Mitsubishi S4Q Manuals

Methods of Indication

3

Abbreviations, Standards, Etc.

4

Units of Measurement

4

General Contents

5

Safety Cautions

6

General

14

Outline

15

External View for Power Unit

15

Engine Left View

15

Engine Right View

15

External View for Power Unit (High Speed Specification)

16

External View for Generator

17

External View for Generator (High Speed Specification)

18

Outline of Fuel System

19

Outline of Lubrication System

19

Outline of Cooling System

20

Outline of Inlet and Exhaust Systems

20

Engine Serial Number

21

Engine Model and Application Code

21

Specifications

22

Maintenance Standards

24

Maintenance Standards Table

25

Tightening Torque Table

31

Important Bolts and Nuts

31

Standard Bolts and Nuts

32

Standard Eyebolts

32

Standard Union Nuts

32

Taper Bolts

32

Sealants Table

33

Basic and Special Tools

34

Basic Tools

35

Special Tools

36

Overhaul Instructions

38

Determination of Overhaul Timing

39

Measurement of Compression Pressure

40

Preparation for Inspection

40

Preparation for Disassembly

41

Removing Electrical Wiring

42

Draining Coolant

42

Draining Engine Oil

42

Disassembly of Engine Main Parts

43

Cylinder Head and Valve Mechanisms

44

Removal of Rocker Shaft Assembly

45

Disassembly of Rocker Shaft Assembly

45

Removal of Cylinder Head Bolts

45

Removal of Valves and Valve Springs

45

Removal of Valve Stem Seals

46

Cleaning of Cylinder Head Bottom Surface

46

Measurement of Piston Protrusions

46

Flywheel

47

Removal of Flywheel

48

Removal of Oil Seal Case (Optional)

48

Removal of Flywheel Housing

48

Timing Gears, Camshaft and Oil Pan

49

Removal of Crankshaft Pulley

50

Removal of Timing Gear Case

50

Measurement of Backlashes

50

Measurement of Idler Gear End Play

51

Removal of Idler Gear

51

Camshaft End Play

51

Reversal of Crankcase

51

Removal of Oil Pan and Oil Pan Gasket

52

Removal of Oil Pump

52

Removal of Camshaft

52

Removal of Front Plate

52

Pistons, Connecting Rods, Crankshaft and Crankcase

53

Laying Crankcase on Its Side

54

Measurement of Connecting Rod End Play

54

Removal of Connecting Rod Caps

54

Preparation for Removal of Pistons

55

Removal of Pistons

55

Removal of Piston Ring

55

Removal of Piston Pins

55

Measurement of Crankshaft End Play

56

Removal of Main Bearing Caps

56

Removal of Crankshaft

56

Arrangement of Bearings

56

Inspection and Repair of Engine Main Parts

57

Measurement of Distortion of Cylinder Head Bottom Surface

58

Measurement of Rocker Arm Inside Diameter and Rocker Shaft Diameter

58

Measurement of Valve Spring Perpendicularity and Free Length

58

Measurement of Pushrod Deflection

59

Measurement of Valve Stem Diameter

59

Measurement of Clearance between Valve Stem and Valve Guide

59

Replacement of Valve Guides

60

Inspection of Valve Faces

60

Replacement of Valve Seats

61

Refacing Valve Faces

62

Regrinding Valve Seats

62

Lapping Valves against Valve Seats

62

Replacement of Combustion Jets

63

Measurement of Flywheel Flatness

64

Replacement of Ring Gear

64

Inspection of V-Belt Groove for Wear

65

Inspection of Oil Seal Contact Surface

65

Replacement of Idler Bushing

65

Replacement of Idler Shaft

66

Measurement of Cam Lift

66

Measurement of Camshaft Journal Diameter and Journal Bore Diameter

66

Measurement of Camshaft Deflection

67

Removal of Camshaft Gear

67

Installation of Camshaft Gear and Thrust Plate

67

Measurement of Piston Outside Diameter

68

Inspection of Pistons and Piston Rings

68

Measurement of Piston Ring End Gap

69

Measurement of Piston Pin Bore and Piston Pin

69

Measurement of Clearance between Connecting Rod Bushing and Piston

69

Replacement of Connecting Rod Bushing

70

Inspection of Connecting Rods for Bend and Twist

70

Inspection of Oil Clearance of Connecting Rod Bearing

71

Inspection of Oil Clearance of Main Bearing

72

Inspection of Oil Contact Surface

73

Measurement of Crankshaft Deflection

74

Removal of Crankshaft Gear

74

Installation of Crankshaft Gear

74

Measurement of Cylinder Bore

75

Measurement of Distortion of Crankcase Upper Surface

76

Inspection of Cam Contacting Surfaces of Tappets

76

Measurement of Clearance between Tappet and Tappet Guide Bore

76

Reassembly of Engine Main Parts

77

Installation of Piston Rings

80

Preparation for Piston Installation

81

Installation of Connecting Rod Bolts and Bearings

81

Installation of Pistons

81

Installation of Connecting Rod Caps

82

Positioning Crankcase Upright

83

Installation of Front Plate

84

Installation of Camshaft

84

Installation of Oil Pump

84

Installation of Oil Pan

85

Installation of Idler Gear

85

Inspection after Timing Gear Installation

86

Installation of Oil Seal

86

Installation of Timing Gear Case

86

Installation of Crankshaft Pulley

87

Installation of Flywheel Housing

88

Installation of Oil Seal Case

88

Installation of Flywheel

88

Measurement of Flywheel Runout

88

Installation of Valve Stem Seals

89

Installation of Valves and Valve Springs

89

Installation of Cylinder Head Gasket

89

Installation of Cylinder Head

90

Tightening of Cylinder Head Bolts

90

Assembly of Rocker Arm and Rocker Shaft Assembly

90

Installation of Rocker Shaft Assembly

90

Adjustment of Valve Clearances

91

Removal of Fuel System

93

Fuel Filter

94

Fuel Injection Pipe, Fuel Leak-Off Pipe and Fuel Injection Nozzle

96

Fuel Injection Pump

98

Removal of Fuel Injection Pump

100

Disassembly, Inspection and Reassembly of Fuel System

101

Disassembly and Inspection of Fuel Filter

102

Reassembly of Fuel Filter

104

Disassembly of Fuel Injection Nozzles

106

Inspection of Fuel Injection Nozzles

106

Reassembly of Fuel Injection Nozzles

108

Installation of Fuel System

109

Installation of Fuel Injection Pump

112

Removal of Lubrication System

117

Oil Filter, Oil Cooler and Relief Valve

118

Oil Pan, Oil Pump and Oil Pressure Switch

119

Disassembly, Inspection and Reassembly of Lubrication System

120

Disassembly and Inspection of Oil Pump

121

Measurement of Clearance between Outer Rotor and Inner Rotor

121

Measurement of Rotor and Case End Play

121

Measurement of Clearance between Outer Rotor and Pump Case

122

Reassembly of Oil Pump

122

Inspection of Oil Filter, Oil Cooler and Relief Valve

123

Adjustment of Relief Valve

123

Installation of Lubrication System

124

Oil Filler, Oil Cooler and Relief Valve

126

Removal of Cooling System

127

Cooling Fan, Fan Pulley and V-Belt

128

Thermostat

129

Water Pump

130

Disassembly, Inspection and Reassembly of Cooling System

131

Disassembly of Water Pump

132

Inspection of Water Pump

132

Disassembly of Thermostat

133

Inspection of Thermostat

133

Inspection of Thermo Switch

134

Installation of Cooling System

135

Removal of Inlet and Exhaust Systems

139

Inlet Manifold

140

Exhaust Manifold

141

Disassembly, Inspection and Reassembly of Inlet and Exhaust Systems

142

Inlet Manifold and Exhaust Manifold

143

Measurement of Exhaust Manifold Distortion

143

Installation of Inlet and Exhaust Systems

144

Removal of Electrical System

147

Starter

148

Alternator

149

Glow Plugs

150

Disassembly, Inspection and Reassembly of Electrical System

151

Disassembly and Inspection of Starter

152

Inspection of Starter

153

Reassembly of Starter

156

Inspection and Adjustment after Reassembly

157

Disassembly of Alternator

160

Inspection and Repair of Alternator

162

Reassembly of Alternator

164

Inspection of Glow Plugs

165

Installation of Electrical System

166

Inspection, Adjustment, Break-In Operation and Performance Tests

170

Adjustment of Engine

171

Draining of Fuel System

172

Bleeding of Fuel System

172

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 Timing

176

Inspection and Adjustment of V-Belt Tension

176

Adjustment of Governor

177

Break-In Operation

182

Starting up

182

Break-In Period

182

Disassembly and Reassembly of General Parts

185

Oil Seals

185

O-Rings

185

Bearings

186

Lock Plates

186

Split Pins and Spring Pins

186

Mitsubishi S4Q Manuals

Mitsubishi S4Q Service Manual (200 pages)

Table of Contents

Mitsubishi S4Q User Manual (174 pages)

Table of Contents

General

1 Outline

2 Specifications

General Instructions

3 Determination of Overhaul Timing

4 Testing the Compression Pressure

5 Tips on Disassembly and Reassembly

6 Precautions for Disassembly and Reassembly

Engine Main Parts

7 Cylinder Heads and Valve Mechanism

8 Flywheel

9 Timing Gears, Camshaft and Oil Pan

10 Pistons, Connecting Rods, Crankshaft and Crankcase

Inlet and Exhaust System

11 Description

12 Disassembly, Inspection and Reassembly

Cooling System

13 Description

14 Water Pump, Fan

15 Thermostat

Fuel System

16 Description

17 Fuel System Bleeding

18 Disassembly

19 Fuel Injection Timing Check

20 Fuel Filter (Paper-Element Cartridge Type)

21 Fuel Injection Nozzles

Lubrication System

22 Description

23 Oil Pump

24 Oil Filter

25 Pressure Relief Valve

Electrical System General

27 Starter

28 Alternator

29 ETR Type Stop Solenoid

30 Glow Plugs

Testing and Adjusting

31 Bench Test

32 Idling Speed and Maximum Speed Setting Inspection and Adjustment

33 Performance Test

Troubleshooting

34 Causes of Engine Problems and Remedies

Maintenance Standards

35 Maintenance Standards Table

36 Tightening Torques

37 Thread Sealants

38 Maintenance Schedule

Special Tools

39 Special Tool List

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