Mitsubishi S4Q - Laying Crankcase on Its Side; Measurement of Connecting Rod End Play; Removal of Connecting Rod Caps

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Methods of Indication3
Abbreviations, Standards, Etc.4
Units of Measurement4
General Contents5
Safety Cautions6
General14
Outline15
External View for Power Unit15
Engine Left View15
Engine Right View15
External View for Power Unit (High Speed Specification)16
External View for Generator17
External View for Generator (High Speed Specification)18
Outline of Fuel System19
Outline of Lubrication System19
Outline of Cooling System20
Outline of Inlet and Exhaust Systems20
Engine Serial Number21
Engine Model and Application Code21
Specifications22
Maintenance Standards24
Maintenance Standards Table25
Tightening Torque Table31
Important Bolts and Nuts31
Standard Bolts and Nuts32
Standard Eyebolts32
Standard Union Nuts32
Taper Bolts32
Sealants Table33
Basic and Special Tools34
Basic Tools35
Special Tools36
Overhaul Instructions38
Determination of Overhaul Timing39
Measurement of Compression Pressure40
Preparation for Inspection40
Preparation for Disassembly41
Removing Electrical Wiring42
Draining Coolant42
Draining Engine Oil42
Disassembly of Engine Main Parts43
Cylinder Head and Valve Mechanisms44
Removal of Rocker Shaft Assembly45
Disassembly of Rocker Shaft Assembly45
Removal of Cylinder Head Bolts45
Removal of Valves and Valve Springs45
Removal of Valve Stem Seals46
Cleaning of Cylinder Head Bottom Surface46
Measurement of Piston Protrusions46
Flywheel47
Removal of Flywheel48
Removal of Oil Seal Case (Optional)48
Removal of Flywheel Housing48
Timing Gears, Camshaft and Oil Pan49
Removal of Crankshaft Pulley50
Removal of Timing Gear Case50
Measurement of Backlashes50
Measurement of Idler Gear End Play51
Removal of Idler Gear51
Camshaft End Play51
Reversal of Crankcase51
Removal of Oil Pan and Oil Pan Gasket52
Removal of Oil Pump52
Removal of Camshaft52
Removal of Front Plate52
Pistons, Connecting Rods, Crankshaft and Crankcase53
Laying Crankcase on Its Side54
Measurement of Connecting Rod End Play54
Removal of Connecting Rod Caps54
Preparation for Removal of Pistons55
Removal of Pistons55
Removal of Piston Ring55
Removal of Piston Pins55
Measurement of Crankshaft End Play56
Removal of Main Bearing Caps56
Removal of Crankshaft56
Arrangement of Bearings56
Inspection and Repair of Engine Main Parts57
Measurement of Distortion of Cylinder Head Bottom Surface58
Measurement of Rocker Arm Inside Diameter and Rocker Shaft Diameter58
Measurement of Valve Spring Perpendicularity and Free Length58
Measurement of Pushrod Deflection59
Measurement of Valve Stem Diameter59
Measurement of Clearance between Valve Stem and Valve Guide59
Replacement of Valve Guides60
Inspection of Valve Faces60
Replacement of Valve Seats61
Refacing Valve Faces62
Regrinding Valve Seats62
Lapping Valves against Valve Seats62
Replacement of Combustion Jets63
Measurement of Flywheel Flatness64
Replacement of Ring Gear64
Inspection of V-Belt Groove for Wear65
Inspection of Oil Seal Contact Surface65
Replacement of Idler Bushing65
Replacement of Idler Shaft66
Measurement of Cam Lift66
Measurement of Camshaft Journal Diameter and Journal Bore Diameter66
Measurement of Camshaft Deflection67
Removal of Camshaft Gear67
Installation of Camshaft Gear and Thrust Plate67
Measurement of Piston Outside Diameter68
Inspection of Pistons and Piston Rings68
Measurement of Piston Ring End Gap69
Measurement of Piston Pin Bore and Piston Pin69
Measurement of Clearance between Connecting Rod Bushing and Piston69
Replacement of Connecting Rod Bushing70
Inspection of Connecting Rods for Bend and Twist70
Inspection of Oil Clearance of Connecting Rod Bearing71
Inspection of Oil Clearance of Main Bearing72
Inspection of Oil Contact Surface73
Measurement of Crankshaft Deflection74
Removal of Crankshaft Gear74
Installation of Crankshaft Gear74
Measurement of Cylinder Bore75
Measurement of Distortion of Crankcase Upper Surface76
Inspection of Cam Contacting Surfaces of Tappets76
Measurement of Clearance between Tappet and Tappet Guide Bore76
Reassembly of Engine Main Parts77
Installation of Piston Rings80
Preparation for Piston Installation81
Installation of Connecting Rod Bolts and Bearings81
Installation of Pistons81
Installation of Connecting Rod Caps82
Positioning Crankcase Upright83
Installation of Front Plate84
Installation of Camshaft84
Installation of Oil Pump84
Installation of Oil Pan85
Installation of Idler Gear85
Inspection after Timing Gear Installation86
Installation of Oil Seal86
Installation of Timing Gear Case86
Installation of Crankshaft Pulley87
Installation of Flywheel Housing88
Installation of Oil Seal Case88
Installation of Flywheel88
Measurement of Flywheel Runout88
Installation of Valve Stem Seals89
Installation of Valves and Valve Springs89
Installation of Cylinder Head Gasket89
Installation of Cylinder Head90
Tightening of Cylinder Head Bolts90
Assembly of Rocker Arm and Rocker Shaft Assembly90
Installation of Rocker Shaft Assembly90
Adjustment of Valve Clearances91
Removal of Fuel System93
Fuel Filter94
Fuel Injection Pipe, Fuel Leak-Off Pipe and Fuel Injection Nozzle96
Fuel Injection Pump98
Removal of Fuel Injection Pump100
Disassembly, Inspection and Reassembly of Fuel System101
Disassembly and Inspection of Fuel Filter102
Reassembly of Fuel Filter104
Disassembly of Fuel Injection Nozzles106
Inspection of Fuel Injection Nozzles106
Reassembly of Fuel Injection Nozzles108
Installation of Fuel System109
Installation of Fuel Injection Pump112
Removal of Lubrication System117
Oil Filter, Oil Cooler and Relief Valve118
Oil Pan, Oil Pump and Oil Pressure Switch119
Disassembly, Inspection and Reassembly of Lubrication System120
Disassembly and Inspection of Oil Pump121
Measurement of Clearance between Outer Rotor and Inner Rotor121
Measurement of Rotor and Case End Play121
Measurement of Clearance between Outer Rotor and Pump Case122
Reassembly of Oil Pump122
Inspection of Oil Filter, Oil Cooler and Relief Valve123
Adjustment of Relief Valve123
Installation of Lubrication System124
Oil Filler, Oil Cooler and Relief Valve126
Removal of Cooling System127
Cooling Fan, Fan Pulley and V-Belt128
Thermostat129
Water Pump130
Disassembly, Inspection and Reassembly of Cooling System131
Disassembly of Water Pump132
Inspection of Water Pump132
Disassembly of Thermostat133
Inspection of Thermostat133
Inspection of Thermo Switch134
Installation of Cooling System135
Removal of Inlet and Exhaust Systems139
Inlet Manifold140
Exhaust Manifold141
Disassembly, Inspection and Reassembly of Inlet and Exhaust Systems142
Inlet Manifold and Exhaust Manifold143
Measurement of Exhaust Manifold Distortion143
Installation of Inlet and Exhaust Systems144
Removal of Electrical System147
Starter148
Alternator149
Glow Plugs150
Disassembly, Inspection and Reassembly of Electrical System151
Disassembly and Inspection of Starter152
Inspection of Starter153
Reassembly of Starter156
Inspection and Adjustment after Reassembly157
Disassembly of Alternator160
Inspection and Repair of Alternator162
Reassembly of Alternator164
Inspection of Glow Plugs165
Installation of Electrical System166
Inspection, Adjustment, Break-In Operation and Performance Tests170
Adjustment of Engine171
Draining of Fuel System172
Bleeding of Fuel System172
Inspection of Fuel Injection Timing (Distributor-Type Fuel Injection Pump Specification)174
Inspection of Fuel Injection Timing (In-Line Fuel Injection Pump Specification)175
Adjustment of Fuel Injection Timing176
Inspection and Adjustment of V-Belt Tension176
Adjustment of Governor177
Break-In Operation182
Starting up182
Break-In Period182
Disassembly and Reassembly of General Parts185
Oil Seals185
O-Rings185
Bearings186
Lock Plates186
Split Pins and Spring Pins186

Mitsubishi S4Q - Laying Crankcase on Its Side; Measurement of Connecting Rod End Play; Removal of Connecting Rod Caps

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