifications for the electrical system components.

TIGHTENING TORQUES

Major Bolts and Nuts

Lists tightening torques for major bolts and nuts.

Torques for Bolts and Nuts with Standard Threads

Provides torques for standard threaded bolts and nuts.

Torques for Plugs with Taperlock Threads

Provides torques for plugs with taperlock threads.