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S4Q
Service manual
Table Of Contents - Mitsubishi S4Q Service Manual
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User manual
(174 pages)
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Table Of Contents
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Contents
Table of Contents
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Table of Contents
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Table of Contents
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
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