Mitsubishi S3L Service Manual page 4

TABLE OF CONTENTS
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
4 / 195 ENGLISH Service Manual Mitsubishi SL-Series diesel engines
Version 08/2004