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Mitsubishi S4L User Manual
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Service Manual Mitsubishi SL-Series diesel engines
V
ersion 08/2004
COMPONENT LOCATION
ENGLISH
GENERAL INFORMATION
2.4
Engine S4L-T/S4L2
-T
RIGHT SIDE VIEW
Oil filler
Fuel injection nozzle
Fuel injection pump
W
ater pump
Oil filler
Crankshaft pulley
Dipstick
FRONT
Oil filter
Oil pressure switch
Air inlet cover
REAR
Thermosta
t
Hanger
Alternator
Fan
V-
b
e
l
t
Exhaust manifold
St
a
r
t
e
r
Oil pan
REAR
FRONT
Flywheel
LEFT SIDE VIEW
Oil drain plug
Hanger
S
top solenoid
Fuel filter
Air vent screw
Thermoswitch
T
urbocharger
Flywheel housing
14
16
Table of Contents
Default Chapter
2
Exploded Views
2
How to Use this Manual
2
Tightening Torques
2
Table of Contents
3
General Information
9
1 Model Identification and Serial Number Location
10
Model Identification Location
10
Serial Number Location
11
2 Component Location
12
S3L/S3L2
12
Engine S3L-T/S3L2-T
13
S4L/S4L2
14
Engine S4L-T/S4L2-T
15
3 Specifications
16
Overhaul Instructions
17
4 Determining When to Overhaul the Engine
18
5 Compression Pressure Measurement
19
Inspection
19
Measurement
19
6 Troubleshooting
20
General
20
Engine Troubleshooting
21
Starting System Troubleshooting
27
7 Basic Precautions for Disassembly and Assembly
29
Disassembly
29
Assembly
29
Disassembly
31
8 Preparation for Disassembly
32
Engine Oil Draining
32
Coolant Draining
32
9 Electrical System
33
Starter
33
Alternator
35
10 Cooling System
38
Cooling Fan Removal
38
Thermostat Case Removal
38
Water Pump Assembly Removal
38
11 Fuel System
39
Fuel Injection Pipe Removal
39
Fuel Injection Nozzle Removal
39
Governor Assembly Removal
39
Governor Weight Removal
40
Fuel Injection Pump Removal
40
12 Lubrication System
41
Oil Filter Removal
41
Pressure Relief Valve Removal
41
Oil Pressure Switch Removal
41
13 Air Inlet System and Exhaust System
42
Exhaust Manifold Removal
42
Air Inlet Cover Removal
42
14 Cylinder Head and Valve Mechanism
43
Rocker Shaft Assembly Removal
44
Rocker Shaft Disassembly
44
Cylinder Head Bolt Removal
44
Cylinder Head Assembly Removal
45
Valve and Valve Spring Removal
45
Valve Stem Seal Removal
45
15 Timing Gears and Flywheel
46
Service Manual Mitsubishi SL-Series Diesel Engines ENGLISH
47
Flywheel Removal
47
Rear Plate Removal
47
Oil Seal Case Removal
48
Tappet Removal
48
Speedometer Driven Gear Removal
48
Crankshaft Pulley Removal
49
Timing Gear Case Removal
49
Timing Gear Backlash Measurement
49
Idler Gear Removal
50
Camshaft Removal
50
Fuel Injection Pump Camshaft Removal
50
Gear Removal (When Required)
51
Oil Pump Removal
51
Front Plate Removal
51
16 Cylinder Block, Crankshaft, Pistons and Oil Pan
52
Oil Pan Removal
53
Oil Screen Removal
53
Thrust Clearance Measurement for Connecting Rod Big End
53
Connecting Rod Cap Removal
54
Piston Removal
54
End Play Measurement for Crankshaft
54
Main Bearing Cap Removal
55
Crankshaft Removal
55
Piston Separation from Connecting Rod
55
Inspection
57
17 Cylinder Head and Valve Mechanism
58
Cylinder Head
59
Rocker Arms and Rocker Shaft
59
Valve Springs
60
Valve Push Rods
60
Valves, Valve Guides and Valve Seats
60
Combustion Jet Replacement
64
18 Timing Gears and Flywheel
66
Camshaft
67
Fuel Injection Pump Camshaft
68
Tappets
69
Idler Gear
69
Flywheel and Ring Gear
70
19 Cylinder Block, Crankshaft, Pistons and Oil Pan
71
Pistons, Piston Rings and Piston Pins
72
Connecting Rods
74
Crankshaft
75
Cylinder Block
79
Assembly
81
20 Cylinder Block, Crankshaft, Pistons and Oil Pan
82
Main Bearing Installation
83
Crankshaft Installation
83
Main Bearing Cap Installation
83
Side Seal Installation
85
Piston Assembling to Connecting Rod
85
Piston Ring Installation
87
Piston and Connecting Rod Installation
87
Connecting Rod Cap Installation
88
Oil Screen Installation
89
Oil Pan Installation
89
21 Timing Gears and Flywheel
91
Front Plate Installation
92
Oil Pump Installation
92
Engine Turning
92
Engine Turning
93
Camshaft Installation
93
Idler Gear Installation
94
Timing Gear Case Installation
94
Crankshaft Pulley Nut Tightening
94
Gear Installation
95
Speedometer Driven Gear Installation
95
Tappet Installation
95
Oil Seal Case Installation
96
Rear Plate Installation
96
Flywheel Installation
96
22 Cylinder Head and Valve Mechanism
98
Cylinder Head Bottom Face Cleaning
99
Valve Stem Seal Installation
99
Valve Spring Installation
99
Installing Valve Block
100
Cylinder Head Gasket Installation
100
Cylinder Head Installation
100
Cylinder Head Bolt Tightening
101
Valve Push Rod Installation
101
Rocker Shaft Assembling
101
Rocker Shaft Assembly Installation
102
Valve Clearance Adjustment
102
Rocker Cover Installation
102
23 Air Inlet System and Exhaust System
103
Air Inlet Cover Installation
103
Exhaust Manifold Installation
103
24 Fuel System
104
Fuel Injection Nozzle Installation
104
Fuel Injection Pump Installation
104
Flyweight Assembly Installation
104
Sliding Sleeve Installation
105
Governor Assembly Installation
105
Fuel Injection Line Installation
105
25 Lubrication System
106
Pressure Relief Valve Installation
106
Oil Filter Installation
106
Oil Pressure Switch Installation
106
26 Cooling System
107
Water Pump Installation
107
Thermostat Installation
107
Cooling Fan Installation
107
Thermoswitch and Thermounit Combination Installation
108
27 Electrical System
109
Glow Plug Installation
109
Alternator Installation
109
Electrical System General
112
Specifications (Standard)
112
Wiring Diagrams
113
29 Starter
115
Disassembly
115
Inspection
116
Assembly
119
Inspection and Testing after Assembly
120
30 Alternator
122
Disassembly
122
Inspection
124
Assembly
127
31 KEY SHUTOFF SYSTEM (ETS Solenoid Type)
128
General
128
Cord Color (Standard)
128
Shutoff Solenoid Installation
128
Inspection after Assembly
129
32 KEY SHUTOFF SYSTEM (ETR Solenoid Type)
130
General
130
Cord Color (Standard)
130
Shutoff Solenoid Installation
131
33 Automatic Glow System
132
General
132
Glow Timer Specification (Standard)
132
Glow Plug Relay Specifications (Standard)
133
Glow Plug Inspection
133
Cooling System
135
34 General
136
Schematic
136
Specifications (Standard)
136
35 Inspection
137
Water Pump
138
Thermostat (Standard)
138
Thermoswitch (Standard)
139
Thermounit (Standard)
139
Lubrication System
141
36 General
142
Schematic
142
Specifications
142
37 Inspection
143
Oil Pump
143
Oil Pressure Switch
143
Pressure Relief Valve
144
Fuel System
145
38 General
146
Schematic
146
Specifications (Standard)
147
39 Fuel Injection Nozzle
148
Inspection
148
Disassembly and Assembly
150
40 Fuel Injection Pump
151
Test on Engine
151
Disassembly
151
Disassembly Procedure
152
Inspection
155
Assembly
156
41 Governor
159
Disassembly and Inspection
159
Assembly
160
Torque Spring Set Installation
161
42 Fuel Pump
162
Inspection
162
43 Fuel Filter
163
Air Inlet System and Exhaust System 44 General
166
Schematic
166
45 Inspection
167
Inspection Procedure
167
Maintenance
169
46 Lubrication and Maintenance Chart
170
47 Engine Oil and Oil Filter
172
Engine Oil Specifications
172
Oil Level Check
172
Oil and Oil Filter Change
173
Oil Filter Change
173
48 Valve Clearance
175
49 Fuel Injection Timing
177
Preparation
177
Adjustment
179
50 Fuel Filter
180
Fuel Filter with [AIR] Valve
180
Cartridge (Air Vent Screw) Type Fuel Filter
180
51 Fuel System Priming
181
Engine with Fuel Filter with [AIR] Valve
181
Engine with Cartridge (Air Vent Screw) Type Fuel Filter
181
52 Idle Rpm Setting
182
53 Fuel Injection Nozzles
183
Injection Pressure (Valve Opening Pressure) Test
183
Orifice Restriction Test
183
Nozzle Tip Washing and Replacement
183
Installation
183
54 Fan Belt
184
Service Data
185
55 Specifications
186
Basic Engine Components
186
Service Data 55 Specifications
186
Lubrication System
188
Fuel System
188
Air Inlet System and Exhaust System
188
Cooling System (Standard)
189
Electrical System
189
56 Tightening Torques
191
Major Bolts and Nuts
191
Torques for Bolts and Nuts with Standard Threads
192
Torques for Plugs with Taperlock Threads
192
57 Sealants
193
58 Special Tools
194
4
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Mitsubishi S4L Specifications
General
Brand
Mitsubishi
Model
S4L
Category
Engine
Language
English
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