Mitsubishi S3L2 - AIR INLET SYSTEM AND EXHAUST SYSTEM

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Service Manual Mitsubishi SL-Series diesel engines

Version 08/2004

ENGLISH

AIR INLET SYSTEM AND EXHAUST

SYSTEM

Main Page

Default Chapter2
- Exploded Views2
- How to Use this Manual2
- Tightening Torques2
- Table of Contents3
General Information9
1 Model Identification and Serial Number Location10
- Model Identification Location10
- Serial Number Location11
2 Component Location12
- S3L/S3L212
- Engine S3L-T/S3L2-T13
- S4L/S4L214
- Engine S4L-T/S4L2-T15
3 Specifications16
Overhaul Instructions17
4 Determining When to Overhaul the Engine18
5 Compression Pressure Measurement19
- Inspection19
- Measurement19
6 Troubleshooting20
- General20
- Engine Troubleshooting21
- Starting System Troubleshooting27
7 Basic Precautions for Disassembly and Assembly29
- Disassembly29
- Assembly29
Disassembly31
8 Preparation for Disassembly32
- Engine Oil Draining32
- Coolant Draining32
9 Electrical System33
- Starter33
- Alternator35
10 Cooling System38
- Cooling Fan Removal38
- Thermostat Case Removal38
- Water Pump Assembly Removal38
11 Fuel System39
- Fuel Injection Pipe Removal39
- Fuel Injection Nozzle Removal39
- Governor Assembly Removal39
- Governor Weight Removal40
- Fuel Injection Pump Removal40
12 Lubrication System41
- Oil Filter Removal41
- Pressure Relief Valve Removal41
- Oil Pressure Switch Removal41
13 Air Inlet System and Exhaust System42
- Exhaust Manifold Removal42
- Air Inlet Cover Removal42
14 Cylinder Head and Valve Mechanism43
- Rocker Shaft Assembly Removal44
- Rocker Shaft Disassembly44
- Cylinder Head Bolt Removal44
- Cylinder Head Assembly Removal45
- Valve and Valve Spring Removal45
- Valve Stem Seal Removal45
15 Timing Gears and Flywheel46
- Service Manual Mitsubishi SL-Series Diesel Engines ENGLISH47
16 Cylinder Block, Crankshaft, Pistons and Oil Pan52
- Oil Pan Removal53
- Oil Screen Removal53
- Thrust Clearance Measurement for Connecting Rod Big End53
- Connecting Rod Cap Removal54
- Piston Removal54
- End Play Measurement for Crankshaft54
- Main Bearing Cap Removal55
- Crankshaft Removal55
- Piston Separation from Connecting Rod55
Inspection57
17 Cylinder Head and Valve Mechanism58
- Cylinder Head59
- Rocker Arms and Rocker Shaft59
- Valve Springs60
- Valve Push Rods60
- Valves, Valve Guides and Valve Seats60
- Combustion Jet Replacement64
18 Timing Gears and Flywheel66
- Camshaft67
- Fuel Injection Pump Camshaft68
- Tappets69
- Idler Gear69
- Flywheel and Ring Gear70
19 Cylinder Block, Crankshaft, Pistons and Oil Pan71
- Pistons, Piston Rings and Piston Pins72
- Connecting Rods74
- Crankshaft75
- Cylinder Block79
Assembly81
20 Cylinder Block, Crankshaft, Pistons and Oil Pan82
- Main Bearing Installation83
- Crankshaft Installation83
- Main Bearing Cap Installation83
- Side Seal Installation85
- Piston Assembling to Connecting Rod85
- Piston Ring Installation87
- Piston and Connecting Rod Installation87
- Connecting Rod Cap Installation88
- Oil Screen Installation89
- Oil Pan Installation89
21 Timing Gears and Flywheel91
- Front Plate Installation92
- Oil Pump Installation92
- Engine Turning92
- Engine Turning93
- Camshaft Installation93
- Idler Gear Installation94
- Timing Gear Case Installation94
- Crankshaft Pulley Nut Tightening94
- Gear Installation95
- Speedometer Driven Gear Installation95
- Tappet Installation95
- Oil Seal Case Installation96
- Rear Plate Installation96
- Flywheel Installation96
22 Cylinder Head and Valve Mechanism98
- Cylinder Head Bottom Face Cleaning99
- Valve Stem Seal Installation99
- Valve Spring Installation99
- Installing Valve Block100
- Cylinder Head Gasket Installation100
- Cylinder Head Installation100
- Cylinder Head Bolt Tightening101
- Valve Push Rod Installation101
- Rocker Shaft Assembling101
- Rocker Shaft Assembly Installation102
- Valve Clearance Adjustment102
- Rocker Cover Installation102
23 Air Inlet System and Exhaust System103
- Air Inlet Cover Installation103
- Exhaust Manifold Installation103
24 Fuel System104
- Fuel Injection Nozzle Installation104
- Fuel Injection Pump Installation104
- Flyweight Assembly Installation104
- Sliding Sleeve Installation105
- Governor Assembly Installation105
- Fuel Injection Line Installation105
25 Lubrication System106
- Pressure Relief Valve Installation106
- Oil Filter Installation106
- Oil Pressure Switch Installation106
26 Cooling System107
- Water Pump Installation107
- Thermostat Installation107
- Cooling Fan Installation107
- Thermoswitch and Thermounit Combination Installation108
27 Electrical System109
- Glow Plug Installation109
- Alternator Installation109
Electrical System General112
- Specifications (Standard)112
- Wiring Diagrams113
29 Starter115
- Disassembly115
- Inspection116
- Assembly119
- Inspection and Testing after Assembly120
30 Alternator122
- Disassembly122
- Inspection124
- Assembly127
31 KEY SHUTOFF SYSTEM (ETS Solenoid Type)128
- General128
- Cord Color (Standard)128
- Shutoff Solenoid Installation128
- Inspection after Assembly129
32 KEY SHUTOFF SYSTEM (ETR Solenoid Type)130
- General130
- Cord Color (Standard)130
- Shutoff Solenoid Installation131
33 Automatic Glow System132
- General132
- Glow Timer Specification (Standard)132
- Glow Plug Relay Specifications (Standard)133
- Glow Plug Inspection133
Cooling System135
34 General136
- Schematic136
- Specifications (Standard)136
35 Inspection137
- Water Pump138
- Thermostat (Standard)138
- Thermoswitch (Standard)139
- Thermounit (Standard)139
Lubrication System141
36 General142
- Schematic142
- Specifications142
37 Inspection143
- Oil Pump143
- Oil Pressure Switch143
- Pressure Relief Valve144
Fuel System145
38 General146
- Schematic146
- Specifications (Standard)147
39 Fuel Injection Nozzle148
- Inspection148
- Disassembly and Assembly150
40 Fuel Injection Pump151
- Test on Engine151
- Disassembly151
- Disassembly Procedure152
- Inspection155
- Assembly156
41 Governor159
- Disassembly and Inspection159
- Assembly160
- Torque Spring Set Installation161
42 Fuel Pump162
- Inspection162
43 Fuel Filter163
Air Inlet System and Exhaust System 44 General166
- Schematic166
45 Inspection167
- Inspection Procedure167
Maintenance169
46 Lubrication and Maintenance Chart170
47 Engine Oil and Oil Filter172
- Engine Oil Specifications172
- Oil Level Check172
- Oil and Oil Filter Change173
- Oil Filter Change173
48 Valve Clearance175
49 Fuel Injection Timing177
- Preparation177
- Adjustment179
50 Fuel Filter180
- Fuel Filter with [AIR] Valve180
- Cartridge (Air Vent Screw) Type Fuel Filter180
51 Fuel System Priming181
- Engine with Fuel Filter with [AIR] Valve181
- Engine with Cartridge (Air Vent Screw) Type Fuel Filter181
52 Idle Rpm Setting182
53 Fuel Injection Nozzles183
- Injection Pressure (Valve Opening Pressure) Test183
- Orifice Restriction Test183
- Nozzle Tip Washing and Replacement183
- Installation183
54 Fan Belt184
Service Data185
55 Specifications186
- Basic Engine Components186
- Service Data 55 Specifications186
- Lubrication System188
- Fuel System188
- Air Inlet System and Exhaust System188
- Cooling System (Standard)189
- Electrical System189
56 Tightening Torques191
- Major Bolts and Nuts191
- Torques for Bolts and Nuts with Standard Threads192
- Torques for Plugs with Taperlock Threads192
57 Sealants193
58 Special Tools194

Mitsubishi S3L2 - AIR INLET SYSTEM AND EXHAUST SYSTEM

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