Mitsubishi S4L2

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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 S4L2 Specifications

General

Compression Ratio	22:1
Aspiration	Naturally Aspirated
Fuel System	Direct injection
Engine Model	S4L2
Starting System	Electric Starter
Cooling System	Water-cooled
Engine Type	4-stroke, water-cooled, diesel engine
Lubrication System	Forced lubrication

Summary

Overhaul Instructions

Determining Engine Overhaul Need

Outlines symptoms like low compression and oil consumption to determine overhaul requirements.

Compression Pressure Measurement

Compression Pressure Measurement Procedure

Details the step-by-step process for measuring engine compression pressure using a gauge.

Troubleshooting Engine Issues

General Troubleshooting Approach

Discusses diagnosing diesel engine troubles and identifying key operational characteristics.

Engine Troubleshooting Guide

Provides diagnostic steps for common engine problems like hard starting and fuel knock.

Starting System Troubleshooting

Offers a flowchart for diagnosing issues within the engine's starting system.

Basic Precautions for Disassembly and Assembly

Disassembly Precautions

Lists critical safety and procedural guidelines for disassembling engine components.

Assembly Precautions

Provides key practices for correctly reassembling engine parts.

Disassembly Procedures

Preparation for Disassembly

Details initial steps for engine disassembly, including draining fluids.

Electrical System Service

Starter Motor Service

Covers testing and removal procedures for the engine starter motor.

Alternator Service

Details inspection, testing, and removal processes for the engine's alternator.

Cooling System Service

Fuel System Service

Fuel Injection Pipe Removal

Details the process of disconnecting and removing fuel injection pipes.

Fuel Injection Nozzle Inspection

Fuel Injection Pump Removal

Explains how to remove the fuel injection pump, including tie rod disconnection.

Fuel Injection Pump Disassembly

Fuel Injection Pump Assembly

Lubrication System Service

Oil Filter Removal

Details the procedure for removing the engine oil filter.

Air Inlet and Exhaust System Service

Exhaust Manifold Removal

Explains how to remove the exhaust manifold from the cylinder head.

Cylinder Head and Valve Mechanism Service

Rocker Shaft Assembly Removal

Details the steps for removing the rocker shaft assembly and valve caps.

Cylinder Head Assembly Removal

Guides on lifting and removing the cylinder head assembly.

Timing Gears and Flywheel Service

Flywheel Removal

Details the procedure for removing the flywheel, including safety warnings.

Timing Gear Case Removal

Details the procedure for removing the timing gear case.

Cylinder Block, Crankshaft, Pistons, and Oil Pan Service

Oil Pan Removal

Explains how to remove the oil pan, including a caution about prying.

Piston Removal

Explains how to remove pistons and connecting rods from the cylinder.

Crankshaft Removal

Explains how to remove the crankshaft, with a caution about bearing damage.

Component Inspection

Cylinder Head and Valve Mechanism Inspection

Introduces the inspection of cylinder head and valve train components.

Cylinder Head Inspection Details

Details the inspection of the cylinder head's bottom face for warpage.

Timing Gears and Flywheel Inspection

Introduces the inspection of timing gears and flywheel components.

Camshaft Inspection

Cylinder Block, Crankshaft, Pistons, and Oil Pan Inspection

Pistons, Piston Rings, and Piston Pins Inspection

Connecting Rods Inspection

Crankshaft Inspection Details

Assembly Procedures

Cylinder Block, Crankshaft, Pistons, and Oil Pan Assembly

Main Bearing Installation

Piston Assembling to Connecting Rod

Piston and Connecting Rod Installation

Timing Gears and Flywheel Assembly

Front Plate Installation

Camshaft Installation

Cylinder Head Gasket Installation

Fuel Injection Nozzle Installation

Alternator Installation

Electrical System Service

Electrical System Wiring Diagrams

Starter Motor Service

Starter Disassembly

Starter Armature Inspection

Starter Inspection and Testing After Assembly

Alternator Service

Alternator Disassembly

Alternator Inspection

Key Shutoff System (ETS Solenoid Type)

Key Shutoff System (ETR Solenoid Type)

Shutoff Solenoid Installation

Automatic Glow System

Glow Plug Inspection

Cooling System Inspection

Water Pump Inspection

Thermoswitch Inspection

Lubrication System Inspection

Oil Pump Inspection

Pressure Relief Valve Inspection

Governor Service

Disassembly and Inspection

Torque Spring Set Installation

Fuel Pump Inspection

Fuel Pump Inspection

Fuel Filter Maintenance

Fuel Filter with [AIR] Valve Maintenance

Air Inlet and Exhaust System Inspection

Manifold Inspection Procedure

Maintenance Schedule

Lubrication and Maintenance Chart

Engine Oil and Filter Maintenance

Valve Clearance Adjustment

Fuel Injection Timing Procedures

Idle RPM Setting

Fan Belt Adjustment