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Service Manual Mitsubishi SQ-Series diesel engines
V
ersion 08/2004
DISASSEMBLY, INSPECTION AND
REASSEMBLY
ENGLISH
INLET AND EXHAUST SYSTEM
INLET AND EXHAU
ST SYSTEM
12
DISASSEMBL
Y
,
INSPECTION AND
REASSEMBL
Y
1.
Air inlet elbow
2.
Gasket
3.
Inlet manifold
4.
Gasket
5.
Exhaust manif
old
6.
Gasket
Check for cracks
Replace
Check for cracks
Put gasket with
rounded side toward
exhaust manifold
when installing it
3
4
2
1
6
5
86
88
Table of Contents
Default Chapter
2
How to Use this Manual
2
Table of Contents
3
General
8
Engine Model and Application Codes
9
Engine Serial Number Location
9
1 Outline
8
External View
8
2 Specifications
10
General Instructions
11
3 Determination of Overhaul Timing
12
4 Testing the Compression Pressure
13
5 Tips on Disassembly and Reassembly
15
Disassembly
15
Reassembly
15
6 Precautions for Disassembly and Reassembly
16
Oil Seals
16
O-Rings
16
Bearings
17
Lock Plates
17
Split Pins and Spring Pins
17
Engine Main Parts
19
7 Cylinder Heads and Valve Mechanism
20
Disassembly
20
Removing Cylinder Head
21
Inspection
24
Reassembly
32
Valve Clearance Adjustment
36
8 Flywheel
38
Disassembly
38
Inspection
40
Reassembly
41
9 Timing Gears, Camshaft and Oil Pan
43
Disassembly
43
Inspection
48
Crankshaft Pulley
49
Reassembly
53
10 Pistons, Connecting Rods, Crankshaft and Crankcase
58
Disassembly
58
Inspection
64
Connecting Rods
68
Reassembly
76
Inlet and Exhaust System
85
11 Description
86
12 Disassembly, Inspection and Reassembly
87
Cooling System
89
Cooling System 13 Description
90
13 Description
90
14 Water Pump, Fan
91
Inspection
91
15 Thermostat
92
Inspection
92
Fuel System
93
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
Disassembly and Inspection
100
21 Fuel Injection Nozzles
101
Disassembly
101
Testing
102
Reassembly
104
Lubrication System
105
22 Description
106
23 Oil Pump
107
Disassembly
107
Inspection
107
Reassembly
108
24 Oil Filter
109
Inspection
109
25 Pressure Relief Valve
110
Inspection
110
Electrical System General
112
Wiring Diagrams
112
27 Starter
114
Inspection before Disassembly (Inspection of Assembly)
114
Removal
116
Disassembly
117
Inspection
118
Reassembly
121
Inspection and Testing after Reassembly
122
28 Alternator
124
On-Vehicle Inspection
124
Removal
126
Disassembly
127
Inspection
129
Assembly
132
Installation
132
29 ETR Type Stop Solenoid
134
General
134
Solenoid Specification
135
Inspection
136
Connecting Rod Adjustment
136
30 Glow Plugs
137
Removal
137
Inspection
137
Installation
137
Testing and Adjusting
139
31 Bench Test
140
Starting up
140
Inspection after Starting up
140
Bench Testing (Dynamometer) Conditions
141
Inspection and Adjustment after Bench Testing
141
32 Idling Speed and Maximum Speed Setting Inspection and Adjustment
142
33 Performance Test
144
Engine Equipment Condition
144
Tests and Their Purposes
144
Other Inspections
144
Adjustment Engine Output
144
Troubleshooting
149
ENGLISH Service Manual Mitsubishi SQ-Series Diesel Engines
156
34 Causes of Engine Problems and Remedies
149
Maintenance Standards
159
35 Maintenance Standards Table
160
36 Tightening Torques
166
Important Bolts and Nuts
166
Standard Bolts
167
Standard Studs
167
Standard Plugs
167
37 Thread Sealants
168
38 Maintenance Schedule
169
Special Tools
171
39 Special Tool List
172
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Mitsubishi S4Q2 Specifications
General
Brand
Mitsubishi
Model
S4Q2
Category
Engine
Language
English
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