Mitsubishi S4L2

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Service Manual Mitsubishi SL-Series diesel engines

Version 08/2004

FUEL INJECTION PUMP

ENGLISH

FUEL SYSTEM

40.3 Inspection

Check delivery valve

for wear or damage

Check tappet for wear.

Check plunger for

wear, rusting or

scoring.

Check control rack

for movement.

Figure 228 Inspection points

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

Table of Contents

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