MITSUBISHI ENGINE SL S3L S3L2 S4L S4L2 WORKSHOP MANUAL

MITSUBISHI ENGINE SL S3L S3L2 S4L S4L2 WORKSHOP MANUAL Mitsubishi Diesel Engine Workshop Repair / Repair Manual S3L S3L2 S3L-T S3L2-T S4L S4L2 S4L-T S4L2-T Manual in PDF format This Repair manual has instructions also procedures for the Mitsubishi SL-series diesel engines turbo also none turbo. Correct servicing, test also Repair procedures will give the engine a long Repair life. Before starting a test, Repair or rebuild job, the Repairman must read the respective sections of this manual to know all the component he will work on. Covers all you need to know in the Repair also Repair of your engine - on CD pdf format, all fully bookmarked. GENERAL INFORMATION 1 MODEL IDENTIFICATION also 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 also 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 also EXHAUST SYSTEM. 42 13.1 Exhaust manifold removal 42 13.2 Air inlet cover removal . 42 14 CYLINDER HEAD also 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 also valve spring removal . 45 14.6 Valve stem seal removal 45 15 Timing Gears also Flywheel. 46 15.1 Flywheel removal . 47 15.2 Rear plate removal. 47 15.3 Oil seal case removal. 48 15.4 Tappet removal 48 15.5 Speedometer driven gear removal. 48 15.6 Crankshaft pulley removal . 49 15.7 Timing gear case removal 49 15.8 Timing gear backlash measurement 49 15.9 Idler gear removal 50 15.10Camshaft removal 50 15.11Fuel injection pump camshaft removal 50 15.12Gear removal (when required) .51 15.13Oil pump removal . 51 15.14Front plate removal 51 16 Cylinder Block, Crankshaft, Pistons also Oil Pan 52 16.1 Oil pan removal 53 16.2 Oil screen removal . 53 16.3 Thrust clearance measurement for connecting rod big end. 53 16.4 Connecting rod cap removal 54 16.5 Piston removal . 54 16.6 End play measurement for crankshaft . 54 16.7 Main bearing cap removal 55 16.8 Crankshaft removal 55 16.9 Piston separation from connecting rod 55 INSPECTION 17 CYLINDER HEAD also VALVE MECHANISM. 58 17.1 Cylinder head. 59 17.2 Rocker arms also rocker shaft 59 17.3 Valve springs . 60 17.4 Valve push rods . 60 17.5 Valves, valve guides also valve seats 60 17.6 Combustion jet replacement 64 18 TIMING GEARS also FLYWHEEL . 66 18.1 Camshaft 67 18.2 Fuel injection pump camshaft 68 18.3 Tappets 69 18.4 Idler gear 69 18.5 Flywheel also ring gear. 70 19 CYLINDER BLOCK, CRANKSHAFT, PISTONS also OIL PAN. 71 19.1 Pistons, Piston Rings also Piston Pins . 72 19.2 Connecting rods. 74 19.3 Crankshaft 75 19.4 Cylinder block 79 ASSEMBLY 20 Cylinder Block, Crankshaft, Pistons also Oil pan. 82 20.1 Main bearing installation 83 20.2 Crankshaft installation 83 20.3 Main bearing cap installation . 83 20.4 Side seal installation 85 20.5 Piston assembling to connecting rod . 85 20.6 Piston ring installation 87 20.7 Piston also connecting rod installation . 87 20.8 Connecting rod cap installation 88 20.9 Oil screen installation. 89 20.10Oil pan installation 89 21 Timing Gears also Flywheel. 91 21.1 Front plate installation 92 21.2 Oil pump installation. 92 21.3 Engine turning 92 21.4 Engine turning 93 21.5 Camshaft installation 93 21.6 Idler gear installation 94 21.7 Timing gear case installation . 94 21.8 Crankshaft pulley nut tightening. 94 21.9 P.T.O. gear installation 95 21.10Speedometer driven gear installation 95 21.11Tappet installation 95 21.12Oil seal case installation 96 21.13Rear plate installation 96 21.14Flywheel installation. 96 22 CYLINDER HEAD also VALVE MECHANISM. 98 22.1 Cylinder head bottom face cleaning. 99 22.2 Valve stem seal installation 99 22.3 Valve spring installation . 99 22.4 Installing valve block 100 22.5 Cylinder head gasket installation . 100 22.6 Cylinder head installation. 100 22.7 Cylinder head bolt tightening . 101 22.8 Valve push rod installation . 101 22.9 Rocker shaft assembling 101 22.10Rocker shaft assembly installation. 102 22.11Valve clearance adjustment . 102 22.12Rocker cover installation 102 23 Air Inlet System also Exhaust System. 103 23.1 Air inlet cover installation . 103 23.2 Exhaust manifold installation . 103 24 Fuel System 104 24.1 Fuel injection nozzle installation 104 24.2 Fuel injection pump installation 104 24.3 Flyweight assembly installation 104 24.4 Sliding sleeve installation. 105 24.5 Governor assembly installation 105 24.6 Fuel injection line installation . 105 25 Lubrication system 106 25.1 Pressure relief valve installation 106 25.2 Oil filter installation. 106 25.3 Oil pressure switch installation. 106 26 Cooling system 107 26.1 Water pump installation . 107 26.2 Thermostat installation. 107 26.3 Cooling fan installation. 107 26.4 Thermoswitch also thermounit combination installation . 108 27 Electrical System. 109 27.1 Glow plug installation . 109 27.2 Alternator installation . 109 ELECTRICAL SYSTEM 28 GENERAL . 112 28.1 Specifications (standard) . 112 28.2 Wiring diagrams . 113 29 STARTER 115 29.1 Disassembly. 115 29.2 Inspection. 116 29.3 Assembly . 119 29.4 Inspection also Testing after Assembly 120 30 ALTERNATOR 122 30.1 Disassembly. 122 30.2 Inspection. 124 30.3 Assembly . 127 31 KEY SHUTOFF SYSTEM (ETS solenoid type). 128 31.1 General 128 31.2 Cord color (standard) . 128 31.3 Shutoff solenoid installation . 128 31.4 Inspection after assembly 129 32 KEY SHUTOFF SYSTEM (ETR solenoid type). 130 32.1 General 130 32.2 Cord color (standard) . 130 32.3 Shutoff solenoid installation . 131 33 AUTOMATIC GLOW SYSTEM 132 33.1 General 132 33.2 Glow timer specification (standard) 132 33.3 Glow plug relay specifications (standard) 133 33.4 Glow plug inspection 133 COOLING SYSTEM 34 GENERAL . 136 34.1 Schematic 136 34.2 Specifications (standard) . 136 35 INSPECTION 137 35.1 Water pump . 138 35.2 Thermostat (standard) . 138 35.3 Thermoswitch (standard) . 139 35.4 Thermounit (standard) . 139 LUBRICATION SYSTEM 36 GENERAL . 142 36.1 Schematic 142 36.2 Specifications. 142 37 INSPECTION 143 37.1 Oil pump. 143 37.2 Oil pressure switch. 143 37.3 Pressure relief valve 144 FUEL SYSTEM 38 GENERAL . 146 38.1 Schematic 146 38.2 Specifications (standard) . 147 39 FUEL INJECTION NOZZLE 148 39.1 Inspection. 148 39.2 Disassembly also assembly . 150 40 FUEL INJECTION PUMP 151 40.1 Test on engine . 151 40.2 Disassembly. 151 40.3 Inspection. 155 40.4 Assembly . 156 41 GOVERNOR . 159 41.1 Disassembly also inspection 159 41.2 Assembly . 160 41.3 Torque spring set installation . 161 42 FUEL PUMP 162 42.1 Inspection. 162 43 FUEL FILTER 163 AIR INLET SYSTEM also EXHAUST SYSTEM 44 GENERAL . 166 44.1 Schematic 166 45 INSPECTION 167 45.1 Inspection procedure . 167 MAINTENANCE 46 LUBRICATION also MAINTENANCE CHART. 170 47 ENGINE OIL also OIL FILTER. 172 47.1 Engine oil specifications. 172 47.2 Oil level check 172 47.3 Oil also oil filter change 173 47.4 Oil filter change 173 48 VALVE CLEARANCE 175 49 FUEL INJECTION TIMING 177 49.1 Preparation 177 49.2 Adjustment . 179 50 FUEL FILTER 180 50.1 Fuel filter alongside [AIR] valve 180 50.2 Cartridge (air vent screw) type fuel filter 180 51 FUEL SYSTEM PRIMING. 181 51.1 Engine alongside fuel filter alongside [AIR] valve 181 51.2 Engine alongside cartridge (air vent screw) type fuel filter . 181 52 IDLE RPM SETTING. 182 53 FUEL INJECTION NOZZLES 183 53.1 Injection pressure (valve opening pressure) test . 183 53.2 Orifice restriction test . 183 53.3 Nozzle tip washing also replacement . 183 53.4 Installation 183 54 FAN BELT . 184 Repair DATA 55 SPECIFICATIONS 186 55.1 Basic engine components 186 55.2 Lubrication system. 188 55.3 Fuel system 188 55.4 Air inlet system also exhaust system 188 55.5 Cooling system (standard) . 189 55.6 Electrical system 189 56 TIGHTENING TORQUES . 191 56.1 Major bolts also nuts. 191 56.2 Torques for bolts also nuts alongside standard threads 192 56.3 Torques for plugs alongside taperlock threads . 192 57 SEALANTS 193 58 SPECIAL TOOLS 194 Covers all you need to know in the Repair also Repair of your engine MITSUBISHI ENGINE SL S3L S3L2 S4L S4L2 WORKSHOP MANUAL Thanks for using our manual download service. Despite compression the files can be very large. Please check you have enough storage space (can be up to 1 Gig) and you have a solid Internet connection. Sizes are mentioned on the page. Mitsubishi Diesel Engine S3L S3L2 S3L-T S3L2-T S4L S4L2 S4L-T S4L2-T Manual in PDF format This service manual has instructions and procedures for the Mitsubishi SL-series diesel engines turbo and none turbo. Correct servicing, test and repair procedures will give the engine a long service life. Before starting a test, repair or rebuild job, the serviceman must read the respective sections of this manual to know all the component he will work on. Covers all you need to know in the service and repair of your engine - on CD pdf format, all fully bookmarked. 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 15.1 Flywheel removal . 47 15.2 Rear plate removal. 47 15.3 Oil seal case removal. 48 15.4 Tappet removal 48 15.5 Speedometer driven gear removal. 48 15.6 Crankshaft pulley removal . 49 15.7 Timing gear case removal 49 15.8 Timing gear backlash measurement 49 15.9 Idler gear removal 50 15.10Camshaft removal 50 15.11Fuel injection pump camshaft removal 50 15.12Gear removal (when required) .51 15.13Oil pump removal . 51 15.14Front plate removal 51 16 Cylinder Block, Crankshaft, Pistons and Oil Pan 52 16.1 Oil pan removal 53 16.2 Oil screen removal . 53 16.3 Thrust clearance measurement for connecting rod big end. 53 16.4 Connecting rod cap removal 54 16.5 Piston removal . 54 16.6 End play measurement for crankshaft . 54 16.7 Main bearing cap removal 55 16.8 Crankshaft removal 55 16.9 Piston separation from connecting rod 55 INSPECTION 17 CYLINDER HEAD AND VALVE MECHANISM. 58 17.1 Cylinder head. 59 17.2 Rocker arms and rocker shaft 59 17.3 Valve springs . 60 17.4 Valve push rods . 60 17.5 Valves, valve guides and valve seats 60 17.6 Combustion jet replacement 64 18 TIMING GEARS AND FLYWHEEL . 66 18.1 Camshaft 67 18.2 Fuel injection pump camshaft 68 18.3 Tappets 69 18.4 Idler gear 69 18.5 Flywheel and ring gear. 70 19 CYLINDER BLOCK, CRANKSHAFT, PISTONS AND OIL PAN. 71 19.1 Pistons, Piston Rings and Piston Pins . 72 19.2 Connecting rods. 74 19.3 Crankshaft 75 19.4 Cylinder block 79 ASSEMBLY 20 Cylinder Block, Crankshaft, Pistons and Oil pan. 82 20.1 Main bearing installation 83 20.2 Crankshaft installation 83 20.3 Main bearing cap installation . 83 20.4 Side seal installation 85 20.5 Piston assembling to connecting rod . 85 20.6 Piston ring installation 87 20.7 Piston and connecting rod installation . 87 20.8 Connecting rod cap installation 88 20.9 Oil screen installation. 89 20.10Oil pan installation 89 21 Timing Gears and Flywheel. 91 21.1 Front plate installation 92 21.2 Oil pump installation. 92 21.3 Engine turning 92 21.4 Engine turning 93 21.5 Camshaft installation 93 21.6 Idler gear installation 94 21.7 Timing gear case installation . 94 21.8 Crankshaft pulley nut tightening. 94 21.9 P.T.O. gear installation 95 21.10Speedometer driven gear installation 95 21.11Tappet installation 95 21.12Oil seal case installation 96 21.13Rear plate installation 96 21.14Flywheel installation. 96 22 CYLINDER HEAD AND VALVE MECHANISM. 98 22.1 Cylinder head bottom face cleaning. 99 22.2 Valve stem seal installation 99 22.3 Valve spring installation . 99 22.4 Installing valve block 100 22.5 Cylinder head gasket installation . 100 22.6 Cylinder head installation. 100 22.7 Cylinder head bolt tightening . 101 22.8 Valve push rod installation . 101 22.9 Rocker shaft assembling 101 22.10Rocker shaft assembly installation. 102 22.11Valve clearance adjustment . 102 22.12Rocker cover installation 102 23 Air Inlet System and Exhaust System. 103 23.1 Air inlet cover installation . 103 23.2 Exhaust manifold installation . 103 24 Fuel System 104 24.1 Fuel injection nozzle installation 104 24.2 Fuel injection pump installation 104 24.3 Flyweight assembly installation 104 24.4 Sliding sleeve installation. 105 24.5 Governor assembly installation 105 24.6 Fuel injection line installation . 105 25 Lubrication system 106 25.1 Pressure relief valve installation 106 25.2 Oil filter installation. 106 25.3 Oil pressure switch installation. 106 26 Cooling system 107 26.1 Water pump installation . 107 26.2 Thermostat installation. 107 26.3 Cooling fan installation. 107 26.4 Thermoswitch and thermounit combination installation . 108 27 Electrical System. 109 27.1 Glow plug installation . 109 27.2 Alternator installation . 109 ELECTRICAL SYSTEM 28 GENERAL . 112 28.1 Specifications (standard) . 112 28.2 Wiring diagrams . 113 29 STARTER 115 29.1 Disassembly. 115 29.2 Inspection. 116 29.3 Assembly . 119 29.4 Inspection and Testing after Assembly 120 30 ALTERNATOR 122 30.1 Disassembly. 122 30.2 Inspection. 124 30.3 Assembly . 127 31 KEY SHUTOFF SYSTEM (ETS solenoid type). 128 31.1 General 128 31.2 Cord color (standard) . 128 31.3 Shutoff solenoid installation . 128 31.4 Inspection after assembly 129 32 KEY SHUTOFF SYSTEM (ETR solenoid type). 130 32.1 General 130 32.2 Cord color (standard) . 130 32.3 Shutoff solenoid installation . 131 33 AUTOMATIC GLOW SYSTEM 132 33.1 General 132 33.2 Glow timer specification (standard) 132 33.3 Glow plug relay specifications (standard) 133 33.4 Glow plug inspection 133 COOLING SYSTEM 34 GENERAL . 136 34.1 Schematic 136 34.2 Specifications (standard) . 136 35 INSPECTION 137 35.1 Water pump . 138 35.2 Thermostat (standard) . 138 35.3 Thermoswitch (standard) . 139 35.4 Thermounit (standard) . 139 LUBRICATION SYSTEM 36 GENERAL . 142 36.1 Schematic 142 36.2 Specifications. 142 37 INSPECTION 143 37.1 Oil pump. 143 37.2 Oil pressure switch. 143 37.3 Pressure relief valve 144 FUEL SYSTEM 38 GENERAL . 146 38.1 Schematic 146 38.2 Specifications (standard) . 147 39 FUEL INJECTION NOZZLE 148 39.1 Inspection. 148 39.2 Disassembly and assembly . 150 40 FUEL INJECTION PUMP 151 40.1 Test on engine . 151 40.2 Disassembly. 151 40.3 Inspection. 155 40.4 Assembly . 156 41 GOVERNOR . 159 41.1 Disassembly and inspection 159 41.2 Assembly . 160 41.3 Torque spring set installation . 161 42 FUEL PUMP 162 42.1 Inspection. 162 43 FUEL FILTER 163 AIR INLET SYSTEM AND EXHAUST SYSTEM 44 GENERAL . 166 44.1 Schematic 166 45 INSPECTION 167 45.1 Inspection procedure . 167 MAINTENANCE 46 LUBRICATION AND MAINTENANCE CHART. 170 47 ENGINE OIL AND OIL FILTER. 172 47.1 Engine oil specifications. 172 47.2 Oil level check 172 47.3 Oil and oil filter change 173 47.4 Oil filter change 173 48 VALVE CLEARANCE 175 49 FUEL INJECTION TIMING 177 49.1 Preparation 177 49.2 Adjustment . 179 50 FUEL FILTER 180 50.1 Fuel filter with [AIR] valve 180 50.2 Cartridge (air vent screw) type fuel filter 180 51 FUEL SYSTEM PRIMING. 181 51.1 Engine with fuel filter with [AIR] valve 181 51.2 Engine with cartridge (air vent screw) type fuel filter . 181 52 IDLE RPM SETTING. 182 53 FUEL INJECTION NOZZLES 183 53.1 Injection pressure (valve opening pressure) test . 183 53.2 Orifice restriction test . 183 53.3 Nozzle tip washing and replacement . 183 53.4 Installation 183 54 FAN BELT . 184 SERVICE DATA 55 SPECIFICATIONS 186 55.1 Basic engine components 186 55.2 Lubrication system. 188 55.3 Fuel system 188 55.4 Air inlet system and exhaust system 188 55.5 Cooling system (standard) . 189 55.6 Electrical system 189 56 TIGHTENING TORQUES . 191 56.1 Major bolts and nuts. 191 56.2 Torques for bolts and nuts with standard threads 192 56.3 Torques for plugs with taperlock threads . 192 57 SEALANTS 193 58 SPECIAL TOOLS 194 MITSUBISHI ENGINE SL S3L S3L2 S4L S4L2 WORKSHOP MANUAL P.S. 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