Mitsubishi S4L2

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Service Manual Mitsubishi SL-Series diesel engines
Version 08/2004
TABLE OF CONTENTS
ENGLISH
TABLE OF CONTENTS
GENERAL INFORMATION
1 MODEL IDENTIFICATION AND SERIAL NUMBER LOCATION.................................................... 10
1.1 Model identification location................................................................................................... 10
1.2 Serial Number Location ......................................................................................................... 11
2 COMPONENT LOCATION.............................................................................................................. 12
2.1 S3L/S3L2 ............................................................................................................................... 12
2.2 Engine S3L-T/S3L2-T ............................................................................................................ 13
2.3 S4L/S4L2 ............................................................................................................................... 14
2.4 Engine S4L-T/S4L2-T ............................................................................................................ 15
3 SPECIFICATIONS .......................................................................................................................... 16
OVERHAUL INSTRUCTIONS
4 DETERMINING WHEN TO OVERHAUL THE ENGINE ................................................................. 18
5 COMPRESSION PRESSURE MEASUREMENT............................................................................ 19
5.1 Inspection............................................................................................................................... 19
5.2 Measurement ......................................................................................................................... 19
6 TROUBLESHOOTING .................................................................................................................... 20
6.1 General .................................................................................................................................. 20
6.2 Engine troubleshooting .......................................................................................................... 21
6.3 Starting system troubleshooting............................................................................................. 27
7 BASIC PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY................................................... 29
7.1 Disassembly........................................................................................................................... 29
7.2 Assembly ............................................................................................................................... 29
DISASSEMBLY
8 PREPARATION FOR DISASSEMBLY............................................................................................ 32
8.1 Engine oil draining ................................................................................................................. 32
8.2 Coolant draining
1
.................................................................................................................. 32
9 ELECTRICAL SYSTEM .................................................................................................................. 33
9.1 Starter .................................................................................................................................... 33
9.2 Alternator ............................................................................................................................... 35
10 Cooling System ............................................................................................................................... 38
10.1 Cooling fan removal ............................................................................................................... 38
10.2 Thermostat case removal ...................................................................................................... 38
10.3 Water pump assembly removal ............................................................................................. 38
11 Fuel System .................................................................................................................................... 39
11.1 Fuel injection pipe removal .................................................................................................... 39
11.2 Fuel injection nozzle removal................................................................................................. 39
11.3 Governor assembly removal .................................................................................................. 39
11.4 Governor weight removal....................................................................................................... 40
11.5 Fuel injection pump removal .................................................................................................. 40
12 Lubrication System.......................................................................................................................... 41
12.1 Oil filter removal ..................................................................................................................... 41
12.2 Pressure relief valve removal................................................................................................. 41
12.3 Oil pressure switch removal................................................................................................... 41
13 AIR INLET SYSTEM AND EXHAUST SYSTEM ............................................................................. 42
13.1 Exhaust manifold removal...................................................................................................... 42
13.2 Air inlet cover removal ........................................................................................................... 42
14 CYLINDER HEAD AND VALVE MECHANISM ............................................................................... 43
14.1 Rocker shaft assembly removal............................................................................................. 44
14.2 Rocker shaft disassembly ...................................................................................................... 44
14.3 Cylinder head bolt removal .................................................................................................... 44
14.4 Cylinder head assembly removal........................................................................................... 45
14.5 Valve and valve spring removal ............................................................................................. 45
14.6 Valve stem seal removal........................................................................................................ 45
15 Timing Gears and Flywheel............................................................................................................. 46