Factory Service Manual For Mitsubishi S3L S3L2 S4L S4L2 Engine. Tons of illustrations, instructions, diagrams for step by step remove and install, assembly and disassembly, service, inspection, repair, troubleshooting, tune-ups.
Format: PDF
Language: English
Pages: 219
Model
Mitsubishi S3L, S3L2, S4L, S4L2
Contents
-SAFETY CAUTIONS
-GENERAL
Service Standards Table
–Tightening Torques Table
Major Bolts and Nuts
Standard Bolts and Nuts
Standard Eyebolts
Standard Union Nuts
Taper Bolts
Sealants List
-SERVICE STANDARTS
Service Standards Table
–Tightening Torques Table
Major Bolts and Nuts
Standard Bolts and Nuts
Standard Eyebolts
Standard Union Nuts
Taper Bolts
Sealants List
-TOOLS LIST
General Tools
Special Tools
-OVERHAUL TIMING
Identifying the Timing for Overhaul
Measuring the Compression Pressure
-REMOVAL PREPARATIONS
Preparations
Removing The Electric Wiring
Draining The Coolant
Draining The Engine Oil
-ENGINE MAIN PARTS – DISASSEMBLY
–Cylinder Head, Valve Mechanism
Removing The Rocker Shaft Assembly
Disassembling The Rocker Shaft Assembly
Removing The Cylinder Head Bolts
Removing The Cylinder Head Assembly
Removing The Valves And Valve Springs
Removing The Valve Stem Seals
–Flywheel, Timing Gear, Camshaft
Removing The Flywheel
Removing The Flywheel Housing
Removing The Rear Plate
Removing The Oil Seal Case
Removing The Tappets
Removing The Crankshaft Pulley
Removing The Timing Gear Case
Measuring The Timing Gear Backlash
Removing The Idler Gear
Removing The Camshaft
Removing The Fuel Injection Pump Camshaft
Separating The Gears From The Shafts (As Required)
Removing The Oil Pump
Removing The Front Plate
–Cylinder Block, Crankshaft, Pistons, Oil Pan
Removing The Oil Pan
Removing The Oil Strainer
Removing The Connecting Rod Caps
Removing The Pistons
Measuring The Crankshaft End Play
Removing The Main Bearing Caps
Removing The Crankshaft
Separating The Piston From The Connecting Rod
-ENGINE MAIN PARTS – INSPECTION AND CORRECTION
–Cylinder Head, Valve Mechanism
Measuring The Cylinder Head Bottom Face Distortion
Measuring The Rocker Arm Bore And The Rocker Shaft Diameter
Measuring The Valve Spring For Squareness And Free Length
Measuring The Push Rod For Bend
Measuring The Valve Stem Diameter
Measuring The Clearance Between The Valve Stem And Guide
Replacing The Valve Guide
Inspecting The Valve Face
Correcting The Valve Face
Correcting The Valve Seat
Lapping The Valve Face Against The Valve Seat
Replacing The Combustion Jets
–Flywheel, Timing Gear, Camshaft
Measuring The Flywheel Flatness
Replacing The Ring Gear
Measuring The Timing Gear Backlash
Measuring The Clearance Between The Idler Gear And The Idler Shaft
Replacing The Idler Shaft
Measuring The Clearance Between The Camshaft Journal And The Bushing
Extracting The Camshaft Bushing
Pressfitting The Camshaft Bushing
Measuring The Camshaft Cam Height
Measuring The Fuel Injection Pump Shaft Cam Height
Inspecting The Camtotappet Contact
Measuring The Clearance Between The Tappet And The Tappet Guide
–Cylinder Block, Crankshaft, Pistons, Oil Pan
Measuring The Piston Diameter
Measuring The Clearance Between The Piston Ring And The Ring Groove
Measuring The Piston Ring Gap
Measuring The Clearance Between The Piston Pin And The Pin Boss
Measuring The Connecting Rod Bend And Twist
Measuring The Connecting Rod End Play
Inspecting The Oil Clearance For Connecting Rod Bearings
Inspecting The Main Bearings Oil Clearance
Measuring The Crankshaft For Bend
Removing The Crankshaft Gear
Installing The Crankshaft Gear
Measuring The Cylinder Bore
Measuring The Cylinder Block Top Face For Distortion
-ENGINE MAIN PARTS – REASSEMBLY
Cylinder Block, Crankshaft, Pistons, Oil Pan
Installing The Main Bearings
Installing The Crankshaft
Installing The Main Bearing Caps
Inserting The Side Seals
Assembling The Piston Onto The Connecting Rod
Installing The Piston Rings
Installing The Piston/Connecting Rod Assemblies
Installing The Connecting Rod Caps
Installing The Oil Strainer
Installing The Oil Pan
Flywheel, Timing Gear, Camshaft
Installing The Front Plate
Installing The Oil Pump
Rotating The Engine
Tapping The Fuel Injection Pump Camshaft Into Place
Installing The Camshaft
Installing The Idler Gear
Installing The Timing Gear Case
Tightening The Crankshaft Pulley Nut
Installing The Pto Gear
Inserting The Tappets
Installing The Oil Seal Case
Installing The Rear Plate
Installing The Flywheel Housing
Installing The Flywheel
Cylinder Head, Valve Mechanism
Cleaning The Bottom Face Of The Cylinder Head
Installing The Valve Stem Seals
Installing The Valve Springs
Installing The Valve Locks
Installing The Cylinder Head Gasket
Installing The Cylinder Head
Tightening The Cylinder Head Bolts
Inserting The Push Rods
Assembling The Rocker Shaft Assembly
Installing The Rocker Shaft Assembly
Adjusting The Valve Clearance
Installing The Rocker Cover
-FUEL SYSTEM – REMOVAL
–Fuel Injection Pipes, Fuel Leak-Off Pipe, Fuel Injection Nozzles
Removing The Fuel Injection Pipes
Removing The Fuel Injection Nozzles
–Governor
Removing The Governor Assembly
Removing The Governor Weights
–Fuel Injection Pumps
Removing The Fuel Injection Pumps
-FUEL SYSTEM – DISASSEMBLY, INSPECTION AND REASSEMBLY
–Fuel Injection Nozzles
Disassembling The Fuel Injection Nozzles
Inspecting The Fuel Injection Nozzle
Reassembling The Fuel Injection Nozzle
–Fuel Injection Pumps
Inspecting The Fuel Injection Pumps On Vehicle
Disassembling The Fuel Injection Pumps
Inspecting The Fuel Injection Pumps
Reassembling The Fuel Injection Pumps
–Governor
Disassembling And Inspecting The Governor
Reassembling The Governor
Installing The Torque Spring Set
–Fuel Pump
Inspecting The Fuel Pump
–Fuel Filter
Disassembling, Inspecting And Reassembling The Fuel Filter (With A Selector Cock)
Inspecting The Fuel Filter (Cartridge Type)
-FUEL SYSTEM – INSTALLATION
–Fuel Injection Pumps
–Installing The Fuel Injection Pumps
Governor
Installing The Governor Weights
Installing The Sliding Sleeve
Installing The Governor Assembly
Fuel Injection Pipes, Fuel Leak-Off Pipe, Fuel Injection Nozzles
Installing The Fuel Injection Nozzles
Installing The Fuel Pipes
-OIL SYSTEM – REMOVAL
–Filter, Relief Valve And Oil Pressure Switch
Removing The Oil Filter
Removing The Relief Valve
Removing The Oil Pressure Switch·
–Oil Pan, Oil Strainer
-OIL SYSTEM – DISASSEMBLY,INSPECTION AND REASSEMBLY
–Oil Pump
–Inspecting The Oil Pump
–Relief Valve
Inspecting The Relief Valve
–Oil Pressure Switch
Inspecting The Oil Pressure Switch
-OIL SYSTEM – INSTALLATION
–Oil Filter, Relief Valve And Oil Pressure Switch
Installing The Oil Pressure Switch
Installing The Relief Valve
Installing The Oil Filter
–Oil Pan And Oil Strainer
-COOLING SYSTEM – REMOVAL
Cooling Fan, Fan Pulley And V-Belt
Removing The Cooling Fan
–Thermostat And Thermoswitch
Removing The Thermostat Case
–Water Pump
Removing The Water Pump
-COOLING SYSTEM – DISASSEMBLY, INSPECTION AND REASSEMBLY
–Thermostat
Disassembling The Thermostat
Inspecting The Thermostat
–Thermoswitch
Inspecting The Thermoswitch
Water Pump
Inspecting The Water Pump
-COOLING SYSTEM – INSTALLATION
Water Pump
Installing The Water Pump
–Thermostat And Thermoswitch
Installing The Thermostat Case
Installing The Thermoswitch
–Cooling Fan, Fan Pulley And V-Belt
Installing The Cooling Fan
-INLET AND EXHAUST SYSTEMS – REMOVAL
Inlet Cover
Removing The Inlet Cover
–Exhaust Manifold
Removing The Exhaust Manifold
-INLET AND EXHAUST SYSTEMS – DISASSEMBLY, INSPECTION AND REASSEMBLY
–Inlet Cover And Exhaust Manifold
Inspecting The Inlet Cover And Exhaust Manifold
Measuring The Exhaust Manifold Mounting Face Distortion
-INLET AND EXHAUST SYSTEMS – INSTALLATION
–Exhaust Manifold
Installing The Exhaust Manifold
–Inlet Cover
Installing The Inlet Cover
-ELECTRICAL SYSTEM – REMOVAL
Starter
Alternator
Stop Solenoid
Glow Plug
-ELECTRICAL SYSTEM – DISASSEMBLY, INSPECTION AND REASSEMBLY
–Starter
Removing The Starter
Inspecting And Correcting The Starter
Reassembling The Starter
–Alternator
Disassembling The Alternator
Inspecting And Correcting The Alternator
Reassembling The Alternator
–Stop Solenoid
Reassembling The Stop Solenoid
Checks After Reassembly
–Glow Plug
Inspecting The Glow Plug
-ELECTRICAL SYSTEM – INSTALLATION
Glow Plug
Stop Solenoid
Altemato
Starter
-ENGINE – INSPECTION / ADJUSTMENT, RUNNING-IN TRIAL AND PERFORMANCE TEST
–Inspection And Adjustment Of Engine
Preparations For Valve Clearance Inspection And Adjustment
Inspecting The Valve Clearance
Adjusting The Valve Clearance
Inspecting And Adjusting The Fuel Injection Timing
Alternative Adjustment Method
Replacing The Fuel Filter
Bleeding The Fuel Filter Of Air
Adjusting The Low And High Idle Speeds
Inspecting The Fuel Injection Nozzle
Inspecting The Vbelt Tension
–Runningin Trial
Starting The Engine
Inspecting The Engine During Runningin
Runningin Timetable
Inspection And Adjustment After Runningin
–Performance Test
Standard Ancillaries
Test Items And Purposes
Other Tests
Adjusting The Engine Power
-MISCELLANEOUS
–Disassembly and Reassembly of General Parts
Oil seals
O-rings
Bearings
Lock plates
Split pins, Spring pins
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