Mitsubishi S4Q

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Service Manual Mitsubishi SQ-Series diesel engines
Version 08/2004
TABLE OF CONTENTS
ENGLISH
TABLE OF CONTENTS
GENERAL
1 OUTLINE........................................................................................................................................... 8
1.1 External View ........................................................................................................................... 8
1.2 Engine Serial Number Location ............................................................................................... 9
1.3 Engine Model and Application Codes ...................................................................................... 9
2 SPECIFICATIONS .......................................................................................................................... 10
GENERAL INSTRUCTIONS
3 DETERMINATION OF OVERHAUL TIMING .................................................................................. 12
4 TESTING THE COMPRESSION PRESSURE................................................................................ 13
5 TIPS ON DISASSEMBLY AND REASSEMBLY.............................................................................. 15
5.1 Disassembly........................................................................................................................... 15
5.2 Reassembly ........................................................................................................................... 15
6 PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY ......................................................... 16
6.1 Oil Seals................................................................................................................................. 16
6.2 O-rings ................................................................................................................................... 16
6.3 Bearings................................................................................................................................. 17
6.4 Lock Plates ............................................................................................................................ 17
6.5 Split Pins and Spring Pins...................................................................................................... 17
ENGINE MAIN PARTS
7 CYLINDER HEADS AND VALVE MECHANISM............................................................................. 20
7.1 Disassembly........................................................................................................................... 20
7.2 Inspection............................................................................................................................... 24
7.3 Reassembly ........................................................................................................................... 32
7.4 Valve Clearance Adjustment.................................................................................................. 36
8 FLYWHEEL..................................................................................................................................... 38
8.1 Disassembly........................................................................................................................... 38
8.2 Inspection............................................................................................................................... 40
8.3 Reassembly ........................................................................................................................... 41
9 TIMING GEARS, CAMSHAFT AND OIL PAN................................................................................. 43
9.1 Disassembly........................................................................................................................... 43
9.2 Inspection............................................................................................................................... 48
9.3 Reassembly ........................................................................................................................... 53
10 PISTONS, CONNECTING RODS, CRANKSHAFT AND CRANKCASE......................................... 58
10.1 Disassembly........................................................................................................................... 58
10.2 Inspection............................................................................................................................... 64
10.3 Reassembly ........................................................................................................................... 76
INLET AND EXHAUST SYSTEM
11 DESCRIPTION................................................................................................................................ 86
12 DISASSEMBLY, INSPECTION AND REASSEMBLY ..................................................................... 87
COOLING SYSTEM
13 DESCRIPTION................................................................................................................................ 90
14 WATER PUMP, FAN....................................................................................................................... 91
14.1 Inspection............................................................................................................................... 91
15 THERMOSTAT................................................................................................................................ 92
15.1 Inspection............................................................................................................................... 92
FUEL SYSTEM
16 DESCRIPTION................................................................................................................................ 94
17 FUEL SYSTEM BLEEDING ............................................................................................................ 95
18 DISASSEMBLY ............................................................................................................................... 96
19 FUEL INJECTION TIMING CHECK ................................................................................................ 98
20 FUEL FILTER (PAPER-ELEMENT CARTRIDGE TYPE) ............................................................. 100