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Mitsubishi S4Q Service Manual

Mitsubishi S4Q
199 pages
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Table of Contents

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Mitsubishi S4Q Specifications

General IconGeneral
BrandMitsubishi
ModelS4Q
CategoryEngine
LanguageEnglish

Summary

Introduction to the Manual

Manual Purpose and Scope

Describes the specifications, maintenance, and adjustment procedures for the Mitsubishi Diesel Engine.

How to Use This Manual

Explains the manual's structure, conventions, and symbols for effective use.

Key Terms and Abbreviations

Defines terms, lists abbreviations, standards, and units of measurement used in the manual.

Safety Cautions

Danger of Fire and Explosion

Precautions to prevent fire and explosion hazards during operation and maintenance.

Danger of Entanglement

Risks associated with rotating parts and measures to avoid entanglement.

Danger of Burns

Warnings about hot surfaces and fluids, and precautions to avoid burns.

Exhaust Gas Poisoning Warning

Advises on operating in well-ventilated areas to prevent exhaust gas poisoning.

Hearing Problems Warning

Highlights risk of hearing damage from engine noise and need for ear protection.

Falling Equipment Warning

Safety measures for lifting and handling equipment to prevent falls.

Engine Oil and LLC Cautions

Guidance on safe handling and use of engine oil and LLC.

Battery Safety Precautions

Safety precautions for handling and working with the engine battery.

Response to Engine Abnormalities

Actions to take if the engine stops or exhibits abnormal behavior.

General Operational Cautions

General precautions including engine modification and break-in procedures.

General Information

Outline of Engine Components

Overview of engine components and systems via diagrams.

External Views

Diagrams of engine external components from various views.

Fuel System Overview

Components and layout of the fuel system.

Lubrication System Overview

Components and arrangement of the lubrication system.

Cooling System Overview

Diagram of the engine's cooling system components.

Inlet and Exhaust Systems Overview

Configuration of engine intake and exhaust manifolds.

Engine Identification Codes

Interpretation of engine serial numbers, models, and application codes.

Engine Specifications

Detailed technical specifications for S4Q and S4Q2 engine models.

Maintenance Standards

Maintenance Standards Table

Standard and limit values for various engine component inspections.

Tightening Torque Table

Specified torque values for critical bolts and nuts.

Sealants Table

Recommended sealants for specific application points.

Tools for Service

Basic Tools

Illustrates and lists common tools required for engine service.

Special Tools

Shows and describes specialized tools needed for specific engine repair procedures.

Overhaul Instructions

Determining Overhaul Need

Explains symptoms and conditions indicating an engine overhaul is necessary.

Measuring Compression Pressure

Details the procedure for measuring engine compression pressure.

Preparation for Disassembly

General Preparation Steps

General steps to prepare for engine disassembly.

Removing Electrical Wiring

Instructions for safely disconnecting and removing engine electrical wiring.

Draining Coolant System

Procedure for draining the engine's cooling system fluid.

Draining Engine Oil

Steps for draining the engine oil before disassembly.

Disassembly of Engine Main Parts

Cylinder Head and Valve Mechanisms

Details the disassembly of the cylinder head and its associated valve components.

Flywheel Removal and Inspection

Covers the removal and inspection procedures for the engine flywheel.

Timing Gears, Camshaft, and Oil Pan

Explains the disassembly of timing gears, camshaft, and oil pan.

Pistons, Connecting Rods, Crankshaft, and Crankcase

Outlines the disassembly of pistons, connecting rods, crankshaft, and crankcase.

Inspection and Repair of Engine Main Parts

Cylinder Head and Valve Mechanisms Service

Procedures for inspecting and repairing cylinder head and valve train components.

Flywheel Inspection and Repair

Details the inspection and repair of the flywheel, including the ring gear.

Timing Gears, Camshaft, and Oil Pan Service

Inspection and repair procedures for timing gears, camshaft, and oil pan.

Pistons, Connecting Rods, Crankshaft, and Crankcase Service

Inspection and repair of pistons, connecting rods, crankshaft, and crankcase.

Reassembly of Engine Main Parts

Pistons, Connecting Rods, Crankshaft, and Crankcase Reassembly

Steps for reassembling pistons, connecting rods, crankshaft, and crankcase.

Timing Gears, Camshaft, and Oil Pan Reassembly

Procedures for reassembling timing gears, camshaft, and oil pan.

Flywheel Reassembly

Instructions for the reassembly of the engine flywheel.

Cylinder Head and Valve Mechanisms Reassembly

Guides on reassembling the cylinder head and valve train components.

Fuel System Removal Procedures

Fuel Filter Removal

Details the removal process for the fuel filter.

Fuel Injection Pipe, Leak-Off Pipe, and Nozzle Removal

Instructions for removing fuel injection pipes, leak-off pipe, and nozzles.

Fuel Injection Pump Removal

Steps for removing the engine's fuel injection pump.

Fuel System Service Procedures

Fuel Filter Service

Procedures for disassembly, inspection, and reassembly of the fuel filter.

Fuel Injection Nozzle Service

Covers disassembly, inspection, and reassembly of fuel injection nozzles.

Fuel System Installation Procedures

Fuel Injection Pump Installation

Instructions for installing the fuel injection pump onto the engine.

Fuel Injection Pipe, Leak-Off Pipe, and Nozzle Installation

Guides for installing fuel lines and injection nozzles.

Fuel Filter Installation

Steps for installing the fuel filter system.

Lubrication System Removal Procedures

Oil Filter, Oil Cooler, and Relief Valve Removal

Details the removal of the oil filter, oil cooler, and relief valve.

Oil Pan, Oil Pump, and Oil Pressure Switch Removal

Instructions for removing the oil pan, oil pump, and oil pressure switch.

Lubrication System Service Procedures

Oil Pump Service

Procedures for oil pump disassembly, inspection, and reassembly.

Oil Filter, Oil Cooler, and Relief Valve Service

Inspection and adjustment of the oil filter, oil cooler, and relief valve.

Lubrication System Installation Procedures

Oil Pan, Oil Pump, and Oil Pressure Switch Installation

Steps for installing the oil pan, oil pump, and oil pressure switch.

Oil Filter, Oil Cooler, and Relief Valve Installation

Guides for installing the oil filter, oil cooler, and relief valve.

Cooling System Removal Procedures

Cooling Fan, Fan Pulley, and V-Belt Removal

Instructions for removing the cooling fan, pulley, and V-belt.

Thermostat Removal

Steps for removing the engine thermostat.

Water Pump Removal

Procedure for removing the engine water pump.

Cooling System Service Procedures

Water Pump Service

Covers disassembly, inspection, and reassembly of the water pump.

Thermostat Inspection and Testing

Inspection and testing procedures for the engine thermostat.

Thermo Switch Inspection

Details the inspection process for the thermo switch.

Cooling System Installation Procedures

Water Pump Installation

Steps for installing the engine water pump.

Thermostat Installation

Instructions for installing the engine thermostat.

Cooling Fan, Fan Pulley, and V-Belt Installation

Guides for installing the cooling fan, pulley, and V-belt.

Inlet and Exhaust Systems Removal Procedures

Inlet Manifold Removal

Procedures for removing the engine inlet manifold.

Exhaust Manifold Removal

Steps for removing the engine exhaust manifold.

Inlet and Exhaust Systems Service Procedures

Inlet and Exhaust Manifold Inspection

Inspection of inlet and exhaust manifolds for damage or distortion.

Inlet and Exhaust Systems Installation Procedures

Exhaust Manifold Installation

Instructions for installing the exhaust manifold.

Inlet Manifold Installation

Steps for installing the inlet manifold.

Electrical System Removal Procedures

Starter Motor Removal

Procedures for removing the engine starter motor.

Alternator Removal

Steps for removing the engine alternator.

Glow Plugs Removal

Instructions for removing the glow plugs.

Electrical System Service Procedures

Starter Motor Service

Disassembly, inspection, and reassembly of the starter motor.

Alternator Service

Inspection and repair procedures for the engine alternator.

Electrical System Installation Procedures

Glow Plugs Installation

Steps for installing the engine glow plugs.

Alternator Installation

Instructions for installing the engine alternator.

Starter Motor Installation

Guides for installing the engine starter motor.

Operation and Performance Tests

Engine Adjustment Procedures

Covers adjustment of valve clearance and fuel injection timing.

Fuel System Draining and Bleeding

Procedure for draining and bleeding the fuel system.

Fuel Injection Timing Inspection

Procedures for inspecting fuel injection timing.

Fuel Injection Timing Adjustment

Guidance on adjusting the engine's fuel injection timing.

V-belt Tension Inspection and Adjustment

How to inspect and adjust V-belt tension.

Governor Adjustment

Procedures for adjusting the engine governor settings.

Engine Break-In Operation

Details on the engine break-in procedure and schedule.

Engine Performance Tests

Methods for conducting engine performance tests.

Other Service Procedures

General Parts Disassembly and Reassembly

Instructions for disassembling and reassembling general engine components.

Oil Seal Installation and Handling

Procedures for installing and handling oil seals.

O-ring Installation and Handling

Guidance on installing and handling O-rings.

Bearing Installation Procedures

Proper methods for installing engine bearings.

Lock Plate Usage

Information on bending and using lock plates.

Split and Spring Pin Installation

Guidance on installing split pins and spring pins.

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