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S3L
Service manual
Mitsubishi S3L Service Manual
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Also See for S3L
:
Operation manual
(44 pages)
,
Service manual
(195 pages)
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Table Of Contents
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Contents
Table of Contents
Bookmarks
Table of Contents
How to Use this Manual
Notes on Descriptions
Terms
Abbreviations and Standards
Units
General Contents
Safety Cautions
Risk of Fire and Explosion
Risk of Burn
Exhaust Gas Is Poisonous
Hearing Difficulty
Beware of Falling Engine
Use Correct Engine Oil and LLC
Handling of Battery
How to Handle Emergencies
Other Considerations
General
Overview
Outline Drawing S3L, S3L2
Engine LH Side View
Engine RH Side View
S4L, S4L2
Fuel System Schematic
Oil System Schematic
Cooling System Schematic
Inlet/Exhaust System Schematic
Engine Serial Number
Engine Model and Application Codes
Model Coding
Specifications
Disassembly / Reassembly Notes
Service Standards
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
Tightening Order for Cylinder Head Bolts
Removing the Cylinder Head Assembly
Removing the Valves and Valve Springs
Removing the Valve Stem Seals
Flywheel, Timing Gear, Camshaft
Flywheel End of Engine
Disassembly of Flywheel
Timing Gear End of Engine
Disassembly of Timing Gear and Camshaft
Removing the Flywheel
Removing the Flywheel Housing
Locking the Flywheel
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
Front Plate Retaining Bolts
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 Conecting Rod
Piston Pin Setting Tool
Removing the Piston Pin
Engine Main Parts - Inspection and Correction
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
Valve Guide Protrusion above the Cylinder Head Face
Valve Seat-To-Face Contact
Correcting the Valve Face
Correcting the Valve Seat
Valve Seat Angle and Width
Lapping the Valve Face against the Valve Seat
Replacing the Combustion Jets
Extracting the Combustion Jet
Tapping the Combustion Jet into Place
Measuring the Flywheel Flatness
Replacing the Ring Gear
Removing the Ring Gear
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
Measuring the Camshaft Journal Diameter
Extracting the Camshaft Bushing
Press-Fitting the Camshaft Bushing
Measuring the Camshaft Cam Height
Measuring the Fuel Injection Pump Shaft Cam Height
Inspecting the Cam-To-Tappet Contsct
Measuring the Clearance between the Tappet and the Tappet Guide
Cam-To-Tappet Contact
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
Using a Connecting Rod Aligner to Measure the Rod Bend and Twist
Using a Dial Gauge to Measure the Connecting Rod for Bend
Measuring the Connecting Rod End Play
Inspecting the Oil Clearance for Connecting Rod Bearings
Measuring the Crank Pin Diameter
Crank Pin Ground Dimensions
Inspecting the Main Bearings Oil Clearance
Crank Journal Ground Dimensions
Measuring the Crank Journal Diameter
Finished Radius Dimension of Fillet
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
Installing the Main Bearings
Installing the Crankshaft
Installing the Main Bearing Caps
Correct Installation of Main Bearing Caps
Inserting the Side Seals
Tightening the Main Bearing Cap Bolts
Ensure that the Crankshaft Rotates Smoothly
Face the Side Seals Correctly
Assembling the Piston Onto the Connecting Rod
Inserting the Piston Pin
Inserting the Piston Pin with a Hydraulic Press
Check that the Piston and the Connecting Rod Slide Smoothly about the Piston Pin
Installing the Piston Rings
Installing the Piston/Connecting Rod Assemblies
Piston Ring Arrangement
Assembling the Oil Ring
Installing the Connecting Rod Caps
Installing the Oil Strainer
Installing the Oil Pan
Applying Sealant to the Oil Pan Mounting Face of the Cylinder Block
Sealant Application Pattern
Cutting the End of Sealant Tube
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
Installing the Thrust Plate
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
Tightening the Flywheel Bolts
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 of Fuel Injection Pumps
Removing the Tie-Rod
Fuel System - Disassembly, Inspection and Reassembly
Fuel Injection Nozzles
Disassembling the Fuel Injection Nozzles
Inspecting the Fuel Injection Nozzle
Inspecting the Injection Valve Opening Pressure
Replacing the Fuel Injection Nozzle Tip Assembly
Fuel Spray Patterns
Cleaning the Fuel Injection Nozzle Tip Components
Reassembling the Fuel Injection Nozzle
Inspecting the Fuel Injection Pump on Vehicle
Disassembling the Fuel Injection Pumps
Removing the Tappet Guide Pin
Removing the Tappet
Removing the Plunger
Removing the Delivery Valve Holder
Removing the Delivery Valve
Removing the Plunger Barrel
Do Not Loosen These Plates
Inspecting the Fuel Injection Pumps
Reassembling the Fuel Injection Pumps
Inserting the Plunger Barrel
Installing the Delivery Valve
Installing the Control Sleeves
Inserting the Plunger
Installing the Tappet
Tightening the Delivery Valve Holder
Inspecting the Control Rack for Smooth Operation
Disassembling and Inspecting the Governor
Reassembling the Governor
Installing the Torque Spring Set
Installing the Levers
Adjusting and Sealing the Torque Spring Set
Fuel Pump
Inspecting the Fuel Pump
Plunger Fuel Pump (Standard)
Plunger Fuel Pump (Compact-Size)
Fuel Filter
Disassembling, Inspecting and Reassembling the Fuel Filter (with a Selector Cock)
Inspecting the Fuel Filter (Cartridge Type)
Fuel System - Installation
Installing the Fuel Injection Pumps
Installing the Fuel Injection Pump Housing Complete with the Pumps
Installing the Tie-Rod
Installing the Governor
Installing the Governor Weights
Installing the Sliding Sleeve
Installing the Governor Assembly
Installation of the Fuel Injection Pipes, Fuel Leak-Off Pipe, and Fuel Injection Nozzles
Installing the Fuel Injection Nozzles
Installing the Fuel Pipes
Oil System - Removal
Oil 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
Inspecting the Oil Pump
Inspecting the Relief Valve
Inspecting the Oil Pressure Switch
Oil System - Installation
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
Disassembling the Thermostat
Inspecting the Thermostat
Inspecting the Thermoswitch
Inspecting the Water Pump
Inspecting the Impeller and Shaft for Smooth Rotation
Cooling System - Installation
Installing the Water Pump
Installing the Thermostat Case
Installing the Thermoswitch
Installing the Thermostat Assembly
Installing the Cooling Fan
Adjusting the V-Belt Tension
Inlet and Exhaust Systems - Removal
Removing the Inlet Cover
Removal of the Inlet Cover and Air Pipe
Removing the Exhaust Manifold
Removal of the Exhaust Manifold and Gasket
Inlet and Exhaust Systems - Disassembly, Inspection and Reassembly
Inspecting the Inlet Cover and Exhaust Manifold
Measuring the Exhaust Manifold Mounting Face Distortion
Inlet and Exhaust Systems - Installation
Installing the Exhaus Manifold
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Operating Manual
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This manual is also suitable for:
S3l2
S4l
S4l2
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